Draft_Attachment_1_-_SOW.pdf

DRAFT

US Department of State

28 March 2016

STATEMENT OF WORK

DEPARTMENT OF STATE

UH-1 HELICOPTER

PROGRAMMED DEPOT

MAINTENANCE (PDM)

28 March 2016

Table of Contents

1. BACKGROUND

2. SCOPE

3. OBJECTIVES

4. TASKS/REQUIREMENTS

4.1. GENERAL

4.1.2. PDM DURATION

4.1.3. PDM COST ESTIMATE

4.1.5. TECHNICAL REFERENCES

4.1.9. PROGRAM MANAGEMENT REQUIREMENTS

4.2. PRE-DELIVERY REQUIREMENTS

4.2.2. CLASSIFIED MATERIAL

4.2.3. AIRCRAFT TRANSFER

4.2.4. ACCEPTANCE CHECK FLIGHT

4.3. INCOMING INSPECTION

4.3.2. PDM COST ESTIMATE

4.3.3. PRELIMINARY INVENTORY, EXAMINATIONS, AND OPERATIONAL TESTS

4.4. INSPECTION REQUIREMENTS

4.4.3. ACCESSORIES AND COMPONENTS

4.4.4. ENGINES

4.4.5. AIRFRAME

4.6. CORRECTION OF DISCREPANCIES

4.7. WARRANTIES

4.8. UNSERVICEABLE/UNUSED DOS ASSETS

4.9. ADDITIONAL MAINTENANCE REQUIREMENTS

4.10. POST MAINTENANCE CLEANING

4.11. CORROSION TREATMENT

4.12. PAINT

4.13. CONFIGURATION RESTORATION

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4.14. WEIGHT AND BALANCE

4.15. ENGINE TREND MONITORING SYSTEM

4.16. COMPASS CALIBRATION

4.17. POST INSPECTION SERVICING

4.18. POST INSPECTION FUNCTIONAL CHECKS

4.18.2. ENGINE PERFORMANCE CHECK

4.18.3. ACCEPTANCE/FUNCTIONAL CHECK FLIGHT

4.18.4. FLIGHT SUPPORT INSPECTION/S

4.19. ACCEPTANCE AND TRANSFER OF POSSESSION

4.20. SCHEDULED MAINTENANCE PRIOR TO DEPARTURE

4.21. AIRCRAFT TRANSPORTATION AND SHIPMENT

4.22. ENGINEERING SUPPORT REQUIREMENTS

4.22.1. PDM ENGINEERING

4.22.2. NON-PDM ENGINEERING AND TECHNICAL ASSISTANCE

4.23. NON-PDM LOGISTICS

4.24. PROPERTY MANAGEMENT PLAN

4.25. SECURITY

4.26. QUALITY ASSURANCE (QA)

5. DELIVERY

6. GOVERNMENT FURNISHED PROPERTY

7. PLACE OF PERFORMANCE

8. PERIOD OF PERFORMANCE

9. APPLICABLE DOCUMENTS

9.2. MANUFACTURER PUBLICATIONS

9.3. MILITARY AND DOS PUBLICATIONS

9.4. FEDERAL AVIATION REGULATIONS

9.5. ADVISORY CIRCULARS

9.6. MISCELLANEOUS

10. MARKING, PACKAGING, AND PRESERVATION

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11. INSPECTION AND ACCEPTANCE

List of CDRLs

Table 1 Corrosion Type Designation

Table 2 Corrosion Severity Designation

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, but not limited to, the eradication and interdiction of illicit drugs, training of Contractor and host nation personnel, embassy support, movement of personnel and equipment, reconnaissance, personnel recovery (PR), medical evacuation, security of personnel and equipment, and convoy escort. At times INL/A equipment, aircraft, and personnel operate from forward operating base locations under primitive conditions and at other times from international airports with the most advanced navigational aids. Aircraft utilized in support of DoS missions must have greater flight endurance; carrying capacity (both cargo and personnel); and range, take-off, climb, and turn performance at high elevations and density altitudes. Furthermore, the aircraft and crews are subject to being targeted by hostile fire. Aircraft subject to hostile fire will generally require aircrew and aircraft survivability systems to be installed such as but not limited to armor, the AN/AAR-47 missile warning system, and ALE-47 countermeasures dispensing system. Finally, aircraft and non-aircraft support systems such as, but not limited to, base operations, aviation ground support equipment, Air Traffic Control (ATC) capability, personnel, and personnel support systems are deployed and established at remote locations around the world to support DoS missions. The DoS operates approximately one-hundred twenty UH-1 series aircraft in support of the aforementioned missions as part of it's worldwide aircraft fleet.

2. SCOPE

2.1. INL/A requires, on a regularly scheduled calendar basis, a source to accomplish recurring Aircraft Condition Inspections (ACIs), aircraft modifications, corrosion identification, removal, treatment, and repair, component and accessory overhaul, and refurbishment of DoS UH-1 aircraft. The previously stated tasks will henceforth be referred to as Programmed Depot Maintenance (PDM) in this statement of work

(SOW).

