Attachment J-1 MAV RCS 5N Thruster SOW 10 May 2021.pdf

MSFC Contract No. TBD Attachment J-1, SOW

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Statement of Work (SOW) For

Mars Ascent Vehicle (MAV) Reaction Control System (RCS) 5N Thruster

1 PURPOSE

The purpose of this procurement is to acquire reaction control thrusters for use on the Mars Ascent Vehicle (MAV), which supports a later stage of the larger Mars Sample Return (MSR) program that will deliver soil samples from the Martian surface to Earth for examination and analysis.

Within this document, following terms are defined:

A “thruster” refers to an integrated engine assembly, inclusive of the propellant valve. This is also frequently referred to as a Rocket Engine Assembly (REA) within the propulsion industry.

A “shipset” refers to a group of six thrusters. Each shipset shall contain two each of the center, left, and right nozzle configuration, as defined in the 5N Thruster Specification, Attachment J-3.

2 OBJECTIVE

The objective of the effort described herein is to provide for the design, manufacture, qualification, acceptance testing and delivery of 42 flight thrusters per the provided schedule.

The proposed thrusters should draw from heritage flight hardware currently in production to the extent possible to minimize cost, schedule, and technical risk.

Hardware deliveries are divided into four categories to support mission preparation, as indicated in the delivery schedules. These categories include: one engineering shipset for initial ground testing, three shipsets for evaluation flights of the integrated system that will not be recovered, one backup shipset for evaluation flights, one shipset for incorporation into the final MAV assembly, and one thruster spare for each of the three nozzle configurations, as defined in the 5N Thruster Specification, Attachment J-3.

3 APPROACH

Thrusters will be integrated into a reaction control system (RCS) that will be located on the MAV interstage to provide roll control authority during first stage operation and 3-DOF attitude control during the coast period prior to upper stage separation. This is a single-mission (expendable) application. The thrusters must be capable of pulsing, off-pulsing, and steady state operation from the Martian surface (at 0.3 psia atmospheric pressure) to vacuum conditions over a 15-30 minute operational period. The thrusters will be integrated into to a pressure-fed system operated in blow-down mode. The approach will utilize a 5N Class Monopropellant thruster, described in detail in the 5N Thruster Specification, Attachment J-3.

The mission approach requires one shipset of six 5N class hydrazine thrusters per vehicle, installed in two groups of three thrusters each at locations 180 degrees apart, to provide attitude control authority for the vehicle prior to upper stage separation. Thrusters will be mounted within the vehicle outer mold line such that the nozzle outer surfaces will have no direct view factor to open space. A nozzle exit lip or other feature (TBR) will be required to connect to a flexible interface with the vehicle. The RCS uses a common pressurization system and common propellant tankage for the monopropellant (N2H4) thrusters. All thrusters are pressure fed.

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4 PERFORMANCE OBJECTIVES

The Contract will be broken into a Base period and an Option period.

4.1 Base Period

The Contractor shall perform the activities described in SOW Section 4.1 during a 2-year period of performance, extending from November 17, 2021 until November 16, 2023.

Engine Design and Fabrication During the Base period, the Contractor shall design, build, qualify, acceptance test, and deliver the first shipset of thrusters per the 5N Thruster Specification, Attachment J-3.

The Contractor shall design and perform supporting analyses for a thruster to the Design Conformance Review (DCR) level. Design requirements for the thruster are provided in Attachment J-3.

The Contractor shall identify all As-Built Electrical, Electronic, and Electromechanical (EEE) Parts List in accordance with DRD 1753DE-001.

The Contractor shall prepare and submit Component Performance Analysis documentation in accordance with DRD 1753DE-007.

The Contractor shall prepare and submit Structural Strength and Fatigue Analysis Reports in accordance with DRD 1753DE-008.

The Contractor shall provide a list of long-lead items containing the item designation, proposed vendor, cost, and lead time to the Contracting Officer (CO) and Contracting Officer Representative (COR) at or prior to the DCR.

The Contractor shall provide manpower, facilities, consumables, and material to complete all required manufacture, assembly, and testing of the thrusters.

The Contractor shall gain permission from the COR if any flight hardware fabrication is planned prior to NASA concurrence of the design post-DCR.

The Contractor shall coordinate with NASA on development of the qualification test plan, test requirements, and test matrix. A minimum of one qualification unit is required to demonstrate compliance with the levied requirements, although additional units (up to 3X) will be considered if deemed necessary.

The Contractor shall provide engine system analyses, including propulsion, performance, fluids, loads/stress, and thermal analyses (as a minimum) to support the milestone reviews.

