Det_Cord_-_SOW-Rev3.doc

Prepared by:

Mary Sherlock (Code R33) Steve Dolina (R14)

STATEMENT OF WORK

Title: Flexible Training Detonation Cord (FTDC)

1. Introduction

The Naval Surface Warfare Center, Indian Head Explosive Ordnance Disposal Technology Division (NSWC IHEODTD) requires a DOD domestic source to manufacture and supply flexible training detonation cord (FTDC) as a modified commercial-off-the-shelf (COTS) or non-developmental Item (NDI). The FTDC shall incorporate a custom, non-detonable low explosive (energetic) content blended filler that, when incorporated into a detonation cord structure, is capable of meeting the requirements of explosive UN Hazard Division/Classification (HD) 1.4S such that burning or attempting to detonate the training detonation cord shall be non-injurious to personnel. The FTDC is intended for training purposes (demolition and explosive operations, tactics, procedures and practice) where the use of standard HD 1.1D detonating cord is undesirable.

1.1. Background

Detonating cord (also called detonation cord, detacord, det cord, and primer cord) is a round, flexible cord containing a core of pentaerythritol tetranitrate (PETN). Detonating cord uses include commercial mining, drilling, and demolitions, as well as military demolition, breeching operations and warfare.

1.2. Scope

The FTDC supplied shall be in accordance with the salient characteristics of the Product Specification: Flexible Training Detonation Cord (FTDC), NSWC IHEODTD document No: SP-FTDC-100. This aforementioned specification provides the requirements for 4.5-mm outer diameter, flexible training detonating cord (FTDC) having a core of non-detonable PETN explosive (energetic) encased in two wraps of counter-spun textile yarns and over-extruded with a blue polyethylene jacket.

The domestic detonation cord manufacturer shall provide a training variant of flexible detonation cord where the PETN content of the core filler is substantially diluted. The FTDC incorporates a custom, non-detonable low explosive (energetic) content blend filler that, when incorporated into a detonation cord structure is capable of meeting the requirements of explosive Hazard Division HD 1.4S. The resulting FTDC is in keeping with industrial manufacturing practices used to manufacture PETN detonation cord for commercial or military operations.

2. APPLICABLE DOCUMENTS

The documents listed in this section are specified in sections 3 and 4 of this Statement of Work.

2.1. Product Specification: Flexible Training Detonating Cord (FTDC), Document No: SP-FTDC-100, Rev 0 (Initial Release), Naval Surface Warfare Center, Indian Head Explosive Ordnance Disposal Technology Division (NSWC IHEODTD).

2.2. International Commission on Illumination (CIE) Color Space Values, Colorimetry - Part 4: CIE 1976 L*a*b* Color Space, ISO 11664-4:2008(E)/CIE S014-4/E: 2007.

2.3. NAVSEAINST 8020.8C Department of Defense Ammunition and Explosives Hazard Classification Procedures. 30 July 2012. (Joint Technical Bulletin TB 700-2/TO 11A-1-47).

2.4. Code of Federal Regulations, Transportation, Title 49, Parts 100 to 185, latest revision, published by the National Archives and Records Administration's (NARA) Office of the Federal Register (OFR), and the Government Printing Office (GPO), http://hazmat.dot.gov/regs/rules.htm.

2.5. United Nations, Recommendations on the Transport of Dangerous Goods—Model Regulations, revisions adopted by CFR Title 49, ST/SG/AC.10/1, United Nations Publication, New York, New York 10017.

2.6. United Nations, Recommendations on the Transport of Dangerous Goods—Tests and Criteria, revisions adopted by CFR, ST/SG/AC.10/11, United Nations Publication, New York, New York 10017, latest revision including all its Amendments.

2.7. US Department of Transportation (DoT) approved Examining Agency: As of April 1, 2008, there exists a list of Examining Agency organizations have been approved by the DoT Associate Administrator to examine and make recommendations concerning new explosives in accordance with 49 CFR 173.56(b)(1). Approved Examining Agencies are listed as follows: https://www.phmsa.dot.gov/hazmat/energetic-materials-approvals/explosive-test-labs.

3. Specific Requirements

General. This specification provides the requirements for 4.5-mm outer diameter, flexible training detonating cord (FTDC) having a core of non-detonable low PETN explosive (energetic) encased in two wraps of counter-spun textile yarns and over-extruded with a blue polyethylene jacket as described in Product Specification: FTDC Document No: SP-FTDC-100.

