Attachment_1-_T56_Performance_Work_Statement_.pdf

ENCLOSURE 1

U.S. NAVY T56 SERIES III ENGINE MODULE REPAIR

PERFORMANCE WORK STATEMENT

05 AUGUST 2014

Type of Work: Depot Level Repair

Type of Equipment: T56-A-14, T56-A-16, T56-A-423, and T56-A-425 Series Propulsion System, Power Section

Unit Assembly, Reduction Gear Unit Assembly, Torquemeter/Anti-icing Shroud Unit Assembly, and

Quick Engine Change Kit

CONTENTS

1.0 SCOPE

2.0 GENERAL INFORMATION

2.1 REFERENCES

2.2 DEFINITION OF TERMS

2.3 NAVY ACRONYMS AND ABBREVIATIONS

2.4 SECURITY

3.0 GENERAL REQUIREMENTS

3.1 TECHNICAL DATA

3.2 RECEIPT OF ITEMS AT CONTRACTOR’S FACILITY

3.2.1 RECEIPT, INSPECTION, AND REPRESERVATION (RIR)

3.2.2 MISSING OR DEFICIENT RECORDS

3.3 REPAIR TASKS

3.3.1 INVENTORY STAGING AND PROCESSING

3.3.2 INSPECTION

3.3.3 REPAIR REQUIREMENTS

3.3.4 NON-DESTRUCTIVE INSPECTION (NDI) REQUIREMENTS

3.3.5 ADDITIONAL REQUIREMENTS

3.3.6 SUPPLY POLICY

3.3.8 CONDEMNATION

3.3.9 TESTING

3.3.10 REPAIR RECORDS

3.3.11 REPORTING REQUIREMENTS

4.0 QUALITY

5.0 PACKAGING, HANDLING, SHIPPING, AND TRANSPORTATION

6.0 TECHNICAL PUBLICATIONS AND DIRECTIVES

6.1 TECHNICAL DIRECTIVES

APPENDIX A: T56 SERIES III QECK REPAIR REQUIREMENTS

A.1 SCOPE

A.2 INTERMEDIATE LEVEL REPAIR REQUIREMENTS

A.3 REPORTING REQUIREMENTS

A.4 QECK TURN-IN CONFIGURATION

A.5 C-130 T56-A-16 QEC WIRING HARNESS REQUIREMENTS

1.0 SCOPE

1.1 This Performance Work Statement (PWS) establishes the minimum work requirements to return items listed in this contract to a Ready For Issue (RFI) material condition and transport. Items will be inspected, repaired and calibrated in accordance with this PWS and applicable technical manuals and directives as specified in Section 6.0.

1.2 Processing requirements for the T56 Series III Propulsion System, modules, Quick

Engine Change Kit (QECK), and components provide for the receipt, inspection, disassembly, repair or modification, assembly, testing, and preservation of these items to a serviceable condition. The repair effort shall result in a product that exhibits its inherent reliability characteristics through its subsequent service tour.

2.0 GENERAL INFORMATION

2.1 REFERENCES

ASTM E 1444-05 Standard Practice for Magnetic Particle Inspection

ASTM-E1742 Practice of Radiographic Evaluation

CEB A-72-4049 Commercial Engine Bulletin

COMNAVAIRFORINST 4790.2 The Naval Aviation Maintenance Program (NAMP)

DFARS Defense Federal Acquisition Regulation Supplement

DoD Directive 4160.21 DoD Personal Property Utilization and Disposal Program

DOD 4160.21-M-1 Defense Demilitarization Manual

FAR Federal Acquisition Regulation

MIL-HDBK-965 Parts Control Program (Reference Only)

MIL-STD-130N DoD Standard Practice Identification Marking of U.S. Military Property

NAVAIR Note 4700 Gas Turbine Engine Three Degrees Of Intermediate Maintenance Activity

Assignments

NAVAIRINST 13700.15 Aircraft Engine Management System

NAVAIRINST 5215.12 Naval Air Systems Command Technical Directives System

NAVSUP P-719 US Navy Guide for the Assignment, Application and Use of the Source, Maintenance and Recoverability Codes

2.2 DEFINITION OF TERMS

2.2.1 The purpose of this glossary is to prevent misinterpretation of engine terminology and processing requirements. Generally accepted descriptions of equipment and processing terminology expressed by using acronyms or colloquialisms are unacceptable unless in exact agreement with all parties involved. Terminology used and not defined elsewhere in this document shall be defined by

COMNAVAIRFORINST 4790.2.

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

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.

Beyond Economical Repair (BER): Engines and modules that are uneconomical to repair.

