US Department of State D R AF T STATEMENT OF WORK DEPARTMENT OF STATE UH-1 HELICOPTER PROGRAMMED DEPOT MAINTENANCE (PDM) 1 28 March 2016 US Department of State Table of Contents BACKGROUND .................................................................................................................. 2 2. SCOPE .............................................................................................................................. 5 3. OBJECTIVES ...................................................................................................................... 7 4. TASKS/REQUIREMENTS..................................................................................................... 8 4.1. GENERAL .......................................................................................................................... 8 4.1.2. PDM DURATION. ............................................................................................................ 12 4.1.3. PDM COST ESTIMATE. ..................................................................................................... 12 4.1.5. TECHNICAL REFERENCES. ................................................................................................ 14 4.1.9. PROGRAM MANAGEMENT REQUIREMENTS .................................................................... 16 4.2. PRE-DELIVERY REQUIREMENTS ....................................................................................... 19 4.2.2. CLASSIFIED MATERIAL ..................................................................................................... 20 4.2.3. AIRCRAFT TRANSFER ....................................................................................................... 20 4.2.4. ACCEPTANCE CHECK FLIGHT ............................................................................................ 20 4.3. INCOMING INSPECTION .................................................................................................. 21 4.3.2. PDM COST ESTIMATE ...................................................................................................... 21 4.3.3. PRELIMINARY INVENTORY, EXAMINATIONS, AND OPERATIONAL TESTS ........................... 22 4.4. INSPECTION REQUIREMENTS .......................................................................................... 29 4.4.3. ACCESSORIES AND COMPONENTS ................................................................................... 29 4.4.5. AF R D 4.4.4. T 1. ENGINES ......................................................................................................................... 29 AIRFRAME ...................................................................................................................... 31 4.6. CORRECTION OF DISCREPANCIES..................................................................................... 38 4.7. WARRANTIES.................................................................................................................. 39 4.8. UNSERVICEABLE/UNUSED DOS ASSETS............................................................................ 39 4.9. ADDITIONAL MAINTENANCE REQUIREMENTS.................................................................. 39 4.10. POST MAINTENANCE CLEANING ...................................................................................... 40 4.11. CORROSION TREATMENT ................................................................................................ 41 4.12. PAINT ............................................................................................................................. 41 4.13. CONFIGURATION RESTORATION ..................................................................................... 42 2 28 March 2016 US Department of State 4.14. WEIGHT AND BALANCE ................................................................................................... 43 4.15. ENGINE TREND MONITORING SYSTEM ............................................................................ 43 4.16. COMPASS CALIBRATION ................................................................................................. 43 4.17. POST INSPECTION SERVICING .......................................................................................... 43 4.18. POST INSPECTION FUNCTIONAL CHECKS .......................................................................... 44 4.18.2. ENGINE PERFORMANCE CHECK ....................................................................................... 44 4.18.3. ACCEPTANCE/FUNCTIONAL CHECK FLIGHT....................................................................... 44 4.18.4. FLIGHT SUPPORT INSPECTION/S ...................................................................................... 46 ACCEPTANCE AND TRANSFER OF POSSESSION ................................................................. 46 4.20. SCHEDULED MAINTENANCE PRIOR TO DEPARTURE ......................................................... 47 4.21. AIRCRAFT TRANSPORTATION AND SHIPMENT ................................................................. 47 4.22. ENGINEERING SUPPORT REQUIREMENTS ........................................................................ 48 T 4.19. AF 4.22.1. PDM ENGINEERING ......................................................................................................... 48 4.22.2. NON-PDM ENGINEERING AND TECHNICAL ASSISTANCE ................................................... 49 NON-PDM LOGISTICS ...................................................................................................... 49 4.24. PROPERTY MANAGEMENT PLAN ..................................................................................... 50 4.25. SECURITY........................................................................................................................ 50 4.26. QUALITY ASSURANCE (QA) .............................................................................................. 50 5. DELIVERY........................................................................................................................ 51 7. D 6. R 4.23. GOVERNMENT FURNISHED PROPERTY............................................................................. 51 PLACE OF PERFORMANCE ............................................................................................... 51 8. PERIOD OF PERFORMANCE ............................................................................................. 51 9. APPLICABLE DOCUMENTS ............................................................................................... 52 9.2. MANUFACTURER PUBLICATIONS ..................................................................................... 52 9.3. MILITARY AND DOS PUBLICATIONS ................................................................................. 53 9.4. FEDERAL AVIATION REGULATIONS .................................................................................. 54 9.5. ADVISORY CIRCULARS..................................................................................................... 55 9.6. MISCELLANEOUS ............................................................................................................ 55 10. MARKING, PACKAGING, AND PRESERVATION .................................................................. 55 3 28 March 2016 US Department of State 11. INSPECTION AND ACCEPTANCE ....................................................................................... 56 List of CDRLs ............................................................................................................................... 57 Table 1 Corrosion Type Designation ............................................................................................ 58 D R AF T Table 2 Corrosion Severity Designation ....................................................................................... 58 4 28 March 2016 US Department of State 1. BACKGROUND 2. SCOPE R AF T 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. D 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: 5 28 March 2016 US Department of State 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. T g) Corrosion evaluation, repair, and treatment. h) Full strip and repaint and application of DoS markings to the exterior of the aircraft. AF 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. R 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. D 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). 6 28 March 2016 US Department of State 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 D R AF T 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. 7 28 March 2016 US Department of State SECTION I General Requirements (PDM) 4. TASKS/REQUIREMENTS 4.1. GENERAL T 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: AF 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: 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), D R 1. 