SOW Engine Major Repair.docx

STATEMENT OF WORK

1. BACKGROUND

1.1 The United States Coast Guard (USCG) currently operates eighteen (18) HC-144A Maritime Patrol Aircraft each powered by two CT7-9C3 turboprop engines. The aircraft is manufactured by AIRBUS MILITARY (formerly EADS CASA) in Seville, Spain. The CT7-9C3 turboprop engines are manufactured by General Electric, Aviation Division of Lynn, MA, USA, Original Equipment Manufacturer, (OEM). While the base CASA CN- 235-300M aircraft provides the foundation for the USCG HC-144A, changes to the base aircraft configuration and the addition of supplementary systems have been combined resulting in a CG0l version of the CN-235-300M.

1.2 This Maritime Patrol Aircraft (MPA) is operated differently from general aviation in support of USCG search and rescue missions, as well as surveillance and reconnaissance missions. USCG HC-144A missions require frequent operation at lower altitudes and in salt-laden environments. These environments accelerate corrosion on airframe structures, engines and components of the aircraft. The aircraft and its components are inspected by USCG personnel In Accordance With (IAW) the OEM periodic requirements and in conjunction with the USCG's specialized Asset Computerized Maintenance System (ACMS).

2. SCOPE

2.1 The scope of this SOW is to obtain repair services for the General Electric (GE) CT7- 9C3 turboprop engine power units, modules, and components, listed in the Schedule on an "as required" basis.

2.2 Levels of Repair shall be defined as:

a. Major Repair - A "Major" repair consists of a minor repair and the complete disassembly of the engine and inspection of modules as required by Small Engine Instruction {SEI)-576/578 returning the engine to service. The Contractor must review and be in compliance with required service bulletins and Airworthiness Directives (AD), re-assembly of the engine, test and prep-to-ship.

b. Minor Repair - A "Minor" repair consists of removal of the hot section module, Power Turbine (PT) Module and Accessory Gearbox (AGB). The hot section module and PT module shall be inspected and repaired as required by SEl- 576/578. The AGB shall be inspected for obvious damage/defects as required by SEI-576/578. Bore Scope Inspection (BSI) shall be performed on the compressor rotor/stator. Compressor case half shall be removed as required addressing any findings identified during the bore scope inspection. The cold section will be held for re-assembly of the engine. The contractor shall review and be in compliance with required service bulletins and airworthiness directives, re-assembly of the engine, test and prep-to-ship.

c. Test Teardown and Evaluation (TT&E) - Based on the removal cause and/or time on the engine, a full BSI may be performed to determine the condition of the engine. If the BSI does not accurately determine the condition of the engine, half casing the compressor may be required for a more detailed inspection. If the removal cause and/or times on the engine were a concern, the engine will be disassembled to module level. If the Government chooses to continue with the contractor for repairs, the cost of TT&E will be included in the repair cost. The Contractor shall submit in writing or via email to the Contracting Officer a proposal for a Minor or Major repair. If approved by the Contracting Officer, a modification will be issued.

d. Performance Run- Requires ONLY a visual and bore scope inspection (no Teardown) if no discrepancies exist, then complete a Test Cell performance run and provide the findings to the USCG Contracting Officer. If the engine or PGB is found to be in serviceable condition IAW OEM testing specifications, the contractor shall return it to the USCG with an FAA authorized airworthiness form attached.

2.3 Repair of listed GE components must be accomplished In Accordance With (IAW) the OEM specifications. This SOW establishes the minimum USCG requirements necessary for repairs of the engine power units, modules, and components and is not intended to be all inclusive, nor detract from the procedures outlined in the manufacturer's drawings, manuals, specifications, and service bulletins. USCG configuration control requires that applicable service bulletins and modifications for all ACMS tracked engine power units, modules, and components not previously configured, shall not be incorporated without prior written approval from the USCG Contracting Officer.

2.4 Designated Engineering Representative (DER) repairs: DER repair procedures may be authorized by the USCG Contracting Officer on a case-by-case basis after review by the USCG Engineering Officer. The contractor shall submit a complete technical package to the USCG Contracting Officer for approval showing the proposed DER repair procedure on an FAA form 8110-3 which shall meet the OEM operational requirements. This information will not be released outside of the Government.

