P-3 Orion’s SMIP Program Keeps on Rolling

P-3 Orion, armed -
note Sidewinder
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The P-3 Orion remains the USA’s main maritime patrol aircraft, and is also finding use in overland surveillance roles despite the fleet’s age. Earlier DID articles have noted the extra effort required to preserve the USA’s P-3C Orion maritime surveillance & patrol aircraft, along with radar and weapons upgrades to improve the fleet. Lockheed has even opened a new production line, to deal with planes whose wings that are so aged and worn that they need a full replacement.

The SMIP (Sustainment, Modification, and Installation Program) is intensive depot-level inspection and repair process that includes P-3 airframe and component inspection, identification of problems, and corrective maintenance. The idea is to ensure safe and reliable P-3 use, while trying to get more hours out of each airframe in order to sustain dwindling global fleets. More intensive “MIP” efforts may be launched once inspection results become clear, such as the USA’s P-3 recovery plan and full “ASLEP” re-winging efforts underway in Norway and Canada…

• SMIP Activities
  
• SMIP Contracts [updated]
  
• Additional Readings
  

SMIP Activities

SMIP work is performed on all types, models and series of P-3 aircraft in the 164-aircraft U.S. Navy fleet, as well as P-3 aircraft supported through U.S. Navy-administered foreign military sales programs.

The US Navy formally launched a P-3 service life assessment program in 2000. That led to a full-scale fatigue test on a P-3C by 2002 – and the results shocked the Navy. Lockheed Martin’s assessment was based on a 1980s software algorithm, but testing showed that the problems were ahead of the algorithm, and new tools predicted very serious failures. That led to the creation of a Special Structural Inspection Kit, with wing undersides receiving extra attention.

SMIP work includes 2 types of activities.

The first type of SMIP activity involves those special structural inspections to ensure that corrosion from salt spray, or the stresses of repeated low-level swoops to near-sea level, haven’t created damage that might make the airframe unsafe before the next inspection. These services include:

• P-3 Special Structural Inspections (SSIs);
  
• Enhanced Special Structural Inspections (ESSIs);
  
• Fabrication and delivery of Special Structural Inspection Kits (SSI-Ks)

To ensure the aircraft remain safe, a Fatigue Life Management Program (FLMP) tracks and updates each P-3′s status every 6 months, and each plane’s flight hours and mission profiles are also monitored.

The inspections do find problems, as one would expect with aircraft this old. Next comes the actual work done. Sometimes, that just means regularly scheduled maintenance. Sometimes, the work involves installing new equipment, from upgraded electronics and radars to entirely new sets of wings. These services are referred to under SMIP as:

• Phased Depot Maintenance (PDM); and
  
• Modification/Installation Programs (MIPs).

The exact bundle of work varies to some extent from customer to customer, and MIPs will have contracts of their own attached to cover the cost of the equipment and any work “above and beyond.”

SMIP Contracts

The age of the fleet has even begun to involve re-winging and “Zone 5″ work under a crash plan to, well, keep the P-3s from crashing. Because of their emergency nature and operational significance, those efforts are covered in a separate article: “US P-3 Recovery Plan Tries to Keep the Fleet in the Air.” Unless otherwise noted, US Naval Air Systems Command in Patuxent River, MD manages these contracts.

Refurb done
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Oct 20/11: L-3 Communications Integrated Systems – Waco Platform Integration Division in Waco, TX receives a $113 million indefinite-delivery/ indefinite-quantity contract modification, exercising an option for services in support of the P-3 (Orion, maritime patrol), EP-3 Aries II electronic surveillance, and NP-3 testing aircraft SMIP services. This includes planned maintenance intervals, structural replacement and fabrication efforts pertaining to special structural inspection kits, center wing assemblies, Zone 5 kits, and outer wing installations and refurbishments.

Work will be performed in Waco, TX, and is expected to be complete in October 2012. $5.6 million will expire at the end of the current fiscal year, on Sept 30/12 (N00019-11-D-0017).

May 25/11: L-3 Communications Integrated Systems – Waco Platform Integration Division in Waco, TX wins a $104 million indefinite-delivery/indefinite-quantity contract for services in support of P-3 (Orion, maritime patrol), EP-3 (Aries II, electronic eavesdropping), and NP-3 (testing plane) SMIP services. This includes planned maintenance intervals, structural replacement and fabrication efforts pertaining to special structural inspection kits, center wing assemblies, Zone 5 kits, and outer wing installations and refurbishments.

Work will be performed in Waco, TX and is expected to be complete in May 2012. $4,105,717 will expire at the end of the current fiscal year, on Sept 30/11. This contract was competitively procured via an electronic request for proposals, with 2 offers received (N00019-11-D-0017). See also L-3 release.

