Attachment 2-Statement of Work (SOW).pdf

Attachment 2 Statement Of Work (SOW)

Automatic Wiring Analyzer Test Adapter Cables

70Z03820QE0000032

1.0 BACKGROUND

1.1 The United States Coast Guard (USCG), Aviation Logistics Center (ALC) provides Programmed Depot Maintenance (PDM) and Heavy Maintenance support for various USCG Maritime Patrol Aircraft. This support includes major aircraft electrical-wire-interconnect-system (EWIS)/avionic assemblies and sub-assembly inspection, repair, upgrade/modification, and/or replacement. After repairs and/or modifications are made, verification of installation conformance and proper configuration management are paramount. Testing of the entire EWIS system/assembly for proper component operation and condition before applying electrical power is vital for component and operator safety and proper systems operation.

1.2 The best method of testing is to use an automatic wiring analyzer (AWA). AWAs are capable of quickly, accurately and consistently testing the entire aircraft wiring systems much faster and more completely than manual testing. AWAs can test the entire aircraft wiring systems in a matter of minutes compared to hours or days for manual testing.

Additionally, once programmed, AWAs perform the same test each and every time which is vital to maintaining proper configuration management. A single, scalable, distributed switching, random adapter hook up AWA with the proper adapter cable libraries is ideal for meeting the needs for the multiple aircraft types maintained by ALC.

2.0 SCOPE

2.1 The scope of this Statement of Work (SOW) is intended to establish and provide the requirements for the build of one (1) set of approximately 170 Test Adapter Cables (TACs) for testing the airframe wiring harnesses for the MH-60T rotary wing aircraft. The vendor must perform the necessary layout, connector grouping, design, of the TACs and provide the parts lists, pin-outs and build drawings. The TACs will be terminated with zero insertion force DL1-156 tester front panel connectors and appropriate aircraft mating connectors. Testing will be performed utilizing a Drive In Theatre Manufacturing Company (DIT-MCO) 2650 AWA with 25,000 total separate test points in addition to over 140 Latching Matrix Switching points, as listed in section 2.3.

2.2 The AWA performs, at a minimum, the following test functions: insulation resistance, breakdown and leakage measurements; circuit continuity, discontinuity, and resistance measurement; Alternating Current (AC) and Direct Current (DC) voltage (V) measurements; capacitance measurements, diode forward/reverse bias tests, Light-Emitting Diode (LED) operation, potentiometer value measurements, and AC Dielectric (HIPOT) testing. Voltages up to 500 volts are routinely used to test the 600 volt rated aircraft wiring.

2.3 Each AWA Module incorporates a Latching Matrix (LM) type switching card capable of individually breaking ten (10) test circuits (via a separate front panel circular connector) and connecting the programmed AC or DC voltages (sections 2.4 and 2.5) into the Unit- Under-Test (UUT) to energize and operate components such as relays, blowers, fans, lights, etc. LM test points power components through specially modified adapter cables

(see section 3.4). The AWA is capable of performing tests listed in section 2.2 using other test points concurrently while injecting programmed voltages on the LM test points.

2.4 The AWA includes a programmable (automatically controlled via the test program) variable AC power source capable of providing 0 to 240 variable AC, 60 to 400hz, 5 Amps or greater.

2.5 The AWA includes a programmable (automatically controlled via the test program) variable DC power source capable of providing at a minimum 0 to 120 variable DC, 5 Amps or greater.

2.6 The AWA includes random TAC hook-up capabilities the switch modules. ALC ACATS personnel require TAC ID programming capability in DIT-MCO NexGen Electrical Test Suite (NETS) language.

2.7 DL1-156 pin out scheme (wiring and ID Chip) will be provided in attachment A.

2.8 The distributed system switching cabinets will be placed on moveable platforms with boom arms to allow strategic placement of tester modules in and around the aircraft to minimize the TAC lengths.

2.9 ALC will provide the vendor with a complete aircraft connector list. Vendor must identify the appropriate mating connector for the TAC’s aircraft mating end.

