J-1 80MSFC23LLVST Valves - SOW (FE).pdf

MSFC Contract No. TBD Attachment J-1, SOW

J-1-1

Statement of Work (SOW) For

Low Leakage Valves

1. PURPOSE

The purpose of this effort is the design, manufacturing, and development testing for Low Leakage Valves concepts used to primarily service liquid hydrogen in-space applications. These in-space applications include envisioned deep space transportation architectures such as cryogenic-based chemical and nuclear propulsion systems.

2. OBJECTIVE

The objective of this effort is to increase the Technology Readiness Level (TRL) of Low Leakage Valve concepts for long duration missions requiring extended cryogenic fluid storage and propellant transfer operations. Critical to the success of these operations are flight-weight cryogenic valves that provide low leakage rates meeting mission requirements. Current TRL values for cryogenic valve technology relevant to these mission needs are in the 4 – 5 range.

Figure 1 shows several critical cryogenic valve types required for a notional deep space propulsion stage.

Figure 1- Critical Cryogenic Valve Types for Notional Deep Space Stage

Completion of this effort will further mature Low Leakage Valve concepts to a TRL value of 6, meaning “prototype demonstration in a relevant environment (ground/space)”. Maturation to a TRL 6 value for these valve types will greatly enhance domestic design knowledge leveraged for future low leakage valve flight component development programs.

The Contractor may utilize the seat technology previously developed by National Aeronautics and Space Administration (NASA) / George C. Marshall Space Flight Center (MSFC) or any other valve technology approach to achieve low leakage per the requirements. The provided NASA/MSFC seat technology utilizes a metallic poppet head with five degrees of freedom that allows the poppet to self-align with the seat, reducing the need for tight tolerances. A spherical poppet and conical seat design is a classic design for poppet valves, but a flexible coupling with load application below the seat contact point is used to reduce the potential for non-uniform seat stress associated with misalignment. NASA/MSFC has demonstrated this seat technology on the following valve type / size combinations, also shown in Figures 2 - 4:

• a liquid hydrogen isolation valve with an inner diameter of 3”

• a liquid hydrogen isolation pre-valve with an inner diameter of 8”

J-1-2

• a hydrogen tank relief valve with an inner diameter of 3”

Figure 2 - Cross-Section of NASA/MSFC Tested Low Leakage, 3” Inner Diameter LH2 Isolation Valve

Figure 3 - Cross-Section of NASA/MSFC Tested Low Leakage, 3” Inner Diameter LH2 Relief Valve

J-1-3

Figure 4 - Cross-Section of NASA/MSFC Tested Low Leakage, 3” Inner Diameter LH2 Pre-Valve

NASA/MSFC development valve sizes were chosen to be at least 3” inner diameter to support successful concept scaling to larger valve designs required for future mission applications, as demonstration at sizes below 3” inner diameter significantly limits design knowledge extensibility for larger scales. Additionally, the liquid hydrogen isolation valve design of at least 3” inner diameter and demonstration was identified as having the most cross-cutting applicability to the other valve design types. NASA anticipates that future low leakage valve designs matured for flight applications would leverage different actuation approaches than those shown in Figures 2 through 4.

3. WORK SCOPE

This effort shall consist of a Base Period of performance and multiple Options as defined in Table 1 – Low Leakage Valve Contract Line Item Numbers (CLINs) below. CLIN durations are provided in Figure 5.

Table 1 - Low Leakage Valve Contract Line Item Numbers (CLINs)

CLIN #

Title Applicable

SOW Section 1 Base – Primary Valve Design 3.1, 4.0-7.0

2 Option – Secondary Valve Design 3.2, 4.0-7.0

3 Option – Tertiary Valve Design 3.3, 4.0-7.0

4 Option – Primary Valve Fabrication and Test 3.4, 4.0-7.0

5 Option – Secondary Valve Fabrication and Test 3.5, 4.0-7.0

6 Option – Tertiary Valve Fabrication and Test 3.6, 4.0-7.0

J-1-4

Valve Designation

Work Scope Months Relative to Contract ATP

0 12 24 36

Primary Design CLIN 1 Base Period Manufacture and Test CLIN 4 Option Period

Secondary Design CLIN 2 Option Manufacture and Test CLIN 5 Option Period

Tertiary Design CLIN 3 Option Period Manufacture and Test CLIN 6 Option Period

Figure 5 - Low Leakage Valve CLIN durations

3.1 Base Period (CLIN 1) Work Scope

The Contractor shall perform the activities described in SOW Section 3.1 as part of the Base Period (CLIN 1). The Base Period duration shall not exceed twelve (12) months from contract award.

