ARMECH RFI -Statement of Objectives-.pdf

CONTROLLED UNCLASSIFIED INFORMATION (CUI)

Controlled Unclassified Information (CUI)

CUI

REQUEST FOR INFORMATION:

“ARMECH”

Atmospheric Research Mission Equipment Case and Handling

3 October 2024

Version 0

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Table of Contents

6.0 Executive Summary

7.0 Level of Effort (LOE)

7.1 Single Vessel Case (SVC)

7.2 Rack-Case-Interface (RCI)

7.3 Weight Constraints

8.0 Programmatic

8.1 Contract Line-Item Number(s)

8.2 Costing

8.3 Government Furnished Items

8.4 Travel and Meetings

9.0 Deliverables

9.1 Technical Data Package

9.2 Pre-Production Prototypes

9.3 Low-Rate Initial Production (LRIP) Integrated Production Plan

10.0 Shipping and Transportation

11.0 Appendix A

12.0 Appendix B

Table of Figures Figure 1: WC-135 Constant Pheonix Aircraft Figure 2: 900 Cubic Inch, 3000 PSI Composite Overwrapped Pressure Vessel (COPV) Figure 3: Legacy 900 cubic inch Spherical Pressure Vessel Figure 4: Sphere with Case Figure 5: WC-135 GCS racks with Spheres in bays Figure 6: Event Driven Plan

Table 1: Glossary of Terms Table 2: Applicable Documents

Table 1: Glossary of Terms

Term Definition

CLIN

Contract Line-Item Number. A line item captures the information about separately identifiable goods and services that the

Government needs to purchase (See FAR 2.101) and a Line-Item

Number (LIN) is the numeric or alphanumeric format to identify a line item.

COA Course of Action. Path(s) taken to achieve the desired end-state.

COPV

Composite Overwrapped Pressure Vessel. A 900 cubic inch, 3000

PSI pressure vessel design was selected to support the WC-135

Constant Phoenix mission in 2022, with the legacy spherical vessels planned for obsolescence.

GCS

Gas Collection System. Mission Equipment that collects atmosphere during flight and compresses the atmospheric gasses. The GCS store the compressed samples in the COPV(s) for analysis.

PPP

Pre-Production Prototype. A geometric model constructed from dimensionally stable materials that support the physical fitting and verification of design features. The PPP is not required to be constructed from materials anticipated in a production unit (e.g. it may be 3D printed) but is required to geometrically match the proposed design.

RCI

Rack-Case Interface. A socket that may remain with the GCS rack and secures the SVC while in flight. Modifying the GCS rack to interface with the SVC is unacceptable within the scope of this effort.

Sphere

Spherical Pressure Vessel. 900 cubic inch legacy pressure vessel in use since the 1960's, featuring a semi-spherical design and manufactured from stainless steel. High manufacturing costs and high-risk lot acceptance criteria created the impetus to pursue the

COPV.

SVC

Single Vessel Case. Proposed case for a single 900 cubic inch

COPV and high-pressure valve assembly. For the purposes of this defining features for the design, the SVC should be understood to contain a COPV assembly and 3000 psi pressurized atmosphere.

WC-135 Constant Phoenix

Mission Aircraft. A special-purpose aircraft derived from the Boeing C-135 Stratolifter and used by the United States Air

Force. Its mission is to collect samples from the atmosphere for the purpose of detecting and identifying nuclear explosions.

Table 2: Applicable Documents

Document ID Document Title Revision

TBD DRAWING - COPV

Composite Overwrapped Pressure Vessel, 900

Cubic Inches, with Hand Valve, Assembly of A

TBD DRAWING - MICD

Mechanical Interface Control Document, Pressure

Vessel Bay, Gas Collection System A

DOT-CFFC

Basic Requirements for Fully Wrapped Carbon-

Fiber Reinforced Aluminum Lined Cylinders

(DOT-CFFC)