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), 8 28 March 2016 US Department of State 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, T 16. All test and flight acceptance support from induction until departure to include up to 10 hours of post acceptance user reliability flights, AF 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, R 20. Drive train hanger bearings removal, overhaul, and reinstallation for all inducted aircraft, 21. All fluid filter replacements, D 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, 9 28 March 2016 US Department of State 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. T 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. AF 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. D R 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 240818 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. 10 28 March 2016 US Department of State AF T 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 NonDestructive 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. D R 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/signoff 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. 11 28 March 2016 US Department of State 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. T 4.1.3. PDM COST ESTIMATE. AF 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. D R 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, 12 28 March 2016 US Department of State 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. T 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: 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: R AF a) i. Transmission, D 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. 13 28 March 2016 US Department of State 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. AF T 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. D R 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 14 28 March 2016 US Department of State 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. AF T 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. R 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. D 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, 15 28 March 2016 US Department of State 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) D R AF T k) 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 16 28 March 2016 US Department of State 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.). T 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. 4.1.9.5. AF 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. POST PDM REPORT R 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 list of all technical directives, Modification Work Orders (MWO), ADs, SBs, and ASBs incorporated since the last PDM and during the present PDM. D a) 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. 17 28 March 2016 US Department of State 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 manhours. DATA T 4.1.9.6. Condition summary reporting general condition of aircraft upon arrival at the PDM facility. Summary shall include pre-induction and post-PDM photos. AF e) R 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. D 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 18 28 March 2016 US Department of State 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. T 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. AF 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. R 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: D 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). 19 28 March 2016 US Department of State 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 4.2.3. AIRCRAFT TRANSFER T 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. AF 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. R 4.2.4. ACCEPTANCE CHECK FLIGHT D 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. 20 28 March 2016 US Department of State SECTION III Incoming Inspection (PDM) 4.3. INCOMING INSPECTION AF T 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 D R 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 21 28 March 2016 US Department of State 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. AF T 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. R 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: 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 D a) 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 22 28 March 2016 US Department of State 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. AF T 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: R 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. 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 D b) 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, 23 28 March 2016 US Department of State T 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. AF 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. D R 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. 4.3.3.2.6.1. PRESERVATION The Contractor shall preserve engines in accordance with the UH-1 Maintenance and Engine Manuals, as follows: 24 28 March 2016 US Department of State 4.3.3.3. a) Engines scheduled for replacement shall be given Type I preservation. b) Engines scheduled for continued service shall be given Type II preservation. 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. T 4.3.3.3.2. Remove panels to the extent necessary to assess airworthiness and accomplish PDM tasks. AF 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. R 4.3.3.3.6. Dispose of drained fluids IAW local, state, and Federal guidelines. D 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. 25 28 March 2016 US Department of State 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 R AF T 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: 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 D a) 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 26 28 March 2016 US Department of State 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). 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. AF T 4.3.3.4.2.1. 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 R 4.3.3.5. D 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 27 28 March 2016 US Department of State expense, with an equivalent serviceable item at the completion of PDM. 4.3.3.6.3. AVIATION LIFE SUPPORT EQUIPMENT (ALSE) AND MISCELLANEOUS ITEMS ALSE and miscellaneous equipment (e.g., survival equipment (harnesses, vests, helmets, etc.), maps, first-aid kits, cargo tiedown 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. D R AF T 4.3.3.6.3.1. 28 28 March 2016 US Department of State SECTION IV PDM Inspection 4.4. INSPECTION REQUIREMENTS T 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. AF 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 D R 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. 4.4.4.1.1.1. INSPECTION, MAINTENANCE, AND REPAIR 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 29 28 March 2016 US Department of State overhauled by a Honeywell certified or P&WC approved repair facility as appropriate for the engine model. 4.4.4.1.1.2. 4.4.4.2. 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. REPLACEMENT PARTS AF T 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. When sourcing replacement parts, the Contractor shall be familiar with and comply with the General Services Administration (GSA), Federal Management Regulation (FMR), Subchapter B, Part 102-33.115, Acquiring Government Aircraft and Aircraft Parts, rules pertaining to Flight Safety Critical Aircraft Parts (FSCAP); FAA Advisory Circular 20-142, Eligibility and Evaluation of U.S. Military Surplus Flight Safety Aircraft Parts, Engines, and Propellers; and, FAA AC 00-56B, Voluntary Industry Distributor Accreditation Program. D R 4.4.4.2.1.1. 4.4.4.2.2. Components and parts found to be in serviceable condition during the inspection, IAW OEM specifications and functional testing, may be reused if the specific component or part meets the time requirements stipulated in section 4.4.4.2.3 of this SOW. 4.4.4.2.3. All life limited parts that are reused shall have sufficient time and/or cycles remaining to reach the next scheduled major engine maintenance or inspection action (i.e., engine midpoint inspection (compressor section components) or hot section inspection (hot end components)) as applicable after PDM completion. 30 28 March 2016 US Department of State 4.4.4.3. TEST CELL 4.4.4.3.1. The Contractor shall only utilize an OEM correlated and certified engine run and test cell for determining DoS engines acceptable performance. 