Section_J_Attachment_1_PSSC_Performance_Work_Statement.pdf

INTERCONTINENTAL BALLISTIC MISSILE (ICBM)

PROPULSION SUBSYSTEM SUPPORT CONTRACT (PSSC)

PERFORMANCE WORK STATEMENT (PWS)

FOR

AIR FORCE NUCLEAR WEAPONS CENTER (AFNWC)

ICBM SYSTEMS DIRECTORATE (ICBMSD)

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

10 September 2014

TABLE OF CONTENTS

SECTION I - DESCRIPTION OF SERVICES

1.0 SCOPE

1.1 PURPOSE

1.2 BACKGROUND

1.3 FUTURE ICBM SUSTAINMENT AND ACQUISITION CONSTRUCT (FISAC)

DESCRIPTION

1.4 PROPULSION SUBSYSTEM DESCRIPTION

1.4.1 Stage 1

1.4.2 Stage 2

1.4.3 Stage 3

1.4.4 Booster Integrating Hardware/Interstage Hardware

1.4.5 Propulsion System Rocket Engine (PSRE)

1.4.6 Flight Controls

1.4.7 Flight Batteries

1.4.8 Weapon System Ordnance Devices

1.4.9 Propulsion Flight Test Support Equipment

1.4.10 Depot Support Equipment

1.4.11 Modeling and Simulation Table

1.5 APPLICABLE DOCUMENTS

1.6 REQUIREMENTS

1.6.1 Basic Description

1.6.2 Integration

1.6.3 Projected Meetings and Estimated Frequencies

1.6.4 Contractor Manpower Reporting

1.6.5 Program Management Support

1.6.5.1 Risk Management

1.6.5.2 Commercial Small Business Involvement

1.6.5.3 Modification/Replacement/New Requirement Oversight

1.6.5.4 Program Task Management

1.6.5.5 Cost Reporting

1.6.5.6 Management Plan

1.6.5.7 Data Rights

1.6.5.8 Transition

1.6.5.9 Program Administration

1.6.6 Propulsion Subsystem Technical Services Required

1.6.6.1 Sustaining Engineering

1.6.6.1.1 Systems Engineering

1.6.6.1.2 Systems Requirements Determination

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1.6.6.1.3 Nuclear Surety

1.6.6.1.4 Nuclear Control

1.6.6.1.5 Environmental Conditions

1.6.6.1.6 Trade Studies

1.6.6.1.7 Configuration Management (CM)

1.6.6.1.8 Software Support

1.6.6.1.9 Maintenance Support

1.6.6.1.10 Technical Order (TO) Support

1.6.6.1.11 Hardware Support

1.6.6.1.12 System Safety

1.6.6.1.13 Demilitarization and Disposal

1.6.6.1.14 Corrosion

1.6.6.1.15 Emergency Response Support

1.6.6.1.16 Weapon System Interface Control

1.6.6.1.17 Subsystem and End-Item Specifications

1.6.6.1.18 Electromagnetic Radiation

1.6.6.1.19 Nameplates and Product Marking

1.6.6.1.20 Diminishing Manufacturing Sources and Materiel Shortages (DMSMS) .. 39

1.6.6.1.21 Test and Evaluation (T&E)

1.6.6.2 Propulsion Subsystem Assessment

1.6.6.2.1 Technical Risk Assessment

1.6.6.2.2 Availability

1.6.6.2.3 Maintainability

1.6.6.2.4 Nuclear Hardness and Survivability

1.6.6.2.5 Reliability and Accuracy

1.6.6.2.6 Aging Surveillance (AS)

1.6.6.2.6.1 Solid Propulsion AS

1.6.6.2.6.2 Liquid Propulsion AS

1.6.6.2.6.3 Ordnance AS

1.6.6.2.6.4 Flight Controls Assessment

1.6.6.2.6.5 Flight Battery AS

1.6.6.2.7 Subsystem Component

1.6.6.2.8 Assessment Data

1.6.6.2.9 Anomaly Resolution

1.6.6.2.10 Modeling and Simulation

1.6.7 Associate Contractor Agreements (ACA)

1.6.8 Travel

SECTION II – SERVICE SUMMARY

2.0 SUMMARY MATRIX

SECTION III – PROPERTY MANAGEMENT

3.0 PROPERTY MANAGEMENT

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3.1 GOVERNMENT-FURNISHED PROPERTY (GFP) AND SERVICES

