MK_54_LWT_Common_Parts_Kits___Industry_Day_Brief.pdf

MK 54 Lightweight Torpedo (LWT) Common Parts Kits Industry Day - Agenda

26 June 2014 Naval Undersea Warfare Center Division, Newport, Bldg 80

Time Topic Presenter

MK 54 Lightweight Torpedo Common Parts Kits Industry Day

Deputy Competition Advocate / Small Business Advocate

26 June 2014

Stephen Stewart

Captain Cramer, DIVNPT CO, has challenged us to implement a comprehensive program to encourage, ensure and increase competition

To achieve these goals:

A Deputy Competition Advocate has been appointed to ensure and increase competition across the DIVNPT “Enterprise”

A Small Business Advocate has been appointed to manage the Office of Small Business Programs (OSBP), and to ensure the achievement of Small Business goals assigned by SEA00K and the DIVNPT CO

Role of DCA/SB Advocate

Both positions report directly to the DIVNPT CO, demonstrating senior leadership commitment and support

Small Business Advocate has corresponding accountability to SEA00K

DCA and Small Business Advocate are complimentary roles

Integral part of an IPT with:

Contracts Department, Office of Counsel, Technical Departments, Technical Department Acquisition Advocates (TDAA’s), Public Affairs, SBA, RI PTAC, Local Trade Groups, etc.

Role of DCA/SB Advocate ~ (con’t)

SeaPort-e is primary service contract vehicle

SeaPort-e Portal https://auction.seaport.navy.mil/Bid/Login.aspx

“Rolling Admissions”/voluntary re-certification each April

Zone 1

Moving back to 5 year Period of Performance

NAICS Code: 541330, Small Business Size Standard:

$35.5M/year

All team members must be approved prior to bid.

Teaming agreement not required to be added to a Prime’s SeaPort-e basic multiple-award contract

NUWCDIVNPT Overview

Federal Business Opportunities (FBO) http://www.fedbizopps.gov/

GSA E-Buy https://www.ebuy.gsa.gov/advantage/ebuy/start_page.do

State Procurement Technical Assistance Centers (PTAC’s) can assist with FBO, GSA searches http://www.riptac.org/

“Cross Departmental” TO’s

Adding subs after contract award

NUWCDIVNPT Overview

Social media and local trade groups/associations

LinkedIn https://www.linkedin.com/

RI Chapter of the National Contract Management Association

(NCMA)

http://ncma-ri.org/contact-us/ http://ncma-ri.org/list-companies/

“On-Line Matchmaker”

Southeastern New England Defense Industry Alliance

(SENEDIA)

http://www/senedia.org/contact-us.html/

Armed Forces Communication and Electronics Association

(AFCEA)

(781) 862-2465

NUWCDIVNPT Overview ~ (Con’t)

DCA/SB Advocate has engaged at the earliest stage of the procurement process Conducted Industry Survey

Best practices and recommendations to increase competition

Sources Sought Process/Instruction

SeaPort-e Council

Industry Days

Advanced Notices

Increased page count for Past Performance

Transition Plans

More detailed SOW’s

Competition Initiatives

RFP Release Timing/Coordination

“Functional” e-mail accounts for each Department

Hypothetical Questions/Sample Tasks

Pre-Solicitation Conferences

Increased Proposal Response Time

Hosted forty-eight (48), to date, events and briefings focused on increasing competition

2-Year Long Range Acquisition Forecast

Electronic Reading Room Website link

Competition Initiatives ~ (Con’t)

Increase overall competition by ensuring all companies have a fair opportunity to compete

Encourage new vendors to bid

Reduce/eliminate SeaPort-e RFP responses by (1) vendor

FY12 to Date Results:

Every RFP that had received multiple bids previously received multiple bids again

Reduced (1) bids by 70%

Several new incumbents

Four (4) new Prime vendors have entered the market

DCA Goals and Metrics

FY 13

NAVSEA-assigned goal: 25%

DIVNPT (Capt. Cramer) assigned “stretch goal”: 35%

Achieved 39%

Awarded a total of $336M to large and small businesses in FY 13 for Products and Services

$126M to small business Additional 51$M

SB Advocate Goals & Metrics

FY 14

Total $ awarded (Services and Products) will remain steady

NAVSEA - assigned goal: 25%

DIVNPT (Capt. Cramer) assigned “stretch goal”: 45%

Upcoming Challenge/Opportunity: several small businesses will graduate from the small business program in June.

SB Advocate Goals & Metrics ~ (Con’t)

FY12 FINAL

FY13 Final

DIVNPT has been nominated for several “Small Business Achievement Awards” for FY13

SB Advocate Goals & Metrics ~ (Con’t)

Oct. TBD, 2014: Small Business Product Vendor Industry Day

Fall 2014: Virginia Payload Tube Industry Day

November TBD, 2014: SDVOSB/VOSB Conference

Dec TBD, 2014: SeaPort-e Council Meeting

April TBD, 2015: SBRT Event “Reverse Matchmaker”

May TBD, 2015: SeaPort-e Council Meeting

Upcoming Events

Events are posted via FBO, SeaPort-e Portal, LinkedIn, NCMA, SENEDIA, AFCEA, RI PTAC)

DIVNPT has implemented a comprehensive and on-going program to encourage, ensure and increase competition

Visibility and support at the highest DIVNPT leadership level

DIVNPT is a vibrant and competitive environment and offers many opportunities to Prime, and/or Sub

The DIVNPT DCA/Small Business Advocate is the ideal entry point for any business (large or small) that wants to do business with DIVNPT http://www.navsea.navy.mil/nuwc/newport/pages/OSBP.aspx

NUWC_NPT_OSBP@navy.mil

Takeways

Thank you

26 June 2014 Mr. Brian Benedict, Contract Specialist

Naval Sea Systems Command

NAVSEA 02641

MK54 Lightweight Torpedo (LWT) Common Parts Kits Production

Procurement Overview

UNCLASSIFIED

UNCLASSIFIED

Undersea Weapons

PMS 404

MK 54 Lightweight Torpedo (LWT) Common Parts Kits Industry Day - Agenda

26 June 2014 Naval Undersea Warfare Center Division, Newport, Bldg 80

Time Topic Presenter

Undersea Weapons

PMS 404

Undersea Weapons

PMS 404

Full and Open Competition Base Plus Four (4) Options

Contract Type

Period of Performance One (1) Year Past the Last Delivery

No. CLINs Contract Type

Undersea Weapons

Undersea Weapons

Capt. David Ogburn

UNDERSEA WEAPONS PROGRAM OFFICE

PMS 404

MK 54 Lightweight Torpedo Production Industry Day Torpedo Acquisition Strategy

Distribution Statement A:

Approved for public release, distribution is unlimited.

