B777-200ER_Viewport_SOW v7 - Updated.pdf

Exhibit 1

Statement of Work

B777-200ER

Viewport Installations

Research Services Directorate

National Aeronautics and Space Administration

Langley Research Center

Hampton, VA 23665

Exhibit 1

Contents

1.0 Introduction

1.1 Scope

1.2 CLIN Summary

2.0 Requirements Definition

3.0 Reference Documents

4.0 Management Requirements

4.1 Project Management

4.2 Project Status Reports

4.3 Contract Surveillance

4.4 Program Management Reviews

5.0 General Requirements

5.1 Viewport Design

5.1.1 General

5.1.2 Materials

5.2 Aircraft Structural Life Limits

5.3 Aircraft Operations and Maintenance

5.4 Verification & Validation

5.4.1 Verification & Validation Plan

5.4.2 Verification & Validation Report

5.5 Analysis

5.6 Quality Management System

5.7 Fabrication & Aircraft Modification

5.7.1 General

5.7.2 Labor, Tooling, and Materials

5.7.3 Hangar Facility

5.7.4 Shoring Plan

5.7.5 Aircraft Corrosion Protection and Painting

5.7.6 Weight and Balance

5.7.7 Foreign Object Debris (FOD) Program

5.7.8 Procurement

5.7.9 Independent Material Testing

5.7.10 Deviations

5.8 Ground & Flight Testing

5.8.1 Ground Testing

5.8.2 Flight Testing

5.9 As-Built Drawing Package

5.10 Operation & Maintenance Manual Change Pages

5.11 NASA Airworthiness Review

5.12 Final Data Package

5.13 NASA Aircraft Inspection & Maintenance

6.0 Detailed Design Requirements

6.1 Reinforced Window Viewports (RWV) Design

6.1.1 General

6.1.2 Size and Location

6.1.3 Exterior Instrument Adapter Plate Mounting System

6.1.4 Portal Structural Capacity

6.1.5 Interior Equipment Mounting and Structural Capacity

6.2 Small Nadir Viewport – Off Centerline (SNV-OC)

6.2.1 General

6.2.2 Size and Location

6.2.3 Portal Instrument Adapter Plate Mounting System

6.2.4 Portal Structural Capacity

6.2.5 Additional Mounting Provisions

6.3 Large Nadir Viewport (LNV)

6.3.1 General

6.3.2 Size and Location

6.3.3 Portal Instrument Adapter Plate Mounting System

6.3.4 Portal Structural and Aerodynamic Capacity

6.3.5 Additional Mounting Provisions

6.4 Over-sized Nadir Viewport (ONV)

6.4.1 Size and Location

6.4.2 Portal Instrument Adapter Plate Mounting System

6.4.3 Portal Structural and Aerodynamic Capacity

6.4.4 Additional Mounting Provisions

6.5 Zenith Viewports (ZV)

6.5.1 General

6.5.2 Size and Location

6.5.3 Portal Instrument Adapter Plate Mounting System

6.5.4 Viewport Structural Capacity

6.5.5 Additional Mounting Provisions

6.6 Shutter System / Aerodynamic Fence

6.6.1 Actuation

6.6.2 Electrical Interface

6.6.3 Aerodynamic Drag

6.6.4 Aerodynamic Fence Sizing

6.6.5 Failure Modes

6.7 Structural Pressure Plugs

6.8 Installation Guidelines

6.8.1 Floor Modifications

6.8.2 Stress Interactions

6.8.3 Aircraft System Relocation

6.8.4 Overhead Compartments

6.8.5 Interior

7.0 Contract Type

7.1 Firm-Fixed Price (FFP)

7.2 Firm-Fixed Price (FFP) Indefinite Delivery Indefinite Quantity (IDIQ) ................ Error!

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8.0 Government Furnished Data or Equipment

9.0 Place of Performance

10.0 Travel

11.0 Shipping

12.0 Schedule

1.0 Introduction

1.1 Scope

The DC-8 owned by the National Aeronautics and Space Administration (NASA) has been a workhorse platform providing the airborne research community a long-range, large payload aircraft that has flown science missions worldwide over the last four decades. The DC-8 with a typical arrangement of in situ sampling probes and inlets installed in structural portals is shown in Figure 1-1.

