DRAFT- SOW- Propulsor Composite.pdf

DD 254 OPSEC

Attachment

Current as of August 2017 1

Propulsor Composite Prototype

Statement of Work

09 June 2020

2017 2

STATEMENT OF WORK

This Statement of Work (SOW) is for design, evaluation, development, and manufacturing of advanced propulsor, shafting and other naval vessel prototype components at a variety of sizes from scale model test to full scale articles for the Naval Surface Warfare Center, Carderock Division.

1. BACKGROUND. The Advanced Propulsor Management Office (APMO) is in the Naval Architecture and Engineering Department of the Naval Surface Warfare Center, Carderock Division (NSWCCD).

The APMO is responsible for the design and manufacture of Government Furnished Equipment (GFE) submarine propulsors on behalf of the Naval Sea Systems Command (NAVSEA). The APMO requires the design, development, and manufacturing demonstrations of advanced material (including composites), and multi-material prototype propulsor, shafting and bearing components, to support the COLUMBIA Class Submarine Program Office (PMS 397), the VIRGINIA Class Submarine Program Office (PMS 450), and future Research & Development (R&D) activities towards the next generation of propulsor and shafting systems. Advanced materials, such as fiber-reinforced composite laminates and engineered elastomers, require specialized knowledge in design, manufacturing, testing, and installation.

Multi-material components and/or structures, herein, are defined as components and/or structures which contain metallic and non-metallic (including composite and polymer) materials.

2. SCOPE. The objective of this SOW is to provide design engineering and manufacturing support from early stage concept design through technology maturation and the completion of and manufacturing efforts for composite and multi-material propulsor, shafting, and other naval vessel components. This includes the manufacturing design drawings, engineering, and fabrication, assembly of prototype propulsor, shafting and bearing components as well as the equipment needed to support propulsor R&D, and testing and evaluation. Development and manufacturing demonstrations will also be conducted for other shipboard components, such as sonar array windows, non-pressure hull hydrodynamic fairings, submarine superstructure components, communications mast enclosures, and surface combatant deck structural components. These manufactured articles include scale model and full scale hardware, as well as hardware suitable for at-sea demonstration. Additionally, this contract can be used to support vendor qualification of fleet hardware.

3. REFERENCES:

3.1. MIL-STD-31000A: Technical Data Packages, dated 26 February 2013

3.2. T9074-AQ-GIB-010/271: Requirements for Non Destructive Testing Methods, dated 15 May 1995

3.3. MIL-STD-2035A SH: Non Destructive Testing Acceptance Criteria, dated 15 May 1995

3.4. DD Form 1694: Request for Variance, dated April 2017

3.5. AS9100 Revision C (2009): Quality Management Systems - Requirements for Aviation, Space and

Defense Organizations Revision C (2009)

3.6. ISO 9001/ISO 9002 (2008)

4. GENERAL REQUIREMENTS

4.1. General Services. The Contractor shall develop and implement a Project Management Plan (CDRL A001) for the efficient and effective administration and control of work performed under the individual task orders (TO). The Contractor shall manage deliveries to meet cost, schedule, and performance of each TO. These TOs will include standard, urgent, or complex situations in fulfillment of the customer’s needs. The Contractor shall provide scheduling, tracking, reviewing, and estimating of projects assigned. The Contractor shall resource material, facilities, personnel, and services for assigned projects. The Contractor shall schedule, prioritize and track all projects, and report any discrepancies or conflicts to the designated Contracting Officer Representative (COR) for resolution. In addition, the Contractor shall:

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4.1.1. Establish and maintain a clear line of authority among all organizational elements, including management of subcontractors.

4.1.2. Designate primary and alternate points of contacts for matters related to technical, finance, and management.

4.1.3. Arrange for Government access to authorized Subcontractor facilities and enable communication at all lower tiers.

4.1.4. Investigate, record facts and observations, and communicate any perceived or actual issues related to quality, schedule, cost control, management, utilization of small business, and regulatory compliance, that if unresolved would adversely impact overall performance of projects specified at the order level.

4.2. Project Scheduling. The Contractor shall design and develop a graphical report, Gantt chart, depicting a comprehensive schedule of all planned technical activities and milestones, Project Planning Chart (CDRL A002). The Gantt chart shall include discrete tasks and activities at the subtask level. Further, the Contractor shall identify the critical path, all major events, and program milestones. Activities shall have a valid total slack or float identified for critical path analysis and impact analysis from delays. This data item may be submitted as an appendix to the Monthly Status Report (CDRL A006).