3.2 NUCLEAR WEAPONS-RELATED MATERIEL (NWRM)

SECTION IV – GENERAL INFORMATION

4.0 GENERAL INFORMATION

4.1 SECURITY REQUIREMENTS

4.2 QUALITY CONTROL

4.3 QUALITY ASSURANCE

4.4 PHYSICAL SECURITY

4.5 HOURS OF OPERATION

4.6 CONSERVATION OF UTILITIES

4.7 RECORDS

4.8 ENVIRONMENTAL CONTROLS

4.9 GOVERNMENT OBSERVATIONS

4.10 SAFETY REQUIREMENTS

4.11 QUALIFICATIONS

4.12 PARTNERING AGREEMENT (PA)

4.13 ANTITERRORISM CONSIDERATIONS

4.14 CONTINUATION OF ESSENTIAL DOD CONTRACTOR SERVICES DURING

CRISIS IAW Department of Defense Instruction (DoDI) 1100.22

4.15 PUBLICATIONS

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SECTION V - APPENDICES

APPENDIX A: ACRONYMS AND ABBREVIATIONS LIST

APPENDIX B: EXAMPLES OF FUTURE EFFORTS OR PROGRAMS

APPENDIX C: SAFETY, FIRE PROTECTION AND HEALTH SPECIFICATION

APPENDIX D: GOVERNMENT FURNISHED PROPERTY/SERVICES/EQUIPMENT

(GFP/GFS/GFE)

APPENDIX E: WORK BREAKDOWN STRUCTURE

APPENDIX F: APPLICABLE DOCUMENTS

APPENDIX G: CONTRACT DATA REQUIREMENTS LIST (CDRL)

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SECTION I - DESCRIPTION OF SERVICES

1.0 SCOPE

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

1.1 PURPOSE

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

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

1.2 BACKGROUND

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

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

The PSSC contractor will assist the Government in its performance of tasks to maintain the weapon system. Contractor assessment operations will be required to conduct materials and subcomponent analysis and test, including aging surveillance test and evaluation. The primary

Page | 1 focus will be to identify aging mechanism, anomalous behavior, and ensure any modifications or changes to the system will maintain and/or improve system-level performance.

1.3 FUTURE ICBM SUSTAINMENT AND ACQUISITION CONSTRUCT (FISAC)

DESCRIPTION

1.3.1 FISAC Structure

The Government has prepared a sustainment concept to ensure a safe, secure, and reliable MMIII ICBM Weapon System through 2030 and disposal. This FISAC replaced the ICBM Prime Integration Contract (IPIC). The FISAC structure and its relationship to the Propulsion Subsystem are described in Figure 1:

Figure 1. FISAC Structure

1.3.1.1 PSSC Contractor/ICBMSD Relationship

The contractor shall perform the subsystem(s) functions shown in Figure 2 and described in this PWS. The contractor will provide the Government with technical expertise. The PSSC contractor will assist the Government in fulfilling its role as the Propulsion Subsystem manager by performing sustaining engineering, maintenance engineering, aging surveillance, modification of systems and equipment, software maintenance, developmental engineering, production engineering, and procurement of Propulsion Subsystem components and related support equipment. The PSSC contractor will provide breadth and depth of capabilities for the elements listed in the Work Breakdown Structure (WBS), Appendix E, across the Propulsion Subsystem.

