Attachment 1 Statement of Work.pdf

DEPARTMENT OF TRANSPORTATION

FEDERAL AVIATION ADMINISTRATION

STATEMENT OF WORK

AJW-L900 RADAR Product Group

Rotary Coupler Refurbishment

January 13, 2025

1.0 BACKGROUND

The mission of AJW-L900 Radar Product Group is to provide logistics support for all FAA ATC Radar systems as well as radar systems within other government agencies and internationally.

The purpose of this Statement of Work (SOW) is to define the services required for the refurbishment of rotary couplers originally designed by Continental Microwave. The services required are defined in Section 2.1.

This Statement of Work describes the detailed procedures to be utilized in the refurbishment of GFE (Government Furnished Equipment) rotary couplers.

NOTE: Any vendors that were not a part of the previous, refurbishment contract No. 6973GH-20-D-00027 or No. 6973GH-20-D-00028 are considered to be Unapproved Vendors (UV) and will need to go through the first article testing approval process, as per Attachment 8 of this SOW.

2.0 SCOPE OF WORK

The contractor shall perform the following major services:

2.1 Furnish all required labor, facilities, equipment, fixtures, parts, materials, tools, test equipment, appropriate technical data and expertise to refurbish FAA-owned rotary couplers to a serviceable condition, at a specified FLAT RATE JOB PRICE in accordance with all other terms, conditions, and provisions set forth herein. Refurbishment shall be performed as stated in paragraph 3.1 of this SOW. Refurbishment shall be completed in accordance with Original Equipment Manufacturer’s (OEM) repair manuals, specifications and drawings. Results of refurbishment shall meet the standards specified in the Attachments 5 thru 7. Vendor shall submit to the FAA via the Contracting Officer an Acceptance Test Procedure (ATP) for each rotary coupler for review and approval. Each ATP shall contain a revision date and revision level and may not be changed without prior FAA approval. Any FAA-approved change shall be described in a Record of Change within the ATP and shall include a description of the change and the affected page(s).

The FLAT RATE JOB PRICE is the price for refurbishment, not subject to upward or downward revision, of the reparable Government-owned units listed in paragraph 9.0 of this SOW. The FLAT RATE JOB PRICE shall include all costs such as preservation, packing, packaging, marking, all materials (direct and indirect), material handling expense, and all other elements of cost incurred in the performance of this contract.

2.2 Miscellaneous parts and labor required to refurbish Government-owned units that are over and above the FLAT RATE JOB PRICE will be performed as stated in paragraph 3.2 of this SOW.

2.3 Engineering Services in support of the rotary couplers will be performed as stated in paragraph 3.3 of this SOW.

3.0 REQUIREMENTS

The Contractor shall furnish all required labor, facilities, equipment, fixtures, parts, materials, tools, test equipment, appropriate technical expertise to refurbish FAA-owned rotary couplers to a serviceable condition in accordance with this Statement of Work.

3.1 TASK 1 - Rotary Coupler Refurbishment: It shall be the responsibility of the contractor to procure and replace ALL parts necessary for refurbishment.

3.1.1 The refurbishment cost shall include the cost to the contractor to procure and replace ALL wear components including, but not limited to, bearings, gears and seals. (SEE SOW ATTACHMENTS 1-2)

3.1.2 The rotary coupler shall be evaluated to determine that no other components have reached the end of their life cycle, other than those wear components mentioned in paragraph 3.1.1, otherwise not covered in the contractor's warranty, or required outside the scope of the contract.The MODE-S rotary couplers (ARSR-1, ARSR-2, FPS, and BOS) should be configured to a 4-beacon channel configuration, not a 6-beacon channel configuration. All extra cavities are to be returned to the FAA in the condition they were received by the vendor.

(SEE SOW ATTACHMENT 4)

3.1.2.1 The slip-ring assembly was removed from the BOS model 1443. The slip-ring assembly will remain on all other models in the table found in Attachment 4 (model 1538, 1537 and 1658).

3.1.2.2 Upper and lower cable assemblies associated with the removed cavities shall also be removed and plugs used in place of the N-type connectors on the rotor Connector Housing Casting.

3.1.3 Following completion of refurbishment, each rotary coupler shall be tested by the vendor and all results recorded and submitted with the refurbished unit to the FAA. Please note that actual measured values shall be recorded, where applicable. Test requirements with allowable limits for each rotary coupler are detailed in Attachment 5. Each refurbished rotary coupler returned to the FAA shall be subjected to equivalent testing by FAA personnel. Please note that due to potential variations in test methodologies utilized by the FAA and various vendors, permissible minimum and maximum values may have changed from previous solicitations. All changes are reflected in Attachment 5. Test results shall include a list of equipment utilized and date of calibration.

