Statement of Work - 70Z03824QB0000030.pdf

STATEMENT OF WORK (SOW)

70Z03824QB0000030

Contractor Requirements

1. This requirement is for the modification and/or repair of item(s) listed in the following table utilized on the United States Coast Guard (USCG)’s MH-65 helicopter.

Description Quantity National Stock Number

Modified National Stock Number

Part Number Modified Part Number

Oil Tank, Equipped

5 1560-01-HS1-5649 1560-01-HS3-4580 365A53-8013-02 WAIMOD-43773

Oil Tank, Equipped

Optional Quantity

1560-01-HS1-5649 1560-01-HS3-4580 365A53-8013-02 WAIMOD-43773

Engine Oil Tank

2 1560-01-HS3-4580 Not Applicable WAIMOD-43773 Not Applicable

Engine Oil Tank

Optional Quantity

1560-01-HS3-4580 Not Applicable WAIMOD-43773 Not Applicable

2. Test and Evaluation. Upon receipt of components, the Contractor shall perform a test and evaluation to determine the condition of the item. If, after visual and functional inspections, an item is found to meet manufacturer's minimum performance specifications and is considered to be Ready for Installation (RFI), the Contractor shall modify the unit (if required) as per applicable Component Maintenance Manuals (CMMs), repair and modification specifications and/or test/acceptance criteria and any other required data. The Contractor will then only charge the USCG for the cost to modify the unit. If an item is considered Beyond Economical Repair (BER) in accordance with (IAW) paragraph 11, or “RFI” and modification is not required, the Contractor will be allowed the firm fixed price test and evaluation fee only. The Contractor shall prepare a failure data report IAW paragraph 13 and shall be included with the returned component. The part(s) shall be marked “RFI” or “BER” IAW paragraph 11, as applicable, and returned as-is. All other items shall be repaired and/or modified IAW this SOW.

3. Repair. Non-RFI components shall be repaired and returned to RFI condition IAW the Original Equipment Manufacturer (OEM) Components Maintenance Manuals (CMMs) minimum functional performance specifications and ALC Engineering Specification H65791010.01B. Components shall be repaired for the specific fault noted on the DD Form 1577-2, Unserviceable (Repairable) Tag-Material, or CG-1577-A (11-90), Unsatisfactory Report Tag, which will be attached to each non-RFI item. The Contractor shall perform an inspection and correct deficiencies found. This shall include, but is not limited to, replacement of missing or broken parts and the removal of any foreign matter or corrosion.

3.1 Repair Procedures for Damage to the Sight Glass.

Note: Care shall be exercised throughout this repair process to prevent unnecessary scratching or marring of the base metal surfaces.

a. Receiving Inspection and preliminary cleaning

b. Removal of necessary hardware

c. Removal of hardened outer shell

d. Modification of the protective shell to accommodate the larger sight glass bezel, as required.

e. Removal of the filler neck and prep for new extension mod, as required.

f. Removal of the existing sight glass and prep for new sight glass bezel, as required.

g. Strip, clean and insure that tank is free of all debris and contamination

h. Re-install, prep and weld filler neck extension

i. Re-install, prep and weld sight glass bezel

j. Preform all necessary Non-Destructive Tests on oil tank around the effected installation areas

k. Install necessary hardware cap and sight glasses for pressure test

l. Pressure test oil tank

m. Re-install hardened out shell

n. Remove all hardware - re-inspect inside tank for debris

o. Prep, prime and paint unit

p. Re-install hardware for final pressure testing and evaluation

q. Final pressure testing

r. Remove hardware, apply labeling

s. Complete paperwork for RFI documentation

t. Item completed prepped to be returned to USCG RFI as per the SOW, which includes the new oil tank part number.

If required, disassemble the noted assembly(s) in accordance with appropriate CMM and ALC Engineering Specification H65791010.01B.

Clean the assembly by degreasing with alcohol, Methyl Ethyl Ketone (MEK), DS 108 Cleaning Solvent, PD 680 type 1 mineral spirits, or acetone. Oxides and discoloration may be removed by grit blasting. Air pressure for grit blasting shall not exceed 60 psi. Perform a visual examination for cracks or other damage to the sight glass. If no visible cracks or leaks can be detected, seal all reservoir openings and perform a leak test by filling the tank with 3 psi air pressure and then applying a mixture of soap and water to detect bubbles caused by leaks. Mark leaks using a black felt tip marker.

Leaks around the sight glass may be repaired by sealing with Proseal 870 Corrosion Inhibitive Sealant or 890 Fuel Tank Sealant and curing per the manufacturer instructions, or fabricate and install a female fitting(s). Weld IAW Drawing WAIMOD-43773 and ALC Engineering Specification H65791010.01B. Install a new sight glass (AEC P/N 365A75143120 or P/N GN743-085A) with O-ring P/N MS28775-128 into female fitting.