2.2. The Contractor shall define and perform the specific PDM requirements developed for the DoS UH-1 aircraft as part of this SOW. PDM requirements are intended to reset all phased and periodic calendar and hourly airframe inspections to ensure a high level of operational availability in-between programmed depot intervals. Additionally, to the greatest extent possible all engine, aircraft, and accessory hourly and/or calendar based time changes, overhauls, and inspections shall be accomplished to preclude such actions coming due within one (1) year or 300 airframe hours (whichever is less) after

PDM accomplishment. The Contractor defined PDM requirements shall include, but are not limited to, the following:

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a) Inspection and evaluation of aircraft for airworthiness.

b) Development and execution of any required repair procedures using established technical data. In case(s) where established procedures do not exist, the Offeror shall have the engineering capability to develop and execute all levels of airworthy repairs for aircraft involved in accidents, incidents, and battle damage requiring major or specialized structural repair.

c) A thorough and comprehensive inspection and repair of the aircraft structure, flight essential systems, and flight critical components.

d) Incorporation of authorized Technical Directives and Modifications.

e) Any scheduled or unscheduled maintenance.

f) Replacement of operating time and/or calendar based time change components.

g) Corrosion evaluation, repair, and treatment.

h) Full strip and repaint and application of DoS markings to the exterior of the aircraft.

i) Adjustment, checks, tests, repairs, and preventive maintenance.

j) A thorough review and reconciliation of aircraft logbooks and historical records.

k) The operational/functional testing of systems.

l) Test and acceptance flights prior to the delivery of reworked aircraft.

m) Program general and aircraft specific reporting requirements to ensure complete documentation of maintenance performed during PDM.

n) Engineering support for planning, implementation, and coordination of any modifications requested by the DoS.

o) PDM induction planning that will take into account current mission requirements and utilization.

p) Cost estimates to include Over and Above (O&A).

q) Property management of all United States Government (USG)

Government Furnished Property (GFP)

r) Facilities Requirements.

s) Engineering Services.

t) Parts procurement and sourcing.

u) Program Management and Status Reporting.

v) Equipment disposal and demilitarization (as necessary).

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2.3. In addition to the PDM, on an as needed basis, when directed by the CO, the Contractor shall provide engineering services, parts procurement, component overhaul, and technical field services.

3. OBJECTIVES

3.1. As part of an overall PDM process, the DoS ACI and Critical Flight Safety Program’s

(CFSP) first objective is to critically evaluate all aircraft on a recurring scheduled basis to assure the responsible airworthiness authority (DoS) all owned and operated aircraft are operationally safe, airworthy, maintainable, reliable, and available for critical mission support. The second objective is to preserve the investment in these capital assets by restoring them to approved technical standards.

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SECTION I

General Requirements (PDM)

4. TASKS/REQUIREMENTS

4.1. GENERAL

4.1.1. Not later than sixty (60) days after contract award, the Contractor shall submit for

DoS review and acceptance a final tailored technical specification detailing the items, equipment, and procedures to be used for the inspection, corrosion control, repair, refurbishment, overhaul, and paint restoration for each model and series

DoS UH-1 aircraft projected to require a PDM inspection for the duration of the contract. (CDRL A001) The technical specification shall contain, but shall not be limited to, the following items:

4.1.1.1. Technical specification divided into the following separate sections:

4.1.1.1.1. Basic tasks required for all PDM aircraft regardless of model and series. These tasks include but are not limited to the following:

1. PDM phase inspection requirements common to all UH-1 series aircraft,

2. Aircraft Inventory (both incoming and outgoing),

3. Support equipment inventory (both incoming and outgoing),

4. Depaneling, and Tear-Down to include removal of all major components; accessories; interior and exterior doors, windows, cowlings, panels, and covers, drive shafting, all blades, and fuels cells (as required),

5. All cleaning to include all accessible areas, components, structure, consumable material (cleaning agents, etc.),

6. Corrosion Inspections, removal, and treatment,

7. NDI inspections (see section 4.4.6.6) to include consumable material (film, treatment solutions, etc.)

8. Post inspection repopulation and reassembly of components, accessories, uninstalled configuration items, panels, doors, windows, covers, drive shafting, all blades, and fuel cells,

9. All functional and operational testing (both maintenance and operation), 28 March 2016

10. All consumable materials (see section 4.1.8.1 of this SOW),

11. Records Review, preparation, and updates,

12. Strip and repaint the aircraft to the approved DoS paint scheme and apply all required DoS markings,

13. Component and accessory touch-up paint to maintain corrosion prevention barrier and protection,

14. All-inclusive quality control processes from aircraft induction to aircraft departure,

15. Rotor blade strip, inspection, minor superficial or cosmetic repairs, paint, and rebalance,

16. All test and flight acceptance support from induction until departure to include up to 10 hours of post acceptance user reliability flights,

17. All POL products (see consumable in section 4.1.8.1 of this

SOW),

18. Post PDM hangar storage for 10 days after DoS acceptance,

19. Post PDM minor repairs after DoS acceptance to support 10 days of user reliability flights,

20. Drive train hanger bearings removal, overhaul, and reinstallation for all inducted aircraft,

21. All fluid filter replacements,

22. All O-rings, gaskets, and seals (not installed on major components, and not included in the O&A section),

23. Inlet barrier filters replaced,

24. All weight and balance actions,

25. Compass swings,

26. Oil samples,

27. All Program Management actions not specified as CDRL requirements,

28. All servicing actions (include but not limited to refueling, defueling, draining, charging, retorquing, oil sampling) from induction until departure to include up to 10 hours of post acceptance user reliability flights, 28 March 2016

29. All pre-induction and post PDM Contractor test flights and

INL/A acceptance flights,

30. Battery storage and inspection.

4.1.1.1.2. Tasks detailing all known overhaul and service life time dependent items that have the potential of coming due during or may not have the time remaining to meet the requirements specified in section.

4.1.1.1.3. All known unique DoS modifications, specific modification inspections, and maintenance that has the potential of requiring additional work during the PDM.

4.1.1.2. The Contractor shall develop and include within the specification an itemized checklist of all necessary and required documents, historical records, logbook forms, and record files required from INL/A prior to aircraft induction.

4.1.1.3. All tasks in section 4.1.1.1.1 shall be identified within the specification whether task is applicable to UH-1H-II, or UH-1N, or UH-1ST or if applicable to all or any combination of models for PDM.

4.1.1.4. Contractor shall include all scheduled OEM or DoS special inspections, overhauls, operating time based and/or calendar based removals that will come due prior to the next scheduled phased inspection interval or within one (1) year, whichever is less, after completion of PDM.

