GP20 BalloonSpec_Rev_L (3-9-2016).pdf

J300-SP005

Revision L Ver. 0.1

March 9, 2016

SUPERSEDING

J300-SP005

Revision L

September 9, 2014

ATTACHMENT I

NATIONAL WEATHER SERVICE

ENGINEERING and ACQUISITION BRANCH

SPECIFICATION FOR

AEROLOGICAL SOUNDING BALLOONS

U.S. DEPARTMENT OF COMMERCE

NATIONAL OCEANIC AND ATMOSPHERIC ADMINISTRATION

Silver Spring, Maryland 20910-3283

PAGE INTENTIONALLY LEFT BLANK

Revision L

TABLE OF CONTENTS

1 INTRODUCTION

1.1 Background

1.2 Scope

1.2.1 Balloon Designations

1.2.2 Specification Paragraph Titles

2 APPLICABLE DOCUMENTS

2.1 General

2.2 Order of Precedence

2.3 Government documents

2.3.1 Toxicology

2.3.2 Federal Aviation Administration

2.3.3 Federal Meteorological Handbook

2.3.4 National Weather Service Manual 10-1401

2.4 Paragraph Referencing

2.5 Statistical Requirements

2.6 Definitions

3 REQUIREMENTS

3.1 General

3.2 Environmental Conditions

3.2.1 Transportation and Storage Environment Conditions

3.2.1.1 Transportation Environment

3.2.1.2 Storage Environment

3.2.2 Preparation and Release Environment Conditions

3.2.3 Flight Environment Conditions

3.3 Flight Performance Requirements

3.3.1 Flight Preparation

3.3.2 Inflation Gas

3.3.3 Preparation

3.3.4 Preparation-to-Release Time

3.3.5 Payload

3.3.6 Ascent Rates

3.3.7 Performance Percentage Requirements

3.3.8 Minimum Sample Size

3.3.9 Balloon Launch

3.3.10 Federal Aviation Administration Requirements

3.3.11 Dispersal of Inflation Gas

3.4 Material

3.4.1 Electrostatic Control

3.4.2 Uniformity

3.4.3 Dusting

3.4.4 Inflation Gas

3.5 Physical Requirements

3.5.1 Maximum Aerological Sounding Balloon Size

3.5.2 Neck

3.6 Manufacturing Requirements

3.6.1 Physical Percentage

3.6.2 Configuration Control

3.6.3 Environmental Impact

4 AEROLOGICAL SOUNDING BALLOON TESTING

4.1 First Article Tests

4.2 Production Testing and Lot Acceptance

4.2.1 Procedures

4.2.2 Inspection and Tests

4.2.3 Production Lots

4.2.4 Selection of Production Lot Samples

5 PACKAGING REQUIREMENTS

5.1 Packaging

5.1.1 Individual Aerological Sounding Balloons

5.1.2 Cartons

5.1.2.1 Production Samples

5.1.2.2 Production Shipments to the NLSC

5.2 Item Lot Number and Month of Manufacture

5.3 Marking of Shipment

5.3.1 Production Test Samples

5.3.2 Production Shipments to NLSC

5.3.2.1 Exterior Container Markings

5.3.2.2 Intermediate and Unit Container Markings

6 WARRANTY

6.1 Warranty Period

6.2 Visible Defects

6.3 Defect Warranty

Appendix A 1 INTRODUCTION .............................................................................................................. A-4

1.1 Balloon Designations...................................................................................................... A-4

1.2 Definitions ...................................................................................................................... A-4

2 METHODOLOGY FOR TEST AND EVALUATION...................................................... A-5

2.1 Methodology for Production Test and Evaluation ......................................................... A-5

2.1.1 Prerequisites for Production Tests ........................................................................ A-5

2.1.2 Production Tests at Government Sites.................................................................. A-6

2.1.2.1 Production Inspection at Government Sites ......................................................... A-6

2.1.2.2 Production Evaluation .......................................................................................... A-6

2.1.2.3 Production Flight Tests at Government Sites ....................................................... A-7 2.1.2.3.1Production Flight Tests......................................................................................... A-7

2.1.2.4 Production Evaluation .......................................................................................... A-8

2.1.3 Production Tests by the COR ............................................................................... A-8

2.1.3.1 Production Evaluation .............................................Error! Bookmark not defined.

2.1.4 Aerological Sounding Balloon Production Test Schedule ................................... A-8

3 QUALITY ASSURANCE .................................................................................................. A-8

3.1 Independence of Tests .................................................................................................... A-8

3.2 COR Reporting ............................................................................................................... A-9

Appendix B A General Description of Requirements................................................................................. B-2 B. Text Information ................................................................................................................. B-3 B.1. Identification markings on unit packs, intermediate containers, and unpacked items ....B-3 B.2. Identification and contract markings on exterior containers ...........................................B-4

B.2.1 Exterior Containers Containing a Quantity of a Single NSN ................................B-5 B.2.2 Exterior Containers of multiple NSN's ..................................................................B-6

C. Shipping label markings ..................................................................................................... B-7 D. Bar Code Markings ............................................................................................................. B-8 D.1. Unit Packs and Intermediate Containers .........................................................................B-8 D.2. External Containers .........................................................................................................B-8

E. Markings and Marking Materials........................................................................................ B-9 F. Packing Slip Documentation............................................................................................. B-10 G. Pallet Requirements .......................................................................................................... B-11