4.3. Post-Award Conference. The Contractor shall host a Post-Award Conference (PAC) at the Contractor’s facility within thirty days after contract award. Specific time and date information for the PAC shall be coordinated with the Contracting Officer’s Representative (COR). The purpose of the PAC is for the Contractor to review and demonstrate to the Government the management procedures, provide progress assessments, review of technical and other specialty area status, and to establish schedule dates for near term critical meeting/actions. The Contractor shall present management, key personnel, and program ramp-up.

4.4. Program Management Reviews (PMR). The Contractor shall plan, host, attend, and conduct meetings and formal reviews as specified in the individual orders. The Contractor shall prepare and submit a proposed conference agenda in accordance with the Conference Agenda (CDRL A003).

The Contractor shall conduct PMRs at Government or Contractor facilities or by other means (e.g.

teleconference) as agreed to by the PCO/COR. Reviews requiring demonstration and/or examination of equipment shall be conducted at the Contractor’s facility. The Government reserves the right to cancel any PMR, modify the PMR, or to require any PMR to be scheduled during the period of performance (PoP).

4.5. Program Review Documentation. The Contractor shall prepare agendas and conference presentation materials and provide minutes and reports following each PMR in accordance with the Presentation Material (CDRL A004). The Contractor shall address the following topics at each

PMR:

4.5.1. Review of pertinent technical, schedule, and cost aspects of each authorized technical effort under individual orders, including an overview of the work to be accomplished in the next month;

4.5.2. Current and anticipated technical and implementation risks;

4.5.3. Identification of outstanding technical decisions. The Contractor shall provide a resolution need date, based on execution schedule, for each outstanding decision provided.

4.5.4. Review of each subcontractor’s technical progress on all orders;

4.5.5. Report status of all Government Furnished Property (CDRL A010) (Received, In Custody, Shipped, Disposed Of);

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4.5.6. Substantiation of assumptions made and methodologies used in arriving at recommendations or conclusions; and

4.5.7. Address action item documentation; assignment of responsibility for completion and due dates shall be determined prior to adjournment of all PMRs.

4.6. Monthly Status Reporting (MSR). The Contractor shall observe and record work progress and status of the program, assigned tasks, costs, and existing or potential problem areas in narrative format with the Monthly Status Report (CDRL A006). The following activities and resulting data items shall be submitted as appendices to the MSR.

4.6.1. Monthly Expenditure Reporting. The Contractor shall observe and record all direct and indirect expenditures for both planned and actual transactions including labor hours against baseline values, and estimates of time and cost at completion in accordance with the Monthly Expenditure Report (CDRL A007).

4.6.2. List of Deliverables. The Contractor shall draft and maintain a comprehensive list including all data items and all physical deliverables, in accordance with List of Deliverables (CDRL A008). Substantiating documentation for tangible items shall include a DD Form 1149 (Requisition and Invoice/Shipping Document).

5. TECHNICAL REQUIREMENTS

The Contractor shall design, manufacture, test, and evaluate prototype Full Scale and Model Scale submarine composite structures with complex geometries and strict geometric tolerances, using advanced manufacturing techniques. This effort includes supporting calculations, analyses and manufacturing demonstrations.

5.1. Fabrication Processes. The Contractor shall be able to perform process studies using design of experiments, systematically varying properties to determine process influence on material or component performance, quality, or consistency, in accordance with Technical Report (CDRL A009). The Contractor shall use manufacturing expertise to provide feasibility assessments of conceptual techniques, iteratively develop new processing capabilities (including necessary tooling and industrialization steps), and assess the manufacturability of designs. The Contractor shall provide all material and equipment necessary to fabricate the components as designed, unless government-furnished property (GFP) is provided at the order level. Typical maximum component sizes will be:

Propulsor components fit within a box 25 ft. by 25 ft. by 25 ft.

Shafting components fit within a cylinder of 5 ft. diameter by 100 ft. length Other naval vessel components fit within a cylinder of 35 ft. diameter by 50 ft. length

Under this SOW the Contractor shall design and manufacture submarine propulsor, shafting, and other naval vessel components utilizing some or all of the following processes

5.1.1. Autoclave curing. Fabrication using autoclave curing composite fabrication processes.

5.1.2. Out of autoclave (OOA). Fabrication using out-of-autoclave (OOA) composite fabrication processes, including Vacuum-Assisted Resin Transfer Molding (VARTM).