3.1. Modified COTS / Non-Development Item. The manufacturer is encouraged to recommend best value substitutions, additions, and changes to specification SP-FTDC-100 and the basic construction of the FTDC in keeping with commercial and industry standards and best practices.

3.2. Kick-off and Systems Requirements Review (CDRL A001 and CDRL A002). The performer shall conduct of a Kickoff Meeting and Systems Requirements Review for the FTDC. Prior to the review, the contractor shall prepare a Technical Review Presentation Package (CDRL A001) that summarizes evaluations, analyses, and recommendations for meeting US government (USG) requirements in keeping with commercial, industry standards and best practices per 3.1. The Technical Review Presentation Package (CDRL A001) shall include a system requirements analysis, the design of FTDC components and construction, existing technology options, survey results, and trade study results as they relate to the supplied initial release of Product Specification: FTDC Document No: SP-FTDC-100.

The location of the review shall be at the performer’s production facility. The contractor shall schedule the event 10-15 days after contract award to allow for USG personnel to plan and receive approval to travel.

The contactor shall provide a Report of the Meeting Minutes and Action Items summarizing evaluations, analyses, actions, recommendations and findings established during the Kick-off and Systems Requirements Review (CDRL A002).

3.3. Low explosive (energetic) core composition filler and Laboratory Samples. The contractor shall prepare and provide samples of a blended lot of the energetic core filler and samples of the outer jacket material meeting the requirements of SP-FTDC-100 before manufacturing the FTDC.

3.3.1. Acceptance Test Report, Core Filler (CDRL A003). The contractor shall conduct compositional analysis IAW established methods and provide an Acceptance Test Report (CDRL A003) that demonstrates the core filler composition meets the requirements of SP-FTDC-100 before manufacturing the First Article FTDC. The contractor shall provide a certificate of analysis of the core filler and other supporting documentation in the Acceptance Test Report (CDRL A003) including mix sheets, weigh out sheets, and associated quality assurance documentation.

3.3.2. Sample for Laboratory Examination – Core Filler. The contractor shall provide a 25-gram sample of the blended low energetic core composition filler to support independent verification testing by the US Government (USG) before manufacturing the First Article FTDC.

3.3.3. Samples for Examination – Jacket material color. The contractor shall provide at least three (3) different material samples of the proposed over extruded jacket material that most closely approximates the International Commission on Illumination (CIE) color space value identified in SP-FTDC-100. The color samples of the jacket material will support the selection of the jacket color by the USG before manufacturing the First Article FTDC.

3.4. First Article FTDC (500-foot partial spool). Tasking under 3.4 shall not commence until the USG has provided written Approval of Laboratory Samples pending: (a) USG acceptance of the Acceptance Test Report for the Core Filler (CDRL A003) per 3.3.1, (b) independent verification testing within 30-days after receipt of the core filler Laboratory Sample per 3.3.2, and (c) independent verification within 30-days after receipt of the over extruded jacket material/color samples for selection per 3.3.3. Upon USG Approval of Laboratory Samples, the contractor shall manufacture and deliver the First Article FTDC. The contractor shall provide at least 500-feet of FTDC to support independent verification testing by the US Government (USG). Independent verification testing will be performed IAW the baseline FTDC Product Specification SP-FTDC-100 (sections 3.5 Required Inspections and 4.0 Verification).

3.5. FTDC Product, Lot Acceptance Testing and Packaging Spares. Tasking under 3.5 shall not commence until the USG has provided written approval for Production Readiness pending independent verification testing of the First Article FTDC within 45-days after receipt of the First Article FTDC.

3.5.1. FTDC Product. Upon USG Production Readiness Approval (PRA), the contractor shall manufacture, package, handle, ship, transport and deliver five (5) spools each containing 1000-linear feet and shipped IAW DoT Interim EX letter authority until the DoT issues a Final EX letter for the FTDC product by analogy to a similar product per 3.5.3.

3.5.2. Product Lot Acceptance Test Report (CDRL A004). The contractor shall perform Lot Acceptance Tests (LAT) and prepare a LAT technical report that demonstrates the FTDC meets the inspection and verification requirements of the baseline FTDC Product Specification SP-FTDC-100 (sections 3.5 Required Inspections and 4.0 Verification) resulting from the 3.2 Systems Requirements Review findings. A USG designated representative will observe all LAT testing.