Welcome The Undersea Weapons Program Office (PMS 404) is responsible for:

Development, Test & Evaluation, Production, and Life Cycle Support of all USN Torpedoes, Targets and Torpedo Launch Accessories

Planning for Production Acquisition of MK 54 MOD 0 Lightweight Torpedo Kits and Common Parts for MK 54 MOD 1 for FY 16-20

Industry Day and Request For Information (RFI) is part of Market Research

Gauge Industry Interest and Capability

MK 54 MOD 0

Lightweight Torpedo

Processor Group Assembly (PGA) Control Group Assembly

(CGA)

Afterbody Kits

W4 Cable Assembly

Warshot Fuel Tank Shell

Nose Warhead

Fuel Tank

Afterbody

LWT Torpedo Evolution

Utilizes the MK 50 sonar, the MK 46 warhead and Afterbody, and MK 48 algorithms with advanced Commercial off-the-shelf (COTS) electronics

Torpedo Acquisition Strategy Intent:

MK 54 MOD 0 Torpedo has been in Full Rate Production (FRP) since FY 05 MK 54 MOD 1 Torpedo will start Low Rate Initial Production (LRIP) in FY 15 In FY 15, MK 54 MOD 1 Common Parts will have been procured on the current FY 11 – 15 MK 54 MOD 0 Kits production contract (N00024-11-C-6410) In FY 16, the new MK 54 MOD 0 production contract will be awarded to produce MK 54 MOD 0 LWT for both USN and FMS, as well as the Common Parts for MK 54

MOD 1

Process:

Full and Open competition One (1) Award – Base Plus Four (4) Options Separate CLINs for up to 550 Kits of Common Parts and 550 MK 54 MOD 0 PGAs per year One (1) POM / First Article CLIN to qualify the obsolescence refresh design and contractor USN and FMS procurements made on the same CLINs to allow for economic orders Current budget projects about 50% of the potential procurement is USN. There are no current FMS cases for this contract but 22 Navies operate the aging MK 46 Torpedo with over 6,000 units, which need to be replaced.

PB-15 Budget Strong support for MK54 Torpedo both in Fleet and Navy Headquarters

Torpedo Acquisition Plan

All quantities are tentative and subject to change

Base OY 1 OY 2 OY 3 OY 4

FY16 FY17 FY18 FY19 FY20

Competition The Program Goal for this procurement is to provide effective, affordable, and high quality products for the USN and FMS. The Prime Factors in this procurement will be:

Technical approach to deal with obsolescence. The USN plans to qualify the design and contractor only one (1) time during the contract.

Risk Management approach that produces low or moderate risk for both the contractor and Government.

Quality approach that produces reliable products and is continuous and predictive to prevent problems (design or workmanship) from escaping to the Fleet.

Demonstrated success and experience in all the above.

Looking for Innovation and/or Proven Processes in Areas Above Process Efficiency and Manufacturing Quality are Critical Factors

Mr. Rod Bragg, Production Manager

UNDERSEA WEAPONS PROGRAM OFFICE

PMS 404

MK 54 Lightweight Torpedo Production Industry Day Program Overview

Distribution Statement A:

Approved for public release, distribution is unlimited.

PMS 404 Interaction Requirements and funding are provided to PMS 404 by OPNAV N96 to support MK 54 LWT program.

NAVSEA Participating Organizations

Contracting (SEA 02) Legal (SEA 00L)

TWH (SEA05)

Spares (SEA04)

Fund Naval Undersea/Surface Warfare Centers

NUWC Newport - Rhode Island NUWC Keyport – Washington NSWC Indianhead - Maryland

PMS 404 Organization

Lightweight Torpedo Production Branch

CAPT David Ogburn

Bob Jackson

Marc Goldenberg

VACANT / Luciano Roberto Diana

Patricia Kirkham

Rod Bragg

Darnell Eaton Glenda Leon

VACANT / Berrocal

Ebal Onyiego

PMS404 LWT Production Group

Juan Berrocal

Mark Kinney

Dave Chesler

From Production

Intermediate Maintenance Activity (IMA)

Install FIRs / Cables Into Forebody Assemble Forebody Into EX Torpedo Test All Up Round on Mk 695 ATE

Deliver Samples For IW Exercise Test In Tube Test and Prelaunch Checkout

Conduct IW Exercise Tests

Return Torpedo To IMA Analyze Run Results

Return FIR Failures To Support Org.

Following Successful IW Test or Lot Acceptance , Deliver Warshot Torpedoes 8 year Deployments

NUWC Responsibilities

MK 54 LWT Evolution

MK46 MOD 5A(S)/(SW) Torpedo

MK50 MOD 0/1 Torpedo

MK54 Torpedo

MK 54 LWT Background The Lightweight Torpedo (LWT) is the primary surface and aviation Anti-Submarine Warfare (ASW) weapon

Consists of MK 46 and MK 54 torpedoes, launch accessories, and training assets

MK 54 Lightweight Torpedo IOC in 2004, currently in Full Rate Production (FRP)

Provides direct and urgent-attack capability for ASW platforms

MK 54 requires various platform modification for full digital capability

Warhead Fuel Tank

Afterbody / TailconeNose

The MK 54 LWT consists of four (4) separate torpedo sections:

1. Nose Section

Array Nose Assembly (ANA) and Transmitter Consists of an Acoustic Array Assembly (AAA):

MOD 0 – A 52-element array (procured on separate contract) MOD 1 – A 112-element array (procured on separate contract)

Processor Group Assembly (PGA) – (2 designs non-interchangeable between MK 54 MOD 0 and MK 54 MOD 1

2. Warhead Section (reused from the MK 46 Torpedo)

3. Warshot Fuel Tank Section

The Control Group Assembly (CGA) Fuel Tank Shell

4. Afterbody Section (MK 46 Torpedo Afterbody plus an MK 54 MOD 0 Afterbody Upgrade Kit)

MK 54 LWT Overview

MK 54 MOD 0 Kit Procurement

MK 54 MOD 0 Kit Competitive Contract Processor Group Assembly (PGA) – Performance Specification Control Group Assembly (CGA) – Performance Specification Inertial Measurement Unit (IMU) – Performance Specification W4 Cable Assembly – Performance Specification Warshot Fuel Tank – Build to Print Afterbody Upgrade Items – Build to Print Functional Item Replacement (FIR) Mounting Hardware – Build to Print Associated Cables – Build to Print

MK 54 MOD 0 Components

Ar ra y

FA

I Tr an sm itt er

PG

A

W ar he ad

Af te rb od y/ Fu el T an k

C G

A/

IM

U

MK 54 MOD 1 Configuration

SBIR Phase III Integrates a new 112 element sonar system with the accompanying electronic interfaces Significant upgrade to MK 54 performance in shallow water, low doppler, and countermeasure environments Uses same CGA, IMU, Fuel Tank, A/B Upgrade Kit and Cables as MK MOD 0

Ar ra y R ec ei ve r

Tr an sm itt er

PG

A

W ar he ad

C G

A/

IM

U

Af te rb od y/ Fu el T an k

MK 54 MOD 1 Components

MK 54 Software Architecture HWT Torpedo SW ArchitectureApplication

Software Application Software

Application Software

Application Software

Hardware and Transport Layers (VME, VPX, PCIe, GgE … )

Operating System and Board Support Packages (VxWorks)

Adaptation and Computational Middleware (SPMW &

DPHAL)

System Unique Application Software

Open Source/Proprietary Middleware

Open Standards

Open Standards

Open Standards

Hardware, Backplanes and Transport Layers ( VME, Ethernet, TCP/IP … )

Operating System and Board Support Package (VxWorks with Modified BSP, Loader and BIT)

Domain Specific Middleware (MW provides a consistent API for HW/SW isolation.