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.

Compressor Rotor Assembly: The assembly of compressor wheel components and parts which include 1 st

-14 th stage wheels, pins, blades, tie bolts, and associated hardware used in the assembly of the Compressor

Rotor.

Consumable Item: An item with a “Z” in the 4 th position of the SM&R code as defined in the NAVSUP

P719.

Customer Service: Non-scheduled work to provide industrial services to Fleet activities for immediate needs both in hardware rework and technical/engineering services. This service includes check, test, repair, and manufacture of components and parts.

Demilitarization: The act of destroying the military offensive or defensive advantages inherent in certain types of equipment or material.

Depreservation: The removal of those protective measures, including containers and barrier paper, installed to preclude material degradation during times of inactivity, storage or shipment.

Disassembly: Teardown of a T56 Series III propulsion system, module, QECK, assembly or component sufficient to permit the type and amount of inspection and work required.

Disposal: The process of redistributing, transferring, donating, selling, abandoning, destroying or other disposition of DoD personal property.

Engine/Propulsion System Module (EPSM): Includes the T56 engine, propulsion system, and modules.

The acronym EPSM will be used interchangeably to describe the engine propulsion system and modules throughout this PWS.

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 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 Readiness Center (FRC): These activities are established by COMNAVAIRFORINST 4790.2. The latest version of NAVAIR Note 4700 defines individual site capabilities.

Fleet Support Team (FST): This activity ensures in-service safety and readiness of assigned systems while reducing the operating and support cost to the Navy.

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.

Induction: The point that the item is depreserved for commencement of repair process. Depreservation associated with RIR shall not constitute induction when that item is represerved IAW paragraph 3.2.1.2.4 of this Performance Work Statement.

In-Service Support Center (ISSC): The field activity that has been assigned the authority and responsibility of maintenance engineering, basic design, and logistics also referred to as Cognizant Field

Activity (CFA), Cognizant Engineering Organization (CEO), and Cognizant Responsible Activity (CRA).

Intermediate Maintenance Manual: Manuals which provide instructions for maintenance performed at

Intermediate Maintenance Activities (IMA). A listing of Intermediate Maintenance Manuals is provided in

Section 6.2.2.5 of this PWS.

Intermediate Maintenance Activities (IMA): These activities are established by

COMNAVAIRFORINST 4790.2. The latest version of NAVAIR Note 4700 defines individual site capabilities.

International Aerospace Quality Standard AS9100: The AS9100 defines additional areas within an aerospace quality management system that must be addressed when implementing an ISO 9000-based quality system.

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

9000 and ISO 14000 are intended to represent the entire ISO family of standards and guidelines for implementation of a Quality and Environmental Management Program. Information about ISO is available at www.iso.org.

Item: Any level of hardware assembly; for example, segment of a systems, sub-systems, equipment, or component part, such as the T56 Series III Propulsion System, Power Section Unit Assembly, Reduction

Gear Unit Assembly, Torquemeter/Anti-icing Shroud Unit Assembly, and Quick Engine Change Kit.

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): Will be comprised of members from the In-Service Support Center

(ISSC), Defense Contract Management (DCMA), and the Contractor.

Maximum Operating Time (MOT): The maximum allowable time a component or accessory is authorized to operate between overhaul intervals. Maximum operating times are established by the FST and listed in the applicable specific Periodic Maintenance Information Card (PMIC) Publication listed in 6.2.2.3 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 III 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 to appear to be airworthy.

Power Section: The Power Section nomenclature is used synonymously with Power Section Unit

Assembly.

Power Section Unit Assembly: The complete assembly of a Power Section as specified in the applicable

IPB listed in Section 6.2.2.4 of the PWS in this contract. The Power Section Unit Assembly shall include, but is not limited to, the Accessory Drive Housing Assembly, fuel control, oil pump, speed sense components, and enrichment valve. The serial number is alphanumeric (e.g., AE123456) and is identified on the data plate attached to the compressor air inlet housing.

Quick Engine Change Assembly (QECA): A Propulsion System comprised of a Quick Engine Change Kit

(QECK) and all modules and accessories, less a propeller System.

Quick Engine Change Kit (QECK): A QECK consists of an aircraft specific engine housing complete with air intakes and ducting, engine accessories but without the Power Section, Reduction Gear Assembly, and Torquemeter. A list of items to be included with the QECK is provided as part of Appendix (A) to this

Performance Work Statement (PWS).

Ready For Issue (RFI): A repairable item which does not require repair of any type, replacement of over-aged parts, or other than 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. RFI also includes packaging and preservation requirements for shipping, handling and storage.

