Attachment 1-SOW MK 1 8 and 14 elem array-DUCU cable set Rev 2 081219_.pdf

6973GH-19-R-00224

AML-7000 8-12-2019

SOW MK 1 8 and 14 elem array-DUCU cable set Rev 2 081219 .doc

STATEMENT OF WORK (SOW)

FOR

Navigation, Landing, and Weather (AML-7000)

MK 1D/E/F 8 and 14 Element DUCU Cable set”

1.0 BACKGROUND

Within FAA ILS systems across the NAS, cables within the MK 1 D/E/F Eight and Fourteen Element arrays deteriorate over time. Failures or even intermittent failures can cause airport delays to sites when these problems arise. To order cabling by normal means, then cut the cables on site for the array can take several weeks. With the availability of a Depot Kit, sites can have the cables installed, and the array prepped within a few days to avoid long term outages for a site.

2.0 SCOPE OF WORK

The scope of this contract is to provide MK 1F Eight (8) Element and Fourteen (14) Element Array Cable sets for depot stock to be released to MK 1D/E/F sites that are showing signs of this problem, where cable deterioration is evident.

3.0 REQUIREMENTS

3.1 First Article Kit

3.1.1 A First Article cable kit shall be submitted to the FAA for inspection and testing prior to build/delivery of remaining kits. This First Article kit will be a sampling, one of each variation of the individual cables provided in the full kits. A list is provided in the SOW of the cable part numbers to be built. All sample cables shall be built as per the drawings with the exception of length noted in 3.1.1.1. This Sample Set pertains to the First Article Samples only. Once the First Article is approved the second first article kits, with noted recommendations and/or changes from First Article inspection, can be built and delivered. The First Article sample cable set will be made not useable during inspection and testing. These cables shall not be considered part of the production units.

3.1.1.1 Part no.: 732662-0001 (DE-B-732662) (Max length required - 2 ft.), 732672-0009, 732669-0007

3.1.2 Vendors who have produced ¼” Heliax cable sets for the FAA Logistics Center may be exempt from producing the First Article kit. Documentation on past production will be required to be submitted for this exemption. Confirmation of this exemption through the CO/COR is required for release from the First Article kit.

3.1.3 A second delivery of two full kits, which will be one each of the Production Kits (noted below) will be used to verify correct build of the kit. All cables will be checked against the cable/other drawings provided to verify correct build, length, labeling, quality, etc. These cables will not be destroyed during verification and will be considered a deliverable so long as the kit(s) conform to the requirements of the contract. This will be done for any vendor and cannot be waived.

Each cable set will be built from the same production run/reel of cable from the cable vendor.

There will be no mixing of cabling between different manufacturing runs within the same cable kit.

3.2 MK 1F 8 Element DUCU cable set

3.2.1 The Contractor shall provide to the government the quantity of fifteen (15) – Localizer Antenna Array Cable sets. These cables shall be manufactured, assembled, and tested in accordance to the documentation/attachments provided within the contract. These items will be packaged as noted below and in accordance with (IAW) the terms and conditions of the resultant contract and delivered to the FAALC. All materials supplied shall be in new condition. All cables shall be free of any damage, abrasions, cuts, etc. over the entire cable surface. No kinks, sharp bends, flat spots or other similar damage shall be present. All kits are subject to further inspection. Each cable set will be built from the same production run/reel of cable from the cable vendor. There will be no mixing of cabling between different manufacturing runs within the same cable kit.

3.2.2 Option years for quantities of 1 to 15 kits will be set within the contract as well.

3.2.3 Cable Kit numbers and cable numbers

016492368

732662-0001 thru -0016 (DE-B-732662), 732672-0009 and 732662.0010 (DE-B-732662), 732669-0007 and 732669-0008 (DE-B-732669)

3.3 MK 1F 14 Element DUCU cable set

3.3.1 The Contractor shall provide to the government the quantity of fifteen (15) – Localizer Antenna Array. All units provided from the vendor shall have the appropriate test documentation included to show the assets meet or exceed factory testing standards as established in the provided documentation. All documentation shall show the correct National Stock Number (NSN), PN, and kit serial number to identify each asset tested. All documentation shall be signed by the tester or the vendor’s Quality Control Representative. Documentation is to be packaged with individual assets. An electronic copy of all documentation is to be provided to the COR. Each cable set will be built from the same production run/reel of cable from the cable vendor. There will be no mixing of cabling between different manufacturing runs within the same cable kit.

3.3.2 Option years for quantities of 1 to 15 kits will be set within the contract as well.

3.3.1.1 Cable Kit numbers and cable numbers

100020990

732670-0001 thru -00028 (DE-B-732670), 732672-0009 and 732672-0010 (DE-B-732672), 732669-0007 and 732669-0008 (DE-B-732669)

3.4 Connector soldering/center pin length

The Contractor shall follow connector manufacturer’s instructions for cable connection assembly. Generic connector pin soldering techniques are supplied below for the contractor to use as needed to produce a quality solder joint within the connector. Poor soldering techniques shall be cause for First Article or standard production kit rejections.