Source made available to contractors)

Weapon Control

CIC & Xmit Control

Signal Processing

PGA

FDFL

C HAL

CGA

FDFL

CDP HAL

Autopilot & Hybrid Interface

Government Software Support

Activity (SSA) Responsibility

Production Contractor

Responsibility

Torpedo System Overview

26 June 2014

Karla Fajardo

What is a MK 54 Torpedo ?

MK 54 Operational Environment

Basic Facts

MK 54 description and weapon processing Major functions

Sections and components

Fleet Lightweight (LWT) in-service cycle

Presentation Overview

MK 54 Torpedo Operational Environment

Length: ~ 9 feet

Diameter: 12.75 inches

Weight: ~ 630 lbs.

Basic Facts

WARSHOT

CONFIGURATION

EXERCISE

CONFIGURATION

Length: ~ 9 feet

Diameter: 12.75 inches

Weight: ~ 608 lbs.

Torpedo MK 54

WARSHOT CONFIGURATION

Fuel Tank Afterbody / Tailcone

EXERCISE CONFIGURATION

Fuel Tank Afterbody / Tailcone

Forebody

Forebody

MK 54 Torpedo Section Functions

WARSHOT EXERCISE

Sonar Section Guidance Sonar Processing Tactical Processing Internal Power Distribution

Warhead Section Exploder Safety

Afterbody / Tailcone Section Propulsion Steering Electrical Power

CGA/IMU Section Navigation Safety Dynamics & Control Inertial Measurement

Fuel Tank Afterbody / Tailcone Fuel Tank Afterbody / Tailcone

Fleet Exercise Section (FES) Performance Data Collection Acoustic Tracking Vehicle Shutdown Vehicle Buoyancy

Fuel Tank Section Fuel for engine

Forebody Forebody

Sonar Section

Warhead Section

Fuel Tank Section

Afterbody / Tailcone Section

WARSHOT CONFIGURATION

CGA / IMU

Section

MK103

Warhead

MK20

Exploder

Fuel Tank MK46 Afterbody Afterbody Kit

SCV

Cables Alternator

ANA

Array Receiver

Transmitter

PGA

CGA

IMU

Torpedo MK 54

EXERCISE CONFIGURATION

Sonar

Section Exercise Section

Fuel Tank Section

Afterbody / Tailcone Section

MK96 Mod1

FES

Fuel Tank MK46 Afterbody Afterbody Kit

SCV

Cables Alternator

ANA

Array Receiver

Transmitter

PGA

CGA

IMU

CGA / IMU

Section

Torpedo MK 54 Spec Tree LHT Performance

Specification 7083713

Forebody CIPS 8210782

MK54 Mod0 Config. Drawing

7083425

External Electrical ICD

8594949

ANA CIPS

8210783

IMU SSS

8595283

CGA SSS

8595281

PGA SSS

8595282

Cables CIPS 8226676

Forebody Mechanical ICD

8210771

External

IRS/IDD

8594950

IMU TRD

8595287

CGA TRD

8595285

PGA TRD

8595286

Forebody Internal Electrical ICD

8595289

Documents currently being updated

Fleet LWT In-Service Cycle

From Production

Intermediate Maintenance Activity (IMA)

Install FIRs / Cables Into Forebody Assemble Forebody Into EX Torpedo Test All Up Round on Mk 695 ATE

Deliver Samples For IW Exercise Test In Tube Test and Prelaunch Checkout

Conduct IW Exercise Tests

Storage & Issue Sites or Magazine

Return Torpedo To IMA Analyze Run Results

Return FIR Failures To Support Org.

Following Successful IW Test or Lot Acceptance , Deliver Warshot Torpedoes 8 year Deployments

IW EX Tests

WS Deployment

WS Deployment

WS Deployment

Keyport

Items to be procured

* = Build to Spec ** = Build to Print

MK 103 Warhead

Receiver

Transmitter

Nose Array

W4 Cable Assembly *

Warshot Fuel Tank Shell **

Afterbody Kits **

Processor Group Assembly (PGA) *

Control Group Assembly (CGA) *

Inertial Measurement Unit (IMU) *

Processor Group Assembly (PGA)

26 June 2014

Tod Camara

Array

Transmitter

Forward Array Interface (FAI) Control Group Assembly (CGA)

PGA ~ Presentation Overview

Warhead

Processor Group Assembly (PGA) W4 Nose Cable Assembly Afterbody

Outline

Mechanical Constraints Interfaces

Warhead Interface Test Interface Fleet Ex. Section (FES) Interface Transmitter Interface Receiver Interface

Functions Power Distribution Ethernet distribution Software Update Capability Scuttle Capability Transmitter & Receiver Control Safety Processing Tactical Processing Sonar Processing

Mechanical Constraints

Mechanical Constraints Located between Transmitter and Warhead Conduction cooled to shell Transmitter/Receiver interface is blind mate

PGA to Warhead Clearance is Very

Limited

Shell Provides PGA Mounting and Thermal Conduction Cooling Support

PGA Cables

W4 – PGA to Warhead Interface

Connects PGA to CGA Connects Transmitter to AC Power From Alternator Must Coil Up to Not Cause Interference When PGA and Warhead are Mated ~ Limited Space Available Build to Spec

Warhead Interface

Warhead Interface Provides main PGA power from the CGA through the warhead (40v) Transmitter power (pass-through) Ethernet communication links:

CGA Communication Link Scuttle control Software Download control

Test Interface

Test Interface Provides PGA analog voltage test points Provides access to defined control signal from inside PGA (per ICD) Provides Ethernet access for test purposes Provides access for providing test power

Test Torpedo Downloader System (TDS) and scuttle power

Fleet Exercise Section (FES) Interfaces

FES Interface (J303 and MRECS backplane) Interfaces the FES to the MRECS (J303)

Serial interface Power and Control signals Extraction Ethernet signals

MRECS (Modular Recording & Control System) Interface PGA Analog voltages and discretes PGA power to support powering MRECS w/o FES connected System Ethernet Recording and Control (100 KBytes/sec)

Shutdown command

Record Interface – Ethernet (4.9 MBytes/sec)

Transmitter and Receiver Interface

Transmitter Interface Transmitter generated by the PGA (5v) Pass through +/-23 volts from warhead interface Serial link to control to the transmitter

Receiver Interface Receiver power generated by the PGA, 5v, +/-12v Control for a tone generator – serial link to pass frequency control Control pattern generator Gain control 16 bit parallel data bus (differential 422)

Power Distribution

Power Distribution Develop internal & forward power from CGA provided power (40v-306 Watts)

Receiver power : 5v, 12v, -12v Transmitter power : 5v MRECS power : 5v Internal power for PGA functions

Distribute transmitter power from warhead interface to the transmitter Proximity to Receiver, Can Result in Sensitivity To Noise / Ripple

