Atch 1 Aging Surveillance Follow-on PWS 30 Mar 12.docx

FA8818-12-R-0025

Attachment 1

Performance-Based Work Statement (PWS) for Peacekeeper (PK) and Minuteman II (MM II) Rocket Motors Aging Surveillance (AS) and Motor Disposal

30 March 2012

TABLE OF CONTENTS

ANNEXES:

1. RSLP TEST MATRIX

2. RSLP 5 YEAR PLAN

INTRODUCTION

Minuteman (MM) motor and component Aging Surveillance (AS) has been provided by the Rocket Systems Launch Program (RSLP) since 1993 by the original motor manufacturers ATK Launch Systems and Aerojet Corp; Peacekeeper (PK) motor and component AS has been provided for the RSLP since 2006 by ATK Launch Systems; MM and PK motor disposal was previously included in AS contracts and applied mainly to motors and components that had been used in AS processes.

Mission This acquisition will procure services necessary to conduct AS testing and AS/excess motor/component disposal. The services may include trade studies, chemical and mechanical propellant testing, component testing, motor and component failure analyses, static fires, support equipment maintenance, other age related trend analyses, special studies, and support development efforts related to the RSLP motors. These various engineering tasks will generally result in the collection and analysis of rocket motor aging test data, which will be compiled into final test reports for each test conducted. Tests are complied into annual State of the Motor Reports that detail the status of the motors for storage and handling safety along with motor flight worthiness.

Background RSLP was established through a Secretary of Defense memorandum to the Secretary of Air Force, dated 21 Aug 72, as the “single agency providing launch vehicle support for the three Services on a cost reimbursable basis...”. RSLP has current authorization under Program Management Directive (PMD) PMD 09-003(1)/PE# 65860F, dated 07 Dec 2009. Per PMD, the Milestone Decision Authority for RSLP is the Air Force Program Executive Officer for Space. This acquisition is a continuation of the AS program conducted from the active Intercontinental Ballistic Missile (ICBM) fleet. In addition, RSLP has maintained an AS program on MMII and PK assets for nearly 20 years.

Scope This Performance Work Statement (PWS) delineates the contractor tasks required to perform AS, motor disposal and related studies in support of the RSLP on MM and PK rocket motors and related components. These tasks provide motor and component life extension and identify aging trends in the motors which may be a significant indication of motor degradation and inclusion of disassembly and disposal of motors and some components. Required tasks to support AS and motor disposal of these assets include AS analysis, engineering and laboratory tests, motor preparation and static fire/support, support equipment maintenance, disposal, transportation, disassembly and disposition reporting.

APPLICABLE DOCUMENTS

Reference Documents The following documents are to be considered as reference material for the purpose of interpreting the requirements of this PWS but are not contractual documents.

AFMAN 91201 EXPLOSIVE SAFETY STANDARDS

12 JAN 11

TO 21-LG118A-2-26CL-1 DEPOT-MISSILE SOLID STAGES TRANSPORTATION AND HANDLING- HILL AFB AND HILL AFB RANGE, UT Compliance Documents The contractor shall comply with the following documents of the exact issue shown to the extent specified in the column entitled "Tailored Application."

I Jul 87

REQUIREMENTS

General Requirements Applicable Document Compliance The contractor shall comply with the applicable documents listed in Section 2.0 in performing PWS tasks. The contractor shall use the referenced documents to determine how to accomplish the tasks. The nature of services designed to facilitate government management and oversight of activities; however, also requires the contractor to adapt to changing direction, guidance, standards, policies and practices while performing the tasks within this PWS. The contractor shall perform the PWS using the most current version of the applicable documents in section 2.0 to be provided by the government.

Environmental Compliance The contractor shall perform environmental compliance activities in accordance with federal, state, and local laws and regulations in order to comply with the requirements of this contract. Environmental activities may include one or more of the following: handling of any hazardous materials used or generated in performance of this effort; environmental analysis to demonstrate compliance with applicable federal, state, or local regulations, laws, or other specifications in accordance with this PWS; and preparation/submittal of environmental documentation to proper organizations. These environmental activities will only be in support of tasks covered by this PWS.

AS Requirements The contractor shall provide AS for Safety of Storage (SoS) and Reliability of Flight (RoF) of former MM and PK rocket motors and components to be performed at contractor’s proposed facility/location. The contractor shall conduct motor and component tests and analyses that result in service life extension and identify aging trends that may affect performance. SoS testing and analysis validates the motors/components are safe to handle and store. RoF testing and analysis validates the motors/components perform to the original specifications. The contractor shall analyze test results and provide a recommendation for continued application/use of the assets considering any impact to data due to changing facilities. Specific requirements by motor/component are located in Annex 1.