Safety wire sight glass per standard practice. Perform visual inspection of all repaired articles. There shall be no evidence of cracks, undercut, lack or fusion arc strikes, surface porosity, or oxidation. Fill the reservoir with air pressure per not to exceed 3.0 psig and apply a soap and water mixture to the surface. Bubbles will form at areas that still contain a leak(s). Check the entire outer surface of the reservoir. No leaks are permitted. After repair, alodine the outside of the reservoir with a conversion coating material that meets the requirements of MIL-C-5541 or MIL-C-81706. Apply per the manufacturer instructions.

Paint or touch up the outside of the reservoir with one coat of BMS 10-11 Type 1 green primer. A topcoat that meets the requirements of MIL-PRF-85285 FSN 16473 Gloss Gray, Type IV, Class H may also be applied. Apply all paint per the paint manufacturer instructions. Protect and store the part in accordance with FAA 14 CFR Part 145 requirements.

3.2 Modification. The Oil Tank Equipped shall be modified from, P/N 365A53-

8013-02 to P/N WAIMOD-43773 IAW the OEM’s most current CMM performance specifications and ALC Engineering Specification H65791010.01B Oil Tank Repairs.

4. During inspection and functional test, the presence of corrosion in a component shall constitute reason for a more thorough disassembly and inspection. Should corrosion be found, disassembly shall be made to the extent necessary to remove corrosion or replace the part, or parts, affected. Corroded parts shall be replaced, except in those cases where removal of corrosion from a part will not impair efficiency or safe operation of the part.

Corrosion removal and treatment of affected areas will be accomplished IAW Original Equipment Manufacturer (OEM) specifications or Federal Aviation Administration (FAA) Advisory Circular AC 43-4B, dated 09/11/2018, Corrosion Control for Aircraft.

5. Work under this purchase order shall be performed at the Contractor’s facility or USCG approved facility. The Contractor shall provide all necessary parts, materials, labor, tooling, test equipment and facilities with the exception of the Government Furnished Material (GFM) listed in subparagraph 5.1 below, to evaluate and repair/modify the components listed in this purchase order at the firm-fixed prices listed in the schedule. If any other parts or materials are not available to the Contractor and need to be provided as additional Government Furnished Material (GFM), the Contractor must make this requirement known in writing to the Contracting Officer for approval and indicate the reason they are unable to provide and the quantity of each GFM needed per component to be repaired/modified. If the USCG provides any additional Government furnished material, other than those listed in subparagraph 5.1, the costs of the material will be subtracted from the cost to repair/modify the unit. The Contractor shall perform all repairs and modifications IAW OEM’s Component Maintenance Manual (CMM) performance specifications, Drawing HH65 Oil Tank Retrofit/Repair 43773, and ALC Engineering Specification H65791010.01B Oil Tank Repairs, and/or applicable test/acceptance criteria. Any deviations must be approved by the Contracting Officer prior to the deviation.

5.1 Government Furnished Material. The following Government Furnished Material (GFM) will be provided by ALC per each repair and/or modification, to be issued once the Non-RFI components are forwarded to the vendor:

a. Two (02) Liquid Sight Indicators, Part Number: 365A75-1431-20, NSN:6680-14-366- 5753;

b. Two (02) O-Rings, Part Number: MS28775-128, NSN: 5331-00-702-5643.

For repair/modification tanks found BER or GFM is not required for the repair only, the GFM shall be returned to ALC.

6. The Contractor must have access to required CMMs, repair and modification specifications and/or test/acceptance criteria and any other required data to ensure all components are tested and repaired IAW the OEM’s current performance specifications and procedures. The USCG may review repair manuals and performance/test/acceptance criteria as required.

Original design or functional capabilities of the end item and parts thereof shall not be changed unless authorized or directed by the requirements of this SOW.

7. The Contractor must have access to all applicable documents and obtain current editions of all applicable documents. The USCG does not own nor can it provide all the technical documents specified herein. Neither the closing date for receipt of offers nor contract award will be delayed pending receipt of these documents for any offeror.

8. Parts of a component found to be in a serviceable condition as a result of functional testing shall be reused. Missing parts and parts found to be defective or that require replacement by manufacturer’s instructions shall be replaced with parts meeting the manufacturer’s specifications and drawings or as otherwise authorized in writing by SRR Engineering.

Replacement parts shall be new and accompanied with OEM traceability. The cost for parts that are replaced systematically during repair shall be included in the price listed in the schedule for these operations.

9. Prices do not include components that have been cannibalized or severely damaged due to mishandling or crash damage. Additionally, the MH-65 helicopter is used primarily around salt water at low altitude for search and rescue missions. Therefore, corrosion is to be anticipated, and is considered "normal" for the aircraft. Corrosion does not constitute unusual damage. The USCG will be notified of components found to have excessive corrosion, which may dictate an exclusion from the prices specified in the contract schedule. Such components shall be inspected, repair costs determined, and authorization to proceed obtained from the Contracting Officer prior to commencement of work.