Power Regulation Unit

PGA Architecture and Interfaces

Exercise Section

PGA

MRECS

Extraction Ethernet

System

Ethernet

Ethernet Communications and Recording

Recording 4.9 MBytes/sec From PGA to MRECS Dynamics and Safety Critical Interface to Autopilot/HI

Tactical

Sonar

Safety Record

Ethernet

Software Update Capability Torpedo Download System (TDS)

Software Update Capability (Torpedo Download System (TDS)) Controlled by TDS command from warhead interface Update of classified operational software and other software/firmware that might need to be updated during weapon deployment Update of exercise data All power must be derived from internal source in PGA (not externally provided)

Limit of 20mA can be provided through warhead

Front Back

TDS Battery Module Up to Six(6) Downloads Safety Approval (Lithium)

TDS/Memory Scuttle Module CIC Back

Scuttle Capability

Scuttle Capability Controlled by scuttle command from warhead link Erasure of PGA software Must be capable of performing function during weapon deployment All power must be derived from internal source in PGA (not externally provided)

Limit of 20mA can be provided through warhead

Scuttle Battery Module Up to Five(5) Scuttles Safety Approved (Lithium)

TDS/Memory Scuttle Module CIC Front

Transmitter and Receiver Control

Transmitter Control Accept commands from operational software(Tactical) Control the transmitter with accurate timing to generate waveforms

Receiver Control Receive sonar data and provide to operational software (Sonar) for processing

CIC

PGA Architecture and Interfaces

VME64

Exercise Section

Transmitter

Ar ra y

Power Module

DP

COTS

Receiver

CIC

PGA

Serial I/O

Ethernet

Forward Power

Sonar Data Path

CIC Controls Transmit Sequence And Timing Sonar data is streamed to the SP for processing via the CIC

Signal Processor (SP) Data Processor (DP) Communications Interface Controller (CIC) Control Group Assembly (CGA)

COTS

SP

CSCI Applications

( OPSW, FDFL)

Domain Specific Middleware (MW) (Adaptation Layer: CSC Comms & Math Libs)

Operating System ( VxWorks, VspWorks, Linux … )

BSP and Transport Layer Drivers (VME, Ethernet, PCI, FPDP, Rapid IO … )

Hardware Layer

Communications Infrastructure MW (Distribution Layer)

Contractor supplied Middleware (MW) & Integration

Loaders

Government supplied Operational Software

Software (SW) Architecture

UNCLASSIFIED

Safety Processing ~ Government Software Requirements

Safety Processing – Government Software Requirements Memory is protected by Error Correction Code (ECC) Power on BIT will verify the system is functioning correctly per STANAG Power on initialization constraint -12 sec Minimum memory constraint Minimum processing power Minimum I/O capability

Record interface (100KBytes/sec)

DP - GE Intelligent Systems

PPC4A

Tactical Processing ~ Government Software Requirements

Tactical Processing – Government Software Requirements Power on BIT will verify the system is functioning Power on initialization constraint -12 sec Minimum memory constraint Minimum processing power Minimum I/O capability

Record interface (400 KBytes/sec)

DP - GE Intelligent Systems

PPC4A

Sonar Processing ~ Government Software Requirements

Sonar Processing – Government Software Requirements Power on BIT will verify the system is functioning (preferred) Power on initialization constraint -5 sec Minimum memory constraint Minimum processing power Minimum I/O capability

Receive Sonar Data

Record interface (4 MBytes/sec) Capable of being restarted/initialized without affecting tactical or safety processing

SP- GE Intelligent Systems

G4ADSP

PGA Architecture

VME64

Exercise Section

Ar ra y

Power Module

DP

COTS

SP

COTS

Receiver

CIC

PGA MRECS

Serial I/O

CGA

Autopilot

Hybrid Interface

Ethernet

Forward Power

Initialization

After Water Entry, CGA Applies Forward Power to PGA Board Images for DP and SP are Downloaded From CTP Flash on CIC PGA SW Must Communicate With CGA Within 12 Sec’s of Power Application

Signal Processor (SP) Data Processor (DP) Communications Interface Controller (CIC)

Control Group Assembly (CGA)

Transmitter

Test and Programming

Test PGA Designed With Self Test Capability

Built-in-Test (BIT) Resident Application, Hardware Testing Part of Torpedo’s Power on Processing

Fault Detection, Fault Location (FDFL) Downloadable System Testing/Verification

Tested With Contractor Supplied PGA FIR Test

PGA Backplane

Manufacturing Challenges

• Power Supply Noise

• Environmental Conditions

Control Group Assembly (CGA) Overview

26 June 2014

Michael H. Funk

Location of the CGA

Current CGA Components

Power Conditioner

Drive Control Module (DCM)

CGA Data Processor (CDP)

Depth Manifold Assembly (DMA)

CGA Functions

Power Conditioner

Power CCA Circuit Card Assembly

Control CCA Circuit Card Assembly

Accepts power from:

Launch Platform (28 VDC)

Command & Control (C&C) Alternator (150 VAC)

Thermal Battery (100 – 200 VDC)

Creates and sequences:

All CGA internal power All power for the IMU +40 VDC to the PGA via the Warhead Cable ±23 VDC to the Transmitter via the Warhead Cable +40 VDC to the Fleet Exercise Section (FES)

Passes three phase power from the Dual Winding Alternator to the Transmitter via the Warhead Cable

Power Conditioner Functions

Depth Manifold Assembly (DMA)

DMA

DMA Installed Into CGA

DMA mounts to the Power Conditioner frame.

Manifold and Tube subassembly is part of Pressure Distribution System.

Physically connects Depth Sensor and Pressure Switch to torpedo pressure port via a quick-disconnect fitting.

Pressure Switch interfaces with Power Conditioner.

Safety Critical component ~ One of Exploder Circuit Interlocks

Depth Sensor interfaces with the CGA Data Processor (CDP).

Depth Sensor is Government Furnished Equipment (GFE).

Depth data is sampled a minimum of 50 times per second.

Separate deep and shallow depth tolerance bands are allocated across the full operating depth range.

DMA Functions

Drive Control Module (DCM)

Aft Side DCM Circuit Card Assembly (CCA)

Fire Control Interface Provides CGA compatibility with various launch platforms

DCM Functions

Afterbody Interface

Safety Critical Interlocks Seawater Sense 15 ft. Sense Engine Start Permit

Squibs CO2 bottle Engine Igniter

Actuator Drive Circuits Upper Rudder motor Lower Rudder motor Elevator motor

Speed Control Valve Drive Circuit Control/Feedback Loop for Speed

EC approval

CGA Data Processor (CDP)

Aft Side

Drive Control Module (DCM )Connectors

CDP Functions

Ethernet

Data Processor

Identification

Depth Sensor

Digital Fire Control

DCM Data

Debug Port

Serial Interfaces

PGA

MRECS (Modular Recording & Ex. Control System)

TDS

Debug Port

Digital

Analog

FES

IMU

Instrumentation

Discrete Control

Speed Control

CSCI Applications

( OPSW, FDFL)

Domain Specific Middleware (MW) (Adaptation Layer: CSC Comms & Math Libs)

Operating System ( VxWorks, VspWorks, Linux … )

BSP and Transport Layer Drivers (VME, Ethernet, PCI, FPDP, Rapid IO … )

Hardware Layer

Communications Infrastructure MW (Distribution Layer)

Contractor supplied Middleware (MW) & Integration

Loaders

Government supplied Operational Software

Software (SW) Architecture

UNCLASSIFIED

UNCLASSIFIED

All Current Operational software is owned by the US Navy

Current CDP software

– Real -Time operating system: Tornado 2.0.2, vxWorks 5.5 with a custom Board Support Package written in “C” for a Freescale MPC8280 microprocessor.