4.1.1.5. Specification shall include all phased and periodic inspection items listed in the individual aircraft scheduled inspection guides for each model and series aircraft. After accomplishment of the PDM, all aircraft time and calendar scheduled based inspections shall be reset to the beginning of the first cycle.

4.1.1.6. Using the Contractor’s experience, best industry practices, FAA standards, and/or OEM recommendations, the Contractor shall include areas of inspection outside the current scope of published technical inspection guidance to ensure the aircraft are subjected to an extensive and thorough examination.

4.1.1.7. All aircraft specific special inspections listed in the aircraft DoS Form 2408-

18 shall be accomplished. Since the number and type of inspections vary from aircraft to aircraft, the Contractor need only list a generic statement stating that all DoS Form 2408-18 inspections will be accomplished during

PDM.

4.1.1.8. Specific NDI locations with method of accomplishment shall be included in accordance with (IAW) TM 1-1520-256-23, Nondestructive Inspection

Procedures for UH-1 Helicopter Series.

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4.1.1.9. Dependent on the model and series of UH-1, the PDM inspection procedures shall contain, but are not limited to, elements from the Bell, Service (DOD based), or DoS UH-1 maintenance manuals; time, cycle, and/or calendar based periodic inspection requirements; inspection and operational check criteria for DoS unique equipment configurations (e.g., AN/ALE 47 countermeasures system, AN/AAR 47 missile warning system, specialized avionics, armor, etc.); checks for all life limited accessories and installed equipment; recurring DoS, FAA, and Original Equipment

Manufacturer (OEM) Airworthiness Directive (AD) compliance requirements; lubrication requirements; special inspection requirements

(e.g., overtorque, turbulent air, hard landing, lightning strike, and/or Non-

Destructive Inspection (NDI)); FAA and OEM supplemental inspection procedures for continued airworthiness; unique corrosion control inspection and corrosion control inhibitor application requirements; exterior repaint and decal application requirements; all airframe, engine, rotor and accessory pre-delivery requirements; all airframe, engine, and accessory post PDM acceptance inspection requirements; and all flight test requirements.

4.1.1.10. The inspection procedures shall include key/critical points within the PDM process for joint Government/Contractor inspections. During each agreed upon critical point, a DoS representative will either inspect the area before subsequent actions are accomplished or waive the requirement via signature. The inspection procedures shall contain the appropriate signature blocks at each agreed upon step. The DoS reserves the right to witness and inspect all Contractor operations during PDM. The following areas are examples that shall be considered for inclusion on the joint inspection/sign-off process:

a) Main Rotor Installation

b) Final Panel Closures

c) Engine Installations

d) Major Structures Modifications

e) Prior to any other major component installation

4.1.1.11. LEVEL OF DETAIL. Where applicable, checklists shall include specific tolerances within each line item. References to specific procedures (volume, page number/s, paragraph/s, and step number/s) from DoS UH-1 or OEM maintenance manuals are acceptable when space limitations dictate.

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4.1.1.12. TOLERANCES. Where applicable, specific tolerances such as, but not limited to, torque values, measurements, pressures, instrument indications, and specific measurement tolerances shall be explicitly stated.

4.1.1.13. CONSUMABLE MATERIALS. When specific types of consumable material per section 4.1.8.1 of this SOW are called for, the specific product or product specification (e.g., OEM specification, military specification, military standard, etc.) shall be cited.

4.1.2. PDM DURATION.

4.1.2.1. All UH-1 PDM activities to include, but not limited to induction, delivery, inspection, maintenance, repair, overhaul, corrosion control, paint, reporting, records checks, acceptance, and delivery should not exceed six

(6) calendar months.

4.1.3. PDM COST ESTIMATE.

4.1.3.1. Once the incoming PDM examination has been accomplished IAW section

4.3 of this SOW, the Contractor shall submit a quote to provide/perform the inspection, repair, corrosion control, paint, and overhaul services requested by the DoS Contracting Officer (CO) IAW section 4.3.2.1 of this

SOW. The quote shall be based on the basic tasks performed at every PDM plus O&A repairs required and additional actions required by the

Contractor developed standard task fee schedule detailed below.

4.1.3.2. The Contractor shall develop and utilize a standardized fee schedule

(catalogue) for routine services required and performed during the PDM process (CDRL A002). Utilizing the Contractor's technical inspection specification (CDRL A001) and the requirements from this SOW, the

Contractor shall maximize and include all basic, normal, and routine PDM task requirements in the standard fee schedule. The cost of each cataloged task shall include all routine actions necessary to complete the required action barring any major process deviations such as discovering additional major discrepancies while accomplishing the task. Non-standard actions shall utilize the O&A process from section 4.5 of this SOW. Each item cost estimate shall include but shall not be limited to the following cost components:

a) Man-hours,

b) Parts,

c) Removal,

d) Inspection, 28 March 2016

e) Reinstallation,

f) Consumable material (IAW section 4.1.8.1 of this SOW),

g) Operational Verifications,

h) Support equipment set-up and use,

i) Administrative tasks,

j) Log-book entries,

k) any other applicable item from section 4.1.1.1.1 of this SOW.

4.1.3.2.1. The Contractor shall update the inclusive items contained on the standardized fee schedule at least annually and, for O&A items, at the end of each task order.

4.1.3.2.2. Additionally, the Contractor shall include in the standardized fee schedule recurring maintenance actions to include but not limited to the following:

a) Engine deck replacement(s),

b) Major structural panel removals, repair, replacement,

c) Seat repairs and refurbishment,

d) Component and accessory overhauls to include but not limited to the following:

i. Transmission,

ii. Gearboxes,

iii. Engine overhaul (to include all basic engine related tasks in this SOW, hot end inspection, fuel control overhaul),

iv. Rotor head overhaul and torsion-tension (TT) strap replacement,

v. All major hydraulic component overhauls,

vi. Fuel Pump overhauls,

vii. Hardware and bolt kits for all applicable items.

