Attachment_(1)_PWS_427_FINAL_101917.docx

Attachment 1

U.S. NAVY T56 SERIES IV ENGINE MODULE REPAIR

PERFORMANCE WORK STATEMENT

18 August 2017

TABLE OF CONTENTS

ENCLOSURE (1) 23

1.0 SCOPE

1.1 This Performance Work Statement (PWS) establishes the work requirements that the Contractor shall perform in order to return items listed in this contract to a Ready For Issue (RFI) material condition. Items will be inspected, repaired, and calibrated In Accordance With (IAW) this PWS and applicable technical manuals and directives as specified in Section 5.0.

1.2 Processing requirements for all T56 Series IV modules and components provide for the receipt, inspection, disassembly, repair or replacement, assembly, testing, and preservation of these items to a serviceable condition.

Additional technical and specific application references are located in Section 5.0.

Required Documents

Reference Documents

2.2 DEFINITION OF TERMS

2.2.1 The purpose of this glossary is to define engine terminology and processing requirements. Generally accepted descriptions of equipment and processing terminology expressed as acronyms or colloquialisms are unacceptable unless all parties agree to such use. Terminology not defined elsewhere in this document shall be defined by COMNAVAIRFORINST 4790.2 Series.

Accessories: Accessories include, but are not limited to, the fuel control, fuel pump, speed sensitive control, speed sensitive valve, fuel nozzles, and oil pumps. Typically, accessories can be removed and replaced at all levels of maintenance.

Advanced Engineering Memorandum (AEM): An engineering change generated by the Contractor.

Aeronautical Equipment Service Record (AESR): An insert to the basic aircraft logbook used as a service record for various aircraft equipment, such as power plant and propellers.

Assembly Service Record (ASR): The ASR provides complete history of repair, installation, removal, modification, and configuration of an assembly.

Bulletin: A Bulletin is a Technical Directive (TD) that directs a one-time inspection to determine if a given condition exists and specifies what action shall be taken if the condition is found. Bulletins may contain instructions for corrective action using approved repair procedures, provided no change in configuration is involved. Bulletins affecting the T56 Series IV Engine are generally titled as Accessory (AYB) or Power Plant Bulletins (PPB).

Cannibalization/Cannibalize: Removal of serviceable parts from an engine or Engine/Propulsion System Module (EPSM) for installation on another EPSM. Cannibalization, with few exceptions, is a manifestation of a logistic or maintenance support system failure.

Cleaning: Cleaning includes the removal and subsequent preventative treatment of negligible and minor corrosion damage.

Compressor Assembly: The Compressor Assembly is defined in the applicable Illustrated Parts Breakdown (IPB) manuals for each Type/Model/Series (T/M/S) as listed in Section 5.0 in this PWS. The compressor assembly shall also include the outer combustion case.

Consumable Item: Items incidental to repair that are not considered repairable (e.g., cleaning cloths, nuts, bolts, etc.). An item with a “Z” in the 4th position of the Source Material and Reliability (SM&R) code as defined in the NAVSUP P719. SM&R codes can be found in the NA 02B-5DG-4.

Critical Safety Item (CSI): An item that contains a characteristic whose failure, malfunction, or absence could cause loss or serious damage to the aircraft or weapons system; an unacceptable risk to personnel; or an uncommanded engine shutdown that jeopardizes safety. The CSI designation is only dependent on the consequence of failure, not the probability of failure. An assembly is considered to be CSI if at least one of its parts has been designated as a CSI.

Decision Knowledge Programming for Logistics Analysis and Technical Evaluation (DECKPLATE): US Navy maintenance and tracking system for engines and engine modules.

Disassembly: Teardown of a T56 Series IV module, or component sufficient to permit the type and amount of inspection and work required.

Engine Tracking System (DeckETR): Used to document movement and status changes in DECKPLATE.

Engineering Change Proposal (ECP): A proposal to change the design or engineering features of material. The term includes both a proposed engineering change and the documentation by which the change is described.

Equipment History Record (EHR): A record that denotes configuration, operation, and maintenance history for a designated item being tracked for age exploration under the Navy Reliability Centered Maintenance (RCM) program by the Fleet Support Team (FST). The EHR accompanies component throughout its service life and is included in the Module Service Record (MSR).

External Accessories: All accessories that are attached to the outside portion of the Power Section, Reduction Gear Assembly, or Torquemeter. External Accessories include, but are not limited to, components of the fuel, lubrication, ignition, control, and bleed systems. External accessories may be routinely removed and replaced by organizational-level maintenance activities to keep a unit in service.

