SOW MK 1 antenna array cable set Vol2.pdf

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STATEMENT OF WORK (SOW)

FOR

Navigation, Landing, and Weather (AJW-L700) 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 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 (3.1.1.1). All sample cables shall be built as per the drawings with the exception that no more than 2 ft. of Heliax cable should be used per sample piece. This Sample Set pertains to the First Article Samples only. Once the First Article is approved the first production kit, 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 Cable Part no.: 732662-0004 (Drawing: DE-B-732662), 732672-0009, 732669-0007

3.1.2 Vendors who have produced ¼” Heliax cable sets for the FAA Logistics Center or other FAA Organizations (including sub-vendor) 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.

3.2 Cable Sets-Production

The first “production” cable set will be reviewed, inspected, evaluated and tested to verify conformance/compliance with the contract requirements and standards herein by the FAA.

Inspection of cable cuts, cable lengths, soldering, and other workmanship related parameters will be evaluated. Unless major problems are identified, and the set does not meet the parameters of the contract and drawings, the set will be part of the production run requested by the Government. Additional production cable sets may be evaluated at the Government’s discretion.

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3.3 MK 1F 8 Element DUCU cable set

3.3.1 The Contractor shall provide to the government the quantity of Localizer 8 Element 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.

All units provided by 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 LCSS Number, 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.

3.3.2 Cable Kit numbers and cable numbers

Cable Kit LCSS: 100041599

Cables PN: 732662-0001 thru -0016 (drawing: DE-B-732662), 732672-0009 and 732672-0010 (drawing: DE-B-732672), 732669-0007 and 732669-0008 (drawing: DE-B-732669)

3.4 MK 1F 14 Element DUCU cable set

3.4.1 The Contractor shall provide to the Government the Localizer 14 Element Antenna Array Cable sets. These cables shall be manufactured, assembled, and tested in accordance with 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.

All units provided by 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 LCSS Number), 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.

3.3.1.1 Cable Kit numbers and cable numbers

Cable Kit LCSS: 100041600

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

3.5 Cable

All cable for a set shall be cut from the same manufacturer’s reel. All cable used shall be phase stabilized/heat treated. Proof of purchase of correct cabling is required. See cable drawings for part number.

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3.6 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.

See Heliax Cable Building document.

3.7 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.

3.8 Documentation:

3.8.1 All units provided by 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.

3.8.2 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.

3.9 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 container should be able to withstand moderate impacts and be stackable. 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. Kits shall be further broken down within the boxes as noted below.

4.2 Individual cable sets shall be packaged and marked using the unique cable number for each cable set, then bagged and marked per the following within the full kit:

4.2.1 Cable Kit LCSS: 100041599

Cable PN: 732662-0001 thru -0008 (1st set), 732662-0009 thru -0016 (2nd set), 732672-0009 and 732662-0010, 732669-0007 and 732669-0008 (3rd set)

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4.2.2 Cable Kit LCSS: 100041600

Cable PN: 732670-0001 thru -0007 (1st set), 732670-0008 thru -0014 (2nd set), 732670-0015 thru -0021 (3rd set), 732670-0021 thru -0028 (4th set)732672-0009 and 732662-0010, 732669- 0007 and 732669-0008 (5th set)

4.2.3 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.

4.3 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.

4.4 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.

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

LCSS#: 100041599

Noun – 8 Element Array cable set

Or

LCSS#: 100041600

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

3.1.1 LOC First Article set #1 NLT 60 days after contract award.

3.2 First Production set. NLT 90 days after First Article approval.

3.5 Proof of phase stabilized cable

Provided with first production run cable set submitted for evaluation (3.2).

3.3 LOC 8 element array sets NLT 90 days after First Article approval

3.4 LOC 14 element array sets NLT 90 days after First Article approval

6.0 KEY PERSONNEL AND QUALIFICATION REQUIREMENTS - The Contractor shall have prior experience in the build/production of similar cables, using the same and/or nearly identical components, and has been a regular manufacturer of these types of cables. Each Contractor must submit detailed proof of prior contracts or production work, more than four (4) within the

SOW MK 1 antenna array cable set Vol2.doc Page 5 of 5 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 PERIOD OF PERFORMANCE

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

8.0 PLACE OF PERFORMANCE

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

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