This contract will be flexible and allow for adjustments to the contractor workforce to gain efficiencies based on the changing requirements, policy, realities of the industrial base, and the Government’s capability to support MMIII.

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Figure 2. FISAC Component Functions

1.3.1.2 ICBMSD/PSSC/ISC Contractor Relationship

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

In order to competently and conscientiously support the MMIII, the Air Force (AF) requires its contractors and their subcontractors to effectively share information concerning the status of programs and technical issues with the weapon system. This communication will need to occur with the Government and among other support contractors to the maximum extent consistent with proper protection of classified and/or other sensitive information. To achieve this, the PSSC contractor will have appropriate Non-Disclosure Agreements (NDA) with other contractors and subcontractors as applicable and demonstrate the ability and willingness to communicate openly. The ISC contractor will only provide contractual direction to its subcontractors. Likewise, the PSSC contractor shall only provide direction to its subcontractors.

See Figure 1.

ICBM Systems Directorate Function: Weapon System Integrator

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1.3.2 PSSC Contractor and Other Subsystem Contractors

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

1.3.3 Technical Council

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

1.3.3.1 Government Members

Director, ICBMSD (Chair); Director of Engineering (Alt Chair); Chief Engineer, ICBM Flight Systems; Chief Engineer, ICBM Ground Systems; Technical Director, ICBM Systems Engineering; and Senior Engineer, ICBM Future Systems. Representatives from the following organizations will also be included: 748th Supply Chain Management Group (SCMG); Air Force Global Strike Command (AFGSC) (HQ/OL-J); Air Force Nuclear Weapons Center (AFNWC)/Engineering and Technical Management Directorate (AFNWC/EN);

AFNWC/Logistics Directorate (AFNWC/LG);AFNWC/Intelligence and Capabilities Integration Directorate (AFNWC/XR); AF Program Executive Officer, Strategic Systems (AFLCMC/SS);

309th Maintenance Wing; and others as determined appropriate by the ICBMSD.

1.3.3.2 Associate Government Members

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

1.3.3.3 Contractor Primary Members

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

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1.3.3.4 Associate Contractor Members

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

1.3.3.5 Ground Rules

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

1.4 PROPULSION SUBSYSTEM DESCRIPTION

The PSSC technical scope includes all Propulsion Subsystem components described in Section 1.4; all associated depot support equipment, including test stands and associated software;

maintenance and test fixtures; and all associated technical data.

The MMIII Propulsion Subsystem is the aerospace vehicle less the Reentry System/Reentry Vehicle (RS/RV) and Guidance Subsystem. The Propulsion Subsystem consists of the Propulsion System Rocket Engine (PSRE) and Propulsion Unit Subassembly (booster) that is comprised of three solid rocket motors, two interstages, an aft skirt, and a raceway system and cover system, plus all the control equipment for the nozzles and safing devices; it also includes weapon system ordnance devices and flight batteries.

Additional component descriptions are provided in subsequent paragraphs.

1.4.1 Stage 1

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

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1.4.2 Stage 2

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

1.4.3 Stage 3

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

1.4.4 Booster Integrating Hardware/Interstage Hardware

The MMIII booster integrating and interstage hardware consists of Stage 1-2 and 2-3 interstage body sections and related hardware, the interstage separation and skirt removal ordnance and its raceway interconnections.

1.4.5 Propulsion System Rocket Engine (PSRE)

The PSRE is a self-contained, prepackaged, liquid bipropellant rocket propulsion system that provides the thrust capability to deploy the MMIII RV. The PSRE is capable of providing precise, on command, vehicle velocity increments to the post-boost vehicle. The PSRE uses a hypergolic mixture of di-nitrogen tetroxide (N2O4) as the rocket oxidizer and monomethyl hydrazine (MMH) as the rocket fuel. The oxidizer and fuel are independently stored in two propellant storage assemblies.