4.1.4. The Contractor shall provide qualified personnel to perform all requirements specified in the individual task orders and this SOW as applicable.

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4.1.5. TECHNICAL REFERENCES.

4.1.5.1. The Contractor shall ensure all employees performing contracted services within this SOW use and reference the most recent versions of DoS, Service

References, FAA and OEM technical publications, directives (including all supplements), changes, and revisions.

4.1.5.2. All maintenance and repairs shall be accomplished in accordance with the applicable Bell/DoS aircraft maintenance manuals; DoS approved military maintenance manuals; FAA Advisory Circular (AC) 43.13-1B and

43.13.2B; and FAA regulations 14 Code of Federal Regulations (CFR) 43.3, 43.5, 43.7, 43.9, 43.13, and 145. All previously installed repairs which do not conform to applicable Structural Repair Manual (SRM) or documented engineering approval shall be reworked to the above standards, upon written approval of the INL/A Engineering Authority and the Contracting Officer.

4.1.5.2.1. ORDER OF PRECEDENCE. In the event of conflicting instructions, the general order of precedence for compliance with technical publications is as follows: 1) Bell UH-1H-II manuals, 2) DoS aircraft model and series maintenance manuals, 3) Service manuals, 4) other applicable OEM manuals, 5) FAA manuals. The Contractor shall notify the COR and the DoS Airworthiness Authority, in writing, of all publication conflicts.

4.1.5.2.2. TECHNICAL DIRECTIVE COMPLIANCE. The Contractor shall notify the Contracting Officer upon receipt of FAA Airworthiness

Directives (ADs), Bell Alert Service Bulletins (ASB), U.S. Army

Safety of Flight messages (SOF), US Army Aviation Safety Action

Messages (ASAM), Service Bulletins (SBs), and Technical Bulletins

(TBs). Prior to accomplishing any of the preceding items, the

Contractor shall provide a quote and request written approval by the

CO.

4.1.5.2.3. SERVICE MANUALS. The Contractor will receive an initial allowance of DoS and DoS approved service manuals, documents, drawings and specifications that are referenced by this specification.

Commercial and FAA publications are to be obtained by the

Contractor.

4.1.6. AIRCRAFT RECORDS DOCUMENTATION

4.1.6.1. In conjunction with the requirements stated in section 4.4.7 of this SOW, the

Contractor shall maintain the aircraft records in accordance with Department of the Army (DA) Pamphlet (PAM) 738-751, 14 CFR part 43, and FAA AC

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43.9 directives from the date of acceptance of the aircraft from the government to the date of delivery to the government.

4.1.6.1.1. Upon completion of the PDM, logbook and historical record entries shall be made stating compliance with the requirements of this SOW and the Contractor’s technical inspection specification developed as part of section 4.1.1 of this SOW. Additionally, the aircraft logbook and historical documents shall reflect the aircraft total flight time accrued.

4.1.6.1.2. All aircraft routine repairs, time changes, bulletins, other directives, major repairs, and modifications accomplished by the Contractor shall be properly recorded in the applicable sections of the aircraft logbook and historical records IAW DA PAM 738-751.

4.1.7. The Contractor shall provide the following support services while the aircraft is located at the Contractor’s facility: towing and ground handling; daily inspections

(pre-flight, between-flights, post-flight, etc.); necessary consumables; servicing;

and basic aircraft handling. The Contractor shall ensure aircraft operations, handling, servicing, maintenance, inspection, repair, and documentation actions on DoS aircraft are performed IAW approved technical publications and other documents specified within this SOW.

4.1.8. Unless otherwise agreed to by the CO or specifically stated in section 6 of this

SOW, the Contractor shall provide all facilities, support equipment, test equipment, consumable materials, and manpower to accomplish all activities stipulated within this SOW.

4.1.8.1. Consumable materials shall include but are not limited to the following:

a) solvents,

b) cleaning agents,

c) emery paper/cloth,

d) masking tape,

e) cutting oils,

f) petroleum, Oils, and Lubricants (POL) to include but not limited to hydraulic fluids, lubricating oils, aviation fuels, and greases,

g) sealants,

h) adhesives,

i) drill bits,

j) electrical splices, 28 March 2016

k) vulcanizing silicone compounds,

l) paints,

m) shop supplies,

n) lock-wire,

o) tapes,

p) packings,

q) seals,

r) light bulbs (Exception: specialty or high cost light bulbs identified in O&A section),

s) instrument range striping/tapes,

t) torque seal or striping,

u) anti-seize compounds,

v) all common or standard hardware and fasteners (e.g., nuts, bolts, screws, studs, washers, rivets, clevis pins, cotter keys, straps, clips, pins, clamps, grommets, safety wire, sleeves, swages, lock-pins, or any other hardware identified in section 11 (Hardware

Identification Tables 7-10 thru 7-15) of AC 43.13-1B that are identified by a FAA recognized standard such as National

Aerospace Standard (NAS), Army-Navy Aeronautical Standard

(AN), Society of Automotive Engineers (SAE), SAE Sematec, Joint Electron Device Engineering Council, Joint Electron Tube

Engineering Council, and American National Standards Institute

(ANSI) (Exceptions: Specialty fasteners manufactured for use on a specific aircraft application with quality and suitability previously approved by the OEM and FAA; or high cost hardware manufactured for a specific application. Specialty hardware that correspond to the aforementioned categories shall be identified separately and not included as Consumable Material)

4.1.9. PROGRAM MANAGEMENT REQUIREMENTS

4.1.9.1. The Contractor shall develop a program management plan which includes schedule, cost, and risk management. (CDRL A003)