5.1.3. Automated fiber placement (AFP). Fabrication using AFP and automated tape layup (ATL) techniques.

5.1.4. Computer Numerically Controlled (CNC) Contour Machining. Execution of CNC machining (such as milling and turning) of metallic, composite, and multi-material components. The Contractor shall have the capability to machine complex, doubly curved

2017 5 geometries that require 5-axis contour machining. Typical multi-axis profile milling and turning tolerances are:

Nominal Part Size

Diameter (in) Height (in) Tolerance (in, +/-)

0-24 6 0.003

24-48 12 0.005

48-180 24 0.008

180-240 60 0.01

5.1.5. Polymer Material Development and Processing.

Development of material formulations, molding processing procedures, and mechanical design incorporation features for polymers in propulsor, shafting, and other naval vessel component applications. Materials developed will be specific to the component and/or system application, defined at the order level, but will require elastic and viscoelastic materials such as natural rubber, urethane rubber and syntactic foams. These materials may be cast or injection molded. Material requirements and applicable component/system requirements will be defined at the order level.

5.1.6. Inspection. Execution of dimensional, destructive, and non-destructive testing (NDT) and inspections to ensure in-process and completed components meet requirements of drawings and manufacturing plan. Required NDT inspection method capabilities include visual, dye penetrant, and ultrasonic testing. Specific inspection standards will be defined at the order level. Dimensional inspection processes and equipment shall be sufficient to confirm the machining tolerances specified per section 5.1.5. Modal testing of components may be required to verify dynamic structural properties of the in-process or completed component;

the Contractor shall conduct modal testing through their own capability or provide access to the Government or other Government contractors to conduct modal testing. Technical Report (CDRL A009) and Test Inspection Report (CDRL A011).

5.1.7. Item Procurement and Assembly. The Contractor shall procure any items not manufactured by the Contractor necessary to complete a component or assembly such as fasteners, castings, forgings, etc. Procured items shall be obtained with all objective quality evidence (OQE) necessary to demonstrate that they meet design specification requirements. The Contractor shall then install and assemble the procured items in accordance with design specifications.

5.2. Design. The Contractor shall generate concepts for and design composite, and multi-material components to support propulsor, shafting, and other naval vessel R&D using requirements for the component(s) specified at the order level. As required at the order level, the Contractor shall execute engineering analysis and document design calculations or other supporting analysis for the component(s) in the Technical Report (CDRL A009).

5.3. Mechanical Design Definition. The Contractor shall document final designs generated for components(s) at the order level. Documentation shall include drawings, digital product definitions (i.e. CAD models), and other applicable information required to manufacture the component.

Drawing and digital product definition formats and requirements, including NAVSEA technical authority approval will be defined at the order level.

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5.4. Advanced Manufacturing Process Development. The Contractor shall provide expertise to develop, demonstrate, and document new processes for fabrication and integration of structures and components that advance composite and multi-material technologies. Specific development strategies may focus on new material types, tooling methods, processing methods, and methods for integration of multi-material structures. These developments shall primarily focus on tailoring the performance of materials, reducing fabrication and life-cycle costs of the designed components, and advancing design and manufacturing approaches. The Contractor shall use manufacturing expertise to provide feasibility assessments of conceptual techniques, iteratively develop new processing capabilities (including tooling and industrialization steps necessary), make and test samples for independent characterization, and support the validation of new materials and processing methods.

Technical Report (CDRL A009) and Test Inspection Report (CDRL A011).

5.5. Manufacturing Plans. The Contractor shall develop detailed plans to reduce the risk of manufacturing as specified at the order level. Manufacturing plan requirements, as defined at the order level, will address: component fabrication and assembly work flow, long lead material procurement strategy, required fixtures and tooling, fabrication and machining processes, and inspection plans, Technical Report (CDRL A009).

5.6. Manufacturing Demonstrations. The Contractor shall conduct manufacturing and assembly demonstrations of their component designs, as specified at the order level. These demonstrations will be used to verify manufacturing techniques, demonstrate conformance to design requirements, provide feedback to the candidate designs, assess manufacturability, and/or support future full scale production planning. The Contractor shall conduct demonstrations on sub-elements, full-scale sections, and large-scale tooling and deliver the demonstration results under Test Inspection Report (CDRL A011). Delivery of fabricated parts, samples, tools, fixturing, molds, etc. shall be delivered at the location specified in the order(s). Demonstrations may include destructive evaluations of demonstration articles to verify the quality of the manufacturing process and demonstrate compliance with the requirements and specifications of the component.

