Draft_SOW_Klystron.pdf

NEXRAD Klystron Repair SOW Page 1

Repair and Refurbish Next Generation RADAR (NEXRAD)

High Power Pulsed Radio Frequency Amplifier (Klystron)

SECTION A GENERAL

The Department of Commerce, National Oceanic and Atmospheric Administration (NOAA) National Weather Service (NWS) issues watches and warnings, public forecasts, and advisories for the United States (U.S.), its territories, adjacent waters and ocean areas. A primary method for gathering data and converting it into meaningful information is accomplished with a network of Weather Surveillance Radars, the WSR-88D (also known as the Next Generation Radar - NEXRAD). NEXRAD radars are operational at key locations for optimum coverage of the continental U.S., its territories and several overseas military bases. The NEXRAD transmitter uses a high power (750kW) klystron electron tube for radar pulsing of weather targets in varying atmospheric conditions.

The anticipated award will be a firm fixed-price, indefinite-delivery indefinite-quantity (IDIQ) multiple award contract with a period of performance of 5 years from the date of award. An estimated minimum quantity of five (5) and an estimated maximum of thirty (30) klystrons are anticipated to be repaired each year. These repaired and refurbished klystrons shall meet specified operational characteristics when installed in NEXRAD radars. The Contractor shall evaluate, repair, and return serviceable klystrons to the NWS.

SECTION B SUPPLIES OR SERVICES AND PRICES/COSTS

Payment amounts to the Contractor shall be based on the Pricing Schedule at the level of repair required. Evaluations are expected to determine the level of repair required and shall occur within 30 calendar days of delivery at the Contractor’s facility. It is expected for the klystron repairs to fall into four categories: No Defect Found (NDF), Minor Repair, Major Repair and Total Rebuild. A fifth category, Beyond Economic Repair (BER) could also occur resulting in no repair work being performed. In the case of a determination of BER following the evaluation, the contractor would be entitled to receive the evaluation fee.

SECTION C WORK STATEMENT

C.1 STATEMENT OF WORK/SPECIFICATION

a. The Contractor shall provide evidence that their company has been reviewed and certified by the NWS Radar Operations Center to perform repairs on this equipment.

b. The Contractor shall furnish the necessary personnel, material, equipment, services, and facilities to perform klystron evaluations and repairs.

c. The Contractor shall evaluate, repair, test for suitable functionality, and return the NEXRAD klystrons to the specified operational characteristics outlined in specification (Drawing) 1213614 Revision C.

NEXRAD Klystron Repair SOW Page 2

C.2 INTRODUCTION

The NEXRAD radar transmitter uses a high-power Klystron amplifier to produce the radio frequency (RF) pulses used to detect weather data. Two versions of klystrons are used in the National Weather Service’s NEXRAD radar transmitters: the Litton (now L-3 Communications) L-5782-20 and the Communication and Power Industries (CPI) VKS- 8287(A). These klystrons conform to National Weather Service specification (Drawing) 1213614 Revision C.

C.3 BACKGROUND

The National Weather Service’s National Reconditioning Center (NRC) is the centralized depot repair facility for all nationally supported NWS equipment utilized to support the NWS mission of protecting life and property through weather forecasts and warnings. As such, the NRC is responsible for the depot repair, reconditioning, and inspection of all types of equipment and parts. The NRC accomplishes its repair and reconditioning mission through a combination of in-house repairs and through repairs accomplished by commercial repair contractors. All repaired parts, whether in-house or contractor repaired, placed in NOAA/NWS stock, are inspected for acceptance or rejection by the NRC’s Technical Inspection & Material Reception Branch.