Electronic/Web

MIL-HDBK-310

Global Climatic Data for Developing Military

Products A

MIL-STD-31000 Technical Data Packages B

MIL-STD-810

Environmental Engineering Considerations and

Laboratory Tests H

NIOSH Applications Manual Applications Manual for the Revised NIOSH

Lifting Equation Electronic/Web

SAE-AMS-STD-595 Colors Used in Government Procurement A

42E1-1-1 Air Force Technical Order; Aviation Hoses and

Manual G

1.0 Executive Summary

Technical Applications Products, Department of the Air Force (DAF), (heretofore “the

Government”), requires the development of a solution, Atmospheric Research Mission

Equipment Case and Handling (ARMECH) to interface the 900 cubic inch Composite

Overwrapped Pressure Vessels (COPVs) with pre-existing mission equipment onboard the

WC-135 aircraft. The ARMECH provides protection to individual COPV’s during transloading or shipping activities; it also acts as the secure, ruggedized, stackable, single person carrying case.

The mission equipment that these products are intended to support is onboard the WC-135

Constant Pheonix aircraft fleet. One of the subsystems, the Gas Collection System (GCS), requires pressure vessels to collect and store gaseous atmospheric samples.

Prior to the acquisition of the Composite Overwrapped Pressure Vessels (COPVs), the

Government deployed 900 cubic inch, stainless steel, spherical pressure vessels. These legacy spherical vessels are of an obsolete design and specification. Due to extremely high manufacturing costs, a suitable replacement pressure vessel, the COPV, was sought and acquired.

Figure 3: Legacy 900 cubic inch

Spherical Pressure Vessel

Figure 4: Sphere with Case

Figure 5: WC-135 GCS racks with Spheres in bays

However, the GCS was designed to secure two (2) 900 cubic inch spherical pressure vessels

(Figure 3, Figure 4) in each “bay” (front-to-back relative to the center aisle) within the

Figure 1: WC-135 Constant Pheonix Aircraft

Figure 2: 900 Cubic Inch, 3000 PSI Composite Overwrapped

Pressure Vessel (COPV) mission equipment rack (Figure 5). Thus, this effort must produce solutions for a Single

Vessel Case (SVC) and an interface for two (2) SVCs to the GCS rack.

Level of Effort (LOE)

The overall goals of this effort are to develop an interface with the aircraft mission equipment, protect the COPV against abrasion and impact, improve COPV manual material handling, and integrate features to support bulk shipment of forty-eight (48) units (minimum, no maximum) on 48-50” width x 48” length x 72” height standard-size, synthetic or metal commercially available pallets.

The Government reserves unlimited data rights for this effort.

1.1 Single Vessel Case (SVC)

The Single Vessel Case (SVC) is intended to protect the COPV and attached high-pressure valve against abrasion and impact, as well as provide outer surfaces that support material handling and shipment. Additionally, the SVC must be demonstrated through modeling and simulation to meet airworthiness requirements. The SVC should be designed with the following high-level guidance:

1.1.1 The Government will provide a technical drawing (see appendix A) as GFI, as well as an exemplar COPV-Valve assembly as GFE.

1.1.2 Maximum manufacturability as defined by production unit cost and schedule.

This is a criteria item for design and influences all follow-on manufacturing. It is possible that there will be multiple awards to the contract, and product manufacturability will be used to determine the Government’s next course of action (COA).

1.1.3 Must meet or exceed DOT-CFFC test requirements of the bare COPV (see Table

2: Applicable Documents, DOT-CFFC for reference).

1.1.4 Must meet airworthiness requirements, including manufacture from a UL-94 or other flame-retardant material meeting or exceeding UL-94 by existing technical specification or newly developed testing to meet contractual requirements.

1.1.5 Additionally, retention against 9G forward loading (axis of flight of the aircraft), 2G vertical loading, and 1.5G horizontal loading (axis of wingspan) is required. The COPV will be loaded into the mission equipment rack from the center aisle, with the vessel’s longitudinal axis parallel to the horizontal axis of the aircraft.

1.1.6 Must include hand-access for the high-pressure valve to be connected to quick disconnect pneumatic line and the valve must be able to be actuated during flight.

1.1.7 Must include hand-access for the quick disconnect pneumatic line routed from the valve to the top of the rack bay, with a minimum bend radius of 2” for the pneumatic line, reference Table 2: Applicable Documents, Air Force

Technical Order 42E1-1-1.