3.1.1. Primary Valve Design Scope

During the Base Period, the Contractor shall design a liquid hydrogen isolation valve, designated ‘Primary,’ with an inner diameter of no less than 3.” This valve will be designed using the Low Leakage Valve Specifications given in Attachments J-4 through J-6 of this solicitation.

The Contractor shall design and perform supporting analyses for the Low Leakage Valves up to the Critical Design Review (CDR) level for each valve design. Design requirements for the Low Leakage Valves are provided in Attachment J-3.

The Contractor shall prepare and submit Component Performance Analysis documentation in accordance with Data Requirements Descriptions (DRD) 1829DE-004 for each valve design.

The Contractor shall prepare and submit Structural Strength and Fatigue Analysis Reports in accordance with DRD 1829DE-005 for each valve design.

3.1.2. Milestone Reviews

During the Base Period, the Contractor shall prepare for and conduct a Kick-Off meeting. The Kick-off meeting shall be held within two weeks after contract award. During the kick-off meeting, the Contractor shall provide values for all To Be Supplied (TBS) items in the requirements document. The contents of the kick-off meeting shall comply with DRD 1829MA-

002. In addition, the kickoff meeting shall also address the heritage of the proposed hardware and provide an overview of the Primary valve design. The Contractor may have a single Kick-Off meeting for all the valves at once or have individual meetings for each valve design.

J-1-5

The Contractor shall prepare for and conduct a Preliminary Design Review (PDR) per DRD 1829MA-003, Major Review Documentation. The contents of the PDR shall comply with DRD 1829MA-003. The Contractor may have a single PDR meeting for all the valves at once or have individual meetings for each valve design. PDR entrance and success criteria are described in

NPR 7123.1A.

The Contractor shall prepare for and conduct a CDR per DRD 1829MA-003, Major Review Documentation. The contents of the CDR shall comply with DRD 1829MA-003. The Contractor may have a single CDR meeting for all the valves at once or have individual meetings for each valve design. CDR entrance and success criteria are described in NPR 7123.1A.

The Contractor, through the Contracting Officer’s Representative (COR), shall invite NASA to attend all milestone reviews. All milestone reviews shall be held at the Contractor’s facility, with a virtual option for attendees unable to travel.

3.1.3. Base Period Deliverables

The Contractor shall provide the following deliverables during the Base Period (CLIN 1):

1. Low Leakage Valve Primary Design PDR Analysis and Design Package

2. Low Leakage Valve Primary Design CDR Analysis and Design Package

3. Low Leakage Valve Primary Design Development Test Plans

4. Low Leakage Valve Primary Design Top-level assembly drawings & CAD model

All other deliverables are due as specified per the applicable DRDs.

J-1-6

3.1.4 Base Period Milestone Schedule

The following Base Period milestone schedule shall be applicable to all major reviews and deliverables identified in Section 3.1.

Milestone No.

Milestone Title

Acceptance Criteria

Timeframe

Kickoff

As defined in DRD

1829MA-003

ATP + 2

weeks

Preliminary Design Review

As defined in

DRD 1829MA-003

ATP + 4

months

Critical Design Review

As defined in

DRD 1829MA-003

ATP + 10

Final Delivery of Base Period Development Test Plans, Top-level Assembly Drawings &

CAD

Model(s)

As Defined in 1829CM-

ATP + 11

3.2 Option - Secondary Valve Design (CLIN 2)

The Contractor shall perform the activities and apply all requirements as described in SOW Section

3.1 for the designated ‘Primary’ valve design to the designated ‘Secondary’ valve design as part of the CLIN 2 Option. The Option for Secondary Valve Design scope shall start at the completion of the CLIN 1 Base Period and shall be twelve (12) months in duration.

3.3 Option - Tertiary Valve Design (CLIN 3)

3.1 for the designated ‘Primary’ valve design to the designated ‘Tertiary’ valve design as part of the CLIN 3 Option. The Option for Tertiary Valve Design scope shall start at the completion of the Base Period (CLIN1) and shall be twelve (12) months in duration.

3.4 Option - Primary Valve Manufacturing and Test (CLIN 4)

The Contractor shall perform the activities described in this section during a period of performance starting at completion of the Base period and extending for up to 12 months from award of the CLIN 4.