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

1.4.6 Flight Controls

1.4.6.1 P89A1 Stage 1 Nozzle Control Unit (NCU)

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

1.4.6.2 P90A1 Stage 2 Attitude Control Group

The P90A1 Stage 2 Attitude Control Group is used to change position of four pintle valves that control injection fluid flow to obtain LITVC of missile attitude in pitch and yaw. The unit, operating in conjunction with the missile guidance system, provides a closed loop position servo for positioning the Stage 2 pintle valves. The control group assembly consists of the following

Page | 6 major components: two hydraulic auxiliary power supplies, four servo injectors, and one roll amplifier assembly.

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

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

1.4.6.4 Raceway Cables and Conduit Support Set

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

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

1.4.7 Flight Batteries

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

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

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

1.4.7.2 Static Random Access Memory (SRAM) Battery

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

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1.4.7.3 Missile Guidance Set (MGS) Battery

The SE-437C battery provides power to the MGS, PSRE, Stage 1, Stage 2, and Stage 3 flight control units and the RS. The SE-437C battery connects to the NS-50A power distribution unit with a 9W05Z adapter cable. The battery consists of 20 silver-zinc cells and has a nominal loaded output of 28V and a capacity of over 20 amperes hour.

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

The Mk21 SSR battery is a remotely activated lithium-aluminum/iron-disulfide thermal battery.

It is located in the aft end of the Mk21 fuze and provides regulated direct-current voltages to the central power conditioner (CPC), as well as various SSR functions during the final phase of the MMIII mission flight. The thermal battery has two independent activation circuits and six outputs, and is started by applying an activation pulse to one or both of the activation circuits.

The six sections are a nominal 40V, 38V, 15V, 9V, -6V and -15V. The battery output remains active, as long as the temperature remains within a range to keep the electrolyte in a molten state and there is sufficient active material in the positive and negative electrodes.

1.4.7.5 Mk21 Arming and Fuzing Assembly (AFA) Battery

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

1.4.7.6 Mk12A AFA Battery

The Mk12A AFA battery provides power to the RV arming and fuzing assembly and is activated following launch of the MMIII missile. The current force configuration consists of Mk12A RVs, containing an AFA battery that is known as the Mk12A battery. The battery consists of 22 silver zinc cells, is a nonrechargeable, reserve design, and activation is accomplished by a self-contained, single squib-activated, gas generator system.

1.4.7.7 Operational Test Batteries

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

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1.4.7.7.1 Premature Stage Separation (PSS) Battery

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

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

1.4.7.7.2 Telemetry Battery

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

1.4.7.7.3 Global Positioning System (GPS) Battery

The GPS battery is a manually activated, secondary (rechargeable), silver-zinc battery that powers the GPS metric tracking system. The battery contains 18 cells and is activated manually by adding KOH electrolyte into the cells (gas generators are not used to inject electrolyte into the battery). The battery has a nominal voltage output of 28V and a design capacity of 1.2 ampere hour. The battery is capable of meeting performance requirements after a 60-day wet stand.

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

1.4.7.7.4 Command Destruct (CD) Battery

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

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

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1.4.8 Weapon System Ordnance Devices

The MMIII utilizes a number of ordnance devices during flight and test operations. These devices do not include the nuclear warhead managed through the Department of Energy (DOE).

1.4.8.1 Launch Facility Ordnance (LFO)

The current MMIII system employs 4 types of ordnance items within each Launch Facility.

Those items are the Launcher Closure Ballistic Gas Generator, Umbilical Disconnect Cartridge, Umbilical Retract Actuator Cartridge, and the Suspension System Explosive Bolt.

1.4.8.1.1 Launcher Closure Ballistic Gas Generator (BGG)

The BGG provides pressure, in the form of hot gases, to drive an actuator that removes the launcher closure door from the silo before missile launch. The BGG detonator contains boron/potassium nitrate (BKNO3) with two redundant ES-003/Mk2 MOD 0 squibs for initiation of the ammonium nitrate-based propellant grain in the BGG cartridge. A replacement gas generator is projected in the near future.