4.4.4.3.2. The Contractor shall perform test cell engine runs for all engines requiring major repair, overhaul, tear-down, or modification actions. The Contractor shall compare results with engine performance checks performed during the incoming inspection (if performed). The Contractor shall investigate and justify any degradation in performance in the historical documentation for the affected engine. 4.4.4.3.3. Additionally, the Contractor shall confirm all test cell engine run and performance documentation is included with the documentation package returned to the DoS IAW section 4.19.1 of this SOW. 4.4.5. AIRFRAME AF T 4.4.4.3.4. The Contractor shall perform and document that all post engine run FOD inspections, leak checks, filter changes, cleaning, oil analysis, and preservation have been accomplished IAW OEM specifications. D R 4.4.5.1. The Contractor shall limit the disassembly of each aircraft to the extent necessary to accomplish required inspections, maintenance, and/or paint procedures. The Contractor shall not perform maintenance that is not authorized by this document; the approved inspection procedures from section 4.1.1 of this SOW; approved O&A work procedures from section 4.5.1 of this SOW; or the CO. 4.4.5.2. The Contractor shall execute all required repair procedures using established technical data. In case(s) where established procedures do not exist, the Contractor shall have the engineering capability to develop the technical data required and execute all levels of airworthy repairs to include repairs for aircraft involved in accidents, incidents, and battle damage requiring major or specialized structural repair. 4.4.5.3. STRUCTURAL REPAIRS 4.4.5.3.1. All structural repairs shall be accomplished IAW authorized UH-1 repair manuals. Repairs beyond the scope of the Bell/DoS UH-1 maintenance and repair manuals may be repaired in accordance with procedures in the Bell structural repair manual (BHT-MED-SRM-1) with prior approval from the COR and DoS Engineering Authority. 31 28 March 2016 US Department of State Repairs shall be subject to the inspection and approval of DoS Airworthiness Authority representatives. For all repairs of a major nature exceeding the depth of the applicable structural repair manual, the Contractor shall submit to the CO and the DoS Engineering Authority, for review and approval, a detailed description of damage; method and details of proposed repair procedures; and associated stress analysis, drawings, and specifications. (CDRL A009) Stress analysis criteria shall be obtained by the Contractor. 4.4.5.3.3. The Contractor shall certify that each structural repair of a major nature, as defined above, meets the structural strength requirements so specified. 4.4.5.3.4. Upon completion of repairs, the Contractor shall update the appropriate aircraft historical record IAW section 4.4.7.3 of this SOW referencing the approval authority organization, name of approving authority, approval format (e.g., letter, fax, email, etc.), and approval date in the documentation. 4.4.5.3.5. Only Bell Helicopter (OEM) certified fixture(s) may be used when a fixture is required during airframe work or when the alignment of the airframe is questionable and requires verification. 4.4.5.3.6. The Contractor shall identify, document, and notify the COR and the DoS Engineering Authority in writing all previously installed repairs, not authorized by the above publications and procedures relative to the standards of repair workmanship enumerated therein. No further work shall be performed on the affected airframe and or components until disposition instructions have been received from the COR. D R AF T 4.4.5.3.2. 4.4.5.3.7. All panels, doors, and covers opened or removed for access or compliance with work requirements herein shall be reinstalled by the Contractor. 4.4.6. REPLACEMENT PART AND SUBSTITUTIONS 4.4.6.1. Replacement parts and material shall be of a traceable OEM or DoS approved source(s) in accordance with the manufacturer’s and DoS maintenance instructions and illustrated parts catalogues. 4.4.6.2. PMA or non-OEM approved parts or material shall not be used without the DoS Engineering Authority approval. When making substitution requests to the DoS, the Contractor’s request shall include a full analysis justifying the substitution by illustrating that the substitute part/s possess 32 28 March 2016 US Department of State properties equal to or greater than those possessed by the originally specified part. Dependent on the item in question, an engineering analysis by the Contractor may be required. 4.4.6.3. ELECTRICAL WIRING. 4.4.6.3.1. Replacement electrical wiring shall conform to the requirements of the applicable aircraft maintenance instructions manual and illustrated parts catalogues. New replacement electrical wiring shall be fabricated and installed in accordance with Advisory Circular 43.13-1B and/or the applicable aircraft maintenance instructions manual. Laser marking must be used to identify wiring. The Contractor shall not use hot stamping. 4.4.6.4. UNSCHEDULED COMPONENT REWORK AF T 4.4.6.4.1. Items not otherwise scheduled for removal/replacement shall be subject to rework only on a discrepancy basis (i.e., when determined defective by operational and functional checks, tests, or inspections) and approved as either a normal PDM event, an O&A work event, or otherwise approved by the CO. 4.4.6.5. SCHEDULED COMPONENT REMOVAL/REPLACEMENT CRITERIA D R 4.4.6.5.1. The Contractor shall determine all aircraft components to be overhauled, repaired, modified, or replaced at flight hour, calendar, or operational time limitations. If the removed component will not be reinstalled on the aircraft, the Contractor shall request disposition of the property IAW the approved property management plan developed under section 4.24 of this SOW. 4.4.6.5.2. After completion of PDM, installed aircraft accessories and components shall have sufficient time remaining to ensure that component replacement is not required within one (1) year or 300 airframe hours (whichever is less) after PDM accomplishment. 4.4.6.6. NON-DESTRUCTIVE INSPECTION (NDI) 4.4.6.6.1. The Contractor shall perform NDI inspections in specific critical areas identified within the technical inspection specification developed in section 4.1.1 of this SOW. The selected areas and techniques shall be model and series specific and incorporate inspection areas from the Bell/DoS maintenance manuals, TM 11520-256-23 (NDI Procedures for UH-1 Helicopter Series), FAA, OEM, and user input sources. All selected NDI areas shall promote 33 28 March 2016 US Department of State safety and continued airworthiness for the DoS UH-1 fleet. The NDI techniques used shall be based on user recommendations, repair facility experience, applicable DoS and or Bell Helicopter Supplemental Inspection Documents (SIDs), and government/industry best practices and recommendations for UH-1 aircraft. 4.4.6.6.2. At a minimum, all NDI areas listed in the Table of Contents (TOC) in TM 1-1520-256-23 shall be included within the technical inspection requirements. Additionally, any DoS identified special areas of attention based on user inputs shall be included as required. AF T 4.4.6.6.3. The Contractor shall only utilize licensed, experience, and qualified personnel able to perform any NDI procedure or task contained in the applicable UH-1 inspection and repair manuals and Contractor developed technical inspection specification. The Contractor shall use procedures contained in FAA AC 43.13-1B (Acceptable Methods, Techniques, and Practices - Aircraft Inspection and Repair) and Technical Order (TO) 33B-1-1 (DA TM 1-1500-33523, (Nondestructive Inspection Methods, Basic Theory) to perform NDI inspections. 4.4.6.7. FUELS SYSTEMS MAINTENANCE R 4.4.6.7.1. The Contractor shall inspect; perform leak and functional checks; and repair UH-1 internal main and auxiliary fuel tanks in accordance with the applicable Bell/DoS series maintenance manual. D 4.4.6.7.2. The Contractor shall calibrate or recalibrate all installed fuel quantity probes to the fuel indicating system indicators as part of the PDM in accordance with the applicable Bell/DoS series maintenance manual. 4.4.6.8. AIRCRAFT BATTERIES 4.4.6.8.1. The Contractor shall remove, store, maintain, charge (as necessary) and perform specific performance checks on aircraft batteries in accordance with the applicable UH-1 and OEM maintenance manuals. A monthly battery health check and recharging shall be accomplished by the Contractor while the aircraft is in PDM. 4.4.6.9. INSTRUMENTATION CHECKS 4.4.6.9.1. ALTIMETER SYSTEM AND ALTITUDE REPORTING EQUIPMENT TESTS AND INSPECTIONS. The Contractor shall accomplish and comply with all requirements specified in FAA regulation 14 CFR 91.411. 34 28 March 2016 US Department of State 4.4.6.9.2. ATC TRANSPONDER TESTS AND INSPECTIONS. The Contractor shall accomplish and comply with all requirements specified in FAA regulation 14 CFR 91.413. 