SATPC0039780 Tab 04 4 SOW Updated.pdf

CUI//SP-CONTRACT/EXPT/SP-PROPIN

TBD Contract # Task Order (TO) #XXX

Task Description

Gateway Quick Disconnect (GQDC) Study Contract

1. BACKGROUND

A Gateway Quick Disconnect (GQDC) is required to support Extravehicular Activity (EVA) and Extravehicular Robotic Activity (EVR) servicing of Active Thermal Control System (ATCS) pump packages on Gateway and similar future missions. The GQDC provides similar functions as the heritage Fluid Quick Disconnect Coupling (FQDC) used on the International Space Station (ISS) but incorporates specific modifications to meet Gateway’s specific operational and environmental requirements, as outlined in Appendix 1. Additional technical details of the heritage FQDC design and functions are available in the attached report, “Fluid Quick Disconnect Coupling for International Space Station Alpha”.

The GQDC is intended for integration into Gateway and used across international partner modules. NASA will serve as the primary point of contact with the vendor and will coordinate with Gateway’s international partners.

To assess feasibility, cost, schedule, and other impacts of delivering GQDC hardware, a study contract is proposed. The goal of this study contract is to advance the GQDC design to a level that reduces design and manufacturing risks, ensuring confidence in proceeding to the next phase. The contract will provide key insights to inform decision-making and aid in selection of a hardware provider for a future flight hardware procurement. However, awarding this study contract does not guarantee selection for the flight contract. It is expected that the contract will be evaluated based on the deliverables of these tasks, but not limited to it.

Each vendor must have and provide as part of their quote details of recent (within the last 3 years), direct, and applicable experience in the design and manufacturing of Fluid Transfer Couplers (for propulsion systems) and/or Quick Disconnects for Internal or External Vehicular Activity (IVA/EVA) for active thermal control system.

2. TASK REQUIREMENTS

a. Task 1: The vendor shall host a project kick-off with virtual (Webex, Teams, or similar) and/or in-person with attendance from international partners.

i. Following the kickoff, monthly project update reviews shall be conducted with

NASA. If meetings with international partners are required to discuss technical topics—such as the Interface Control Document (ICD) for pump packages, integration, or delivery schedules—separate one-time meetings may be scheduled as needed.

b. Task 2: The vendor shall develop a conceptual design of the GQDC with sufficient resolution to mitigate design and manufacturing risks and develop plans for delivery of flight and spare hardware.

i. Unlike the ISS heritage FQDC, which utilizes two flow passages, the GQDC design shall incorporate three flow passages within a single unit. The vendor may choose to base the design on the ISS design or propose an entirely new design.

1. Depending on the vendor’s chosen technical approach, this effort may involve innovative GQDC designs or the development of components compatible with heritage hardware, enabling integration of ISS spares and legacy components into the proposed GQDC concept. NASA can provide 3D scans of existing hardware upon request and potentially some sample components for further investigation.

ii. The effort shall enable the vendor to develop capabilities and confidence in designing each critical component of the proposed GQDC. This includes, but is not limited to, conducting risk mitigation activities such as procurement and testing of key technologies, including welding, hardware acquisition, flow testing, and leak testing.

iii. The effort shall allow the vendor to mature requirements and vehicle/GQDC interfaces for possible follow-on flight fabrication activities.

iv. Technical requirements are provided in the Appendix 1.

v. Required unit quantities for flight and spare hardware are specified in Section 3.

vi. Task 2, Deliverable 1 - GQDC Design Approach: Report (PDF, Word, Power Point and CAD files) detailing the following:

1. Company Overview: Overview of experience, heritage qualification, facilities, and in-house capabilities for manufacturing the GQDC.

2. Basis of Proposed Design: Justification for selected design approach and feasibility.

3. Manufacturing Plans: Summary of production processes, material selection, and scalability considerations.

4. Design & Requirements Compliance Matrix: High-level assessment of compliance with technical requirements in Appendix 1 as well as in-house verification capabilities.

5. Risk Assessment: Identification of key GQDC technical risk areas and proposed mitigation strategies.

6. Preliminary CAD Models: Delivery of draft CAD digital models for feasibility analysis and integration studies.

7. Optional Supporting Hardware: 3D-printed models, sample components, or prototypes (if feasible, but not required).

vii. Task 2, Deliverable 2 - Assessment of GQDC Production: High-level, project plan report (PDF, Word, Power Point) for delivery of flight and spare hardware including:

1. Cost Estimate: High-level estimate of expected costs for design, prototyping, testing, and production of flight and spare units.