Reduction Gear Assembly: The Reduction Gear Assembly nomenclature is used synonymously with

Reduction Gear Unit Assembly.

Reduction Gear Unit Assembly (RGA): The complete assembly of the reduction gear assembly as specified in the applicable IPB listed in Section 6.2.2.4 of the PWS in this contract. The Reduction Gear

Assembly shall also include, 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 RGA front housing.

Repairable Items: An item 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.

Scheduled Removal Component (SRC) Card: A part of the logbooks that provides for the recording of complete maintenance history, installation, usage, and configuration data. 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 III Engines: T56-A-14, T56-A-16, and T56-A-425.

Serviceable: A part is considered serviceable if it meets the allowed serviceable limits as defined by the technical publications listed in Sections 6.0 and can be returned to service as is.

Service Tour: Operating time from the time that a T56 Series III propulsion system and/or module(s) are issued by Contractor to the time it is removed due to a discrepancy.

T56 Propulsion System: It is comprised of a QECK, Power Section, Reduction Gear Assembly, and a

Torquemeter. Propulsion System Serial Number (PSSN) appears as an alphanumeric label located on the engine QECK (e.g., 0TH1234 or lTH1234).

Technical Directives (TD): A document authorized and issued by Naval Air Systems Command

(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. TDs include, but are not limited to, the following:

Formal Change: A Formal Change TD is the primary

NAVAIRSYSCOM document for implementing a configuration change and contains instructions and information which direct accomplishment and recording of a material change, a repositioning, modification, or alteration in the characteristics of a system. Changes effecting T56 Propulsion Systems are generally titled as Accessory or Power Plant changes.

Interim Change: A change released in message format for purposes of urgency. Interim Changes are generally followed by a Formal Change release.

Bulletin: A Bulletin is a TD which 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 Engine are generally titled as Accessory or

Power Plant Bulletins.

Rapid Action Maintenance Engineering Change (RAMEC):

RAMEC TDs direct accomplishment and recording of minor configuration changes processed and approved under NAVAIRINST 5215.12A.

Torquemeter: The Torquemeter nomenclature is used synonymously with Torquemeter/Anti-icing Shroud

Unit Assembly.

Torquemeter/Anti-icing Shroud Unit Assembly (TM): The complete assembly of a Torquemeter as specified in the applicable IPB listed in Section 6.2.2.4 of the PWS in this contract.

Turn Around Time (TAT): The number of calendar days from the induction of a T56 Series III Propulsion

System or module, by the Contractor to the signature date of the DD250 providing final acceptance of the

RFI asset by the Navy.

2.3 NAVY ACRONYMS AND ABBREVIATIONS

ACC Aircraft Controlling Custodian

ACO Administrative Contracting Officer

ADRL Automatic Distribution Requirements List

AEMS Aircraft Engine Management System

AESR Aeronautical Equipment Service Record

AFB Airframe Bulletins

AFC Airframes Change

AIMD Aircraft Intermediate Maintenance Department

APML Assistant Program Manager Logistics

ASR Assembly Service Record

ATCM Aeronautical Time Cycle Management

AWM Awaiting Maintenance

AWP Awaiting Parts

AYB Accessory Bulletin

AYC Accessory Change

BCM Beyond Capability Maintenance

BER Beyond Economical Repair

CDRL Control Data Requirements List

CEB Commercial Engine Bulletin

CFA Cognizant Field Activity (Now Fleet Support Team)