– Operational software: Written in IBM Rational ADA (vxWorks Required to Load).

– Loader Software written in “C”

– The CDP software is Safety Critical: Government safety processing requirements include:

All memory is protected by Error Correction Code (ECC) Platform BIT will verify the system is functioning correctly Operational software must boot in less than 1 second

CGA Software

Exploder Interface

UNCLASSIFIED

Power Conditioner

Depth Manifold Assembly

CDP

Color Key

Warhead

Fire Control Interface

Afterbody 5608 Connector

Ethernet Switch

PGA

Microprocessor

Non-volatile Memory

Microcontroller

Non-volatile Memory

Stepper Switch Emulation

CDP

DCM

Color Key

TDS Ethernet

Digital Fire Control

Digital Serial

Multiplexer

CGA is mounted to the Warhead or FES

– The CGA has no direct contact with the torpedo shell

– The CGA is conduction cooled through its mounting

All CGA external electrical interfaces are allocated to ten connectors. Each connector is defined by a specific part number and pinout

IMU is mounted on the rear of the CGA but is not considered to be part of it

CGA Mechanical Interfaces

Component obsolescence arises due to MK 54 long life cycle.

Wide variety of electrical devices and assemblies in close proximity.

– Produce high system electrical noise.

– Noise sources include Actuator kickback and Power Conditioner.

Various operational scenarios expose MK 54 to high shock and vibration levels.

Challenges

LWT Software Overview

26 June 2014

Michael H. Funk

CSCI Applications

( OPSW, FDFL)

Domain Specific Middleware (MW) (Adaptation Layer: CSC Comms & Math Libs)

Operating System ( VxWorks, VspWorks, Linux … )

BSP and Transport Layer Drivers (VME, Ethernet, PCI, FPDP, Rapid IO … )

Hardware Layer

Communications Infrastructure MW (Distribution Layer)

Contractor supplied Middleware (MW) & Integration

Loaders

Government supplied Operational Software

Software (SW) Architecture

Hardware changes will impact SW and could impact government SW design.

Contractor could mitigate system impact by performing a thorough assessment of candidate replacement circuit cards

Impacts to government software can protract contractor development and test schedule

Changes that affect software should be assessed thoroughly

Proper planning and development of SW can effectively reduce overall system cost and schedule

Software Updates

UNCLASSIFIED

UNCLASSIFIED

Safety requires visibility at all levels of development to verify processes are followed and testing is performed

FPGA (Field Programmable Gate Array) development and verification has very similar requirements to torpedo software development and verification.

All software must be presented to SSSTRP/WSESRB SSSTRP = Software Systems Safety Technical Review Panel WSESRB = Weapon System Explosives Safety Review Board

Role of Safety

Data Processor & Signal Processor Middleware (MW) (Safety Critical)

All SW below the MW SW interface that allows OPSW and FDFL to execute and run on the hardware. Includes VxWorks Board Support Package.

FDFL

Used with FTE to test and sell off hardware to the government

Loader (Safety Critical) Executes power-on BIT Downloads and executes software at run-time

Contractor is responsible for the maintenance, documentation, support and validation for these SW items.

PGA Software

UNCLASSIFIED

UNCLASSIFIED

Functions implemented as software in the current design:

CTP Interface Card (CIC) software performs TDS download (Safety Related) Scuttle function Receiver processing Transmitter processing Recording Messages Simulation Messages Sonar Reset

PGA Software

UNCLASSIFIED

UNCLASSIFIED

Contractor is responsible for the maintenance, documentation, support and validation for these SW items.

Control Data Processor (CDP) Middleware (Safety Critical)

All software below the defined software interface that allows OPSW and FDFL to execute and run on the hardware. Includes VxWorks Board Support Package.

FDFL

Used with FTE to test and sell off hardware to the government

Loader (Safety Critical) Supports TDS Selects software to execute at run-time (OPSW or FDFL)

CGA Software

UNCLASSIFIED

UNCLASSIFIED

Contractor is responsible for the maintenance, documentation, support and validation for these SW items.

Contractor Modification to specification or design

Government/Safety review

Software review of modification Government/Safety review

Software testing of modification Government/Safety review

Integration and verification on FIR hardware Sell off of new software Government/Safety review

Process for Software Change

Government Activities Software testing and verification

Integration with OPSW on torpedo system Government performance and reliability testing

ATE compatibility testing

Safety and red-path testing

Platform compatibility testing

System Level Risk mitigation testing

In-water runs

Process for Software Change ~ (Con’t)

UNCLASSIFIED

Torpedo Factory Test Equipment (FTE)

26 June 2014

Rick Moore

Technical Specifications Description – AutoLITS is used to perform functional Factory Acceptance Test (FAT) on the MK 54 Mod 0 Functional Item Replacements (FIR)

Fault Detection and Localization – AutoLITS identifies failures at a functional level as defined by the FIR Critical Item Performance Specifications (CIPS)

Hardware Architecture (VXI, GPIB, USB, and Ethernet) Function Generator Custom Electric Start Test Enclosure with a BASIC Stamp microcontroller Oscilloscope Self-test Panel VMEbus eXtensions for Instrumentation (VXI) chassis

8-Channel Digital to Analog Converter (DAC) Module

6.5 Digit Digital Multi-meter (DMM) Module

Digital Input/Output Signal Module General Purpose Relay and Multiplexor (Signal & RF) Modules

Pressure Controller (Requires pressurized air) Power supplies (Six Low-Voltage DC, One High-Voltage DC, & One 3-Phase AC) Stand-alone Windows XP Computer (not rack-mounted or networked)

Software Architecture National Instruments Test Stand (Version 3.1) executables National Instruments Labview (Version 7.1) functions Borland C++ executable and functions

MK 54 FTE - AutoLITS

MK 54 Mod 0 FTE - AutoLITS

Test Capabilities FIR Level Factory Acceptance Tests (FAT)

Control Group Assembly (CGA) FAT Processor Group Assembly (PGA) FAT

Sub–FIR Level Confidence Test CGA Control Module Assembly (CMA) Confidence Test CGA Power Conditioner Unit (PCU) Confidence Test

Self Tests (Verify nearly 100% of signal paths to Unit Under Test -UUT) CGA Interface Test Adapter (ITA) PGA Interface Test Adapter (ITA)