April 28/11: Lockheed Martin Aeronautics Global Sustainment Services in Greenville, SC receives a not-to-exceed $64.4 million indefinite-delivery/ indefinite-quantity multiple award contract modification. The money will pay for continued P-3 airframe sustainment support: phase depot maintenance, special structural inspections, special structural inspection kits and installations, and modification installations.

Work will be performed in Greenville, SC (100%), and is expected to be complete in December 2012 (N00019-05-D-0013).

April 27/11: L-3 Communications Corp. in Waco, TX wins a not-to-exceed $84.5 million indefinite-delivery/ indefinite-quantity multiple award contract modification for continued P-3 airframe sustainment support: phase depot maintenance, special structural inspections, special structural inspection kits and installations, and modification installations.

Work will be performed in Waco, TX (96%), and Greenville, SC (4%), and is expected to be complete in December 2012 (N00019-05-D-0008).

April 18/11: Lockheed Martin receives a $23.8 million order for procurement of 76 acoustic processor and receiver tech refresh kits for the AN/USQ-78V acoustic subsystems aboard the P-3C Orion. Work will be performed in Manassas, VA, and is expected to be completed in February 2014. As one might guess, this is a P-3 MIP activity.

P-3 with CG 54
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March 24/10: US NAVAIR discusses one aspect of the P-3 fleet non-structural efforts to stay ahead of obsolescence via MIP: radio replacement. According to P-3 Critical Obsolescence Program (COP) Team Lead Danny Hartwell, the existing Army/Navy Piloted ARC-161 analog radio was “costly and time consuming. We were required to replace the system organically…”

To hat end, the U.S. Navy recently began installation of an Organic Depot at Fleet Readiness Center South West (FRCSW) in San Diego, CA, to install AN/ARC-243 high-frequency radios in P-3s beginning in 2011. This is the same system that will be used for the Orion’s P-8A Poseidon; high-frequency radio provides instant over-the-horizon communications without the use of satellites, by bouncing signals off of the ionosphere.

Oct 17/09: Lockheed Martin announces a $17.5 million contract to upgrade existing AN/USQ-78V acoustic subsystems aboard the P-3C Orion. The contract includes upgrades and technical refreshes to software and Acoustic Receiver Tech Refresh hardware designed to comply with the Navy’s open architecture directives, replace obsolete components, provide increased processing capacity, and provide the framework for future aircraft upgrades. Work will be performed at Lockheed Martin’s Undersea Systems facility in Manassas, VA; Undersea Systems VP and GM Denise Saiki says that:

“This update provides an open Commercial Off-The-Shelf digital architecture using a modern digital receiver that is common across all maritime patrol and reconnaissance aircraft and helicopters… That helps drive down the total ownership cost of the platforms…”

Sept 17/09: L-3 Communications Integrated Systems LP in Waco, TX receives a $39.7 million modification to a previously awarded indefinite-delivery/ indefinite-quantity multiple award P-3 SMIP contract (N00019-05-D-0013), for special structural inspection kit installation.

Work will be performed in Waco, TX, and is expected to be complete in July 2011. Contract funds in the amount of $7.05 million will expire at the end of the current fiscal year.

June 11/09: Lockheed Martin Services, Inc. in Greenville, SC received a $49.6 million modification to a previously awarded indefinite-delivery/ indefinite-quantity multiple award P-3 SMIP contract (N00019-05-D-0013), for special structural inspection kit installation. Work will be performed in Greenville, SC, and is expected to be complete in July 2011.

March 13/09: US NAVAIR releases a solicitation for the next set of P-3 SMIP and Zone 5 replacement contracts, with a planned base year and 4 option years. The actual contract(s) will not be awarded for many months. FedBizOpps.

Dec 17/08: L-3 Communications Integrated Systems in Waco, TX is being awarded a ceiling priced $136.1 million modification to a previously awarded indefinite-delivery/ indefinite-quantity contract for the P-3C SMIP effort. Work will be performed in Waco, TX and is expected to be complete in December 2009 (N00019-05-D-0008).

Nov 24/08: Lockheed Martin Services, Inc. in Greenville, Sc received a not-to-exceed $11.8 million modification to a previously awarded indefinite-delivery/ indefinite-quantity contract for Special Structural Inspection Kit (SSIK) Revision 7 inspection/ installation on 5 P-3 aircraft. Work will be performed in Greenville, SC, and is expected to be complete in June 2010 (N00019-05-D-0013).

June 12/08: Lockheed Martin Services, Inc., DBA Lockheed Martin Aircraft and Logistics in Greenville, SC received a $9.4 million modification to a previously awarded firm-fixed-price, indefinite-delivery/ indefinite-quantity multiple award contract (N00019-05-D-0013) for additional Special Structural Inspection-Kits (SSI-K) for the P-3 aircraft. Work will be performed in Greenville, SC and is expected to be complete in June 2010.

