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March 31, 2020 | International, Aerospace

USAF Announces New Major Deficiency On KC-46

Lee Hudson

The U.S. Air Force has upgraded an existing deficiency for the KC-46A Pegasus fuel system to Category 1.

The service's program office first identified “excessive fuel leaks” in July after an air refueling test. The Air Force and Boeing are working together to determine the root cause and implement corrective actions. A Category 1 deficiency means the government has identified a risk that jeopardizes lives or critical assets.

“The KC-46 Program Office continues to monitor the entire KC-46 fleet and is enhancing acceptance testing of the fuel system to identify potential leaks at the factory where they can be repaired prior to delivery,” according to an Air Force statement.

Boeing is contractually obligated to rectify this deficiency at no additional cost to the Air Force.

“We are disappointed to learn of this development and are already implementing assembly and installation improvements to correct the issue,” Boeing spokesman Larry Chambers said in a statement to Aerospace DAILY. “We have repaired several of the airplanes and will continue to implement repairs as needed. Boeing is working with urgency to address this issue.”

The Air Force discovered several required fuel-system repairs, Chambers said. The fuel system is equipped with redundant protection for fuel containment.

“In some cases with this issue, aircraft maintenance crews are finding fuel between the primary and secondary fuel barriers within the system,” Chambers said.

The KC-46A program still faces other unresolved Category 1 deficiencies that involve the Remote Vision System (RVS) and the boom telescope actuator. The problem with the RVS is what the Air Force calls a “rubber sheet” effect that distorts the image on the visual display used by the boom operator during refueling operations. The actuator on the boom needs to be more sensitive to smaller receiver aircraft, such as A-10s and F-16s. Boeing has agreed to pay for the RVS design fix, while the Air Force will finance the design change to the actuator.

“There's profound problems with the system,” Air Force Chief of Staff Gen. David Goldfein said March 3 during a Senate Armed Services Committee hearing.

The service is certifying the aircraft to conduct airlift and medical evacuation missions. The plan is for the Air Force to employ the KC-46 in those roles while a long-term fix is being developed, Goldfein said.

Goldfein told new Boeing CEO Dave Calhoun to focus on the KC-46 program, even as it is fixing the 737 MAX. Calhoun said the KC-46 is his top military priority.

“I have seen a change in the behavior of that company since he took over, and so that's why we're more confident sitting here today that we have a serious fix on the table,” Goldfein said. “We're in final negotiations, so we can't go into any more detail than that. But I will say that it's looking better today than it was even six months ago.”

https://aviationweek.com/defense-space/aircraft-propulsion/usaf-announces-new-major-deficiency-kc-46