Milestone Reviews During the Base Period, the Contractor shall prepare for and conduct a Kick-Off meeting. The Contractor shall conduct a kick-off meeting within one month of contract award. During the kick-off meeting, the Contractor shall provide values for all To Be Supplied (TBS) items in the requirements document. The contents of the kick-off meeting shall comply with DRD 1753MA-

003. In addition, the kickoff meeting shall also address the flight heritage of proposed hardware.

The Contractor shall prepare for and conduct a Design Conformance Review per DRD 1753MA-

003. The contents of the DCR shall comply with DRD 1753MA-003.

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The Contractor shall prepare for and conduct a Test Readiness Review per DRD 1753MA-003 for acceptance and qualification testing. The contents of the TRR shall comply with DRD 1753MA-003. These reviews may be held either at the same time or as separate events, at the discretion of the Contractor.

The Contractor shall prepare for and conduct an Acceptance Review per DRD 1753MA-003.

The contents of the AR shall comply with DRD 1753MA-003.

The Contractor shall prepare for and conduct a Qualification Review per DRD 1753MA-003.

The contents of the QR shall comply with DRD 1753MA-003.

The Contractor, through the COR, shall invite NASA to attend all milestone reviews, as well as any sub-contractor and component reviews. All milestone reviews shall be held at the Contractor’s facility, with a virtual option for attendees unable to travel.

Testing The Contractor shall test the thrusters. The Contractor shall perform testing per Section 4 of the requirements document located in Attachment J-3. The Contractor shall hold a Test Readiness Review (TRR) prior to the start of Acceptance and Qualification testing. The Contractor shall also provide a test data distribution to NASA.

The Contractor shall prepare and submit an Acceptance Test Plan in accordance with DRD

1753DE-002.

The Contractor shall prepare and submit an Acceptance Test Procedure in accordance with DRD

1753DE-003.

The Contractor shall prepare and submit a Qualification Test Plan in accordance with DRD

1753DE-004.

The Contractor shall prepare and submit a Qualification Test Procedure in accordance with DRD

1753DE-005.

The Contractor shall prepare and submit a Qualification Test Report in accordance with DRD

1753DE-006.

Base Period Deliverables All hardware developed and tested during the Base Period shall be delivered to the government during the Base Period, unless directed to defer deliver until the Option Period by the COR. In the event that the Option Period is not exercised, any hardware manufactured during the contract, as well as any long-lead procurements, shall be delivered to the Government at the conclusion of the Base Period.

The Contractor shall provide the following deliverables during the Base Period:

1. Thruster DCR Analysis and Design Package

2. Acceptance Test Plan

3. Acceptance Test Procedure

4. Acceptance Data Packages

5. Qualification Test Plan

6. Qualification Test Procedure

7. Qualification Test Report

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8. One complete shipset of six flight-ready thrusters (6X) for use in engineering models

9. Top-level assembly drawings

10. Thruster IDD and Associated Component Specifications

11. Thruster User’s Manual addressing operational and usage constraints

4.2 Option Period

Upon activation of the Option Period, the Contractor shall perform the activities described in SOW Section 4.2 during a period of performance starting at completion of the Base period and extending until April 30, 2024.

Engine Fabrication During the Option Period, the Contractor shall build, acceptance test, and deliver the remainder of the thrusters procured per the 5N Thruster Specification, Attachment J-3, as indicated in Section 2 of this document.

The Contractor shall also provide up to 40 hours of engineering technical support to aid in addressing questions and/or issues related to integration and testing of the hardware by the Purchaser. No travel is required of the Contractor for this support, support will be requested by phone, email or virtual meeting.

The Contractor shall provide manpower, facilities, consumables, and material to complete all required manufacture, assembly, and testing of the thrusters.

At the government’s discretion, the Option period may be activated and work begun prior to the end of the Base period if it is agreed that schedule acceleration is possible by doing so.

Milestone Reviews There are no planned Milestone Reviews during the Option Period

Option Period Deliverables The Contractor shall provide the following deliverables during the Option Period:

1. Thirty-six (36X) flight thrusters, consisting of:

a. Three complete shipsets of six thrusters each (18X) for use in flight tests

b. One complete backup shipset of six flight thrusters (6X) for use in flight tests

c. One complete shipset of six flight thrusters (6X) for use on the MAV spacecraft

d. Three thruster spares (3X), one for each individual nozzle configuration defined in the 5N Thruster Specification, Attachment J-3

e. All qualification thrusters (3X)

5 PROJECT MANAGEMENT

The Contractor shall perform management functions and establish a management structure to plan, direct, and integrate all activities required by this Statement of Work (SOW) to assure compliance with technical, schedule, and financial commitments of the contract. The Contractor shall include a process for the timely disposition of corrective actions and provide for the reporting of technical data and financial management data as required. The Contractor shall utilize established management structures and assign a Project Manager (PM) with the authority

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The Contractor shall accomplish the management and technical control of interdivisional, subcontractor, and vendor activities required to fulfill the contract requirements. The financial and monthly progress performance data provided by the Contractor shall include management visibility into aspects of interdivisional, subcontractor, and major vendor activities relevant to accomplishing the contract requirements.