Motor Static Fire Tests The contractor shall provide support for static fire tests of MM and PK rocket motors conducted at the Utah Test and Training Range (UTTR) and conduct/support motor static fire tests at the contractor’s proposed facility.

UTTR Static Fire Tests The contractor will provide day-of -test support as well as post-fire inspections and analysis. The contractor shall provide a report on the post-fire analyses and inspections data. Results of these tests and inspections shall be provided for inclusion in the annual summary report. (CDRL A001, CDRL A002, CDRL A003) Contractor Facility Static Fire Tests The contractor shall provide static fire capability including but not limited to planning, preparation, execution and data analysis, including post-fire analysis and post-fire inspections. Ballistics analysis will be conducted by the contractor. The contractor shall provide a report on the post-fire analysis and inspections. The contractor shall maintain the static fire capability, regardless of static fire schedule. Results of these tests and inspections shall be included in an annual report. (CDRL A001, CDRL A002, CDRL A003) Component Static Fire Tests The contractor shall provide static fire tests of Igniters and Gas Generators (GG) conducted at the contractor’s proposed facility, which may include Government range facilities.

Igniter Static Fire Tests The contractor shall plan, prepare, and execute the static fire tests of Igniters, and data analysis. Pre-test environments (temperature cycling/transport and handling) shall be imposed by the Government. The contractor shall perform all necessary planning to delineate pre-test inspections and instrumentation requirements. The contractor shall prepare a final report for each test to include but not limited to data resulting from pre-fire testing, post-fire inspections and comparison to historical data. (CDRL A001, CDRL A002, CDRL A003) GG Static Fire Tests The contractor shall plan, prepare, execute static fire test of Thrust Vector Actuated (TVA)/Liquid Injected Thrust Vector Control (LITVC) GG, Extendable Nozzle Exit Cone (ENEC) GG, Deployment Actuation System (DAS) GG, Roll Control (RC) GG and analyze the data. Pre-test environments (temperature cycling/transportation and handling) will be imposed by the Government. The contractor shall prepare a test plan detailing test conditions, pre-test inspections, and instrumentation. The contractor shall prepare a final report for each test to include but not limited to data resulting from pre-fire inspections, post-fire inspections, ballistics, and comparison to historical data. (CDRL A001, CDRL A002, CDRL A003) Nozzle Inspections and Tests Fired and unfired nozzle inspection and test are performed to determine effects of aging and provide service life extension of MM and PK nozzles. The contractor shall support the planning, preparation, execution, and data analysis of the testing of flexseal, TVA, and nozzles to identify aging trends. The contractor shall prepare a test plan detailing test conditions and instrumentation. The contractor shall prepare a final report for each test to include but not limited to data resulting from the testing, and comparison to historical data. (CDRL A001, CDRL A002, CDRL A003) Propellant Tests These tests are performed to determine effects of aging on motor and component propellant. The contractor shall perform/support the testing and/or analysis. Quantity and location of samples and test conditions shall be commensurate with previous test programs. The contractor may assess the effects of changes in mechanical properties on structural margins of safety.

Loaded Motor Propellant Material Properties Test & Analysis The contractor shall plan, prepare, execute and provide data analysis to identify any age related trends and provide a recommendation for continued application/use of the assets. The contractor shall prepare a final report for each test to include but not limited to data resulting from the testing, and comparison to historical data. (CDRL A001, CDRL A002, CDRL A003) Motor Dissection/Plugging The contractor shall conduct motor dissection periodically to ensure samples for conducting propellant material properties test. The timing and test required shall be approved by the Government according to the approved test plan. The contractor shall support this planning and provide analysis of the propellant and bondline mechanical property data to support the trend analysis and useful life estimates. (CDRL A001, CDRL A002, CDRL A003) Propellant Hazards Sensitivity Tests The contractor shall conduct propellant hazards sensitivity tests on motor propellants. These are primarily follow-on tests to the previous operational AS programs. The contractor shall support test planning and provide analysis of the propellant to support the trend analysis and useful life estimates with comparison to historical data base. (CDRL A001, CDRL A002, CDRL A003) Component Laboratory Tests Loaded Igniter Dissection The contractor shall dissect propellant loaded and unloaded Igniters. Tests and inspections shall be comparable to previous test programs. This effort includes Igniter dissection, analysis, test, storage and disposal. (CDRL A001, CDRL A002, CDRL A003) GG Dissection The contractor shall dissect RC, TVA, ENEC, and Nozzle GGs to obtain propellant chemical and mechanical properties. Tests and inspections shall be comparable to previous test programs. This effort includes GG dissection, storage, propellant testing and analysis. (CDRL A001, CDRL A002, CDRL A003) Ordnance Tests