TABLES

I Balloon Designations…………………………….…………………………. 2 II Transportation Environment…………………………….…………………… 6 III Storage Environment ………………………………………………………… 7 IV Preparation and Release Environment Conditions……………….………… 7 V Flight Environment Conditions…………………………………………….… 8 VI Specific Release Conditions for Nozzle Lift ………………………………… 9 VII Performance Percentage Requirements……………………………………… 10 VIII Minimum Sample Sizes…………………………………………….………… 10 IX Maximum Aerological Sounding Balloon Size……………………………… 11 X Defect Warranty…………………………………………………………. 18

FIGURES

Figure 1 Nozzle Assemble Length Dimensions……………………………………….. 20 Figure 2 Clamping Tool Length Dimension…………………………………………… 21 Figure B1 Identification and Contract Marking for Unit Pack and Intermediate Cont B-12 Figure B2 Typical Exterior Container Text Markings………………………………….. B-12 Figure B3 Barcode Markings on Unit Packs and Intermediate Containers…………….. B-13 Figure B4 Typical Exterior Container Text and Bar Code……………………………... B-13 Figure B5 Acceptable bar-code layout formats for exterior containers………………… B-14

Specification No. J300-SP005

1 INTRODUCTION

1.1 Background

The National Oceanic and Atmospheric Administration (NOAA)'s National Weather Service (NWS) uses 78,000 General Purpose 26 km (GP-26) and GP20 km aerological sounding balloons annually to support NWS radiosonde observations required by the Office of Observations (OBS) and its NWS Weather Forecast Offices. A aerological sounding balloon is a balloon used to carry radiosondes aloft. Radiosondes measure atmospheric temperature, humidity, pressure, wind speed, and wind direction from the surface to an altitude of approximately 30,000 meters. The radiosonde observations are a critical source of meteorological data for these weather forecast models. The NWS radiosonde observations provide atmospheric observations for development of watches, warnings, weather forecasts and aviation support. The NOAA/NWS publishes 3-hour, 6-hour, 12-hour, 24-hour, and 48-hour upper level atmospheric models for watches, warnings, forecasts, and aviation support.

The aerological sounding balloons are launched at all 102 NWS Upper-Air sites and thus must survive a wide variety of launch and flight weather conditions, while providing an average ascent rate of 5 m/s for accurate sensor measurements. The aerological sounding balloon performance is critical to accurate sensor readings on the supported radiosonde observations. The aerological sounding balloon performance specification provides the radiosonde sensors with optimal ascent rate and burst altitude necessary for reliable and accurate radiosonde observations.

1.2 Scope

This specification defines the NWS aerological sounding balloons performance requirements. Appendix A describes tests used to evaluate the balloons.

1.2.1 Balloon Designations.

Balloon types are designated as General Purpose (GP) followed by a two digit numeric suffix designating their minimum bursting height in kilometers (km) above sea level. For example, GP20 is the designation for the General Purpose type balloon with a minimum bursting altitude of 20.0 km. The balloon designations are in TABLE I.

TABLE I. Balloon Designations

DESIGNATION NATIONAL STOCK NO. AGENCY STOCK NO.

GP20 NWS1-20-960-0001 J352-3

1.2.2 Specification Paragraph Titles.

The paragraph titles used in this specification are for convenience. The paragraph titles shall not be construed to imply that all requirements related to the title are contained in the paragraph.

2 APPLICABLE DOCUMENTS

2.1 General.

The following documents form a part of this specification to the extent specified herein.

2.2 Order of Precedence.

In the event of conflict between this specification and documents referenced, this specification shall take precedence. In the event of conflict with the body of this specification and the appendices, the body shall take precedence. The applicable document revision of a reference document for this contract shall be the revised document in effect on the day of release of the solicitation for this contract. Nothing in this document, however, supersedes applicable laws and regulations unless a specific exemption has been obtained.

2.3 Government documents.

2.3.1 Toxicology.

United States Center for Disease Control Agency for Toxic Substance and Disease Registry (ATSDR) Minimal Risk Levels (MRL) for Hazardous Substances

Available from: Agency for Toxic Substance and Disease Registry

ATSDR/OIRM,

1600 Clifton Road (E29), Atlanta, Georgia 30333 USA http://www.atsdr.cdc.gov/mrls/inde x.html

2.3.2 Federal Aviation Administration.

Federal Aviation Requirement Part 101 (14 CFR 101.31 to 101.39)

Available from: Federal Aviation Administration 800 Independence Ave, SW. Room 700W, AJW-281 Attn: NAS Documentation Control Center (DCC) Washington, DC.

20591 http://www.gpoaccess.gov/cfr/index.html

2.3.3 Federal Meteorological Handbook.

Federal Meteorological Handbook No. 1 (FCM-H1-2005)

Available from: Office of the Federal Coordinator for Meteorology 8455 Colesville Road, Suite 1500 Silver Spring, MD 20910 http://www.ofcm.gov/fmh- 1/fmh1.htm

2.3.4 National Weather Service Manual 10-1401.

http://www.atsdr.cdc.gov/mrls/index.html http://www.atsdr.cdc.gov/mrls/index.html http://www.gpoaccess.gov/cfr/index.html http://www.ofcm.gov/fmh-1/fmh1.htm http://www.ofcm.gov/fmh-1/fmh1.htm

Operations and Services Upper Air Program NWSPD 10-14 Rawinsonde Observations, dated

June 2010 Available from: Office of Climate, Water, and Weather Services

1325 East West Hwy, Room 14201 Silver Spring, MD 20910 http://www.nws.noaa.gov/directives/sym/pd01014001curr.pdf

2.4 Paragraph Referencing.

A citation to a paragraph of this specification or a referenced document shall include all subordinate paragraphs of the cited paragraph.