The Contractor shall provide technical information concerning any invention, discovery, improvement, or innovation made by the Contractor in the performance of work under this contract. Technology Reports shall be prepared in accordance with DRD 1753CD-001.

The Contractor shall prepare and submit an Organizational Conflict of Interest (OCI) Plan in accordance with DRD 1753MA-001.

5.1 Resource Planning

The Contractor shall maintain a Program/Project Schedule in accordance with DRD 1753MA- 002.

5.2 Financial, Technical, and Schedule Reporting

The Contractor shall prepare and submit Financial Management Reports (533M and 533Q) in accordance with DRD 1753MA-004.

5.3 Meetings and Reviews

Manpower, facilities, and data shall be prepared to support the formal reviews required within this scope of work. Data required for each review shall be delivered in accordance with DRD

1753MA-003.

The format for the status shall be in form of a quad chart listing the following as a minimum:

current status, planned upcoming activities, financial/schedule status, issues. Other status information too detailed for a quad chart shall be presented as a separate presentation package.

The length of the weekly meetings shall be planned at one hour maximum each (this time may be extended based on Contractor need).

All weekly status information shall be delivered to the COR no less than 24 hours prior to the weekly meeting.

Weekly Technical Meetings The Contractor shall conduct weekly technical meetings to provide NASA with a current status of the Contractor’s technical, schedule and financial performance under the contract.

Subcontractor and vendor activities required to fulfill the contract requirements shall be included as part of these meetings. The meetings may be conducted by telecon from the Contractor’s facility.

Other Meetings and Reviews The Contractor shall support other project meetings and reviews. These meetings shall comprise up to four (4) technical and four (4) budget reviews per year, status meetings, anomaly resolution meetings, and Government and non-contractor design reviews that impact the Contractor’s area of responsibility. The Contractor shall provide for subcontractor participation where necessary.

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The Government, through the COR, shall be invited to attend all design reviews with subcontractors. The Government will respect the privacy of contracts between the Contractor and its subcontractors during these meetings.

5.4 Configuration Management and Control (CM&C)

The Contractor shall perform the configuration management and control required to ensure that the configuration of the hardware for which the Contractor is responsible is reflected in the hardware deliverables, data deliverables, and Contractor drawings. The utilized CM&C, as well as associated released engineering, shall support conversion/release of documentation in a format appropriate and associated with non-human-rated system hardware with minimal cost.

The Contractor shall prepare an Acceptance Data Package (ADP) for all hardware deliverables, also referred to as Contract Items (CIs). The ADP shall provide the Government with the documentation necessary to determine the acceptability of the delivered item(s). The ADP shall accompany the CI at delivery and will be retained by the Government. The ADP shall be prepared and delivered in accordance with the requirements of DRD 1753CM-001.

Contractor desired deviations and waivers to Government controlled documentation shall be generated and processed in accordance with DRD 1753CM-002.

Engineering changes and related data to Government controlled configuration documentation shall be generated and processed in accordance with DRD 1753CM-003.

Engineering drawings and associated lists shall be provided to meet the requirements of ASME Y14.100 and ASME Y14.41 in accordance with DRD 1753CM-004. This documentation shall define the detail design of the hardware for the component. Detailed manufacturing procedures and process specifications will be made available to NASA at the Contractor facility but will not be delivered. The interface control drawing and parts list shall be delivered to NASA.

5.5 Data Management

The Contractor shall perform data management for the contract deliverables including documentation (in any agreed upon media), automated databases, and related products. The utilized CM&C, as well as associated released engineering, shall be developed in a way that will economically facilitate a conversion of the media into a format that is compatible with the development of non-human-rated system hardware.

The Contractor shall report and document the performance of the work in this SOW and fulfill the requirements of the associated Data Requirements Description (DRD) as outlined in the Data Procurement Document (DPD) 1753 (Attachment J-2). The contractor shall determine the data restriction that applies to each data deliverable and mark or transmit the data restriction in accordance with section 2.3.3 of the DPD.

5.6 Government Furnished Equipment

No Government furnished equipment or facilities are planned for use on this contract.