1.1.8 Must be capable of some environmental resistance to light rain, UV solar radiation, and debris ingress, such as including feature such a removeable cap or panel to access the high-pressure valve, reference MIL-HDBK-310, MIL-

STD-810. SVC does not have to be hermetically sealable.

1.1.9 Must include some features that aid in manual handling of the SVC with contained COPV, such as handholds or handles. A handhold or handle is desired at the long end of the SVC to aid in loading individual SVCs through a trapdoor and ladder behind the cockpit.

1.1.10 Maximum SVC weight defined after Rack-Case-Interface (RCI) guidance below.

1.1.11 Must include features that support high-density packing on a 48-50” width x

48” length x 84” height standard-size, synthetic or metal commercially available pallets. Non-removable interlocking features are desirable. A minimum palletized load is forty-eight (48) SVC’s, with no maximum other than the outer geometric constraints and a maximum pallet weight of

10,000lbs.

1.1.12 Color(s) chosen must be in accordance with IAW SAE-AMS-STD-595.

1.2 Rack-Case-Interface (RCI)

A Rack-Case-Interface (RCI) is required to secure the two SVCs within the rack bay with no modification to the GCS rack and be demonstrated through modeling and simulation to meet airworthiness requirements. The SVC may be designed with features that eliminate the need for an RCI part or assembly or the RCI may be designed as a separate part or assembly.

1.2.1 The Government will provide a technical drawing (see appendix B) as GFI, as well as an exemplar Mechanical Interface Control Document [Part] as GFE.

1.2.2 Maximum manufacturability as defined by production unit cost and schedule.

This is a criteria item for award of a follow-on manufacturing contract. It is possible that there will be multiple awards to the contract, and product manufacturability will be used to determine the best option to the Government.

1.2.3 The RCI may a separate construct or integrated features in the SVC.

1.2.4 No modification of the Mission Equipment Gas Collection System (GCS) racks is authorized.

1.2.5 The RCI may stay installed in the GCS rack with or without one (1) or two (2)

SVCs. If the RCI is a separate construct, then it is intended to leave the RCI always installed in the racks.

1.2.6 Must meet airworthiness requirements, including manufacture from a UL-94 or other flame-retardant material, as well as retention against 9G forward loading

(axis of flight of the aircraft), 2G vertical loading, and 1.5G horizontal loading

(axis of wingspan). The COPV will be loaded into the mission equipment rack from the center aisle, with the vessel’s longitudinal axis parallel to the horizontal axis of the aircraft. These requirements must be met whether the SVC(s) are present or not.

1.3 Weight Constraints

The GCS rack bay was designed to restrain two (2) 900 cubic inch Spheres within their respective cases. Thus, the ARMECH solution of two (2) SVC’ restrained in the rack by the

RCI product or integrated features must not exceed 110 lbs. Individual SVC’s containing

COPV assemblies with pressurized atmosphere to 3000psi must, at a minimum, meet NIOSH

Applications Manual guidance of 51 lbs. or less. However, it is desirable to minimize the mass of the SVC’s as much as possible to aid in manual handling tasks and reduce loading on palletized SVC’s during transport activities.

2.0 Programmatic

The overall goal of this effort is to select a design suitable for mission needs and designed in a manner that supports maximal manufacturability. Thus, the LOE of this effort is constrained to the “Phase 1” engineering and design activities necessary to produce a Level

3 TDP as defined by MIL-STD-31000, LRIP plan, and Pre-Production Prototype.

Figure 6: Event Driven Plan

2.1 Contract Line-Item Number(s)

This effort will only cover the “Design” phase as depicted in Figure 6. Thus, there are two

(2) Contract Line-Item Number(s) (CLINS):

2.1.1 CLIN001 is comprised of the award of contract, the receipt of Government

Furnished Items, and completion of the Kickoff Meeting, and the initiation of the design activity.

2.1.2 CLIN002 is comprised of the delivery of all deliverables listed in Section 0, Deliverables.

2.2 Costing

Respondents should provide a Rough Order Magnitude (ROM) cost based on a Firm Fixed

Price (FFP) contract structure.