3.0 REQUIREMENTS

3.1 Unless otherwise specified, each TAC identified in section 2.1 must be capable of permitting the tester to meet or exceed the requirements specified in Table 1. Each TAC must meet the minimum design requirements depicted in ALC Engineering Specification ALC GENES05000.04 series (available upon request) and meet the following minimum requirements:

a. Shall be designed for optimum length between Tester Switch Box and the applicable UUT connectors (approximately twenty-five (25) foot long unless further inspection proves an alternate optimum length requirement).

b. Make low resistance (4-wire Kelvin) measurements of < 0.100 ohms.

c. Be capable of being bent to tight radiuses needed to reach all aircraft harness connectors.

d. Be capable of repeated coiling and uncoiling to a diameter of 18 inches for storage.

e. Be manufactured of/or protected by materials of sufficient strength, such as E103867 braided monofilament sleeving, to prevent damage from chafing against knife edges and window frames while being routed into and out of aircraft before as well as being able to withstand the effects of repeated trampling by aircraft workers during and after testing.

f. Be designed so that the UUT end connectors are grouped to test as closely co-located aircraft connections as possible, i.e.: connectors in cockpit shall not be on same TAC as connectors in the cabin; connectors in forward cabin (Av-Rack) shall not be on same TAC as tail connectors.

g. Because the AWA must detect momentary (10 microseconds or longer) breakdowns or arcs in the UUT and if current exceeds a programmed limit, the dielectric test must fail even if the current returns to normal prior to the completion of the test, the TACs must be able to withstand such testing without influencing the test results.

h. TACs must be capable of withstanding high current/constant current testing of items such as circuit breakers and current sensing relays, etc.

i. Each UUT connector back-shell must be connected to the lowest address in the UUT connector’s address string.

j. Each UUT connector must be addressed in order matching the DL1-156 order.

k. Coaxial cables must be addressed with shield addressed lower than center conductor.

Tri-axial cables should have outer shield addressed lower than the inner shield and the center conductor addressed higher than the inner shield.

l. TACs must be strong enough to be self-supporting when dangling from 10-15 foot high boom arms.

3.2 The TACs must operate without accuracy fluctuations within all temperature and humidity conditions found in a non-environmentally conditioned space of an open aircraft hangar.

Humidity levels may reach 100% with occasional surface condensation occurring.

3.3 Design and construction must be in accordance with best industry practices. All components must be current technology and currently available.

3.4 UUT circuits that require LM provided power shall have a two (2) pin disconnect inserted into the TAC conductor (pin 1 from tester connector, pin 2 goes to the UUT mating connector). This disconnect shall connect to a mate wired to the LM circular front panel connector (MS3476L20-39PN).

3.5 Spare Random Hook-Up TAC ID chips: Provide enough uninstalled programmable TAC ID chips to outfit every available front-panel TAC cable connector plus thirty (30) additional spares for future TACs needed for proper operation of the random hook-up capability.

3.6 The TACs must comply with Federal Communications Commission (FCC) Electromagnetic Suppression regulations applicable at the time of manufacture.

4.0 APPLICABLE DOCUMENTS

4.1 Government Documents

ALC INST 13020.14 (series) Drawing Control Procedures

ALC INST 13020.10 (series) Parts Manufacture

ALC GENES05000.04 (series) ALC Engineering Specification

Graphics Style Process Guide (CGTO PG-85-00-240-A)

ALC ESD 04 (series) FORM, FIT, FUNCTION (FFF) FORM

4.2 The vendor shall provide at the earliest possible date or no later than (NLT) the delivery specified in section 8.0, all draft copies of the TAC wiring diagrams and build sheets for review and approval. Upon delivery of TACs the vendor shall provide at a minimum an electronic copy of all Original Equipment Manufacturer (OEM) finalized drawings and any other documentation necessary for the ease of maintenance and use of the TACs. The manufacturer must also provide ALC with drawings, hook-up and parts lists for each TAC cable in a format compatible with .DXF and .PDF drawing software programs in accordance with ALC INST 13020.14 (series) Drawing Control Procedures (available upon request).

4.3 US Coast Guard and ALC shall have unlimited rights and reserves the right to build or have built additional cables utilizing these drawings as the pattern.

5.0 MARKING AND PACKAGING

The USCG ALC is a supply depot; therefore, items will be stored and transshipped to various users. The container shall be packed and labeled suitable for shipment via land, air, or sea. Packaging material shall NOT consist of the following: popcorn, shredded paper, Styrofoam of any type, or peanut packaging.

Each part shall be individually packed in a separate envelope, box, carton or crate.

For bulk packages, packaging of items up to 100 each per package is acceptable.

Each individual container shall be labeled on the inside with the NSN, Part Number, Serial

Number, Quantity, Nomenclature, Purchase Order Number, and Purchase Order Line Item Number.

Packing List and Certification/Documentation shall be placed on the outside of individual containers.

The internal packing material shall be sufficient to prevent damage during shipment, handling and storage. Preservation and protection shall be provided to prevent corrosion, deterioration or decay during warehouse storage for a period of one year.