2.5 Statistical Requirements.

Statistical requirements apply to each balloon type manufactured by each balloon manufacturer. A manufacturer cannot average the results of multiple balloon types to meet the specification statistical requirements.

2.6 Definitions.

Valid Flight For the purpose of balloon requirements and testing, a valid flight is one where either a) the balloon meets its performance requirements regardless of the cause of the flight termination or b) a properly launched flight is terminated by balloon burst and the flight environment conditions are within the requirements of this specification regardless of whether the balloon has met its performance requirements.

Invalid Flight For the purposes of balloon requirements and testing, an invalid flight is one where either a) the radiosonde or ground station fails prior to the balloon reaching its minimum burst height or b) the balloon struck some object in the launch process or c) the flight environment conditions are outside the requirements of this specification.

Flight Test Performance Percentage

The flight test performance percentage is 100 times the ratio of the number of balloons meeting their performance requirements to the total number of valid flights.

Free Lift Free lift is the number of grams of lift available over and above the number of grams of lift required by a balloon to support the weight of a complete radiosonde train.

Nozzle Lift Nozzle lift is the number of grams of free lift plus the grams of lift required by a balloon to support the weight of a complete radiosonde train excluding the weight of the balloon. The radiosonde train not including the weight of the balloon consists of the radiosonde, parachute, light stick, dereeler or train regulator, and twine.

http://www.nws.noaa.gov/directives/sym/pd01014001curr.pdf

Gross Lift Gross lift is the nozzle lift plus the grams of lift required to support the weight of the balloon.

Nominal Test samples performance is in accordance with these requirements.

Deficiency A deficiency is an inadequate performance or quality of sample(s) as a result of a defect, design or manufacturing.

Examples of deficiencies include, but are not limited to: samples exhibiting out-of-box defects, poor/inconsistent manufacturing quality, Suspended Deficiencies have been encountered that prevent continuation of the test, but are not severe enough to cause termination. The Contracting Officers Representative (COR) or Test Review Committee (TRC) will determine if a test should be suspended. A potential contractor shall have no more than four (4) weeks to correct the deficiencies and resume the test. Otherwise, a termination test status may result.

Examples of suspension conditions include, but are not limited to:

Deficient performance in a limited portion of the release / flight conditions identified in Tables 3.2.2 and 3.2.3. More than the minimally acceptable percentage of physical defects identified in section 3.5.

Termination Results from test samples that have failed one or more tests with such a severity of deficiencies that to continue testing would not be in the Government’s interest. Only the COR will make this determination and report the findings to the CO.

Some examples for test Termination include, but are not limited to;

samples failing a retest of a previous deficiency or samples with performance percentages below those identified in Table 3.3.7.

Deficiencies that the manufacture is unable or unwilling to address.

3 REQUIREMENTS

3.1 General.

a) Aerological sounding balloons supplied in accordance with this specification shall meet all requirements herein. Balloons shall be capable of being safely and successfully released by one person from outside the inflation building and from a launch shelter in the environmental conditions of 3.2.2.

b) All requirements of this specification shall apply to all aerological sounding balloon types and designations except for those requirements specifically identified as applying to a particular aerological sounding balloon type or designation.

3.2 Environmental Conditions.

The aerological sounding balloons shall meet all specification requirements when subjected to all combinations of the encountered environmental conditions.

3.2.1 Transportation and Storage Environment Conditions.

Aerological sounding balloons shall conform to the requirements of this specification after exposure to the environmental conditions for transportation and storage.

3.2.1.1Transportation Environment.

Aerological sounding balloons, when transported for up to 2 weeks in the Contractor-provided carton packaging during the 16 months after Government acceptance, shall conform to meet all requirements of this specification after exposure to all combinations of the following conditions:

TABLE II. Transportation Environment

Condition Range Air Temperature -60.0 °C to +60.0 °C Air Relative Humidity 5.0 % to 100.0 % including condensation Dust 1 million particles per cubic meter, various sizes Altitude -50.0 m to 12.0 km, MSL Radiation Solar radiation at an altitude of 3.0 km Vibration and Mechanical Shock Conditions encountered during transportation by commercial carrier.

The balloons and their packing shall arrive at the National Logistics Support Center (NLSC) without shipping damage to enable NLSC to reship the balloons by only remarking the exterior carton.

3.2.1.2 Storage Environment.

Aerological sounding balloons, when stored in the Contractor-provided individual packaging, shall conform to the requirements of this specification after exposure to all combinations of the following conditions, for up to 16 months after delivery to the National Logistics Support Center.

TABLE III. Storage Environment

Air Temperature 0 °C to 35 °C (32°F to 95°F) Air Relative Humidity 15 % to 75 % Dust 1 million particles per cubic meter, various sizes Altitude - 50.0 m to 3.0 km, MSL Radiation Sunlight through office windows and ultraviolet light from office fluorescent lights

3.2.2 Preparation and Release Environment Conditions.

Aerological sounding balloons shall meet the requirements of this specification after exposure without packaging to all combinations of the following conditions during preparation, inflation, and release during both day and night:

TABLE IV. Preparation and Release Environment Conditions

Air Temperature -60.0 °C to +50.0 °C Air Relative Humidity 5.0 % to 100.0 % (condensing) Dust 1 million particles per cubic meter, various sizes Altitude -50.0 m to 3.0 km, MSL Surface Wind Speed GP balloons: 0.0 to 25.0 Knots Hydrometeors (liquid and frozen precipitation)

GP balloons: 0 to 150.0 mm per hour

Maximum Icing Conditions GP balloons: 0.0254 cm in 6 minutes.

