Attachment_014_SEMA_Appendix_J_PWS

W58RGZ-15-R-0045 APPENDIX J to SEMA PWS

C-12 Service Life Extension Program

(SLEP)

(Revision VI, 10 Sep 2014)

TABLE OF CONTENTS

1. Background………………………………………………………………………

2. Conditions……………………………………………………………………..….3 - 4

3. Period of Performance………………………………………………………………5

4. Scope………………………………………………………………………………5 - 6

1. Background

As a result of OEM analysis, it has become necessary to perform certain structural repairs and upgrades in order to extend the life of the Army C-12/RC-12 fleet. This work will be performed as required by the USG and IAW this appendix.

2. Conditions

A. All work shall be performed IAW the OEM maintenance manuals and FAA AC’s.

Proper data entries in all aircraft log books are to be completed in accordance with the Contract requirements. Repairs outside the OEM process will adhere to the requirements described in PWS section 3.3.1.1.2.1.

B. The subcontractor(s) and vendor(s) shall maintain a quality system achieving control of the quality of the services and supplies they provide. The contractor's/ subcontractor’s Quality Assurance procedures shall be made available and kept current at each site. As a minimum, the Contractor's, sub-contractor(s) and vendor(s) QA Plans, if applicable, shall address the following areas: Safety Procedures, Quality Control Procedures, Site Internal Inspections, Management Review Intervals, FOD Prevention, Corrosion Control/Paint Procedures, HAZMAT Handling and Disposal, Tool Control, Calibration System, Electro-static Discharge (ESD), and Non-Destructive Inspection/Test.

C. All defects caused by the contractor or subcontractor shall be corrected in accordance with FAA regulations (FAR’s) to include Part 145 Repair Station Criteria at no charge to the Government.

D. The vendor shall provide all facilities, labor, consumables, and materials not listed in item (F. i-vii) below to accomplish the requirements of the scope. The facility shall have proper tooling to accomplish the potential fabrication of parts, to include jigs, fixtures and proper FAA Designated Engineering Authority to approve repairs as required.

E. Additional work may be required above and beyond what is detailed below and will be handled by the over and above process.

F. Government provided parts are as listed below. Use part numbers listed or equivalent part numbers

i. 101-4077-X Cold Working Kit.

ii. 101-1200-1S Main Spar Access Cover (as required)

iii. 101-1202-1S Kit, Attach Angle

iv. 130-1220-0001 Cover Assembly Left wing bolt

v. 130-1220-0002 Cover Assembly Right wing bolt

vi. 101-11008X-X Spar Assembly, Left, except for BW series aircraft

vii. 101-11008X-X Spar Assembly, Right, except for BW series aircraft o BP-046 through BP-063 spar part numbers are 101-110086-1 and -2 o BP-64 through BP-071, spar part numbers are 101-110084-1 and -2 o BL-073 through BL-123 may require NDI/NDT if newer style spar is installed. If it doesn’t have newer style spar then it must be replaced with new style spar. Spar part number is 101-110084-1 and -2 or OEM approved equivalent part number.

o BW-002 through BW-029 are 101-110084-7001 and -7002 and do not require spar replacement but must have spar caps eddy current inspected for deformities. (NDI/NDT)

G. Discrepancies discovered, outside the scope of the FFP, will be submitted as Over and above (O&A) to the PCO for approval. O&A proposed man-hours and materials shall be submitted through the appropriate PCO representative as Work Requests for each of the discrepancies found that are not covered by the FFP scope. Work Requests requiring more than 8 hours will need to be broken down IAW current contractual and Federal Acquisition Regulation requirements.

H. If the correction of O&A discrepancies requires outside services, then those services will be listed as Material costs, e.g. contracted pilot services, outside vendor repairs or services, and subcontracted NDT, etc.

NOTE

Due to the nature of this effort, some aircraft will not require installation of ALL of the SLEP kits. As these aircraft are scheduled into the facilities, we will know the extent of work required and will notify the Contractor of those requirements and list all requirements on the ATP.

3. Period of Performance

The Period of Performance shall not exceed 90 calendar days.

4. Scope

A. Only for aircraft that will have the spar(s) changed. Prior to disassembly for spar change, complete a symmetry check to establish the condition of the aircraft. The results of the symmetry check will be recorded in the historical records.

B. Complete all actions required to cold work the rear center section spar IAW 101- 4077-X (1 or 3, depending on aircraft Serial Number), Cold working kit drawings and instructions. (Customer Supplied Kit)

C. Complete all actions required to replace the wing attachment angles IAW 101-1202- 1S kit, attach angle drawings and instructions.

