Attachment 2 - Amend 2_ FA8307-25-R-B023 Statement of Objectives.pdf

Statement of Objectives

“ARMECH”

Atmospheric Research Mission Equipment Case and Handling

28 January 2025 Version 1.3

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Points of Contact

Project Lead:

Jerry Perkins Technical Applications Products Ronald.perkins.4@us.af.mil

Contracting Officer:

Rebecca Natal

HNCKA

Rebecca.natal.1@us.af.mil

Alternate Project Lead:

Joseph Herring Technical Applications Products Joseph.herring.1@us.af.mil mailto:Ronald.perkins.4@us.af.mil mailto:Rebecca.natal.1@us.af.mil mailto:Joseph.herring.1@us.af.mil

1. Executive Summary

2. Glossary of Terms

3. Applicable Documents

4. Background Context

4.1. Gas Collection System, Mission Equipment Context

4.2. Mission Activity Context

5. Programmatic Strategy

5.1. Schedule

5.2. Data Rights and Content

5.3. Cost Structure

5.4. Contract Line-Item Number(s)

5.5. Government Furnished Items

5.6. Travel and Meetings

6. Project Scope

7. Design Guidance

7.1. Mechanical Interface Control Document (MICD)

7.2. Retention

7.2.1. Retention of the COPV within Case

7.2.2. Retention to GCS Rack

7.3. Mass

7.4. Materials

7.5. Manufacturability

8. Requirements Matrix

9. Work Breakdown Structure

10. Statement of Objectives (SOO)

11. Shipping Information

1. Executive Summary

Technical Applications Products (TAP), Department of the Air Force (DAF), (heretofore “the Government”), requires the development of a solution, Atmospheric Research Mission Equipment Case and Handling (ARMECH) to interface 900 cubic inch Composite Overwrapped Pressure Vessels (COPVs) with pre-existing Gas Collection System (GCS) mission equipment onboard the WC-135 aircraft.

The overall scope of ARMECH is to design, prototype, and fabricate at least 250 cases and up to 144 GCS rack interfaces, if required. ARMECH is intended to provide limited environmental protection for individual COPV’s and include features, such as handles or tie-points, that will support improved handling onboard the aircraft in-flight and bulk shipment and storage activities on the ground. The ARMECH solution must support air and/or over-the-road transport of the COPVs on a pallet containing at least 27 units.

Prior to the acquisition of the Composite Overwrapped Pressure Vessels (COPVs), the Government deployed 900 cubic inch, stainless steel, spherical pressure vessels. These legacy spherical vessels are of an obsolete design and specification. Due to high manufacturing costs, a suitable replacement pressure vessel, the COPV, was sought and acquired.

The Gas Collection System, or GCS, rack was designed to secure two 900 cubic inch spherical pressure vessels housed in cases resembling cubes in each “bay”. This effort will produce a solution to insert two

(2) COPVs into each rack “bay” and physically secure the COPV’s during flight operations. The GCS rack shall not be modified to interface the ARMECH solution and may require the design, prototype, and fabrication of interface assemblies between the COPV case and the GCS rack.

Figure 1: Palletized Spheres

Figure 2: GCS Rack

Figure 3: GCS Rack Pressure Vessel “bays”

Figure 4: Sphere

Figure 5: Sphere in “Cubic”

Case

Figure 6: COPV

2. Glossary of Terms

Terminology used in this document include, but is not limited to, those terms defined in Table 1 below:

Table 1: Glossary of Terms

Term Definition 463L The HCU-6/E or 463L Master Pallet is a standardized pallet used for transporting military air cargo.

ARMECH Title of Effort. Atmospheric Research Mission Equipment Case and Handling. Scope includes the COPV case and interface to the GCS rack.

ATP Authorization to Proceed. This is a formal communication that authorizes the Contractor to continue to the next WBS item. If the Contractor proceeds on the WBS schedule without the ATP, then Contractor assumes financial risk for those activities.

CLIN Contract Line-Item Number. A line item captures the information about separately identifiable goods and services that the Government needs to purchase (See FAR 2.101), and a Line-Item Number (LIN) is the numeric or alphanumeric format to identify a line item.

COA Course of Action. Path(s) taken to achieve the desired end-state.

COPV Composite Overwrapped Pressure Vessel. A 900 cubic inch, 3000

PSI pressure vessel design was selected to support the WC-135 Constant Phoenix mission in 2022, with the legacy spherical vessels planned for obsolescence.

DFM Design for Manufacture. An engineering practice that involves designing products to be easier to manufacture, which can lead to lower costs and better products. The goal of DFM is to make products more cost-effective and easier to produce by simplifying, optimizing, and refining the design.

FAR Federal Acquisition Regulation. Public document that defines the terms of Government contracting.

GAT Government Airworthiness Team. Government Team that is comprised of Airworthiness Authorities and 3rd Party Technical Evaluators.

GCS Gas Collection System. Mission Equipment that collects atmosphere during flight and compresses the atmospheric gases. The GCS stores the compressed samples in the COPV(s) for analysis.

GPT Government Program Team. Government Team that is comprised of Program Leads, the Contracting Officer (KO), and Government Subject Matter Experts (SMEs).

KO Contracting Officer. Individual assigned as the official point-of-contact for all matters regarding the disposition of funds and the extent of contractual scope for this effort. Only the KO can authorize a change of scope, funding, or issue an Authorization to Proceed.

Physical Engineering Model Pre-Production Prototype. A 1:1 scale geometric model constructed from dimensionally stable materials that support the physical fitting and verification of design features. The PPP is not required to be constructed from materials anticipated in a production unit (e.g. it may be 3D printed) but is required to geometrically match the proposed design and include functional material surrogates for features critical to the operation of the unit (e.g. latches, etc.).

PRR Production Readiness Review. The PRR is a meeting that evaluates the tooling design, manufacturing plan, and acceptance test criteria prior to the fabrication or manufacture of a first article or production quantity.

RCI Rack-Case Interface. A socket that may remain with the GCS rack and secures the SVC while in flight. Modifying the GCS rack to interface with the SVC is unacceptable within the scope of this effort.

SIL System Integration Lab. GCS mission equipment configured identically to mission equipment onboard the WC-135R, located at JBSA Lackland and maintained by TAP.