3.2.3 Flight Environment Conditions.

Aerological sounding balloons, when configured for a flight, shall meet the requirements of this specification when exposed to all combinations of the following conditions during both day and night flights:

TABLE V. Flight Environment Conditions

Air, Pressure 3.0 hectopascals (hPa) to 1070.0 hPa where the minimum air pressure for a particular balloon designation is limited to the actual atmospheric pressure at the minimum specified bursting altitude

Air, Temperature GP balloons: -70.0 °C to +50.0 °C Air, Relative Humidity 0.0 percent to saturation Dust 1 million particles per cubic meter, various sizes Wind speed in flight 0 meters/second (m/s) to 165 m/s Hydrometeors (liquid and frozen precipitation)

GP balloons: 0.0 mm to 150.0 mm per hour

Maximum Icing Conditions GP balloons: 0.0254 cm in 6 minutes.

Radiation and Atmospheric Chemistry

Exposure during flight to all radiation and chemicals occurring in the atmosphere up to the minimum specified burst altitude over the USA, US Possessions, and adjoining ocean areas.

3.3 Flight Performance Requirements.

3.3.1 Flight Preparation.

Aerological sounding balloons shall meet the requirements of this specification after being inflated and tied off with a cotton string. The aerological sounding balloon shall be adequately sealed with the amount of inflation gas specified by the Contractor to meet the requirements of this specification when the cotton string is tied with a tension 25 lbs to 35 lbs.

3.3.2 Inflation Gas.

Performance requirements of this specification shall be met when hydrogen gas only, natural gas only, or helium gas only is used to inflate the balloon. The maximum inflation gas required shall not exceed 2.7 cubic meters in the ambient conditions of 25°C and 1013.25 hPa. The preparation documentation shall specify the nozzle lift required (for helium, hydrogen and natural gas) to meet the specification requirements in the release conditions identified in TABLE V.

TABLE VI. Specific Release Conditions for Nozzle Lift

Condition # Parameter Range 1 Moderate Breeze* 11 to 16 knots* 2 Fresh Breeze* 17 to 21 knots* 3 Strong Breeze* (limited) 22 to 25 knots* 4 Light Rain** (liquid and frozen) Less than 2.8 mm per hour** 5 Moderate Rain** (liquid and frozen) 2.8 – 7.62 mm per hour** 6 Heavy Rain**(liquid and frozen) More than 7.62 mm per hour**

* Beaufort Scale ** Federal Meteorological Handbook No. 1 (FCM-H1-2005)

3.3.3 Preparation

Preparation in the environmental conditions identified in 3.2.2 shall include all tasks necessary to cause the aerological sounding balloon to be ready-to-release. One person shall be able to successfully and routinely accomplish both preparation and launch of the balloon in the environment of 3.2.2. The preparation instructions shall include, but not be limited to removing the aerological sounding balloon from its individual packaging required by 5.1.1; placing the aerological sounding balloon on the Aerological Sounding Balloon Nozzle Assembly (FIGURE 1) and held by the Aerological Sounding Balloon Clamping Tool (FIGURE 2); identifying the recommended nozzle lift for the conditions identified in 3.3.2 and Table VI, for full specification compliance; tying or sealing the aerological sounding balloon to prevent inflation gas escape; and removing the aerological sounding balloon from the nozzle assembly.

3.3.4 Preparation-to-Release Time

Total preparation-to-release time in the environmental conditions identified in 3.2.2 for aerological sounding balloons supplied in accordance with this specification shall not exceed 45 minutes including preparation, inflation, and release. The time to inflate the aerological sounding balloon to the recommended amount of inflation gas shall not exceed 15 minutes. The aerological sounding balloons shall conform to the requirements of this specification when exposed to the environmental conditions identified in 3.2.2 during and after inflation and prior to release for up to 45 minutes.

3.3.5 Payload

Flight performance requirements shall be met with no more than a 600 gram payload. The flight payload for each flight may vary between 400 and 600 grams, based on the radiosonde type and other flight train materials.

3.3.6 Ascent Rates

The aerological sounding balloon ascent rates required by 3.3.7 of this specification shall be the average rate of ascent from the launch height to the actual burst altitude when the sample size is at least as large as required by 3.3.8. The maximum ascent rate from launch to 400.0 hPa shall not exceed 360.0 m/min (1181.1 ft/min).

3.3.7 Performance Percentage Requirements

At least 90.0 percent of the balloons shall meet the minimum burst altitude and minimum average ascension rate of TABLE VII when the sample size is at least as large as required by 3.3.8.

TABLE VII. Performance Percentage Requirements

TYPE

of Aerological sounding balloon

MINIMUM BURST ALTITUDE

with respect to Mean Sea Level

(km) that must be met by at least

90.0 % of balloons (km)

MINIMUM AVERAGE ASCENSION RATE

Launch height to the actual burst altitude

(meters/min)

GP20 20.0 275

3.3.8 Minimum Sample Size

The requirements of 3.3.6 and 3.3.7 shall be met when the sample sizes are at least as large as shown in

TABLE VIII.

TABLE VIII. Minimum Sample Sizes

Type of Test Minimum Number of Valid Flight Tests Initial Production Test 100 Lot Acceptance Test 40

If the number of failures occurring during a test makes it mathematically impossible to pass the test with the minimum sample size shown in TABLE VIII, then the Government reserves the right to discontinue testing and declare the balloons have failed the test. For example, during Production Acceptance tests, if 10 flights have been performed and 5 failures have occurred, the Government may discontinue testing since even if no further failures were to occur, the balloons would fail the test.

3.3.9 Balloon Launch

One person shall be able to launch the balloon, radiosonde, and parachute from outside a balloon launch shelter and from a balloon launch shelter in the environment of 3.2.2. The Contractor shall supply all special fixtures or machinery for launch, if required.