June 4/08: Lockheed Martin Aeronautics Global Sustainment in Greenville, SC received a $142.5 million ceiling-priced modification to a previously awarded firm-fixed-price, indefinite-delivery, indefinite-quantity multiple award contract (N00019-05-D-0013) to exercise an option for the P-3C SMP effort. Work will be performed in Greenville, SC and is expected to be complete in June 2009.

Feb 26/08: L-3 Communications Integrated Systems, LP in Greenville, TX received a $10.7 million modification to a previously awarded indefinite-delivery/ indefinite-quantity contract for the P-3C SMIP effort. Work will be performed in Waco, TX (60%) and Greenville, TX (40%), and is expected to be complete in December 2008 (N00019-05-D-0008).

Dec 27/07: L-3 Communications Integrated Systems, LP in Greenville, TX received a $123.4 million modification to a previously awarded indefinite-delivery/ indefinite-quantity contract for the P-3C SMIP effort. Services to be provided include phase depot maintenance, special structural inspections, and special structural inspection kits. Work will be performed in Waco, TX and is expected to be complete in December 2008 (N00019-05-D-0008).

P-3C drops sonobuoy
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Sept 25/07: BAE Systems Technology Solutions and Services in Rockville, MD receives a $10.5 million modification to a previously awarded cost-plus-award-fee, indefinite-delivery, indefinite-quantity contract (N00421-06-D-0038) for the manufacture of 13 P-3 Special Structural Inspection airframe kits.

This effort entails production of Emergency Rate Initial Production quantities of end item component parts, including engineering, analytical and manufacturing efforts in support of the Aging Aircraft Program; the original $14 million contract was announced on Sept 26/06. Work will be performed in St. Louis, MO (56%); Rockville, MD (24%); and Brea, CA (20%) and is expected to be complete in September 2009. The Naval Air Warfare Center Aircraft Division at Patuxent River, MD issued the contract.

June 1/07: Lockheed Martin Aeronautics Global Sustainment in Greenville, SC received a $133.8 million ceiling-priced modification to a previously awarded indefinite-delivery/ indefinite-quantity multiple award contract (N00019-05-D-0013), exercising an option for the P-3C sustainment, modification and installation program (SMIP). This is an extension of a previous contract that ends this month.

Work will be performed in Greenville, SC, and is expected to be complete in June 2008.

Dec 26/06: L-3 Communications Integrated Systems LP in Greenville, TX received a $109.4 million ceiling-priced modification to a previously awarded indefinite-delivery/ indefinite-quantity multiple award contract (N00019-05-D-0008), extending its work by exercising an option under the P-3C Sustainment, Modification and Installation Program (SMIP).

Work will be performed in Greenville, TX (50%); Waco, TX (25%); and Birmingham, AL (25%), and is expected to be complete in December 2007.

Jan 30/06: L-3 Communications Integrated Systems LP in Greenville, TX received a $104.2 ceiling-priced modification to previously awarded firm-fixed-price indefinite-delivery/ indefinite-quantity multiple award contract N00019-05-D-0008. It exercises an option for the P-3C Sustainment, Modification and Installation Program (SMIP). Work will be performed in Greenville, TX (50%); Waco, TX (25%); and Birmingham, AL (25%), and is expected to be complete in December 2006. L-3 IS release.

June 9/06: Lockheed Martin Aircraft and Logistics Centers in Greenville, SC received a $125.8 million ceiling-priced modification to a previously awarded firm-fixed-price indefinite-delivery/ indefinite-quantity multiple award contract (N00019-05-D-0013), exercising an option for the P-3C Sustainment, Modification and Installation Program. Work will be performed in Greenville, SC and is expected to be complete in June 2007.

June 10/05: Lockheed Martin Aircraft and Logistics Centers in Greenville, SC received a $121.4 million firm-fixed-price, indefinite-delivery/ indefinite-quantity, multiple-award contract for phased depot maintenance, special structural inspections, enhanced special structural inspections, special structural inspection kits, and modification and installation programs for P-3 and EP-3 aircraft. Work will be performed in Greenville, SC, and is expected to be completed in June 2006. This contract was competitively procured under an electronic request for proposals; 2 offers were received (N00019-05-D-0013).

June 10/05: L-3 Communications Integrated Systems, Greenville, TX received a $104.2 million firm-fixed-price, indefinite-delivery/ indefinite-quantity multiple award contract for phased depot maintenance, special structural inspections, enhanced special structural inspections, special structural inspection kits, and modification and installation programs for P-3 and EP-3 aircraft. Work will be performed in Greenville, TX, and is expected to be complete in June 2006. This contract was competitively procured under an electronic request for proposals; 2 offers were received (N00019-05-D-0008).

Additional Readings

• Flight International (Nov 9/10) – US Navy Overcomes Mass P-3 Grounding Scare