2. Schedule Estimate: High-level timeline for completing key development phases.

3. Production Risk Assessment: Identification of key technical risk areas and proposed mitigation strategies for producing flight and spare GQDCs.

4. Resource Requirements: General Identification of key personnel, facilities, and partnerships/sub-contracts necessary for development and production of flight hardware.

c. Task 3: The vendor shall host a final Technical Interchange Meeting (TIM), with virtual or in-person attendance from NASA and international partner, to formally close out the project.

3. ANTICIPATED FLIGHT/SPARE QUANTITIES AND DELIVERY SCHEDULE

a. Quantities

i. Initial intended modules have a total of 2 pump packages (one per loop), each with 3 flow paths (one inlet, two outlets). Delivery of the GQDCs to international partners for integration for the initial module is the most pressing need. The quantities needed for flight, spare, and ground support equipment is listed below.

1. Flight Module: 2 pairs (one per loop) with both active and passive sides launched with the vehicle

2. Spares: 3 active spares

3. Ground Support Equipment: 3 active and passive spares

4. Engineering Model: 2 pairs (qualification units acceptable)

ii. Future modules may need similar hardware, but it is anticipated that the thermal control system will be similar to the initial module and the specifications defined in this document are still relevant.

1. Flight Module: 2 pairs (one per loop) with both active and passive sides launched with the vehicle

2. Spares: 3 active spares

3. Ground Support Equipment: 3 active and passive spares

4. Engineering Model: 2 pairs (qualification units acceptable)

b. Schedule/delivery dates

i. It is anticipated that two Gateway modules will need GQDCs, each with its own need-by dates. See chart below for anticipated delivery dates of GQDC to each program.

1. Delivery dates are estimates only. Actual delivery dates and launch dates may be significantly different from what is provided below.

2. It is recognized that the contractor may not be able to meet the proposed deadlines. NASA would like to know what is the best possible schedule that can be met by vendor for the proposed GQDC concept.

Priority of delivery is for Flight Modules and the delivery schedule should prioritize these flight GQDC.

ii. Spares for both intended and future modules would be provided to each program +1, +6, +11 years after vehicle launch, but could be provided sooner and in bulk.

4. PERIOD OF PERFORMANCE

a. Period of performance is 6 months upon receipt of Authority to Proceed (ATP) from the

Gateway Contracting Officer.

5. ACCEPTANCE

a. Deliverables will be considered accepted upon COR review and concurrence that the deliverable meets the intent of the order requirements.

6. EXPORT CONTROL AND DATA PROTECTION

a. Technical material generated shall be intended for ultimate export to all Gateway

International Partners utilizing Gateway Program Export Control Process.

7. DELIVERABLES

a. The contractor shall deliver the items listed in Table 4-1.

Table 4 1: Deliverables

Deliverable Description Due Date Payment Due

D1 Task: 1: Project Kickoff Meeting ATP 30%

D2 Task 2, Deliverable 1: Delivery of “GQDC Design Approach” Report

ATP + XX

months

25%

D3 Task 2, Deliverable2: Delivery of “Assessment of GQDC Production” Plan

ATP + XX

months

25%

D4 Task 4: Final GQDC Study TIM ATP+6 Months 20%

Appendix 1 – Detailed Technical Requirements

The following key technical requirements are to be used in the design trade of the GQDC development.

Vendor inputs are welcome if the requirement drives cost or schedule. The proposed design should minimize delta pressure through the device while maximizing flow rate capabilities while then meeting other requirements. The ISS FQDC technical specification are also provided with this solicitation and can be used as a reference requirement as a flight hardware requirements are still in development.

1. Flow passage configuration needed for the GQDC

a. 3 total flow passages (reversable flow capability while meeting requirements)

b. ¾” diameter interface stainless steel series tubing suitable for a welded interface

2. Mass

a. The objective is to significantly reduce the mass compared to the two-flow path per

FQDC assembly configuration used on ISS. The ISS FQDC mated pair is approximately 20 lbs (15 lbs active, 5 lbs passive). It is desired to reduce this mass for the GQDC concept.

3. Envelope/Interface

a. Note: Because the design of the GQDC the and flight modules are not mature, it is expected that contractor, NASA, and international partners will iterate on choosing the best interface locations to reduce manufacturing time and complexities while meeting interface requirements on flight modules

4. Leakage

a. The GQDC total external helium leakage in the mated and demated (each half) condition shall not exceed 1.0 x 10-6 sccs across the full temperature range.

b. Note: This value is based upon current FQDC performance, exact Gateway values are

TBD.