3.3.10 Federal Aviation Administration Requirements

The balloon shall conform to all requirements of Federal Aviation Requirement 101 (14 CFR 101.31 to 101.39).

3.3.11 Dispersal of Inflation Gas

The inflation gas of the extensible balloon shall be released to the atmosphere.

3.4 Material

3.4.1 Electrostatic Control

Aerological sounding balloon material shall not contribute to, or permit the buildup of, electrostatic charges on the aerological sounding balloon surface. An antistatic agent, if required, applied to the balloon meeting

3.0 requirements is not prohibited

3.4.2 Uniformity

The aerological sounding balloons shall be of uniform texture and have a consistent aerodynamic cross-section during flight.

3.4.3 Dusting

Aerological sounding balloons manufactured using construction techniques requiring powder dusting shall have uniform dusting with a non-toxic, dry, powdered material which effectively prevents adhesion of the material. The powder shall not react with hydrogen, helium, or Natural Gas. The powered material shall not contribute to the formation of an electrostatic charge during preparation, release, or flight.

3.4.4 Inflation Gas

Aerological sounding balloons shall not react with hydrogen, natural gas, or helium inflation gas.

Aerological sounding balloon materials shall not expel or emit any chemical that will react with hydrogen, natural gas, or helium gas.

3.5 Physical Requirements

Aerological sounding balloons physical features shall meet the requirements set forth below.

3.5.1 Maximum Aerological Sounding Balloon Size

The size of the aerological sounding balloons supplied under this specification shall not exceed the following limits when fully inflated at 850 +10 hPa pressure.

TABLE IX. Maximum Aerological Sounding Balloon Size

BALLOON

DESIGNATION

MAX INFLATED

VERTICAL SIZE

(meters)

MAX INFLATED

HORIZONTAL SIZE

(meters)

GP20 2.44 1.98

Vertical measurements do not include the neck-size requirements of 3.5.2.

3.5.2 Neck

Aerological sounding balloons shall be supplied with a neck securely attached to the body. The neck shall be at least 15.24 cm long and have an inside diameter between 3.073 cm to 4.52 cm. The neck shall not rip, shred, perforate, or separate from the balloon body when filled or removed from the nozzle. The edge (free end) of the neck of the aerological sounding balloon shall be free of nicks or folds. Aerological sound balloons shall be supplied with a body securely attached to the neck. When inflated the body shall conform to the dimensions in TABLE IX

As an alternative, the Contractor may submit aerological sounding balloons having different tubular-neck dimensions than those listed, but shall then be required to supply alternate Aerological Sounding Balloon Nozzle Assemblies and Aerological Sounding Balloon Clamping Tools. The alternate Aerological Balloon Nozzle Assemblies shall use the same eye ring assembly and a brass inflation gas fitting as shown in Figure

1. The alternate Aerological Balloon Nozzle Assemblies shall not contribute to the formation of an electrostatic charge during preparation. The alternative Aerological Sounding Balloon Nozzle Assembly and Aerological Sounding Balloon Clamping Tool shall be supplied at no cost to the Government. The quantity of Aerological Sounding Balloon Nozzle Assemblies and Aerological Sounding Balloon Clamping Tools provided by the Contractor for Initial Production Testing shall be seven (7). After successfully completing the Initial Production Testing, the Contractor shall supply the alternate Aerological Sounding Balloon Nozzle Assemblies and Aerological Sounding Balloon Clamping Tools to the Government at no charge for 102 sites plus 10 spares.

The neck shall consist of one or more structures to meet the following functional requirements:

a) The neck shall provide a means to inject the inflation gas during preparation and then to prevent the loss of the inflation gas.

b) The neck shall provide an ergonomic handle for the person to hold the balloon during its release.

c) The neck shall transmit the restraining forces from the operator encountered during release in the winds of 3.2.2 to the rest of the balloon so that the balloon is not overstressed.

d) The neck shall provide a means to attach the cotton string connected to the flight train to the balloon.

3.5.3 Material

3.6 Manufacturing Requirements

3.6.1 Physical Percentage

At least 99.0 percent of the aerological sounding balloons of each lot shall meet the size requirements of TABLE IX. The mean arithmetic deviation of the actual weights of individual balloons in a lot shall not differ by more than 10.0 percent. No more than 1 percent of a lot shall have physical defects (e.g. pinholes, thin spots, patches, etc).

3.6.2 Configuration Control

No change shall be made in design, material chemistry, or production process without prior written approval by the Contracting Officer.

3.6.3 Environmental Impact

Aerological sounding balloons required by this specification and factory equipment used to produce aerological sounding balloons required by this specification shall not cause exposure to hazardous substances exceeding the recommended limits provided in United States Center for Disease Control, Agency for Toxic Substance and Disease Registry, Minimal Risk Levels for Hazardous Substances in all of the following circumstances:

a) Aerological sounding balloon preparation.

b) Flight of the aerological sounding balloons.

c) Contamination of ground water and streams after flight due to leaching of chemicals from the aerological sounding balloon.

d) Ingestion of aerological sounding balloon remains in the ground water and in water bodies.

e) Disposal of aerological sounding balloons.

f) Exposure of Government employees visiting the factory(s) in preparation for, during, and after manufacture and test of aerological sounding balloons.

All other environment exposure limits imposed by other Government or Government agencies having jurisdiction are also required as though textually incorporated herein. This includes, but is not limited to, those requirements to protect the factory employees and the community(s) where the factory(s) is (are) located. The Contractor shall supply Material Safety Data Sheet (MSDS) to the Contracting Officer with the Offer for the balloons and, if used, also for dusting material.