C.4 DEFINITIONS

C.4.1 REPAIR EVALUATION – Each klystron sent to the Contractor shall be evaluated within 30 days of receipt at the Contractor’s facility. Each Klystron sent to the Contractor shall be tracked by part and serial number. The Contractor shall use its own processes to evaluate the received condition of each Klystron and prepare an Evaluation and Repair Recommendation Report, for Government review and approval, that documents the physical, operational condition, and failure analysis of the klystron and the Contractors recommended repair option. The evaluated klystron will receive a status code of:

1. No Defect Found (NDF) (serviceable, evaluation and touch-up only)

2. Minor Repair (feasible to repair, minor effort)

3. Major Repair (feasible to repair, major effort)

4. Total Rebuild (complete refurbishment)

5. Beyond Economic Repair (not economical to repair)

C.4.2 NO DEFECT FOUND - Klystrons sent to the Contractor originated from a field site that made the determination that the unit was defective for various reasons. Occasionally the field technician may have removed a klystron from service that was not truly defective. During the evaluation of a klystron, the Contractor may find that a klystron under test was received in a fully serviceable condition. A klystron received in serviceable condition will be reported as a No Defect Found (NDF). A repair determination of NDF shall include the work required to give the unit a “like new” appearance (may include cleaning, painting and new labeling).

NEXRAD Klystron Repair SOW Page 3

C.4.3 MINOR REPAIR - Each klystron found defective but needing only “minor” repairs shall be repaired to the specification outlined in paragraph C.2 above. Each klystron entering a repair process shall have attached a repair traveler document that describes the part number, serial number, diagnosis, repair action and parts replaced or modified. Minor repairs would not require the klystron sealed cavity to be opened. Minor repairs could include repairs to the electronic components that are outside of the sealed cavity. A repair determination of Minor Repair shall include the work required to give the unit under repair a “like new” appearance.

C.4.4 MAJOR REPAIR - Each klystron found defective but needing major repairs shall be repaired to the specification outlined in paragraph C.2 above. Each klystron entering a repair process shall have attached a repair traveler document that describes the part number, serial number, diagnosis, repair action and parts replaced or modified. A major repair may or may not require the klystron sealed cavity to be opened. If the cavity is opened, then upon completion of the repairs, the specified vacuum must be established in the newly sealed klystron cavity (requires specialized equipment). A repair determination of Major Repair shall include a discussion of the work and components required to repair the unit.

C.4.5 TOTAL REBUILD - Each klystron found defective with repair needs resulting in the total rebuild of the klystron shall be repaired to the specification outlined in paragraph C.2 above.

Each klystron entering a repair process shall have attached a repair traveler document that describes part number, serial number, diagnosis and repair action, parts replaced or modified. A total rebuild will result in the klystron sealed cavity to be opened and may include replacement of the cathode. Upon completion of the repairs, the specified vacuum must be established in the newly sealed klystron cavity (requires specialized equipment). A repair determination of Total Rebuild shall include a discussion of the work and components required to repair the unit.

C.4.6 REPAIR - The repair and refurbishment of klystrons shall be to “like new” condition. The repair and refurbishment shall include the appropriate external connection points, external mating surfaces and Original Equipment Manufacturer labeling and painting requirements outlined in Section 2 of the specification (Drawing) 1213614 Revision C. Each repaired and refurbished klystron shall be tested for a period of a minimum of 48 hours in accordance with Sections 2.6 and 2.8 of the specification (Drawing) 1213614 Revision C, with the specific technical characteristics recorded on Test Data Sheets which shall be provided with the repaired and refurbished unit.

C.4.7 BEYOND ECONOMIC REPAIR (BER) - Each Klystron found to be BER shall have attached a traveler document that describes part number, serial number, diagnosis and reason it is uneconomical to repair. The unit shall be returned to the Government after evaluation.

Note: Klystron evaluations resulting in a status code of Total Rebuild may not be economical to repair. The Contractor shall make the determination of whether a status code of Total Rebuild should be considered Beyond Economic Repair and shall present this recommendation in the Evaluation and Repair Recommendation Report.

C.4.8 REJECT - The Government inspects the Test Data Sheets returned with the refurbished klystrons and randomly tests Klystrons returned from the contractor in a NEXRAD transmitter.

NEXRAD Klystron Repair SOW Page 4

A REJECT from the Government is a determination that a klystron does not meet the specifications and hence, the terms of the contract, either operationally or administratively. In the case of a REJECT, the klystron will be returned to the Contractor with the reason for the REJECT notice. The contractor will have 90 calendar days to rectify the REJECT.

C.4.9 LIKE NEW - “Like New” Condition means reconditioned to the listed specification to meet all applicable electrical, mechanical, cosmetic, and appearance specifications and engineering documentation, including the replacement of damaged, missing, or non-functioning parts.