1.4.8.1.2 Umbilical Disconnect Cartridge

The umbilical disconnect cartridge shears a pin to disconnect the upper umbilical cable from the missile just before launch. Only one cartridge is used per missile. The cartridge has three pins and two bridge-wires for redundancy. One pin is a common ground for the two bridge-wires.

The cartridge contains a primer mix and main charge.

1.4.8.1.3 Umbilical Retract Actuator Cartridge

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

1.4.8.1.4 Suspension System Explosive Bolt

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

0.5 inch.

1.4.8.2 Reentry System Reentry Vehicle (RS/RV) Ordnance

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

1.4.8.2.1 Mk12A Spin Gas Generator

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

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1.4.8.2.2 Mk12A Spin Gas Generator Initiator

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

1.4.8.2.3 Mk21 Rear Cover Assembly

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

1.4.8.2.3.1 Mk21 Spin Gas Generator

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

1.4.8.2.4 Mk21 Delay Initiator

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

1.4.8.2.5 Shroud Rocket Motor

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

1.4.8.2.6 Shroud Rocket Motor Initiator

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

1.4.8.2.7 Thruster Bolt Impulse Cartridge

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

1.4.8.2.8 Ball Lock Impulse Cartridge

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

1.4.8.3 Solid Rocket Motor Ordnance Components

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

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1.4.8.3.1 Igniter Safe/Arm Device

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

1.4.8.3.2 Circumferential and Longitudinal Detonation Cord

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

1.4.8.3.3 Detonators

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

1.4.8.3.4 H-Boosters

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

1.4.8.3.5 Time Delays

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

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

1.4.8.3.6 Mechanical Safe/Arm Devices

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

1.4.8.3.7 Arm/Disarm (A-D) Switch

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

1.4.8.3.8 All Ordnance Thrust Termination System (AOTTS)

The AOTTS consists of multiple ordnance components that initiate thrust termination for the Stage 3 motor.

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1.4.8.3.9 Arm-Disarm and Safe-Arm (AD&SA)

The AD&SA provides the safing and arming function for the AOTTS detonators, the roll control gas generator (RCGG) igniter initiator, and the LITVC squib-actualed valve .

1.4.8.3.10 ES-003 Squib

The ES-003 squib converts an electrical signal to a explosive force to initiate multiple ordnance devices.

1.4.8.4 Liquid Propulsion Ordnance Components

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

1.4.8.4.1 Pyrocartridge

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

1.4.8.4.2 Ordnance Module

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

1.4.8.5 Unique Operational Test Ordnance

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

1.4.8.5.1 All Ordnance Destruct System (AODS)

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

1.4.8.5.2 Modular Mechanical Ordnance Destruct System (MMODS)

The MMODS is installed at the test range to provide a reliable method for in-flight missile destruction. The system is mainly a modular mechanical system, relying on lanyard actuated devices to sever the pressure vessels and render them non-propulsive. MMODS consists of linear shaped charges, a Pull Actuated Device System (PADS), and CD safe/arm devices.

1.4.9 Propulsion Flight Test Support Equipment

ICBM flight tests are scheduled three to four times each year and are conducted by the AF’s cognizant flight test authority at VAFB. Various flight and non-flight components are necessary to support this effort in addition to the AODS and MMODS ordnance systems described in

Page | 13

Sections 1.4.8.5.1 and 1.4.8.5.2. Technical Order (TO) 21M-LGM30F-4-1-1 describes each of the parts listed below in additional detail (TO Figure reference in parenthesis). This table is intended for reference only, not intended to be inclusive of all flight test support equipment:

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

1.4.10 Depot Support Equipment

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

EQUIPMENT DESCRIPTION

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

PSRE

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

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EQUIPMENT DESCRIPTION

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 functionality of pumps for the flight controls Pump Static Test Stands (Static) Tests 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 Explosive Set Circuitry Test Set