6 SYSTEMS ENGINEERING

The systems engineering effort shall include the design and engineering essential to evaluate and allocate hardware performance and operability requirements. Technical metrics shall be

J-1-7 established, with NASA concurrence, and shall be tracked and reported to ensure that the evolving design meets the requirements.

The Contractor shall develop, document, and implement a verification and validation program that confirms the deliverable product is in compliance with requirements and is ready for a particular use, function, or mission.

Determining the product’s ability to meet the set of requirements and readiness for a particular use, function, or mission shall be based on the assessment of the verification/validation report(s).

The verification/validation compliance assessment which identifies and correlates all submitted reports against the products' set of requirements shall be in accordance with DRD 1753SE-001.

The Contractor shall provide technical data and analyses which describe the studies, analyses, and results of specific engineering activities at DCR. The data shall include such technical specialties as theoretical analyses, models, engineering verifications, engineering design trades, current problems and proposed solutions, and conclusions and recommendations.

7 SAFETY, HEALTH, AND MISSION ASSURANCE

The Contractor shall develop, document, and implement plans to ensure that safety and mission assurance (safety, reliability, maintainability, and quality) activities are implemented and are effective in the mitigation of risk for the program, including methods to measure their performance. In addition, the Contractor shall ensure that subcontractors implement similar safety and mission assurance plans.

7.1 Reliability

The Failure Modes and Effects Analysis (FMEA) effort is one of the most important program tasks to facilitate enhanced safety and mission success. FMEA shall be initiated as part of an up-front integrated design effort with participation of component designers and pursued through all the phases of the program. FMEA shall identify design strengths and opportunities with respect to safety and/or mission risks and this analysis shall support integrated system design efforts.

The Contractor shall prepare the Failure Modes and Effect Analysis (FMEA) and Critical Items List (CIL) in accordance with DRD 1753RM-001.

The Contractor shall provide a Limited Life Items List in accordance with DRD 1753RM-002.

The Contractor shall develop a Reliability Analysis Report in accordance with DRD 1753RM- 003.

7.2 Quality Assurance and Engineering

The Contractor’s quality system shall be compliant to SAE AS9100 and ANSI/ISO/ASQ Q9001- 2015 or SAE AS9003 requirements. The Contractor can satisfy this requirement by current registration by a recognized registrar that shall be followed up by a verification audit performed by MSFC. The Contractor shall detail their planned quality controls for the product being procured and their quality system controls in a quality plan prepared in accordance with DRD

1753QE-001.

The Contractor shall have a means to identify, document, and correct non-conformances, problems, and failures. The Contractor shall notify the NASA COR of any issues that may affect function, schedule, or cost during this contract effort. This notification shall be by telecon and e-mail from the Program Manager within 48 hours of the awareness of the issue.

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Right to Access All facilities and documentation used by the Contractor and its sub-tier Contractors shall be open to evaluation by NASA. In these cases, the Contractor shall arrange to provide NASA authorized representatives with access to areas in which work is being performed. NASA will provide reasonable notification prior to any evaluations. The Contractor shall comply with FAR 46.202-4 “High Level Contract Quality Requirements.”

Certificate of Compliance (C of C) The Contractor shall provide a certification with each shipment to attest that the parts, assemblies, subassemblies, or detail parts conform to the Order requirements. When applicable, the true manufacturers, lot, heat, batch, date code, and/or serial number shall appear on the certification. MSFC shall perform inspection, as necessary, to determine the acceptability of all articles under this order. All articles submitted by the Contractor under this Order are subject to final inspection by MSFC.

Calibration System The Contractor shall have a documented Calibration System that meets the requirements of ISO 10012, “2003 Measurement Management System” quality assurance requirements for measuring equipment, or the American National Standard Institute (ANSI)/National Conference of Standards Laboratories (NCSL) Z540-1, General Requirements for Calibration Laboratories and Measuring and Test Equipment. The use of alternate calibration system requirements documents requires NASA approval for use.

100% Attribute Clauses The Contractor shall maintain, on file, as objective evidence, one reproducible copy of all inspection documentation stamped by the responsible quality inspector showing 100% inspection for all critical attributes noted on the drawings and/or manufacturing instructions, for all parts submitted under this Contract/Purchase Order.

Packaging, Handling & Labeling The Contractor shall meet the Packaging, Handling & Labeling requirements specified in the component specification.

Workmanship The Contractor shall perform the workmanship standard for surface mount technology in accordance with NASA-STD-8739.2.

Shipping Documents The Contractor shall generate the DD250 form and the MSFC QAR shall be one of the approving officials for the DD250. The DD250 will be a part of the MAV 5N Reaction Control Thruster documentation that is shipped with the hardware. Final product acceptance will occur at Pre-Ship Review. This will follow the MSFC management review and acceptance, including the MSFC S&MA Quality Lead review and acceptance.