C.4.10 CONTRACTOR TURNAROUND TIME - Contractor turnaround time is measured from the time a transport carrier delivers a Klystron to the Contractor facility until a transport carrier picks up a repaired Klystron from the Contractor facility that is being returned to the Government.

SECTION D PACKAGING AND MARKING

D.1 MARKING - Original Equipment Manufacturer labeling and painting requirements for repaired klystrons are outlined in Section 2 of the specification (Drawing) 1213614 Revision C.

D.2 Klystrons are shipped to the Contractor in special re-useable shipping containers suitable for Air or Ground transportation. The Contractor is responsible for returning repaired products in a shipping container designed to withstand the vibration and shock encountered during transportation by ship, rail, truck, and aircraft. The units shall be packaged to prevent damage to include: physical, electrical, mechanical, cosmetic, and the units shall not be damaged or lose performance capability.

D.2.1 the return container shall be addressed to:

U.S. Department of Commerce, NOAA NWS, National Reconditioning Center 14200 Merritt Road Grandview, Missouri 64030

SECTION E INSPECTION AND ACCEPTANCE

E.1 INSPECTION AND ACCEPTANCE

(a) The Contracting Officer’s Representative or the duly authorized representative will perform inspection and acceptance of supplies and services to be provided under this contract.

(b) Inspection/acceptance will be performed at:

U.S. Department of Commerce, NOAA, NWS, National Reconditioning Center 14200 Merritt Road Grandview, Missouri 64030

NEXRAD Klystron Repair SOW Page 5

(c) Klystrons shall be to “like new” operating condition and shall include the appropriate external connection points, external mating surfaces and Original Equipment Manufacturer labeling and painting requirements outlined in Section 2 of the specification (Drawing) 1213614 Revision C. Klystrons will be inspected for material workmanship and operation in accordance with the specification (Drawing) 1213614 Revision C and with the specific technical characteristics recorded on Test Data Sheets that include tuning pre-settings, which shall be provided with each Klystron by serial number.

E.1.2 PERIOD OF ACCEPTANCE

E.1.2.1 The Government shall test, inspect, accept, or reject Klystrons evaluated or repaired under this contract within fifteen (15) working days after delivery to the Government by transport carrier from the Contractor.

SECTION F DELIVERABLES AND PERFORMANCE

F.1 DELIVERABLES – Two deliverables are required for each of the klystrons sent for repair under this contract: the Evaluation and Repair Recommendation Report (paragraph C.4.1) and a repaired and functional klystron including the Test Data Sheets that include tuning pre-settings (paragraph C.4.6).

F.2 DELIVERY

F.2.1 F.O.B. DESTINATION

Prices offered shall include cost of return transportation from the Contractor's facility to the Government facility identified in paragraph F.2.2 below and includes industry standard packing, packaging materials, and crating of the Klystrons in accordance with section D.

F.2.2 Shipment of deliverable items, shall be to:

U.S. Department of Commerce, NOAA, NWS, National Reconditioning Center 14200 Merritt Road Grandview, Missouri 64030

F.3 PERFORMANCE

F.3.1 Contractor turnaround time is the time period between transporter's recorded delivery time to the recorded time the klystron is picked up by a transporter (section C.4.10).

F.3.2 When a klystron is received back from the Contractor, is inspected and found by the government to be in unserviceable condition, it shall be rejected back to the Contractor and no compensation will be given for Contractor evaluation or repair until it is returned to the Government in a serviceable condition.

NEXRAD Klystron Repair SOW Page 6

F.3.3 When a klystron is determined to be Beyond Economic Repair, then only the evaluation will be considered to be payable.

F.3.4 The Contractor will provide a 1-year warranty against material workmanship and against faults occurring during operation. This 1-year warranty will begin after passing the final equipment inspection and acceptance for stock.

SECTION REPORTS

BI-WEEKLY REPORTS

(a) The National Reconditioning Center (NRC) is requesting a video conference every two weeks with the contractor to discuss any issues that may arise. This process will keep the Government up to date and abreast of any concerns and provides the contractor an opportunity to ask questions of the government.