Figure 1-1: NASA DC-8, Instrument Probes Highlighted

However, the DC-8 is facing several near-term obsolescence issues that puts the continuation of this capability at risk. Following a National Academies of Science study that endorsed the need to maintain this type of research platform, NASA’s Airborne Science Program (ASP) purchased a B777-200ER, S/N 32892, to replace the DC-8 (Figure 1-2). Given that it had previously served as a passenger aircraft for an international airline, ASP has initiated multiple modification projects to provide the necessary provisions to support payload integrations and science operations. NASA Langley Research Center (LaRC) plans to complete a series of “in-house” modifications to include the interior, power systems, avionics, intercom system, antenna layout, etc. as part of this effort.

Figure 1-2: NASA B777-200ER, S/N 32892

The purpose of this Statement of Work (SOW) is to outline payload integration requirements and complete the heavy structural modifications for the aircraft to reach Initial Operating Capability (IOC) for science missions. The SOW includes the design, analysis and installation of window, nadir, and zenith structural viewports. This requirement is broken up into a series of Contract Line-Item Numbers (CLINs) to provide the Government flexibility in choosing which modifications to pursue based on the pricing provided in proposal responses and the project budget. The CLINs are broken up in to two categories: 1) An NRE-only CLIN for the engineering design of Reinforced Window Viewports (RWV) and 2) design, analysis, fabrication, and installation of Small Nadir Viewports (SNV), Large Nadir Viewports (LNV), Oversized Nadir Viewports (ONV), and Zenith Viewports (ZV). The government does not intend to award all CLINs.

1.2 CLIN Summary

The following table and figure provide a summary of the activities and locations associated with each CLIN.

Table 1-1: CLIN Summary

The zones indicated in the above table are shown in the following figure.

Figure 1-3: Portal Zones

The Contractor should note the following.

1) CLIN #1 is associated with NRE-only for the RWV design. CLINs #2 - #4 are associated with the costs for the analysis, fabrication, and installation of the RWVs. The Contractor shall assume the RWVs are split evenly and mirrored about the aircraft centerline for the total portal quantity provided in each CLIN.

2) CLINs #5 - #11 are for the design, system relocation, analysis, fabrication, and installation of the indicated portal types and quantities. Note that any NRE for the design and installation peculiar costs as outlined in Section 6.8 shall be captured in proposed costs.

3) CLINs #13 and CLIN #14 combine multiple portal sizes and locations.

4) Zone Locations

a. Zone 1: Between FS634 to FS739, bottom of aircraft

b. Zone 2: Between FS825 to FS930, bottom of aircraft

c. Zone 3: Between FS1748 to FS1832, bottom of aircraft

d. Zone 4: Between FS613 to FS739, top of aircraft

e. Zone 7: Between FS1685 to FS1874, top of aircraft

5) Detailed technical requirements for all portal types are provided in Section 6.0.

CLIN # Portal Type Zone # Task Portal Qty Notes

1 RWV NRE, Design 1 2 4 3 8 4 10 5 1 1 6 1,2 2 QTY 1 EA LNV in Each Zone 7 3 1 8 1 2 Off Centerline, Colocated on Same FS 9 2 2 Off Centerline, Colocated on Same FS

10 ONV 1 1

11 4 or 7 1 12 4 or 7 2 13 LNV,SNV 1 CLINS 5/8 Executed Together 3 14 LNV,SNV 1 and 2 CLINS 6/8/9 Executed Together 6 15 Firm-Fixed Price (FFP) Indefinite Delivery Indefinite Quantity (IDIQ)

RWV

LNV

SNV

ZV

Analysis, Fabrication, Installation

Design, System Relocation, Analysis, Fabrication, Installation

2.0 Requirements Definition

The following definitions differentiate between requirements and other statements contained in this statement of work:

Shall This is the only verb used for binding requirements.

Should/May These verbs are used for stating non-mandatory goals.

Will This verb is used for stating facts or declaration of purpose.

3.0 Reference Documents

The documents shown in Table 3-1 are referenced in this statement of work.

Table 3-1: Reference Documents

Document # Title NAII 7900.3 Airworthiness Review Process for the Eastern Region Airworthiness Board LPR 1710.16J Aviation Operations & Safety Manual AOD 33843 Flight Test

SAE AS9100 Quality Management Systems - Requirements for Aviation, Space, and Defense Organizations

14 CFR Part 25 Title 14, Code of Federal Regulations

LMS-OP-0940 Langley Research Center General Aircraft Maintenance Manual for Research Services Directorate (RSD)

4.0 Management Requirements

4.1 Project Management

The Contractor shall provide project management support for the work accomplished under this statement of work such as integrated master schedule, cost, and technical supervision.

4.2 Project Status Reports

The Contractor shall provide weekly project status reports via teleconference. The status reports shall cover important project tasks (e.g. design, fabrication, aircraft modification) and shall include a running list of actions items and action item status (e.g. action item tracking spreadsheet).