Sphere Spherical Pressure Vessel. 900 cubic inch legacy pressure vessel in use since the 1960's, featuring a semi-spherical design and manufactured from stainless steel. High manufacturing costs and high-risk lot acceptance criteria created the impetus to pursue the

COPV.

SVC Single Vessel Case. Proposed case for a single 900 cubic inch COPV and high-pressure valve assembly. For the purposes of defining features for the design, the SVC should be understood to contain a COPV assembly and 3000 psi pressurized atmosphere.

TAP Technical Applications Products. Air Force Life Cycle Maintenance Center (AFLCMC) Depot Maintenance Engineering Group charged with provided engineering and sustainment services to the WC-135R mission.

TDP Technical Data Package. Further defined in applicable document

MIL-STD-31000.

WC-135R Constant Phoenix Mission Aircraft. A special-purpose aircraft derived from the Boeing C-135 Stratolifter and used by the United States Air Force. Its mission is to collect samples from the atmosphere for the purpose of detecting and characterizing radiological phenomenon.

3. Applicable Documents

Applicable documents for this effort include, but are not limited to, those listed in Table 2 below:

Table 2: Applicable Documents

Document ID Document Title Revision DOT-CFFC Basic Requirements for Fully Wrapped Carbon-

Fiber Reinforced Aluminum Lined Cylinders

(DOT-CFFC)

Electronic/Web

Federal Acquisition Regulation Federal Acquisition Regulation Website Electronic/Web IEC 60529 Degrees of protection provided by enclosures

(IP Code) Electronic/Web

MIL-HDBK-310 Global Climatic Data for Developing Military Products

Electronic/Web

MIL-STD-31000 Technical Data Packages Electronic/Web MIL-STD-810 Environmental Engineering Considerations and

Laboratory Tests Electronic/Web

NIOSH Applications Manual Applications Manual for the Revised NIOSH Lifting Equation

Electronic/Web

SAE-AMS-STD-595 Colors Used in Government Procurement Electronic/Web 1-COPV-001 Composite Overwrapped Pressure Vessel, 900

Cubic Inches, with Hand Valve, Assembly of A

GCS-MICD-001 Mechanical Interface Control Document, Pressure Vessel Bay, Gas Collection System

A

TO 42E1-1-1/NAVAIR 01-1A-20 Aviation Hose and Tube Manual 0 https://www.phmsa.dot.gov/sites/phmsa.dot.gov/files/docs/technical-resources/55751/basic-requirements-fully-wrapped-carbon-fiber-reinforced-aluminum-lined-cylinders.pdf https://www.phmsa.dot.gov/sites/phmsa.dot.gov/files/docs/technical-resources/55751/basic-requirements-fully-wrapped-carbon-fiber-reinforced-aluminum-lined-cylinders.pdf https://www.phmsa.dot.gov/sites/phmsa.dot.gov/files/docs/technical-resources/55751/basic-requirements-fully-wrapped-carbon-fiber-reinforced-aluminum-lined-cylinders.pdf https://www.acquisition.gov/sites/default/files/current/far/pdf/FAR.pdf https://webstore.iec.ch/en/publication/2452 https://webstore.iec.ch/en/publication/2452 https://quicksearch.dla.mil/qsDocDetails.aspx?ident_number=202658 https://quicksearch.dla.mil/qsDocDetails.aspx?ident_number=202658 https://quicksearch.dla.mil/qsDocDetails.aspx?ident_number=276980 https://quicksearch.dla.mil/qsDocDetails.aspx?ident_number=35978 https://quicksearch.dla.mil/qsDocDetails.aspx?ident_number=35978 https://stacks.cdc.gov/view/cdc/110725 https://stacks.cdc.gov/view/cdc/110725 https://www.sae.org/standards/content/amsstd595a/

4. Background Context

The intent of this section is to provide a summary of the technical systems, interfaces, and challenges addressed in this document. The Government may provide additional information, host in-person visits to available equipment, and/or provide equipment as determined per contractual requirements.

Figure 7: Aircrew Returning from Sampling Mission

4.1. Gas Collection System, Mission Equipment Context

The Gas Collection System (GCS) is a system designed to collect whole air samples and store these samples in pressure vessels for post-analysis of suspected radiological material. The system is comprised of two (2) compressors that draw air in to the GCS through the engine intake, pressurize it to 3000 psi, and direct the filling of specific pressure vessels through a computer controlled valve-manifold subsystem. The timing of these fills is important, as it directly relates to the location, speed, and altitude of the aircraft. The fill rate is defined by pre-established flight mission profiles and cannot be altered.

Figure 8: SIL GCS Manifold

Figure 9: SIL GCS Rack with Empty “Bays”

Figure 10: GCS Compressor

The legacy pressure vessels are 900 cubic inch, stainless steel, “spheres”. They were manufactured using a hot-press forming operation to shape plate stainless steel alloy into a hemisphere that is subsequently post-machined to provide a weld-notch and flat-facing-interface with the opposing hemisphere. One hemisphere is drilled with an aperture to weld a boss that provides the threadwell for a valve assembly. The two hemispheres are circumfrentially welded together, inspected, and assembled into roto-molded “cubic” case with the aforementioned valve assembly attached to the sphere. This roto-molded case is approximately 15” on each side and provides two (2) spring-loaded handles for transloading activities, see Figure 11. The upper and lower components of the case are held together by straps. A single “sphere” and associated components (e.g. valve, case, straps) weigh approximately 55 lbs. The GCS “rack” was designed to constrain two (2) of these spheres (in their cases) back-to-back relative to the center aisle of the WC-135 cabin (see Figure 13).

Figure 11: Sphere Case, Complete

Figure 12: Sphere in Case

Figure 13: WC-135 GCS

The pressure vessel design intended to supercede the legacy “spheres” is a Composite Overwrapped Pressure Vessel (COPV) (see Figure 14, Figure 15). Additional geometric dimensioning and tolerancing This pressure vessel resembles a SCUBA tank, and is at least an order-of-magnitude lower cost to produce per-vessel. However, the GCS “rack” was designed for the “spheres” in their “cubic” cases. Thus, the principal scope of this effort is to develop a case for the COPV that interfaces with the existing GCS rack.