2.3 Government Furnished Items

Respondents should anticipate that the Government will provide both GFI and GFE to support this design effort.

2.3.1 Government Furnished Information (GFI)

2.3.1.1 Drawing # XXXXXX, “Composite Overwrapped Pressure Vessel, 900 Cubic

Inches, with Hand Valve, Assembly of”

2.3.1.2 Drawing # XXXXXX, “Mechanical Interface Control Document, Pressure

Vessel Bay, Gas Collection System”

2.3.1.3 Additional GFI upon request/approval

2.3.2 Government Furnished Equipment (GFE)

2.3.2.1 Two (2) COPV assemblies, per Drawing # XXXXXXXX

2.3.2.2 One (1) MICD 1:1 model, per Drawing # XXXXXXXX

2.3.2.3 Additional GFE upon request/approval

2.4 Travel and Meetings

The government reserves the right to visit the contractor facility at any time, provided five

(5) business days advance notice. Respondents should anticipate travel and meetings for the following activities:

2.4.1 Kickoff Meeting

2.4.1.1 The Kickoff Meeting agenda includes discussion of the overall system requirements, anticipated technical approach, support a forum for Government

SME interaction, and provide access to a physical GCS rack assembly. This meeting is anticipated to occur at Lackland Air Force Base, San Antonio, TX.

2.4.2 Preliminary Design Review (PDR)

2.4.2.1 The PDR is a review of the proposed design and preliminary manufacturing plan. The intent of this meeting is to provide a forum for the Government to give critical feedback on the design, if required, in preparation for final delivery of the listed deliverables. This meeting is anticipated to occur at Lackland Air

Force Base, San Antonio, TX.

2.4.3 Critical Design Review (CDR)

2.4.3.1 The CDR is a review of the modified design if, at PDR, critical feedback required a full or partial redesign effort. Additional CDRs may be required at the contractor expense if the contractor is unable to demonstrate that the proposed design will meet the system requirements. This meeting is anticipated to occur at Lackland Air Force Base, San Antonio, TX.

2.4.4 Final Design Review (FDR)

2.4.4.1 The intent of the FDR is a final review and acceptance of the contractor deliverables and provides a forum for discussing the available courses of action

(COAs) to bring the design to Low-Rate Initial Production. This meeting is anticipated to occur at Lackland Air Force Base, San Antonio, TX.

3.0 Deliverables

The deliverables for this design effort will include a Technical Data Package, Pre-Production

Prototypes (PPP) of the Single Vessel Case (SVC) and Rack Case Interface (RCI), as well as a formal Low-Rate Initial Production (LRIP) price quotation for up to 3,072 SVC units and up to 250 RCI units.

3.1 Technical Data Package

3.1.1 The Technical Data Package (TDP) for this effort is comprised of:

3.1.1.1 Level 3 production drawings and models, as defined by MIL-STD-31000 for the

SVC and RCI.

3.1.1.2 Finite Element Analysis (FEA) electronic data files and reports that support claims of conformance to Airworthiness requirements

3.2 Pre-Production Prototypes

3.2.1 Pre-Production Prototypes of two (2) SVC units and one (1) Rack-Case-Interface

(if applicable).

3.3 Low-Rate Initial Production (LRIP) Integrated Production Plan

3.3.1 The LRIP Integrated Production Plan should, at minimum, include market survey documentation that supports cooperation or partnership with an identified transition-to-manufacture industry partner and a formal quote for Low-Rate Initial

Production (LRIP) unit costs of:

SVC Quantities: 48, 96, 384, 1536, and 3072

RCI Quantities: 50, 100, 150, 200, 250

Shipping and Transportation

The hardware deliverables for this effort will be shipped to the following address:

ATTN: Loretta Lopez

Technical Application Products (TAP), AFLCMC/HNCBML

230 Hall Blvd, Bldg 2028, Central Receiving Suite 158

San Antonio, TX 78243

Phone: 210-925-4749

Appendix A

COPV Assembly Drawing

Appendix B

MICD Drawing