3.2.5.1 Interstage Ordnance (IO)

The contractor shall provide IO Functional Testing, including RSLP unique items and legacy hardware. A test report will be issued to document the test results from functional tests as well as all the plots of the various environmental testing. Tests and inspections shall be comparable to previous test programs. (CDRL A001, CDRL A002, CDRL A003)

3.2.5.2 Ordnance Initiation Set

The contractor shall evaluate the hardware used to initiate igniters, gas generators and separation ordnance. This hardware consists of the through bulk-head initiator (TBI), and the type I and III ordnance transmission assemblies (OTA). The contractor shall prepare a test plan detailing test conditions and instrumentation. The contractor shall prepare a final report for each test to include results of the testing, and comparison to the historical database. (CDRL A001, CDRL A002, CDRL A003)

0. Ordnance/Range Certification Test Requirements The Government will provide Flight Termination Ordnance System (FTOS) test per Range Commanders Council (RCC) 319-07 using Government Range personnel and test facilities to the maximum extent possible. This effort can be accomplished via paragraph 3.4 or 3.5 depending on the complexity required by the Government.

Motor Disposition/Disposal Requirements The contractor shall be responsible for the disposal of motors/components and related assets as necessary to support RSLP requirements. The contractor shall be capable of disposing of Firing Units (FUs) taking radiation elements into account.

AS Related Disposal The contractor shall disposition and dispose of residual material resulting from AS for assets tested/consumed at the contractor’s facility. This shall include, but is not be limited to, residual propellant from dissections/plugging operations, and motor/component static fire. AS related disposal will be included in each prepriced service of the VSPT. Motors subject to the Strategic Arms Reduction Treaty (START) will be disposed per treaty requirements.

Excess Motor Disposal The contractors shall transport, disassemble, and dispose of unusable motors per Government plan, through proven and effective methods, including but not limited to, wash out, motor fire or detonation. The contractor will provide a final report of motor disposition. (CDRL A005) Storage of Assets The contractor shall store selected assets required for AS and disposal to ensure availability when needed or as directed by the Government. Tasks required for this storage shall include the monitoring of the temperature and humidity to ensure proper environmental control.

Special Studies Requirements The contractor shall conduct special studies, which may be required due to changing AS or motor disposal requirements. The contractor shall provide engineering, technical and analysis support for system engineering and safety related issues of the motors/components. The contractor shall perform AS and disposal testing and analyses related to transportation, maintenance, safety, processing, test, long term storage and use. Special studies may result in either a recommendation or solution to an identified need, and/or procure support equipment as requested by the Government. (CDRL A001, CDRL A002, CDRL A003, CDRL A004) Special Requirements/Anomaly Investigations The contractor shall conduct special requirements studies/investigations related to motors/ components and disposal requirements, as directed by the Government. This includes activities such as failure investigations, anomaly investigations, and modification or development of tooling to support unique program requirements. The contractor shall also conduct other special requirements studies related to requirements in this PWS when, due to the uncertain nature of the effort involved, it is not practical to establish a firm fixed price. Special Requirements/Anomaly Investigations could result in recommendations or solutions to an identified need. (CDRL A001, CDRL A002, CDRL A003, CDRL A004) Materials and Test Equipment (TE) Support The offeror shall provide and/or procure motor/component unique materials necessary for the refurbishment, aging surveillance testing, ordnance related items, disposal related items, launch support, and maintenance as required by the Government to support RSLP. This effort can be accomplished via paragraph 3.4 or 3.5 depending on the complexity of the procurement and level of documentation required by the Government.

Materials Provide materials including chemicals, soft goods, lubricants, hardware, ordnance, and other components as required in support of AS testing and disposal efforts.

Electrical TE Maintenance Provide periodic maintenance of electrical TE to include minor repairs and labor.