CFM Contractor Furnished Material

CLIN Contract Line Item Number

COR

CORR TMHP

CORR SFC

Contracting Officer’s Representative

Corrected Torquemeter Horsepower

Corrected Specific Fuel Consumption

DCMA Defense Contracting Management Agency

DECKPLATE Decision Knowledge Programming for Logistics Analysis and Technical

Evaluation

DFARS Defense Federal Acquisition Regulations Supplement

DMI

DOD

Depot Maintenance Instructions

Department of Defense

DRMO Defense Reutilization and Marketing Office

EHR Equipment History Record

EPSM Engine/Propulsion System Module

ETR Engine Transaction Report

FOD Foreign Object Damage

FRC Fleet Readiness Center

FRFI

FST

First-Received-First-Inducted

Fleet Support Team

GFM Government Furnished Material

IAW In Accordance With

ILS Integrated Logistics Support

IM Item Manager

IPB Illustrated Parts Breakdown

IPO Industrial Performance Overview

IRAC Interim Rapid Action Changes

ISO International Organization for Standardization

ISSC In-Service Support Center

IUID Item Unique Identification

JCMIS Joint Configuration Management Information System

IVD Ion Vapor Deposition

LES Local Engineering Specification

MCR Manual Change Request

MOI Missing On Induction

MOR Missing On Receipt

MOT Maximum Operating Time

MRB Material Review Board

MRC Maintenance Requirements Cards

MSR Module Service Record

NATEC Naval Aviation Technical and Engineering Services Command

NAVAIR Naval Air Systems Command

NAVICP Navy Inventory Control Point

NTS Negative Torque System

OEM Original Engine Manufacturer

PCO Procuring Contracting Officer

PMIC Periodic Maintenance Inspection Cards

PPB Power Plant Bulletin

PPC Power Plant Change

PQDR Product Quality Deficiency Report

PSSN Propulsion System Serial Number

PWS Performance Work Statement

QA Quality Assurance

QECA Quick Engine Change Assembly

QECK Quick Engine Change Kit

RCM Reliability Centered Maintenance

REI Request for Engineering Information

RFI Ready for Issue

RGA Reduction Gear Assembly

SFC Specific Fuel Consumption

SHP Shaft Horse Power

SM&R Source, Maintenance & Recoverability

SRC Scheduled Removal Component

SRDA Special Repair/Deviation Authority

TAT Turn Around Time

TD Technical Directives

TDSA Technical Directive Status Accounting

TEI Temporary Engineering Instructions

TM

TMHP

Torquemeter/Anti-icing Shroud Unit Assembly

Torqemeter Horsepower

TMS Type Model Series

TMSDR Technical Manual Source Data Record

TPDR Technical Publications Discrepancy Report

TSN Time Since New

TSO Time Since Overhaul

TSR Time Since Repair

UID Unique Identification

2.4 SECURITY

The Contractor shall implement and maintain security procedures and controls to prevent unauthorized disclosure of For Official Use Only and controlled unclassified information and to control distribution of For Official Use Only and controlled unclassified information in accordance with the

National Industrial Security Program Operating Manual (NISPOM), DoD 5400.7 and SECNAV M

5510.36. All Contractor facilities shall provide an appropriate means of storage for For Official Use Only and controlled unclassified documents and materials. All For Official Use Only and controlled unclassified technical information shall be appropriately marked IAW DoD 5400.7. The following distribution statement applies for technical data:

Distribution Statement D: Distribution authorized to the Department of Defense and U.S. DoD

Contractors only (critical technology) (December 2006). Other request shall be referred to Naval Air

Systems Command Headquarters, PMA-290, 22347 Cedar Point Road., B2185 R3190, Patuxent River, MD

20670-1547.

3.0 GENERAL REQUIREMENTS

The Contractor shall repair T56 Series III Propulsion Systems (Quick Engine Change Assemblies

(QECAs)), Power Sections, Reduction Gear Assemblies, Torquemeters, and Quick Engine Change Kits (QECKs).

The Contractor shall provide facilities, labor, test equipment, material and arrange for outside services, 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, with the exception of tooling required for incorporation of Technical Directives (TDs). The Contractor shall repair and correctly configure each item IAW current depot maintenance manuals, intermediate maintenance manuals, Illustrated Parts Breakdown (IPB), Local Engineering Specifications (LES), Temporary Engineering Instructions

(TEI), Government approved Class I and Class II ECPs, Formal Technical Directives, and Maintenance

Requirements Cards (MRC) as listed in Section 6.0 of this PWS.

3.1 TECHNICAL DATA

3.1.1 The Contractor shall comply with the applicable technical manuals and directives listed in Section 6.0 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 6.0 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 6.0 of this PWS.

3.1.4 The Contractor shall notify the Assistant Program Manager for Logistics (APML/COR), Contracting Officer’s Representative (COR), and Fleet Support Team (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 Request for Engineering Information (REI), Source Maintenance & Recoverability (SMR) Code

Change Request, and Technical Publications Discrepancy Report (TPDR). The Contractor is responsible to comply with the Turn Around Time (TAT) while awaiting response from the FST.

3.1.5 In the event of a conflict between the requirements in this PWS and applicable technical manuals and directives listed in Section 6.0, the PWS shall take precedence.

3.2 RECEIPT OF ITEMS AT CONTRACTOR’S FACILITY

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 by this PWS and applicable technical manuals and directives identified in Section 6.0. 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. The Contractor will be authorized access to the Decision Knowledge

Programming for Logistics Analysis and Technical Evaluation (DECKPLATE) Engine Management database under this contract to comply with the Engine/Propulsion System Module (EPSM) reporting procedures IAW the

NAVAIRINST 13700.15D as changes in custody, status, and/or conditions occur.