4 AEROLOGICAL SOUNDING BALLOON TESTING

4.1 First Article Tests.

Deleted.

4.2 Production Testing and Lot Acceptance

4.2.1 Procedures

Steps in a successful aerological sounding balloon manufacturing and production lot acceptance are:

a) The Contractor shall supply specification compliant aerological sounding balloons.

b) Production Lot Samples shall be selected per 4.2.4.

c) Production Lot Samples shall be shipped at Contractor expense to NLSC at the address set forth in the contract.

d) Government test sites will perform tests as specified in APPENDIX A - J300-TP003 TEST

PROCEDURES FOR AEROLOGICAL SOUNDING BALLOONS and supply the results to the Contracting Officer’s Representative (COR).

e) The COR will review test results and notify the Contractor of successful lot sample test completion.

f) The lot of aerological sounding balloons shall be shipped at Contractor expense to the NLSC in Kansas City, Missouri.

g) NSLC will inspect the shipping cartons for damage in accordance with 3.2.1.1 and the carton marking for compliance with 5.3.2 and Appendix B - Marking for Shipment.

h) NSLC will accept the lot of aerological sounding balloons F.O.B. NLSC. (NLSC will send a receiving report to the COR).

i) The Contractor shall send the invoice to the COR.

4.2.2 Inspection and Tests

The Government will perform inspection and tests on production lots of aerological sounding balloons on a random basis to determine compliance with this specification. In lieu of performing random inspection and testing of production lots, the Government may use aerological sounding balloon field performance data to verify compliance with specification requirements. The Government reserves the right to perform additional tests and the right to limit or eliminate tests without prior notification to the Contractor.

4.2.3 Production Lots

Aerological sounding balloons shall be accepted in lots. A production lot shall:

a) Not exceed 7,800 aerological sounding balloons;

b) Contain only aerological sounding balloons manufactured during a 14 consecutive day period; and

c) Be of the same type and designation. Individual aerological sounding balloon packaging and marking shall be in accordance with APPENDIX B - MARKING FOR SHIPMENT.

4.2.4 Selection of Production Lot Samples

Aerological sounding balloons of each production lot will be selected by a Government representative or, for the convenience of the Government, may be selected by the Contractor at the Contracting Officer’s direction prior to placing individual aerological sounding balloon boxes into cartons. The aerological sounding balloons chosen for test shall be evenly distributed throughout the production lot.

Once selected, all samples will be forwarded to Government aerological sounding balloon test sites. The Production Samples from acceptable lots will be considered as partial delivery on the contract if the production lot is accepted.

The Contractor shall provide the COR documentation addressing use, handling, storage, preparation, and inflation requirements with both hydrogen only and helium only for each aerological sounding balloon contract.

5 PACKAGING REQUIREMENTS

5.1 Packaging

5.1.1 Individual Aerological Sounding Balloons

All aerological sounding balloons supplied in accordance with this specification shall be individually packaged in a manner that will ensure compliance with this specification. A simple method shall be provided for opening the individual packages without the use of a sharp instrument.

5.1.2 Cartons

5.1.2.1 Production Samples

Individually packed aerological sounding balloons shall be packaged in a manner ensuring compliance with this specification including 3.2.1.1 and 3.2.1.2.

5.1.2.2 Production Shipments to the NLSC

The individually packed aerological sounding balloons shall be shipped to the Government in cartons. An exterior carton of GP type balloons shall contain 30 individually packaged aerological sounding balloons of a specific lot. Intermediate cartons may be provided. The weight of a fully packed exterior carton shall not exceed 31.75 kg (70.0 lbs) and the girth plus length shall not exceed 2.74 m (108 in) to comply with postal regulations. All shipments exceeding ten cartons shall be transported on pallets and have plastic stretch wrapped over the cartons. All cartons shall be packaged in a manner that will ensure compliance with this specification when delivered to NLSC.

5.2 Item Lot Number and Month of Manufacture

The individually packaged aerological sounding balloons shall be shipped to the Government with a production lot number identified with the NSN and ASN. The production lot number shall be marked on the outside of the individually packaged aerological sounding balloon or on printed material contained within the packaging. The production lot numbers assigned to aerological sounding balloons shall conform to the code pattern WWWWWWWW-MMYYYY. Up to eight alphanumeric characters shall be traceable by the Contractor to their manufacturing operations, for example:

LOT: 260801DB-02-2010

or

LOT: DB26-801-02-2010

LOT: 801-02-2010

5.3 Marking of Shipment

Each exterior, intermediate, and unit carton shall be clearly marked to identify its contents.

5.3.1 Production Test Samples

The boxes shall be marked as required in 5.3.2 to include the aerological sounding balloon type and designation, the Contractor, and the production lot number. Production Test Samples in cartons shall be shipped to NLSC at the address set forth in the contract.

5.3.2 Production Shipments to NLSC

Once the COR has sent the Contractor a letter certifying successful lot sample test completion, the Contractor shall ship the production lot of individually packaged aerological sounding balloons in cartons to the NLSC marked as required below and in APPENDIX B - MARKING FOR SHIPMENT.

5.3.2.1 Exterior Container Markings

The exterior container shall be marked as shown in APPENDIX B except as described herein.

Upper Left Corner

• National Stock Number

• “CAGE” followed by the manufacturer’s cage code.

• “Balloon” followed by the balloon designation

• “ASN:” followed by the agency stock number

• “30 EA” (GP20 balloons)

• “WT” followed by the exterior package weight in pounds. “CU” followed by the exterior package volume in cubic feet.