Pressure Transducer Calibration Provide calibration of pressure transducers as requested by the Government. (CDRL A001, CDRL A002) Program Management (PM) Requirements PM & Engineering Support The contractor shall manage the overall schedule and annual report. The contractor shall provide an annual report that summarizes all contract activities, testing and recommendations. The contractor shall develop, maintain, and deliver to the Government an electronic monthly program schedule which details required activities, progress achieved, and required dates for Government Furnished Property (GFP) delivery. The contractor shall provide a monthly Contract Funds Status Report (CFSR) report that identifies actual and projected commitments, expenditures, billings, and Government invoices for all CLINs on this contract. (CDRL A002, CDRL A007, CDRL A008) Meetings The contractor shall prepare and support Technical Interchange/Technical Direction meetings. Meetings will last no more than two days at either contractor or government facility. Meetings will require prepared materials, presenter(s), minimal technical support, and post meeting support for action item(s) collected by contractor at meeting through closeout/acceptance by both the Government. At the Government’s discretion, these meetings can support other mission integration activities. (CDRL A006) Data The contractor will provide a copy of all test plans and test reports to the Government for motor and component testing and motor/component disposition provided under this contract. (CDRL A001, CDRL A002, CDRL A003) Emergency Response Cleanup The contractor shall have the ability to provide environmental and site remediation/recovery in the event of a hazardous mishap.

Non-Personal Services The Government shall neither supervise contractor employees nor control the method by which the contractor performs the required tasks. Under no circumstances shall the Government assign tasks to, or prepare work schedules for, individual contractor employees. It shall be the responsibility of the contractor to manage its employees and to guard against any actions that are of the nature of personal services, or give the perception of personal services. If the contractor believes that any actions constitute, or are perceived to constitute personal services, it shall be the contractor's responsibility to notify the Procuring Contracting Officer (PCO) immediately.

Subcontract Management The contractor shall be responsible for any subcontract management necessary to integrate work performed on this requirement and shall be responsible and accountable for subcontractor performance on this requirement. The prime contractor will manage work distribution to ensure there are no Organizational Conflict of Interest (OCI) considerations. Contractors may add subcontractors to their team after notification to the Procuring Contracting Officer (PCO) or Contracting Officer Representative (COR).

Travel/Temporary Duty (TDY) Travel to other government facilities or other contractor facilities may be required and will be specified in the PWS. All travel requirements (including plans, agenda, itinerary, or dates) shall be pre-approved by the government (subject to local policy & procedures), and is on a strictly cost reimbursable basis. Costs for travel shall be billed in accordance with the regulatory implementation of Public Law 99-234, FAR 31.205-46 Travel Costs, and JTR (subject to local policy & procedures; may reference FAR).

Transition The contractor shall follow the transition plan submitted as part of the proposal and keep the Government fully informed of status throughout the transition period. Throughout the phase-in/phase-out periods, it is essential that attention be given to minimize interruptions or delays to work in progress that would impact the mission. The contractor must plan for the transfer of work control, delineating the method for processing and assigning tasks during the phase-in/phase-out periods.

GENERAL CONSIDERATIONS

Five year Plan The Government has developed a 5 year plan, located at Annex 2, forecasting requirements for AS and disposal activities anticipated for this contract.

Services Summary

Quality Assurance In compliance with Federal Acquisition Regulation (FAR) 52.246-4 “Inspection of Services—Fixed Price” the Contractor shall provide and maintain an inspection system acceptable to the Government covering the services under this contract. Complete records of all inspection work performed by the Contractor shall be maintained and made available to the Government during contract performance and for as long afterwards as the contract requires. The Government has the right to inspect and test all services called for by the contract, to the extent practicable at all places and times during the term of the contract. The Government shall perform inspections and tests in a manner that will not unduly delay the work. If any of the services performed do not conform with the contract requirements, the Government may require the Contractor to perform the services again in conformity with contract requirements, at no increase to contract price or for no additional fee. When the defects in services cannot be corrected by re-performance, the Government may --

· Require the Contractor to take necessary action to ensure that future performance conforms to contract requirements; and

· Reduce the contract price or any fee payable under the contract to reflect the reduced value of the services performed.

If the Contractor fails to promptly perform the services again or take the action necessary to ensure future performance in conformity with contract requirements, the Government may --

· By contract or otherwise, charge to the Contractor any cost incurred by the Government that is directly related to the performance of such service or

· Terminate the contract for default.