4.4.6.10. EMERGENCY LOCATOR TRANSMITTER (ELT) 4.4.6.10.1. The Contractor shall ensure proper installation, battery serviceability, and activation of the 121.5 and 243.0 MHz broadcast signal of the ELT. Additionally, proper functionality of the 406 MHz signal and data transmission shall be tested IAW established OEM procedures and NOAA Search and Rescue Satellite Aided Tracking (SARSAT) guidelines. 4.4.6.11. WEIGHT AND BALANCE T 4.4.6.11.1. The Contractor shall maintain weight and balance control of the aircraft during PDM in accordance with the AR 95-1 and TM 551500-342-23. AF 4.4.6.11.2. The Contractor shall perform a post-PDM weighing of the aircraft after completion of all maintenance and painting. 4.4.6.12. DISTURBED SYSTEMS R 4.4.6.12.1. Aircraft systems, not otherwise assigned a requirement for a functional/operational check/test, that are disturbed during PDM processing to the extent that the system's integrity (i.e., installation and operation) cannot be assured shall receive a functional/operational check/test as necessary to verify proper installation and operation. D 4.4.6.12.2. Any work beyond the basic tasks of the PDM inspection shall be addressed IAW section 4.5 of this SOW (Over and Above costs). 4.4.7. MAINTENANCE AND INSPECTION DOCUMENTATION 4.4.7.1. INSPECTION WORK SHEETS 4.4.7.1.1. The Contractor shall utilize inspection work sheets to show inspection activities accomplished and to record certifying officials for each task accomplished. The worksheets shall include, but are not limited to, the following information: 1.) aircraft serial number; 2.) total airframe time (TAT); 3.) Date of inspection; 4.) Type of Inspection; 5.) Airframe, engine and rotor inspection items; 6.) Non-Destructive Inspection (NDI) areas and results; 7.) FAA and OEM airworthiness directives compliance; 8.) Service bulletin compliance; 9.) Lubrication requirements; 10.) Critical item (e.g., Engine, Tail Boom, 35 28 March 2016 US Department of State or other major component) checklist compliance; 11.) Special inspection checklist compliance; 12.) FAA/OEM special action notice checklist compliance (if required); 13.) Acceptance checklist compliance; 14.) Pre-delivery checklists; 15.) Engine run checklist compliance; 16.) Certifications of work accomplishment, and other inspection requirements deemed necessary by the inspecting organization. Inspection tasks shall be signed off by mechanic and inspector to include pre-determined Quality Assurance (QA) checks by DOS inspectors. 4.4.7.2. DISCREPANCY DOCUMENTATION T 4.4.7.2.1. Discrepancies found and fixed during the inspection shall be documented by the Contractor IAW DA Pamphlet (PAM) 738-751, or similar Contractor developed form that captures the following key information for each discrepancy found and repaired: a) Repairing Organization AF b) Aircraft Nomenclature and Model c) Aircraft Registration and Serial Number d) Total Airframe Time (TAT) e) Type Inspection R f) Inspection Checklist item Number g) Severity of discrepancy (Reference Status Symbols in DA PAM 738-751) D h) Discrepancy Description i) Corrective Action j) Repair Method Reference k) Signature or initial of the person correcting each discrepancy l) Supervisory validation that work is accomplished IAW acceptable repair data 4.4.7.2.2. Items, accessories, and structural components removed to facilitate other maintenance (FOM) shall be documented with the following additional information: a) Nomenclature of item removed, b) Reason for removal, 36 28 March 2016 US Department of State c) Corrective action/disposition 4.4.7.2.3. Discrepancies not repaired prior to flight testing shall be documented in the aircraft logbook on DA Form 2408–13–1, Aircraft Maintenance and Inspection Record, IAW DA PAM 738-751 for review by aircrew personnel prior to flight. 4.4.7.2.4. All open/closed discrepancy and action forms shall be included in the final historical document package provided to the DoS IAW section 4.19.1 of this SOW 4.4.7.3. HISTORICAL RECORDS DOCUMENTATION 4.4.7.3.1. The Contractor shall document all maintenance actions of a historical nature IAW DA PAM 738-751 on DA Form 2408-15. At minimum, the following items shall be documented: Accomplishment of PDM, b) Accomplishment of applicable inspections, c) Incorporation of compliance with Technical Directives, d) Installation or Removal of DoS directed Modifications, e) Replacement of assemblies, accessories and major components, and all serial number tracked components, f) Accrual of flight time during the period of aircraft custody by the Contractor R AF T a) D 4.4.7.3.2. Applicable aircraft records shall be annotated showing the type of inspection/repair/overhaul/modification/time-change, date, TAT, aircraft serial number, and work order number. The entries shall also reflect the Contractors name and the Task Order number. 4.5. OVER AND ABOVE (O&A) ESTIMATES 4.5.1. Once the overall PDM inspection (section 4.4 of this SOW) has been accomplished, the Contractor shall determine whether any deficiencies discovered during the PDM process constitute over and above (O&A) requirements. If the case, the Contractor shall submit to the CO an O&A report (CDRL A010) listing the following: a) The repairs needed that are outside the basic PDM requirements of the SOW. b) A written quotation for all actions necessary to repair O&A items. 37 28 March 2016 US Department of State c) The projected time to complete all necessary actions. (Either within the stipulated length of time for PDM (section 4.1.2.1 of this SOW) or Contractors additive estimate beyond that timeframe. 4.5.2. Only those O&A repairs approved by the CO shall be performed on the affected aircraft. 4.5.3. A follow-up quote shall be submitted to the CO for approval prior to executing any additional O&A work discovered. 4.5.4. O&A quote shall be based on the standardized fee schedule developed in section 4.1.3.2 of this SOW (CDRL A002). 4.6. CORRECTION OF DISCREPANCIES 4.6.1.1. CRITICAL DEFECTS T 4.6.1. The Contractor shall be responsible for the maintenance of the aircraft when in Contractor’s possession and the correction of all defects unless otherwise stipulated by the CO. 4.6.1.2. AF 4.6.1.1.1. All critical defects discovered as a direct result of or incidental to, compliance with PDM requirements shall be corrected in accordance with applicable documents. MAJOR DEFECTS R 4.6.1.2.1. All major defects discovered as a direct result of compliance with PDM requirements shall be corrected in accordance with applicable documents. D 4.6.1.2.2. Major defects discovered incidental to compliance with PDM requirements that require skills, tools, or other support available only at depot maintenance, or are located in an area not normally opened or inspected by organizational maintenance, shall be corrected in accordance with applicable documents. 4.6.1.3. MINOR DEFECTS. 4.6.1.3.1. Minor defects located in an area not normally opened or inspected by organizational maintenance shall be corrected in accordance with applicable documents. 4.6.1.4. DEFECTS CAUSED BY REWORK ACTIVITY. 4.6.1.4.1. All defects caused by the Contractor shall be corrected at the Contractor's sole expense and in accordance with applicable documents. 38 28 March 2016 US Department of State 4.6.2. CLASSIFICATION OF DEFECTS. Classification of defects shall be subject to the review and final approval of the DoS. 4.6.3. NON-STANDARD INSTALLATIONS. Rework shall not be performed on non-standard installations unless specifically requested by the DoS. When non-standard installations interfere with authorized rework, those installations shall be removed to the extent necessary to facilitate the authorized rework. Cases of this nature shall be referred to the DoS for disposition instructions. 4.7. WARRANTIES T 4.7.1. The Contractor shall establish and provide a warranty plan to ensure all replacement parts, workmanship, and services are covered by warranty. The warranty plan shall provide a warranty repair process to include, but not limited to, procedures for notification, processing, validation, length of warranty (specified from time of aircraft acceptance or date placed in service), shipping instructions and a point of contact (POC) between the Contractor and INL/A. (CDRL A011) AF 4.7.2. The Contractor shall provide a warranty period for all replacement parts and or for workmanship of not less than one (1) year or 600 hours aircraft time. Additionally Contractor or vendor component overhauls shall be warranted for a period no less than the warranty for an OEM overhauled component. 