4.1.9.2. The Contractor shall provide a single Point of Contact (POC) for all activities.

4.1.9.3. The Contractor shall coordinate with INL/A to develop and maintain a Master Schedule of major contract milestones and events. The

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Master Schedule shall include planned aircraft induction and completion dates that have been coordinated with INL/A and meet the requirements within this SOW. (CDRL A004)

4.1.9.4. WEEKLY STATUS REPORT

4.1.9.4.1. During PDM events or when DoS aircraft or any open task order are in the Contractor’s possession, the Contractor shall provide a weekly status and progression report. (CDRL A005) The report shall be sent to

INL/A by the COB each Tuesday of every week and shall include, but is not limited to, the following items:

4.1.9.4.1.1. Any significant maintenance events such as major airframe repairs/alterations or major component replacements (e.g., engines, main rotor, etc.).

4.1.9.4.1.2. A percentage estimate of all PDM activities completed for each aircraft inducted as of the date of the report.

4.1.9.4.1.3. Any issues affecting the cost and delivery schedule to include but not limited to task order status updates, schedule/cost deviations, recovery plans, cost Estimate at Completion (EAC), cost

Estimate to Completion (ETC), and funding status.

4.1.9.5. POST PDM REPORT

4.1.9.5.1. The contractor shall prepare and submit Post PDM reports (CDRL

A006) for all aircraft inducted. The Post PDM reports must contain at a minimum the following data elements:

a) A list of all technical directives, Modification Work Orders (MWO), ADs, SBs, and ASBs incorporated since the last PDM and during the present PDM.

b) A list of components and life limited parts removed for scheduled rework (Time Between Overhaul (TBO) items) or retirement.

c) Defects discovered during PDM to include the following:

i. Complete description of defect including size, severity, and criticality (critical, major, and minor).

ii. Accurate location of the defect.

iii. Description of corrective action taken.

iv. Man-hours to repair defect.

v. PDM task number performed when defect discovered.

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vi. Additionally, for corrosion, report type and severity as defined in

Tables 1 and 2 at the end of this SOW. A chronological photographic log showing initial state, in process treatment, and post treatment progress shall be included for all corrosion events.

d) Aircraft identification and total flight hours including:

i. Tail number, base location.

ii. Induction date and completion date.

iii. Total flight hours and operational months.

iv. Flight hours and operational months since last PDM.

v. Inspection man-hours, defect man-hours, and total PDM man-hours.

e) Condition summary reporting general condition of aircraft upon arrival at the PDM facility. Summary shall include pre-induction and post-PDM photos.

4.1.9.6. DATA

4.1.9.6.1. The Contractor shall prepare and deliver data to the government in

Contractor format except where specifically called out elsewhere in this SOW. The Contractor shall establish and maintain procedures to ensure accurate identification, preparation, marking, tracking, and delivery of all contract data.

4.1.9.6.2. The Contractor shall ensure all technical data, including drafts and working papers, are marked and controlled in accordance with appropriate distribution statements and export control warning notices.

The Contractor shall not include any “Contractor Proprietary” or similar statements or markings on technical data developed for DoS as part of this contract.

4.1.9.6.3. The Contractor shall grant the Government unlimited authority to reproduce, update, or change any data developed and/or delivered under this contract

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SECTION II

Pre-Delivery (PDM)

4.2. PRE-DELIVERY REQUIREMENTS

4.2.1. LOGS AND RECORDS

4.2.1.1. INL/A will:

4.2.1.1.1. Identify aircraft requiring PDM at least 45 days prior to date of induction.

4.2.1.1.2. Conduct a pre-PDM inventory check prior to delivery for induction.

4.2.1.1.3. Remove and retain all unnecessary loose gear, equipment, classified material, pyrotechnic devices, and any item not required for PDM activities.

4.2.1.1.4. Deliver the aircraft with a current and complete logbook. Deliver all relevant aircraft historical documentation necessary to perform a thorough records review for PDM requirements. DoS personnel will coordinate with the Contractor prior to aircraft delivery to ensure the

Contractor receives all pertinent records.

4.2.1.1.5. Deliver hard copies of the daily, six-month file, and historical records to the Contractor’s facility upon delivery of the aircraft.

4.2.1.2. The Contractor shall:

4.2.1.2.1. Utilizing the checklist developed in the section 4.1.1.2 coordinate with the INL/A regarding all pertinent record requirements.

4.2.1.2.2. Schedule the following life limited components for replacement during

PDM:

4.2.1.2.2.1. Components that are predicted to reach time limitations prior to the next scheduled phased inspection interval after PDM, or within one (1) year after completion of PDM (whichever is less) shall be considered for replacement on a case-by-case basis during the pre-delivery records review.

4.2.1.2.2.2. Aircraft Components remaining on the aircraft after completion of PDM shall have sufficient time remaining to ensure that scheduled component replacement is not required prior to the next scheduled phased inspection interval or within one (1) year after completion of PDM (whichever is less).

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4.2.1.2.2.3. The DoS may direct additional replacement items and/or components on a case-by-case basis.

4.2.1.2.2.4. Schedule unique mission systems such as instrumentation, navigation, or self-defense equipment for hardware/software/firmware upgrades as necessary.

4.2.1.2.3. Ensure all contract actions required to proceed have been completed.

4.2.2. CLASSIFIED MATERIAL

4.2.2.1. Classified material will be removed prior to delivery of aircraft for PDM.

However, if the Contractor suspects classified equipment is installed on aircraft upon arrival, the Contractor shall limit access to the aircraft equipment in question and notify the Contracting Officer Representative

(COR) immediately for disposition instructions.