Torpedo Download System (TDS) PGA and CGA programming of software image files

MK 54 Mod 0 FTE - AutoLITS

PGA Interface Test Adapter

CGA Interface Test Adapter

FTE Planning AutoLITS will be available as GFE/GFI

Total quantity of four (4) AutoLITS are available as GFE Technical Data Package will be provided as GFI along with operational and maintenance manuals Contractor to procure spares as needed

AutoLITS Status Technical Data Package - TDP exists and will be updated to final GFE baseline prior to providing as GFI Existing issues – Presently no known technical or programmatic issues

Contractor Responsibility Contractor is responsible to update and recertify AutoLITS should changes be required to accommodate MK 54 Mod 0 FIR interface or performance modifications

MK 54 Mod 0 FTE - AutoLITS

Inertial Measurement Unit (IMU)

26 June 2014

Jeremiah Bruning

System Overview Interface

Mechanical Electrical

Requirements System Gyroscope Accelerometer Environmental Overview & Excerpts

Strap-down IMU measures torpedo body movement relative to inertial frame:

Changes in linear velocity along three primary axes

Changes in angular orientation around three primary axes

IMU ~ Self contained unit :

Operates on +15 VDC torpedo power input

Output sensor data update rate ~ 150 Hz

Provides status of IMU sensor data

System Overview

System Overview

Inertial Measurement

Unit

+15 VDC

Dynamics

Linear Acceleration

Angular Velocity

Status

Physical Characteristics Diameter: 4.5 In. max.

Height: 4.5 In. max.

Volume: Approx. 71 In.3

Weight: 5.5 Lbs. Max.

Mounting Arrangement:

Mounting flange 4 Bolt pattern Alignment Pins

Mechanical Interface

Input Power Characteristics Voltage: +15 + 1.5 VDC Ripple: < 300 mv P to P Current: < 0.75 Amps. over input range

Digital Communication Interface: RS - 422 Serial Interface Data output rate: 150 Hz + 500 parts per million Data block: 32 bytes Byte 10 bits Data transfer rate: 115,200 bits per second + 2 %

Electrical Interface

IMU Start-up Time after power applied Output data with valid < 1.25 sec.

status indication

Full performance < 5.0 sec.

Frequency Response System response: 75 Hz and less Internal filtering: 50 Hz Low Pass Filter with forth order roll-off

System Requirements

Input Range: + 500 deg. / sec min.

Scale Factor Accuracy error: 0.3% max.

Scale Non-Linearity: 1000 parts per million (1 )

(< 200 deg. / sec.) 3000 parts per million max.

Bias (Zero Offset): + 3 deg. / hr. (1 )

+ 10 deg. / hr max.

Maximum Output Noise: 0.03 deg. / sec. (1 )

Axis Alignment Error: + 0.2 deg. Max.

Axis Cross-Coupling Error: + 0.35% max. axis to axis

Frequency Response: 50 Hz

Gyroscope Requirements

Input Range: + 5 g min.

Scale Factor Accuracy error: 0.5% max.

Scale Non-Linearity: 2000 parts per million (1 )

6000 parts per million maximum

Bias (Zero Offset): + 10 mg max.

Maximum Output Noise: 2 mg (1 )

Axis Alignment Error: + 0.4 deg. Max.

Axis Cross-Coupling Error: + 0.7% max. (Axis to Axis)

Frequency Response: 40 - 50 Hz

Accelerometer Requirements

Sensitivity to Noise and Vibration Engine and Electronics Based Vibration

Mechanical isolation Internal filtering

Packaging Mechanical Interference with Cabling

IMU Cage

Operational Life

Speed Control Valve (SCV)

26 June 2014

William Lauder

MK54 SCV ~ Presentation Overview

Functional Description Critical Piece Part Overview Key Factors

Manufacturing Assembly Testing

Manufacturing Challenges

Speed Control Valve ~ Description

SCV ~ Fuel Pressure Regulating Device Regulating pressure, also Regulates Fuel Flow

Mounts Directly to Fuel Pump Head Component of Afterbody Kit

Regulates Fuel Flow Controls Volume of Fuel Returning From High Pressure Fuel Pump Outlet to Low Pressure Fuel Pump Inlet

Modification of HWT SCV Variant Tuned for Improved Performance at Low Flow Rates

Fluid: Otto Fuel II ~ Monopropellant

Build to Print Item

Speed Control Valve ~ Description

SCV

Speed Control Valve ~ Details

Critical Areas/Piece Parts Armature Housing (8) Armature Valve (9) Valve Pole Piece (10) Armature Guide (11) Relief Valve Housing (15) Valve Piston (19) Valve Orifice (22) Speed Control Valve Manifold (16)

Multiple Critical Dimensions and/or Surface Finishes

Requirements Must be Verified Prior to Final Assembly

Speed Control Valve ~ Key Factors

Assembly Level Issues:

Contaminants

Small Orifices Tight Fluid Passageways

Piece Parts With Travel – Cannot Restrict This Movement Very Sensitive Response

Manufacturing Challenges:

Proper Surface Finish Maintain Cleanliness Tight Piece Part Tolerances Proper Sealing Surfaces Removal of Burrs

Speed Control Valve ~ Key Factors

Final Assembly Level Testing Conducted on Navy Test Set (Speed Control Valve Test Set)

Certifies Proper Function of SCV (Ability to Meet Flow and Pressure Requirements)

Verifies Proper Component Assembly and Seals

Permits Setting of SCV for In-Water Run

Otto Fuel Substitute Used as Test Fluid

Mostly Glycerin and Water

MK 103 MOD 1 Warhead

Joe LiVolsi

MK 54 Lightweight Torpedo Common Parts Kits Industry Day

ITEM PART #

MK 103 MODS WH UNLOADED 2132049

MK 20 MOD 0 EXPLODER 1210554

MK 50 MOD 0 EXPLODER BOOSTER 2301742

ROTOR ASSEMBLY 2132110

BARRIER PLATE ASSEMBLY 2595551

WARHEAD SHELL 2132048

GROUND STRAP 2047481

FORWARD COVER 2048393

EXPLODER WELL 1660969

CABLE CLAMP 1660967

WARHEAD CABLE ASSY 1660970

MINOR MISCELLANEOUS ITEMS VARIOUS

MK 103 MOD 1 Warhead (WH) Overview

Major Warhead Subassemblies

MK 20 MOD 1 Exploder Mechanism Warhead Cable Assemblies

Technical Specifications Bulk charge warhead

PBXN-103 high explosive Multiple fuzing modes

Testing MK 444 MOD 1 Cable Test Set

(CTS)

MK 440 MOD 1 Exploder Test Set

(ETS)

FIR-level requirements flow-down

MK 20 MOD 1 Exploder Mechanism Cables Control Group Assembly (CGA) Processor Group Assembly (PGA)

Status Section spec: 1977

CM Control 2006

Not up for procurement

Production timeline In-service since 1965 Last delivery in 1988

MK 103 MOD 1 Warhead Overview

Multiple fuzing methods

Provides explosive train to

MK 103 WH

No single point of failure:

Rotor provides mechanical lockout Requires depth pressure to unlock Requires power from engine to unlock

MK 20 MOD 0 Exploder Mechanism

Torpedo interfaces:

Processor Group Assembly Control Group Assembly Exploder Mechanism

Type I Cables:

Not required to be watertight

Warhead Cable Assemblies

Afterbody Kit

26 June 2014

Jason Turner

• Afterbody Kit Overview

• Description of Items

– Key Attributes

– Testing

– Manufacturing Challenges

Afterbody Kit Overview

W10

Afterbody Kit Overview

MK46 Torpedo Afterbody + Afterbody

Kit = Speed Control Valve

Cables (W6,7,8,9,10,11) Accessory Bulkhead

Dual-Winding Alternator (DWA) Alternator Geartrain

Fuel Pump Head Seawater Pump Manifold Thermal Battery Holder

Miscellaneous Items (Tubing, etc.)