Fleet Support Team (FST): A US Navy field activity that has been assigned the authority and responsibility of maintenance engineering, and logistics. This activity ensures in-service safety and readiness of assigned systems while reducing the operating and support cost to the Navy. The T56 FST is located at the In-Service Support Center, Jacksonville, Florida.

Formal Change: A Formal Change TD is the primary Naval Air System Command (NAVAIRSYSCOM) document for implementing a configuration change and contains instructions and information that direct accomplishment and recording of a material change, repositioning, modification, or alteration in the characteristics of a system. Changes affecting T56 Series IV propulsion systems are generally titled as Accessory (AYC) or Power Plant Changes (PPC).

Induction: The point at which a T56 Series module, Compressor Assembly, or Turbine Unit Change Assembly enters the Contractor’s repair process subsequent to issuance of a task order.

Inherent Reliability: The maximum reliability an asset can achieve based on its design and manufacturing process, assuming an ideal maintenance environment and operation within design parameters. Reliability is the probability that an asset will perform its intended function for a specified period of time under specified operating conditions.

Interim Change: A change released in message format for purposes of urgency. Interim Changes are generally followed by a Formal Change release. Interim changes are either Accessory (IAYC) or Power Plant Changes (IPPC).

Intermediate Maintenance Activities (IMA): These activities are established by COMNAVAIRFORINST 4790.2 Series. The latest version of NAVAIR Note 4700 defines individual site capabilities.

Intermediate Maintenance Manual: Manuals that provide instructions for maintenance performed at Intermediate Maintenance Activities (IMA). A listing of Intermediate Maintenance Manuals is provided in Section 5.0 of this PWS.

International Organization for Standardization (ISO) 9000 and 14000: The ISO 9000 family addresses quality management. The ISO 14000 family addresses environmental management. References made to ISO 9001 and 14000 are intended to represent the entire ISO 9000 and 14000 family of standards and guidelines for implementation of a Quality Management Program. Information on the ISO 9000 family is available at www.iso.org/iso/home.htm.

Item: Any level of hardware assembly; for example, segment of a system, sub-system, equipment, or component part such as the T56 Series IV propulsion system, Power Section Unit Assembly, Reduction Gear Unit Assembly, Torquemeter, and Quick Engine Change Assembly (QECA).

Maintenance Record: General reference to an Aeronautical Equipment Service Record, Module Service Record, Assembly Service Record, or Scheduled Removal Component Card.

Material Review Board (MRB): Comprised of members from the Contractor and T56 FST as required.

Maximum Operating Time (MOT): The maximum allowable time a component or accessory is authorized to operate. Maximum operating times are established by the FST and listed in the applicable specific Periodic Maintenance Information Card (PMIC) Publication listed in this PWS.

Modify: Incorporation of a Technical Directive or Engineering Change Proposal (ECP) resulting in the physical change of a component where no other repair process is required.

Module: The sectionalized portion of a propulsion system which, when combined with other modules, makes up a propulsion system. The T56 Series IV propulsion system consists of three modules: Power Section Unit Assembly, Reduction Gear Unit Assembly, and Torquemeter/Anti-icing Shroud Unit Assembly.

Module Service Record (MSR): Equipment record for one of the three modules, which denotes configuration of a module and its service history. The MSR provides repair history, installation, modification, removal, and usage for a specific module. It accompanies the module throughout its service life and is included in the AESR when installed in a propulsion system.

Mutilation: To render a part beyond repair and incapable of being reworked.

Power Plant Bulletin (PPB): Technical directive that directs a one-time inspection of a power section, reduction gear assembly or torquemeter. The PPB contains related instructions and disseminates administrative and management information as related to the maintenance of the power plant.

Power Section Unit Assembly: The complete assembly of a Power Section as specified in the applicable IPB listed in Section 5.0 of the PWS in this contract. The Power Section Unit Assembly shall include, but is not limited to, the fuel control, oil pump, and speed sense components. The serial number is alphanumeric (e.g., AE113456) and is identified on the data plate attached to the compressor air inlet housing.

Ready For Issue (RFI): A repairable item that does not require any repair, replacement of over-aged parts, or non-routine pre-installation and post- installation condition verification prior to use. RFI items are not necessarily new or like new but meet applicable performance specifications. Packaging and preservation do not enter into the process of producing an RFI item, but are required in order to maintain the item identity and condition and to prevent damage during subsequent shipping, handling, and storage.

Reclamation: The process of end-item disassembly to recover serviceable or economically repairable spare parts.

Reduction Gear Unit Assembly (RGA): The complete assembly of the reduction gear assembly as specified in the applicable IPB listed in Section 5.0 of the PWS in this contract. The Reduction Gear Unit Assembly includes, but is not limited to, the oil pump, thrust sensitive switch, and prop control linkage. The serial number is alphanumeric (e.g., AG012345) and is identified on the data plate attached to the Reduction Gear Assembly front housing.