(ESCTS)

- Performs electronic tests on cables and ordnance items at the weapon system level in the field

Note: Upgrades and Mods to software and or redesign efforts to support new assets, as well as technical support for failures and anomalies

Safety and Arming Test Set Performs electrical check out of Ordnance Safe and Arm Devices

Note: Upgrades and Mods to software and or redesign efforts to support new assets, as well as technical support for failures and anomalies

Ordnance AS test fixtures AS testing fixtures to include: Closed Bombs, Shock and Vibe Plates, Cables, Mounts

Note: Design changes, Fixture Surveys, Structural Analysis

Guided Missile Test Set Performs tests the MM booster and rocket motors, including functional and final acceptance testing of all circuits and flight control functions

Electrical Cable Test Set Performs continuity check on MM rocket motors Raceway Cable Test Set Performs cable checks to identify functionality and validate repairs Pressure Transducer Test Set Tests solid rocket motor pressure transducers Roll Control Valve Test Set Tests solid rocket motor roll control valve functionality Motor Leak Test Set Tests solid rocket motor chamber ability to hold static pressure

Table 2. Depot Support Equipment

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1.4.11 Modeling and Simulation Table

The PSSC contractor will maintain the ability to develop, maintain, run, and update models in support of ICBM Propulsion systems sustainment. The following is a current list of models used for ICBM sustaining engineering and engineering assessment activities.

Model Description

Propulsion Model Contains equations and propulsion performance data for the boost and post-boost phases of flight. Derives system performance for software and simulation studies.

Mass Properties Model

Contains equations to compute center of gravity, instantaneous mass, and inertia tensors transformation relations. Derives sequential mass properties for system performance models - these models contain mass properties data for the various missile configurations.

Multiple Independently Targeted Reentry Vehicle Single Reentry Vehicle Propulsion Replacement Program (PRP) PRP/Safety Enhanced Reentry Vehicle

(SERV)

Propulsion System Rocket Engine (PSRE)

Boost Aerodynamics Model

Contains equations and data required to calculate MMIII aerodynamic forces acting on missile during flight.

Control System Model -

GRP

Contains algorithms and data used for boost Thrust Vector Control (TVC) and roll control systems and post boost TVC system performance calculations for missile pitch, yaw, and roll.

Separation Model Contains lateral impulse data for 1-2 and 2-3 staging events, axial separation velocity for stage 3/PBV separation, and skirt jettison timing for stages 2 and 3.

Structural Dynamics Model

Used to determine missile control bending data.

Documents MMIII stiffness and mass properties and data sources. Also documents NASTRAN digital files on tape and disk of various substrates.

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Model Description

Thermal and Structural Models

Used to determine the thermal and/or structural condition of Propulsion items to include (but not limited to) solid propellant grain, motor cases (metal and composite), stage structural hardware, pressure vessels, inter-stage hardware, component mounting hardware, and nozzle components.

Internal Ballistics Models

Used to determine the internal operational characteristics of Propulsion components such as solid rocket motors, gas generators, igniters, and initiator assemblies.

Propellant Residual Model

Defines/Contains Stage 3 propellant reserve (for Stage 3, including the Management Reserve) and PSRE performance reserve to meet the targeting performance reliability of 97P/90C.

Boost Steering Model Contains algorithms and data used to determine stages 1 and 2 steering coefficients and sequencing coefficients (K1, K2).

Pitch Steering and Staging Coefficients Model

Contains stages 1 and 2 steering coefficients K24 through K32 and K39. Classified.

Propulsion Parameter Perturbations Model

Contains the propulsion perturbation data required for Monte Carlo and off-nominal analyses.

Mass Properties Perturbation Model

Contains mass property perturbation data required for Monte Carlo and off-nominal analyses.

Aerodynamics Perturbation Model

Contains aerodynamic perturbation data required for Monte Carlo and off-nominal analyses.