4.2.3. AIRCRAFT TRANSFER

4.2.3.1. Aircraft transfer from INL/A to the Contractor for the PDM shall be in accordance with TM 1-1500-328-23, Aeronautical Equipment Maintenance

Management Policies and Procedures and the approved Government

Property Management Plan.

4.2.3.2. The location of the transfer will be determined by the condition and configuration of the aircraft and will be designated in the task order.

4.2.4. ACCEPTANCE CHECK FLIGHT

4.2.4.1. If condition and configuration of the aircraft allows, the Contractor shall perform a maintenance acceptance check flight at the Contractor’s facility no more than 7 days prior to aircraft induction into PDM. The acceptance check flight shall be a joint flight between INL/A or the delivery crew and the Contractor.

4.2.4.1.1. The Contractor shall perform and document maintenance test flight

IAW Technical Manual (TM) 1-1500-328-23 (Chapter 3), DoS approved test flight manuals, and the INL/A Operations Directive.

4.2.4.1.2. Discrepancies discovered during the maintenance test flight shall be documented in the aircraft logbook and all discrepancies documented in the logbook shall be processed for repair IAW section 4.3.2.

28 March 2016

SECTION III

Incoming Inspection (PDM)

4.3. INCOMING INSPECTION

4.3.1. The Contractor shall perform incoming inspections on all UH-1 aircraft. Once an aircraft is received at the Contractor’s facility, the Contractor shall, within 21 calendar days from receipt of aircraft at the Contractor’s facility, evaluate the aircraft and records for all projected actions required to fulfill the requirements within this SOW. The UH-1 incoming inspection and evaluation shall reflect all projected costs associated to examine and inspect; validate and repair reported discrepancies; perform operational checks; perform repairs within the scope of the PDM; perform outstanding DoS, FAA and OEM technical airworthiness directives; overhaul accessories and engines; apply additional modifications (as applicable and per DoS requests); treat corrosion; paint aircraft; and perform all pre and post PDM activities.

4.3.2. PDM COST ESTIMATE

4.3.2.1. Once the preliminary inspection has been accomplished, the Contractor shall combine pertinent items from the standardized fee schedule developed in section 4.1.3.2 of this SOW, any unscheduled actions requiring resolution, any special DoS requests, and all other items not specifically addressed in the standardized fee schedule and submit to the CO a report detailing all actions (e.g., inspection, repair, overhaul, paint, and modification) and estimated time required to execute the complete PDM to include a written quotation (CDRL A007). No further expenses shall be incurred against the affected aircraft without written direction from the CO. Considering the basic elements of performing the Contractor’s inspection and repair process developed IAW section 4.1.1 of this SOW, the following actions shall be included in the Contractor’s initial evaluation of costs:

4.3.2.1.1. AIRCRAFT RECORD ANALYSIS

4.3.2.1.1.1. Aircraft logbook historical records, to include the six month file, shall be reviewed to determine the existence and extent of conditions that might affect the planned sequence of inspection requirements. In particular, historical system performance shall be analyzed to determine possible chronic system and component

28 March 2016 trouble areas on which to apply added emphasis, preventive maintenance, or upgrades during the aircraft examination.

4.3.2.1.2. OVERHAUL AND REPLACEMENT ITEMS

4.3.2.1.2.1. Review aircraft and engine logbooks; inventory component serial number records; applicable Maintenance, Repair and Overhaul

(MRO) manuals; SBs; Alert Service Bulletins (ASB); Service

Instruction Letters (SIL); and/or other OEM and FAA ADs for any installed overhaul and replacement item that is considered high time, will become high time during PDM, or will become high time within a period of one (1) year or 300 airframe hours

(whichever is less) after PDM completion. If any of the previously stated conditions exist, the Contractor shall include the appropriate rework during PDM.

4.3.2.1.3. USER SPECIFIED. Determine and document additional items of rework such as user specified areas of concern, and task order technical directives and modifications.

4.3.2.1.4. MODIFICATIONS

4.3.2.1.4.1. Aircraft modifications shall be designed and installed in accordance with section 4.22.1 of this SOW.

4.3.2.1.4.2. If required and directed by the CO, modifications shall be developed and incorporated during the PDM. Examples of recent modifications include:

a) 406 Mhz ELT installation

b) Cross Tube Support Bracket

c) Satellite Communications and Tracking Equipment

Installation

d) Rewire and Avionics Upgrades

e) NVG and Covert lighting modifications

f) Special mission equipment installations and upgrades

4.3.3. PRELIMINARY INVENTORY, EXAMINATIONS, AND OPERATIONAL

TESTS

4.3.3.1. AIRCRAFT CONFIGURATION

4.3.3.1.1. The Contractor shall accept the aircraft in the configuration in which it arrives. Unless otherwise specified by the CO, all mission specific

28 March 2016 modifications shall be considered part of the aircraft and shall be visually and functionally checked as part of the PDM process. In cases where the Contractor does not have the installation and functional checkout procedures and are not able to obtain the technical procedures, the Government will provide the technical information as

Government Furnished Property (GFP).

4.3.3.1.2. Any DoS loose stores or equipment not directly installed on the aircraft at arrival and not required for the inspection and repair processes shall be safeguarded, tagged, stored, and reinstalled in its original location prior to acceptance and transfer of possession during post PDM activities.

4.3.3.1.3. The following is a partial list of DoS aircraft modifications (not all are installed in all aircraft dependent on operating location and mission) with unique requirements that the Contractor shall provide as part of the PDM process. If an installed modification is not specifically referenced, the Contractor shall inspect and functionally check (as required) the system or modification per OEM data, drawings, and/or recommendations.

a) AN/ALE-47 Countermeasures Dispenser. Note:

All pyrotechnic devices (flares) and confidential equipment

(programmer) will be removed by the DoS prior to delivery.

