PSSC_Performance_Work_Statement_20140122.pdf

INTERCONTINENTAL BALLISTIC MISSILE (ICBM) 14

PROPULSION SUBSYSTEM SUPPORT CONTRACT (PSSC) 15

PERFORMANCE WORK STATEMENT (PWS) 16

FOR 18

AIR FORCE NUCLEAR WEAPONS CENTER (AFNWC) 20

ICBM SYSTEMS DIRECTORATE (ICBMSD) 21

Flight Systems Division (AFNWC/NIB) 22 ICBM Propulsion Branch (AFNWC/NIBB) 23

Version 20140122 25

TABLE OF CONTENTS 45

SECTION I - DESCRIPTION OF SERVICES ......................................................................... 1 46

1.0 SCOPE ............................................................................................................................... 1 47

1.1 PURPOSE .......................................................................................................................... 1 48

1.2 BACKGROUND ............................................................................................................... 1 49

1.3 FUTURE ICBM SUSTAINMENT AND ACQUISITION CONSTRUCT (FISAC) 50

DESCRIPTION ................................................................................................................. 2 51

1.4 PROPULSION SUBSYSTEM DESCRIPTION ............................................................ 6 52

1.4.1 Stage 1 ............................................................................................................................ 6 53

1.4.2 Stage 2 ............................................................................................................................ 6 54

1.4.3 Stage 3 ............................................................................................................................ 6 55

1.4.4 Booster Integrating Hardware/Interstage Hardware................................................ 6 56

1.4.5 Propulsion System Rocket Engine (PSRE) ................................................................. 6 57

1.4.6 Flight Controls .............................................................................................................. 7 58

1.4.7 Flight Batteries .............................................................................................................. 7 59

1.4.8 Weapon System Ordnance Devices ........................................................................... 10 60

1.4.9 Peacekeeper Post-Boost Propulsion System (PBPS) ................................................ 13 61

1.4.10 Propulsion Flight Test Support Equipment ......................................................... 14 62

1.4.11 Depot Support Equipment ..................................................................................... 15 63

1.4.12 Modeling and Simulation ....................................................................................... 17 64

1.5 APPLICABLE DOCUMENTS ...................................................................................... 18 65

1.6 REQUIREMENTS .......................................................................................................... 18 66

1.6.1 Basic Description ......................................................................................................... 19 67

1.6.2 Integration ................................................................................................................... 19 68

1.6.3 Projected Meetings and Estimated Frequencies ...................................................... 20 69

1.6.4 Contractor Manpower Reporting ............................................................................. 22 70

1.6.5 Program Management Support ................................................................................. 22 71

1.6.5.1 Risk Management ................................................................................................. 22 72

1.6.5.2 Commercial Small Business Involvement ............................................................ 22 73

1.6.5.3 Modification/Replacement/New Requirement Oversight ..................................... 22 74

1.6.5.4 Program Management Information ....................................................................... 23 75

1.6.5.5 Cost Reporting ...................................................................................................... 23 76

1.6.5.6 Management Plan.................................................................................................. 24 77

1.6.5.7 Data Rights............................................................................................................ 25 78

1.6.5.8 Transition .............................................................................................................. 25 79

1.6.5.9 Program Administration........................................................................................ 27 80

1.6.6 Propulsion Subsystem Technical Services Required ............................................... 27 81

1.6.6.1 Sustaining Engineering ......................................................................................... 27 82

1.6.6.1.1 Systems Engineering ....................................................................................... 28 83

Page | ii

1.6.6.1.2 Systems Requirements Determination ............................................................ 29 84

1.6.6.1.3 Nuclear Surety ................................................................................................. 29 85

1.6.6.1.4 Nuclear Control ............................................................................................... 31 86

1.6.6.1.5 Toxic Products and Formulations ................................................................... 31 87

1.6.6.1.6 Environmental Conditions............................................................................... 32 88

1.6.6.1.7 Trade Studies ................................................................................................... 33 89

1.6.6.1.8 Configuration Management (CM) ................................................................... 33 90

1.6.6.1.9 Software Sustainment ...................................................................................... 34 91

1.6.6.1.10 Hardware Sustainment .................................................................................. 35 92

1.6.6.1.11 Technical Order (TO) Support ...................................................................... 36 93

1.6.6.1.12 Maintenance Support..................................................................................... 36 94

1.6.6.1.13 System Safety ................................................................................................ 37 95

1.6.6.1.14 Disposal ......................................................................................................... 38 96

1.6.6.1.15 Corrosion ....................................................................................................... 39 97

1.6.6.1.16 Emergency Response Support ....................................................................... 40 98

1.6.6.1.17 Weapon System Interface Control ................................................................ 40 99

1.6.6.1.18 Subsystem and End-Item Specifications ....................................................... 41 100

1.6.6.1.19 Electromagnetic Radiation ............................................................................ 41 101

1.6.6.1.20 Nameplates and Product Marking ................................................................. 41 102

1.6.6.1.21 Diminishing Manufacturing Sources and Materiel Shortages (DMSMS) .... 41 103

1.6.6.1.22 Test and Evaluation (T&E) ........................................................................... 42 104

1.6.6.2 Propulsion Subsystem Assessment ....................................................................... 44 105

1.6.6.2.1 Technical Risk Assessment ............................................................................. 44 106

1.6.6.2.2 Availability and Accuracy ............................................................................... 44 107

1.6.6.2.3 Maintainability ................................................................................................ 45 108

1.6.6.2.4 Nuclear Hardness and Survivability ................................................................ 45 109

1.6.6.2.5 Reliability ........................................................................................................ 45 110