Repairable Items: A durable item which, when unserviceable can be economically restored to a serviceable condition through regular repair procedures. These items are identified by the character in the fourth position of its SM&R code, i.e. "O", "F", "G", "H", "K", "L", "D", or "B”, as defined in the NAVSUP P-719. For a specific item, the SM&R code can be located in the NA 02B-5DG-4.

Salvageable: A part that is within the acceptable limits specified in the technical limits for service or can be returned to a serviceable condition through a repair process IAW the technical manuals listed in Section 5.3 of this PWS.

Scheduled Removal Component (SRC) Card: A part of the logbook that provides for the recording of complete maintenance history, installation, usage, and configuration data. The SRC Card accompanies the component at all times when not installed and is made a part of the Aeronautical Equipment Service Record (AESR) when installed.

Series IV Engine Modules: T56-A-427 Power Section, Torquemeter, and Reduction Gear Assembly.

Serviceable: A part that meets the allowed serviceable limits, as defined by the technical publications listed in Section 5.3 of this PWS, and can be returned to service as is.

Service Tour: Operating time from the time that a T56 Series IV propulsion system or module is issued by the Contractor to the time it is removed due to a discrepancy.

T56 FST: The Government Fleet Support Team (FST) comprised of Engineers and Logisticians that provide an array of technical and logistical services in direct support of fleet operations.

Technical Directives (TDs): A document authorized and issued by NAVAIRSYSCOM to provide technical information necessary to properly and systematically inspect or alter the configuration of an item subsequent to establishment of each respective baseline configuration. TDs include all types of changes and bulletins and consist of information that cannot be disseminated satisfactorily by revisions to technical manuals.

Technical Directive Status Accounting (TDSA)/Configuration Management Information System (CMIS): US Navy reporting and tracking system for configuration changes and TD compliance.

Technical Manual Source Data Record (TMSDR): An electronic form used by FST to implement changes to technical manuals.

Request for Engineering Information (REI)/ Temporary Engineering Instruction (TEI): Contractor submits an REI /TEI for discrepant/non-conforming components with inadequate technical procedures/criteria, or deviation from existing standards when discovered during the execution of this PWS. FST engineering will review/approve/disapprove proposed REI/TEIs by the Contractor.

Torquemeter/Anti-icing Shroud Unit Assembly (TM): The complete assembly of a Torquemeter as specified in the applicable IPB listed in Section 5.0 of the PWS in this contract.

Turbine Unit Assembly: The turbine unit assembly is specified in the applicable IPB manual identified in Section 5.0 of this PWS and includes the combustion liners, thermocouples, and external oil lines IAW Section 5.0 of the PWS in this contract.

Turn Around Time (TAT): Calculated based on the number of calendar days between the physical induction of a T56 Series IV Propulsion System, module, or component by the Contractor and the signature date of the DD250 providing final acceptance of the RFI asset by the Navy.

2.4 SECURITY

All controlled unclassified technical information shall be appropriately identified and marked with the following distribution statement(s):

Distribution Statement D: Secondary distribution authorized to the Department of Defense and U.S. DoD Contractors only (Critical Technology) (12 Aug 2013). Other requests shall be referred to Program Executive Officer Tactical (PEO(T)), PMA-231, 47123 Buse Rd, RADM William A. Moffett Building, Patuxent River, MD 20670-1547.

Public Release. Any controlled unclassified information pertaining to this contract shall not be released for public dissemination, including posting to any social media sites such as Facebook or Twitter, unless it has been approved for public release by appropriate U.S. Government authority. Proposed public releases shall be submitted for approval prior to release through PEO (T), Public Affairs Office, 47123 Buse Road, RADM William A. Moffett Building, Patuxent River, MD 20670-1547.

OPSEC (Operational Security). The Contractor shall develop, implement, and maintain an OPSEC program to protect controlled unclassified and classified activities, information, equipment, and material used or developed by the Contractor and any subcontractor during performance of the contract. This program may include Cyber Security and Communications Security (COMSEC). The OPSEC program shall be in accordance with National Security Decision Directive (NSDD) 298 and DoD 5205.02-M, and at a minimum shall include:

1) Assignment of responsibility for OPSEC direction and implementation.

2) Issuance of procedures and planning guidance for the use of OPSEC techniques to identify vulnerabilities and apply applicable countermeasures.

3) Establishment of OPSEC education and awareness training.

4) Provisions for management, annual review, and evaluation of OPSEC programs.