3.1.4 Each refurbished rotary coupler shall have the full length of each slip ring path electrically tested for isolation and continuity. Isolation testing shall be from each pin to every other pin and each pin to ground.

Voltage and isolation requirements are detailed in Attachment 7. Continuity, isolation and pressure test results are to be recorded and submitted to the FAA with each refurbished unit. Test results shall include a list of equipment utilized and date of calibration.

3.1.5 All testing of N-type connectors shall be completed in accordance with the industry standard SOLT (Short/Open/Load/Thru) methodology. Test results shall include a list of equipment utilized and date of calibration.

3.1.6 The contractor shall perform final azimuth jitter testing for all rotary couplers. Azimuth jitter shall not exceed 10% total from either of the 12-bit outputs while the coupler is being rotated at either 5 RPM (for P/N 1537, 1538, 1443 and 1658) or 12.5 RPM (for P/N 1639). Test results shall include a list of equipment utilized and date of calibration.

3.1.7 All used slip ring and brush block assemblies shall be returned to the FAA in the condition they were received and in properly protected packaging.

3.1.8 The contractor shall return each refurbished unit in the same packaging and configuration in which it is supplied (utilizing the same crate, internal foam, and separated into smaller components where appropriate). Each return shipment shall include G-force impact (10G, maximum) and Tip-N-Tell labels.

One G-force impact label shall be mounted on an interior end of the crate and a second shall be mounted on an exterior side of the crate.

3.1.9 The FAA will perform technical inspection and testing of each refurbished rotary coupler upon receipt.

If the unit fails any part of the inspection, it will be returned to the vendor for correction. The vendor will have 30 days upon receipt to correct the unit and return it to the FAA. If the correction requires additional time, contact the Contracting Officer for approval.

3.1.10 Any cavities removed from the original configuration to the new reduced cavity configuration shall be returned to FAA in a properly protected packaging.

3.2 TASK 2 –Over and Above, Miscellaneous Parts/Labor

3.2.1 The purpose of this section is to allow for parts or labor that is required outside the scope of refurbishment on a case-by-case basis. For each task that may require labor and materials outside the scope of refurbishment as found under the paragraphs of this Statement of Work, the contractor will provide for labor and materials on a time-and-material/reimbursable basis. Please note that all proposed Over and Above parts shall be exact Form, Fit and Function replacements, consistent with original configuration. All actions must be requested and approved in advance by the Contracting Officer (CO). The Contractor shall not use this line item to make the contractor whole for shortfalls in work already negotiated elsewhere under this contract.

3.2.2 APPROVAL PROCESS: The actual cost of the work outlined, regardless of dollar value must be approved in advance of expending labor effort, equipment/material/supply dollars. The contractor shall submit a written proposal to the assigned CO; complete with back up documentation necessary to substantiate proposed costs. Proper back up includes labor categories, rates and estimated hours, equipment/material/supply catalog cuts or rates, and subcontractor quotes. The CO will review the requested action, proposed cost, schedule required, and provide either approval or disapproval to the Contractor in writing through a modification to the applicable delivery order.

3.2.3 The Contractor shall submit copies of invoices from vendors for materials and for which payment is requested. Payment will be made after review and acceptance by the Government for allowable, allocable, and reasonable costs against the proposed effort and prices in the proposal. Efforts may only be invoiced to the Government after Government acceptance of the deliverable completed under the delivery order. Invoices for such work must include the specific delivery order number for tracking purposes, and if billed with other work under the delivery order, must be called out separately. Progress payments for delivery order efforts are not allowable.

3.2.4 Pricing of over and above Miscellaneous Parts/Labor shall be billed under the Over and Above Contract Line Items (CLINs) identified in Section B of the contract. The Contractor shall not, in any case, expend more than the amount of funds obligated under contract for reimbursable efforts. Copies of the approved proposal, backup documentation, and a consolidated tracking list for all delivery orders to date shall be submitted with each invoice containing a request for payment of reimbursable work.

3.2.5 At the end of the contract, (and prior to contract close-out), the Contractor and the Government will reconcile all invoices and payments made on a reimbursable basis and determine the amount of funds unexpended by funding appropriation as outlined on the contract documents. The Contractor will initiate this annual reconciliation prior to request for final payment under the contract, unless requested earlier by the CO.

Upon agreement of the unexpended amounts, all remaining funds will be de-obligated from the contract by a formal contract modification.