1.6.6.2.6 Aging Surveillance (AS) ................................................................................. 46 111

1.6.6.2.6.1 Solid Propulsion AS ..................................................................................... 46 112

1.6.6.2.6.2 Liquid Propulsion AS ................................................................................... 48 113

1.6.6.2.6.3 Ordnance AS ................................................................................................ 49 114

1.6.6.2.6.4 Flight Controls AS ....................................................................................... 52 115

1.6.6.2.6.5 Flight Battery AS ......................................................................................... 53 116

1.6.6.2.7 Subsystem Component .................................................................................... 55 117

1.6.6.2.8 Assessment Data ............................................................................................. 55 118

1.6.6.2.9 Contractor Assessment Support ...................................................................... 55 119

1.6.7 Associate Contractor Agreements (ACA) ................................................................. 56 120

1.6.8 Travel ........................................................................................................................... 56 121

SECTION II – SERVICE SUMMARY .................................................................................... 57 122

2.0 SUMMARY MATRIX.................................................................................................... 57 123

SECTION III – PROPERTY MANAGEMENT...................................................................... 66 124

3.0 PROPERTY MANAGEMENT ..................................................................................... 66 125

Page | iii

3.1 GOVERNMENT-FURNISHED PROPERTY (GFP) AND SERVICES ................... 66 126

3.2 NUCLEAR WEAPONS-RELATED MATERIEL (NWRM) ..................................... 66 127

SECTION IV – GENERAL INFORMATION ........................................................................ 71 128

4.0 GENERAL INFORMATION ........................................................................................ 71 129

4.1 SECURITY REQUIREMENTS .................................................................................... 71 130

4.2 QUALITY CONTROL ................................................................................................... 72 131

4.3 QUALITY ASSURANCE .............................................................................................. 73 132

4.4 PHYSICAL SECURITY ................................................................................................ 73 133

4.5 HOURS OF OPERATION............................................................................................. 74 134

4.6 CONSERVATION OF UTILITIES .............................................................................. 75 135

4.7 RECORDS ....................................................................................................................... 75 136

4.8 ENVIRONMENTAL CONTROLS ............................................................................... 75 137

4.9 GOVERNMENT OBSERVATIONS ............................................................................ 76 138

4.10 SAFETY REQUIREMENTS ......................................................................................... 76 139

4.11 QUALIFICATIONS ....................................................................................................... 77 140

4.12 PARTNERING AGREEMENT (PA) ........................................................................... 77 141

4.13 ANTITERRORISM CONSIDERATIONS .................................................................. 78 142

4.14 CONTINUATION OF ESSENTIAL DOD CONTRACTOR SERVICES DURING 143

CRISIS IAW Department of Defense Instruction (DoDI) 1100.22 ............................ 78 144

4.15 PUBLICATIONS ............................................................................................................ 78 145

Page | iv

SECTION V - APPENDICES .................................................................................................... 79 146

APPENDIX A: ACRONYMS AND ABBREVIATIONS LIST ............................................. 80 147

APPENDIX B: EXAMPLES OF FUTURE EFFORTS OR PROGRAMS .......................... 90 148

APPENDIX C: SAFETY, FIRE PROTECTION AND HEALTH SPECIFICATION ....... 91 149

APPENDIX D: GOVERNMENT FURNISHED PROPERTY/SERVICES/EQUIPMENT 150

(GFP/GFS/GFE) .......................................................................................................................... 98 151

APPENDIX E: WORK BREAKDOWN STRUCTURE ........................................................ 99 152

APPENDIX F: APPLICABLE DOCUMENTS .................................................................... 101 153

Page | v

SECTION I - DESCRIPTION OF SERVICES 155

1.0 SCOPE 156

This contract is required to support the Minuteman III (MMIII) Intercontinental Ballistic Missile 157 (ICBM) Propulsion Subsystem to include solids, liquids, flight controls, system ordnance, and 158 flight batteries for an estimated 5-year period in the areas of sustaining engineering, maintenance 159 engineering, aging surveillance, modification of systems and equipment, software maintenance, 160 developmental engineering, production engineering and procurement. This subsystem contractor 161 will be responsible for all elements of the Performance Work Statement (PWS) to include 162 integration of these efforts with the Government and all ICBM contractors. 163

1.1 PURPOSE 164

The purpose of this document is to provide a description of the types of services the Propulsion 165 Subsystem Support Contract (PSSC) contractor will perform, not to specify to the contractor how 166 to perform required services. It is in no way intended to suppress innovative ideas or approaches 167 for performing required services. 168

The Propulsion Mission Statement is to integrate and coordinate all activities necessary to assess, 169 report, and sustain the operational capability and reliability of the ICBM Propulsion Subsystem 170 through 2030. 171

1.2 BACKGROUND 172

The MMIII is a mature weapon system that is in the Operations and Support Phase of its life 173 cycle. The primary ICBM activity is the sustainment of the operational force in a state of 174 readiness such that national defense strategies involving these systems can be successfully 175 executed. Weapon system sustainment includes the following: incorporation of changes to 176 ICBM weapon systems in response to requirements for performance improvements; to make 177 appropriate use of advances in technology; correction of system deficiencies; determining the 178 need for and executing life extension programs; implementation of policies mandated by 179 Congress or directed by other higher authorities; addressing threat or safety driven changes or 180 other changes in the operational or support environment. 181