2.5 The Contractor shall be responsible for all necessary functions to perform services requested. This includes, but is not limited to, required tooling, manuals, test equipment, parts, material, engineering services, management, maintenance, documentation, preservation, and shipping of the CT7-9C3 engine power units, modules, and components.

2.6 Test cell runs must be accomplished on test cells certified as correlated to the CT7-9C3 engine OEM test cells. Test cell runs will be performed in accordance with the shop manual. In addition, all engines will have a borescope performed after test and prior to shipment.

2.7 The Contractor shall track and document for USCG specialized ACMS and Significant Component History Reports (SCHR) the necessary calendar time, flight time, and appropriate flight cycle requirement for the CT7-9C3 engine power units, modules, and components which must be accomplished to maintain the integrity of any OEM high-time hourly intervals and life cycle limits.

2.8 The Contractor shall maintain a current list and status of all OEM Component Maintenance Manuals (CMM), Shop Manuals(SM) including Revisions (Rev), Temporary Revisions (TR), Service Bulletins (SB), Modifications (MOD), Amendments (AMD) or other specifications applicable to the overhaul, repair and modification of the USCG CT7-9C3 engine power units, modules, and components. The contractor shall be on the regular distribution with the OEM for automatic notifications of updates for all the above data.

3. CONTRACT REQUIREMENTS

3.1 The Contractor shall be a Federal Aviation Administration (FAA) Part 145 authorized repair center or European Aviation Safety Agency (EASA) certification equivalent to effectively inspect, test, troubleshoot, clean, and repair GE CT7-9C3 engine power units, modules, and components to current OEM configurations while maintaining any USCG specific requirements for return to service in a Ready For Issue (RFJ) condition and USCG operational use. The engine power units, modules, and components must remain configured for installation on USCG HC-144A aircraft. For Production Approval Holder (PAH), a Certificate of Conformance (COC) and a copy of the FAA Parts Manufacturer Approval (PMA) or other manufacturing authority shall be provided. The certificate must be signed by an authorized official representing the approved source and must specify the manufacturer's part number and date of manufacture.

3.2 CT7-9C3 engine power units, modules, and components must be fully inspected, repaired IAW OEM repair specifications, and CMMs, SMs, including revisions, service bulletins, modifications, and amendments. All items must be returned to service with FAA airworthiness Form 8130-3 or other FAA authorized airworthiness form attached. If the Contractor for any reason loses its Federal Aviation Administration (FAA) or European Aviation Safety Agency (EASA) certification during the period of performance, this constitutes a material breach of contract which may, at the discretion of the USCG Contracting Officer, result in contract termination. The Contractor shall notify the Contracting Officer verbally and in writing, not later than five (5) calendar days after certification forfeiture, and disclose all facts relevant to the forfeiture.

3.3 The Contractor shall notify or confirm, in writing within 10 calendar days, to the USCG Contracting Officer receipt of all assemblies and components. Contract item receipts must include, but are not limited to, the following information: nomenclature, National Stock Numbers (NSN), Part Numbers (PIN), Serial Numbers (SIN), contract number, Contract Line Item Numbers (CL™), and dates of receipt. Contract item receipts via facsimile/email are acceptable and may contain single or multiple notification entries.

3.4 CT7-9C3 engine power units, modules, and components shall be repaired for return to service within 120 calendar days after receipt of material at contractors repair facility. Earlier delivery is acceptable and desired.

3.5 The Contractor shall follow USCG ACMS requirements which are used to track and document calendar time, flight time, engine flight/life cycles, all work and services performed on CT7-9C3 engine power units, modules, and specific components. Tracking provides significant component historical records of component installations, removals, overhauls, repairs, and modifications including component transit, storage, status, and locations. ACMS tracking provides an effective means of configuration control to maintain the integrity of OEM overhaul/high time hourly intervals including flight and life cycle limits as applicable to CT7-9C3 engine power units, modules, and components. For configuration control prior written approval of the USCG Contracting Officer shall be obtained for any configuration changes to engine power units, modules and components.

3.6 Environmental Requirements

3.6.1 All parts must be thoroughly cleaned IAW applicable CMMs or 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 ALC. ALC 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).