Figure 14: COPV Parametric Model

Figure 15: COPV Product

4.2. Mission Activity Context

Prior to a mission, the aircrew prepares at least forty-eight (48) pressure vessels. These vessels arrive to the aircraft equipment staging area on a pallet (commercial or 463L) from the Mission Equipment Depot with a quantity of at least 27 “spheres” per pallet (loaded in a 3x3x3 stack, see Figure 16). The equipment checkout procedure includes verifying that the vessel has a current inspection/pressure rating. This is accomplished on the “spheres” by opening the “cubic” case and visually confirming the date stamp for pressure rating, thus requiring a window or aperture in the case to verify the inspection label on the COPV.

The aircraft is then manually loaded with the empty pressure vessels plus an indeterminate quantity of spares. These vessels may be loaded through a man-door on either side of the aircraft, a cargo door located on the port side forward of the wing (see Figure 17) , or the crew entry chute via a ladderwell behind the pilot seat (see Figure 18), thus requiring the minimal cross-sectional area possible, in addition to hand-holds or handles, to support ease-of-transloading. The crew entry chute presents the most challenging transloading activity, as the distance from the cabin deck to the ground exceeds 12 feet, and the trapdoor aperture is approximately 24 inches by 24 inches. Once onboard, these vessels are secured into the GCS “rack” by inserting the pressure vessels into numbered “bays” and latching them with two sliding “keepers” (see Figure 19).

Figure 16: Palletized Spheres

Figure 17: WC-135 Cargo Door

Figure 18: WC-135 Crew Entry Chute

Figure 19: Sliding Latches/Keepers on each GCS Rack “Bay”

During the flight mission, the aircrew selects the specific bay and begins the pressurization activity by initializing the compressors and computer-controlled valve manifold subsystem. Once a pressure vessel has been filled, the aircrew closes the computer-controlled manifold and selects an unfilled vessel to continue the mission. The filled containers are notated with the associated telemetry (e.g. location, speed, heading, altitude, etc.) and the valve is physically locked shut, thus requiring hand-access to the valve dial during flight. Spares may be used in a scenario where significant collection must be made during a single flight, or to provide up to an additional compliment of vessels for a subsequent flight. Other scenarios for sparing exist, such as a following flight by a cargo aircraft, or pre-positioned pressure vessels at mission “waystations”. In these spare-support scenarios, it is the intent of this effort to provide a case solution that protects the brass valve during transloading activities, provides measurable environmental protection to the pressure vessel assembly during routine operations in various climatic locales, includes features that support man-portability during manual-loading, and is adequately robust in design to support stacking operations in both static and transportation-vibration scenarios. Impact testing of the case must not degrade the “naked” COPV performance, as tested with DOT CFFC.

Post-mission, if no radiological material is detected, the pressure vessels are loaded onto a pallet and transported to a storage facility or maintenance depot for cleaning. If radiological material is detected, then the pressure vessels are expedited to a laboratory for analysis via air and/or over-the-road transport. Thus, the ARMECH solution must not degrade the DOT-CFFC certfication of the “naked” pressure vessel.

While in storage, these encased-vessels may be subjected to a variety of climatic and solar radiation conditions for extended time periods. These climatic and diurnal conditions, as defined in MIL-STD-810, range the full spectrum of cold-wet to hot-dry climatic conditions in diurnal (e.g. solar radiation) zones ranging in latitude from 75N to 60S (see Figure 20). In addition to climatic and diurnal zones, the operational and storage locations are commonly in close proximity to salt water. Thus, material choices for the design of the ARMECH solution must support climatic locale, diurnal, and salt-fog operational environments.

Figure 20: Global Map with Lat/Long

5. Programmatic Strategy

The intent of this section is to provide an overview of programmatic items that define the overall programmatic strategy.

5.1. Schedule

The Period of Performance (POP) for this effort will be 12 months.

5.2. Data Rights and Content

The Government reserves unlimited data rights for this effort as defined by FAR 27.401, insofar “Unlimited rights means the rights of the Government to use, disclose, reproduce, prepare derivative works, distribute copies to the public, and perform publicly and display publicly, in any manner and for any purpose, and to have or permit others to do so.”

5.3. Cost Structure

The Government requires solicitations to be structured as Firm Fixed Price (FFP) with milestone payments.

The respondent is required to propose a milestone payment plan.

5.4. Contract Line-Item Number(s)

This effort will cover all three phases as depicted in Figure 6. Thus, there are five (5) Contract Line-Item Number(s) (CLINS):

5.4.1. CLIN001(KICKOFF) is comprised of the award of contract, the receipt of Government

Furnished Items, and completion of the Kickoff Meeting, and the initiation of the design activity.

5.4.2. CLIN002 (PDR)

5.4.3. CLIN002 (FDR) is comprised of the delivery of a preliminary TDP, acceptance test plan, and pre-production prototypes.

5.4.4. CLIN003 (ACCEPTANCE TEST REPORT) is comprised of delivery of the acceptance test report which contains all artifacts demonstrating conformance to technical requirements.

5.4.5. CLIN004 (FIRST ARTICLE ACCEPTANCE) is comprised of delivery of the final TDP and first article exemplar unit(s).

5.4.6. CLIN005 (LOW-RATE INITIAL PRODUCTION) is comprised of the low-rate initial production units (250 SVC and, if applicable 125 RCI).

5.5. Government Furnished Items

Respondents should anticipate that the Government will provide both GFI and GFE to support this design effort.

5.5.1. Government Furnished Information (GFI)

5.5.1.1. Drawing # 1-COPV-001, “Composite Overwrapped Pressure Vessel, 900 Cubic Inches, with Hand Valve, Reference Assembly of”

5.5.1.2. Drawing # GCS-MICD-001, “Mechanical Interface Control Document, Pressure Vessel Bay, Gas Collection System”

5.5.1.3. Additional GFI upon request/approval

5.5.2. Government Furnished Equipment (GFE)

5.5.2.1. Two (2) COPV assemblies, per Drawing # 1-COPV-001

5.5.2.2. Additional GFE upon request/approval

5.6. Travel and Meetings

The government reserves the right to visit the contractor facility at any time, provided five (5) business days advance notice. Additionally, contractors may request to visit government facilities provided five (5) business days advanced notice. Additional notice may be necessary if access to Government System Integration Lab (SIL) is required. Respondents should anticipate travel and meetings for the following activities:

6. Project Scope

The overall goals of this effort are to develop, test, and produce an interface with the aircraft mission equipment, protect the COPV against abrasion and impact, improve COPV manual material handling, and integrate features to support bulk shipment of one hundred and twenty (120) units (minimum, no maximum) on a HCU-6/E or 463L Master Pallet.