D. Replace the outer wing spar assemblies as applicable to the S/N aircraft.

o BP-046 through BP-063 are 101-110086-1 and -2 or OEM approved equivalent o BP-64 through BP-071 are 101-110084-1 and -2 or OEM approved equivalent o BL-073 through BL-123 are 101-110084-1 and -2 or OEM approved equivalent o BW-002 through BW-029 are 101-110084-7001 and -7002 spars. Replacement of these spars is not required but must have a NDT/NDI inspection completed to check for deformities.

E. Unless already complete. Complete all actions required to install the kit PN: 101- 1200-1S main spar access cover.

F. Unless already complete. Complete the installation of 130-1220-0001 and -0002 Cover Assemblies; wing bolt IAW the 130-1220-000X drawings and instructions.

G. Perform Center Section Belly Skin NDI IAW SRM 57-17-02 Chart 201 Index 4 Figure

H. Perform Center Section Lower Forward Spar Cap NDI IAW SRM 57-17-02 Chart 201 Index 3 Figure 203

I. Gather all needed data for Appendix XXX - Continuing Analysis and Surveillance System

J. Only for aircraft that will have the spar(s) changed. Once spar change re-assembly is complete, perform a symmetry check to establish the condition of the aircraft. The results of the symmetry check will be recorded in the historical records.

K. The contractor shall provide a Flight Check List of sufficient depth and content to thoroughly evaluate all aircraft systems and satisfy CASS requirements. The Flight Check list will be approved by PMO FW.

L. A post SLEP flight shall be performed. All faults discovered during the post test flights will be recorded on the DA Form 2408-13-1.

M. Perform a daily inspection prior to delivery

RC-12 Service Life Extension Program

(SLEP)

(Revision IV, 25 August 2014)

TABLE OF CONTENTS

1. Conditions…………………………………………………………………………3 - 4

2. Period of Performance…………………………………………………….………...4

3. Scope……………………………………………………………………………….4 - 7

4. Point of Contact (POC)………………………………………….………………..….7

1. Conditions A. Provide a Firm Fixed Price Proposal to complete the tasks contained in this document.

B. All work shall be performed IAW the OEM maintenance manuals and FAA AC’s.

Proper data entries in all aircraft log books are to be completed in accordance with the Contract requirements. RDO or a DER will have to approve repairs that are not covered by Beechcraft manuals, FAA AC’s and kit instructions. Non-standard repairs will also have to be approved by AED.

C. The subcontractor(s) and vendor(s) shall maintain a quality system achieving control of the quality of the services and supplies they provide. The contractor's/subcontractor’s Quality Assurance procedures shall be made available and kept current at each site. As a minimum, the Contractor's, sub-contractor(s) and vendor(s) QA Plans, if applicable, shall address the following areas: Safety Procedures, Quality Control Procedures, Site Internal Inspections, Management Review Intervals, FOD Prevention, Corrosion Control/Paint Procedures, HAZMAT Handling and Disposal, Tool Control, Calibration System, Electro-static Discharge (ESD), and Non-Destructive Inspection/Test.

D. All defects caused by the heavy Maintenance activity shall be corrected in accordance with FAA, Part 145 Repair Station Criteria at no charge to the Government.

E. Proposal shall apply to all facilities that could be used for this work.

F. The vendor shall provide all facilities, labor, consumables, and materials not listed in item (H. i-v) below to accomplish the requirements of the scope. The facility shall have proper tooling to accomplish the potential fabrication of parts, to include jigs, fixtures and access to Beechcraft RDO or proper FAA Designated Engineering Authority to approve repairs as required.

G. Additional work may be required above and beyond what is detailed below and will be handled by the over and above process.

H. Government provided parts are as listed below. Use part numbers listed or equivalent part numbers

i. 101-4077-X Cold Working Kit.

ii. 101-1200-1S Main Spar Access Cover (as required)

iii. 101-1202-1S Kit, Attach Angle

iv. 101-110087-1 Spar Cap, Left

v. 101-110087-2 Spar Cap, Right

I. Over and above (O&A) proposed man-hours and materials will have to be submitted through the appropriate government representative as Work Requests for each of the requirements in the scope. Work request that require more than 8 hours will need to be broken down IAW current contractual requirements.

J. Items that are outside services will be listed as Material costs, e.g. contracted pilot services, outside vendor repairs or services, and subcontracted NDT if not part of kit installation.

K. Firm fixed Price Proposal shall be applicable to all aircraft inducted during the contract period.

L. Maintenance that should have been performed at the Beddown base shall be the responsibility of the contractor and may be deferred back to the Beddown base if it does not affect airworthiness.

2. Period of Performance

The Period of Performance shall not exceed 90 calendar days. During this 90 day period, the aircraft will be reported in an NRT status. Unless and extension to the NRT is granted for USG induced delays, the aircraft will then be reported in an NMC condition.

3. Scope

A. Prior to disassembly for spar cap change, complete a symmetry check to establish the condition of the aircraft. The results of the symmetry check will be recorded in the historical records.

