SOW_PW_Engines_Overhaul_and_Repair.pdf

SAQMMA15R0653

Atch 1: Statement of Work (SOW)

Sep 22, 2015

STATEMENT OF WORK

REPAIR/OVERHAUL/MODIFICATION

OF

PRATT & WHITNEY CANADA TURBINE AIRCRAFT ENGINES

1. BACKGROUND

1.1. The United States Department of State (DoS), Bureau for International Narcotics and Law

Enforcement Affairs, Office of Aviation (INL/A) provides aviation support for the eradication and interdiction of illicit drugs, training of contractor and host nation personnel, embassy transport support, movement of personnel and equipment, reconnaissance, personnel recovery (PR), medical evacuation, security of personnel and equipment, and ferrying of aircraft. To support the aforementioned missions, INL/A maintains a fleet of fixed and rotary wing aircraft (various types) utilizing one-hundred and three (103) Pratt &

Whitney Canada (PWC) turbine engines (various models).

2. SCOPE

2.1. INL/A requires, on an as needed basis, for a period of 5 years, an Original Equipment

Manufacture (OEM) approved source to provide limited life cycle support of (overhaul, repair, and/or modify) DoS provided PWC turbine engines listed in, but not limited to table

1 below. The OEM approved source must have the capability to overhaul, repair, and/or modify PWC engines to the most current OEM specifications to include, but not be limited to the following:

all applicable OEM production, repair and overhaul specifications all OEM Service Bulletins (SBs) all Federal Aviation Administration (FAA) and Transport Canada Airworthiness

Directives (ADs)

TABLE 1

Model

Current

Inventory

Projected

O/H and

Repairs

5 years

PT6A-67D 12 8

PT6A-67AG 16 1

PT6A-67F 9 5

PT6A-114A 8 4

PT6A-67R 3 2

PW123E 18 7

PT6T-3B 24 11

PT6A-27 3 1

3. TASKS/REQUIREMENTS

3.1. Certification

3.1.1. The Contractor facility shall be a PWC approved facility specializing in the inspection, testing, troubleshooting, cleaning, overhauling, repairing, and preservation of PWC turbine engine power units, modules, and components.

3.2. Capabilities

3.2.1. The Contractor shall be responsible for all necessary resources required to perform the services required to comply with all OEM and regulatory certification requirements. This includes, but is not limited to, technically qualified, trained, and certified personnel, quality systems, required tooling, manuals, test equipment, parts, material, engineering services, management, maintenance, documentation, preservation, and shipping of the PWC engine power units, modules, and components. All special tooling, test equipment, and engine test cells shall be approved by and correlated to PWC performance standards.

3.2.2. Utilizing the support items from the previous section (3.2.1 of this SOW), the

Contractor shall maintain the expertise necessary to satisfactorily inspect, test, troubleshoot, clean, overhaul, repair, modify, and preserve PWC engine power units, modules, and components IAW OEM specifications, to include the most current revisions of PWC applicable Technical Data and Drawings, Maintenance, Repair and

Overhaul (MRO) manuals, Service Bulletins (SB), Alert Service Bulletins (ASB), Service Instruction Letters (SIL), and or other PWC Airworthiness Directives (AD) as well as all FAA and Transport Canada directives.

3.3. Warranty

3.3.1. The Contractor shall establish and provide a warranty plan (CDRL A001) to ensure that all replacement parts and workmanship are covered by warranty. The warranty plan shall provide a warranty repair process to include, but not limited to, procedures for notification, processing, validation, length of warranty from time of service, shipping instructions and a point of contact (POC) between the Contractor and

INL/A.

3.3.2. All overhauled and repaired engines shall carry a minimum of two year/1000 hour, whichever comes first, warranty on new parts and workmanship from the

Contractor’s repair facility.

3.3.3. All warranty discrepancies shall be validated, corrected, return shipped and accepted by INL/A in a time frame not to exceed 180 calendar days from initial notification.

3.3.3.1. The Contractor shall expedite the repair or replacement of validated and warranted defective components at the Contractor’s expense.

3.3.3.2. Non-validated warranty repairs shall be quoted and expensed to INL/A utilizing the procedures established in section 3.8 of this SOW.

3.4. Documentation

3.4.1. The Contractor shall provide the following documentation for each PWC contracted repair/overhaul event:

3.4.1.1. Vendor specific repair/overhaul documentation to include but not limited to

Teardown Inspection Report (TIR), photos, engine log, engine history record, engine operating record, engine maintenance record, maintenance release record, and engine test cell run data and findings record. (CDRL A002)

3.4.1.2. FAA airworthiness Form 8130-3 or other FAA authorized airworthiness forms.

3.5. Test Cell Certification

3.5.1. The Contractor shall only utilize an OEM correlated and certified engine run and test cell for all DoS engines to determine acceptable engine performance.