5) Flow down of OPSEC requirements to subcontractors when applicable.

2.4.3 Information Assurance: The Contractor shall ensure the system design and engineering processes for IT and IT systems employed comply with the requirements in DODI 8510.01, Risk Management Framework (RMF) for DoD Information Technology (IT).

3.0 GENERAL REQUIREMENTS

The Contractor shall repair T56 Series IV Power Sections, Reduction Gear Assemblies, and Torquemeters. The Contractor shall provide facilities, labor, test equipment and material, as required, to return items to an RFI condition. The Contractor shall repair or replace out of limit parts or components regardless of the cause of the out of limit condition. Additionally, the Contractor shall be responsible for forecasting all material requirements. NAVAIR will not supply tooling to the Contractor for performance of repairs, other than the Government property listed in Section J, with the exception of tooling required for incorporation of TDs. The Contractor shall repair and correctly configure each item IAW current depot maintenance manuals, intermediate maintenance manuals, IPB, Local Engineering Specifications (LES), TEI, Government approved Class I and Class II ECPs, formal TDs, and MRCs as listed in Section 5.3 of this PWS.

3.1 TECHNICAL DATA

3.1.1 The Contractor shall comply with the applicable technical manuals and directives listed in Section 5.3 of this PWS.

3.1.2 IPB manuals listed in this PWS are the baseline configurations to be used in the part replacement requirements of the contract. Replacement parts shall conform to the configurations stipulated in these basic manuals as supplemented by other applicable technical manuals and directives listed in Section 5.0 and instructions in this PWS.

3.1.3 The Contractor shall comply with the latest change(s) to technical manuals and directives as listed in Section 5.0 of this PWS.

3.1.4 The Contractor shall notify the Assistant Program Manager for Logistics/Contracting Officer’s Representative (APML/COR), and FST Engineering Lead of discrepant or inadequate technical information discovered during the execution of this PWS. Requests for clarification of, or deviation from existing standards shall be directed to the APML/COR and FST Engineering Lead in writing. Examples include REI, SMR Code Change Request, and Technical Publications Discrepancy Report (TPDR).

3.2 RECEIPT OF ITEMS AT CONTRACTOR’S FACILITY

3.2.1 The Contractor shall take physical custody of all items received at its facility and shall maintain constant care over these items while in storage. The Contractor shall keep any property received under this contract separate from other property. All property received under this contract shall be in an enclosed and covered area accessible only to authorized personnel and protected against loss, damage, and theft. The historical average per year for storage requirements have been 30 Power Sections, 25 Reduction Gear Assemblies, 20 Torquemeter, and 2 propulsion systems.

3.2.2 Item Unique Identification (IUID) markings shall be placed on the power section and gearbox identification plates and the Torquemeter. Markings shall be adhered to the surface housing assembly near the pickup mounting block ensuring no etched or vibro peened numbers are covered by the label IAW MIL-STD-130N.

3.3 RECEIPT, INSPECTION, AND REPRESERVATION

3.3.1 The Contractor shall perform the following tasks after receipt of item and a corresponding task order. Upon receipt of an item for repair, the Contractor shall inventory, visually inspect the condition of the unit, account for all major components and the logbook, and represerve the item as specified in the applicable technical manuals and directives identified in Section 5.3. The Contractor shall inspect humidity indicators, perform periodic maintenance inspections and maintain preservation for all items stored in Level II and Level III facilities as defined in NAVAIR 15-01-500. The Contractor will be authorized access to the DECKPLATE Engine Management database under this contract to comply with the EPSM report procedures IAW the NAVAIRINST 13700.15D as changes in custody status conditions occur.

3.3.2 Represervation shall be performed in accordance with the manuals in Section 5.0.

3.3.2.1 Report Receipt of Items: The Contractor shall submit Engine Transaction Reports (ETR) via DECKPLATE Engine Management on all EPSMs no later than midnight, local time, the first working day after receipt of the unit. Lost or missing maintenance records shall not prevent the reporting of receipt of modules or T56 Series IV Propulsion systems in DECKPLATE ETR Entries shall annotate the records that were not received with the unit in these instances. All maintenance records shall be protected from damage or loss. The Contractor shall update CDRL A001, Production Plan and Status Report, showing receipt of all items. Items received that do not correspond to those shown on Section B of this contract shall be reported to the PCO or ACO.

3.3.2.1.1 CDRL A001 shall include the additional data fields not covered in DI-ILSS-80620: Shipping Type Commander (TYCOM), Shipping Activity, SHP% at Military power, SFC% at Military power, Fuel Flow at Military power, Turn Around Time (TAT), Shipping Sequence Number and TYCOM, Estimated Monthly Induction Summary including plan and actual quantities, Estimated Monthly Production Summary including plan and actual quantities, Actual received and on-hand quantities for each month, Shortfalls in Retrograde needed to meet Task Order requirements, Remarks (to include material problems, improper preservation, and any additional comments required to provide status and condition of assets).