3.5.3. Approved PHST and Final DoT EX Letter. The contractor shall design and provide the appropriate logistical package, handle, store, and transport (PHST) configuration for a single, 1000-ft spool of FTDC. The contractor shall obtain an explosive classification approval (EX Letter) that is unique to the FTDC product as a placeholder until HD 1.4S Assignment Tests are completed. The contractor shall obtain a Final DoT EX approval for the FTDC product that allows for shipment of cord lengths of 1000-linear feet or less. The contractor can seek Hazard Classification by Analogy for the initial lot of FTDC using hazard classification test data for similar ammunition and explosive (AE) to hazard classify the new FTDC (i.e., the parent AE must have been tested) or by other means at their disposal.

3.5.4. Safety Data Sheet (CDRL A005). The contractor shall prepare and provide a Hazard Communication Standard, Safety Data Sheet (SDS) for the FTDC product.

3.5.5. PHST Logistical Spares IAW Final DoT EX Letter Provisions. The DoT explosive classification approval (EX Letter) requires that AE must be stored or transported in the same or equivalent packaging in which the manufacturer offers the AE for transportation. As a minimum, the packaging must comply with the packaging instruction associated with the hazard classification assigned that meets the requirements set out in 49 CFR 173.24 and is in new or “like new” condition. The integrity of such packaging can be compromised due to low consumption rates of FTDC and frequency of handling used in training. As such, the contractor shall provide fifteen (15) additional packaging spares (spools and logistical packaging/fiber board boxes) that meet the PHST requirements of the Final DoT EX Letter per 3.5.3.

3.6. DoD HD 1.4S Final Hazard Classification (FHC). The contractor shall pursue a HD 1.4S Final Hazard Classification (FHC) for the FTDC product in accordance with paragraph 3-2 of NAVSEAINST 8020.8C for storage and transportation of the FTDC. Section 5-5 of NAVSEAINST 8020.8C provides the Harmonized HD 1.1, HD 1.2.1, HD 1.2.2, HD 1.3, and HD 1.4 Assignment Tests (UN Series 6). The contractor shall design and pursue a logistical packaging configuration for a single 1000-linear feet spool in a single package for assignment as HD 1.4S, United Nations (UN) identification number 0349: ARTICLES, EXPLOSIVE. The logistical packaging configuration and FHC shall provide for shipment of FTDC cord lengths of 1000-linear feet or less.

3.6.1. HD 1.4S Assignment Tests. The contractor shall have HD 1.4S Assignment Tests performed and reported by a qualified DoT approved Examining Agency that is recognized by the United States DoT to test and examine explosives or potentially explosive substances and recommend the proper shipping classification per 49 CFR 173.62 (b). The contractor shall ensure the approved DoT approved Examining Agency provides the necessary technical rigor and test methods to pursue and test for a Final Hazard Classification for Compatibility Group S of Hazard Division 1.4, including the additional provision of 3.6.2.

3.6.2. Additional 1.4S Assignment Tests. In the near future, Hazard Class 1.4S Assignment Tests may retroactively be required to undergo UN Test 6(d): Three unconfined single package tests for the continued assignment of UN 0349 / HD 1.4S, where the results of Test series 6 (d) have demonstrated that any hazardous effects arising from functioning are confined within the package. The manufacturer shall proactively require the DoT approved Examining Agency perform and report on UN Test 6(d) test results. The contractor shall watch for any changes to paragraph 5.5 c (1) of NAVSEAINST 8010.5 (Department of Defense Ammunition and Explosives Hazard Classification Procedures) and shall ensure the most current NAVSEAINST 8010.5 procedures are implemented.

3.6.3. PHST Logistical Spares Letter Report, HD 1.4S Assignment Tests (CDRL A006). The contractor shall provide a PHST Logistical Spares Report that discloses the drawing, drawing number, replenishment part number and vendor source for logistical packaging spares (spool and fiberboard box) designed and used in the HD 1.4S Assignment Tests.

3.6.4. HD 1.4S FHC TDP (CDRL A007). The contractor shall prepare and provide a HD 1.4S Final Hazard Classification (FHC) technical data package (TDP) that includes all FHC documentation for submission to the designated Service Hazard Classifier, NOSSA. The contractor shall provide both the parent FHC TDP (grandfathered EX number), if available, and the new FHC TDP used to seek HD 1.4 S Assignment. The FHC TDP shall include: logistical packaging drawings used in HD 1.4S Assignment Tests, FTDC description, detailed drawings, net explosive weight (NEW), gross weight, part number, number of articles per package, package dimensions, and description of packaging material. The contractor shall supply the HD 1.4S Assignment Test matrix, the final recommendation, and final HD 1.4S test report issued by the US DoT approved Examining Agency as part of the FHC TDP.