Requirements for changes or modifications to fielded systems are usually applicable at the 182 subsystem or lower level. These changes will be performed primarily by the subsystem 183 contractors although the Government reserves the right to compete these changes among a 184 variety of vendors. Satisfying these requirements involves acquisition activities that can 185 potentially impact system-level performance. The ICBM Systems Directorate (ICBMSD) will 186 lead and coordinate efforts with the Integration Support Contract (ISC) contractor and the PSSC 187 contractor to manage the contracts required to change, modify, and sustain ICBM systems. 188

The PSSC contractor will assist the Government in its performance of tasks to maintain the 189 weapon system. Contractor assessment operations will be required to conduct materials and 190 subcomponent analysis and test, including aging surveillance test and evaluation. The primary 191 focus will be to identify aging mechanism, anomalous behavior, and ensure any modifications or 192 changes to the system will maintain and/or improve system-level performance. 193

Page | 1

1.3 FUTURE ICBM SUSTAINMENT AND ACQUISITION CONSTRUCT (FISAC) 195

DESCRIPTION 196

1.3.1 FISAC Structure 197

Figure 1 is a graphical representation of the FISAC structure. The Technical (Tech) Council is 198 not in the management chain. The light green box associated with the Tech Council identifies 199 further details of the Tech Council. The dark blue box containing “Other ICBMSD led efforts” 200 shows that the ICBMSD has other direct contracts supporting the ICBM weapon system. 201

Figure 1. FISAC Structure 203

1.3.2 FISAC Working Relationships 204

Although the Government is the Lead System Integrator for the ICBM weapon system, the PSSC 205 contractor is responsible for all elements of the PWS to include integration of these efforts with 206 the Government and all ICBM contractors. Figure 2 shows major functions of the ISC, 207 ICBMSD, and subsystem contractor. 208

Page | 2

Figure 2. FISAC Component Functions 210

1.3.2.1 PSSC Contractor/ICBMSD Relationship 211

The PSSC contractor will assist the Government in fulfilling its role as the Propulsion Subsystem 212 manager by performing sustaining engineering, maintenance, engineering, aging surveillance, 213 modification of systems and equipment, software maintenance, developmental engineering, 214 production engineering, and procurement of Propulsion Subsystem components and related 215 support equipment. The PSSC contractor will provide breadth and depth of capabilities for the 216 elements listed in the Work Breakdown Structure (WBS), Appendix E, across the Propulsion 217 Subsystem. 218

1.3.2.2 ISC/ICBMSD/PSSC Contractor Relationship 219

While the PSSC contractor will provide the preponderance of sustaining engineering support to 220 the Propulsion Subsystem, the ISC contractor will also provide subsystem expertise to validate 221 subsystem contractor analyses and produce requirements and other documentation for subsystem 222 acquisitions that would create an Organizational Conflict of Interest (OCI) if produced by the 223 subsystem contractor. 224

In order to competently and conscientiously support the MMIII, the Air Force (AF) requires its 225 contractors and their subcontractors to effectively share information concerning the status of 226 programs and technical issues with the weapon system. This communication will need to occur 227

ICBM Systems Directorate Function: Weapon System Integrator

Page | 3 with the Government and among other support contractors to the maximum extent consistent 228 with proper protection of classified and/or other sensitive information. To achieve this, the 229 PSSC contractor will have appropriate Non-Disclosure Agreements (NDA) with other 230 contractors and subcontractors as applicable and demonstrate the ability and willingness to 231 communicate openly. The ISC contractor will only provide contractual direction to its 232 subcontractors. Likewise, the PSSC contractor shall only provide direction to its subcontractors. 233 See Figure 1. 234

The ICBM Prime Integration Contract (IPIC) was structured with the F-900 clause to prevent 235 disruption of repairs, modifications, or additional tasks. Performance on these will continue until 236 completion of the task, subject to availability of funds, unless terminated, regardless of whether 237 or not a succeeding option for Engineering Services is exercised. Additional F-900 tasks will not 238 be added to the IPIC after the end of the period of performance of the last exercised option. 239 F-900 programs are efforts continuing beyond September 30, 2012 under the current IPIC 240 (F42610-98-C-0001). The PSSC contractor will interface with F-900 programs; for example, the 241 Propulsion System Rocket Engine (PSRE) Life Extension Program (LEP), Solids Depot Support 242 Equipment (SDSE) program, and the Mk12A Batteries and High Impulse Transducers (HIT) 243 program. Along with the ISC contractor, the PSSC contractor will also interact with additional 244 ICBMSD-managed programs to integrate those efforts and ensure weapon system needs are 245 being met. The relationships with other contractors are the same as the subsystem contractor(s) 246 relationship described in this section. 247

1.3.3 Technical Council 248

The PSSC contractor will be a key participant on the ICBM Technical Council. The ICBMSD 249 will establish and chair this council which will meet at a minimum semi-annually and maximum 250 quarterly, as determined by the Director, ICBMSD, and be comprised of contractor and 251 ICBMSD representatives from each of the subsystems. The Technical Council will provide a 252 forum where the ICBMSD and key suppliers at various levels can directly, and on an equal level, 253 engage on issues important to ICBM systems. 254

1.3.3.1 Government Members 255

Director, ICBMSD (Chair), Director of Engineering (Alt Chair), Chief Engineer, ICBM Flight 256 Systems, Chief Engineer, ICBM Ground Systems, Technical Director, ICBM Systems 257 Engineering, Senior Engineer, ICBM Future Systems. Representatives from the following 258 organizations will also be included: 748th Supply Chain Management Group (SCMG), Air 259 Force Global Strike Command (AFGSC) (HQ/OL-J), Air Force Nuclear Weapons Center 260 (AFNWC)/Engineering and Technical Management Directorate (AFNWC/EN), 261 AFNWC/Logistics Directorate (AFNWC/LG), AFNWC/Intelligence and Capabilities Integration 262 Directorate (AFNWC/XR), AF Program Executive Officer, Strategic Systems (AFLCMC/SS), 263 309th Maintenance Wing, and others as determined appropriate by the ICBMSD 264