B. Without removing additional equipment, sufficiently clean areas accessed to comply with tasks in this Statement Of Work to allow for inspection

C. Comply with 101-4077-3 Cold Working Kit

D. Comply with 101-1202-1S Kit, Attach Angle

E. Install Kit 101-1200-1S lower nacelle inspection panels

F. Replace the left and right lower forward outboard wing spar cap

G. Perform 5 year wing attach fitting NDI requirement per SIRM 57-17

H. Replace wing attach bolts, nuts and washers

I. Once spar cap change re-assembly is complete, perform a symmetry check to establish the condition of the aircraft. The results of the symmetry check will be recorded in the historical records.

J. Inspect wing pods per table below:

Pod Inspection – GR & FE series aircraft with Pods installed

Tech PID Inspector

PID

Will be completed during Phase 4 or 24 months whichever occurs first. An alignment flight and assistance from Mission Equipment support personnel may be required

Support Wing Tip Pod Antenna BEFORE removing access door assembly

DISASSEMBLY:

WARNING Electrical equipment attached to back of access door assembly, remove slowly and with caution

1. Remove center section door assy. Install 4 ea. temporary support bolts in corners of door opening.

2. Remove fwd, aft, and center section ballast assemblies.

3. Remove fwd and aft tip assemblies.

4. Remove fwd and aft barrel assemblies.

INSPECTION:

Tip Assemblies

1. Inspect fwd and aft tip assemblies for delaminating, corrosion, loose or missing inserts, and general condition of internal structures.

2. Inspect fwd tip assy. deice boot for de-bonding, holes, and tears.

3. Inspect electrical wires/connectors and pneumatic lines for condition.

Barrel Assemblies

1. Inspect fwd and aft barrels for delaminating, corrosion, loose or missing inserts.

2. Inspect attach rings for fretting corrosion loose or missing nut plates and general condition of internal structure, minimum material thickness .050”.

3. Inspect electrical wires/connectors and pneumatic lines for condition.

Center section

1. Inspect center section for delaminating, corrosion, loose or missing inserts.

2. Inspect attach rings for fretting corrosion, delaminating, loose or missing nut plates, minimum material thickness .050

3. Inspect 4 ea. lower bonding straps for corrosion along edges. If corrosion is found remove suspect bonding straps for further evaluation.

4. Inspect electrical wires/connectors for condition.

5. Inspect center section to wing attach angles and adjacent structure for cracks, corrosion, and general condition.

Center section door assembly

1. Inspect center section door assembly for delaminating, loose or missing inserts.

2. Inspect electrical wires/connectors and pneumatic lines for condition.

3. Inspect die pole antenna (if installed) for condition.

REASSEMBLY:

CAUTION

Ensure electrical equipment is reconnected during center section door installation.

WARNING

Electrical equipment attached to back of access door assembly, install slowly and with caution

1. Remove 4 ea. temporary support bolts in corners of door opening and install center section door assembly.

2. Install fwd, aft, and center section ballast assemblies; torque fasteners to specified value.

3. Install fwd and aft tip assemblies; torque fasteners to specified value.

4. Install fwd and aft barrel assemblies; torque fasteners to specified value.

MAKE APPROPRIATE HISTORICAL LOGBOOK ENTRIES UPON COMPLETION OF INSPECTION

REQUIREMENTS:

Signature Lead/Inspector Date

K. Inspect Vertical Stabilizer Front Spar Cap Angles per King Air Series Communiqué #

2012-03

L. Comply with King Air 200/300/350 Communiqué No. 59 Wing Root Fairing 200

i. Perform option 2

ii. Inspect for corrosion reference 43.13-1B Para 5-15

M. Inspect inside of wet wing fuel bay for corrosion

N. Strip & Paint; IAW Contract, IML 20-00-08, TM 55-1500-345-23, MIL-DTL-53039D, MIL-DTL-64159B, Appendix XXX and Paint and Marking Technical Data Package C-

12/RC-12/C12J

O. Perform corrosion Inspection per criteria contained in Appendix XXX

i. Paint inside of cowlings with epoxy primer

P. Refurbish complete interior and install soundproofing if not already installed.

Q. Provide entries in logbooks and historical records as required for tasks performed

R. The contractor shall provide a Flight Check List of sufficient depth and content to thoroughly evaluate all aircraft systems. The Flight Check list will be approved by

PMO FW.

S. A post SLEP flight shall be performed. All faults discovered during the post test flights will be recorded on the DA Form 2408-13-1.

T. Perform a daily inspection prior to delivery

5. Point Of Contact

The POC for this action is Mr. Scott Hobbs 256-842-3402.

Noted discrepancies that do not affect airworthiness may be returned to a Beddown Base for corrective action with prior approval of the PMO FW. These items will be provided on a Noted but Not Corrected (NBNC) document to the Fixed Wing Heavy Maintenance Leadership via e-mail in Excel format prior to paint.