4.3 Contract Surveillance

NASA reserves the right to conduct surveillance inspections at the Contractor’s facility at any time during the contract period to ensure compliance with contract requirements. The Contractor shall support these surveillance activities as required. Should NASA choose to provide on-site oversight, the contractor shall facilitate aircraft access and meeting attendance for the oversight crew.

4.4 Program Management Reviews

The Contractor shall conduct program management reviews as follows:

a) Complete the program management reviews provided in Table 4-1. The Contractor shall reference NAII 7900.3 and LPR 1710.16J for review requirements.

b) Provide an agenda, presentation charts, and a schedule update with percent completion of tasks at each review. (Preliminary presentation materials shall be provided no later than 3 business days prior to each review)

c) If requested, provide computer aided design models, analysis models, or other data prior to reviews.

d) Following all reviews, provide meeting minutes with action items up through and including the Final Engineering Review.

Table 4-1: Program Management Reviews

# Review Criteria/Objective Location

4.4.1 Pre-bid Aircraft Survey NASA will afford any bidder the opportunity to view the aircraft and review NASA documentation to aid in proposal development.

LaRC

4.4.2 System Requirements

Review (SRR)

Review statement of work requirements.

Review project schedule.

Contractor location

4.4.3 Conceptual Design

Review

Review design concept Review analysis plan.

Review draft verification & validation plan.

Review procurement, fabrication, & modification plan Review project schedule.

LaRC

4.4.4 Preliminary

Engineering Review

(PER)

To be conducted when approximately 10% of the design is complete.

Review design, drawings, analysis, etc.

Review preliminary verification & validation plan.

Review procurement, fabrication, & modification plan Review project schedule.

Contractor location

4.4.5 Final Engineering

Review (FER)

To be conducted when approximately 90% of the design, analysis, and drawings are complete.

Review design, drawings, analysis, etc.

Review final verification & validation plan.

Review procurement, fabrication, & modification plan Review project schedule.

LaRC

4.4.6 Ground Test

Readiness Reviews

Review ground test plan. Contractor location

4.4.7 NASA Airworthiness

Review

See Section 5.11. via teleconference

4.4.8 Flight Readiness

Review (FRR)

Review flight test plan.

Contractor location

4.4.9 Acceptance Review

(May be combined with FRR)

To be conducted prior to the delivery of the aircraft for the baseline contract or options following completion of all tasks. Objective is to ensure all components perform as specified and that all documentation and data deliverables are complete.

Contractor location

5.0 General Requirements

5.1 Viewport Design

5.1.1 General

The Contractor shall:

1) Consider all loading sources, both singular and combined, (e.g. static, pressure, aerodynamic, vibration, temperature) and all aircraft operating conditions (e.g. ground, maneuver, landing, emergency) when analyzing aircraft structural modifications per 14 CFR, FAR Part 25.

2) Design the portals to significantly limit or redistribute the load-transfer of undesirable stresses (e.g. bending stresses) from the aircraft to the viewport payloads; the loads applied to the payloads shall primarily result from cabin pressurization and payload installations and not be a load path for airframe stresses.

3) Design the viewport installation using best aviation practices (e.g. minimal changes to aircraft outer mold line, blended fairing, adherence to the Aircraft Maintenance Manual) to minimize aerodynamic drag when the viewport pressure plugs are installed.

4) Design the ZNV and SNVs with identical interfaces for payload integration.

5.1.2 Materials

All materials used in the structural modification, repair, or design for vehicle modification shall have documented A-basis allowables referenceable in the most recent version of MMPDS.

Materials shall be procured from NASA approved sources, contain HEAT lot traceability, certificates of conformance (CoC), and sourcing data.

5.2 Aircraft Structural Life Limits

The Contractor shall provide a written report demonstrating that all aircraft modifications meet or exceed the Original Equipment Manufacturer’s (OEM’s) aircraft structural life limit. Structural Life limits and related computations shall be based on commercially published materials static and fatigue allowables from MMPDS or equivalent as required. A rationale method shall be used to predict the fatigue-life limit impacts to vehicle structures modifications using a combination of handbook, finite element methods (FEM), hand calculations and similarity where applicable. For critical (primary) structures, a safe-life “rationale method” for substantiating fatigue-driven structural elements that results in a cycle-count prediction which exceeds the planned vehicle use life-span, as determined in conversations with NASA LaRC, is preferred.