3.7 Service Bulletins and Modifications

3.7.3 Service bulletin and modification configurations are subject to change during the course of the contract period. Service bulletins and modifications not previously incorporated shall be identified for the Contracting Officer and will be negotiated on a case by case basis. The Contractor is responsible for obtaining and notifying the Contracting Officer of service bulletin changes and modifications and for disposition approval prior to incorporation of those changes and modifications.

3.7.4 Service bulletins and modifications incorporated during performance of this requirement may create new part number configurations, which supersede the previous configurations. In cases where the older configurations cannot be modified to the newer configurations, the new configuration part numbers may be added lo the contract. The Contractor must notify and request disposition instructions from the Contracting Officer for superseded parts, which have been removed and replaced by newer configurations.

3.7.5 Upon receipt of notification and authorization from the Contracting Officer that a service bulletin or modification is to be incorporated, the Contractor shall submit, within thirty (30) calendar days after receipt of that notification, a firm-fixed price proposal for each time the service bulletin or modification is incorporated in a component. The proposal shall contain a breakdown of material and labor hours and rates as identified in Contract Line Item Number (CLIN 0024) of the schedule and associated out year CLINs, labor categories, and applicable mark ups. The charge negotiated for incorporation of a service bulletin shall apply only to those components into which the Contractor incorporates a required service bulletin or modification, and not those into which the service bulletin or modification has been previously incorporated. Upon completion of negotiations and issuance of a task order to reflect this change, the service bulletin or modification shall be incorporated into each subsequent component received at the Contractor's facility for which the service bulletin or modification has not already been incorporated. When service bulletin or modification incorporation changes the Contract Line Item Number (CLIN) part number, the new part number shall be added to the contract. The same procedures apply if removal of service bulletins or modifications is required.

3.8 Teardown Inspection Reports (TIR) (As requested by the USCG) 3.8.l TIRs are required in support of a USCG Engineering incident, safety investigation, warranty determination, or for other failure analysis.

3.8.2 TIRs, when requested, shall be forwarded to the USCG Contracting Officer prior to commencement of work, pending USCG Engineering final review and release. TIRs shall include: nomenclature, NSNs, P/Ns, S/Ns, Contract number, CLINs, including descriptions, photos, illustrations, and drawings, as necessary before and during teardown, for documentation of the failure, and list all parts and costs as would be required for repair of the component or assembly.

3.9 Replacement Parts

3.9.1 Component parts found to be in serviceable condition IAW OEM specifications and functional testing shall be reused.

3.9.2 USCG life and cycle limited components shall be deemed at life limit if the component has 2% or less hours or cycles remaining until the published airworthiness limit is reached.

3.9.3 Defective parts which cannot otherwise be repaired IAW OEM specifications, shall be scrapped IAW GE Aviation approved scrap procedures and replaced with new OEM parts. The cost of repair or replacement of defective parts, high time, life, or cycle limited parts is inclusive to the component repair contract price. High time, life, or cycle limited parts which have reached their respective limits shall not be repaired, but shall be replaced with other USCG serviceable parts or replaced with new OEM parts.

3.10 Beyond Economical Repair (BER)

3.10.1 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 shall contact the USCG Contracting Officer, in writing or via e-mail, with specific rationale for the BER condition. The rationale shall include and provide: nomenclature, NSN, PIN, SIN, contract number, and CLIN along with a cost breakdown of additional parts and labor hours and hourly rate as identified in CLIN 0024 of the schedule and associated out year CLINs, as would be necessary to actually repair the component to serviceable status.

3.10.2 Once an item or component is determined to be BER, no further repair work on that item or component will be performed and the item in question will be placed in a bonded storage room for safekeeping until written authorization with disposition instructions are received from the USCG Contracting Officer.

3.11 Missing or Cannibalized Components

3.11.1 Missing Components: Within 10 working days after the receipt and inspection of the components the Contractor shall notify the Contracting Officer in writing of any missing parts or sub-assemblies required for final inspection and acceptance. The Contracting Officer shall then have 45 days to provide formal disposition instructions to the Contractor.