1.3.3.2 Associate Government Members 265

Associate Government members are designated by the relevant Integrated Product Team (IPT) 266 Chief or Director of Engineering. 267

Page | 4

1.3.3.3 Contractor Primary Members 268

Contractor primary members are System Engineering contractors, Guidance Subsystem 269 contractors, Propulsion Subsystem contractors, Reentry Subsystem contractors, Ground 270 Subsystems contractors, and Integration and Test contractors. 271

1.3.3.4 Associate Contractor Members 272

Associate contractor members are designated by the relevant Government IPT Chief or ICBMSD 273 Director of Engineering from among the contractors or subcontractors currently on contract to 274 perform ICBM support. Examples of expected members are inertial instrument designers and 275 producers, solid propulsion provider, liquid propulsion provider, flight control provider and 276 Rapid Execution and Combat Targeting (REACT) console provider. If an associate contractor is 277 also a subsystem contractor and primary Technical Council member, then additional membership 278 is not required. 279

1.3.3.5 Ground Rules 280

Meetings of the ICBM Technical Council are expected to be a place of frank and open discussion 281 of ICBM issues. Classified discussion at the SECRET level may occur, requiring proper visitor 282 clearances be on file with the ICBMSD security office. The Technical Council is not intended to 283 be a decision making body, nor does it provide contractual direction. The technical council shall 284 be conducted in a non-attribution environment with clear attention paid to protection of property 285 rights. Prior to each meeting a call for topics and agenda will go out to all participating 286 members. Topics for discussion will be prioritized by the Director of Engineering. The Director 287 of Engineering reserves the right to defer topics to another meeting to maintain focus on priority 288 topics. Each meeting will allow time for review of all Action Items to ensure the proper 289 personnel are assigned and aware. 290

1.3.4 PSSC Contractor and Other Subsystem Contractors 291

Each subsystem support contract in the FISAC is designed to include Sustaining Engineering 292 efforts for that subsystem and any relevant support tasks required to sustain the subsystem not 293 accomplished on a different contract or by an organic entity. Test equipment programs and 294 modifications may also be performed on the contract, as long as the dollar threshold for the 295 contract is not exceeded. The intent of the Air Force is that major modification programs will be 296 separately competed as these programs will be Acquisition Category (ACAT) 1D programs and 297 are likely to provide an opportunity for innovation from the larger industrial base to improve 298 weapon system performance. However, subsystem integration support of ACAT 1D programs 299 may be executed under the PSSC. ACAT II, ACAT III and non-ACAT programs may be 300 executed by a subsystem contractor. Nuclear Safety Cross Check Analysis (NSCCA), 301 Performance Analysis Technical Evaluation (PATE), and Independent Verification and 302 Validation (IV&V) for software will be managed by the AF and performed by an independent 303 contractor. 304

Page | 5

1.4 PROPULSION SUBSYSTEM DESCRIPTION 305

The PSSC technical scope includes all Propulsion Subsystem components described in Section 306 1.4, all associated depot support equipment, including test stands and associated software, 307 maintenance and test fixtures, and all associated technical data. 308

The MMIII Propulsion Subsystem is the aerospace vehicle less the Reentry System/Reentry 309 Vehicle (RS/RV) and Guidance Subsystem. The Propulsion Subsystem consists of three solid 310 rocket motors, the Propulsion System Rocket Engine (PSRE), two interstages, an aft skirt, and a 311 raceway cable system, plus all the control equipment for the nozzles and safing devices; also 312 includes ordnance and batteries. 313

Additional component descriptions are provided in subsequent paragraphs. 314

1.4.1 Stage 1 315

The MMIII Stage 1 is a cylindrically-shaped solid propellant rocket motor located at the aft end 316 of the downstage. Stage 1 has four independent nozzles and flight control is provided via an 317 electro-hydraulic nozzle control unit (NCU). The Stage 1 forward skirt attaches the Stage 1 318 motor to the 1-2 interstage. The motor and controls are operated by signals from the Missile 319 Guidance and Control (G&C) system. 320

1.4.2 Stage 2 321

The MMIII Stage 2 is a cylindrically-shaped solid propellant rocket motor that is installed in the 322 middle of the downstage. Stage 2 has a single, fixed submerged nozzle, an exit cone extension, a 323 liquid injection thrust vector control (LITVC) system, and a roll control system (RCS). The 324 forward skirt of the Stage 2 attaches the Stage 2 motor to the 2-3 interstage. The Stage 2 aft skirt 325 attaches the Stage 2 motor to the 1-2 interstage. 326

1.4.3 Stage 3 327

The MMIII Stage 3 is a cylindrically-shaped solid propellant rocket motor that is located at the 328 forward end of the downstage. Stage 3 has a single fixed exhaust nozzle, LITVC, RCS, and 329 thrust termination system. The Stage 3 motor is attached to the 2-3 interstage at the aft skirt and 330 the propulsion system rocket engine attached at the forward skirt. 331

1.4.4 Booster Integrating Hardware/Interstage Hardware 332

The MMIII booster interstage hardware consists of the interstage separation and skirt removal 333 ordnance and the raceway interconnections. 334