5.3 Aircraft Operations and Maintenance

The Contractor shall design all aircraft modifications to accommodate and not negatively impact:

a) Normal flight operations for all phases of flight

b) OEM specified in-flight routine or contingency procedures (e.g. emergency oxygen bottle gauge inspection)

c) OEM specified maintenance procedures (e.g. oxygen system servicing)

The contractor shall deliver Instructions for Continued Airworthiness (ICAW) for all modifications to the aircraft (e.g. Viewport maintenance, system inspections, et al).

5.4 Verification & Validation

5.4.1 Verification & Validation Plan

The Contractor shall provide a written verification & validation plan for all requirements and conduct all verification and validation activities. The verification plan shall include a compliance matrix describing the type of verification activity to be used for each requirement (e.g. analysis, demonstration, inspection, test) and shall include all verification and validation activities required for public use certification in accordance with NAII 7900.3. The verification and validation plan shall be approved by NASA prior to verification and validation activities.

5.4.2 Verification & Validation Report

The Contractor shall provide a written report documenting all verification and validation results.

5.5 Analysis

The Contractor shall perform all required analyses, (e.g. structural, aero, fatigue, damage tolerance) required to satisfy NASA airworthiness requirements. The Contractor shall:

a) Document and review analysis plan with NASA prior to analysis start. Analysis plan shall include modeling approach, loads, safety factors, fasteners analysis method, analysis verification process, etc.

b) Deliver formal written reports documenting the analyses and compliance basis.

c) Obtain completed Federal Aviation Administration (FAA) Form 8110’s

5.6 Quality Management System

The Contractor shall have a quality management system that is compliant with the requirements of the current Society of Automotive Engineers (SAE) AS9100, Quality Management Systems - Requirements for Aviation, Space, and Defense Organizations.

5.7 Fabrication & Aircraft Modification

5.7.1 General

The Contractor shall:

a) Perform aircraft modifications IAW this SOW and approved drawings and data as approved by the Government

b) Perform maintenance activities in accordance with applicable aircraft OEM technical data.

c) Follow specific aviation and workmanship standards (e.g. FAA, Aerospace Industries Association, Society of Automotive Engineers Aerospace Standards, Aircraft Maintenance Manual) for all aircraft modifications (e.g. wire harness fabrication, tube fabrication, part marking, wire marking, electrical terminal crimping, electrical bonding/grounding, cable/tube clamping, heat treating). The selected standards shall be communicated to NASA.

5.7.2 Labor, Tooling, and Materials

The Contractor shall provide all labor, tooling, and materials to perform all modification activities for the baseline contract and exercised options. The Contractor shall present for NASA approval a tool control plan prior to engaging in modification activities.

5.7.3 Hangar Facility

The Contractor shall provide, as part of their proposal, a plan to hangar and fully contain NASA’s B777-200ER aircraft for all aircraft modification activities. The Contractor can propose the use of NASA LaRC’s hangar in Hampton, VA, to complete touch labor associated with all portal modification events. The Contractor shall execute the aircraft housing plan throughout the duration of modification and maintenance activities.

5.7.4 Shoring Plan

The Contractor shall develop a written aircraft shoring plan that demonstrates how fuselage dimensions and other critical aircraft features will be dimensionally monitored and maintained during the modification to prevent fuselage structures failure or OML deviation during the modification process and removal of structure.

5.7.5 Aircraft Corrosion Protection and Painting

The Contractor shall apply appropriate aircraft corrosion protection finishes, sealants, primer, and paint (interior and exterior) for all aircraft modifications including any required touch-up finishing/paint.

5.7.6 Weight and Balance

The Contractor shall complete an aircraft weight and balance per the B777-200ER maintenance manual prior to the first flight after the completion of any on-aircraft modification work.

5.7.7 Foreign Object Debris (FOD) Program

The Contractor shall maintain a foreign object debris program for all aircraft modification work to ensure removal of all foreign objects that could impact safe aircraft operations.

5.7.8 Procurement

The Contractor shall:

a) Procure serviceable materials and hardware to support fabrication and modification.

b) Provide Manufacturer’s Test Reports (MTRs) for all raw materials (e.g. chemical analysis composition, mechanical properties testing, heat treat strip charts).

c) Provide certificates of conformance for all hardware and third-party processes (e.g.

HEAT-Lot number traceability).

d) Ensure that counterfeit materials and hardware are not purchased for, or installed on, NASA aircraft.

5.7.9 Independent Material Testing

The Contractor shall:

a) Provide independent material testing for raw materials used to fabricate safety critical components (e.g., failure of a component could result in a catastrophic hazard such as critical damage to an aircraft or injury to personnel). The testing shall be performed after all critical material treatments/processes have been completed (e.g. following heat treat).

b) Deliver material test reports to NASA following testing. The test reports shall clearly identify the part number of the associated component.

c) Deliver the as-tested material coupons to NASA. The coupons shall be bagged and tagged for traceability (e.g. include associated part number).

