RSLP AS Follow-on PWS 11 Jan 12 v2.docx

PERFORMANCE-BASED WORK STATEMENT (PWS)

for

Rocket Systems Launch Program (RSLP) Aging Surveillance (AS) and Disposal

Solicitation/Contract Number:

FA8818-12-R-0025

11 January 2012

TABLE OF CONTENTS

ANNEXES:

1. RSLP TEST MATRIX

2. RSLP 5 YEAR PLAN

3. GFP LIST

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.

Scope This Performance Work Statement (PWS) delineates the contractor tasks required to perform AS and motor disposal 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. Additionally, this new contract will incorporate disassembly and disposal of unusable 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.

TO 21-LG118A-26-1 OPR AND MAINT (DEPOT) -- HANDLING AND RADIOGRAPHIC PREPARATION INSTR FOR PEACEKEEPER SOLID STAGE ROCKET MOTORS AND COMPONENTS, STAGE I, II AND III, PN 54576, 1175641 AND 10529 SERIES (HERCULES INC) LGM118A

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 A&AS services designed to facilitate government management and oversight of weapon system activities, however, also requires the contractor to adapt to changing direction, guidance, standards, policies and practices while performing the tasks within this PWS. To ensure both the Government and contractor remain synchronized relative to applicable guidance and documents, the contractor shall perform the PWS using the most current approved version of the applicable documents in section 2.0.

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. 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. 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 shall provide 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 analyses and inspections data. Results of these tests and inspections shall be provided for inclusion in the annual 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 of Thrust Vector Actuated (TVA), Extendable Nozzle Exit Cone (ENEC), Deployment Actuation System (DAS) 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 (TP) 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 Nozzle inspection and Static Fire tests 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 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 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 TP. 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) Loaded Motor Plugging/Excise Sampling The intent of this test series is to provide insight and assess the condition of the liner and propellant along the longitudinal axis of the case. The contractor shall plug and remove excise samples from the loaded motor case. This effort includes motor plugging, and test and analysis of samples. Quantities and locations of samples and testing conditions shall be consistent with previous test programs. (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 Roll Control (RC), TVA 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

The contractor shall provide IO Functional Testing, including RSLP unique items and legacy hardware. A test report (TR) 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 transfer 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 (FTS) and Ordnance test per Range Commanders Council (RCC) 319-07 using Government Range personnel and test facilities to the maximum extent possible. The contractor shall support FTS and ordnance test as requested 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.

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. Motors subject to the Strategic Arms Reduction Treaty (START) will be disposed per treaty requirements.

Excess Motor/Component Disposal The contractors shall disassemble and dispose of unusable motors/components per Government plan, through proven and effective methods, including but not limited to, wash out, motor/component 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 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 motor/component unique materials necessary for the refurbishment, testing, and maintenance as required by the Government to support RSLP.

Materials Provide materials including chemicals, soft goods, lubricants, hardware, ordnance, and other components as requested by the Government.

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. The CFSR shall be submitted by the 10th day of each month, with data accurate to the previous month. (CDRL A002, CDRL A007, CDRL A008) Meetings The contractor shall support four Technical Interchange/Technical Direction (TI/TD) meetings per year for AS support and two Technical Interchange meetings (TIM) for disposal to be conducted in or near the contractor’s facility. At the Government’s discretion, these meetings can support other mission integration activities. One of these meetings may be held at Kirtland AFB. (CDRL A006) Data The contractor will provide a copy of all TPs and TRs to the Government for motor and component testing and motor/component disposition provided under this contract. (CDRL A001, CDRL A002, CDRL A003)

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. Any action taken by the Contracting Officer (CO) as a result of inspections will be according to the terms of this contract.

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 referred to the CO.

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 remain in place upon contract termination or 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

This contract will follow the DoD 5200.22M, National Industrial Security Operating Manual (NISPOM). To accomplish this work the contractor will require access to For Official Use Only (FOUO) Information and the Government Local Area Network. Additionally the contractor will receive and generate classified material at the SECRET level, be authorized to use the services of Defense Technical Information Center (DTIC) or other secondary distribution center, have TEMPEST and Operations Security (OPSEC) requirements, and have access to DoD Space System Protection Guide Information. Contract security requirements are defined in the contract DD 254, Contract Security Classification Specification.

GOVERNMENT FURNISHED EQUIPMENT/PROPERTY

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. GFP available for this contract are included in Annex 3.

ACRONYMS

CFSR

CO

Contract Funds Status Report Contracting Officer

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

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; tested at Gov facility X - 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.

RSLP AS AND DISPOSAL PWS

ANNEX 2: GOVERNMENT 5 YEAR PLAN

Minuteman M55A1

Calendar Year

Static Fire Test

Loaded Motor Plugging

Prop. & Bondline Testing

Igniters

Static Test with Environments

Dissection/Propellant Testing

Minuteman SR19-AJ-1

Calendar Year

Static Fire Test

Loaded Motor Plugging

Prop. & Bondline Testing

Igniters

Dissection/Propellant Testing

RC Gas Generator

Dissection/Propellant Testing

TVA Gas Generator

Static Test with Environments

Dissection/Propellant Testing

Flexseal

Full-Scale Unit

Flexseal Removal From Full-Scale Motor

Minuteman M57A1

Calander Year

Static Fire Test

Loaded Motor Plugging

Prop. & Bondline Testing

Igniters

Dissection/Propellant Testing

Post Fire Burst Test

Peacekeeper SR118

Calendar Year

Static Fire Test

Fired Nozzle

Insulation Erosion

Prop. & Bondline Testing Analysis

Propellant Hazards Testing

Dissection/Propellant Testing

Igniters

Static Test with Environments

Dissection/Propellant Testing

TVA Gas Generator

Static Test

Dissection/Propellant Testing

TVA System

Flexseal

Full-Scale Unit

Flexseal Removal From Full-Scale Motor

Peacekeeper SR119

Calendar Year

Static Fire Test

Post Fire Inspections

Insulation Erosion

Prop. & Bondline Testing Analysis

Propellant Hazards Testing

Nozzles

Igniters

Dissection/Propellant Testing

ENEC Gas Generator

Dissection/Propellant Testing

TVA Gas Generator

Dissection/Propellant Testing

Flexseal

Full-Scale Unit

Flexseal Removal From Full-Scale Motor

Peacekeeper SR120

Calendar Year

Static Fire Test

Post Fire Inspections

Insulation Erosion

Loaded Case

Dissection

Prop. & Bondline Testing and Analysis

Propellant Hazards Testing

Igniters

Static Test with Environments

Dissection/Propellant Testing

DAS Gas Generator

Static Test with Environments

TVA Gas Generator

Static Test with Environments

TVA System

Flexseal

Full-Scale Unit

Flexseal Removal From Full-Scale Motor

ORDNANCE

Calendar Year

PK FTOS LSCA (Range Safety)

SR118/SR119

SR120

PK Ordnance Initiation Set

Thru-Bulk Head Initiator

Type I OTA

Type III OTA

PK Interstage

ASE/SR118

SR118/SR119

SR119/SR120

MM Interstage

Explosive Assembly (Longitudnal)

Exploosive (H) Booster

Mechanical S/A

Pellet Assembly

Page of 3

RSLP AS AND DISPOSAL PWS

ANNEX 3: GOVERNMENT FURNISHED PROPERTY

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