1.4.5 Propulsion System Rocket Engine (PSRE) 335

The PSRE is a self-contained, prepackaged, liquid bipropellant rocket propulsion system that 336 provides the thrust capability to deploy the MMIII RV. The PSRE is capable of providing 337 precise, on command, vehicle velocity increments to the post-boost vehicle. The PSRE uses a 338 hypergolic mixture of di-nitrogen tetroxide (N2O4) as the rocket oxidizer and monomethyl 339

Page | 6 hydrazine (MMH) as the rocket fuel. The oxidizer and fuel are independently stored in two 340 propellant storage assemblies. 341

The PSRE is contained in the CD2-4 shell, located between the Missile Guidance Set (MGS) and 342 the Stage 3 motor. The PSRE attaches to the aft end of the MGS and the forward end of the 343 Stage 3 motor. 344

1.4.6 Flight Controls 345

1.4.6.1 P89A1 Stage 1 Nozzle Control Unit (NCU) 346

The P89A1 Stage 1 NCU controls four moveable exhaust nozzles that, in turn, control thrust 347 vector orientation, providing pitch, yaw, and roll control. The NCU is powered in flight by a 348 SE-13G squib-activated battery. 349

1.4.6.2 P90A1 Stage 2 Attitude Control Group 350

The P90A1 Stage 2 Attitude Control Group is used to change position of four pintle valves that 351 control injection fluid flow to obtain LITVC of missile attitude in pitch and yaw. The unit, 352 operating in conjunction with the missile guidance system, provides a closed loop position servo 353 for positioning the Stage 2 pintle valves. The control group assembly consists of the following 354 major components: two hydraulic auxiliary power supplies, four servo injectors, and one roll 355 amplifier assembly. 356

1.4.6.3 P116A1 Stage 3 Liquid Injection Thrust Vector Control (LITVC) 357

The P116A1 Stage 3 LITVC is an electromechanical system used to control liquid injection into 358 the Stage 3 motor plume for maintaining missile control through thrust vectoring. The control 359 group consists of a main structure containing the electronics assembly, four flexible cable arms, 360 and four servo-injectors. 361

1.4.6.4 Raceway Conduit Support Set 362

The Raceway Conduit Support Set, CVK-103, is part of the LGM-30G (MMIII) “Dust 363 Hardened” operational missile providing support and environmental protection for the G&C 364 cables in Stages 1, 2 and 3. The conduit support set also provides means for G&C cable 365 separation during missile staging. 366

The G&C cables carry the electrical signals from the MGS to and from the various stages and 367 PSRE. Each stage and skirt contains an assembly to house the cables on the outer skin. Typical 368 signals include guidance commands, destruct commands, and instrumentation. 369

1.4.7 Flight Batteries 370

The MMIII utilizes a number of batteries during flight and test operations. This list is not all 371 inclusive, new batteries developed or deployed for use may become a part of the MMIII weapons 372 system inventory. 373

Page | 7

1.4.7.1 Stage 1 Flight Control Unit (FCU) Battery (SE-13G) 374

The Stage 1 FCU battery has a nominal loaded output of 28 volts (V) and a capacity over 12 375 amperes hour. This battery consists of 20 silver-zinc cells. It is a non-rechargeable reserve 376 design and activation is accomplished by a self-contained squib activation system. The battery 377 assembly consists of two gas generators that provide activation redundancy. 378

1.4.7.2 Static Random Access Memory (SRAM) Battery 379

The NS-50A MGS uses SRAM to retain operational software, data and codes, and MGS 380 maintenance data when an MGS is removed from ground power. The SRAM, a 381 non-rechargeable, active battery located in the NS-50A MGS is used to provide the required 382 power when the primary MGS power is removed from the missile. Two different battery designs 383 are used for SRAM. One type is a battery with two, DD-sized lithium/sulfuryl chloride cells 384 with a rated capacity of 30 amperes hour. The second type is made with two lithium/carbon 385 monofluoride DD-sized cells and has a capacity rated at 32 amperes hour. 386

1.4.7.3 Missile Guidance Set (MGS) Battery 387

The SE-437C battery provides power to the MGS, PSRE, Stage 2 and Stage 3 flight control 388 units, and the RS. The SE-437C battery connects to the NS-50A power distribution unit with a 389 9W05Z adapter cable. The battery consists of 20 silver-zinc cells and has a nominal loaded 390 output of 28V and a capacity of over 20 amperes hour. 391

1.4.7.4 Mark (Mk)21 Solid State Radar (SSR) Battery 392

The Mk21 SSR battery is a remotely activated lithium-aluminum/iron-disulfide thermal battery. 393 It is located in the aft end of the Mk21 fuze and provides regulated direct-current voltages to the 394 central power conditioner (CPC), as well as various SSR functions during the final phase of the 395 MMIII mission flight. The Thermal Battery has two independent activation circuits and six 396 outputs, and is started by applying an activation pulse to one or both of the activation circuits. 397 The six sections are a nominal 40V, 38V, 15V, 9V, -6V and -15V. The battery output remains 398 active as long as the temperature remains within a range to keep the electrolyte in a molten state 399 and there is sufficient active material in the positive and negative electrodes. 400

1.4.7.5 Mk21 Arming and Fuzing Assembly (AFA) Battery 401

The Mk21 AFA battery is used to provide power for the RV arming and fuzing assembly and is 402 located in the forward section of the RV. The Mk21 AFA battery has a nominal, loaded output 403 of 35V and a capacity of over 650 ampere second. The battery consists of 24 silver-zinc cells, is 404 a nonrechargeable, reserve design, and activation is accomplished by a self-contained, single 405 squib-activated, gas generator system. 406