Government Inspection The Government will evaluate the contractor's performance under this contract in accordance with the Quality Assurance Surveillance Plan. Government methods of inspection other than those listed in the PWS (such as provided for by the Inspection of Services clause) may occur during the performance period of this contract. Such surveillance will be done according to standard inspection procedures or other contract provisions.

Contracting Officer’s Representative (COR) CORs are representatives of the contracting officer and will participate in the administration of this contract. Subsequent to contract award, the contractor will be provided with a letter identifying CORs and setting forth their duties and authorities.

Scope Changes Any matter concerning a change to the scope, prices, terms or conditions of this contract shall be accomplished by modification of the contract prior to work beginning.

Administrative Records All records, documents, and associated papers provided by the Government and generated during the period of this contract become Government property and will be returned upon contract completion. During the period of the contract, records, documents, and associated papers shall be available for review.

DELIVERABLES

Contract Deliverables Requirements List (CDRL):

CONTRACT SECURITY REQUIREMENTS

Contract security requirements are defined in the contract DD 254, Contract Security Classification Specification.

GOVERNMENT FURNISHED EQUIPMENT/PROPERTY (GFP)

The Contractor shall be responsible and accountable for all Government property provided under this contract and shall comply with FAR Subpart 45.5 Records of Government property. The Contractor shall create and maintain records of all Government property accountable to the contract, including Government-furnished and Contractor-acquired property.

ACRONYMS

CFSR

CO

Contract Funds Status Report Contracting Officer

Attachment 1 PWS 30 March 2012

FA8818-12-R-0025

Attachment 1 PWS 30 March 2012

RSLP AS AND DISPOSAL PWS

ANNEX 1: RSLP TEST MATRIX

X

RC Gas Generator

X

Nozzle Gas Generator

X

RC Gas Generator

X

Nozzle Gas Generator

X

Motor

X

X

Unfired Nozzle Test

Fire Nozzle Test

Safe and Arm (1)

Arm/Disarm Switch (1)

TT Port Frangible Sector

G2

TVA Gas Generator Igniter

G2

Sounding Rocket Destruct System

Mechanical Modular Ordnance System (1)

X

Greases

X

O-rings

Gaskets (Metal)

X

Liner Kits

X

Notes:

(1) - Common for all MM applications; Historically tested at Gov facility X – Historically tested at contractor facility G1 - Testing performed at government facility. Contractor responsible for post-test disassembly/ inspections G2 - For information only. Testing performed at Government facility. No contractor involvement currently required.

Attachment 1 PWS/Annex 1 30 March 2012

RSLP AS AND DISPOSAL PWS

ANNEX 2: GOVERNMENT 5 YEAR PLAN

Minuteman M55A1

Calendar Year

Static Fire Test

Igniters

Dissection/Propellant Testing

Minuteman SR19-AJ-1

Calendar Year

Static Fire Test

Igniters

Static Test with Environments

RC Gas Generator

Static Test with Environments

TVA Gas Generator

Flexseal

Full-Scale Unit

Flexseal Removal From Full-Scale Motor

Minuteman M57A1

Calander Year

Static Fire Test

Igniters

Static Test with Environments

Post Fire Burst Test

Peacekeeper SR118

Calendar Year

Prop. & Bondline Testing Analysis

Igniters

Static Test with Environments

TVA Gas Generator

Static Test

TVA System

Flexseal

Full-Scale Unit

Flexseal Removal From Full-Scale Motor

Motor Disposal

Peacekeeper SR119

Calendar Year

Nozzles

Igniters

ENEC Gas Generator

TVA Gas Generator

Flexseal

Full-Scale Unit

Flexseal Removal From Full-Scale Motor

Motor Disposal

Peacekeeper SR120

Calendar Year

Static Fire Test

Post Fire Inspections

Insulation Erosion

Loaded Case

Igniters

Static Test with Environments

Dissection/Propellant Testing

DAS Gas Generator

Static Test with Environments

TVA Gas Generator

Static Test with Environments

Flexseal

Full-Scale Unit

Flexseal Removal From Full-Scale Motor

Motor Disposal

ORDNANCE

Calendar Year

PK FTOS LSCA (Range Safety)

SR118/SR119

SR120

PK Ordnance Initiation Set

PK Interstage

MM Interstage

Delay Booster (1 sec)

Delay Booster (16 sec)

Explosive (H) Booster

Mechanical S/A

Pellet Assembly

Attachment 1 PWS/Annex 2 30 March 2012

FA8818-12-R-0025

Attachment 1 PWS/Annex 2 30 March 2012 image1.png image2.png