3.2.1 RECEIPT, INSPECTION, AND REPRESERVATION (RIR)

3.2.1.1 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. Warehouse storage space shall be of adequate size to store approximately 250 modules while awaiting induction and/or shipment after repair.

3.2.1.2 The Contractor shall perform the following tasks within 7 calendar days of receipt of item and a corresponding task order.

3.2.1.2.1 Report Receipt Of Items: The Contractor will 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 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 and/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 Administrative

Contracting Officer (ACO).

3.2.1.2.2 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. 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 comply with COMNAVAIRFORINST 4790.2 and Section 3.2.2 of this PWS.

3.2.1.2.3 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

Receipt report (MOR) 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.

3.2.1.2.3.1 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 represervation task.

Container damage shall be considered minor if the estimated cost to repair the container is less than $500.00.

Engine/Module shipping container repairs shall be made IAW Section 6 of this Performance Work Statement.

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

3.2.1.2.4 Represerve Items: All items not inducted within 7 calendar days of the receipt inspection shall be preserved IAW NAVAIR 15-01-500. Represervation shall occur within the 7 calendar day period. 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-5DH-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.

3.2.2 MISSING OR DEFICIENT RECORDS

3.2.2.1 Items shall not be inducted with missing, incomplete, or illegible records without written authorization from the T56 Series III APML/COR. Every effort shall be made by the Contractor to restore records

IAW COMNAVAIRFORINST 4790.2 to avoid unnecessary and costly repair. The previous custodian and designated T56 Series III FST representative shall be notified within 7 calendar days after receipt of any missing, deficient or erroneous records. The procedures for locating or restoring records consist of the following:

3.2.2.1.1 Attempt to locate records by contacting the previous custodian, T56 Series III

FST, and supply activities. When required, the Contractor shall contact COMNAVAIRSYSCOM (AIR-

6.8.4.3), JCMIS/ATCM Central Repository for a duplicate copy of lost records IAW COMNAVAIRFORINST

4790.2. The Contractor shall include in the correspondence the item part number, stock number, nomenclature, and serial number.

3.2.2.1.2 Contractor shall search in-house documents and reports to reconstruct missing or illegible records.

3.2.2.1.3 After all efforts to restore records have been exhausted, the Contractor shall contact the T56 Series III FST for assistance in creating a new record or for disposition instructions. New records shall be developed by the Contractor with the historical information provided by the T56 Series III FST.

3.3 REPAIR TASKS

Repair of an item shall include, but not be limited to, the tasks listed in this section.

3.3.1 INVENTORY STAGING AND PROCESSING

3.3.1.1 The Contractor shall repair all items received under this contract in a First-

Received-First-Inducted (FRFI) process to support continuous inventory movement. If MOR items or missing or deficient records prevent the induction of a unit within the fiscal quarter in which the task order is issued to the

Contractor, requests for deviations from the FRFI process shall be forwarded to the 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 MOR as Government Furnished Material (GFM) or authorized to purchase them

(see Para 3.3.1.2).

3.3.1.2 The Contractor shall be responsible for the replacement of all MOR / MOI material up to, but not to exceed $2,500.00 per module. 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 MOR part. In these cases, the Contractor shall submit a written request to the ACO and T56

Series III 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 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 MOR material prior to the authorization of funds via an executed contractual document.

3.3.1.3 The Contractor shall submit a Production Plan and Status Report, IAW CDRL

A001. This plan shall provide for the induction of all items within the fiscal quarter that the task order is awarded.

Any deviation or delay preventing the induction of an item within the quarter the task order is received, shall require approval from the ACO, with the concurrence of the T56 Series III APML/COR.

3.3.1.4 Turnaround Time (TAT) for the Power Section, RGA, and the Torquemeter shall be in accordance with Section F of this contract, and negotiated on a case by case basis for the Propulsion

System.

3.3.2 INSPECTION

3.3.2.1 Upon induction, the Contractor shall disassemble, clean, and inspect all items.

Inspection shall be accomplished IAW applicable depot maintenance manuals in Section 6.2 and Appendix B of this

PWS. The Contractor shall submit an inspection report IAW CDRL A003, Teardown and Inspection Report.

3.3.2.2 The Contractor shall inspect all exposed parts for obvious defects and surface damage and shall submit a Request for Engineering Instruction (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.