1.4.7.6 Mk12A AFA Battery 407

The Mk12A AFA battery provides power to the RV arming and fuzing assembly and is activated 408 following launch of the MMIII missile. The current force configuration consists of Mk12A RVs 409 containing an AFA battery that is known as the Mk12A battery. The battery consists of 22 silver 410

Page | 8 zinc cells, is a nonrechargeable, reserve design, and activation is accomplished by a 411 self-contained, single squib-activated, gas generator system. 412

1.4.7.7 Operational Test Batteries 413

The AF conducts Operational Test Launches (OTL) from Vandenberg Air Force Base (VAFB) 414 as part of ICBM Force Development Evaluation (FDE). The OTL batteries installed in the MOD 415 7 lightweight (LW) wafer and motor raceways are used to power equipment for telemetry, 416 tracking, and command and destruct purposes for test flights only. The MOD 7LW wafer 417 contains four batteries: one S-band telemetry subsystem battery, two command destruct (CD) 418 subsystem batteries, and one global positioning system (GPS) battery. Each motor stage is 419 equipped with ordnance to terminate motor thrust in the event of inadvertent separation of the 420 missile motor stages. The mounting area of the premature stage separation (PSS) battery on each 421 solid motor stage is in the missile cable raceway. 422

1.4.7.7.1 Premature Stage Separation (PSS) Battery 423

The PSS destruct system terminates motor thrust in the event of premature motor separation. If 424 premature separation occurs, a squib in a Safe/Arm device is initiated activating the explosive 425 destruct package (linear shape charge) located on each stage. The first, second, and third stage 426 cable raceways contain a Safe/Arm device and a PSS battery. Upon arming the Safe/Arm, the 427 battery circuit completes, allowing the detonation sequence to occur. PSS destruct of all 428 downstage motors occurs if premature separation occurs between any of the first, second, or third 429 stage or post-boost vehicle interfaces. 430

The PSS battery is comprised of silver oxide positive plates and zinc negative plates. The 431 battery monoblock contains two independent, 6V sections of four silver-zinc cells each for 432 redundancy. Battery activation occurs when an electrical signal initiates a gas generator located 433 in the rear of the coil reservoir containing approximately 27 milliliters of Potassium Hydroxide 434 (KOH) electrolyte. The battery, activated during terminal countdown at approximately T-14 435 minutes, attains required voltage within 2 minutes. The battery must meet all performance 436 requirements following a minimum 6-hour wet stand in a lightly loaded condition of 60 437 micro-amperes in the event of a launch hold. 438

1.4.7.7.2 Telemetry Battery 439

The MOD 7LW telemetry battery is a non-rechargeable, silver-zinc battery. The battery has a 440 nominal voltage output of 28V and a capacity greater than 160 amperes minute. Battery 441 activation is complete within 2 minutes when voltage is above the specified minimum. The 442 battery, activated during terminal countdown at T-14 minutes, is required to meet all 443 performance requirements following a minimum 6-hour, no-load, wet stand in the event of a 444 launch hold. 445

1.4.7.7.3 Global Positioning System (GPS) Battery 446

The GPS battery is a manually activated, secondary (rechargeable), silver-zinc battery that 447 powers the GPS metric tracking system. The battery contains 18 cells and is activated manually 448 by adding KOH electrolyte into the cells (gas generators are not used to inject electrolyte into the 449

Page | 9 battery). The battery has a nominal voltage output of 28V and a design capacity of 1.2 ampere 450 hour. The battery is capable of meeting performance requirements after a 60-day wet stand. 451

The GPS battery has also been qualified for use on the MOD 7LW as the CD battery. 452

1.4.7.7.4 Command Destruct (CD) Battery 453

The CD system used for MMIII OTLs consists of two independent systems that provide 454 redundancy. Each OTL uses two CD batteries. 455

A remote-activated battery was used for many years; currently a manually-activated battery is 456 being used for this application. The current configuration (manually activated battery) has also 457 been designed and qualified for use in the GPS application. 458

1.4.8 Weapon System Ordnance Devices 459

The MMIII and Peacekeeper Post-Boost Propulsion System (PK PBPS) utilize a number of 460 ordnance devices during flight and test operations. These devices do not include the nuclear 461 warhead managed through the Department of Energy (DOE). 462

1.4.8.1 Launch Facility Ordnance (LFO) 463

The current MMIII system employs 4 types of ordnance items within each Launch Facility. 464 Those items are the Launcher Closure Ballistic Gas Generator, Umbilical Disconnect Cartridge, 465 Umbilical Retract Actuator Cartridge, and the Suspension System Explosive Bolt. 466

1.4.8.1.1 Launcher Closure Ballistic Gas Generator (BGG) 467

The BGG provides pressure, in the form of hot gases, to drive an actuator that removes the 468 launcher closure door from the silo before missile launch. The BGG detonator contains 5 to 10 469 grams of boron/potassium nitrate (BKNO3) with two redundant ES-003 squibs for initiation of 470 the ammonium nitrate-based propellant grain in the BGG cartridge. A replacement gas generator 471 is projected in the near future. 472

1.4.8.1.2 Umbilical Disconnect Cartridge 473

The umbilical disconnect cartridge shears a pin to disconnect the upper umbilical cable from the 474 missile just before launch. Only one cartridge is used per missile. The cartridge has three pins 475 and two bridge-wires for redundancy. One pin is a common ground for the two bridge-wires. 476 The cartridge contains a primer mix and main charge. 477

1.4.8.1.3 Umbilical Retract Actuator Cartridge 478

The umbilical retract actuator charge operates the ballistic rotary actuator to retract the G&C 479 system umbilical cable from the missile to the launch tube wall before Stage 1 ignition. The 480 cartridge contains two redundant Mk2 Mod 0 squibs, BKNO3, and two propellants. 481