• Lot Number

• “Manufacture Date” followed by the date of manufacture in o month (spelled out) and year.

• “Warranty End Date” followed by the month (spelled out) and year 16 months following the expected delivery date to NLSC but not before step e of 4.2.1. (See Note).

NOTE: The warranty period starts with the actual delivery to NLSC. Since there is uncertainty as to when a shipment will arrive at NLSC, a one-month error will be tolerated in the marked date.

Lower Left Corner

• The contract number.

• The name of the Contractor.

• The Contractor’s city, state, and zip code.

The bar codes shall show:

• The national stock number

• The contract number

• The Contractor’s cage code

5.3.2.2 Intermediate and Unit Container Markings

The intermediate and unit containers, if used, shall be marked as shown in APPENDIX B MARKING

FOR SHIPMENT.

6 WARRANTY

6.1 Warranty Period

The warranty period shall start on the actual delivery date of the balloon to NLSC and last for 16 months.

6.2 Visible Defects

All aerological sounding balloons exhibiting out-of-box defects (e.g. pinholes, thin spots, patches, etc) will be replaced at the Contractor’s expense provided the Contractor is notified of the defect within the warranty period.

6.3 Defect Warranty

Should the flight test performance percentage of aerological sounding balloons for any production lot, at any individual or group of NWS site(s), fall below the requirements of Section 3.3.6 or TABLE VII within the 16- month warranty period, the COR will notify the Contractor of a defect. The Contractor may elect to have the lot (or a portion thereof) returned for inspection. The return shall be at the Government’s discretion and at the Contractor’s expense. The COR will supply the Contractor with information on the failure rate and other data that may be available. After evaluation, the Contractor may elect to either repair the remaining units or replace them. In either case, the balloons shall then be submitted for production lot acceptance in accordance with 4.2.

For warranty claims, the number of failed balloons must be at least as great as shown below:

TABLE X. Defect Warranty

PASS RATIO MINIMUM NUMBER OF VALID TEST FLIGHTS

If the pass ratio less than 50.0 percent 20 If the pass ratio is greater than 50.0 percent but less than 80.0 percent

If the pass ratio is greater than 80.0 percent, but less than 90.0 percent

If the number of failures during a test makes it mathematically impossible to pass the test with the minimum sample size shown in above, then the Government reserves the right to suspend or terminate testing and declare the balloons are UNSATISFACTORY. For example, if 13 flights have been performed and 11 failures have occurred, the Government may discontinue testing since the balloons would fail the test should no further failures were to occur.

FIGURE 1. Nozzle Assembly Length Dimensions

FIGURE 2. Clamping Tool Length Dimensions

Appendix to: J300-SP005

January 15, 2016

ENGINEERING and ACQUISITION BRANCH

Test Procedures for

Appendix A to

NATIONAL OCEANIC AND ATMOSPHERIC ADMINISTRATION

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TEST PROCEDURES FOR AEROLOGICAL SOUNDING BALLOONS

1 INTRODUCTION

This test plan outlines the requirements for free-flight, single-envelope, freely-expanding aerological sounding balloon testing. Aerological sounding balloons are used to carry radiosondes through the atmosphere to measure profiles of pressure, temperature, humidity, wind speed and wind direction. The National Weather Service (NWS) uses various types and designations of aerological sounding balloons to obtain these measurements. Radiosonde soundings are usually made at 00 UTC and 12 UTC, which, depending on longitude could be day-time or night-time conditions. The NWS flies over 60,000 aerological sounding balloons throughout its network of 92 stations and supplies balloons internationally. The NWS upper-air network extends south from Barrow, AK (71N) to Pago Pago, Samoa (14S) and west from Caribou, ME (68W) to Koror, Palau (134E).

1.1 Balloon Designations

Aerological sounding balloons are designated as General Purpose (GP) type and in accordance with their minimum bursting height in kilometers (km) above sea level.

1.2 Definitions

Valid Flight For the purpose of balloon requirements and testing, a valid flight is one where either a) the balloon meets its performance requirements regardless of the cause of the flight termination or b) a properly launched flight is terminated by balloon burst and the flight environment conditions are within the requirements of this specification regardless of whether the balloon has met its performance requirements.

Invalid Flight For the purposes of balloon requirements and testing, an invalid flight is one where either a) the radiosonde or ground station fails prior to the balloon reaching its minimum burst height or b) the balloon struck some object in the launch process or c) the flight environment conditions are outside the requirements of this specification.

Flight Test Performance Percentage

The flight test performance percentage is 100 times the ratio of the number of balloons meeting their performance requirements to the total number of valid flights.

Free Lift Free lift is the number of grams of lift available over and above the number of grams of lift required by a balloon to support the weight of a complete radiosonde train.

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Nozzle Lift Nozzle lift is the number of grams of free lift plus the grams of lift required by a balloon to support the weight of a complete radiosonde train excluding the weight of the balloon. The radiosonde train not including the weight of the balloon consists of the radiosonde, parachute, light stick, dereeler or train regulator, and twine.

Gross Lift Gross lift is the nozzle lift plus the grams of lift required to support the weight of the balloon.

Nominal Test samples performance is in accordance with these requirements.

Suspended Deficiencies have been encountered that prevent continuation of the test, but are not severe enough to cause termination. The Contracting Officers Representative (COR) or Test Review Committee (TRC) will determine if a test should be suspended. A potential contractor shall have no more than four (4) weeks to correct the deficiencies and resume the test. Otherwise, a termination test status may result.

Termination Results from test samples that have failed one or more tests with such a severity of deficiencies that to continue testing would not be in the Government’s interest. Only the COR will make this determination and report the findings to the CO.