Bending Mode Tolerances

Contains control bending mode data required for Monte Carlo and off-nominal analyses. Results in bending mode tolerances.

Thrust Misalignment and Offset Data

Contains thrust vector misalignment and offset data required for Monte Carlo and off-nominal analyses of booster and post boost propulsion systems.

Table 3. Model List

1.5 APPLICABLE DOCUMENTS

Compliance and reference documents related to specifications, standards, handbooks, regulations, instructions, and applicable to the work required in the performance of this contract are listed in APPENDIX F: APPLICABLE DOCUMENTS. The documents in Appendix F form a part of this PWS to the extent specified. In the event of conflict between the document referenced and contents of this PWS, the PWS shall be considered a superseding requirement. If

Page | 17 vendors are knowledgeable of critical documents or requirements not listed in this draft PWS, it is expected they inform the Government to ensure adequate coverage.

The contractor shall comply with the current versions of compliance documents unless specifically exempted by the Government.

1.6 REQUIREMENTS

The requirements in this section are intended to describe the capabilities necessary to sustain the weapon system and encompass the scope of effort expected to be executed for this contract.

Capabilities may be applied to future programs, technology insertion, major modifications, integration, or requirements definition for a follow-on system. Use of the PSSC capabilities for future Propulsion-related efforts would be incorporated as new Contract Line Item Numbers (CLIN) on the contract as the tasks and/or funds are identified and available.

1.6.1 Basic Description

1.6.1.1 The PSSC contractor shall support the Government in their effort to integrate and coordinate all activities necessary to assess, report, and sustain the operational capability and reliability of the ICBM Propulsion Subsystem through 2030 and disposal.

1.6.1.2 The PSSC contractor shall support the Propulsion IPT(s). The PSSC contractor will provide this support at the individual Propulsion IPT level and will support the Government who is responsible for weapon system-level engineering and program management support.

1.6.1.3 The PSSC contractor shall support the Government in the following functional areas:

Program Management Support, Technical Services, assessment operations, and all corresponding Assess-Fix-Buy activities required for the subsystem that are not accomplished on a different contract or by an organic entity outside the ICBMSD.

1.6.1.4 The PSSC contractor shall coordinate with the Government and Directorate Security Manager to ensure its personnel attain appropriate access levels to the applicable information systems. Access to Government information systems shall be restricted to PSSC contractor personnel requiring access to accomplish their PSSC responsibilities.

1.6.1.5 The PSSC contractor shall coordinate their activities for the purpose of integration with the 748 SCMG, Global Ammunition Control Point (GACP), the 309th Missile Maintenance Group (MMXG), the 75th Air Base Wing (ABW), Department of Defense (DoD) and Department of State (DOS) agencies, the Department of Transportation (DOT), the DOE, the National Aeronautics and Space Administration (NASA), Missile Defense Agency (MDA), and other Government agencies as required.

1.6.2 Integration

1.6.2.1 The PSSC contractor shall support and staff all subsystem integration efforts by performing the following activities: assessing and managing requirements changes; addressing and documenting internal and external interfaces; designing, testing, and integrating hardware and software, and accomplishing the associated documentation changes; accomplishing all

Page | 18 associated verification and validation activities, as directed by the Government; and supporting integration working group meetings as defined elsewhere in the PWS.

1.6.2.2 The PSSC contractor shall collaborate with the Government, ISC contractor, Partial Bridge Contract (PBC) contractor, and all other subsystem contractors to include new start acquisition contractor(s), e.g., the ICBM Fuze Modernization Program contractor, in the process of ensuring full compatibility with the subsystem and the weapon system.

1.6.2.3 The PSSC contractor shall assess all modifications to include replacements, life extensions, and any changes proposed by the contractor or their subcontractors for any potential integration impact(s) on the subsystems and/or the weapon system as a whole.