6.0 WARRANTY

The contractor must provide a minimum one (1) year warranty that covers 100 percent of the drawings and lists, and labor and guarantees the TAC drawings to be 100 percent error free within 48 hours following government notification of an error. Warranty period will begin at time the TACs are first put into use after acceptance from the build vendor (date Government signs the Form DD250) by the Government.

7.0 INSPECTION AND ACCEPTANCE

All work is subject to Government Quality Assurance (QA) review in process and upon completion for compliance with requirements, instructions, specifications, shop practices and procedures. Any work that is considered unsatisfactory shall be corrected at no additional cost to the USCG. Work will not be accepted by the Government until the QA inspector considers all work complete and acceptable.

The vendor shall provide draft copies of the TAC wiring diagrams and build sheets as stated in section 4.1 to the USCG, ALC, Automatic Circuit Analysis Test System (ACATS) Group for inspection and specification compliance prior to building the complete set of TACs. Final inspection and acceptance will be performed by ALC ACATS personnel for quantity, condition, and FFF to ensure compliance with the contract SOW. All design drawings and TACs shall be inspected in accordance with ALC INST 13020.10 (series) Parts Manufacture (available upon request).

8.0 DELIVERY AND INSTALLATION

Draft Design (All TAC Wiring Diagrams and Build Sheets IAW section 4.1) – 90 Days after Receipt of Order (ARO)-early delivery is acceptable.

TAC Production Units – 240 Days ARO

8.1 Delivery Location

Items ordered under this purchase order will be ordered by and delivered to the USCG/ALC in Elizabeth City, NC.

USCG Aviation Logistics Center Receiving Section, Bldg. 63 Attn: Kathrine R. Leach, ESD 1664 Weeksville Road Elizabeth City, NC 27909-5001 Purchase Order Number (to be determined at time of issuance)

The contractor must pack and ship the TAC drawings and lists to their final delivery point in Elizabeth City, NC.

9.0 SETUP AND STARTUP ACCEPTANCE

Following installation, the contractor shall be required to repair of any defects found in the TAC’s after the initial verification of proper operation of the entire AWA and to make corrections on any TAC drawings found defective, i.e. mis-drawn, mis-labeled, etc.

10.0 TRAVELING TO ALC

10.1 Identification of Contractor Employees

The Contractor shall ensure all employees present a professional appearance appropriate for the position held. All Contractor personnel shall be identified by a distinctive nameplate, emblem, or patch attached in a prominent place on an outer garment so as not to present a Foreign Object Debris (FOD) hazard and clearly identifying the employee as a representative of the contracted firm.

10.2 Compliance with Local Regulations, Instructions, Directives Contractor personnel shall comply with all local base regulations, instructions, directives, orders and special procedures as promulgated by the Commanding Officer, USCG Base Support Unit (BSU), Elizabeth City, NC or the respective product line at which work is being completed.

10.3 Access to ALC/Vehicle Pass

The USCG will coordinate personnel and vehicle access to each product line prior to the contractor arrival. The contractor will still be responsible for obtaining a temporary pass with the respective product line in conformance with local procedures in effect at the time of registration for all contractor-provided vehicles, including rental vehicles and/or contractor employees’ vehicles, used in performance of this contract. This shall be completed prior to commencement of work at the product line to prevent delays due to the inability to access the base.

10.4 Removing Employees for Misconduct or Security Reasons

The Contracting Officer may direct the Contractor to remove any Contractor employee from USCG facilities for misconduct or security reasons. Removal does not relieve the Contractor of the responsibility to continue providing the services required under the contract. The Contracting Officer will provide the Contractor with a written explanation to support any request to remove an employee.

10.5 Tobacco Policy

The USCG prohibits the use of smoking tobacco and smokeless tobacco in the workplace to protect the health of all its workers. The workplace includes any area inside or outside of a building or facility over which the USCG has custody and control where work is performed by active duty personnel, civilian employees, or personnel under contract to the USCG. The use of tobacco is prohibited in all USCG Government vehicles (including Cushman type), in all USCG aircraft, floating unit, or any other aircraft contracted for use in the USCG. The use of tobacco products (smoking and smokeless) is permitted only in designated areas as defined in USCG ALC Instruction 6280.1 (series). Contractors may only use tobacco products in designated smoking areas during authorized break and lunch periods and are accountable for appropriately discarding their smoking material and/or spit tobacco. Tobacco spit and residue shall be held in containers with sealing lids to prevent odor and accidental spills and disposed of in a sanitary manner which prevents public exposure. Employees caught violating the tobacco policy may be subject to immediate removal IAW section 10.4.