4.8. UNSERVICEABLE/UNUSED DOS ASSETS R 4.8.1. Defective, unserviceable, beyond economical to repair (BER), unused, or otherwise excess DoS parts and assets generated as part of the PDM process shall be dispositioned IAW section 4.24 (Property Management Plan) of this SOW. D 4.9. ADDITIONAL MAINTENANCE REQUIREMENTS 4.9.1. As directed by the CO, the Contractor shall accomplish all additional DoS maintenance requirements to include modifications and upgrades. Each additional requirement shall be accomplished per the task order. 39 28 March 2016 US Department of State SECTION V Po s t I n s p e c t i o n Ac t iv i t i e s ( P D M ) 4.10. POST MAINTENANCE CLEANING 4.10.1. The Contractor shall inspect and clean all interior and exterior work areas after completion of work (i.e., remove all filings, chips, loose hardware and debris, secure and close all doors, access plates and panels). T 4.10.1.1. METAL SURFACES. The Contractor shall clean aircraft external and accessible internal metal surfaces using methods and materials specified by the applicable UH-1 Maintenance Manual. After cleaning, the Contractor shall take special precautions to assure thorough draining of all liquids from between facing surfaces, crevices, and inspection doors. The Contractor shall re-clean all areas as necessary. AF 4.10.1.2. TRANSPARENT AND REINFORCED PLASTIC SURFACES. The Contractor shall clean transparent and reinforced plastic surfaces using methods and materials specified by the applicable UH-1 Maintenance Manual. R 4.10.1.3. VINYL AND RUBBER SURFACES. The Contractor shall clean and treat upholstery, floors, vinyl and rubber surfaces and trim using methods and materials specified by the applicable UH-1 Maintenance Manual. D 4.10.2. The Contractor shall take adequate precautions during stripping and subsequent cleaning operations to prevent ingress of moisture, chemical, and cleaning compounds to areas such as engine inlet/exhaust openings, static ports, pitot tubes, and vent openings. The Contractor shall protect bearings, bearing surfaces, electrical switches, relays, connectors, wires and all other electrical and electronic components during any stripping and cleaning operations. The Contractor shall protect plastic, glass, and rubber parts during stripping and cleaning operations. 4.10.2.1. The Contractor shall comply with all applicable local, State, and Federal guidelines and safety precautions/procedures when using stripping compounds. 4.10.3. ENVIRONMENTAL. The Contractor's repair facility must utilize FAA Advisory Circular 43-205, Guidance for Selecting Chemical Agents and Processes for Depainting and General Cleaning of Aircraft 40 28 March 2016 US Department of State and Aviation Products, to ensure DoS equipment is as free as practicable of all hazardous dust to hexavalent chromium, cadmium, lead, etc., prior to being returned to DoS. Information on these hazards can be found in Occupational Safety and Health Standards 1910.1025 (lead), 1910.1026 (Hexavalent Chromium) and 1910.1027 (Cadmium). 4.11. CORROSION TREATMENT 4.11.1. The Contractor shall inspect and treat corrosion in accordance with the Bell/DoS UH-1 maintenance manuals; Advisory Circulars (AC) 43.13.1B and 43.13-2B; and Technical Order (T.O.) 1-1-691, Cleaning and Corrosion Prevention and Control, Aerospace and Non-Aerospace Equipment. No scheduled corrosion control inspections or treatments shall be due prior to the next scheduled major inspection listed on the DoS Form 2408-18 after PDM. Chemical based corrosion removal products shall not be used on DoS aircraft. 4.11.1.2. The Contractor shall replace all post corrosion treatment repaired parts when the remaining post repaired surface dimensional tolerances exceed the limits allowed by applicable overhaul or structural repair manuals. 4.11.1.3. To prevent water intrusion, the Contractor shall seal all faying surfaces, seams, lap joints, and skin seams using approved sealants listed in and IAW the applicable UH-1 Maintenance Manuals. R AF T 4.11.1.1. The Contractor shall remove all previously applied loose or deteriorated sealants and contamination from the seams prior to application of new sealants. D 4.11.1.3.1. 4.11.1.4. Removal of fasteners at seams and lap joints is not required unless visual examination indicates corrosion of faying surfaces. 4.12. PAINT 4.12.1. The Contractor shall restore the aircraft paint scheme (both interior and exterior) during PDM. The internal paint scheme will normally be Night Vision device compliant black to prevent glare. External paint shall include a full strip and repaint IAW TM 1-1500-345-23 as well as application of DoS markings. Both internal and external paint schemes will normally be identical to the paint scheme as arrived at induction unless otherwise specified by the task order. 41 28 March 2016 US Department of State 4.12.2. The level of paint restoration required shall be reflected in the Contractor’s basic cost estimate in section 4.3.2.1 of this SOW. 4.12.3. Paint restoration shall include all internal and external extraneous equipment (e.g. pylons, stores, etc.) in accordance with applicable technical data. 4.12.3.1. The Contractor shall coat uninhabited interior metal surfaces using methods and paint materials specified in the applicable UH-1 maintenance manual and TM 55- 1500-345-23 (Painting and Marking of Army Aircraft). The Contractor shall apply the number of coats specified by manufacturer’s structural repair manual. 4.12.3.2. The Contractor shall treat and refinish battery boxes and battery bay area's using materials specified by the applicable UH-1 Maintenance Manual. AF T 4.12.4. The Contractor shall use non-aircraft specific portions of TM 55-1500-34523, Painting and Marking of Army Aircraft, for all stripping and painting activities. Different DoS operating locations may require different or specialized markings. To determine the exact markings required for different aircraft, the Contractor shall submit a recommended rendering (CDRL A013) using the existing markings as a guide to DoS for approval. D R 4.12.5. The Contractor shall be responsible for replacing all interior and exterior markings due to normal “wear and tear”; maintenance damage; or strip and paint activities to include standard exterior finish colors, markings, insignia, placards (e.g., Rescue, Danger, Plane of Rotation, etc.), and DoS specified Logos. The Contractor shall apply all markings in accordance with the applicable UH-1 Maintenance Manual and TM 55-1500-345-23 (Painting and Marking of Army Aircraft). Application of aircraft serial number or registration number will be specified by the COR. 4.12.5.1. The Contractor shall conduct and document at least one wet tape adhesion test on the completed base finish system. The test may be conducted on a test panel carried through processing with the aircraft or on an easily repainted access panel. 4.12.6. The Contractor shall perform weight and balance after the new paint has been applied. 4.13. CONFIGURATION RESTORATION 4.13.1. Prior to final test flights, the Contractor shall reinstall and functionally check all extraneous equipment (e.g. tanks, pylons, stores, etc.) in accordance with applicable technical data. 42 28 March 2016 US Department of State 4.14. WEIGHT AND BALANCE 4.14.1. Prior to weighing the aircraft, the Contractor shall accomplish and document a complete inventory of the aircraft utilizing the aircrafts Chart A, Basic Weight Check List Record, DD Form 365-1, IAW TM 1-1500342-23, Army Aviation Maintenance Engineering Manual – Weight and Balance, to reflect the actual equipment inventory. As required, incorporation of any technical orders/directives or modifications shall be annotated on the Chart A. 4.14.2. The Contractor shall weigh the aircraft in accordance with TM 1-1500342-23 and the individual aircraft’s DD Form 365-2, Weighing Record. Chart C (DD 365-3), Basic Weight and Balance record, DD Form 365-3, shall be updated by the Contractor to reflect the actual inventory of Chart A (DD 365-1), plus the effect of any technical orders/directives or modifications incorporated during PDM. 4.14.4. The Contractor shall complete a Weight and Balance Clearance Form F, DD Form 365-4, to reflect actual load disposition for all test and/or ferry flights. AF T 4.14.3. ENGINE TREND MONITORING SYSTEM 4.15. R 4.15.1. If aircraft is so configured, the Contractor shall calibrate engine trend monitoring system and determine system to be operational prior to the maintenance test flight phase. 4.16. COMPASS CALIBRATION D 4.16.1. The Contractor shall perform Compass Calibration as part of the maintenance test flight for all aircraft. 4.16.1.1. 4.17. The Contractor shall make a record logbook entry IAW DA PAM 738751 and place the working half copy of compass calibration card into the historical record logbook. The Contractor shall place the second copy into the appropriate location in the cockpit. POST INSPECTION SERVICING 4.17.1. After completion of rework, the Contractor shall de-preserve applicable areas of the aircraft and engines; check for structural and mechanical completeness and integrity; check for proper assembly; and service and lubricate all systems in accordance with applicable maintenance manuals. 