3.3.2.2 Verify Maintenance Records: The Contractor shall examine maintenance records received with each item. Maintenance records shall be inspected to ensure accurate reporting of serial number information and completeness of each record IAW COMNAVAIRFORINST 4790.2 Series. If the serial number on the maintenance record is not the same as the item received, or if records are missing or deficient, the Contractor shall inform the COR and comply with COMNAVAIRFORINST 4790.2 Series and Section 3.4 of this PWS.

3.3.2.3 Inspect Items: The Contractor shall inspect all items received. Inspection of each unit shall require opening of the container, verifying contents and documentation, and submitting a Missing On Induction (MOI) Report IAW CDRL A002 if applicable. The Contractor shall update CDRL A001, Production Plan and Status Report, with inspection findings. The Contractor shall report receipt of improperly preserved items IAW CDRL A001.

3.3.2.3.1 The Contractor shall inspect each engine/module shipping container for minor damage and its ability to maintain preservation. Minor repair of the shipping container, including replacement of consumable parts, shall be part of the receipt, inspection and re-preservation task. Container damage shall be considered minor if the estimated cost to repair the container is less than $500.00 and shall be covered by the FFP repair. Engine/Module shipping container repairs shall be made IAW Section 5.0 of this PWS.

3.3.2.3.2 Engine/Module shipping containers requiring repair that will exceed $500.00 shall be turned-in and requisitioned via USN/NAVSUP supply procedures.

3.3.2.4 Re-preserve Items: The Contractor shall preserve all modules inducted in accordance with Section 5.0. Modules received in containers incapable of maintaining nitrogen pressurization shall be considered temporarily preserved until induction by placing the applicable amount of 16- unit desiccant bags into the module container desiccant basket IAW NAVAIR 02B-5DG-6-1. The Contractor shall inspect humidity indicators, perform periodic maintenance inspections, and maintain preservation for all for items stored in Level II and Level III IAW NAVAIR 15-01-500.

3.4 MISSING OR DEFICIENT RECORDS

Items shall not be inducted with missing, incomplete, or illegible records without written authorization from the T56 APML/COR. Every effort shall be made by the Contractor to restore records IAW COMNAVAIRFORINST 4790.2 Series to avoid unnecessary and costly repair. The previous custodian and designated T56 FST representative shall be notified within 7 calendar days after receipt of an item with missing, deficient, or erroneous records. The Contractor shall use the following procedures for locating or restoring records:

3.4.1 Attempt to locate records by contacting the previous custodian, T56 FST, and supply activities. If the previous custodian does not have a record copy, the Contractor shall ask the NAVAIR Code 6.8.4.2 (Repository) for a duplicate copy of lost records IAW COMNAVAIRFORINST 4790.2 Series. Include in the correspondence the item part number, stock number, nomenclature, and serial number.

Repair of an item shall include the tasks listed in this section.

3.5.1 INVENTORY STAGING AND PROCESSING

3.5.1.1 The Contractor shall repair all items received under this contract in a First-Received-First-Inducted (FRFI) process to support continuous inventory movement. If MOI items or missing or deficient records prevent the induction of a unit, requests for deviations from the FRFI process shall be forwarded to the PCO or ACO for approval. If approved, the Contractor shall induct the delayed item at the first opportunity following resolution. The Contractor will be provided those parts found to be MOI as Government Furnished Material (GFM) or authorized to purchase them (see Para 3.5.1.2).

3.5.1.2 The Contractor shall be responsible for the replacement of all MOI material up to, but not to exceed $2,500.00 per module and shall be covered under the FFP repair. Items that exceed the cumulative value of $2,500.00 will be provided by the Government. The Government may, at its discretion, authorize the Contractor to procure a replacement for an MOI part. In these cases, the Contractor shall submit a written request to the PCO or ACO and T56 APML/COR documenting, at a minimum, the missing part description, part number, serial number of the affected module, replacement price, and expected date of delivery. After funding has been identified and sent to the cognizant administration office, the PCO or ACO will issue a delivery order or a modification to an existing delivery order authorizing the appropriated funds for the purchase of the material. The Government will not be held liable for any pre-contract costs incurred by the Contractor for MOI material prior to the authorization of funds via an executed contractual document.