The final deliverable to this project will be 250 single vessel cases and, if applicable, 125 rack case interfaces. More information for each component is described below.

The Government reserves unlimited data rights for this effort. Production level technical data shall be produced and delivered per MIL-STD-31000.

6.1. Single Vessel Case (SVC)

The Single Vessel Case (SVC) is intended to protect the COPV and attached high-pressure valve against abrasion and impact, as well as provide outer surfaces that support material handling and shipment. Additionally, the SVC must be demonstrated through modeling, simulation, and testing to meet airworthiness requirements. The SVC should be designed with the following high-level guidance:

The Government will provide a technical drawing (see appendix A) as GFI, as well as an exemplar COPV- Valve assembly as GFE.

6.1.1. Maximum manufacturability as defined by production unit cost and schedule. This is a criteria item for design and influences all follow-on manufacturing. It is possible that there will be multiple awards to the contract, and product manufacturability will be used to determine the Government’s next course of action (COA).

6.1.2. Must meet or exceed DOT-CFFC test requirements of the bare COPV (see Table 2:

Applicable Documents, DOT-CFFC for reference).

6.1.3. Must meet airworthiness requirements, including manufacture from a UL-94 or other flame-retardant material meeting or exceeding UL-94 by existing technical specification or newly developed testing to meet contractual requirements.

6.1.4. Additionally, retention against 9G forward loading (axis of flight of the aircraft), 2G vertical loading, and 1.5G horizontal loading (axis of wingspan) is required. The COPV will be loaded into the mission equipment rack from the center aisle, with the vessel’s longitudinal axis parallel to the horizontal axis of the aircraft.

6.1.5. Must include hand-access for the high-pressure valve to be connected to quick disconnect pneumatic line and the valve must be able to be actuated during flight.

6.1.6. Must include hand-access for the quick disconnect pneumatic line routed from the valve to the top of the rack bay, with a minimum bend radius of 2” for the pneumatic line, reference Table 2: Applicable Documents, Air Force Technical Order 42E1-1-1.

6.1.7. Must be capable of some environmental resistance to light rain, UV solar radiation, and debris ingress, such as including feature such a removeable cap or panel to access the high-pressure valve, reference MIL-HDBK-310, MIL-STD-810. SVC does not have to be hermetically sealable.

6.1.8. Must include some features that aid in manual handling of the SVC with contained COPV, such as handholds or handles. A handhold or handle is desired at the long end of the SVC to aid in loading individual SVCs through a trapdoor and ladder behind the cockpit.

6.1.9. Maximum SVC weight defined after Rack-Case-Interface (RCI) guidance below.

6.1.10. Must include features that support high-density packing on a 48-50” width x 48” length x 84” height standard-size, synthetic or metal commercially available pallets. Non-removable interlocking features are desirable. A minimum palletized load is forty-eight (48) SVC’s, with no maximum other than the outer geometric constraints and a maximum pallet weight of 10,000lbs.

6.1.11. Color(s) chosen must be in accordance with IAW SAE-AMS-STD-595.

6.2. Rack-Case-Interface (RCI)

A Rack-Case-Interface (RCI) may be required to secure the two SVCs within the rack bay with no modification to the GCS rack and be demonstrated through modeling and simulation to meet airworthiness requirements. The SVC may be designed with features that eliminate the need for an RCI part or assembly or the RCI may be designed as a separate part or assembly.

The Government will provide a technical drawing (see appendix B) as GFI, as well as an exemplar Mechanical Interface Control Document [Part] as GFE.

6.2.1. Maximum manufacturability as defined by production unit cost and schedule.

6.2.2. The RCI may be a separate construct or integrated features in the SVC.

6.2.3. No modification of the Mission Equipment Gas Collection System (GCS) racks is authorized.

6.2.4. The RCI may stay installed in the GCS rack with or without one (1) or two (2) SVCs. If the RCI is a separate construct, then it is intended to leave the RCI always installed in the racks.

6.2.5. Must meet airworthiness requirements, including manufacture from a UL-94 or other flame-retardant material, as well as retention against 9G forward loading (axis of flight of the aircraft), 2G vertical loading, and 1.5G horizontal loading (axis of wingspan). The COPV will be loaded into the mission equipment rack from the center aisle, with the vessel’s longitudinal axis parallel to the horizontal axis of the aircraft. These requirements must be met whether the SVC(s) are present or not.

7. Design Guidance

The intent of this section is to provide an explanation of the critical mechanical interfaces relevant to this effort.

7.1. Mechanical Interface Control Document (MICD)

The MICD represents the geometric limits of the ARMECH solution, and has been physically validated in all GCS rack “bay” positions. The faces on this volume are designated as “must meet” (blue) or “do not exceed” (green). Reference Drawing Number “GCS-MICD-001” for the released drawing; images below extracted from drawing and are not to scale. Drawing will be provided as a Government Furnished Item.

7.2. Retention

Retention of the COPV within the case as well as the case to the GCS rack are critical for this effort. The Government requires airworthiness evaluation for these subystems, thus modeling and simulation results must be provided as early as Preliminary Design Review that demonstrate that the proposed design meets the required crash rating criteria: 9g forward loading, 4g downward loading, 2g upward loading, 1.5g lateral loading.

7.2.1. Retention of the COPV within Case

The proposed COPV case design must be demonstrated, through modeling and simulation, that the filled COPV, with a mass of 21 lbs, can support the aforementioned crash rating criteria in Section 6.2.

7.2.2. Retention to GCS Rack

The proposed interface between the COPV case and the GCS rack must be demonstrated, through modeling and simulation, to support the aforementioned crash rating criteria in Section 6.2. The interface between the COPV case and the GCS rack, whether as a direct interface from the case to the GCS rack, or with the inclusion of an intermediary component or assembly, must interact with the guiding faces of the GCS rack “bay” and lock into position using the existing sliding “keepers”. The geometric requirements of this interface is defined by the color-coded and dimensioned faces of the MICD. No modification, including the addition of fasteners or attachment of additional support structures to the GCS rack is allowable.

7.3. Mass

The proposed ARMECH design must be equal to or less than the total mass of two (2) filled legacy “sphere” assemblies, including cases, with a total mass per GCS rack “bay” of 110lbs.