43 28 March 2016 US Department of State 4.18. POST INSPECTION FUNCTIONAL CHECKS 4.18.1. Prior to any test flights, the Contractor shall accomplish a complete aircraft maintenance operational check on the ground for all components or systems disturbed during the PDM. The Contractor shall functionally check systems in sufficient depth to ensure operational reliability in accordance with all applicable technical documents. 4.18.2. ENGINE PERFORMANCE CHECK During the post inspection ground maintenance checks, the Contractor shall perform an engine performance check run-up and compare the results to the incoming inspection performance run (if accomplished in section 4.3.3.2.3 of this SOW). Any degradation in performance shall be investigated and justified by the contractor prior to flight testing. The Contractor shall document the results and include them within the final PDM documentation package. The Contractor shall correct all discrepancies prior to flight. T 4.18.2.1. 4.18.3.1. AF 4.18.3. ACCEPTANCE/FUNCTIONAL CHECK FLIGHT A minimum of two test flights shall be conducted after PDM. The first test flight shall be a functional check flight (FCF) performed by the Contractor. The FCF shall be a post maintenance check flight and performed with a minimum of two (2) qualified pilots with one being a maintenance test pilot qualified in the UH-1 model being flown. The FCF shall be accomplished and documented IAW the UH-1 maintenance test flight procedures manual, appropriate UH-1 flight manuals, AR 95-20, and the INL/A FCF procedural manual. Discrepancies discovered during the FCF shall be documented, repaired, and reported to the COR prior to making the request for an acceptance test pilot IAW section 4.18.3.1.2 of this SOW. D R 4.18.3.1.1. 4.18.3.1.2. The second test flight shall be a joint Contractor/DoS acceptance test flight. The Contractor shall coordinate with the COR to schedule a DoS FCF qualified pilot to perform the FCF portion of the test flight. The acceptance check flight shall be accomplished and documented IAW the UH-1 maintenance test flight procedures manual, appropriate UH-1 flight manuals, INL/A FCF procedural manual, and INL/A Operations Directive. The required number of test flights shall be at the discretion of the DoS and shall be dependent on the number and 44 28 March 2016 US Department of State severity of discrepancies documented during the flight(s) and the necessity to verify functionality after the discrepancies are repaired. 4.18.3.2. Aircraft mission equipment/systems shall be included in flight check requirements. 4.18.3.3. If installed, the engine trend monitoring system shall be operational and checked prior to the test flight. 4.18.3.4. The Contractor shall ensure the Contractor test pilots comply with the requirements of the respective DoS Operations Directive and chapter 3 of TM 1-1500-328-23, Aeronautical Equipment Maintenance Management Policies and Procedures, for flight check and acceptance procedures. Prior to the DoS acceptance test flight, the Contractor shall ensure all special, loose, miscellaneous equipment, furnishings, and publications reflected as "installed" in the aircraft inventory record are appropriately stowed and that all required logbook entries have been accomplished in accordance with DA PAM 738- 751. 4.18.3.6. The Contractor shall provide support services during acceptance and flight testing. The services shall include, but are not limited to, the following: AF T 4.18.3.5. Hangar Space for storage of aircraft during normal and inclement weather conditions, b) Aircraft maintenance, c) Flight planning facilities, d) Required flight materials, e) Briefings, f) Servicing, g) Pre-flight, turn-around, and post-flight inspections; h) POL (e.g. aircraft fuel, nitrogen, hydraulic fluid, grease, oil, etc.) and any other aircraft consumables as defined in section 4.1.8.1 of this SOW, i) Aircraft launch and recovery support. D R a) 45 28 March 2016 US Department of State 4.18.4. SUPPORT INSPECTION/S 4.18.4.1. Prior to the first check/acceptance flight of the day, the Contractor shall perform a pre-flight inspection in accordance with the Bell/DoS UH-1 maintenance/operators checklist. If multiple flights are required within the same day, the Contractor shall perform turnaround inspections IAW the Bell/DoS UH-1 maintenance/operators checklist before each subsequent flight. 4.18.4.2. The Contractor shall conduct basic post-flight inspection/s at the end of the flying day IAW Bell/DoS UH-1 maintenance/operators checklist. 4.18.4.3. All discrepancies found shall be fixed in accordance with the appropriate UH-1 maintenance manual. Logbook and historical records shall be updated IAW DA PAM 738-751. T 4.18.4.4. 4.19. ACCEPTANCE AND TRANSFER OF POSSESSION AF 4.19.1. The Contractor shall prepare and update the applicable forms and records required for transfer of aircraft responsibility back to the DoS. The Contractor shall verify all records initially provided to the Contractor at initial transfer of possession are included in the final forms transfer. (See section 4.2.1.1.4 of this SOW) R 4.19.2. Final acceptance of the aircraft and maintenance performed shall be by the CO or designated representative via DoS Form DS-127, Receiving and Inspection Report, upon successful completion of all required work. D 4.19.3. Unless otherwise directed, the Contractor shall prepare the aircraft in the same configuration as received (e.g. external/internal fuel tanks, pylons, stores, etc.). 4.19.4. The Contractor shall maintain the completed aircraft in accordance with applicable technical directives for a period not to exceed ten (10) calendar days after the aircraft acceptance (DS-127) has been signed pending return of the aircraft to the using activity. During this timeframe, the Contractor shall support up to 10 flight hours of DoS initiated local area “reliability” flights prior to aircraft departure to the location designated on the task order. Local area flight support as well as unplanned aircraft storage beyond the ten day window shall be quoted and authorized using O&A Work Procedures as defined in section 4.5 of this SOW. 46 28 March 2016 US Department of State 4.20. SCHEDULED MAINTENANCE PRIOR TO DEPARTURE 4.20.1. The Contractor shall review the scheduled maintenance requirements in the aircraft forms package, specifically DA Form 2408-18, and perform any overdue tasks or tasks projected to become due or overdue within 30 days after the projected aircraft departure. Any additional scheduled or unscheduled maintenance performed outside the basic PDM shall be quoted and authorized using the O&A Work Procedures as defined in section 4.5 of this SOW. 4.21. AIRCRAFT TRANSPORTATION AND SHIPMENT T 4.21.1. When required and as directed by the CO, the Contractor shall provide transportation and delivery of aircraft from unspecified CONUS and OCONUS locations in support of DoS requirements. Transportation and delivery shall consist of various modes of transportation to include, but not be limited to, the following: Ferry Flight b) Overland Truck Shipment c) Seaborne Cargo Shipment d) Airborne Cargo Shipment AF a) R 4.21.2. The Contractor shall have the capability and resources necessary to execute required ferry flights (either from the PDM facility to DoS operational location, or vice-versa). D 4.21.3. FERRY REQUIREMENTS 4.21.3.1. Aircraft ferry, either over-water flight or over-land, require certain systems and survival equipment to be installed and operational for the flight. The Contractor shall comply with the Minimum Equipment List (MEL) for the aircraft and all requirements within the INL/A Operations Directive to ensure safe delivery of DoS aircraft. 4.21.3.2. The Contractor shall be responsible for, but not limited to, the following list of actions necessary to ferry DoS aircraft from one location to another location: a) Aircrew qualifications/currency, b) Aircraft flight modifications (when necessary such as extended range fuel tanks, etc.), 47 28 March 2016 US Department of State Safety equipment (environmental suits, life rafts, personal locator beacons, etc.), d) Route planning, e) En-route maintenance, f) Spare parts, g) Flight and country clearances, h) If planned, coordination for use of military bases, i) Personnel lodging, transportation, and meals, j) Fuel, unless specifically provided by INL/A per the task order k) All international customs requirements, l) CONUS and International communications T 4.22. c) ENGINEERING SUPPORT REQUIREMENTS AF 4.22.1. PDM ENGINEERING 4.22.1.1. The Contractor shall provide engineering expertise to perform continuous surveillance of the rework processes; to solve problems; and to develop rework procedures/processes/repairs not otherwise provided for in applicable UH-1 technical publications. D R 4.22.1.2. Major rework or repair not otherwise provided in applicable UH-1 technical publications or FAA approved procedures shall require a repair plan approved by the COR and DoS Engineering Authority. 