3.5.1.3 The Contractor shall document the induction of all items IAW CDRL A001, Production Plan and Status Report. Any deviation or delay preventing the induction of an item, the Contractor shall obtain approval from the PCO or ACO, with the concurrence of the T56 APML/COR.

3.5.1.4 Turnaround Time (TAT) for the Power Section, RGA, and the Torquemeter shall be in accordance with Section F of this contract.

3.5.2 INSPECTION

3.5.2.1 Upon induction, the Contractor shall disassemble, clean, and inspect all items. Inspection shall be accomplished IAW applicable depot maintenance manuals in Section 5.3 of this PWS. The Contractor shall submit an inspection report IAW CDRL A004, Teardown and Inspection Report. CDRL A004 shall include the additional data fields not covered in DI-PSSS-81534A: Date Received, Induction Date, Module Type, Module Serial Number, Shipping Activity (AIMD), Hrs since last Depot Repair, Number of previous Depot Repairs, Location of Last Depot Repair, Date of Last Depot Repair, Time Since New (TSN), Time Since Last Repair (TSR), Date of Last Repair.

3.5.2.2 The Contractor shall inspect all exposed parts for obvious defects and surface damage and shall submit a REI for any discrepancies, not specifically listed in TDs or manuals. Examples of surface damage, as defined by the technical manuals, include: abrasion, brinelling, burning, burr, chafing, chipping, corrosion, crack, crazing, grain boundary oxidation, dent, erosion, flaking, fretting, galling, gouging, grooving, inclusion, nick, peening, pick-up, pitting, scoring, scratches, scuffing, and spalling.

3.5.2.3 Missing On Induction (MOI): The Contractor shall inventory each item for completeness IAW the applicable technical manuals listed in Section 5.0. If an item is received with missing repairable parts, the Contractor shall report the MOI item on the Missing on Induction (MOI) Report, CDRL A002.

3.5.3.1 The Contractor shall be responsible for identification, selection, ordering, and stocking of required parts to support all repairs. All procured parts shall be from the Original Equipment Manufacturers (OEM), OEM approved sources, or other sources listed in the IPB Manuals specified in Section 5.0. Parts classified as Critical Application Item (CAI) or CSI shall be from OEM, OEM approved sources, or USN approved sources. All commercially procured parts shall be new, not reused, recycled, remanufactured, or reconditioned. Substitution of parts not listed in the manual shall be submitted as a REI on FRCSE 13051/7 for authorization (Enclosure 1) to FST Engineering for technical concurrence and to the PCO for approval on a case by case basis. A .pdf fillable copy is available.

3.5.3.2 Replacement of failed parts shall not result in an item’s configuration changing to an older configuration (downgrading/reconfiguration).

3.5.4 CANNIBALIZATION

3.5.4.1 The Contractor shall request approval for cannibalization IAW CDRL A005 Cannibalization Report. CDRL A005 shall include the additional data fields not covered in DI-MISC-80508B: Delivery Order Number, Module Type, Module Serial Number, Date of Induction, Estimated Completion Date, Cannibalized Item Information: NIIN (if applicable), Part Number, Nomenclature, Pricing Information (source and cost), Quantity of Units per Assembly, Quantity of Units to be Cannibalized, Forecasted material usage for fiscal year, and Estimated Delivery Date (EDD).

3.5.4.2 Cannibalization approval by the Government shall not constitute grounds for extended TAT of the item from which the parts were cannibalized.

3.5.5 CONDEMNATION

3.5.5.1 No item other than parts shall be considered for condemnation. A part shall be considered condemned if it exceeds the repairable limits specified in the applicable technical manuals listed in Section 5.3 of this PWS. The Contractor shall not repair condemned parts unless authorized in writing by an approved T56 FST REI. All condemned parts with a value greater than $500.00 shall be reported IAW CDRL A006, Material Demilitarization and Disposition Listing. CDRL A006 shall include the additional data fields not covered in DI-SAFT-81640: Serial Number (if applicable), Part Number and NSN (if applicable). Disposed items shall remain on Material Demilitarization and Disposition List through the life of the contract or until the Plant Clearance Officer prepares an SF 1424, Inventory Disposal Report and disposes of the item on the SF 1424.

3.5.5.2 Contractor’s Disposal Procedures: The Contractor shall prepare and submit to the Government Property Administrator a written plan that sets forth procedures for handling condemned materials IAW CDRL A007, Contractor’s Disposal Procedures. These procedures shall include the requirements stipulated in the Federal Acquisition Regulation (FAR) 45.5, titled “Management of Government Property in the Possession of Contractors”, DOD 4160.21M, “DoD Personal Property Utilization and Disposal Program” and DOD 4160.21-M-1 titled “Defense Demilitarization Manual”.