7.4. Materials

Material selection for the proposed ARMECH solution must be influenced by a variety of environmental and airworthiness factors. Plastics used in this design must meet UL-94 requirements, and metals must be non-corrosive or coated with a corrosion inhibitor. Fasteners must be MS or NAS type, with corrosion resistance either by alloy or coating. Use of phenolic composites is acceptable.

7.5. Manufacturability

The proposed ARMECH solution must be designed-for-manufacture (DFM), as the intent of this effort is to provide a Low Rate Initial Production that predicates future acquisition efforts of quantities exceeding 3,000 units over multiple fiscal years. Thus, the proposed design will be partially evaluated on the manufacturability of the unit and anticipated per-unit-cost.

7.6. Weight Constraints

The GCS rack bay was designed to restrain two (2) 900 cubic inch Spheres within their respective cases. Thus, the ARMECH solution of two (2) SVC’ restrained in the rack by the RCI product or integrated features must not exceed 110 lbs. Individual SVC’s containing COPV assemblies with pressurized atmosphere to 3000psi must, at a minimum, meet NIOSH Applications Manual guidance of 51 lbs. or less. However, it is desirable to minimize the mass of the SVC’s as much as possible to aid in manual handling tasks and reduce loading on palletized SVC’s during transport activities.

Note: A single COPV and valve assembly weighs approximately 16 lbs unpressurized and 22 lbs pressurized.

Figure 21: MICD Isometric View and Notation

Figure 22: MICD Top View; Blue Faces: Must Meet, Green Faces: Do Not Exceed

Figure 23: MICD Front/Forward View; Blue Faces: Must Meet, Green Faces: Do Not Exceed

Figure 24: Detail View of GCS Rack-MICD Interface Demonstrating an Intended Gap

Figure 25: MICD Right View; Blue Faces: Must Meet, Green Faces: Do Not Exceed

Figure 26: MICD Left View; Blue Faces: Must Meet, Green Faces: Do Not Exceed

8. Requirements Matrix

UNIQUE ID ITEM PARAMETER CATEGORY PARAMETER

DESCRIPTION KPP THRESHOLD PARAMETER OBJECTIVE PARAMETER SOURCE

1.1.1 CASE Environmental

VESSEL INSIDE CASE

SHALL REMAIN BELOW

MAXIMUM STORAGE

TEMPERATURE WHEN

EXPOSED TO SOLAR

RADIATION TESTS PER

MIL-STD-810H, METHOD

505.7, PROCEDURE 1,

CLIMATE A1

YES COPV REMAINS BELOW 200F COPV REMAINS BELOW 160F MIL-STD-810H,

MIL-HDBK-310

1.1.2 CASE Environmental

SHALL OPERATE IN

COLD-WET CLIMATIC

CONDITIONS PER MIL-

STD-810H, PART THREE,

TABLE I, STORAGE AND

TRANSIT

YES MIL-STD-810H,

MIL-HDBK-310

1.1.3 CASE Environmental

SHALL OPERATE IN

HOT-DRY CLIMATIC

CONDITIONS PER MIL-

STD-810H, PART THREE,

TABLE I, STORAGE AND

TRANSIT

YES MIL-STD-810H,

MIL-HDBK-310

1.1.4 CASE Environmental

SHALL OPERATE IN

SALT-FOG CLIMATIC

CONDITIONS PER MIL-

STD-810H, METHOD

509.8, PROCEDURE 1,

FOUR CYCLES

YES MIL-STD-810H,

MIL-HDBK-310

1.1.5 CASE Environmental

CASE SHALL MAINTAIN

STRUCTURAL

INTEGRITY AFTER

SOLAR RADIATION

EXPOSURE PER MIL-STD-

810H, METHOD 505.7,

PROCEDURE 2, CLIMATE

A1, TEN CYCLES

YES MIL-STD-810H,

MIL-HDBK-309

1.2.1 CASE Geometric

DOES NOT EXCEED

MECHANICAL

INTERFERENCE

CONTROL DOCUMENT

(MICD) MAXIMUM

DIMENSIONS;

SUFFICIENTLY UTILIZES

CONTROL SURFACES TO

MEET OTHER

REQUIREMENTS

YES GCS-MICD-001

1.2.2 CASE Geometric

VALVE HANDWHEEL IS

CAPABLE OF

MANIPULATION DURING

FLIGHT

ACTIVITES/MOUNTED IN

RACK

YES

1.2.3 CASE Geometric

CASE SHALL REMAIN

FULLY ASSEMBLED AND

ALL PARTS CONTAINED

DURING OPERATION.

STORAGE OF

REMOVABLE

COMPONENTS NOT

AVAILABLE ON

AIRCRAFT

YES

1.2.4 CASE Geometric

VESSEL AND VALVE

SHALL BE PROTECTED

AGAINST INGRESS FROM

SOLIDS

IP4X IP5X ANSI/IEC 60529-

1.2.5 CASE Geometric

VESSEL AND VALVE

SHALL BE PROTECTED

AGAINST INGRESS FROM

LIQUIDS

IPX4 IPX5 ANSI/IEC 60529-

1.2.6 CASE Geometric

CASE SHALL SECURE

THE PRESSURE VESSEL

IN BOTH

UNPRESSURIZED AND

PRESSURIZED STATE

AND MEET LOADING

REQUIREMENTS AS

STATED IN RQ ID

(SOURCES)

YES ACCEPTANCE

TEST PLAN

1.2.7 CASE Geometric MAXIMUM ACCEPTABLE

WEIGHT N/A 20 LBS 15 LBS ACCEPTANCE

TEST PLAN

1.2.8 CASE Geometric

CASE CAN BE

INTERLOCKED AND

STACKED ON TOP OF

EACH OTHER

YES 10 FOOT ACCEPTANCE

TEST PLAN

1.2.9 CASE Geometric

CASE CAN BE SHIPPED

STACKED ON 463L

PALLET

YES 120 CASES/PALLET 360 CASES/PALLET ACCEPTANCE

TEST PLAN

PERKINS, RONALD J CIV USAF AFMC AFLCMC/HNCBMT

Needs to be updated to match master document

1.2.10 CASE Geometric

CASE SHALL BE

SYMETRIC SUCH THAT

THERE WILL NOT BE A

RIGHT/LEFT OR

UP/DOWN

CONFIGURATION.