4.22.1.3. Engineering information developed shall be prepared in accordance with FAA and/or Department of Defense (DOD) directives with engineering drawings prepared, as required, in accordance with American Society of Mechanical Engineers (ASME) Y.14-100, Standard Engineering Drawing Practices, and Air Force Instruction (AFI) 21-402. A copy of all engineering modification/repair directives and drawings shall be forwarded to: US Department of State, INL/A Chief of Aircraft Maintenance 1038 South Patrick Drive Patrick AFB, FL 32925 48 28 March 2016 US Department of State 4.22.2. NON-PDM ENGINEERING AND TECHNICAL ASSISTANCE AF T 4.22.2.1. Throughout the period of performance DoS may require technical and engineering assistance at unspecified CONUS and OCONUS locations. The type of engineering and technical assistance includes, but is not limited to, aircraft repairs; aircraft maintenance; determination of airworthiness; special inspections; retrofit modifications; performance evaluations; accident investigations; training; installation; test and demonstrations; production and retrofit; engineering change proposals (ECPs); technical documentation development; logistics support and sustainment; simulations; warranties; and any other improvement type effort to correct production, operational, and safety deficiencies. In addition, the Contractor, at the direction of the CO, may be required to perform Engineering Service Tasks (ESTs) for engineering analyses; trade studies; systems engineering; investigations; kit development and integration; planning; prototyping; qualification/test; flight-test infrastructure for proposed upgrades and improvements; and diminishing manufacturing sources and material shortages (DMSMS) solutions. 4.22.2.2. When requested by the CO, the Contractor shall source and provide qualified personnel to support DoS engineering and technical assistance requirements. D R 4.22.2.2.1. The Contractor shall be responsible for all personnel travel arrangements and communications for personnel deploying in support of DoS requirements. The Contractor shall ensure all personnel who are required to travel outside the United States have current and valid passports and/or visas and approved Government directed country clearances. 4.22.2.2.2. The Contractor shall be prepared to provide quick reaction procurement actions and services designed to rapidly develop and deliver unplanned safety corrective actions; reliability and maintainability (R&M) improvements; and mission performance capability improvements in support of DoS missions. 4.23. NON-PDM LOGISTICS 4.23.1. When directed by task order, the Contractor shall source, procure, repair or overhaul approved UH-1 replacement parts for DoS. 49 28 March 2016 US Department of State 4.24. PROPERTY MANAGEMENT PLAN 4.24.1. The Contractor shall develop a United States Government (USG) property management plan based on Federal Acquisition Regulations (FAR) Part 45 and approved by the DoS Government Property Administrator. (CDRL A012) 4.25. SECURITY 4.25.1. The contractor shall be responsible for safeguarding all USG property in the Contractor’s possession. At the close of each work period, USG property and materials shall be secured. The Contractor shall ensure that only authorized Contractor and USG personnel or other authorized persons as determined by the CO have access to USG property (equipment, material, publications) to include all work and storage areas. QUALITY ASSURANCE (QA) T 4.26. AF 4.26.1. The Contractor shall have and maintain a higher level quality system with current certifications to include AS 9100 rev C “Quality Management Systems – Requirements for Aviation, Space, and Defense Organizations and AS 9110 rev B “Quality Management Systems – Requirements for Aviation Maintenance Organizations”. R 4.26.2. The Contractor shall maintain a tool control system, which includes procedures for accountability of all Contractor and/or personal tooling. The method selected must be effective in timely identification of lost or missing items. D 4.26.3. The Contractor's quality control manual shall include a FOD prevention program. This program shall include the tool accountability system and procedures to control parts and materials used to accomplish maintenance actions. The program must identify techniques and procedures to minimize foreign objects created during maintenance actions (i.e. metal shavings, rivet heads, etc.). 4.26.4. The Contractor shall be registered with the US Department of State Directorate of Defense Trade Controls (DDTC). 4.26.5. The Contractor and the Contractor’s facility shall be certified and shall maintain compliance with current version of AR 95-20 “Contractor’s Flight and Ground Operations”. 4.26.6. The Contractor and the Contractor’s repair station shall be FAA and or European Aviation Safety Agency (EASA) Part 145 approved with an FAA Repair Station Certificate, required manuals and processes, and approved capabilities list inclusive of Bell model helicopter related capabilities of repair. 50 28 March 2016 US Department of State 4.26.7. Contractor shall use an OEM certified fixture(s), with current certifications, when a fixture is required by repair procedure and or when determining the alignment of any airframe or airframe structure. 5. DELIVERY 5.1. As required, contract equipment and other aircraft items shipped directly to INL/A shall be delivered to the following address at Melbourne, Florida: US Department of State, INL/A Logistics Division 2765 Business Center Blvd Melbourne, FL 32940 Tel. 321-783-9865 5.2. Delivery for all other contractual services and deliverables will be specified in individual task orders or as specified by the CO. T 6. GOVERNMENT FURNISHED PROPERTY AF 6.1. The Government will provide the following property to the Contractor for work required under this contract: a. UH-1N aircraft b. DoS UH-1ST aircraft c. Bell Model UH-1H-II aircraft R d. Non-Commercially available Military and DoS publications and directives listed in section 9.3. The Contractor shall not use Government Furnished Military and DoS publications and directives provided under this contract to perform work on any unrelated aircraft, part, or program not associated with this contract. D i. 7. PLACE OF PERFORMANCE 7.1. Place of performance shall be the Contractor's repair facility meeting the requirements of this SOW or as identified within individual task orders. 8. PERIOD OF PERFORMANCE 8.1. The Contractor shall provide the services required by this SOW for a period of 5 years from date of contract award. 51 28 March 2016 US Department of State 9. APPLICABLE DOCUMENTS 9.1. The following specification, drawings, directives, and publications form a basic part of this specification. Compliance with the latest issue date of all technical manuals, directives, specifications, and publications is mandatory when: 9.1.1. a. They are pertinent to the aircraft and installed equipment, and the rework activity is authorized to accomplish the work therein. b. The prescribed rework policies, use of materials and procedures for rework. Several references have multiple numbers assigned (one for each service that uses the manual) but only the Department of the Army reference number is listed in the following text. T 9.2. MANUFACTURER PUBLICATIONS Bell Helicopter Technical Manual, BHT Pub 92-004-23, Aviation Unit & Intermediate Maintenance Manual Airframe Bell Model UH-1H-II Helicopter, Volumes 1&2. 9.2.2. Bell Helicopter, BHT Pub 92-004-23P, Model UH-1H-II Helicopter Illustrated Parts Manual. 9.2.3. Bell Helicopter, BHT Pub 92-004-10, Huey II Operators Manual 9.2.4. Bell Helicopter, BHT Pub 92-004-MTF, Maintenance Test Flight Manual UH- 1H-II 9.2.5. BHT-MED-SRM-1 Bell Helicopter Structural Manual D R AF 9.2.1. 