3.6. Shipping

3.6.1. All PWC engines requiring repair and/or overhaul will be shipped from/to the INL

Logistics Center in Melbourne, Florida. Upon notification from the CO, or his designated INL/A representative that a DoS owned PWC model engine asset requires repair, overhaul, or conversion, the Contractor shall coordinate shipping schedules and verify assets are ready for shipment. Within 7 days after consensus between the two organizations has been reached, the Contractor shall take all the necessary actions required to take possession and ship the PWC engines from the INL Logistics

Center at Melbourne, Florida to the Contractor’s repair facility. The Contractor shall utilize only transportation carriers that are certified, both drivers and equipment, to transport aviation jet engines. The Contractor shall be responsible for any

International Traffic in Arms Regulation (ITARs) and all required customs clearances and documentation.

3.6.2. The Contractor shall notify, in writing, the CO confirming receipt of all assemblies and components. Notification of item receipts shall include, but are not limited to, the following information: Nomenclature, Part Numbers (P/N), Serial Numbers

(S/N), Contract Number, Contract Line Item Numbers (CLIN), and dates of receipt.

Notifications of item receipts via facsimile/email are acceptable and may contain single or multiple notification entries. (CDRL A003)

3.7. Inventory Upon Arrival

3.7.1. Upon arrival at the Contractor facilities, an incoming inventory shall be performed on all PWC engine power units, modules, components and shipping containers. If inventory irregularities are identified upon receipt of PWC engines or components, the Contractor shall notify the CO, or authorized point of contact, within 7 calendar days of receipt of shipment. The CO will provide guidance for inventory shortages within 7 calendar days of receipt of notification by the Contractor. If no guidance is received from the CO after 7 calendar days, the Contractor shall quote the costs associated for replacement and/or repair of missing inventory within the quote for repair/overhaul of the PWC engine assembly (section 3.8 of this statement of work

(SOW)) under a sub-heading labeled “Shortage upon Arrival”. Notifications of missing inventory discrepancies via facsimile/email are acceptable and may contain single or multiple notification entries. (CDRL A004).

3.7.1.1. Missing Components: Within 7 calendar days after the receipt and inspection of the components, the Contractor shall notify the CO in writing of any missing parts or sub-assemblies required for final inspection and acceptance.

(CDRL A004)

3.7.1.2. Counterfeit or Suspect Components: Upon receiving components exhibiting evidence of being counterfeit, the Contractor shall notify the CO, in writing

(CDRL A004) and in detail, within 7 calendar days and discontinue all actions until receipt of written authorization to proceed from the CO. The

CO reserves the right to appoint a technical representative who shall witness the remaining teardown and inspection of the component.

3.7.1.3. INL/A reserves the right to provide OEM approved, documented, and traceable Government Furnished Property (GFP) to replace parts or hardware identified as missing or determined to be unserviceable.

3.8. Incoming Inspections

3.8.1. Incoming inspections shall be performed on all PWC engine power units, modules, and components. Once assets are received at the Contractor’s facility, the Contractor has 30 calendar days to inspect and evaluate the PWC engine for all necessary repairs. The PWC engine inspection and evaluation report shall reflect all costs associated to repair or overhaul engine power units, modules, and components to current OEM and FAA specification standards. All applicable Service Bulletins

(Category 1 through 6) for the specific engine model will be incorporated during repair or overhaul. Once the inspection has been accomplished, the Contractor shall submit to the CO a teardown, inspection and analysis report (CDRL A002) for the affected engine along with a written quotation (CDRL A005) for all actions necessary (repair, overhaul, or modification) and projected time to bring the affected

PWC engine up to current OEM standards. Notifications via email are acceptable and may contain single or multiple notification entries. No further expenses shall be incurred against the affected engines without direction from the CO. The CO will review the quotation for repairs and will direct the Contractor to execute one of the following actions:

3.8.1.1. Quotation is acceptable: Contractor shall execute all actions as stated in the quotation.

3.8.1.2. Partial Approval: Contractor shall execute only quoted items specified by the

CO.

3.8.1.3. Beyond Economical Repair (BER): When the cost of returning the component to serviceable condition exceeds the current replacement cost of that component or when the component cannot be worked due to damage or wear beyond the material properties, characteristic, or specifications of the item being repaired, the Contractor upon direction from the CO shall take the necessary actions to demilitarize and dispose of the equipment per the DoS

Property Administrator approved property disposal plan addressed in section

3.9 of this SOW.