5.7.10 Deviations

The Contractor shall obtain written approval from NASA for any deviations from approved drawings or technical data that are beyond those allowed by the aircraft OEM.

5.8 Ground & Flight Testing

5.8.1 Ground Testing

The Contractor shall prepare written ground test plans and perform ground testing as required to verify design requirements and aircraft modifications (e.g. ground pressure test). The written test plans shall be approved by NASA prior to test start. In particular, the test program shall include instrumented tests to verify the structural design requirements. The Contractor shall document the results of all tests in a written report. Reference AOD 33843.

5.8.2 Flight Testing

The Contractor shall prepare written flight test plans as required to verify design requirements and aircraft modifications (e.g. functional test flight). The written test plans shall be approved by NASA prior to test start. In particular, the test program shall include instrumented tests to verify the structural design requirements. The Contractor shall document the results of all tests in a written report. The Contractor shall support flight testing as required. Reference AOD 33843.

5.9 As-Built Drawing Package

The Contractor shall provide a complete drawing package (piece part, assembly, component removal, and installation) containing all drawings required for the modification (mechanical, electrical, etc.) The drawing package shall document the as-built configuration, i.e. all approved redlines and material review board (MRB) recommendations shall be incorporated on drawing formats approved by LaRC RSD. The drawings shall include all information necessary to fabricate and install the components such as dimensions, electrical schematics, tube bend tables, tube/cable clamp locations, rivet/bolt hole locations, fastener torques, notes, bill of materials, etc. The drawings shall also include all special process and procedure notes such as material finishing, electrical bonding, oxygen service cleanliness requirements, etc. The Contractor shall deliver to NASA any referenced process specifications that are not easily obtained by NASA in the open market. The Contractor shall deliver all drawings in both AutoCAD DXF/DWG format and Adobe vector PDF (i.e. not bitmap) and all 3D CAD models in native and STEP and/or Parasolid XT format. All CAD/Solid-modelled hardware modifications shall be delivered in the aircraft coordinate system (CSYS). The contractor shall utilize an established configuration management system (CMS) process that incorporates drawing quality checks and pre-release reviews prior to government acceptance. The CMS shall control drawing reviews, document release, and Engineering Change Notice (ECN) process with version controls and an electronic file Database Management System (DMS).

5.10 Operation & Maintenance Manual Change Pages

The Contractor shall provide change pages to the aircraft operation and maintenance manuals (including Illustrated Parts Catalog (IPC)). for all aircraft structures or systems affected by the modification. The change pages shall include inspection and maintenance requirements for continued airworthiness related to the modifications IAW CFR Part 25, Appendix H.

5.11 NASA Airworthiness Review

The Contractor shall support NASA’s airworthiness review process to approve the aircraft for flight. Reference NAII 7900.3.

5.12 Final Data Package

The Contractor shall deliver an electronic data package containing all data generated/required for the modification. All documents shall be legible and complete. The Contractor shall provide the Government with an unlimited rights license to use the data. Examples include but are not limited to:

1. Design

a. Computer Aided Design (CAD) models in native and STEP and/or XT format

b. Finite element models in native format (Nastran bulk data files preferred)

c. As-built drawing package (see Section 5.9)

2. Reports

a. Structural analysis reports

b. Structural life limit report

c. Verification & Validation Plan/Report

d. Damage Tolerance Analysis (DTA) reports

e. Test plans and reports

f. Instructions for Continued Airworthiness (as required/needed)

g. Certification compliance matrix-checklists

h. Updated aircraft operation and maintenance manuals (See Section 5.10)

3. Procurement & Fabrication

a. Material test reports / certifications

b. Certificates of Conformance

c. Independent Material Test Reports

d. Specification sheets for commercial-off-the-shelf items that are not MS, AN, NAS, NASM components

e. Quality review documentation

f. Weight & Balance report

5.13 NASA Aircraft Inspection & Maintenance

If the aircraft is hangared at a Contractor-chosen location (not NASA LaRC) for modification, the Contractor shall perform all storage and preservation activities and all back to service activities defined in the Boeing OEM 777-200 Aircraft Maintenance Manual based on the duration of the modification. The Contractor shall allow NASA civil servant and/or NASA contractor personnel to perform aircraft inspection and maintenance actions at the Contractor’s hangar facility (if used).

6.0 Detailed Design Requirements

These sections outline the requirements for the design of each style of viewport NASA is requesting.