J-1-7

3.4.1 Option – Primary Valve Manufacturing and Test Milestone Reviews

During the Option for Primary Valve Manufacturing and Test (CLIN 4), the Contractor shall prepare for and conduct a Test Readiness Review (TRR) per DRD 1829MA-003, Major Review Documentation, for development testing for the Primary valve design. The contents of the TRR shall comply with DRD 1829MA-003, Major Review Documentation.

The Contractor shall prepare for and conduct a Development Review (DR) per DRD 1829MA-003, Major Review Documentation. The contents of the DR shall comply with DRD 1829MA-003.

The Contractor, through the COR, shall invite NASA to attend all milestone reviews. All milestone reviews shall be held at the Contractor’s facility, with a virtual option for attendees unable to travel.

3.4.2 Option – Primary Valve Manufacturing and Test: Valve Fabrication

The Contractor shall provide manpower, facilities, consumables, and material to complete the manufacture, assembly and development testing of the Primary Valve Design.

3.4.3 Option – Primary Valve Manufacturing and Test: Testing

The Contractor shall test Primary Valve Design. The Contractor shall perform testing per Section 4 of the requirements document located in Attachment J-3. The Contractor shall hold a TRR prior to the start of Development testing. The Contractor shall also provide a test data distribution to NASA. The Primary Valve design concept shall be a TRL 6 at the completion of the test program.

The Contractor shall prepare and submit a Development Test Procedure in accordance with DRD 1829DE-002 for the Primary Valve design. Additionally, the Contractor shall prepare and submit a Development Test Report in accordance with DRD 1829DE-003 for the Primary Valve design.

3.4.4 Option – Primary Valve Manufacturing and Test: Deliverables

All hardware developed and tested during this Option shall be delivered to the government. The Contractor shall also provide all Development Test Reports generated during this Option.

All other deliverables are due as specified per the applicable DRDs.

J-1-8

3.4.5 Option – Primary Valve Manufacturing and Test: Milestone Schedule

The following milestone schedule shall be applicable to all major reviews and deliverables identified in Section 3.4.

Milestone No.

Milestone Title

Acceptance

Criteria

Timeframe

Option (CLIN

4) Kickoff

Option Period

(CLIN 4) ATP

+ 2 weeks

Test Readiness

Review

+ 6 months

Development

Review

10 months

Final Delivery of all

Option (CLIN 4) Tested Valves, Development Test Procedures, and

Development Test Reports

As Defined in

1829CM-001,

1829DE-002, and

1829DE-003

11 months

3.5 Option - Secondary Valve Manufacturing and Test (CLIN 5)

3.4 for the designated ‘Primary’ valve design to the designated ‘Secondary’ valve design as part of the Option (CLIN 5). The Option for Secondary Valve Manufacturing and Test scope shall start at the completion of the Option Secondary Valve Design (CLIN 2) and shall be twelve (12) months in duration.

3.6 Option - Tertiary Valve Manufacturing and Test (CLIN 6)

The Contractor shall perform the activities and apply all requirements as described in SOW Section 3.4 for the designated ‘Primary’ valve design to the designated ‘Tertiary’ valve design as part of the Option (CLIN 6). The Option for Tertiary Valve Manufacturing and Test scope shall start at the completion of the Option Tertiary Valve Design (CLIN 3) and shall be twelve (12) months in duration.

J-1-9

4. PROJECT MANAGEMENT

The Contractor shall perform management functions and establish a management structure to plan, direct, and integrate all activities required by this SOW to assure compliance with technical, schedule, and financial commitments of the contract. The Contractor shall include a process for the timely disposition of corrective actions and provide for the reporting of technical data as required. The Contractor shall utilize established management structures and assign a Project Manager (PM) with the authority to direct contract activities. The PM shall assure that the technical, schedule and cost requirements of this contract are fully met.

The Contractor shall accomplish the management and technical control of interdivisional, subcontractor, and vendor activities required to fulfill the contract requirements. The monthly progress performance data provided by the Contractor shall include management visibility into aspects of interdivisional, subcontractor, and major vendor activities relevant to accomplishing the contract requirements.

The Contractor shall provide technical information concerning any invention, discovery, improvement, or innovation made by the Contractor in the performance of work under this contract. Technology Reports shall be prepared in accordance with DRD 1829CD-001.