Page | 10

1.4.8.1.4 Suspension System Explosive Bolt 482

The suspension system explosive bolt assembly disengages the missile restraining (or 483 articulating) arms at the time of launch. The explosive bolt is 4.7 inches long with a diameter of 484

0.5 inch. 485

1.4.8.2 Reentry System Reentry Vehicle (RS/RV) Ordnance 486

The RS/RV Subsystems contain items for the Mk12A, Mk21, and RS components that include 487 rocket motors, initiators, and other cartridge-actuated devices. 488

1.4.8.2.1 Mk12A Spin Gas Generator 489

The spin gas generator generates high-pressure gases for RV spin. The generator is five (5) 490 inches in length and five (5) inches in diameter. 491

1.4.8.2.2 Mk12A Spin Gas Generator Initiator 492

The Mk12A Spin Gas Generator initiator ignites the Mk12A Spin Gas Generator to enable 493 proper RV axial stabilization. 494

1.4.8.2.3 Mk21 Rear Cover Assembly 495

The Mk21 rear cover assembly is the aft end of the Mk21 RV which contains the Mk21 Spin Gas 496 Generator. This assembly shall be controlled using Nuclear Weapons-Related Materiel 497 (NWRM) processes. 498

1.4.8.2.3.1 Mk21 Spin Gas Generator 499

The Mk21 Spin Gas Generator is a subcomponent of the Rear Cover Assembly and by itself is 500 also considered NWRM. This device provides high-pressure gases required for RV spin. 501

1.4.8.2.4 Mk21 Delay Initiator 502

The initiator/delay combination ignites the Mk21 Spin Gas Generator to enable proper RV axial 503 stabilization. 504

1.4.8.2.5 Shroud Rocket Motor 505

The Shroud Rocket Motor is located in the forward end of the shroud and is used to pull the 506 shroud away from the support payload bulkhead and RVs. 507

1.4.8.2.6 Shroud Rocket Motor Initiator 508

The Shroud Rocket Motor igniter ignites the Shroud Rocket Motor. The igniter is one (1) inch in 509 length, 0.9 inches in diameter, and is an electrically-initiated hot-bridge wire device. 510

Page | 11

1.4.8.2.7 Thruster Bolt Impulse Cartridge 511

The Thruster Bolt Impulse Cartridge shears the thruster bolt in the v-band clamp to release the 512 Shroud Assembly. 513

1.4.8.2.8 Ball Lock Impulse Cartridge 514

The Ball Lock Impulse Cartridge provides pressure to move a piston within the Ball Lock to 515 release the RV. There are six cartridges for each RV. 516

1.4.8.3 Solid Rocket Motor Ordnance Components 517

These ordnance components serve a variety of functions, including stage separation, skirt 518 jettison, stage ignition, roll control, LITVC pressurization, and thrust termination. 519

1.4.8.3.1 Igniter Safe/Arm Device 520

This electro-mechanical switch provides the energy to ignite the solid rocket motor stages and 521 serves as a safety mechanism to prevent inadvertent initiation. 522

1.4.8.3.2 Circumferential and Longitudinal Detonation Cord 523

This 12.3 grain-per-foot lead sheath Royal Detonating Explosive (RDX) detonation cord helps 524 provide proper stage separation and skirt jettison. 525

1.4.8.3.3 Detonators 526

Detonators consist of an electrical connection that mates to the 7300 Arm/Disarm (A-D) switch 527 and includes all propellants necessary to initiate the linear explosive assemblies. 528

1.4.8.3.4 H-Boosters 529

H-Boosters contain RDX explosives and provide redundancy to the ordnance firing train. 530

1.4.8.3.5 Time Delays 531

Stage 2 uses redundant time-delay boosters to delay skirt removal. The time delay is 532 approximately 16 seconds from initiation by the linear explosive assembly. 533

Stage 3 uses redundant time-delay boosters for separation of the skirt. The time delay is one (1) 534 second from initiation by the linear explosive assembly. 535

1.4.8.3.6 Mechanical Safe/Arm Devices 536

Mechanical safe/arm devices provide mechanical alignment of ordnance transfer charges upon 537 stage separation via lanyard. 538

Page | 12

1.4.8.3.7 Arm/Disarm (A-D) Switch 539

The PSRE employs two A-D switches and each interstage within the booster employs one A-D 540 switch. Although not an energetic device, the Government’s ordnance experts also manage A-D 541 switches due to their integration within the ordnance systems and application throughout the 542 flight vehicle 543

1.4.8.4 Liquid Propulsion Ordnance Components 544

The ordnance components within the PSRE and PBPS are responsible for propellant 545 pressurization and separation from the third stage. 546

1.4.8.4.1 Pyrocartridge 547

Five Pyrocartridges located within the PSRE, each of which creates an impulse to drive an 548 isovalve piston to allow proper gas or liquids propellant flow. 549

1.4.8.4.2 Ordnance Module 550

The Ordnance Module provides pressure to provide an electrical and mechanical disconnect 551 between the Stage 3 and the PSRE. 552

1.4.8.5 Unique Operational Test Ordnance 553

This ordnance is unique to operational test and evaluation. It provides the means to destroy the 554 missile in the event of a flight anomaly. 555

1.4.8.5.1 All Ordnance Destruct System (AODS) 556

The AODS is installed at the test range to provide a reliable method for in-flight missile 557 destruction. This system consists of the CD Safe/Arm device, detonating cords, boosters, 558 crossover assemblies, launch safety closures, PSS Safe/Arm devices, actuators, timers, 559 acceleration switches, and batteries. 560