9.2.6. Bell Information Letters Bell Information Letters 9.2.7. Bell Component R & O Bell Component Repair and Overhaul Manual 9.2.8. Honeywell Report 286.2 Standard Practices Manual 9.2.9. Honeywell 290.2 T-53-L-703 Engine Maintenance Manual 9.2.10. Honeywell 290.4 T-53-L-703 Engine Illustrated Parts Book 9.2.11. Honeywell Service Bulletin Letters Honeywell Service Bulletins and 9.2.12. Honeywell Service Index Honeywell Service Index, Engine, Systems 9.2.13. Pratt & Whitney 3017042 Pratt & Whitney PT6 Engine Manual 9.2.14. Pratt & Whitney 3017044 Pratt & Whitney PT6 Illustrated Parts Manual 52 28 March 2016 US Department of State 9.3. MILITARY AND DOS PUBLICATIONS 9.3.3. TM 55-1500-345-23, Painting and marking of Army Aircraft 9.3.4. TM 1-1500-328-23, Aeronautical Equipment Maintenance Management Policies and Procedures 9.3.5. TM-1-1500-344-23 Series, Aircraft Weapon Systems Cleaning and Corrosion Control ,Avionics Cleaning and Corrosion Prevention/ Control Technical Manual 9.3.6. TM-55-1520-210-23-2, Aviation Unit and Intermediate Maintenance Instructions for Army Model UH-1H/V/EH-1H/X Helicopters, dated September 1987 with change 11 9.3.7. TM 1-1500-204-23-10, Aircraft General Structural Repair 9.3.8. T.O. 1-1A-9, Aerospace Metals General use Factors Engineering Series for Aircraft Repair 9.3.9. Technical Order (T.O.) 1-1-691, Cleaning and Corrosion Prevention and Control, Aerospace and Non-Aerospace Equipment AF T 9.3.2. TM-1-1500-344-23(-1 thru -5), Cleaning and Corrosion Control, Volumes 1-5 TM 55-1500-322-24, Maintenance of Aeronautical Antifriction Bearings 9.3.1. R 9.3.10. Technical Order (T.O.) 1-1-8, Application and Removal of Organic Coatings, Aerospace and Non-Aerospace Equipment D 9.3.11. TO 33B-1-1 (DA TM 1-1500-335-23, Nondestructive Inspection Methods, Basic Theory) 9.3.12. TM 55-1500-342-23, Aircraft Weight and Balance Procedures 9.3.13. 1H-1(U)N-2-1, Organizational Maintenance Manual, USAF Series UH1N Helicopter 9.3.14. 1H-1(U)N-4, Illustrated Parts Breakdown, USAF Series UH-1N Helicopter 9.3.15. C-12-135-000/MB-000, CH-135 Helicopter Operating Instructions 9.3.16. C-12-135-000/MF-001, Description and Maintenance Instructions 9.3.17. C-12-135-000/MY-003, CH-135 Twin Huey Parts List 9.3.18. DoS INL/A TM 1-UH-1ST-10, Flight Operators Manual 9.3.19. DoS INL/A TM 1-UH-1ST-23, Maintenance Manual 9.3.20. DoS INL/A TM 1-UH-1ST-23P, Illustrated Parts Breakdown 53 28 March 2016 US Department of State 9.3.21. DoS INL/A TM 1-UH-1ST-CL, Operator’s Checklist 9.3.22. DoS INL/A UH-1H-II CL, Operator's Checklist 9.3.23. INL/A, Operations Directive 9.3.24. Air Force Instruction (AFI) 21-402, Engineering Drawing System 9.3.25. AR 95-20 (DCMA INST 8210.1C and DCMA-INST-8210.2 (IPC-1)),Contractor's Flight and Ground Operations 9.3.26. DA PAM 738-751 (TAMMS), Functional User’s Manual for the Army Maintenance Management System–Aviation 9.3.27. DA PAM 750-8, Maintenance of Supplies and Equipment 9.3.28. AR 750-1, Army Material Maintenance Policies 9.4. FEDERAL AVIATION REGULATIONS 14 CFR 43.3, Persons Authorized to Perform Maintenance, Preventative Maintenance, Rebuilding, and Alterations 9.4.2. 14 CFR 43.5, Approval for Return to Service after Maintenance, Preventative Maintenance, Rebuilding, and Alterations 9.4.3. 14 CFR 43.7, Persons Authorized to Approve Aircraft Airframes, Aircraft Engines, Propeller, and Appliances for Return to Service after Maintenance, Preventative Maintenance, Rebuilding, and Alterations 9.4.4. 14 CFR 43.9, Content, Form and Disposition of Maintenance, Rebuilding and Alteration Records (except 100-hour, annual and progressive inspections) 9.4.5. 14 CFR 43.13, Performance Rules (General) 9.4.6. 14 CFR 145, Repair Stations 9.4.7. 14 CFR 25.1529, subpart H, FAA guidance for continued airworthiness 9.4.8. 14 CFR 91.411, Altimeter System and Altitude Reporting Equipment Tests and Inspections 9.4.9. 14 CFR 91.413, ATC Transponder Tests and Inspections 9.4.10. 14 CFR 145.211, Repair Station Quality Control System 9.4.11. 14 CFR Part 43, Maintenance, Preventive Maintenance, Rebuilding, and Alteration D R AF T 9.4.1. 54 28 March 2016 US Department of State 9.5. ADVISORY CIRCULARS FAA Advisory Circular 43-205, Guidance for Selecting Chemical Agents and Processes for Depainting and General Cleaning of Aircraft and Aviation Products 9.5.2. FAA AC 43.13-1B, Acceptable Methods, Techniques, and Practices Aircraft Inspection and Repair 9.5.3. FAA AC 43.13-2B, Acceptable Methods, Techniques, and Practices Aircraft Alterations 9.5.4. FAA Advisory Circular 20-142, Eligibility and Evaluation of U.S. Military Surplus Flight Safety Aircraft Parts, Engines, and Propellers 9.5.5. FAA AC 43.9C, Maintenance Records, General Aviation Aircraft 9.5.6. FAA Advisory Circular 20-142, Eligibility and Evaluation of U.S. Military Surplus Flight Safety Aircraft Parts, Engines, and Propellers 9.6. MISCELLANEOUS T 9.5.1. MIL-STD-3009, Lighting, Aircraft, Night Vision Imaging System (NVIS) Compatible 9.6.2. American Society of Mechanical Engineers (ASME) Y.14-100, Standard Engineering Drawing Practices 9.6.3. Federal Acquisition Regulation (FAR) 52.246, Contractor Inspection and Quality Requirements 9.6.4. OSHA Hazard Communication Standard, Title 29 Code of Federal Regulations 1910.1200 D R AF 9.6.1. 9.6.5. Federal Acquisition Regulations (FAR) Part 45, Government Property 9.6.6. ASTM D3951-10, Standard Practice for Commercial Packaging 9.6.7. General Services Administration (GSA), Federal Management Regulation (FMR), Subchapter B, Part 102-33.115, Acquiring Government Aircraft and Aircraft Parts, rules pertaining to Flight Safety Critical Aircraft Parts (FSCAP) 10. MARKING, PACKAGING, AND PRESERVATION 10.1. Unless otherwise specified in specific task orders, items shipped to INL/A shall be shipped to the following address: 55 28 March 2016 US Department of State US Department of State, INL/A Logistics Division 2765 Business Center Blvd Melbourne, FL 32940 Tel. 321-783-9865 10.2. Packaging shall be in accordance with ASTM D3951-10 and OEM best commercial practices. Packaging shall provide protection from normal climatic / weather conditions and incidental mishandling during shipping. 10.3. All DoS aviation products, aircraft, accessories, components, and engines shall be preserved IAW OEM specifications prior to return shipment to INL/A. 10.4. On items large enough to accommodate stenciling, marking shall include the following information in either one (1) inch or two (2) inch block letters. As appropriate: AF 11. INSPECTION AND ACCEPTANCE T Property of the Department of State Office of Aviation 11.1. To ensure that delivered equipment conforms to the terms of the contract and in accordance with manufacturer's specifications, inspection and acceptance of material under this contract shall be performed both at the Contractor’s facility and at destination by a designated INL/A Quality Assurance (QA) person. D R 11.2. For newly manufactured or overhauled FAA approved appliances and accessories, a FAA Form 8130-3 (Authorized Release Certificate) or comparable documentation such as Certificate of Compliance (COC) shall be required. For military parts, accessories, and appliances; traceable documentation shall be provided containing date/place of manufacture/overhaul, description, part number, current serviceability condition, status of work performed on item, organization and signature of authorized airworthiness/serviceability certification authority, and installation/removal history. All airworthiness and traceability certificates and documentation must be signed by an authorized official of the approved source and must specify the nomenclature, manufacturer's part number, and date of manufacture. 11.3. All other specific inspection and acceptance criteria will be stated in the individual task orders. (End of SOW) 56 28 March 2016 US Department of State List of CDRLs: D R AF A009 A010 A011 A012 A013 UH-1 Inspection and Refurbishment Technical Document Standardized Fee Schedule/Catalogue Program Management Plan Master PDM Schedule Weekly Status Report Post PDM Report Initial PDM Assessment and Price Quote Inventory/Support Equipment Shortage or Suspected Counterfeit Part Notification Major Structural Repair Proposal Over and Above Cost Estimate Warranty Plan Property Management Plan Paint Scheme Proposal T A001 A002 A003 A004 A005 A006 A007 A008 57 28 March 2016 US Department of State TABLE 1 CORROSION TYPE DESIGNATION CODE A. B. C. D. E. F. G. H. I. J. DEFINITION Direct surface attack Galvanic or dissimilar metal corrosion Pitting Intergranular attack including exfoliation Crevice attack or concentration cell corrosion Fretting corrosion Stress corrosion cracking Corrosion fatigue Filiform corrosion Microbiological corrosion T TABLE 2 CORROSION SEVERITY DESIGNATION AF CODE DEFINITION 1. Light corrosion removable by chemical cleaners and repairable by chemical treatment. Light to moderate corrosion removable by manual application of mild abrasive compounds or soft grit blasting and repairable by chemical treatment. 3. Moderate to severe corrosion removable by mechanical methods and repairable by chemical treatment. 4. Severe corrosion removable by mechanical methods and repairable by Structural Repair Manual. D 5. R 2. Severe corrosion not removable by any method and requires replacement of the affected part. 58 28 March 2016