The Contractor shall physically inspect and functionally test the dispenser to the extent possible without the programmer per OEM instructions.

b) AN/AAR Missile Warning System

c) Crew Station Armor

d) Auxiliary Ballistic Tolerant Fuel Tanks

e) IR Suppression System

f) External Cargo Hook with weight indicator in cockpit

g) Internal/External Hoist Systems

4.3.3.2. ENGINE INSPECTION

The Contractor shall:

4.3.3.2.1. Perform incoming inspections on all Honeywell and P&WC (as applicable) engine power units, modules, and components. The

Contractor shall inspect and evaluate engines for all necessary repairs, 28 March 2016 overhauls, major inspections, and modifications. Overhauls, time changes, and major inspections shall not come due within one (1) year or 300 airframe hours (whichever is less) after PDM accomplishment.

Engine inspections and evaluations shall reflect all costs associated to inspect, repair, modify, or overhaul engine power units, modules, and components to current DoS, OEM and FAA specification standards.

All applicable Service Bulletins (Category 1 through 6) for the specific engine model shall be incorporated during repair or overhaul.

In conjunction with section 4.3.2.1 of this SOW, the Contractor shall submit cost estimates for affected engines in the initial PDM cost proposal stating all actions necessary (run-up, inspection, repair, overhaul, or modification) to bring the affected engines up to current

OEM/FAA/DoS standards. The DoS reserves the right to have the engine(s) delivered to a DoS contracted vendor for evaluation, repair, or overhaul.

4.3.3.2.2. Perform at a minimum a visual and compressor section borescope inspection for Foreign Object Damage (FOD) on all incoming aircraft engines. The inspection shall include an examination of the air intake/inlet and the visually accessible compressor rotor blades for damage. If damage is found, the Contractor shall request instructions from the COR before proceeding.

4.3.3.2.3. Prior to any engine disassembly and if the action can be safely performed, an engine performance check run-up shall be accomplished to establish an initial functional baseline. The Contractor shall document the results, compare them with post-PDM performance checks, and include them within the final PDM documentation package.

4.3.3.2.4. Accomplish engine oil sampling and servicing in accordance with the DoS and OEM maintenance manuals.

4.3.3.2.5. If possible, conduct an engine performance recovery wash. The

Contractor shall accomplish this task in accordance with the appropriate UH-1 engine maintenance manual prior to inspection, maintenance, or preservation.

4.3.3.2.6. PRESERVATION

4.3.3.2.6.1. The Contractor shall preserve engines in accordance with the UH-1 Maintenance and Engine Manuals, as follows:

28 March 2016

a) Engines scheduled for replacement shall be given Type I preservation.

b) Engines scheduled for continued service shall be given Type

II preservation.

4.3.3.3. AIRFRAME INSPECTION

The Contractor shall:

4.3.3.3.1. If possible, during the receiving inspection, service all systems and inspect and perform operational checks in accordance with the applicable aircraft maintenance instructions as necessary to determine the condition and extent of adjustment or repairs required on all systems.

4.3.3.3.2. Remove panels to the extent necessary to assess airworthiness and accomplish PDM tasks.

4.3.3.3.3. Thoroughly evaluate interior seats, seat belts, and sound proofing for full functionality, safety, and airworthiness.

4.3.3.3.4. Perform hydraulic fluid contamination check in accordance with the

Bell/DoS UH-1 Maintenance Manual.

4.3.3.3.5. Inspect fuel for contamination in accordance with the criteria of the

Bell/DoS UH-1 Maintenance Manual.

4.3.3.3.6. Dispose of drained fluids IAW local, state, and Federal guidelines.

4.3.3.3.7. Document all discrepancies discovered during aircraft checks and schedule corrective action at an appropriate rework sequence.

4.3.3.3.8. Identify, document, and bring to the attention of the COR and DoS

Engineering Authority all previously installed repairs, not authorized or documented by acceptable and approved publications relative to the standards of repair and workmanship enumerated therein. The

Contractor shall not perform further work on the affected structure until disposition instructions have been received from the COR and

DoS Engineering Authority.

4.3.3.3.9. Report to the COR and the DoS Engineering Authority all existing installations that do not conform to established engineering instructions and are not documented in historical aircraft records.

28 March 2016

4.3.3.3.10. PAINT, SEALANT, AND CORROSION ASSESSMENT

4.3.3.3.10.1. The Contractor shall thoroughly examine exterior surface of the aircraft for corrosion, defective sealants, and deteriorated seals.

Regardless of the condition of the exterior paint condition at aircraft induction, the Contractor shall perform a complete strip and repaint of the aircraft exterior during the PDM process unless directed otherwise by the CO.

4.3.3.3.10.2. The Contractor shall thoroughly examine accessible interior surfaces of the aircraft for defective paint finishes. The

Contractor shall strip and repaint interior finishes only to the extent necessary to inspect for corrosion and defects and to restore protective coatings.

4.3.3.4. AIRCRAFT INVENTORY UPON ARRIVAL

4.3.3.4.1. A joint Contractor/Government aircraft inventory shall be accomplished on all aircraft, engines, accessories, and support equipment. The Contractor shall annotate aircraft records accordingly to reflect the aircraft configuration as received. Aircraft mounted items shall be inventoried using the weight and balance records chart A. The

Contractor shall inventory separately on a Contractor developed inventory sheet items found but not specifically listed on the chart A weight and balance inventory records such as loose equipment (e.g., ALSE, aircraft ground safety equipment, cargo tie-down equipment, etc.) . The Contractor developed inventory sheet must include the following minimum information:

a) Date inventoried

b) Description

c) Serial or Tag number if available

d) Location

e) Quantity

f) Inspection/Replacement status (If any, list due date)

g) Name of person(s) performing inventory

4.3.3.4.2. If inventory irregularities are identified upon receipt of DoS assets, the

Contractor shall notify the CO, or authorized point of contact, within 7 calendar days of examination completion. The CO will provide guidance for inventory shortages within 7 calendar days of receipt of

28 March 2016 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 initial PDM costs (section 4.3.2 of this 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 A008).