MK54 Afterbody

Afterbody Kit Overview

Accessories Bulkhead

Build-to-Print NAVSEA Drawing 7265921

Aluminum Plate

Significant Machining

Fluid Passages are Drilled and Plugged

Anodize Coating

Dual-Winding Alternator (DWA)

Permanent Magnet Alternator

Two Windings, 3 Phase: Sonar, G&C

42A @ ~150 VDC, 12A @ ~100 VDC

Manufacturing Challenges Stator Windings (High Density Wiring) Rotor Balance (21,000-51,000 RPM)

Build-to-Print

WS33114

NAVSEA Drawing 7609114

Fuel Pump Head

Build-to-Print

WS18849

NAVSEA Drawing 7265883

Aluminum Manifold

Flatness at Pump Interface

DWA Geartrain Assembly

Alternator Geartrain (19:1) Engine (~2,000 RPM) to DWA (~40,000 RPM) Stainless Steel Plates Steel Gears

Black Oxide Finish

COTS Ball Bearings Manufacturing Challenges

Bearing Surfaces & Pockets

Build-to-Print NAVSEA Drawing 7265884

Seawater Pump Manifold

Build-to-Print

WS33615

NAVSEA Drawing 7608233

Steel Manifold

Flatness at O-Ring Interface

Thermal Battery Holder

Build-to-Print NAVSEA Drawing 7265890

Aluminum Sheet Metal Weldment

Warshot Fuel Tank Shell

26 June 2014

Jason Turner

Overview Key Attributes Manufacturing Challenges Testing

36 inches ~ Overall Length

12.75 inches ~ Outer Diameter NAVSEA Drawing 7108992

WS Fuel Tank (FT) Shell ~ Overview

Material: 7075-T6510 Aluminum Made from extruded tube IAW ASTM B221

Anodize: Non-dyed Hard Anodize IAW AMS 2469 .002 - .003 inches thick Duplex Seal

5% Dichromate (20 min.)

1% Nickel Acetate (20 min.)

Deionized Water (5 min.)

WS FT Shell ~ Key Attributes

WS FT Shell ~ Manufacturing Challenges

Standard O-Ring Bore Sealing Surfaces

Visual Inspection to Drawing Hydrostatic Test

Assemble with Bulkheads 900 psig min. for 5 Minutes

WS Fuel Tank Shell ~ Testing

Torpedo Cable Overview

26 June 2014

Stan Poon

Torpedo Cables ~ Presentation Overview

Cabling Diagram

Key Attributes

Description of Cables W6 Fuel Tank Cable (8325439) W7 Afterbody Cable (8325558) W8 Alternator Cable (8325559) W9 Lanyard Start Adapter (8226666) W10 Disarm Plug (8226673) W11 Squib Cable (8325560)

Requirements and Testing

Cabling Diagram

W10 Disarm Plug

W4

W6 W11

W7

W8

W9

W10

W6

Build - to – Print Cables Route Power and Signals

Many Require Twisted Pairs and Shielding Connector and Cable Types are Specified on Drawings

Most use crimped-style connectors Most Use Potted Molding Due to Space Constraints and Durability Requirements Most use Estane® (Polyurethane) for cable jackets

Examples of Requirements are:

Dielectric Strength, Insulation Resistance, Flexibility – some need to work with tight bending radius Etc.

Connectors NOT Required to be Water-Tight

Key Attributes

W 6 ~ Fuel Tank Cable

Function Routes Power and Signals Through the Fuel Tank

Notable Features For Use in Tight Space

P603

P601

P602 P5530 P5524

P5523

W 6 ~ Fuel Tank Cable

Forward End

Aft End ~ Knuckle

Forward End

Aft End

W 7 ~ Afterbody Cable Assembly

Function Routes Signals Through Afterbody

W7 to Steering Actuators, Fire Control Connector, Speed Control Valve

P5520

P820

J5608

P5620

W 8 ~ Alternator Cable Assembly

Function Routes Power Through Afterbody

W8 to Alternator (x2), Thermal Battery

Notable Features Circular MILSPEC Connectors

P87

P72 P86

P5510

W 9 ~ Lanyard Start Assembly Adapter

W9W11

Function Connects “Torpedo” to Startup Battery

W11 to Lanyard Start Assembly (LSA)

Notable Features Circular MILSPEC Connectors Aluminum body

LSA

Function Used to safe the Electro Explosive Devices or EEDs in the afterbody & fuel tank

Notable features Circular MILSPEC connector Aluminum body

W 10 ~ Disarm Plug

W 11 ~ Squib Cable Assembly

W9 Function

Routes Signal Through Afterbody

Notable Features Circular MILSPEC Connectors

P5540

P96

P830

P5629

Requirements and Testing

Requirements Individual cable drawings

NAVSEA 8226676

CRITICAL ITEM PERFORMANCE SPECIFICATION (CIPS),

CABLE ASSEMBLIES

Inspection and Acceptance Testing Visual Inspection Electrical Test

Dielectric Strength Insulation Resistance Conductor Resistance

Government Facilities

26 June 2014

Alison Richards

Two Locations support the test, repair and certification of torpedoes

NUWC Division Newport

NUWC Division Keyport

NUWC Overview

Intermediate Maintenance Activity (IMA) MK 54 Lightweight Torpedo Depot Environmental Test Facility (ETF) Failure Analysis Lab IW Test Ranges

Life Cycle Support Facility (LCSF) Weapons Analysis Facility (WAF) Survivability Test Facility

NUWC Division Keyport Facilities

Intermediate Maintenance Activity (IMA) MK 54 Lightweight Torpedo Depot Environmental Test Facility (ETF) Failure Analysis Lab In-Water (IW) Test Ranges

MK 54 Lightweight Torpedo IMA

Intermediate Maintenance Activity (IMA) Provide repair, overhaul, maintenance and upgrade capabilities to ensure a continued source of torpedoes are ready and available for Fleet exercise and warshot inventory requirements.