3.3 TASK 3 - Engineering Services

3.3.1 When requested, non-recurring engineering services shall be provided for engineering studies related to rotary coupler performance, quality, and operational issues such as providing analysis for systemic problems. Engineering services also includes but is not limited to updating and providing manufacturer’s drawings with FAA or Original Equipment Manufacturer (OEM) initiated modifications.

3.3.2 The contractor will prepare and submit a written proposal (description of parts and labor required and proposed costs) for requested engineering services. Negotiations between the contractor and FAA will be completed prior to commencement of work, related specifically to the Engineering Services CLIN under this contract.

3.3.3 Written authorization by the Contracting Officer (CO) to proceed on work for engineering services must be received by the contractor prior to performance.

4.0 SUBSTITUTION OF PARTS

4.1 Offeror’s price should be based on parts as listed in the Statement of Work. In no event shall any approval made in accordance with the procedures identified in the Statement of Work entitled “Substitution of Parts or Materials” constitute grounds for any upward or downward revision to prices offered or contract delivery schedule after award. The decision to approve or disapprove any Request for Approval (RFA) for the substitution of parts or materials is solely at the Government’s discretion and shall not constitute grounds for a claim after contract award.

4.1.1 RFAs must be submitted and approval received from the FAA prior to substitution of parts by the contractor.

5.0 CONFIGURATION CHANGES

5.1 Any proposed changes to configuration of Government-furnished rotary couplers must be submitted to Contracting Officer (CO) and Contracting Officer’s Representative (COR) prior to implementation by the contractor. Approval for configuration changes must be made in writing by the CO and/or COR.

5.1.1 In no event shall any approval made in accordance with this clause paragraph constitute grounds for any upward or downward revision to prices offered or contract delivery schedule after award. The decision to approve or disapprove any proposed configuration changes is solely at the Government’s discretion and shall not constitute grounds for a claim after contract award.

6.0 REFURBISHMENT-GENERAL INFORMATION

6.1 The following conditions shall apply to the refurbishment process:

6.1.1 The FAA reserves the right to refuse the return of a refurbished rotary coupler to the vendor if the refurbished unit fails FAA testing more than once.

6.1.2 The FAA reserves the right to terminate any further shipments of a given type of rotary coupler for refurbishment purposes in the event that two (2) or more of that type rotary coupler fail FAA testing upon return.

6.1.3 Vendor may request a real-time comparative test for any refurbished rotary coupler that fails FAA testing upon return. Real-time comparative testing shall take place at the Mike Monroney Aeronautical Center, Oklahoma City, Building 218. Any and all expenses including, but not limited to, travel, lodging, shipment of test equipment, etc. shall be borne solely by the vendor.

6.1.4 No invoice for a given refurbished rotary coupler shall be submitted by the vendor until after the unit has been formally accepted by the Contracting Officer Representative. The COR will notify the vendor once acceptance has occurred.

6.2 The FAA is the final authority in determining whether a refurbished rotary coupler passes or fails and is deemed suitable for use in the National Airspace System or by the Department of Defense.

7.0 PLACE OF PERFORMANCE

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

8.0 PERIOD OF PERFORMANCE

This contract consists of one (1) base year and four (4) one-year option periods.

9.0 ROTARY COUPLER NATIONAL STOCK NUMBERS (NSN)

TDWR 5985 01 393 3806

ASDE-3 5985 01 319 8304

ASR-9 5985 01 313 7839

MODE-S BOS 5985 01 394 3849

NAS ASR-11 5985 01 649 4498

ARSR-1 5985 01 394 3848

ARSR-2 5985 01 394 3847

MODE-S FPS 5985 01 394 3850

SOW ATTACHMENT 1

100% Replacement Parts for Enroute Rotary Couplers

SOW ATTACHMENT 3

100% Replacement Parts for ASR-9 7839 / NAS ASR-11 4498

SOW ATTACHMENT 3

Government Furnished Equipment List

NSN Encoder NSN

System Part Number

ASR-9

5990-01-319-5667 (5v)

5985-01-313-7839 VOE-35-2542

ASR-11

5985-01-649-4498

5865-01-512-6746

BIC35-14G6

MODE-S (FPS)

5998-01-312-9752

5985-01-394-3850 INC35-12G25A

MODE-S (BEACON ONLY)

5985-01-394-3849 INC35-12G25A

MODE-S (ARSR-1)

5985-01-394-3848 INC35-12G25A

MODE-S (ARSR-2)

5985-01-394-3847 INC35-12G25A

SOW ATTACHMENT 4

Four (4)-Cavity NEW

Configuration (SOW Section 3.1.2)

SOW ATTACHMENT 5

SOW ATTACHMENT 6

SOW ATTACHMENT 7

SOW ATTACHMENT 8

First Article Testing-Unapproved Vendors

1. First Article Testing: All vendors that have not been previously approved to refurbish any or all of the rotary couplers listed within this SOW shall be considered an Unapproved Vendor (UV) until approved.