5.7. Material and Component Testing. The Contractor shall conduct full-spectrum material sample (coupon) characterization testing for mechanical properties, including fatigue conditions as required at the order level. Test capabilities such as dynamic mechanical analysis (DMA), tensile, shear, and fatigue are required. The Contractor shall conduct material testing to assess and/or verify the material characteristics, such as strength, void content, and fiber volume fraction as required by the component specifications and design drawings, and/or as defined at the order level. The Contractor shall conduct component and assembly level testing as required to support design development, certification, or demonstrate functionality as defined at the order level. Technical Report (CDRL A009) and Test Inspection Report (CDRL A011).

5.8. Engineering support. The Contractor shall provide engineering, technical, and manufacturing support to activities related to submarine composite and multi-material structures, including installation, maintenance, modification, and repair as required at the order level. These activities shall be provided as necessary for fleet assets, and large scale vehicles/test models. The Contractor shall provide in-situ engineering and fabrication support in the field to support ship/model surveys, component assessment, installation support, field test events, and non-standard repair assessment and execution, and system performance assessments of components to address life cycle requirements. Component assessment shall be conducted by on-site inspections, engineering calculations to determine condition, non-destructive inspection, monitoring systems and time-performance studies. Additionally, the Contractor shall provide recommended repair, replace, re-design and/or damage mitigation procedures for in service composite and multi-material structures.

Findings shall be documented as defined in the individual order(s), Technical Report (CDRL A009). The Government will provide on-site access agreed to at the individual order level, to the

2017 7 component if it is deployed in the field. Engineering Support may occur either in the field or at the Contractor’s facility, as appropriate for the work procedure and the component.

6. CONTRACTOR MANAGEMENT AND QUALITY CONTROL

6.1. Quality Control (QC) Program. The Contractor shall conduct all work in accordance with reference 2, AS9100 Revision C (2009), Quality Management Systems - Requirements for Aviation, Space and Defense Organizations or, reference 2, ISO 9001/ISO 9002 applicable to all types and phases of engineering and machining, Program Management Plan (CDRL A001).

7. GOVERNMENT FURNISHED PROPERTY/INFORMATION

7.1.1. Government Furnished Information (GFI). The Government will provide GFI required by the Contractor for performance of this contract as defined in individual orders. At the completion of the order, all GFI and any unclassified\classified data derived from GFI shall be returned to the Government within 60 days.

7.1.2. Government Furnished Property (GFP). The Government will provide GFP required by the Contractor for performance of this contract as defined in individual TOs. The Contractor shall provide a quarterly inventory of GFP (CDRL A010). All GFP shall be returned to the Government as specified in the individual order.

8. SECURITY REQUIREMENTS

8.1. Personnel Security Clearance. All key personnel and non-key personnel shall hold a clearance as defined by the DD Form 254, attached to this contract, before being granted access to classified information.

8.2. Classified Information Handling. The Contractor shall have the capability to handle and store information, models, and data up to the CONFIDENTIAL level, as defined by the DD Form 254.

8.3. Classified Information Access. During performance of DOs the Contractor may have access to information classified to the level indicated on the attached DD Form 254, Contract Security Classification Specification.

9. TRAVEL. CONUS travel will be required under this SOW and will be identified at the order level.

10. PERSONNEL. If the PCO questions the qualifications of any person performing under the contract, the burden of proof to sustain that the person is qualified as prescribed herein shall be upon the Contractor.

11. . OPSEC.

NSWCCD OPERATIONS SECURITY (OPSEC) REQUIREMENTS

1. All work is to be performed in accordance with Department of Defense (DoD) and Department of Navy (DON) Operations Security (OPSEC) requirements, per the following:

a. DoDD 5205.02E, DoD Operations Security (OPSEC) Program

b. DoD 5205.02M, DoD Operations Security (OPSEC) Program Manual

c. SECNAVINST 3070.2, Operations Security

d. OPNAVINST 3432.1A, DON Operations Security

e. NAVSEAINST 3432.1A, NAVSEA OPSEC Policy

f. CARDEROCKDIVINST 3070.1, NSWCCD OPSEC Program

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2. The contractor will accomplish the following minimum requirements in support of Naval Sea Systems Command (NAVSEA) OPSEC Program:

a. Determine Critical Information (Cl) in accordance with DoD 5205.02m (App 1 to Encl 3). CI includes those facts, which individually, or in the aggregate, reveal sensitive details about NAVSEA or the contractor's security or operations related to the support or performance of this Statement of Work (SOW), and thus require a level of protection from adversarial collection or exploitation not normally afforded to unclassified information.