6.1 Reinforced Window Viewports (RWV) Design

6.1.1 General

The Contractor shall design a structural modification to the aircraft that enlarges the viewing aperture of the side windows and strengthens the load carrying capability to accommodate installation of in situ sampling probes and other science instruments. The design shall include a bolt pattern interface as described in Section 6.1.3. See Figure 6-1 for a typical payload integration into the DC-8 window portals.

Figure 6-1: DC-8 Window Port Example

6.1.2 Size and Location

The Contractor shall provide a design for a modified RWV that can be applied to any of the windows in the constant radius fuselage section of the aircraft (From FS508 to FS1832). Each RWV shall have an approximate clear aperture of 17” x 24” (longitudinal x vertical) and be approximately centered on the existing window.

6.1.3 Exterior Instrument Adapter Plate Mounting System

The RWV shall incorporate a structural flange that provides a serviceable fastener interface for a flat plate and the pressure plugs noted in Section 6.7.

6.1.4 Portal Structural Capacity

The RWV shall be capable of supporting a 350 lb installation centered on the portal extending 24 inches internally from the attachment flange. The RWV shall be capable of supporting a 350 lb installation extending 24 inches externally from the attachment flange with a drag load of 500 lbs and a lifting load of 1000 lbs (positive or negative). The center of pressure for the lift and drag loads shall extend 12 inches from the aircraft Outer Mold Line (OML). It can be assumed that NASA will space the RWV’s with at least 3 unmodified windows in between when considering load interactions between installations.

6.1.5 Interior Equipment Mounting and Structural Capacity

The RWV design shall incorporate an internal mounting mechanism (e.g. seat track rails) installed above and below the viewing aperture. The mounting mechanism shall have the capacity to support 200 in-lb of installed equipment at 24 inches in/normal to the interface.

6.2 Small Nadir Viewport – Off Centerline (SNV-OC)

6.2.1 General

The Contractor shall design a structural modification to the aircraft that provides two (2) downward (nadir) viewing apertures, symmetrically offset from the centerline of the aircraft to accommodate installation of science instruments.

6.2.2 Size and Location.

The Contractor shall provide a design for a viewport that can be installed in the installation zones identified in Section 1.2. The viewports shall have a clear aperture that maximizes the longitudinal opening between fuselage frames (i.e. does not require the removal of large sections of primary structure) and that maximizes the lateral opening cutting through a maximum of four longerons stringers.

6.2.3 Portal Instrument Adapter Plate Mounting System

The SNV-OCs shall incorporate a structural flange identical to the ZVs (See Section 6.5.3) that provides a fastener interface for a flat plate and the structural pressure plugs. The design shall include a roll angle offset so as to keep the viewport interface flange oriented parallel to the floor. (i.e. x-y plane of the aircraft).

6.2.4 Portal Structural Capacity

The SNV-OCs shall be capable of supporting a 500 lb installation centered on the portal extending 24 inches internally from the attachment flange. The SNV-OCs shall be capable of supporting a 500 lb installation extending 24 inches externally from the attachment flange with a drag load of 500 lbs and a lateral load of 1000 lbs (left or right). The center of pressure for the lateral and drag loads shall extend 12 inches from the aircraft Outer Mold Line (OML). The contractor shall provide a minimum spacing requirement for NASA to follow when choosing specific installation locations that minimizes stress interactions between adjacent installations.

6.2.5 Additional Mounting Provisions

The viewports shall incorporate an internal mounting mechanism (e.g. seat track rail) installed port and starboard of each portal. The mounting mechanism shall have the capacity to support 500 in-lb of installed equipment at 24 inches in/normal to the interface.

6.3 Large Nadir Viewport (LNV)

6.3.1 General

The Contractor shall design a structural modification to the aircraft that provides a downward (nadir) viewing aperture on the centerline of the aircraft to accommodate installation of science instruments.

6.3.2 Size and Location

The Contractor shall provide a design for a viewport that can be installed in the installation zones identified in Section 1.2. The viewport shall have a clear aperture that maximizes the longitudinal opening by cutting/removing no more than a single fuselage frame and that maximizes the lateral opening cutting through a maximum of six longerons stringers.

6.3.3 Portal Instrument Adapter Plate Mounting System

The LNV design shall incorporate structural flanges that provide a fastener interface to which a flat plate and the structural pressure plugs (see Section 6.7) can be bolted. The interface shall be identical for any installation of an LNV.