1.4.8.5.2 Modular Mechanical Ordnance Destruct System (MMODS) 561

The MMODS is installed at the test range to provide a reliable method for in-flight missile 562 destruction. The system is mainly a modular mechanical system, relying on lanyard actuated 563 devices to sever the pressure vessels and render them non-propulsive. MMODS consists of 564 linear shaped changes, Pull Actuated Devices (PADs) and CD Safe/Arm devices. 565

1.4.9 Peacekeeper Post-Boost Propulsion System (PBPS) 566

The PBPS, located between the PK Stage III and RS, is integral with a removable Missile G&C 567 System (MGCS). It provided similar operational functionality to the MMIII PSRE while the PK 568 ICBM was operational. The PBPS includes a structure, axial and attitude control propulsion 569 subsystems, electromechanical axial engine actuators, external shielding, the ordnance initiation 570 set, stage III-IV separation ordnance, electrical cables, the airborne power supply (batteries), the 571

Page | 13

MGCS cavity (all MGCS units have been removed), the in-flight coolant system, the umbilical 572 connector, and instrumentation and flight safety system components. The PBPS also utilizes 573 MMH and N2O4 propellants, but in greater quantities (~882 pounds oxidizer, 542 pounds fuel) 574 than the MMIII PSRE. 575

1.4.10 Propulsion Flight Test Support Equipment 576

ICBM flight tests are scheduled three to four times each year and are conducted by the AF’s 577 cognizant flight test authority at VAFB. Various flight and non-flight components are necessary 578 to support this effort in addition to the AODS and MMODS ordnance systems described in 579 Sections 1.4.8.5.1 and 1.4.8.5.2. Technical Order (TO) 21M-LGM30F-4-1-1 describes each of 580 the parts listed below in additional detail (TO Figure reference in parenthesis). This table is 581 intended for reference only, not intended to be inclusive of all flight test support equipment: 582

Components, Post-Boost Propulsion System (2-4)

Box Assembly, Protective Device, Inadvertent Ignition Ordnance (2-28)

Cable Assembly, Electrical Power (Explosive Bolt Cable), (2-81)

Rails, Missile Support (2-149)

Band, Retaining, Rocket Motor, Combat Training Launch Instrumentation (CTLI) (2-150)

Work Platform, Missile Access (2-159)

Test Set, Electrical Cable (2-168) Panel, Downstage Electrical System (2-169) Lead Set, Test, Destruct Package Installation Facility (DPIF), CTLI Test Set, Explosive Set Circuitry (2-171)

Test Chamber, Safety, CTLI (2-172)

Lead Set, Test, Launcher, CTLI Test Set, Explosive Set Circuitry (2-173)

Test Set, Electrical, Cable, AN/GSM-144 (2-174)

Cable Simulator, Self-Test (2-175) Circuit Analyzer (2-176) Power Supply Assembly (2-177) Relay, Chassis Assembly (2-178) Detector Assembly (2-179) Tester, Safety and Arming Device Test Set

(2-180) Test Set, Missile System Components

(MSC) (2-202)

Test Unit, MSC, AN/GSM-349A (2-203)

Cable Assembly, Video Display Power (2- 204)

Chassis Assembly, Peripheral Component Interface Extension for Information (PXI), 14-slot (2-205)

Cable Assembly, CD Safe and Arm (S/A) (2-206)

Support Fixture, Post-Boost Propulsion System (2-209)

Retainer, Electrical Connector (2-211)

Table 1. Parts List 583

Page | 14

1.4.11 Depot Support Equipment 585

The PSSC contractor will have the responsibility to assist the Government in ensuring continuing 586 functionality of the following Government-owned and maintained (unless otherwise noted) 587 support equipment and software. PSSC level of support is engineering support to troubleshoot 588 unless otherwise noted in the description. This table is intended for reference only, not intended 589 to be inclusive of all depot support equipment and software. 590

EQUIPMENT DESCRIPTION

Minuteman PSRE Test Set (MPTS) Tests the electrical and pneumatic functions of the

PSRE

Note: Currently PSRE LEP maintains with a contract to the original equipment manufacturer

Cablemaster Test the electrical functions of the PSRE cables P106 actuator console P106 Actuator component level tests Guided Missile Components Test Stand Performs functional testing of assembled flight control units prior to NHA activities Servocomponents Test Stands Tests the electrical and physical functionality of the

Servocomponents for the flight controls Auxiliary Power Supply Test Stands (APS Test Stands)

Tests the functionality of APSs for the flight controls

Fill and Bleed Test Stands Fills and Bleeds the flight controls Injector Cycling Test Station Test P116A1 injectors Pump Dynamic Test Stands (Dynamic) Tests the functionality of pumps for the flight controls Pump Static Test Stands (Static) Tests the functionality of pumps for the flight controls Static Leak Test Stand Tests the static leak behavior of the flight controls Large Motor Test Stand (Large Customizable Motor Test Stand

(CMTS))

Tests the functionality of the dc motors for flight controls

Small Motor Test Stand (Small CMTS) Tests the functionality of the dc motors for flight controls

Brush Run-in Stands Runs in brushes for the flight control dc motors Shaker Physically shakes flight controls Aqueous Motor Cleaner Cleans flight control motors Self-Test Calibration Adapters (Cal Carts)

Provides calibration capabilities for the test stands in the flight control shop

Spray Flush Booth Cleans flight control components Vapor Degreasers Degreases flight control components ESCTS Explosive Set Circuitry Test Set - Performs electronic tests on cables and ordnance items at the weapon system level in the field

Note: Upgrades and…