10. Components received which indicate obvious misuse, cannibalization or severe damage due to mishandling or crash damage may dictate an exclusion from the prices specified in the contract schedule. Such components shall be inspected, repair costs determined, and authorization to proceed obtained from the Contracting Officer prior to commencement of work. Once notified of a possible exclusion, The Contracting Officer will make a written determination within thirty (30) days as to exclusion validity. The Contracting Office may approve the quote, decline the quote and have the item returned as-is, or consider the item BER IAW paragraph 11.

11. The contractor may request an item to be determined BER if after initial inspection of the component the contractor feels that the part requires significant repair/overhaul outside of the scope of the normal repair/overhaul procedures provided in the OEM’s CMM. The contractor’s request shall be sent to the KO for consideration. Only USCG can determine a component BER. The KO will review the request and either accept or deny the BER determination. If the KO denies the BER determination, the contractor shall repair the component back to RFI condition at the firm-fixed price rate agreed upon in the schedule. If the KO determines an item to be BER, the KO shall make a unilateral decision as to component disposition. The contractor shall return all BER items to ALC. The contractor shall not return any BER item until they have been notified by a written modification to the order. The contractor shall prepare a failure data report IAW section 13 in these instances.

This report shall be included with the returned component. When returning items to ALC, the items shall be clearly marked as “BER” with the supporting evidence.

12. The Government shall not be liable for any amount expended by the Contractor in excess of the applicable firm fixed price reflected in the schedule unless prior written authorization has been given by the Contracting Officer.

13. The Contractor shall submit a failure data report for each repaired/modified and BER component. This report shall include NSN, Part Number, Serial Number, nomenclature, date of repair and modification, contract delivery order number, line item number, description of repaired failure, the USCG’s reported failure, a listing of parts repaired and a listing of parts replaced. The Contractor’s in-house work order may be used to satisfy this requirement if it includes the information requested above. This report shall be attached to the packing slip and shipped with the repaired/modified/BER component.

14. The Contractor is required to be certified and maintain a quality system that complies with the requirements of ISO 9001 Quality Management Systems – Requirements, AS9110, or equivalent. The Contractor is responsible for performing or assuring all inspections, tests and calibration necessary to substantiate that the goods or services furnished conform to Government’s requirements. The Contractor shall take prompt action to correct conditions that have or could result in goods or services that do not conform to contractual requirements.

Records of conformance shall be maintained on file at the Contractor’s facility and made available or provided for review by the Government upon request. The Government reserves the right to conduct surveillance at Contractor’s facility to verify the existence, adequacy and effectiveness of the quality system. Upon request of the Government, the Contractor(s) shall forward a copy of their current certification and Quality Assurance Manual for review.

15. The Contractor shall maintain, at a minimum, one of the following: FAA, European Aviation Safety Agency (EASA), Department of Defense (DOD), OEM, Industry Standard Certification (i.e., National Aerospace and Defense Contractors Accreditation Program (NADCAP)) and/or USCG certifications for repair of components identified in the Schedule for the entire duration of this Purchase Order. The Contractor shall provide immediate notification to the Contracting Officer upon loss of any required certifications. The Contractor shall also:

Comply with the certification/documentation requirements specified herein.

Attach certifications/documentation to the outside of the shipping container.

16. All parts repaired under the provisions of this contract must be airworthy and suitable for installation on USCG aircraft. Each returned component shall be tagged with a DD Form 1574 Serviceable Condition Code Tag completed in its entirety. The Contractor shall furnish a Certificate of Conformance (COC) IAW FAR 52.246-15 for all components. These forms shall be packaged with each component.

17. The COC shall 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, a COC AND a copy of the FAA Parts Manufacturer Approval (PMA), if applicable, or other manufacturing authority shall be provided. Contractors shall also provide documentation reflecting the complete unbroken history of ownership of the parts from purchase from the approved manufacturing source until delivery to the USCG.

18. ALC considers components ready for issue (RFI) upon acceptance. Components determined to be non-RFI upon installation may be returned to the Contractor with deficiencies described in a Product Quality Deficiency Report (PQDR).

19. All parts must be thoroughly cleaned IAW applicable CMMs 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).

Purchase Order Requirements

The following table shows the required delivery for each priced line item listed in the schedule. Early deliveries, when appropriate, are desired and acceptable.

Line Item Item Description Due No Later Than:

0001 Test and Evaluation Fifteen (15) calendar days after receipt of components

0002 Modification/Repair Ninety (90) calendar days after receipt of components

0003 Modification/Repair (Optional Quantity)

Ninety (90) calendar days after receipt of components

0004 Repair Only Sixty (60) calendar days after receipt of components

0005 Repair Only (Optional Quantity)

Sixty (60) calendar days after receipt of components