3.3.2.3 Missing On Induction (MOI): The Contractor shall inventory each item for completeness IAW the applicable technical manuals listed in Section 6.0. If an item is inducted with missing parts, the Contractor shall submit a Missing on Induction IAW CDRL A002. The Contractor shall be responsible for the replacement of all MOI material up to, but not to exceed $2,500.00 per module. Items that exceed the cumulative value of $2,500.00 will be provided by the Government. The Contractor will be provided parts as Government

Furnished Material (GFM) or authorized to purchase them (see paragraph 3.3.2.4). The Contractor shall repair or replace out of limit parts or components regardless of the cause of the out of limit condition.

3.3.2.4 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 ACO and NAVAIR

6.0 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 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.

3.3.2.5 T56 Series III Propulsion System unique requirements: In addition to the inspection, requirements above, the Contractor shall submit CDRL A004, Condition Report.

3.3.2.6 Beyond Economical Repair (BER): No items provided to the Contractor for processing/repair shall be considered BER.

3.3.3 REPAIR REQUIREMENTS

3.3.3.1 Each item received for induction shall be repaired and reassembled IAW this

PWS. The Contractor shall screen the Aeronautical Equipment Service Record (AESR), Module Service Record

(MSR), Assembly Service Record (ASR) and Scheduled Removal Components (SRCs) 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. All Technical Directives requirements shall be complied with IAW the applicable TD, NAVAIR 00-25-300 and Section 6.0 of this PWS.

3.3.3.1.1. Implementation of the UID clauses will be at the engine, QECK, and Power Section, Reduction Gear Assembly, and Torquemeter module level. Marking shall be based on the criteria provided in the Department of Defense Standard Practice Identification Marking of U.S. Military Property, MIL-STD-130N. The IUID Machine Readable Information (MRI) marking shall be two (2) Data Matrix ECC 200 symbols using UII Construct #1. For the engine and module the first 2D Matrix symbol shall contain the Rolls

Royce, Inc. CAGE Code (63005) and the engine or module serial number. For the QECK the first 2D matrix shall contain the Lockheed Martin CAGE Code (98897) or Northrop Grumman CAGE Code (26512) and QECK serial number as applicable. The second symbol shall contain the current part number. (Note: In instances where the part number changes with new configurations, the new part number shall be included within the MRI. The original part number is never removed).

3.3.3.1.2 Location of the 2D Matrix symbols shall be as follows: Power

Section, Reduction Gear Assembly and QECK: On the data plate in each of the upper corners; Torquemeter: on

Housing below Torquemeter external pick-up block mounting boss. The Engine 2D Matrix symbols shall be placed on the Propulsion System Serial Number data plate located on the QECK.

3.3.3.2 The following tasks shall be performed on all items repaired regardless of condition.

3.3.3.2.1 Reduction Gear Unit Assembly (RGA): All RGAs inducted for repair shall be fully disassembled to facilitate inspection, IAW applicable depot maintenance manuals, and thorough cleaning of all internal components and passages. The front and rear cases and the main and inner diaphragms shall be thoroughly inspected for cracks. The front case, main diaphragm, inner diaphragm and rear case shall be line bore inspected and repaired. RGA case sets shall be serial number matched upon completion of line boring checks and bearing cage repairs. The case set serial number shall be the rear case serial number. The anti-corrosion treatment and paint shall be restored on all RGA cases. All bearings, including the planetary bearings, shall be removed, cleaned and thoroughly inspected. RGA Propeller Shaft Roller Bearings P/N 23064143, 23055955, or

23066782, regardless of condition, shall be replaced with other approved configurations as listed in the applicable

IPB. All gears and shafts shall be dimensionally inspected to ensure compliance with the applicable technical manuals. All RGA propeller brake assemblies, pressure and scavenge pumps shall be disassembled, inspected, repaired, and bench tested. T56-A-16 and T56-A-425 main scavenge pump gear P/N 6738426 shall be replaced with

P/N 6876478. Accessories suspected of contamination or damage, external or internal, or those that have failed during testing procedures, shall be disassembled, cleaned, and repaired or replaced as necessary. T56-A-425GA

(Incorporating PPC-125) RGA must have a minimum of 600 hours (minimum build window) remaining service life on the propeller shaft, (P/N 23085228, Life Limit 3050 HRS). All the above tasks shall be accomplished IAW

Section 6.2 and Appendix B of this PWS.

3.3.3.2.1.1 Module Conversion: In addition to repair requirements, the Contractor shall convert T56-A-423 RGA’s to the T56-A-16 configuration IAW the following:

Remove T56A-423 data plate

Remove generator drive gear (P/N 6829383) and associated parts

(Reference NAVAIR 02B-5DE-4, F0061-00, Usable On Code B) and install gasket and pad cover.