3.11.2 Cannibalized Components: Upon receiving components exhibiting cannibalization, the Contractor shall notify the Contracting Officer, in writing and in detail, within 10 working days and discontinue all actions until receipt of written authorization from the USCG Contracting Officer. The Contracting Officer reserves the right to appoint a USCG Representative who shall witness the remaining teardown and inspection of the component. A letter of notification and an inspection/teardown report shall be submitted to the Contracting Officer for disposition.

3.11.3 The USCG reserves the right to provide Government Furnished Property (GFP) to replace parts or hardware identified as missing or cannibalized.

3.11.4 Tum Around Time (f AT) stops as of the date on the correspondence giving notification that work must cease due to missing or cannibalized parts. Unless the USCG Contracting Officer elects to have the component returned to the USCG as is, the TAT will re-start effective as of the date of the receipt of replacement part. The clock shall begin once more starting with the last numbered day plus one.

3.12 Corrosion

3.12.1 Low altitude flight over salt water contributes to greater corrosion damage in USCG components than that experienced in commercial aircraft components. The Contractor shall consider the presence and effects of corrosion to be "normal" in this case and provide for correction and removal of corrosion in the Firm-Fixed-Price repair. During inspection and functional testing, the presence of corrosion in an item or part thereof shall constitute reason for a more thorough disassembly and inspection.

3.12.2 Corroded parts shall be replaced, except in those cases where removal of corrosion from a part will not impair the efficiency or safe operation of the part. Corrosion removal and treatment of any affected areas shall be accomplished IAW the manufacturer's specifications.

3.13 Exclusions

3.13.1 Components received in the following conditions are to be considered exclusions and may indicate an exclusion from the price in the contract schedule:

· Catastrophic crash damage, foreign object damage, domestic object damage traceable to a USCG documented repair on the engine assembly, Acts of God, war, and accidents attributable to USCG responsibility.

· Maintenance, repair work, installation, storage, operation or use by the Government which is not in compliance with applicable OEM or Government approved publications, directions and instructions.

· Alteration, modification or repairs that were not completed by the USCG IAW technical data approved by the FAA, OEM, or USCG.

3.13.2 If a component is considered (by the Contractor) to fit the exclusion description, the Contractor must notify the USCG Contracting Officer within 10 working days, and discontinue all actions until the Contracting Officer makes a determination. The USCG may appoint a USCG Representative to witness the remaining teardown and inspection of the component. A letter of notification and the inspection/teardown report must be submitted to the Contracting Officer for disposition. The Contractor must make the affected equipment available to a USCG Representative to view the exclusionary damage. If the Government elects not to physically view the equipment, the Contractors findings report shall stand.

3.13.3 Upon request by the Contracting Officer, the Contractor shall submit a Firm Fixed-Price proposal to include an itemized breakdown of material including nomenclature, part number, cost, and quantity of replacement parts, replacement percentages used to develop the original Firm Fixed-Price contract and the number of labor hours and rates as identified in CLIN 0024 and associated out year CLINs, proposed for additional funding required to restore exclusionary damage. This proposal shall include all necessary supporting rationale and shall be submitted within forty-five (45) calendar days after notification is given to the Contracting Officer.

4. CT7-9C3 ENGINE, MODULE, AND COMPONENT CONFIGURATIONS

4.1 The following configurations are provided to identify, but are not limited to, the CT7- 9C3 engine, modules, and components that fall within the scope of this SOW.

4.1.1 The cage codes listed identify the OEM associated with each assembly or component part number. 99207 - GE - AVIATION

4.1.2 Part Numbers (PIN) identified in this section are as installed on the delivered aircraft, as procured for maintenance sparing and as identified in the GE CT7- 9C3 Engine Technical Manuals GEK# 112181 Version 8.5 Revision Date 11/15/2013 which included the following:

4.1.2.l Maintenance Manual (CMM) SEl-576

4.1.2.2 Shop Manual(SM) SEI578

4.1.2.3 Illustrated Parts Catalog (IPC} SEl-723

4.1.2.4 Operations Engineering Bulletins (OEB)

4.1.2.5 Service Bulletins (SB)

5. APPLICABLE DOCUMENTS

5.1 All GE shop, inspection, repair, or other OEM Component Maintenance Manuals (CMMs) and revisions as applicable to the CT7-9C3 engine power units, modules and components.