YES ACCEPTANCE

TEST PLAN

1.3. 1 CASE Material

SHALL MEET OR

EXCEED UL94 HB SLOW

BURNING

FLAMMABILITY

REQUIREMENTS

YES UL94

1.3.2 CASE Material SHALL OPERATE IN -40F YES MIL-STD-810H, MIL-HDBK-310

1.3.3 CASE Material SHALL OPERATE IN 165F N/A

1.4.1 CASE Performance

CASE SHALL NOT

IMPACT MINIMUM

BURST PRESSURE OF

COPV

YES NO IMPACT TO VESSEL

PERFORMANCE PER CFFC-10(B) DOT-CFFC

1.4.2 CASE Performance

CASE SHALL NOT

INHIBIT OR DEGRADE

DOT-CFFC DROP TEST

FOR COPV

YES NO IMPACT TO VESSEL

PERFORMANCE PER CFFC-10(C) TEST PER CFFC-10(C) DOT-CFFC

1.4.3 CASE Performance

CASE SHALL NOT

DEGRADE COPV

AMBIENT

TEMPERATURE

CYCLING

PRESSURIZATION TEST

YES NO IMPACT TO VESSEL

PERFORMANCE PER CFFC-10(D) DOT-CFFC

1.4.4 CASE Performance

CASE SHALL NOT

DEGRADE COPV

ENVIRONMENTAL

CYCLING TESTS

YES NO IMPACT TO VESSEL

PERFORMANCE PER CFFC-10(E) DOT-CFFC

1.4.5 CASE Performance

CASE SHALL NOT

DEGRADE COPV

THERMAL CYCLING

TESTS RESULTS

YES NO IMPACT TO VESSEL

PERFORMANCE PER CFFC-10(F) DOT-CFFC

1.4.6 CASE Performance

CASE SHALL NOT

DEGRADE COPV

PERFORMANCE DURING

GUNFIRE TESTS

YES NO IMPACT TO VESSEL

PERFORMANCE PER CFFC-10(G) DOT-CFFC

1.4.7 CASE Performance

CASE SHALL NOT

DEGRADE COPV

PERFORMANCE DURING

BONFIRE TESTS

YES NO IMPACT TO VESSEL

PERFORMANCE PER CFFC-10(I) DOT-CFFC

1.4.8 CASE Performance

CASE SHALL BE FULLY

ASSEMBLED AT DEPOT

AND SHIPPED FULLY

OPERATIONAL TO

FIELD

YES

NO ADDITIONAL ASSEMBLY

REQUIRED TO TRANSPORT,

INSTALL, AND OPERATE THE

CASE-VESSEL ASSEMBLY

2.1.1 RACK Geometric

MAXIMUM ACCEPTABLE

WEIGHT WITH TWO

UNPRESSURIZED

VESSELS INSTALLED

YES 100 LBS

2.1.2 RACK Geometric

SHALL CLEAR ALL

PNEUMATIC LINES BY

AT LEAST 0.25"

YES T.O. 42E1-1-1

2.1.3 RACK Geometric

RACK INTERFACE

SHALL BE EITHER

INTEGRAL TO THE CASE

OR SHALL REMAIN

WITHIN THE GCS RACK

WHEN NOT IN

OPERATION.

YES

2.1.4 RACK Geometric

RACK INTERFACE

SHALL RETAIN THE

VESSEL UTILIZING

EXISTING RACK

FEATURES. NO

ADDITIONAL

HARDWARE OR

MODIFICATION

PERMITTED

YES

2.1.5 RACK Geometric

DOES NOT EXCEED

MECHANICAL

INTERFERENCE

CONTROL DOCUMENT

(MICD) MAXIMUM

DIMENSIONS;

SUFFICIENTLY UTILIZES

CONTROL SURFACES TO

MEET OTHER

REQUIREMENTS

YES MICD_A

2.2.1 RACK Material

SHALL MEET OR

EXCEED UL94 HB SLOW

BURNING

FLAMMABILITY

REQUIREMENTS

YES

2.3.1 RACK Performance

RETENTION OF CASE

DURING 9G FWD LOADS

IN ACCORDANCE WITH

YES ACCEPTANCE

TEST PLAN

ACCEPTANCE TEST

CRITERIA

2.3.2 RACK Performance

RETENTION OF CASE

DURING 1.5G AFT LOADS

IN ACCORDANCE WITH

ACCEPTANCE TEST

CRITERIA

YES ACCEPTANCE

TEST PLAN

2.3.3 RACK Performance

RETENTION OF CASE

DURING 1.5G PORT

LOADS IN ACCORDANCE

WITH ACCEPTANCE

TEST CRITERIA

YES ACCEPTANCE

TEST PLAN

2.3.4 RACK Performance

RETENTION OF CASE

DURING 1.5G

STARBOARD LOADS IN

ACCORDANCE WITH

ACCEPTANCE TEST

CRITERIA

YES ACCEPTANCE

TEST PLAN

2.3.5 RACK Performance

RETENTION OF CASE

DURING 2G UPWARD

LOADS IN ACCORDANCE

WITH ACCEPTANCE

TEST CRITERIA

YES ACCEPTANCE

TEST PLAN

2.3.6 RACK Performance

RETENTION OF CASE

DURING 4.5G

DOWNWARD LOADS IN

ACCORDANCE WITH

ACCEPTANCE TEST

CRITERIA

YES ACCEPTANCE

TEST PLAN

9. Work Breakdown Structure

The intent of this section is to provide a notional summary of the anticipated WBS (Figure 27) as well as to define the WBS items and their associated deliverables and caveats. Note: Adhering to this anticipated WBS is not a requirement. PoP is 12 months IAW Section 5.1 and vendor should develop their WBS accordingly.

Figure 27: WBS; Notional Start Date of 6/2/25.

9.1. Phase I: Design

Phase I: Design is intended to encompass all work items leading to the contractor receipt of an authorization to proceed to production.

9.1.1. Kickoff Meeting

The Kickoff Meeting task is a work item that requires the contractor to host a meeting with the Government at their location. The intent of this meeting is to provide an engagement forum to discuss or clarify any issue not previously addressed prior to award, transfer Government Items to the Contractor, and establish a working schedule for upcoming events.

9.1.2. Preliminary Design Activity

The Preliminary Design Activity work item is defined as all tasks that support the creation of a preliminary design, such as Computer Aided Design (CAD) models and drawings, Modeling and Simulation results, and market surveys for materials, manufacturing subcontractors, etc..