3.5.5.3 Disposition of Material: The Contractor shall dispose of all condemned Government property as directed by the Government Property Administrator and the applicable demilitarization code.

3.5.5.4 Disposition of Critical Alloys and Precious Metals: Disposition of parts containing critical alloys or precious metals shall be per DOD 4160.21M, Chapter XI, Precious Metals Recovery Program.

3.5.6 REPAIR REQUIREMENTS

3.5.6.1 Upon module induction into the repair process, a DeckETR entry shall be submitted changing the status to in-work undergoing repair, IAW NAVAIRINST 13700.15 series. Additionally, the Contractor shall make DeckETR entries any time a change in module status, condition or custody occurs. Examples of required entries would be the receipt of a module, awaiting EI or PQDR determination, induction/in-work undergoing repair, and transferring the module back to the Fleet.

3.5.6.2 Each item received for induction shall be repaired and reassembled IAW this PWS. The Contractor shall screen the AESR, MSR, ASR, and SRC Cards of all items inducted to determine which TDs require incorporation during repair in order to provide the latest configuration upon completion. The Contractor shall incorporate all active TDs as a part of the repair process to the latest configuration. All TD requirements shall be incorporated IAW NAVAIR 00-25-300 and Section 5.3 of this PWS.

3.5.6.3 The following tasks shall be performed on all items repaired regardless of condition. All repairs shall include the review and update of logbooks in accordance with the COMNAVAIRFORINST 4790.2 Series for all life limited components.

3.5.6.4 Reduction Gear Assembly

3.5.6.4.1 Reduction Gear Unit Assembly (RGA): All RGAs inducted shall be inspected and repaired IAW with applicable technical manuals listed in Section 5.0.

3.5.6.5 Power Section Assembly

3.5.6.5.1 All Power Section Assemblies inducted shall be inspected and repaired IAW applicable technical manuals listed in Section 5.0.

3.5.6.6 Torquemeter

3.5.6.6.1 Repair of the Torquemeter shall be IAW applicable technical manuals listed in Section 5.0.

3.5.7 NON-DESTRUCTIVE INSPECTION (NDI) REQUIREMENTS

3.5.7.1 The Contractor shall perform all NDI for any part with a depot maintenance manual NDI requirement by methods outlined in NAVAIR 01-lA-16 and detailed NDI requirements listed in depot maintenance instructions. The Contractor’s NDI program shall be in compliance with requirements outlined in NAVAIR 01-1A-16 and ASTME 1444-5 with regards to quality, process controls and documentation of the NDI process and operator training and certification.

3.6. ADDITIONAL REQUIREMENTS

3.6.1.2 Minor Repair. Upon receipt of a task order from the PCO, the Contractor shall disassemble and inspect the module. Based upon the information provided from the teardown and inspection, the Government may determine the condition of the modules requires a minor repair. Examples of minor repairs include but not limited to:

· Oil leaks

· PQDRs

· Accessory drive housing failure

· Combustion liner replacement

· Limited turbine stator/rotor assembly

· Limited compressor stator/rotor assembly

· Damage during shipping or installation that does not require full disassembly of the module.

In these cases, the module will be identified as a minor repair prior to induction and the Contractor shall provide the material and labor cost to return the unit to RFI condition IAW CDRL A009, Depot Maintenance Cost Report. The Contractor may recommend a minor repair but determination of minor repairs shall be made by the Government. For module repairs that fall under CLINs 0X07 and 0X08, after completion of the repair the Contractor shall document all repair actions IAW CDRL 0001 Production Plan and Status Report and CDRL A004, Teardown and Inspection.

3.6.1.2.3 Power Sections that have been dropped. All items not installed in shipping containers which have been dropped, and all items installed in shipping containers which have been dropped from 18 inches or higher, shall be disassembled for inspection. All main shaft bearings shall be removed and inspected. Damaged bearings shall be discarded. Deformed or visually damaged components shall be removed and replaced. All mounting areas shall have NDI performed. All items in shipping containers dropped from less than 18 inches shall be inspected for visible damage on external components and shipping container mounts. The results of these inspections shall be forwarded via email to the T56 APML/COR and Engineering Lead. Based on damage assessment, the T56 APML/COR or Engineering Lead will provide disposition instructions for the affected parts. All of above tasks shall be accomplished IAW Section 5.3 of this PWS.