5.2 All GE or other OEM service bulletins, amendments, modifications, and specifications as applicable to the CT7-9C3 engine power units, modules and components.

5.3 Any Contractor, GE, 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 parties. If the Contractor receives information more current than that previously provided to the USCG, the Contractor must identify the GE or other OEM Manuals, CMMs, revisions, and specifications, including service bulletins, amendments, and modifications, and provide a brief synopsis of the revisions and dates lo the USCG's Contracting Officer for review and approval.

6. USCG ACMS REQUIREMENTS

Contractor Must:

6.1 Comply with all USCG ACMS documentation requirements.

CT7-9C3 engine power units, modules and some components are serial number tracked under USCG ACMS. This tracking provides historical records of repairs, modifications, overhauls, flight times, cycles, item location, status, and is an effective method of configuration control. Components that are serial number tracked under USCG ACMS should, at the time of receipt, have a blank Component Repair Record (CRR), and a current Significant Component History Report (SCI-IR) attached to the component.

6.1.1 A copy of the Test Cell Run data sheet that was used to certify the repaired engine as airworthy is required for entry in to ACMS by the USCG.

6.1.2 A copy of the Acceptance Test Data Sheet is required for all repaired components.

6.1.3 Verify the SCHR and CRR correspond with the NSN, PIN, and S/N of the component received. Promptly report discrepancies to the USCG Contracting Officer prior to performing any work.

6.2 Complete the CRR as applicable, describing the work performed, cite the technical data used to perform the work, and any significant parts replaced.

6.2.1 The CRR shall provide a complete description of the work performed, the component status (repaired, modified, BER, scrap, etc.) and include, but not be limited to: the Contract number, CLIN, the Contractor's Work Order number, the date work was completed, any changes to the Time Since Overhaul (TSO), and total time, landings, or cycles as applicable.

6.2.2 The information provided in the CRR will be used by the USCG to update the component SCHRs.

6.3 Provide three copies of the completed CRR as follows:

6.3.1 One copy of the CRR shall remain attached to the material inside the container and the second copy will be attached to the outside. The CRR is to be returned with the component upon completion of the repair or any changes to the item.

6.3 .2 A third copy of the CRR shall be mailed to:

COMMANDING OFFICER ATI'N:ACMS

USCG AVIATION LOGISTICS CENTER 1664 WEEKSVILLE ROAD BLDG 63 ELIZABETH CITY, NC 27909-500 l

6.3.3 The CRR is considered a deliverable under the contract, and noncompliance with instructions here in, will result in the delay or nonpayment of the invoice.

7. MARKING, PACKAGING, AND PRESERVATION

7 .1 All USCG engine power units shall be shipped in a USCG owned reusable engine shipping container provided by the USCG. The Contractor will notify the Contracting Officer in writing within IO working days of receipt of the engine at its facility in the event the engine is not received in the appropriate USCG owned shipping container, if the container is damaged, or if it is not in reusable condition.

7.2 Modules and components of the engine will be shipped IAW ASTM D 3951-10. All containers must be labeled on the outside with the National Stock Number (NSN), P/N, S/N, Nomenclature, Contract number, CLIN(s) and vendor CAGE CODE. The internal packaging material shall be sufficient to prevent damage during shipment, handling, and storage. Preservation protection must be sufficient to prevent corrosion, deterioration or decay during warehouse storage for a period not less than one year. Packaging matter shall not consist of the following materials: popcorn, shredded paper, Styrofoam or any type of peanut packaging. Bar coding is authorized but not required.

8. INSPECTION AND ACCEPTANCE

8.1 Inspection and acceptance of material under this contract, to ensure that all equipment is in accordance with manufacturer's specifications, shall be performed at destination by local USCG Quality Assurance (QA) person.

8.2 A FAA Form 8130-3 or Certificate of Conformance (COC) 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. For Production Approval Holder (PAH), a COC AND a copy of the FAA Parts Manufacturer Approval (PMA) or other manufacturing authority shall be provided. The certificate must be signed by an authorized official representing the approved source and must specify the manufacturer's part number and date of manufacture.