9.1.3. Preliminary Design Review (PDR)

The PDR is a meeting at the Contractor’s location that provides a forum to present the proposed design solution and engage with the Government stakeholders.

9.1.3.1. PDR Deliverables

At least five (5) working days prior to the PDR, the Contractor will provide a read-ahead copy of the proposed design report or PowerPoint, associated models, as well as modeling and simulation results.

9.1.3.2. PDR Physical Engineering Model

The contractor will deliver a PDR Physical Engineering Model, scaled 1:1, that incorporates representative features to communicate the concept of operation, physical characteristics, and ergonomics of the proposed design.

9.1.4. Caveats

The Government may choose to provide critical feedback for the Preliminary Design that will require alterations, modifications, or additions to the concept of operation, physical characteristics, or ergonomics if the proposed design does not meet the requirements enumerated in this document. These changes will be implemented by the Contractor and presented at a Critical Design review at the Contractor’s expense. The design review deliverables will be sent to an Air Worthiness Authority for initial assessment of the proposed design.

9.1.5. Air Worthiness Initial Assessment

Early engagement of the GAT is critical to reduce risk to schedule during this effort. Thus, upon delivery of PDR deliverables to the GPT, the GAT will begin analysis and provide airworthiness input to the GPT.

9.1.6. PDR Response

The GPT will provide a PDR response no later than five (5) days after receipt of PDR deliverables. This response will either start the Critical Design Cycle or provide the Contractor with an ATP to the Production Phase.

9.2. Critical Design Activity

The Critical Design Cycle is a recurrent effort at the expense of the Contractor, should the Contractor fail to meet the requirements of this document.

9.2.1. Critical Design Review (CDR)

The CDR is a meeting at the Contractor’s location that provides a forum to present the updated design solution with intregrated Critical Feedback and engage with the Government stakeholders.

9.2.2. CDR Deliverables

At least five (5) working days prior to the CDR, the Contractor will provide a read-ahead copy of the proposed design report or PowerPoint, Technical Data Package comprised of drawings and models, as well as modeling and simulation results.

9.2.3. CDR Physical Engineering Model

The contractor will deliver a CDR Physical Engineering Model, scaled 1:1, that incorporates representative features to communicate the concept of operation, physical characteristics, and ergonomics of the updated proposed design.

9.2.4. Caveats

The Government may choose to provide critical feedback for the Critical Design that will require alterations, modifications, or additions to the concept of operation, physical characteristics, or ergonomics if the proposed design does not meet the requirements enumerated in this document. These changes will be implemented by the Contractor and presented at a subsequent Critical Design review at the Contractor’s expense. The design review deliverables will be sent to an Air Worthiness Authority for assessment of the updated design.

9.2.5. Airworthiness Review

This process is anticipated to take no longer than 90 days and will result in a verdict from the Government Airworthiness Team (GAT) that will provide critical feedback to the Government Program Team (GPT). If the GPT receives initial approval for the proposed design from the GAT, then the GPT will issue an Authorization to Proceed (ATP) to the Contractor to begin the Production Phase.

9.2.6. Authorization to Proceed

An ATP to the Production Phase will be provided by the GPT to the Contractor upon successful integration of the Critical Design Elements, as required, to the proposed design.

9.3. Production Phase

The Contractor, upon receipt from the GPT for an ATP, will proceed to the Production Phase. The intent of this phase is to capture the scope of work items specific to the manufacturing process, such as the design and fabrication of required tooling, authorship of a manufacuring plan, authorship of an acceptance test plan, fabrication of the approved design, and acceptance testing.

9.3.1. Tooling

The Contractor will manufacture necessary tooling required to produce the approved design.

9.3.2. Manufacturing Plan

The Contractor will produce a manufacturing plan, comprised of the processes, procedures, equipment, anticipated unit cost, and production schedule of the proposed design.

9.3.3. Acceptance Test Plan

The Contractor will produce an Acceptance Test Plan that results in a test report demonstrating that the manufactured unit meets the requirements of this document.

9.3.4. Production Readiness Review

The Contractor will host a PRR to present the tooling design, manufacturing plan, acceptance test plan, as well as provide a forum for discussion with the Government.

9.3.5. First Article Prototype

The First Article Prototype is a unit manufactured using the tooling, manufacturing plan, and acceptance testing approved by the GPT during the PRR. For this effort, the First Article Prototype will comprise the necessary components to secure two (2) COPVs within the GCS rack “bay” in accordance with the requirements of this document.

9.3.6. First Article Acceptance

The Government will provide the Contractor with critical feedback or formal acceptance of the First Article Prototype, should the first article prototype be demonstrated meet the requirements of this document.

9.3.6.1. Deliverables

The Contractor will deliver the First Article Prototype to the GPT, along with the associated acceptance test report.

9.3.6.2. Caveats

If the First Article Prototype does not meet the requirements of this document, then the Contractor, at the Contractor’s expense, will begin a recurrent Critical Design Cycle to address items identified by the GPT.

If the First Article Prototype meets all requirements in this document, then the GPT will issue a formal ATP to the contractor to proceed to Low Rate Initial Production.

9.4. Low-Rate Initial Production

The Contractor will manufacture the approved design units in accordance with the approved manufacturing plan and acceptance test plan.

9.5. Acceptance Testing

The Contractor will conduct acceptance testing in accordance with the approved acceptance test plan.

9.6. Final Deliverables

The Contractor will deliver the final TDP, with integrated redlines typically identified during a Production Phase, in final form to Level 3 in accordance with MIL-STD-31000. Additionally, the Contractor will deliver the acceptance test reports and final manufacturing plan with integrated redlines typically identified during a Production Phase.

10. Statement of Objectives (SOO)

The intent of the SOO is to instruct the Contractor on the limits of acceptable technical approach and specify the deliverables for this effort. The requirements listed in this section are based on the requirements matrix provided in Section 7. These requirements are defined by the following value categories: Key Performance Parameter (KPP), Threshold Parameter (TP), or Objective Parameter (OP). KPP’s are defined values that must be met, Threshold Parameters must be met but may be exceeded, and Objective Parameters are desired to be met or exceeded. Requirements with a quantitative value assigned to the value category must be met for Government acceptance of deliverable. The application of the requirement is defined as the COPV case, or the interface between the COPV “Case” and the GCS “Rack”.