10.6 Environmental, Safety, And Occupational Health (ESOH)

The Contractor is solely responsible for compliance with all federal, state and local laws, including but not limited to the Occupational, Safety and Health Act (OSHA) (Public Law 91-596) and the resulting standards, OSHA Standard 29 CFR 1910 and any ALC Instructions as applicable, and the protection of their employees. Note: ALC Instructions are annotated because many of the USCG/ALC standards exceed the OSHA standard criteria. If a conflict is noted, the most stringent requirement takes precedence. The

Government shall assume no liability or responsibility for the Contractor's compliance or non-compliance with such requirements. In addition, the Contractor is required to flow down the safety requirements/specifications to all subcontracts/subcontractors. Safety requirements listed herein that do not concern Contractor’s operations or services shall be considered self-deleting as mutually agreed by the Contracting Officer and the Contractor.

10.6.1 The Contractor shall ensure their employees are made aware that the performance of these services will occur in industrial areas. The industrial complex at ALC has the potential to expose workers to hazardous materials, which may include, but is not limited to hexavalent chromium, cadmium, beryllium, lead and others. Areas where exposures are expected to exceed the permissible exposure limits set by 29 CFR 1910 Occupational Safety and Health Standards, Subpart Z - Toxic and Hazardous Substances are clearly marked as regulated areas. There may also be contact hazards with these materials during cleanup of dust, metal shavings, etc. The Contractor shall ensure proper protective measures are taken to ensure contracted employees are protected from these hazards, including the use of personal protective equipment. While working in regulated areas where the exposure to hazardous dust is expected, the USCG recommends, at a minimum, the use of Powered Air Purifying Respirators (PAPR) with a protection factor of 1000 when exposure levels may reach the OSHA permissible exposure levels.

10.6.2 The Contractor shall be subject to safety inspections of its work sites by the Government. Contractor safety records shall be available upon request by the Contracting Officer. The Contractor shall be liable for, and shall indemnify and hold harmless the USCG against, all actions or claims pertaining to the “personal” safety requirements of employees. The Contractor shall provide all personal protective equipment (respiratory protection, hearing protection, gloves, steel-toed shoes, safety glasses, protective clothing, etc.). In addition, the Government is not responsible for medical examinations, hearing testing, substance abuse testing, or any other type of testing for Contractor employees.

11.0 INVOICING

11.1 Invoicing Instructions

The Contractor’s invoice shall be submitted IAW FAR 52.212-4 to the designated billing office for payment as noted below. The invoice shall include the purchase order number, contract line item number (CLIN), CLIN description, quantity, unit price, and extended price. The offeror shall also submit copies to the Contract Specialist. The Contractor is HIGHLY encouraged to submit invoices electronically to ALC-Fiscal@uscg.mil.

Chief, Fiscal Branch

USCG ALC

Fiscal Branch, Bldg. 63 1664 Weeksville Road Elizabeth City, NC 27909 Purchase Order Number: (to be determined at time of issuance)

11.2 Payment Information

All payments will be made electronically IAW FAR 52.232-33. The contractor may submit invoice five (5) days after shipment of items. The invoice will not be approved until all items have been receipted.

*The remainder of the page is left blank.

12.0 AWA PERFORMANCE SPECIFICATIONS

TABLE 1

STIMULUS

SOURCE RANGE ACCURACY

Low DC Voltage 0.2 to 30 V ±5% or better High DC Voltage 30 to 2000V ±5% or better

Constant DC Current 0.005 to 3.0 A ±5% or better

CONSTANT CURRENT RESISTANCE MEASUREMENTS

STIMULUS (AMPS DC) RANGE (OHMS) ACCURACY

0.1 to 2.0 (Minimum range) 0.1 to 99.9 K Minimum ±1% or better

0.1 to 0.975 (4-Wire only) 0.1 to 999 Minimum ±2% or better

1.0 to 2.0 (4-Wire only) 0.01 to 0.0999 Minimum ±1% or better

DIELECTRIC DETECTOR

STIMULUS LIMITS (AMPS) ACCURACY

250 to 2000 DC in 2 V steps 0.5 to 2.5 Amps Minimum Range ±20% or better

VOLTAGE MEASUREMENTS

DC VOLTAGE (VOLTS) ACCURACY AC VOLTAGE (VOLTS) ACCURACY

0.01 to 1500 ±5% ± 10 mV 1 to 500 ±10% or better

CAPACITANCE MEASUREMENTS

RANGE ACCURACY

10 pf to 5000 µf ±5% +10 pf