Install a new data plate and electro etch T56-A-16 (P/N 23073933 for

PPC-123 incorporated.)

Change MSR from T56-A-423 (P/N 6876304) to T56-A-16 (P/N

23073933 for PPC-123)

Annotate MSR Card to reflect module conversion

3.3.3.2.1.2 RGA Case Set Repair: All RGA Case Sets shall be line bore inspected and repaired. RGA case sets shall be serial number matched upon completion of line boring checks and bearing cage repairs. The case set serial number shall be the rear case serial number. The anti-corrosion treatment and paint shall be restored on all RGA cases.

3.3.3.2.2 Power Section Unit Assembly: All inducted Power Sections, including the Accessory Drive Housing Assembly, shall be fully disassembled to facilitate inspection IAW applicable depot maintenance manuals. All Compressor rotors shall be disassembled and non-destructively inspected (NDI). All compressor vanes and previously coated wheels deemed serviceable upon inspection shall be recoated with an Ion Vapor Deposition (IVD) coating. All compressor wheels and vanes received with Nickel-

Cadmium (Ni-Cad) plating shall be stripped of Ni-Cad plating prior to IVD coating. The MSR shall be annotated that this power section has a “CAD Free” Gas Path. All compressor cases shall be recoated and pilot diameters shall be inspected and repaired. Fuel nozzles are assigned a maximum operating time (MOT) limit and shall be replaced if within 600 hrs of the MOT limit listed in the applicable engine Periodic Maintenance Inspection Cards (PMIC) listed in paragraph 6.2.1.3. Fuel nozzle disassembly or repair is not authorized, however all fuel nozzles shall be inspected, cleaned and flow checked prior to re-installation. If any fuel nozzle(s) fail inspection or flow requirements, nozzle(s) shall be replaced with new nozzle(s) and shall be penalized to reflect the operating time accumulated on the remaining nozzles. Compressor rear bearing P/N 6846717, 6871643, and 23058592 shall be removed and replaced by bearing P/N 23057662 or 597384.MIL. All non-Inconel 718 Turbine Vane Cases shall be replaced with the Inconel 718 Turbine Vane Case, P/N 23009372, or later configuration. All 1 st Stage Turbine Vanes shall be of the “Pin Fin” design (ECP 2142), P/N 23031780, 23031781, 23031782, and 23031783, or later configuration as applicable. All non-rub tolerant 2 nd and 3 rd

Stage Turbine Vanes shall be replaced with Rub-tolerant Vanes, part number 23009988 and 23009375, or later configuration. First and second stage turbine blades may have the AEP coating replaced a maximum of two times over the blade’s life. Accessories suspected of contamination or damage, external or internal, or those that have failed during testing procedures, shall be disassembled, cleaned, and repaired or replaced as necessary. All external accessory preformed packings shall be replaced. All power section main pressure and scavenge pumps, rear turbine and external scavenge pumps shall be completely disassembled, inspected, and repaired per NAVAIR 02B-5DH-6-2, as well as bench tested. Turbine rotors shall be fully disassembled, including removal of blades, to allow for NDI. Turbine rotors must have a minimum of 3500 hrs (minimum build window) remaining service life in accordance with life limits listed in

NAVAIR 02B-5DH-6-2. All thermocouples shall be replaced with new thermocouples. All the above tasks shall be accomplished IAW Section 6.2 of this PWS. Compressor diffuser assembly P/N 6876496 and 6894133 shall be cleaned, stripped, inspected, and repaired. T56-A-425 diffuser assemblies shall incorporate enhanced weld repair

IAW Rolls Royce Engineering Department Report (EDR) 20391 dated 30 March 2004 and shall be re-identified by adding an “A” suffix to the part number using vibropeen method.

3.3.3.2.3 Torquemeter: Each Torquemeter shall be repaired IAW Section

6.2 of this PWS.

3.3.3.2.4 QECK: Each QECK shall be repaired IAW with Appendix (A) of this PWS.

3.3.4 NON-DESTRUCTIVE INSPECTION (NDI) REQUIREMENTS

3.3.4.1 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.

3.3.4.2 NDI documentation shall include but not be limited to:

Training and the demonstrated practical skills of inspectors;

Inspection environment (e.g. temperature, specific type and levels of light, safety and human engineering);

Material control and verification of proper condition;

Equipment control and verification of proper operation;

Written inspection instructions;

Adherence to written inspection instructions.

3.3.5 ADDITIONAL REQUIREMENTS

3.3.5.1 SPECIAL PROCESSING: Items subjected to the following conditions shall require special processing in addition to Section 3.3.3. For the following special processing requirements, the

Contractor may employ any method or tooling necessary, provided that method or tooling shall not further damage serviceable or repairable items.