Bangor Weapons Complex Ordnance Handling, Storage and Load Explosive Operations (5 Buildings) 89 Explosive Storage Bunkers Certified to Handle Class 1.1 - 1.4 Ordnance Full Lightning Protection

Keyport Weapons Maintenance Complex Automated Material Handling Facility

MK 54 Lightweight Torpedo IMA

Torpedo Intermediate Level Repair & Overhaul

Lightweight Torpedoes Weapons Disassembly, Defueling & Teardown Engine Overhaul & Reassembly Weapons Assembly & Fueling System Functional Testing and Fault Diagnostics Strict Procedural Control & Ordnance Standards Fuel Reclamation and Recovery Government Furnished Equipment Upgrade Programs Fleet & Hardware Acceptance Support

RDT&E Support Hardware Integration with Unique Test Vehicle Support

MK 54 Lightweight Torpedo Depot

Provide repair, overhaul, maintenance, upgrade, reverse engineering and reliability insertion capabilities

Mitigate effects of obsolescence, poor reliability, OEM abandonment, lost supply sources and poor or unavailable documentation

Establish New Depot Support Capabilities and Take On New Challenges when Previous Repair Sources Abandon Product Lines

Ensure a Continued Source of Material Availability for Navy and DoD Equipment

MK 54 Transmitter Waveform Generator Board

MK 54 Transmitter Power Amplifier Board

MK 54 AutoLITS AND LITS

Environmental Test Facility (ETF)

Vibration 3-axis simultaneous vibration

HALT/HASS

Single axis, large displacement, large payload

Shock SRS Replication of field data Drop and shaker shock up to 4,500 lb.

Climatic Temperature extremes from -148 oF to 392 oF, 100,000 ft.

altitude, humidity, salt, fog

Unique Equipment 3-axis rate table with temperature conditioning and ship sway simulation Centrifuge for 1,000 lb. payload Hydrostatic testing

Automated test equipment Hardware and software solutions for complex test environments LabVIEW and MATLAB software development Signal analysis

The Environmental Test Facility specializes in design verification and development, reliability assurance and lab simulation of environmental conditions. Many environments can be combined such as temperature, vibration and functional testing. Capabilities include:

Failure Analysis Laboratory

SEM image of electrical overstress in an IC. Leak path revealed by dye in towed array.

Cause Analysis Causal analysis of organizational issues (critique facilitation) Root cause tree construction

Imaging and Inspection Digital microscope: up to 1000X magnification and 3D surface image Thermal microscope Scanning electron microscope (SEM): up to 300,000X magnification Real-Time X-ray

Material Characterization Energy dispersive X-ray spectroscopy (EDS) for elemental analysis Fourier transform-infrared (FT-IR) for organic analysis

Mechanical Analysis Metallurgical sample preparation and analysis Tension and compression testing Hardness testing Cable depotting Fracture analysis

Electrical Analysis Electrical fault isolation Integrated circuit decapsulation and sectioning Die level electrical microprobing Electrical and thermal characterization of integrated circuits (IC) and circuit cards LabVIEW, MATLAB, and PSpice test

Thermal image of a decapsulated integrated circuit.

3D surface digital microscopy image of raise lip on seal.

The Failure Analysis Lab specializes in independent root cause failure analysis, reverse engineering and materials characterization. Capabilities include:

British Columbia

Vancouver Island

C A N A D A

U S A

Pacific Northwest Ranges Sites

Washington State

Seattle

Tacoma

Bremerton

Keyport Range Site

Bremerton

Silverdale

Poulsbo

W-237A Naval Operating Area Pacific Beach

NUWC Division Keyport

WG

Nanoose Range Site

Indian Island Pier Site Whidbey Navy-7 Water Space R-6701 Restricted Air Space

Dabob Bay Range Complex

Including Hood Canal

NBK Bangor KB Docks

Ediz HookW-237B Naval Operating Area

Northwest Range Capabilities

AIR OR SURFACE

LAUNCH

N A V Y

A

RD

12 34 Y

CABLE

LINKS TO

SHORE

TRACKING

SENSORS

TORPEDO

WITH TRACKING

PINGER

TRACKING

CENTER

RADAR AND

GPS TRACKING

T&E TARGET MOBILE TARGET

WITH TRACKING

PINGER

AIR OR

SURFACE

RETRIEVAL

N.U.W.C.RECOVERY

BOTTOM

RECOVERY

VEHICLE

ACOUSTIC

MEASUREMENT

SYSTEMS

Obsolescence Management NAVSEA Naval Undersea Warfare Center Division Keyport's Obsolescence Management Division is a DOD recognized Center of Excellence in Diminishing Manufacturing Sources and Material Shortages

(DMSMS).

NUWC Division Newport Facilities

Life Cycle Support Facility (LCSF) Weapons Analysis Facility (WAF)

Life Cycle Support Program Library

Depot Factory Test Equipment

Automatic Test Equipment

VAX Operations

Collaboration Center

Nose Array Test Set

Life Cycle Support Facility (LCSF)

MK 695 MOD 0 Torpedo System Test Set MK 695 MOD 0 Torpedo System Test Set – MK 54 Torpedo variants

MK 695 MOD 1 Torpedo System Test Set – MK 46 and MK54 Torpedo variants

MK 1 MOD 1 Torpedo Firing and Evaluation Equipment – Common data extraction for MK54 and MK48 Torpedo variants

MK 707 MOD 1 Speed Control Valve Test Set – Speed Control Valves

MK 54 In-Service Support Equipment

MK 695 MOD 1 Torpedo System Test Set

The LCSF Supports Research, Development, Integration, Testing and Maintenance of Torpedo Systems/Test Equipment Hardware and Software

Supports Program Life Cycle Needs Through Hardware-in-the-Loop Modeling & Simulation

The need to cost effectively develop and evaluate the performance of undersea systems can only be achieved with the aggressive application of modeling and simulation to complement an in-water testing program.

Weapons Analysis Facility (WAF)

Unit Under Test

Hardware in the Loop

NUWCDIVNPT Bldg. 114, 23,000+ ft2 dedicated to survivability and environmental testing of:

Submarine electromagnetic communications and ESM systems Submarine combat systems Submarine and surface ship sonar, weapon, launcher, CM systems

Conducts broad range of tests ~ specialized experiments to full Mil Spec environmental qualifications.

Houses large embedded pressure vessels specifically designed for testing coiled towed array sonar sensors Large vib.& shock test machines with embedded seismic masses Full Room/Walk-In temperature and humidity chambers Materials Measurement Laboratory

Conducts full range of Military-Specification environmental qualification testing.

MK 54 MOD 0 Lightweight Torpedo Industry Day Public-Private Partnerships (PPP)

26 June 2014

Alison Richards

Public-Private Partnerships (PPP)

Benefits for Private Industry and the Navy Facilitates low-rate production

Reduced NRE through use of existing infrastructure, capabilities Leverages maintenance and test and evaluation expertise and proficiencies

Reduces technical risk to private industry, DoD programs, and the Fleet

Reduces cost impact of contractor support and test equipment (S&TE) and learning curve Encourages greater competition

“There is ample evidence that participants are finding justification, and partnering agreements are “win-win-win” situations for organic depots, commercial firms and the warfighters and their agents.” LMI, Public-Private Partnerships 2002

PPP Federal Statutes

Various statutes authorize Public Private Partnership (PPP) agreements. The five most commonly used by Keyport are:

Title 10 U.S.C. 2539b – Testing…