b. Practice OPSEC and implement countermeasures to protect Cl and other sensitive unclassified information and activities, especially those activities or information which could compromise classified information or operations, or degrade the planning and execution of military operations performed or supported by the contractor in support of the mission. Protection of Cl will include the adherence to and execution of countermeasures which the contractor initiates or provided by NAVSEA, for Cl on or related to the SOW.

c. Sensitive unclassified information is that information marked FOR OFFICIAL USE ONLY (or FOUO), Controlled Unclassified Information (CUI), Privacy Act of 1974, COMPANY PROPRIETARY, and also information as identified by NSWCCD Security SME, Program Manager, or Contracting Officer Representative (COR).

d. NAVSEA has identified the following as Cl (not exhaustive list; more can be added):

i. Known or probable vulnerabilities to any U.S. system and their direct support systems

ii. Details of capabilities or limitations of any U.S. system that reveal or could reveal known or probable vulnerabilities of any U.S. system and their direct support systems

iii. Details of Information about military operations, missions and exercises

iv. Details of U.S. systems supporting combat operations (numbers of systems deployed, deployment timelines, locations, effectiveness, unique capabilities, etc.)

v. Operational characteristics for new or modified weapon systems (Probability of Kill (Pk), Countermeasures, Survivability, etc.)

vi. Required performance characteristics of U.S. systems using leading edge or greater technology (new, modified or existing}

vii. Telemetered or data-linked data or information from which operational characteristics can be inferred or derived

viii. Test or evaluation Information pertaining to schedules of events during which Cl might be captured (advance greater than 3 days)

ix. Details of NAVSEA unique Test or Evaluation capabilities (disclosure of unique

x. capabilities}

xi. Existence and/or details of Intrusions Into or attacks against DoD Networks or Information Systems, including, but not limited to, tactics, techniques and procedures used, network vulnerabilities exploited, and data targeted for exploitation

xii. Network User ID's and Passwords

xiii. Counter-lED capabilities and characteristics, including success or failure rates, damage assessments, advancements to existing or new capabilities

xiv. Vulnerabilities in Command processes, disclosure of which could allow someone to circumvent security, financial, personnel safety, or operations procedures

xv. Force Protection specific capabilities or response protocols (timelines/equipment/numbers of personnel/training received/etc.)

xvi. Command leadership and VIP agendas, reservations, plans/routes etc.

xvii. Detailed facility maps or Installation overhead photography (photo with annotation of Command areas or greater resolution than commercially available)

xviii. Details of COOP, NAVSEA emergency evacuation or emergency procedures

xix. Government personnel Information that would reveal force structure and readiness (such as recall rosters or deployment lists)

xx. Compilations of information that directly disclose Command Cl

3. All Cl developed by the contractor and/or NAVSEA, in electronic or hardcopy form, must be protected by a minimum of the following countermeasures:

a. All emails containing Cl must be DoD Public Key Infrastructure (PKI) signed and PKI encrypted when sent

b. Cl may not be sent via unclassified fax

c. Cl may not be discussed via non-secure phones

d. Cl may not be provided to individuals that do not have a need to know it in order to complete their assigned duties

e. Cl may not be disposed of in recycle bins or trash containers

f. Cl may not be left unattended in uncontrolled areas

g. Cl in general should be treated with the same care as CUI/FOUO or Proprietary information

h. Cl must be destroyed in the same manner as CU1/FOUO

i. Cl must be destroyed at contract termination or returned to the government at the government's discretion

4. The contractor shall document items of Cl that are applicable to contractor operations involving information on or related to the SOW. Such determinations of Cl will be completed using the DoD OPSEC 5-step process as described in DoD 5205.02M (App 1 to Encl 3).

5. Per DoD 5205.2M (Encl 6), OPSEC training must be included as part of the contractors ongoing security awareness program. NAVSEA's OPSEC Computer Based Training (CBT) can be accessed via https://securityawareness.usalearning.gov/opsec/index.htm.

6. The contractor will not disclose sensitive unclassified information pertaining to a classified contract to the public without prior review and approval by NSWCCD OPSEC Program Manager and NSWCCD PAO.

7. If contractor cannot resolve an issue concerning OPSEC they will contact the

COR (who will consult with the NSWCCD OPSEC Program Manager).

8. All above requirements MUST be passed to all Sub-contractors.