5. Leakage - Helium External-to-Internal

a. The external-to-internal helium leakage rate shall be less than 1x10-6 standard cubic centimeter per second (TBD) with GQDC in each of its mated and demated conditions and subject to an internal vacuum of 1 x 10-3 torr or less with atmospheric pressure and ambient temperature (70 ±10 degrees Fahrenheit) applied externally.

b. Note: This value is based upon current FQDC performance, exact Gateway values are

TBD.

6. Temperature – Non-operating

a. The GQDC shall be capable of withstanding the temperature range of -80C (-112F) to

+60C (140F) at 1103 Kpa (160 psi).

7. Temperature – Operating

a. The GQDC shall be capable of operating continuously over the temperature range of - 70C (-94F) to +50C(140F) at 1103 Kpa (160 psi).

8. Thermal Fluid Temperature Cycles – Operational

a. The GQDC shall be designed to withstand a minimum of 10,000 thermal cycles (TBD)of fluid temperature from -70C (-94F) to +60C (140F) at 1103 Kpa (160 psi).

9. Maximum Operating Pressure – In flight

a. The GQDC shall be designed to maintain structural integrity at the on-orbit MOP of 1103 Kpa (160 psi).

10. Flow Rate

a. Low flow Rate: 475kg/hr

b. Nominal Flow Rate: 950 kg/hr

b. Faulted Flow Rate: 1,800 kg/hr

11. Pressure Drop - Passive-to-Active Half

a. The GQDC passive-to-active half pressure drop shall be less than 1.5 psi when NOVEC-

7200 fluid at 20 degrees Fahrenheit is flowing from the passive to active half at 950 kg/hr.

12. Pressure Drop - Active-to-Passive Half

a. The GQDC active-to-passive half pressure drop shall be less than 1.5 psi when NOVEC-

7200 at 20 degrees Fahrenheit is flowing from the passive to active half at 950 kg/hr.

13. Redundant Seals

a. Any leak path from the GQDC fluid passages to the external environment shall have a minimum of two seals.

14. Working fluid

a. NOVEC-7200

b. IPA, GN2, and GHe, and air (for ground processing).

15. Actuation Pressure Range

a. The GQDC shall be capable of being actuated to each of its mated, engaged and demated condition when pressurized from one atmosphere to 1103 Kpa (160 psi).

16. Material Compatibility

a. The components which come in contact with NOVEC-7200 coolant shall be compatible with the NOVEC-7200 coolant and all other working fluids listed

b. The Flexible Hose Assembly tubing interface and Passive half tubing interface materials shall be compatible with welding to stainless steels (316L).

17. EVA and Robotic Interface Temperature Limits

a. The surface temperature of items requiring robotic interface shall be between -70°C (-

94°F) and 90°C (194°F).

b. Assume the EVA interface temperature limits are the same as the heritage ISS limits.

18. Force to Engage, Mate, or Demate

a. The actuation force required to engage, mate, and demate the GQDC shall not exceed

12.5 pounds (TBD) of axial force or 1 pound (TBD) of axial force in conjunction with the torque allowed by requirement #19 at the hex drive nut (where a motorized or manual tool would be used to actuate the GQDC), when the GQDC is filled with NOVEC-7200.

19. Torque to Engage, Mate, or Demate

a. The GQDC shall be capable of being actuated to each of its engaged, mated, and demated conditions when either of the following torque’s are applied at the hex drive nut (where a motorized or manual tool would be used to actuate the GQDC) in conjunction with the one pound axial (TBD) force allowed by Requirement #18, when the GQDC is filled with NOVEC-7200 pressurized to 160 psia:

i. 130 ±20 percent inch-pounds (TBD)

ii. 10 ±10 percent foot-pounds (TBD)

20. Misalignment Compensation – Dynamic

a. The GQDC self-alignment features shall be incorporated which prevent the GQDC from violating a TBD dynamic envelope when undergoing the dynamic displacements bulleted below and result in the GQDC being fully operable after undergoing the displacements.

The maximum dynamic displacements during launch are: (Heritage ISS requirement, GW may be similar or TBD)

i. Translation in the x direction ±0.152 inch (TBD)

ii. Translation in the yz plane ±0.276 inch (TBD)

iii. Rotation about the x, y, and z axes ±0.5 degree (TBD)

21. EVA and Robotic Actuated Fasteners

a. All EVA/EVR actuated bolts shall conform to an 11mm hex head screw in order to interface with the standard EVA/EVR hand power tools and robotic arm.

c. Note: The GQDC is intended to be serviceable from the robotic arm at the top of pump package as pictured in Figure 1.

Figure 1: Pump package on flight module with pump cover removed, 2 ISS-heritage FQDC’s pictured here, only 1 GQDC is envisioned. EVR interface (11 mm) on top of pump package envisioned.