Prior to soldering (initial assembly) one should be able to see the center conductor of the cable easily within the hole in the pin assembly. If done correctly, the cable conductor is of sufficient length when it just goes past the hole toward the tip of the pin. The center pin shall be visible for at least ¾ of the hole to just to the top edge of the hole. Having a center conductor that is too short produces inadequate soldering of the cable inner conductor. Having a center conductor that is too long can have the conductor bottom out within the pin before it is fully seated in the proper position on the rest of the cable.

Proper soldering: The solder should be visible in the hole of the pin of the connector, filling the cavity within the pin assembly itself. If the hole is slightly filled with a small dimple in the solder near the top which indicates the solder pulled down into and around the cable conductor this is acceptable. A minimal solder quantity would be if one can see the cable center conductor still, but the pin cavity is filled. Solder should not flow outside of the pin hole. If it does flow outside, it must be cleaned off.

Testing

In addition to the testing called out within the drawings for cable length, etc. the vendor shall perform both resistance testing of the center pin to outer shield, and a “meg” check.

Resistance as noted shall be zero (0) ohms (+ 2 ohm, - 0 ohm). When performing the “Megger” test, equipment shall be set at a minimum 1000V scale or better. The Megger test shall show an infinity reading.

3.5 Documentation:

3.5.1 All units provided from the vendor shall have the appropriate test documentation included to show the assets meet or exceed factory testing standards as established in the provided documentation. All documentation shall show the correct National Stock Number (NSN), PN, and kit serial number to identify each asset tested. All documentation shall be signed by the tester or the vendor’s Quality Control Representative. Documentation is to be packaged with individual assets. An electronic copy of all documentation is to be provided to the COR.

3.5.2 Documentation from the cable manufacturer is required to verify the correct cable was purchased by the contractor; swept, phase stable. This documentation shall be submitted with the First Article, and each cable package.

3.6 Warranty

The manufacturer’s standard warranty shall apply. A minimum of 1 year is required on each cable.

4.0 Packaging, Handling, Storage, and Transportation (PHS&T)

4.1 The Localizer Antenna Array Cable sets shall be provided in the following configurations. The contractor shall pack cable sets in heavy cardboard containers or equivalent. The outside labeling/packing list, in addition to the standard information set below, shall provide the cable quantities and serial numbers for each unit within. If more than one container is used, the containers shall be clearly marked and/or identified as; i.e. 1 of 2, and 2 of 2 in addition to the other required information.

4.2 Individual cables shall be packaged and marked using the unique cable number for each cable.

4.3 Cable sets within the kit, identified with the six digit base number shall be separated into these set groups for ease of use at field facilities.

4.4 All components and equipment shall be packaged to meet American Society for Testing and Materials (ASTM) D3951-10 Standard Practice for Commercial Packaging. Performance testing of packaging will be IAW ASTM D 4169 assurance level II distribution cycle 18.

4.5 All items shall be marked IAW MIL- STD-129R “Marking for Shipment and Storage”. Bar coding is required, 2D (PDF417) is preferred; however, (39 Code) will be accepted.

4.6 The contractor shall label the packaging with the following information:

National Stock Number (NSN) – 5895-01-649-2368

LCSS#: 016492368

Noun – 8 Element Array cable set

Or

National Stock Number (NSN) – NA

LCSS#: 100020990

Noun – 14 Element Array cable set

(including below for both)

Kit Number – 00000000000000

Manufacturer – XXXXXXXX

CAGE Code – 000000

Contract Number – (As found on the contract)

Serial Number – 0000

5.0 DELIVERABLES

TASK DESCRIPTION DUE DATE

3.1 LOC First Article set NLT 60 days after contract award.

3.1.3 LOC First Article, 2 cable sets NLT 60 days after First Article (3.1)approval.

3.2 LOC 8 element array sets NLT 90 days after First Article approvals

3.3 LOC 14 element array sets NLT 90 days after First Article approvals

6.0 KEY PERSONNEL AND QUALIFICATION REQUIREMENTS - The Contractor shall have prior experience in the build/production of similar cables and has been a regular manufacturer of these types of cables. Each Contractor must submit proof of prior contracts or production work, more than four (4) within the past two years. Such proof of manufacturing shall show the scale of the build: dollar value/revenue, quantity, type (material, etc.) and the buyer with contact information.

7.0 TRAVEL – Not Applicable

8.0 GOVERNMENT FURNISHED EQUIPMENT (GFE) - Not Applicable

9.0 PERIOD OF PERFORMANCE

Delivery of First Article shall be in 60 days after contract award. Delivery of remaining materials shall be 90 days after First Article approval.

10.0 PLACE OF PERFORMANCE

The Contractor shall perform the work of the contract on the Contractor’s premises.