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Fiscal 2020 procurement of ammunition (Army) funds in the amount of $2,047,464 to Day & Zimmermann Lone Star LLC (N00104-20-F-VL01); and $1,455,992 to Tech Ord (N00104-20-F-VM01) will be issued as delivery orders that will be awarded concurrently with the contracts and funds will not expire at the end of the current fiscal year. This was a fully competitive requirement, with six offers received. Naval Supply Systems Command Weapon Systems Support, Mechanicsburg, Pennsylvania, is the contracting activity. Viasat Inc., Carlsbad, California is awarded a $13,965,530 modification to an existing indefinite-delivery/indefinite-quantity contract for a maximum potential value of $17,822,995 for the production of KOR 24A multi-channel small tactical terminals. The KOR 24A is interoperable with the Multifunctional Information Distribution System (MIDS) family of radios. This contract supports Foreign Military Sales (FMS) cases for international partner nations. No contract funds will be obligated on the contract modification. Non-appropriated contract funds for FMS in the amount of $649,672 will be obligated on the second delivery order and will not expire at the end of the current fiscal year. Work will be performed in Carlsbad, California. The ordering period is through September 2021. This sole-source contract was not competitively procured in accordance with 10 U.S. Code 2304(c)(4) – International Agreement (Federal Acquisition Regulation subpart 6.302-4). Naval Information Warfare System Command San Diego, California, is the contracting authority and awarded the contract on behalf of the MIDS Program Office (N00039-19-D-0036). ProSecure LLC,* Fairfax, Virginia, is awarded a $10,083,876 indefinite-delivery/indefinite-quantity contract for regional security services at various installations in the Naval Facilities Engineering Command (NAVFAC) Northwest area of operations. The maximum dollar value including the base period and four option years is $55,075,836. The work to be performed provides for armed security guard services to meet region operational requirements. Such actions include access control, surveillance, screening, detaining and conducting preliminary investigations of real or potential violations of installations orders and/or applicable regulations. Work will be performed at various NAVFAC Northwest installations in Washington (96%); and Idaho (4%), and is expected to be completed by Sept. 30, 2025. No funds will be obligated at time of award. Fiscal 2021 operations and maintenance (Navy) contract funds in the amount of $9,502,242 for recurring work will be obligated on an individual task order issued during the base period. This contract was competitively procured via the Federal Business Opportunities website with seven proposals received. NAVFAC Northwest, Silverdale, Washington, is the contracting activity (N44255-20-D-5018). Bristol Engineering Services Co. LLC,* Anchorage, Alaska, is awarded an $8,819,114 firm-fixed-price task order (N62473-20-F-5251) under a multiple award construction contract to replace fuel farm tanks at Naval Auxiliary Landing Field, San Clemente Island. The task order also contains one unexercised option, which if exercised would increase cumulative task order value to $10,214,469. The work to be performed replaces six single wall diesel fuel tanks with double wall tanks, including all associated appurtenance: pipes, valves and catwalk. The new fuel storage tanks and associated piping/distribution system will support the required training and testing missions. The option, if exercised, provides for a new above ground pipeline and associated control systems connecting the power plant, fueling station and the six tank fuel compounds. Work will be performed in San Diego, California, and is expected to be completed by November 2022. Fiscal 2020 defense working capital funds (Defense-wide) in the amount of $8,819,114 are obligated on this award and will not expire at the end of the current fiscal year. Four proposals were received for this task order. The Naval Facilities Engineering Command, Southwest, San Diego, California, is the contracting activity (N39430-20-D-2221). Hydraulics International Inc.,* Chatsworth, California, is awarded an $8,002,881 firm-fixed-price contract to procure 38 diesel portable hydraulic power supplies and 16 electric portable hydraulic power supplies. Additionally, this contract includes a physical configuration audit and a request for variance for the units being procured in support of the V-22 aircraft program for the Navy and government of Japan. Both the diesel and electric portable hydraulic power supplies are designed to power the aircraft hydraulic systems for operational maintenance and testing of aircraft hydraulic components while on the aircraft. Work will be performed in Chatsworth, California, and is expected to be completed in August 2021. Fiscal 2018 aircraft procurement (Navy) funds in the amount of $6,854,327; fiscal 2019 aircraft procurement (Navy) funds in the amount of $282,915; and Foreign Military Sales funds in the amount of $865,639 will be obligated at time of award, $6,854,327 of which will expire at the end of the current fiscal year. The Naval Air Warfare Center Aircraft Division, Lakehurst, New Jersey, is the contracting activity (N68335-20-C-0224). SPACE DEVELOPMENT AGENCY Lockheed Martin Corp., Littleton, Colorado, is awarded a $187,542,461 firm-fixed-price contract for the Space Development Agency Transport Layer Tranche 0. The proposal was received and evaluated under request for proposal HQ0850-20-R-0001. The work to be performed under this contract will include on-time delivery of space vehicles and paths to optical intersatellite link interoperability success. Work will be performed in Littleton, Colorado (54.2%); Irvine, California (24.4%); Backnang, Germany (10.6%); Centennial, Colorado (5.9%); Camarillo, California (1.3%); San Diego, California (1.3%); Tempe, Arizona (0.7%); Quebec, Canada (0.5%); Madrid, Spain (0.4%); Cedar Rapids, Iowa (0.3%); Annapolis Junction, Maryland (0.2%); Bedford, New Hampshire. (0.2%); and Ottawa, Canada (0.1%). Fiscal 2020 defense wide research, development, test and evaluation funds will be obligated at the time of award. The Space Development Agency, Washington, D.C., is the contracting activity (HQ0850-20-C-0009). York Space Systems,* Denver, Colorado, is awarded a $94,036,666 firm-fixed-price contract for the Space Development Agency Transport Layer Tranche 0. The proposal was received and evaluated under request for proposal HQ0850-20-R-0001. The work to be performed under this contract will include on-time delivery of space vehicles and paths to optical intersatellite link interoperability success. Work will be performed in Denver, Colorado (45.5%); San Diego, California (13.4%); Los Gatos, California (11.0%); Carlsbad, California (9.0%); Los Angeles, California (6.5%); Scottsdale, Arizona (4.4%); Longmont, Colorado (4.1%); Bothell, Washington (3.3%); and Colorado Springs, Colorado (2.8%). Fiscal 2020 defense wide research, development, test and evaluation funds will be obligated at the time of award. The Space Development Agency, Washington, D.C., is the contracting activity (HQ0850-20-C-0008). DEFENSE ADVANCED RESEARCH PROJECTS AGENCY Raytheon Co., Missile Systems, Tucson, Arizona, was awarded a $32,493,889 modification (P00022) to contract HR0011-15-C-0081, adding Phase 3 tasks to the previously-awarded procurement contract for the Multi- Azimuth Defense Fast Intercept Round Engagement System (MAD-FIRES) program. During the 27-month Phase 3 baseline program, the Raytheon team will focus on seeker development and performance. Raytheon proposes to make performance enhancements to the successful Phase 2 projectile and develop a functional demonstration illuminator and engagement manager to engage and defeat a representative surrogate target. The modification brings the total cumulative face value of the contract to $100,325,347 from $67,831,458. Work will be performed in Tucson, Arizona (95%); Chelmsford, Massachusetts (2%); and McKinney, Texas (3%), with an expected completion date of November 2022. Fiscal 2020 research and development funds in the amount of $29,435,306 are being obligated at time of award. The Defense Advanced Research Projects Agency, Arlington, Virginia, is the contracting activity. DEFENSE LOGISTICS AGENCY Thomas Scientific LLC, Swedesboro, New Jersey, has been awarded a maximum $12,644,524 indefinite-delivery/indefinite-quantity contract for medical and surgical products. This was a competitive acquisition with one response received. This is a one-year base contract with nine one-year options periods. Location of performance is New Jersey, with an Aug. 30, 2021, ordering period end date. Using customers are Army, Navy, Air Force, Marine Corps and federal civilian agencies. Type of appropriation is fiscal 2020 through 2021 warstopper funds. The contracting agency is the Defense Logistics Agency Troop Support, Philadelphia, Pennsylvania (SPE2D0-20-D-0013). AM General LLC, South Bend, Indiana, has been awarded a maximum $7,232,621 firm-fixed-price, indefinite-delivery/indefinite-quantity contract for High Mobility Multi-Purpose Wheeled Vehicle diesel engine cylinder heads. This was a sole-source acquisition using justification 10 U.S. Code 2304 (c)(1), as stated in Federal Acquisition regulation 6.302-1. This is a five-year contract with no option periods. Location of performance is Indiana, with an Aug. 30, 2025, ordering period end date. Using military service is Army. Type of appropriation is fiscal 2020 through 2025 Army working capital funds. The contracting activity is the Defense Logistics Agency Land and Maritime, Warren, Michigan (SPRDL1-20-D-0130). *Small Business https://www.defense.gov/Newsroom/Contracts/Contract/Article/2331179/

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