1.6.2.3.1 The PSSC contractor shall ensure assessment and analysis of modifications are accomplished using Government integration processes as defined in the following ICBMSD documents as guidance: ICBMSD Operating Instruction (OI) 62-08, Requirements Validation Board, ICBMSD OI 63-19, Data Management, and all other relevant systems integration guidance that may apply at a future date.

1.6.2.3.2 The PSSC contractor shall proactively engage with the Government, ISC contractor, other subsystem contractors, and those contractors awarded future modification efforts to ensure any proposed modifications will have no negative impact on the subsystem or the weapon system as a whole.

1.6.2.3.3 The PSSC contractor shall establish NDAs with the ISC contractor and the other subsystem and acquisition contractors, as required, to enable successful integration efforts.

1.6.3 Projected Meetings and Estimated Frequencies

The following are projected meetings (not all inclusive) and estimated frequencies:

MEETING FREQUENCY PWS REFERENCE

Technical Council Minimum semi-annual and maximum quarterly

PWS 1.3.3

Program Management Reviews

Quarterly or as indicated in PWS Section II

PWS SECTION II –

SERVICE SUMMARY

Reliability Scoring Panel

Semi-Annual PWS 1.6.6.2.5

Technical Interchange Meetings

As required PWS 1.6.6.1.1.5

Corrosion Prevention Advisory Board

As required PWS 1.6.6.1.9

Launch Anomaly Group

As required PWS 1.6.6.2.9

Task Log Review (Management Review)

Quarterly PWS 1.6.5.4.3

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MEETING FREQUENCY PWS REFERENCE

Interface Control Working Group

As required PWS 1.6.6.1.16.2

DMSMS Working Group

Monthly PWS 1.6.6.1.20

Material Review Boards

As required PWS 1.6.6.1.9

Configuration Control Board (CCB)

- Technical Evaluation Review Board

(TERB)

Preliminary meetings to support CCBs

As required

- Weekly meetings, contractor would only be required on an as-requested basis

PWS 1.6.6.1.7.1.1

Product Improvement Working Groups

Twice annually PWS 1.6.6.1.9

Subsystem IPT Meeting

Weekly PWS 1.6.1.2, 1.6.5.4.1

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MEETING FREQUENCY PWS REFERENCE

Nuclear Surety:

ICBMSD System Engineering, Environment, Safety & Technical Data (NIEV) Safety IPTs

ICBM Nuclear Surety Working Group

(NSWG)

Air Force Nuclear Weapon System Safety Groups

(NWSSG)

ICBM Project Officers Working Group (POG)

Nuclear Security Working Groups

ICBM Codes Conference

Monthly

Quarterly

Minimum Once Every 3 Years, Program Could Trigger Additional Meetings

Annually

PWS 1.6.6.1.3

System safety support:

Program IPTs

Safety IPTs

ICBM POG

Weekly

Monthly

PWS 1.6.6.1.12.1

Risk Management Boards

Monthly PWS 1.6.5.1

Table 4. Projected Meetings and Estimated Frequencies

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1.6.4 Contractor Manpower Reporting

1.6.4.1 The contractor shall report all contractor labor hours (including subcontractor labor hours) required for performance of services provided under this contract for the PSSC via a secure data collection site. The contractor is required to completely fill in all required data fields at http://www.ecmra.mil.

1.6.4.2 Reporting inputs will be for the labor executed during the period of performance for each Government fiscal year (FY), which runs 1 October through 30 September. While inputs may be reported any time during the FY, all data shall be reported no later than 31 October of each calendar year. Contractors may direct questions to the Contractor Manpower Reporting Application (CMRA) help desk.

1.6.5 Program Management Support

1.6.5.1 Risk Management

1.6.5.1.1 The PSSC contractor shall provide standardized risk assessment and management functions through the Government, utilizing techniques consistent with the Government’s most current risk management process, reference ICBMSD OI 62-10, Risk Management.