3.9. Property Disposal Plan

3.9.1. The Contractor shall develop a USG property disposal plan based on Federal

Acquisition Regulations (FAR) Part 45 and approved by the DoS Government

Property Administrator. (CDRL A006)

3.10. Turn-around Time

3.10.1. Once authorization to proceed has been given to execute the actions specified by the

CO in section 3.8 (item #3.8.1.1 and item #3.8.1.2 only) of this SOW, the Contractor, upon given the notice to proceed, shall have a maximum of 180 calendar days from the time of notification to accomplish the tasks necessary to repair, overhaul, modify, and deliver the affected engine and or components to the INL Logistics Center in

Melbourne, Florida. Unless otherwise specified by the CO, early completion of repair/overhaul/modification of USG assets is authorized and encouraged. The time to accomplish item #3.8.1.3 of this SOW shall be IAW the approved Contractor developed USG approved property disposal plan from section 3.9 of this SOW.

3.11. Environmental Requirements.

3.11.1. All engine parts must be thoroughly cleaned IAW applicable OEM repair/overhaul manuals. In lieu of specific Pratt & Whitney cleaning procedures, the repair facility must utilize FAA Advisory Circular 43-205, Guidance for Selecting Chemical

Agents and Processes for Depainting and General Cleaning of Aircraft and Aviation

Products, to ensure they are as free as practicable of all hazardous dust to include hexavalent chromium, cadmium, lead, etc., prior to being returned to DoS. DoS may take random samples of parts to ensure they are free as practicable of all hazards. Information on these hazards can be found in Occupational Safety and

Health Standards 1910.1025 (lead), 1910.1026 (Hexavalent Chromium) and

1910.1027 (Cadmium).

3.12. Replacement Parts Used During Overhaul or Repair

3.12.1. All replacement parts utilized in the overhaul or repair of DoS PWC engines shall be traceable new OEM parts or parts and materials that are OEM authorized, traceable, and overhauled IAW P&WC specifications. FAA certified Parts Manufacturer

Approval (PMA) replacement parts are not acceptable for use on INL/A PWC engines.

3.12.2. Component parts determined to be in serviceable condition IAW OEM specifications and functional testing can be reused.

3.12.3. All life limited parts that are reused shall have sufficient time and/or cycles remaining to reach the next scheduled heavy maintenance action or next scheduled hot end inspection.

3.13. Maintenance and Repair

3.13.1. All internal and external engine components and accessories shall be repaired or overhauled by an approved PWC facility using PWC approved technical data.

3.13.2. All Fuel Regulators and Governors shall be overhauled in accordance with PWC data by a PWC approved facility.

3.14. Work In Progress Discrepancies or Safety of Flight (SOF) identified discrepancies

3.14.1. If in-work or in-progress discrepancies are identified after the initial TIR (CDRL

A002)/quotation process (CDRL A005), the Contractor is authorized to repair and invoice without notifying the CO as long as the cost of the additional work is below ten percent (10%) of the originally agreed upon cost to repair.

3.14.2. In conjunction with section 3.14.1 of this SOW, if unforeseen SOF items are directed from the OEM, FAA, Transport Canada, or the CO, the Contractor is authorized to repair and invoice without notifying the CO as long as the cost of the additional work (cumulative cost of both 3.14.1 and 3.14.2 of this SOW) is below ten percent (10%) of the originally agreed upon cost of repair.

3.14.3. Under no circumstances is the Contractor authorized to exceed, without CO authorization, the previously agreed upon cost to repair (CDRL A005) if projected unforeseen work-in progress and SOF expenditures either reach or exceed ten percent. If unforeseen (both work-in progress and SOF) costs are projected to either reach or exceed ten percent (10%), the Contractor shall stop work immediately on the affected DoS PWC engine and submit a request in writing (CDRL A007) to the

CO justifying the additional expenses and requesting authorization to exceed the originally quoted cost of repair.

3.15. Test Cell/Engine Runs

3.15.1. Test cell engine runs shall be performed for all post manufacture, maintenance, repair, overhaul, or modification events. Additionally, the Contractor shall confirm all test cell engine run and performance documentation is included with the documentation package returned to INL/A (IAW with this SOW, section 3.4.1).

Furthermore, the Contractor shall perform and document that all post engine run

Foreign Object Damage (FOD) inspections, leak checks, filter changes, cleaning, oil analysis, and preservation have been accomplished IAW OEM specifications prior to shipment.

3.16. Return Shipping

3.16.1. The Contractor shall not ship any DoS assets utilizing unserviceable shipping materials. Engines shall be preserved, packaged and marked (IAW section 9 of this

SOW), and secured IAW OEM instructions prior to shipment. Prior to shipment, the

USG reserves the right to inspect the engine, shipping container, and all technical documentation and paperwork.

3.16.2. The Contractor shall return ship (FOB destination) PWC engines to the INL

Logistics Center in Melbourne, Florida, utilizing procedures from section 3.6 and section 4.0 of this SOW.

3.16.3.