6.3.4 Portal Structural and Aerodynamic Capacity.

The LNVs shall be capable of supporting a 1000 lb installation centered on the portal extending 30 inches internally from the attachment flange. The LNVs shall be capable of supporting a 1000 lb installation extending 30 inches externally from the attachment flange with a drag load of 2300 lbs and a lateral load of 1000 lbs (left or right). The center of pressure for the lateral and drag loads shall extend 20 inches from the aircraft Outer Mold Line (OML).

6.3.5 Additional Mounting Provisions

The LNV design shall incorporate an internal mounting mechanism (e.g. seat track rail) installed port and starboard of each viewport. The mounting mechanism shall have the capacity to support 1000 in-lb of installed equipment at 30 inches in/normal to the interface.

6.4 Over-sized Nadir Viewport (ONV)

The Contractor shall design a structural modification to the aircraft that provides a downward (nadir) viewing aperture on the centerline of the aircraft to accommodate installation of science instruments.

6.4.1 Size and Location

The Contractor shall provide a design for a viewport that can be installed in the installation zones identified in Section 1.2. The viewport shall have a clear aperture that maximizes the longitudinal opening by cutting/removing two (2) fuselage frames and that maximizes the lateral opening cutting through a maximum of eight longerons stringers.

6.4.2 Portal Instrument Adapter Plate Mounting System

The ONV design shall incorporate structural flanges that provide a fastener interface to which a flat plate and the structural pressure plugs (see Section 6.7) can be bolted. The interface shall be identical for any installation of an ONV.

6.4.3 Portal Structural and Aerodynamic Capacity.

The ONVs shall be capable of supporting a 2000 lb installation centered on the portal extending 30 inches internally from the attachment flange. The ONVs shall be capable of supporting a 2000 lb installation extending 30 inches externally from the attachment flange with a drag load of 3000 lbs and a lateral load of 1500 lbs (left or right). The center of pressure for the lateral and drag loads shall extend 20 inches from the aircraft Outer Mold Line (OML).

6.4.4 Additional Mounting Provisions

The ONV design shall incorporate an internal mounting mechanism (e.g. seat track rail) installed port and starboard of each viewport. The mounting mechanism shall have the capacity to support 2000 in-lb of installed equipment at 30 inches in/normal to the interface.

6.5 Zenith Viewports (ZV)

6.5.1 General

The Contractor shall design a structural modification to the aircraft that provides an upward (zenith) viewing aperture on the centerline of the aircraft to accommodate installation of science instruments. The design shall include a bolt pattern interface as described in Section 6.5.3.

6.5.2 Size and Location

The Contractor shall provide a design for a viewport that can be installed in the installation zones identified in Section 1.2. The viewport shall have a clear aperture that maximizes the longitudinal opening between fuselage frames (i.e. does not require the removal of large sections of primary structure) and that maximizes the lateral opening cutting through a maximum of four longerons stringers.

6.5.3 Portal Instrument Adapter Plate Mounting System

The small viewport design shall incorporate a structural flange that provides a fastener interface for a flat plate and the structural pressure plugs (see Section 6.7).

6.5.4 Viewport Structural Capacity

The ZVs shall be capable of supporting a 350 lb installation centered on the portal extending 24 inches internally from the attachment flange. The SNV-OCs shall be capable of supporting a 350 lb installation extending 24 inches externally from the attachment flange with a drag load of 500 lbs and a lateral load of 1000 lbs (left or right). The center of pressure for the lateral and drag loads shall extend 12 inches from the aircraft Outer Mold Line (OML).

6.5.5 Additional Mounting Provisions

The viewport design shall incorporate an internal mounting mechanism (e.g. seat track rails) installed around the viewing aperture (either fore-aft or left-right). The mounting mechanism shall have the capacity to support 200 in-lb of installed equipment at 24 inches in/normal to the interface

6.6 Shutter System / Aerodynamic Fence

A Shutter system shall be designed for each type of nadir viewport, providing a clear and unobstructed aperture equal to the portal dimensions. The shutters shall be designed to be optional for flight (i.e. easily removable with minimal flight impacts) and shall have provisions for a removable aerodynamic fence installed forward of the opening.

6.6.1 Actuation

The retraction and opening actuation shall be possible within three minutes from surface to 15,000 feet and 0 to 250 KCAS. The shutter systems shall have a manual opening and closing capability that is easily accessible in the applicable cargo area. The manual capability may make use of a tool that allows connection to the shutter door to allow manipulation of the door.

The force required for opening and closing shall be a one-person operation.

6.6.2 Electrical Interface

The shutter systems interface and control wiring shall be easily accessible inside the cargo areas and provide the necessary input power and position status discrete signals. All signals and control wiring shall be extendable for up to 150 ft.

