Warning_Horn_SOW_Final_20June2013.docx

Statement of Work for

Warning Horn Replacement Kit

Permanent Modification for the

KC-135 R/T

Date: 20 June 2013

Purchase Request No. GFD2030-12-39994

PREPARING ORGANIZATION: AFLCMC/WKDMB TINKER AFB OK 73145

Table of Contents……………………...…………………………………………. 2

1. Scope……………………………………………………………… 3

2. Applicable Documents…………………………………………… 3

Tables Table 1: Specifications………………………………………………………………. 3 Table 2: Standards…………………………………………………………………... 4 Table 3: Warning Horn Replacement Kit Delivery Schedule ………………………. 9 Table 4: Initial Spares Quantities…………………………………………………… 9 Table 5: Initial Spares Shipping Addresses……….………………………………. 10

Figures

1. Scope This Statement of Work (SOW) defines the work to be performed by the contractor necessary to manufacture the Warning Horn Replacement articles. The work performed by the contractor shall consist of providing the following resources: kitted materials, data, and management. These resources are required to acquire, document, and deliver the production of warning horns, forward mounting brackets, aft mounting brackets, and connectors.

1.1. Background

The KC-135 R/T warning horn provides an audible warning signal in case of emergencies.

1.2. Problem

The current KC-135 R/T warning horn is not explosion atmosphere qualified and operates in a known fuel vapor environment.

1.3. Solution

Procure a qualified explosive atmosphere warning horn to replace existing horn.

2. Applicable Documents The requirements for the warning horn are described within MIL-S-6904B and this document. When the requirements of this document and MIL-S-6904B are in conflict, the requirements of this document shall govern. Review Table 1 and Table 2 for specification and standard notes.

Unless otherwise indicated, copies of specifications, standards and handbooks listed below are available from the Standardization Document Order Desk, 700 Robbins Ave, Bldg 4D, Philadelphia PA 19111-5094.

2.1. Department of Defense (DoD) Specifications

Table 1: Specifications

2.2. DoD Standards

Table 2: Standards

3. Program Management Requirements The contractor shall designate a single point of contact (POC) to the contracting officer for all tasks required for the program. The POC shall be responsible and shall have authority for the control and coordination of all work performed and kits delivered under this SOW.

3.1. Post Award Conference

A post award conference shall be held in accordance with (IAW) FAR Part 15.

4. Technical Requirements This section provides a description of the Warning Horn Replacement Kit.

4.1. System Requirements

The warning horn system shall be qualified to operate within a fuel vapor bearing area that meets or exceeds MIL-STD-810G, Method 511.5, Procedure I or equivalent industry standard.

The test article shall be placed in a chamber and exposed to an environment containing percentage volumetric fuel vapor, air/vapor ratio (AVR) by weight. The test article shall be turned on and off as many times as can be completed during the test interval. The test shall be conducted in an atmosphere equivalent to 30,000 ft and at ground level. No ignition must occur during this test.

The contractor shall provide the government with all necessary technical data/information used in the development of the system. This information will be used to satisfy airworthiness and defense stock listing requirements.

At a minimum the technical data required shall address the following:

1. Proof of explosion proof testing per MIL-STD0810G, Method 511.5, Procedure 1, or equivalent.

2. Structural integrity paperwork to satisfy KC-135 crash loading service bulletin (Attachment 1) 11 Oct 2001

3. Drawings as stated in section 6.1 of this document.

4. Copies of all technical information used to satisfy section 6.2, airworthiness criteria certification report, of this document.

4.2. Component Requirements

A kit shall consist of a forward horn, aft horn, any necessary forward and aft mounting brackets, mounting fasteners, and electrical connectors.

The forward horn shall direct sound aft and the aft horn shall direct sound forward. The aft horn must bolt into 4 nut plates, NAS680A3, in the dimensions shown in Figure 1. The forward horn must mount into the dimensions shown in Figure 2; there are no nut plates currently in this area. Mounted warning horn shall be able to withstand a crash loading of 9G forward, 1.5G aft, 8G down, 4G up, and 4G inboard and outboard.

The current horns operate on a 28VDC circuit using a MS3102C-10SL-4P connector. Replacement horns must not exceed 28VDC and must use a two wire connector as long as connector is sealed to be operated in a fuel vapor bearing area, as described in section 4.1. If connector MS3102C-10SL-4P is used the male connector shall be provided. If a connector other than a MS3102C-10SL-4P is used, both female receptacle and male connector must be provided in the kit for both horns.