3.6.1.2.4 Reduction Gear Assemblies that have been dropped. All items not installed in shipping containers which have been dropped, and all items installed in shipping containers which have been dropped from 18 inches or higher, shall be disassembled for inspection. Propeller shaft bearings, rear carrier bearing, main drive gear bearing, and pinion bearings shall be removed and inspected. Damaged bearings shall be discarded. All items in shipping containers dropped from less than 18 inches shall be inspected for visible damage on external components and shipping container mounts. The results of these inspections shall be forwarded via email to the T56 APML/COR and FST Engineering Lead. Based on the damage assessment, the T56 APML/COR or FST Engineering Lead will provide disposition instructions for the affected modules. All of the above tasks shall be accomplished IAW Section 5.3 of this PWS.

3.6.1.2.5 Torquemeters that have been dropped. All items not installed in shipping containers which have been dropped, and all items installed in shipping containers which have been dropped from 18 inches or higher, shall be disassembled for inspection. Torquemeter mid-bearing shall be removed and inspected. Damaged bearings shall be discarded. All items in shipping containers dropped from less than 18 inches shall be inspected for visible damage on external components and shipping container mounts. The results of these inspections shall be forwarded via email to the T56 APML/COR and Engineering Lead. Based on the damage assessment, the T56 APML/COR or FST Engineering Lead will provide disposition instructions for the affected parts. All of above tasks shall be accomplished IAW Section 5.3 of this PWS.

3.6.2 ENGINEERING AND TECHNICAL SERVICES: The Contractor shall provide engineering and technical support upon PCO approval and issuance of a task order. Each task will be reported IAW CDRL A004, Teardown and Inspection Report. These tasks include, but are not limited to, the following:

3.6.2.1 Coordinate engineering investigations of items that have been designated to be of special interest by the Navy. The T56 FST will coordinate with the Contractor on the induction of Engineering Investigation (EI) exhibits. Disposition instructions and release of the EI exhibit will be provided by FST engineering upon completion of the EI.

3.6.4.1 The Contractor shall internally track and document repair of all items. Documentation shall include, but not be limited to; item nomenclature, part number, serial number, discrepancy noted, corrective action, work accomplished, technical directive incorporated, certification and verification of work performed, and test results. This documentation shall be available to the Government upon request.

3.6.5 REPORTING REQUIREMENTS

3.6.5.1 The Contractor shall ensure that AESRs, ASRs, MSRs, and SRC Cards are updated with the latest item configuration. The Contractor shall also update DECKPLATE via DeckETR Report and update the Technical Directive Status Accounting (TDSA) to reflect accurate information for all items inducted and shipped. These updates shall be IAW COMNAVAIRFORINST 4790.2 Series and NAVAIR 00-25-300. All life limited components listed in the PMIC, Section 5.0 of this PWS, shall require an entry on applicable ASR or SRC Cards IAW COMNAVAIRFORINST 4790.2 Series. The Contractor shall retain a copy of all AESR, MSR, ASR, SRC, and EHR Cards for all modules and material shipped for a period of 2 years from the ship date.

3.6.5.2 A copy of the original and updated (or new) AESR, MSR, ASR, EHR and SRC Cards for each item shipped shall be forwarded to the T56 FST, the COMNAVAIRSYSCOM (AIR-6.8.4.3), CMIS Repository IAW COMNAVAIRFORINST 4790.2 and CDRL A003, Maintenance Record Submission.

4.0 QUALITY

4.1 The Contractor shall establish and maintain a quality and inspection system IAW ISO 9001. The Contractor shall perform all inspection requirements IAW the above standard.

5.0 TECHNICAL DIRECTIVES AND PUBLICATIONS

5.1 TECHNICAL DIRECTIVES

5.1.1 The Contractor shall notify NAVAIR Code 6.8.5 when a kit is required for TD compliance. The Contractor shall requisition TD kits IAW procedures outlined in NAVAIR 00-25-300, Management and Procedures Manual for Naval Air Systems Command Technical Directive System. This manual is available for download from the Naval Aviation Technical and Engineering Services Command’s (NATEC) website www.natec.navy.mil. All kit material, including kit components, shall be inventoried and inspected upon receipt, and stored in a secure facility. The Contractor shall be responsible for tracking all kit material by P/N, serial number, and nomenclature.

5.1.2 The Contractor shall record all TDs incorporated on the AESR, MSR, ASR, EHR, or SRC Cards IAW the “Records Affected” paragraph of the applicable TD and COMNAVAIRFORINST 4790.2.

5.1.3 The Contractor shall report to the Government all technical directive compliances accomplished on units reworked IAW this PWS by submitting a Technical Directive Compliance Report, CDRL A010.

5.1.4 A TD listing shall be maintained in an electronic format at the Contractor’s facility for all repaired items. Data shall be made available to the Government upon request.

5.1.5 Changes and Bulletins

5.2 TECHNICAL PUBLICATIONS AND DOCUMENTS

5.2.1 The following technical…