Required process for all UV’s is as follows:

a. UV may request one (1), repairable model rotary coupler per approval cycle

b. UV shall complete all necessary refurbishments/processes as stipulated within this SOW

c. Following refurbishment, UV shall then ship the rotary coupler back to the FAA for formal inspection/testing. Shipping shall be carried out in accordance with this SOW.

i. As part of the shipping process, UV shall notify the COR of the model rotary coupler being shipped and provide the following information:

1. Item part number

2. Item serial number

3. Ship date

4. Ship To address

5. Tracking number

d. Upon formal receipt, the FAA shall inspect and test the rotary coupler as described in Attachment 8, Section 2 and following.

2. Testing at Government facilities will include the following:

Phase I Qualification Testing:

a. Visual Inspection

Phase II Qualification Testing: (Phase I and II testing combined, 30 days)

a. Radio Frequency (RF) operation

b. Non-RF Circuit Continuity

c. High Voltage Isolation

d. Pressurization (where applicable)

e. All electrical parameter and pressure testing in operational Rotation Test stand at Operating Speed for 7 Days including encoder outputs to Government azimuth jitter specifications.

Phase III qualification testing: (Phase III testing, 90 days minimum)

a. System test in an FAA Academy system for 90 days or system test in a National Airways System (NAS) Key Site for 90 days. FAA personnel will install and the coupler must function without failure, or cause the system degradation for 90 days of continuous operation. (Phase III testing will not begin until an FAA test site is available.) Scope of required testing of any first article unit may be decreased or shortened at the sole discretion of the FAA.

Phase IV qualification testing: (Phase IV testing, 30 days)

a. Disassembly Inspection: After 90 day system test, the refurbished unit will be removed by FAA personnel and returned to the FAA Logistics Center repair center and disassembled for inspection and validation of refurbishment processes per the contract specifications.

Item will be inspected for premature wear, indicators of premature failure modes, and conformance to government quality control specifications.

b. Reassembly and issuance to FAA Serviceable stock as qualified unit for warranty operation.

c. Contracting Officer will notify contractor of approval/disapproval of first article unit.

3. Contractor’s Facilities Test and Inspection:

A pre-qualification meeting will take place at the FAA Logistics Center, the Contractor’s facility or virtually.

The FAA reserves the right to perform an In-Process Quality Inspection at the contractor’s facility at any time during the refurbishment and qualification testing process. The in-process inspection may include but not be limited to the following:

1. Parts Inspection

2. Facilities and Test Capabilities Demonstration

3. Disassembly

4. Re-Assembly and Testing

5. Refurbishment process demonstration and inspection

6. Process inspection to confirm and validate internal steps not observable or measurable on assembled coupler.

7. Electrical test demonstration

8. Pressure test demonstration

9. Jitter Test Demonstration (Run in/simulation dynamic test stand)

4. Government Furnished Equipment (GFE):

GFE encoders (Attachment 3) will be supplied to the vendors for final testing and verification of the rotary couplers. One pair of encoders will be supplied to the vendor for each rotary coupler type that is to be refurbished by the specific vendor.

5. Conditions of Qualification:

Refurbished couplers that fail any phase of the First Article testing will be returned to the contractor for re-work. All costs related to re-work of first articles will be the responsibility of the contractor.

The contractor will be allowed one attempt at re-work of first article refurbishments. Any reworked coupler must start over, and undergo all phases of qualification testing. If the reworked unit fails testing a second time, the contractor will not be considered qualified and no further attempts will be allowed to qualify or refurbish that NSN for the term of the contract. The unqualified first article coupler will then be retained by/returned to FAALC.

Should a total of three (3) separate NSNs referenced in paragraph 9.0 above fail any phase of qualification, after it has been received as a reworked unit (2nd attempt to qualify an NSN), no more first article test qualification units of any NSN will be considered for qualification testing under this contract. Any future coupler refurbishments with the contractor will be limited to only those units that successfully met the requirements of this first article testing and the four phases of the qualification plan.

Payment for first article refurbishment is made only if unit passes first article testing.