2 METHODOLOGY FOR TEST AND EVALUATION

The methodology employed in this test plan will determine whether the Production Samples comply with NWS specifications by inspection, static tests, and flight tests of performance characteristics. Evaluation criteria will match the requirements given in their respective specification sections.

Specific specification paragraphs are shown for most of the tests of this procedure. The paragraphs shown are envisioned to be those where a deficiency revealed by the test would most likely be. A deficiency could also be found with other specification requirements.

2.1 Methodology for Production Test and Evaluation

2.1.1 Prerequisites for Production Tests

Aerological sounding balloons of each production lot will be selected by a Government representative or, for the convenience of the Government, may be selected by the Contractor at the Contracting Officer’s direction prior to placing individual aerological sounding balloon boxes into cartons. The aerological sounding balloons chosen for test shall be evenly distributed throughout the production lot. Once selected, all samples will be forwarded to Government test

A-6 sites. The Production Samples from acceptable lots will be considered as partial delivery on the contract if the production lot is accepted.

Documentation provided by the balloon vendor addressing the use, handling, storage, preparation, MSDS, and inflation requirements of hydrogen, natural gas and helium for each aerological sounding balloon type and designation.

Aerological Sounding Balloon Nozzle Assemblies and Aerological Sounding Balloon Clamping Tools shall be provided separately with the initial production lot samples if the alternative Aerological Sounding Balloon Nozzle Assembly and Aerological Sounding Balloon Clamping Tool are proposed.

2.1.2 Production Tests at Government Sites

The Government will conduct inspections and flight tests of Production Test Samples of all aerological sounding balloon lots.

2.1.2.1 Production Inspection at Government Sites

Upon receipt of the Production Test Samples, a physical inspection will be made of all aerological sounding balloon lots during flight preparation to determine compliance with specification sections:

3.2.1 Transportation and Storage Environment Conditions

3.2.2 Preparation and Release Environment Conditions

3.2.3 Flight Environment Conditions.

3.3.1 Flight Preparation

3.3.2 Inflation Gas

3.3.3 Preparation

3.3.4 Preparation-to-Release Time

3.3.5 Payload

3.4.1 Electrostatic Control

3.4.2 Uniformity

3.4.3 Dusting

3.4.4 Inflation Gas

3.5.1 Maximum Aerological Sounding Balloon Size

3.5.2 Neck

5.1.1 Individual Aerological Sounding Balloons

5.1.2.1 Production Samples

5.2 Item Lot Number and Month of Manufacture

5.3 Marking of Shipment

2.1.2.2 Production Evaluation

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During flight preparation, the Government test participant shall note any physical deficiency with the aerological sounding balloons and include the notes with the flight data sheet.

2.1.2.3 Production Flight Tests at Government Sites

The Government will conduct a series of flight tests, day and night, of Production Test Samples of all aerological sounding balloon lots.

The aerological flight train and radiosonde will be prepared according to established NWS procedures. Aerological sounding balloon shall be prepared in accordance with the documentation submitted by the Contractor. The balloon will be inflated to the lift in grams as specified by the Contractor’s instructions for 25 °C and 1013.25 hPa compensated for presented conditions. The total payload will be no more than 600 grams.

A surface observation will be made within ten minutes prior to release. Physical inspection and flight performance remarks will be recorded. A number of flights will be released in light to moderate precipitation, if possible. A number of flights will be released in surface winds greater than 15 kts, if possible.

After aerological sounding balloon release, the Upper Air ground system will track the radiosonde until burst. The Upper Air computer system will be used to compute the height of burst, as well as the ascent rate.

2.1.2.3.1 Production Flight Tests

The Government will prepare and conduct flight tests of Production Test Samples of all aerological sounding balloon types and designations to determine compliance with Specification Sections:

3.2.2 Preparation and Release Environment Conditions

3.2.3 Flight Environment Conditions.

3.3.5 Payload

3.3.6 Ascent Rates

3.3.7 Performance Percentage Requirements

3.4.1 Electrostatic Control

3.4.2 Uniformity

3.4.3 Dusting

3.4.4 Inflation Gas

3.5.1 Maximum Aerological Sounding Balloon Size

3.5.2 Neck

3.6.1 Physical Percentage

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The Government reserves the right to request and test additional lot samples at operational sites located in the arctic or the tropics or to test aerological sounding balloons using precision radar tracking.

2.1.2.4 Production Evaluation

During flight preparation or the test flight, the Government test participant shall note any deficiency with the aerological sounding balloons.

2.1.3 Production Tests by the COR

During inspections and tests of Production Test Samples of all aerological sounding balloon lots, the COR shall note any deficiency with the aerological sounding balloons. In order for the aerological sounding balloons to be considered ACCEPTABLE during inspection, laboratory test, environmental tests, and flight tests, the aerological sounding balloons must meet the specification requirements. Additionally, in order for the aerological sounding balloons to be considered ACCEPTABLE during flight preparation and flight test, at least 90.0 percent of the aerological sounding balloon flights by the COR and at Government test sites must meet the specification requirements.

If aerological sounding balloons fail to meet the specification requirements, the aerological sounding balloon lot is considered UNSATISFACTORY. If at any time the performance of the aerological sounding balloons fails to meet the specification requirements, the COR may suspend further inspections and tests and forward all data to the Contracting Officer for resolution.

2.1.4 Aerological Sounding Balloon Production Test Schedule

The approximate duration for inspections and tests is ten workdays for each type of aerological sounding balloon lot. This estimate needs to be multiplied by the number of aerological sounding balloon lots for the total time required.