Refer to Figure 28 below for ARMECH loading cardinal directions relative to the aircraft in flight.

Figure 28: Cardinal Directions Relative to Flight

1. Objectives 1.X define parameters for the COPV case:

1.1. Objectives 1.1.X define environmental parameters for the COPV case:

1.1.1. The contractor shall design, produce, and test an ARMECH solution that supports sufficient solar radiation protection to the COPV to keep the COPV below 200F (TP) or 160F (OP);

Case; Environmental; Source(s): MIL-STD-810H, METHOD 505.7, PROCEDURE 1, CLIMATE A1.

1.1.2. The contractor shall design, produce, and test an ARMECH solution that supports operation in cold-wet climatic conditions; Environmental; Source(s): MIL-STD-810H, PART THREE, TABLE I, STORAGE AND TRANSIT

1.1.3. The contractor shall design, produce, and test an ARMECH solution that supports operation in hot-dry climatic conditions; Environmental; Source(s): MIL-STD-810H, PART THREE, TABLE I, STORAGE AND TRANSIT

1.1.4. The contractor shall design, produce, and test an ARMECH solution that supports operation in salt-fog climatic conditions; Environmental; Source(s): MIL-STD-810H, METHOD 509.8, PROCEDURE I, FOUR CYCLES

1.2. Objectives 1.2.X define the geometric parameters for the COPV case:

1.2.1. The contractor shall design, produce, and test an ARMECH solution that does not exceed the control volume set by the Mechanical Interface Control Document (MICD) maximum dimensions; shall sufficiently utilize critical interface surfaces set by the Mechanical Interface Control Document (MICD); Geometric; Source(s): MICD_A

1.2.2. The contractor shall design, produce, and test an ARMECH solution that enables the valve handwheel to be manipulated during flight activities while mounted in the rack; Geometric.

1.2.3. The ARMECH solution shall remain fully assembled and all parts contained during operation and no parts shall be stored away from the GCS rack; Geometric.

1.2.4. The contractor shall design, produce, and test an ARMECH solution that protects the vessel and valve against ingress of solids per ANSI/IEC 60529-2020 IP4X (TP) and IP5X (OB);

Geometric; Source(s): ANSI/IEC 60529-2020

1.2.5. The contractor shall design, produce, and test an ARMECH solution that protects the vessel and valve against ingress of liquids per ANSI/IEC 60529-2020 IP4X (TP) and IP5X (OB);

Geometric; Source(s): ANSI/IEC 60529-2020

1.2.6. The contractor shall design, produce, and test an ARMECH solution that secures the pressure vessel in both unpressurized and pressurized state and meet loading requirements; Geometric.

1.2.7. The contractor shall design, produce, and test an ARMECH case solution that weighs no more than 20 lbs. (TP) or 15 lbs. (OB) without the vessel; Geometric.

1.2.8. The contractor shall design, produce, and test an ARMECH case solution that can interlock and stack on top of each other; Geometric.

1.2.9. The contractor shall design, produce, and test an ARMECH case solution that can be shipped stacked on a 463L pallet in lots no smaller than 120 cases/pallet (TP); Geometric.

1.2.10. The contractor shall design, produce, and test an ARMECH case solution that shall be symmetric such that there will not be a right/left or up/down configuration; Geometric.

1.3. Objective 1.3.X defines the material parameters for the COPV case:

1.3.1. The contractor shall design, produce, and test an ARMECH case solution that shall meet or exceed UL94 HB slow burning flammability requirements; Material; Source(s): UL94.

1.3.2. The contractor shall design, produce, and test an ARMECH case solution that shall operate in temperatures as low as -40F, Material.

1.3.3. The contractor shall design, produce, and test an ARMECH case solution that shall operate in temperatures as high as 165F, Material.

1.3.4. Objective 1.3.3 defines the performance parameters for the COPV case:

1.3.5. The contractor shall design, produce, and test an ARMECH case solution that shall not impact the COPV’s minimum burst pressure; Performance; Source(s): DOT-CFFC, Part 10(B)

1.3.6. The contractor shall design, produce, and test an ARMECH case solution that shall not degrade the COPV’s drop test performance qualification; Performance; Source(s): DOT- CFFC, Part 10(C)

1.3.7. The contractor shall design, produce, and test an ARMECH case solution that shall not degrade the COPV’s ambient temperature cycling pressurization performance qualifications;

Performance; Source(s): DOT-CFFC, Part 10(D)

1.3.8. The contractor shall design, produce, and test an ARMECH case solution that shall not degrade the COPV’s environmental cycling performance qualifications; Performance;

Source(s): DOT-CFFC, Part 10(E)

1.3.9. The contractor shall design, produce, and test an ARMECH case solution that shall not degrade the COPV’s thermal cycling performance qualifications; Performance; Source(s):

DOT-CFFC, Part 10(F)

1.3.10. The contractor shall design, produce, and test an ARMECH case solution that shall not degrade the COPV’s gunfire performance qualifications; Performance; Source(s): DOT- CFFC, Part 10(G)

1.3.11. The contractor shall design, produce, and test an ARMECH case solution that shall not degrade the COPV’s bonfire performance qualifications; Performance; Source(s): DOT- CFFC, Part 10(I)

1.3.12. The contractor shall design, produce, and test an ARMECH case solution that shall be fully assembled at depot; no additional assembly required to transport, install, or operate the case;

Performance; Source(s): DOT-CFFC, Part 10(I)

2. Objective 2.X defines the parameters for the interfacing to the GCS rack:

2.1. Objective 2.1.X defines the geometric parameters for interfacing to the GCS rack:

2.1.1. The contractor shall design, produce, and test an ARMECH solution whose rack weight per bay (two SVCs with COPV assembly and RCI, if applicable) is no greater than 110lbs pressurized; Geometric.

2.1.2. The contractor’s ARMECH solution shall clear all pneumatic lines by at least 0.25 inches;

Geometric.

2.1.3. The contractor’s ARMECH RCI solution shall either be integral to the case or shall remain within the GCS rack; Geometric.

2.1.4. The contractor’s ARMECH RCI solution shall retain the vessel using existing rack features without any additional hardware or modification; Geometric.

2.1.5. The contractor shall design, produce, and test an ARMECH RCI solution that does not exceed the control volume set by the…