The Contractor shall prepare and submit an Organizational Conflict of Interest (OCI) Plan in accordance with DRD 1829MA-001.

4.1. Resource Planning

The Contractor shall maintain a Program/Project Schedule in accordance with DRD 1829MA- 002.

4.2. Financial, Technical, and Schedule Reporting

The Contractor shall prepare and submit a Monthly Progress Report in accordance with

DRD 1829MA-004.

4.3. Meetings and Reviews

Manpower, facilities, and data shall be prepared to support the formal reviews required within this scope of work. Data required for each review shall be delivered in accordance with DRD 1829MA-003, Major Review Documentation.

4.4 Bi-Weekly Technical Meetings

The Contractor shall conduct bi-weekly technical meetings to provide NASA with a current status of the Contractor’s technical and schedule performance under the contract. Subcontractor

J-1-10 and vendor activities required to fulfill the contract requirements shall be included as part of these meetings. The meetings may be conducted by telecon from the Contractor’s facility.

The format for the status shall be in form of a quad chart listing the following as a minimum:

current status, planned upcoming activities, schedule status, issues. Other status information too detailed for a quad chart shall be presented as a separate presentation package.

The length of the bi-weekly meetings shall be planned at one hour maximum each (this time may be extended based on Contractor need).

All bi-weekly status information shall be delivered to the COR no less than 24 hours prior to the bi-weekly meeting.

4.5 Configuration Management and Control (CM&C)

The Contractor shall perform the configuration management and control required to ensure that the configuration of the hardware for which the Contractor is responsible is reflected in the hardware deliverables, data deliverables, and Contractor drawings. The utilized CM&C, as well as associated released engineering, shall support conversion/release of documentation in a format appropriate and associated with non-human-rated system hardware with minimal cost.

Engineering drawings and associated lists shall be provided to meet the requirements of ASME Y14.100 and ASME Y14.41 in accordance with DRD 1829CM-001. This documentation shall define the detail design of the hardware for the component. Detailed manufacturing procedures and process specifications will be made available to NASA at the Contractor facility but will not be delivered. The interface control drawing and parts list shall be delivered to NASA.

4.6 Data Management

The Contractor shall perform data management for the contract deliverables including documentation (in any agreed upon media), automated databases, and related products. The utilized CM&C, as well as associated released engineering, shall be developed in a way that will economically facilitate a conversion of the media into a format that is compatible with the development of non-human-rated system hardware.

The Contractor shall report and document the performance of the work in this SOW and fulfill the requirements of the associated DRD as outlined in the Data Procurement Document (DPD) 1829 (Attachment J-2). The contractor shall determine the data restriction that applies to each data deliverable and mark or transmit the data restriction in accordance with section

2.3.3 of the DPD.

4.7 Government Furnished Data

J-1-11

The Government is providing the NASA seat technology design information as Attachments J-4, J- 5, and J-6.

5. SYSTEMS ENGINEERING

The systems engineering effort shall include the design and engineering essential to evaluate and allocate hardware performance and operability requirements. Technical metrics shall be established, with NASA concurrence, and shall be tracked and reported to ensure that the evolving design meets the requirements.

The Contractor shall develop, document, and implement a verification and validation program that confirms the deliverable product complies with requirements, is at TRL 6, and is ready for a particular use, function, or mission.

Determining the product’s ability to meet the set of requirements and readiness for a particular use, function, or mission shall be based on the assessment of the verification/validation report(s).

The verification/validation compliance assessment which identifies, and correlates all submitted reports against the products' set of requirements shall be in accordance with DRD 1829SE-001.

The Contractor shall provide technical data and analyses which describe the studies, analyses, and results of specific engineering activities at the PDR and CDR. The data shall include such technical specialties as theoretical analyses, models, engineering verifications, engineering design trades, current problems and proposed solutions, and conclusions and recommendations.

6. SAFETY, HEALTH, AND MISSION ASSURANCE

The Contractor shall develop, document, and implement plans to ensure that safety and mission assurance (safety and quality) activities are implemented and are effective in the mitigation of risk for the program, including methods to measure their performance. In addition, the Contractor shall ensure that subcontractors implement similar safety and mission assurance plans.

6.1. Safety

The Contractor shall prepare and submit an Off-Site Safety, Health, and Environmental (SHE) Plan in accordance with DRD 1829SA-001.