Upon successful completion of testing at the Contractor’s facility, the hardware and documentation shall be packaged and shipped by the Contractor in accordance with the contract instructions or as provided by the COR. The hardware deliverables shall be declared “Program

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Critical Hardware” and as such shall conform to Class I and Class II of NPR 6000.1E, Requirements for Packaging, Handling and Transportation for Aeronautical and Space Systems, Equipment and Associated Components.

Record Retention The Contractor and their sub-tiers shall maintain verifiable objective evidence of all inspections and tests performed, results obtained and dispositions of nonconforming articles. These records shall be made available to MSFC and/or Government Representatives upon request and shall be retained in a safe, accessible location for the life of the program. The Contractor’s records associated with the manufacture of serialized or lot controlled articles shall provide for continued traceability of serial number or lot number identification through all phases of manufacturing, commencing with the raw material and continuing through final acceptance of the end item.

Records shall be held for 10 years after delivery of the hardware. These records shall not be destroyed without the MSFC's written concurrence.

Contamination Control, Manufacturing and Processing The Contractor shall prepare and submit Contamination Control Plan (CCP) with Foreign Object Debris (FOD) Control Plan in accordance with DRD 1753MP-001.

The Contractor shall prepare and submit a Materials and Processes Identification and Usage List (MIUL) in accordance with DRD 1753MP-002. Special attention shall be made to address concerns with material compatibility with the hydrogen operating media.

The Contractor shall prepare and submit Material Usage Agreements (MUAs) in accordance with DRD 1753MP-003.

Flow-Down of Requirements All requirements that are identified or applied to the MSFC purchasing document, including this clause, shall be flowed down to the Contractor’s sub-tier suppliers.

7.3 Anomaly Reporting

Reporting of hardware anomalies to the NASA/MSFC COR shall begin no later than the start of acceptance testing. Any anomaly during fabrication that delays the planned start of acceptance testing shall also be reported. The NASA/MSFC COR shall be notified within 24 hours of each anomaly.

The Contractor’s processes for review, disposition and approval of anomaly reports shall be described in their quality plan/manual or provided as a supplemental document. In addition, the Contractor’s anomaly reporting document shall describe the members of the Material Review Board (MRB) and Failure Review Board (FRB). The MRB and FRB shall include MAV MSFC participation. These processes shall ensure that positive corrective action has been taken to preclude recurrence and that appropriate audits and tests are performed to verify the implementation of the corrective action.

The Contractor shall routinely inform the MAV Project of MRB and FRB meeting schedules and agendas with sufficient notice to permit MAV Project participation if desired by MAV.

At the Contractor’s facility, NASA/Government representatives may participate in MRB/FRB activities as deemed appropriate by Government management or contract.

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The NASA/MSFC COR reserves disapproval rights on MRB and FRB decisions. To assure process consistency, the Contractor shall provide the MAV Project on-line access to their MAV anomaly-reporting database.

The Contractor shall provide, as part of the monthly report, a list of all open anomaly reports and a separate list of the anomaly reports closed during the month. For each reported anomaly, deviation, or non-conformance, there shall be a report that documents the investigation and engineering analysis needed to determine the cause and corrective actions to disposition the nonconformance, and identify any closed problem reports that do not have a definitive cause or corrective action. Reports shall be submitted to the NASA/MAFC COR for review and approval of the disposition.

The Contractor shall establish and maintain documented procedures to ensure product that does not conform to specific requirements is prevented from unintended use or installation. This control shall provide for identification, documentation, evaluation, segregation (when practical), disposition of nonconforming product, and for notification to the functions concerned.”

7.4 Safety, Health and Mission Assurance Deliverables

Safety, Health, and Mission Assurance deliverables shall include:

1. Reliability Prediction Analysis

2. Failure Mode and Effects Analysis

3. Anomaly Reports

8 DATA REQUIREMENTS

8.1 Other Data Deliverables

The Contractor shall conduct the necessary efforts to ensure all data for this task, required and deliverable, are prepared and managed in accordance with this contracted effort. Data shall be made available to the Government in hardcopy and electronic format. Communication of the data may include on-site reviews, electronic data transfer, or other means used to provide information in advance of activities, to report status, and to document formal reviews, requirement compliance, and hardware performance.

8.2 Documentation

The Contractor shall ensure the generation and delivery of all documentation as called out in the attached Data Procurement Document (reference Section J-2) and Data Requirement Descriptions (DRDs) (reference Section J-2).