Replacement horns must produce an audible warning signal of at least 100 dB at a distance of 3 feet, measured on a standard sound meter in a soundproof room.

4.3. Assembly Requirements

The warning horn assembly shall mount in the existing locations. Current warning horn fits within a 12.000 x 5.375 x 8.500 inch envelope; replacement assembly is not constricted to this envelope but must not create interference with surrounding structures. Figure 1 and Figure 2 display the maximum envelope available for the new warning horn, and shall not exceed this limit. The current warning horns used on the KC-135 at the aft and forward locations are shown in Figure 3 and Figure 4 with general location of the mounting areas.

Figure 1: Aft Mounting Envelope

Figure 2: Forward Mounting Envelope

Figure 3: Existing KC-135 Aft Warning Horn

Figure 4: Existing KC-135 Forward Warning Horn

5. Production and Delivery

5.1. Kit Production

The contractor shall provide 398 Warning Horn Replacement Kits (NSN: 1560-K0-109-343A FL) to the Government IAW Table 3.

Table 3: Warning Horn Replacement Kit Delivery Schedule Note: Expedition of kits deliveries will be accepted

5.2. Physical Configuration Audit (PCA)

The contractor shall provide three production representative Warning Horn Replacement Kits for a PCA. The government will facilitate the PCA at Tinker AFB, contractor participation is required. No Functional Configuration Audit will take place.

5.3. Green Procurement

The Contractor shall comply with the Green Procurement Program (GPP). GPP is a mandatory federal acquisition program that focuses on the purchase and use of environmentally preferable products and services. FAR 23.404 applies and states the GPP requires 100% of EPA designated product purchases that are included in the Comprehensive Procurement Guidelines (CPG) list that contains recovered materials, unless the item cannot be acquired: a) competitively within a reasonable timeframe; b) within appropriate performance standards; or c) at a reasonable price. The prime contractor is responsible for ensuring that all subcontractors comply with this requirement.

5.4. Initial Provisioning Spares

The contractor shall provide initial provisioning spares quantities IAW Table 4. All initial provisioning spares will be individually packaged for shipment. All spares will be provided with first lot delivery.

Warning Horn Initial Provisioning Spares

Table 4: Initial Spares Quantities

5.5. Packaging and Handling

The contractor shall package the Warning Horn Replacement Kits and initial spares for shipment in accordance with ASTM-D-3951, Commercial Packaging or MIL-STD-2073-1E W/Change 1, the Standard Practice for Military Packaging. The contractor shall mark the packages for shipping and storage in accordance with MIL-STD-129P, Military Marking for Shipment and Storage. Shipping will operate under the FOB Destination structure, with the contractor paying for shipping and retaining ownership of all packages until they are accepted by the government at their destination.

5.5.1. Kit Shipping Location

Ship all 398 Warning Horn Replacement Kits to the following address:

FB2039 OC-ALC

Bldg. 506 CML PH (405) 739-2349 7401 Arnold St. Door 22 Tinker AFB, OK 73145-9013 Mark for: Account 09

5.5.2. Spares Shipping Location

Ship all initial spares in accordance with Table 5. (12 horns/6 sets)

BLDG 2045 CML PHN 509 247 3828

400 S GATE 35 RD

FAIRCHILD AFB WA 99011-9685

CML PHN 316 759 7622

57330 MUSTANG DR STE 13

MCCONNELL AFB KS 67221-9013

BLDG P49 CP 813 828 1800

8307 CYPRESS STAND DR

TAMPA FL 33621-5511

Table 5: Initial Spares Shipping Address

6. Data/Documentation Requirements

6.1. Product Drawings

The Contractor shall deliver all production level (3) technical data for the aft mounting bracket and forward mounting bracket to the Government IAW CDRL A001.

The Contractor shall deliver all conceptual level (2) technical data for the Warning Horn Replacement Kit and the warning horn and connector to the Government IAW CDRL A001.

6.2. Airworthiness Certification Criteria Report

The Contractor shall deliver initial and final MACC IAW CDRL A002.

Attachments:

1. KC-135 Crash Loading Requirements Memo.pdf (11 Oct 2001)

2. Warning Horn Modified Airworthiness Certification Criteria (MACC) image2.jpeg image3.png image4.png image1.jpeg