The Contractor shall prepare and submit Space Technology Mission Directorate (STMD) Mishap Preparedness and Contingency Plan (MPCP) Supplemental Document in accordance with DRD 1829SA-002.

J-1-12

6.2 Quality Assurance and Engineering

The Contractor shall have a means to identify, document, and correct non-conformances, problems, and failures. The Contractor shall notify the NASA COR of any issues that may affect function or schedule during this contract effort. This notification shall be by telecon and e-mail from the Program Manager within 48 hours of the awareness of the issue.

6.2.1 Right to Access

All facilities and documentation used by the Contractor and its sub-tier Contractors shall be open to evaluation by NASA. In these cases, the Contractor shall arrange to provide NASA authorized representatives with access to areas in which work is being performed. NASA will provide reasonable notification prior to any evaluations. The Contractor shall comply with FAR 46.202-4 “High Level Contract Quality Requirements.”

6.2.2 Certificate of Compliance (C of C)

The Contractor shall provide a certification with each shipment to attest that the parts, assemblies, subassemblies, or detail parts conform to the Order requirements. When applicable, the true manufacturers, lot, heat, batch, date code, and/or serial number shall appear on the certification.

MSFC shall perform inspection, as necessary, to determine the acceptability of all articles under this order. All articles submitted by the Contractor under this Order are subject to final inspection by MSFC.

6.2.3 Calibration System

The Contractor shall have a documented Calibration System that meets the requirements of ISO 10012, “2003 Measurement Management System” quality assurance requirements for measuring equipment, or the American National Standard Institute (ANSI)/National Conference of Standards Laboratories (NCSL) Z540-1, General Requirements for Calibration Laboratories and Measuring and Test Equipment. The use of alternate calibration system requirements documents requires NASA approval for use.

6.2.4 100% Attribute Clauses

The Contractor shall maintain, on file, as objective evidence, one reproducible copy of all inspection documentation stamped by the responsible quality inspector showing 100% inspection for all critical attributes noted on the drawings and/or manufacturing instructions, for all parts submitted under this Contract/Purchase Order.

6.2.5 Packaging, Handling & Labeling

The Contractor shall meet the Packaging, Handling & Labeling requirements specified in the component specification.

J-1-13

6.2.6 Shipping Documents

The Contractor shall generate the DD250 form and the MSFC QAR shall be one of the approving officials for the DD250. The DD250 will be a part of the Low Leakage Valve documentation that is shipped with the hardware. This will follow the MSFC management review and acceptance, including the MSFC SMA Quality Lead review and acceptance.

Upon successful completion of testing at the Contractor’s facility, the hardware and documentation shall be packaged and shipped by the Contractor in accordance with the contract instructions or as provided by the COR.

6.2.7 Record Retention

The Contractor and their sub-tiers shall maintain verifiable objective evidence of all inspections and tests performed, results obtained and dispositions of nonconforming articles. These records shall be made available to MSFC and/or Government Representatives upon request and shall be retained in a safe, accessible location for the life of the program. The Contractor’s records associated with the manufacture of serialized or lot controlled articles shall provide for continued traceability of serial number or lot number identification through all phases of manufacturing, commencing with the raw material and continuing through final acceptance of the end item.

Records shall be held for 10 years after delivery of the hardware. These records shall not be destroyed without the MSFC's written concurrence.

6.2.8 Contamination Control, Manufacturing and Processing

The Contractor shall prepare and submit a Materials and Processes Identification and Usage List (MIUL) in accordance with DRD 1829MP-001. Special attention shall be made to address concerns with material compatibility with the hydrogen operating media.

The Contractor shall prepare and submit Material Usage Agreements (MUAs) in accordance with DRD 1829MP-002.

6.2.9 Flow-Down of Requirements

All requirements that are identified or applied to the MSFC purchasing document, including this clause, shall be flowed down to the Contractor’s sub-tier suppliers.

7. DATA REQUIREMENTS

7.1. Other Data Deliverables

The Contractor shall conduct the necessary efforts to ensure all data for this task, required and deliverable, are prepared and managed in accordance with this contracted effort. Data shall be made available to the Government in hardcopy and electronic format. Communication of the data may include on-site reviews, electronic data transfer, or other means used to provide

J-1-14 information in advance of activities, to report status, and to document formal reviews, requirement compliance, and hardware performance.

7.2. Documentation

The Contractor shall ensure the generation and delivery of all documentation as called out in the attached DPD (reference Section J-2) and DRDs (reference Attachment J-2).