6.6.3 Aerodynamic Drag

The shutter systems and aerodynamic fences shall be designed to minimize aerodynamic drag in both the open and closed positions.

6.6.4 Aerodynamic Fence Sizing

The aerodynamic fence shall be sized appropriately to reduce any unwanted aerodynamic effects over the window viewport recesses such as cavity resonances, aerodynamic induced vibration, or other issues that may negatively impact aircraft structure. The aerodynamic fence shall be removable and not interfere with shutter operations.

6.6.5 Failure Modes

Failure of the shutter mechanism in any position shall not impact safe and normal flight operations.

6.7 Structural Pressure Plugs

The Contractor shall design a structural pressure plug for each of the above style viewports that will close out the port when not in use by a science payload. The pressure plugs shall be airworthy throughout the entire aircraft flight envelope and shall be conformal with the Outer Mold Line (OML) of the aircraft.

6.8 Installation Guidelines

The following section provides guidance for peculiar details that should be considered by the Contractor for various portal installations. An example of this type of work is depicted in the following figure.

Figure 6-2: Cargo Bay Considerations for Portal Designs

6.8.1 Floor Modifications

The nadir portal installation will require structural modifications to the cargo pit floors. NASA will remove the cargo rollers from Zones 1, 2 and 3, however the vendor shall be responsible for modifying the underlying support structure to accommodate the viewport modifications.

6.8.2 Stress Interactions

For multiple portal installations in zones 1 and 2, the stress interaction between the installations shall be accounted for in the structural analyses.

6.8.3 Aircraft System Relocation

With the exception of antennas, the Contractor shall relocate all necessary aircraft systems to provide clearance for the viewports. The aircraft systems shall be relocated to provide a clear and unobstructed access to the nadir portals.

Example aircraft systems that may need to be relocated include but are not limited to:

1. Avionics equipment cooling duct

2. Electrical Wiring

3. Hydraulic lines

6.8.4 Overhead Compartments

The Contractor shall minimize the removal of the overhead storage bin compartments to accommodate the zenith portals. The remaining sections of the overhead compartments shall remain fully functional and finished/closed out to match the aircraft interior.

6.8.5 Interior

For installations inside the main cabin area, the Contractor shall finish/closeout all side wall and overhead panels surrounding the viewports and interior equipment mounting mechanisms to functionally (Acoustic, thermal, etc.) match the aircraft interior.

7.0 Contract Type

The B777-200ER contract will consist of a maximum of fifteen (15) Contract Line-Item Numbers (CLINs), as detailed below.

7.1 Firm-Fixed Price (FFP)

CLINS 1 – 14 are provided in Section 1.2. A combination of CLINS will be awarded to meet the programmatic requirements as provided by Sections 4.0 to 6.0.

7.2 Firm-Fixed Price (FFP) Indefinite Delivery Indefinite Quantity (IDIQ) CLIN 15 is for potential unknown aircraft maintenance actions or other Government-directed changes such as engineering design, engineering analysis, fabrication, or other unknown aircraft modification tasks that result during the performance of this contract. All additional work shall be approved prior to the commencement of any work by the Contractor.

8.0 Government Furnished Data or Equipment

The Government will furnish the items shown in Table 8-1.

Table 8-1: Government Furnished Data or Equipment

# Document/Part # Title/Description

8.1 S/N 32892 NASA B777-200ER Aircraft

8.2 Reference Documents See Section 3.0 (NASA documents & drawings only)

9.0 Place of Performance

The Contractor shall perform all work specified in this contract as given in Section 5.7.3.

10.0 Travel

The Contractor shall travel to NASA LaRC in Hampton, VA, for the reviews outlined in Section

4.4. Additionally, based on aircraft availability and at the Contractor’s discretion, the Contractor may travel to NASA LaRC for on-aircraft inspections during periods when the aircraft is not at the Contractor’s facility.

11.0 Shipping

Drawings and data shall be delivered in electronic format either via email or mailed to:

NASA Langley Research Center Attn: Martin Nowicki 6 East Taylor Rd

BLDG 1244

Hampton, VA 23681

12.0 Schedule

The Contractor shall deliver a schedule 30 days after contract award that defines the necessary project elements to implement requirements of the baseline contract. The schedule shall include all programmatic reviews detailed in Table 4-1, deliverables, and aircraft modification work in sufficient detail to gauge progress on a weekly basis. The schedule shall be reviewed, discussed, and accepted by NASA LaRC prior to work commencing. The aircraft will be available for modification / maintenance touch labor no earlier than March 2024 and no later than June 2024.