3.3.5.1.1 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 to the T56 Series III APML/COR and Engineering Lead. Based on damage assessment, the T56 Series III APML/COR or Engineerin Lead will provide disposition instructions for the affected parts. All of above tasks shall be accomplished IAW Section 6.2 of this PWS.

3.3.5.1.2 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 to the T56 Series III APML/COR and Engineering Lead. Based on damage assessment, the T56 Series III

APML/COR or Engineering Lead will provide disposition instructions for the affected parts. All of above tasks shall be accomplished IAW Section 6.2 of this PWS.

3.3.5.1.3 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 to the T56 Series III APML/COR and Engineering Lead. Based on damage assessment, the T56 Series III APML/COR or Engineering Lead will provide disposition instructions for the affected parts. All of above tasks shall be accomplished IAW Section 6.2 of this PWS.

3.3.5.1.4 Over-Speed Power Sections. All compressor and turbine rotors installed on Power Sections that experienced an over-speed condition greater than 120% shall be condemned and disposed of IAW Section 3.3.8 of this PWS.

3.3.5.2 ENGINE DEPOT FIELD TEAMS: The Contractor shall provide T56 Series

III Engine Field Team support upon ACO approval and issuance of a task order. These teams shall provide on-site depot level support for field activities. Ordered Field Team tasks shall be reported in a cumulative monthly status report IAW CDRL A005, Field Team Status Report.

3.3.5.3 ENGINEERING AND TECHNICAL SERVICES: The Contractor shall provide engineering and technical support upon ACO approval and issuance of a task order. Each task will be negotiated separately by the ACO and will be reported IAW CDRL A005, Engineering and Technical Services

Report. These tasks include, but are not limited to, the following:

a. Coordinate engineering investigations of items that have been designated to be of special interest by the Navy. The T56 Series III FST will coordinate with the Contractor on the induction of engineering investigation (EI) exhibits. This work will include only Contractor efforts expended supporting the engineering investigation that are over and above what is normally required.

Specific disassembly, inspection and data recording instructions will be provided on a case by case basis. Disposition instructions and release of the EI exhibit will be provided by FST engineering upon completion of the EI;

b. Develop solutions to emergent problems relating to the depot level repair of T56 Series III engines;

c. Follow-up monitoring of system performance;

d. Investigate and correct in-service deficiencies;

e. Investigate and process defective items reported by operating activities. (Items determined defective due to workmanship by the Contractor shall not be reimbursed).

3.3.5.4 T56 SERIES III OVER AND ABOVE WORK: The Contractor shall perform additional required work as approved by the ACO and IAW DFARS 252.217-7028 and Section H of this contract for efforts deemed warranted as over and above the normal repair requirements for those units already inducted under the applicable CLINs of this contract. Approved over and above work shall be reported IAW CDRL A006, Over And Above Status Report.

3.3.5.5 CUSTOMER SERVICE SPECIAL REPAIR: All components, and parts inducted for customer service special repair shall be inspected, repaired and assembled to RFI condition by the

Contractor. The Contractor shall review all accompanying documentation detailing the unit’s reason for customer service special repair, disassemble to the minimum extent possible, clean, inspect and evaluate the unit. The

Contractor shall detail the teardown results, total labor hours and labor dollars required for the disassembly, cleaning inspection and evaluation. The Contractor shall submit CDRL A004, Condition Report. 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 is not required to incorporate all active TDs as a part of the repair process. All Technical Directives requirements that are incorporated shall be complied with IAW the applicable TD, NAVAIR 00-25-300 and Section 6.0 of this PWS. The unit will be repaired and reassembled IAW the technical manuals as specified in Section 6.2.2.5 of this PWS. Customer service special repair shall not be used for depot level module repairs.

3.3.5.6 T56 SERIES III PROPULSION SYSTEM INTERMEDIATE LEVEL

REPAIR: The Contractor shall teardown, inspect, and repair the T56 Series III Propulsion System, to include

QECK, to an RFI status. The propulsion system, including QECK, shall be repaired and reassembled IAW the technical manuals as specified in section 6.2.1.5 and A.5 of this PWS. The Contractor shall submit CDRL A004, Condition Report. The Contractor shall screen the AESR, MSR, ASR, SRC, and EHR 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 TD as a part of the repair process All Technical Directives requirements shall be complied with IAW the applicable TD, NAVAIR 00-25-300 and Section 6.0 of this PWS.

Accessories suspected of contamination or damage, external or internal, or those that have failed during testing procedures, shall…