3.17. Technical Field Service Support

3.17.1. On an as needed basis, DoS may require technical assistance personnel to travel to/from locations away from the Contractor’s facility. Examples include but are not limited to minor repairs, warranty repairs, performance evaluations, accident investigations, training, etc. When requested by the CO, the Contractor shall send personnel to the required location to support DoS requirements. DoS expects no more than 200 man-hours/year will be required for technical assistance away from the Contractor’s facility.

3.18. Status Reporting

3.18.1. The Contractor shall submit a formal status report for each engine in the repair cycle.

The report shall be submitted to the CO, or designated representative, on the first and third Monday of each month. (CDRL A008)

4. DELIVERY

4.1. All completed PWC engine power units, modules, and components shall be delivered (FOB

Destination) to the following address :

US Department of State, Logistics Division

2765 Business Center Blvd

Melbourne, FL 32940

4.2. Engines shall be delivered to the address in section 4.1 of this SOW no later than 187 calendar days after initial receipt at the Contractor’s repair facility unless a different date has been negotiated with the CO. Early delivery is authorized.

5. GOVERNMENT FURNISHED PROPERTY

5.1. Pratt and Whitney PWC Aircraft Engine (various models) listed in Table 1

6. PLACE OF PERFORMANCE

6.1. PWC engine maintenance, repair, overhaul, or modification shall be accomplished only at a

Pratt & Whitney Canada approved facility described in section 3.1 of this SOW.

7. PERIOD OF PERFORMANCE

7.1. The Contractor shall provide the services required in this SOW for a period of 5 years from contract award.

8. APPLICABLE DOCUMENTS

8.1. All Pratt & Whitney technical drawings, shop, inspection, repair and overhaul, or other

OEM Component Maintenance Manuals (CMMs) and revisions as applicable to PWC engine power units, modules and components.

8.2. All Pratt & Whitney or other OEM SBs, ASBs, SILs, ADs, amendments, modifications, and specifications as applicable to the PWC engine power units, modules and components.

8.3. All FAA and Transport Canada ADs as applicable to the PWC engine.

8.4. All Pratt & Whitney, or other OEM applicable documentation or specifications revealed, published, or updated during the course of the contract period, shall be considered as being within the scope of this SOW and may be added to the contract as agreed upon by both parties. If the Contractor receives information more current than that previously provided to DoS, the Contractor must identify the Pratt & Whitney or other OEM Manuals, CMMs, revisions, and specifications, including service bulletins, amendments, and modifications, and provide a brief synopsis of the revisions and dates.

9. MARKING, PACKAGING, AND PRESERVATION

9.1. All DoS PWC engines shall be preserved IAW OEM specifications prior to return shipment to INL.

9.2. Packaging shall be in accordance with ASTM D3951-10 and OEM best commercial practices. Packaging shall provide protection from normal climatic / weather conditions and incidental mishandling during shipping.

9.3. All PWC engines shall be shipped to the following address:

US Department of State, INL/A

Logistics Division

2765 Business Center Blvd

Melbourne, FL 32940

Tel. 321-783-9865

9.4. Marking shall include the following information:

Location: Longitudinally on either side of packaging in 1 inch block letters stencil the following:

1. Nomenclature: Engine Model

2. Mfr. Part Number: As Applicable

3. Engine Serial Number: As Applicable

4. Manufacturer: Pratt & Whitney Canada

5. Contract #: TBD

Location: Longitudinally across both sides of the packaging in 2 inch block letters stencil the following:

Property of the Department of State

Office of Aviation

10. INSPECTION AND ACCEPTANCE

10.1. Inspection and acceptance of material under this contract, to ensure that equipment is in accordance with manufacturer's specifications, shall be performed at destination by a designated INL/A Quality Assurance (QA) specialist.

10.2. A FAA Form 8130-3 or other FAA authorized airworthiness form shall be required for all items provided on this contract. The certificate must be signed by an authorized official of the approved source and must specify the nomenclature, manufacturer's part number and date of manufacture.

(End of SOW)

List of CDRLs:

A001 Warranty Plan

A002 Teardown Inspection Report (TIR)

A003 Confirmation of receipt after shipping

A004 Notification of Missing Inventory

A005 Quotation for Repair/Overhaul Services

A006 Property Disposal Plan

A007 Justification for additional over-and above costs

A008 Status Reporting (Info for CDRL)

Type Engine: Self Explanatory (SE)

Engine Serial Number: SE

Status – State at what major step in the repair cycle the item is currently at.

For instance, In Transit (repair station or Melbourne Fl), Inventory, TIR, Repairs in-work, Test Cell, etc.

Date Received: SE

Missing Inventory: Y/N (If Yes, identify items)

Approved Quote: Y/N

Type of Repair: State the repair expected to receive

Estimated Completion/Delivery Date: SE

On Schedule: Y/N (If No, explain)

Within Authorized Approved Funding: Y/N (If No, explain)