4.3.3.4.2.1. Missing Components: Within 7 calendar days after the receipt and inspection of the aircraft, the Contractor shall notify the CO in writing of any missing parts or sub-assemblies required for initial inspection and acceptance. (CDRL A008)

4.3.3.4.2.2. Counterfeit or Suspect Components: Upon receiving components exhibiting evidence of being counterfeit, the

Contractor shall notify the CO, in writing (CDRL A008) and in detail, immediately 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/s.

4.3.3.5. The DoS reserves the right to provide Government Furnished Property

(GFP) to replace parts or hardware identified as missing, counterfeit, or determined to be unserviceable.

4.3.3.6. SUPPORT EQUIPMENT INVENTORY

4.3.3.6.1. The Contractor shall conduct a joint fly away gear (e.g., blade tie downs, engine inlet and exhaust covers, pitot covers, etc.) inventory with a representative of the delivering activity. Accountability and shortages shall be determined by comparing actual inventory with aircraft inventory records. The Contractor shall document inventoried items not reflected on aircraft records IAW section 4.3.3.4.1 of this

SOW.

4.3.3.6.2. The Contractor shall ensure that aircraft fly away gear is tagged, stored, and returned with the same aircraft in the same condition as received. Missing support equipment, except for items misplaced while the aircraft is at the maintenance facility, shall not be replenished. The Contractor shall notify the CO of missing equipment upon completion of the aircraft incoming inspection. (CDRL A008)

4.3.3.6.2.1. Inventoried items that are lost or reported missing during PDM shall be replaced by the Contractor, at the Contractor’s sole

28 March 2016 expense, with an equivalent serviceable item at the completion of PDM.

4.3.3.6.3. AVIATION LIFE SUPPORT EQUIPMENT (ALSE) AND

MISCELLANEOUS ITEMS

4.3.3.6.3.1. ALSE and miscellaneous equipment (e.g., survival equipment

(harnesses, vests, helmets, etc.), maps, first-aid kits, cargo tie-down straps, and any other items discovered that are not directly part of the aircraft shall not be repaired or replaced. The

Contractor shall identify, pack, and ship to Patrick AFB, FL first aid kits and personnel survival equipment IAW section 5.1 of this SOW. All items shipped to Patrick AFB will be updated or replaced and returned to the Contractor prior to aircraft final acceptance by the DoS when requested by the Contractor and prior to aircraft final delivery. All other items shall be inventoried, tagged, and stored by the Contractor to prevent damage or deterioration during the PDM process and returned with the outgoing aircraft. The Contractor shall compare any actual life limited or inspections limited markings with the aircraft records (DA 2408-18) and update the records accordingly IAW DA PAM 738-751.

28 March 2016

SECTION IV

PDM Inspection

4.4. INSPECTION REQUIREMENTS

4.4.1. The Contractor shall perform all required PDM tasks for each aircraft identified by DoS IAW the approved inspection procedures for each specific UH-1 model and series and the requirements of this SOW. As required, the Contractor shall perform all items listed in the overall list of required services from section 2.2 of this SOW. The Contractor shall document all unsafe/unsatisfactory conditions identified during the inspection. The Contractor shall report to the CO all items considered outside of the basic PDM and handle said items in accordance with the

Over and Above (O&A) Work Procedures as defined in section 4.5 of this SOW.

4.4.2. IAW the approved inspection procedures from section 4.1.1.10 of this SOW, the

Contractor shall notify the DoS 10 days prior to any projected joint inspection requirements. If no DoS representative is available or the verification is waived, the sign off will be made by the Contractor stipulating that the Government has waived physical inspection along with the waiving written reference (e.g., email, fax, etc.) signed by the COR.

4.4.3. ACCESSORIES AND COMPONENTS

4.4.3.1. The Contractor shall identify, tag, protect, and ensure safe storage of all removed parts and components. If the removed part or component will not be reinstalled on the aircraft, the Contractor shall initiate appropriate property actions IAW the approved property management plan developed under section 4.24 of this SOW.

4.4.4. ENGINES

4.4.4.1. The following paragraphs apply to engines that are projected to require major maintenance, a major inspection, component time changes, or overhaul due within one (1) year or 300 airframe hours (whichever is less) after completion of the PDM.

4.4.4.1.1. INSPECTION, MAINTENANCE, AND REPAIR

4.4.4.1.1.1. The Contractor’s repair facility shall execute all normal engine inspections, maintenance, and repair IAW published OEM repair manuals. Engine repairs beyond the capability and scope of OEM published repair procedures shall be repaired or

28 March 2016 overhauled by a Honeywell certified or P&WC approved repair facility as appropriate for the engine model.

4.4.4.1.1.2. All Fuel Regulators and Governors shall be repaired or overhauled when required in accordance with either P&WC or

Honeywell data and in the case of Pratt & Whitney engines by a P&WC facility. The DoS reserves the right to send the affected components to another DoS contracted vendor at it's discretion.

4.4.4.2. REPLACEMENT PARTS

4.4.4.2.1. All replacement parts utilized in the overhaul or repair of DoS P&WC and Honeywell engines shall be traceable to their original place of manufacture from the following sources: new OEM parts; parts and materials that are OEM authorized; serviceable parts authorized for use by the DoS; or, parts overhauled IAW OEM specifications. FAA certified Parts Manufacturer Approval (PMA) replacement parts are not acceptable for use on INL/A Honeywell or P&WC engines. The

INL/A airworthiness authority shall have final authority for all matters related to installation of replacement parts.

4.4.4.2.1.1. When sourcing replacement parts, the Contractor shall be familiar…