3.6.5. Submission and Monitoring of the FTDC HD 1.4S FHC documentation package. The contractor shall use the test report and recommended shipping classification letter issued by the US DoT approved Examining Agency to prepare and submit a HD 1.4S Final Hazard Classification (FHC) documentation package IAW NAVSEAINST 8020.8C to the designated Service Hazard Classifier: the Naval Ordnance Safety and Security Activity (NOSSA). NOSSA coordinates the review within the Department of Defense (DoD) and the DoD Explosive Safety Board (DDESB) requests explosive classification approval (EX Letter) for FTDC as a DoD-Owned, Non-Stock-Listed Commercial Explosive Item. The contractor shall provide a single point of contact to monitor, answer questions, and provided additional data to facilitate the process during the DoD review and DoT approval process timelines.

4. Deliverables / Schedule Product deliverables are identified by their contract line item number (CLIN). Data deliverables are identified by their associated Contract Data Requirements List (CDRL).

Table 1 provides the product deliverables (CLINs) and the product deliverable schedule. The required delivery dates (RDD) are specified as days after the effective date of the contract award (DAC). The CLINs are summarized as follows:

· CLIN 0001: First Article

· CLIN 0002: Production (5 spools) and LAT

· CLIN 0003: HD 1.4S Assignment Tests and FHC TDP Table 1 also cross-references the CDRL(s) related to the given product. For convenience, Table 2 provides a summary of the documentation deliverables (CDRL) identified in this Statement of Work.

Table 1. Product Deliverables List and Schedule

CLIN 0001

First Article

10-15 DAC

Conduct Review:

30 DAC

CDRL A001

CDRL A002

Sample for Laboratory Examination – Core Filler

25-gram sample of the low energetic core composition filler independent verification testing by the USG before manufacturing the First Article FTDC.

First Article FTDC (partial spool).

At least 500 feet of FTDC for independent verification testing by the US Government (USG) IAW the baseline FTDC Product Specification SP-FTDC-100

Table 1. Product Deliverables List and Schedule, continued

CLIN 0002

Production (5 spools) and LAT

3.5.1

(3.5.2)

(3.5.3)

(3.5.4)

CDRL A005

Final DoT EX Letter and PHST.

Final US DoT Explosive classification approval (EX Letter) for the FTDC product.

3.5.3

(3.5.1)

310 DAC

PHST Logistical Spares IAW Final DoT EX Letter Provisions.

Fifteen (15) additional packaging spares (spools and logistical packaging/fiber board boxes) that meet the PHST requirements of the Final DoT EX Letter per 3.5.3 for the FTDC product.

CLIN 0003

HD 1.4S Assignment Tests and FHC TDP

Submission of the FTDC HD 1.4S FHC documentation package IAW NAVSEAINST 8020.8C to NOSSA where:

· HD 1.4S Assignment Tests shall be performed by an DoT approved Examining Agency recognized by the US DoT

· HD 1.4S Assignment Tests shall include UN Test 6(d): Three unconfined single package tests

· HD 1.4S FHC submission includes the HD 1.4S Assignment Test Report and Recommendation issued by the US DoT approved Examining Agency

CDRL A007

Table 2. Summary of Data Deliverables

(DID)

3. Subtitle (As identified in SOW)

5. Contract Reference

(SOW Paragraph)

5. Security The Product Specification for the FTDC, Document No: SP-FTDC-100 is classified as DISTRIBUTION D, where distribution is authorized to U.S. Department of Defense and their contractors: Administrative or Operational Use. Other requests for this document shall be referred to Commanding Officer or Technical Director, NSWC Indian Head EOD Technology Division.

Further, Product Specification No: SP-FTDC-100 contains technical data whose export is restricted by the Arms Export Control Act (Title 22 U.S.C. Sec 2751, et seq.) or the Export Administration Act of 1979, as amended, Title 50, U.S.C., App. 2401 et seq. Violators of these export laws are subject to severe criminal penalties. Disseminate in accordance with provisions of DoD Directive 5230.25. Interested contractors will also be required to execute and return a Non-Disclosure and Non-Use Agreement prior to obtaining the Baseline Product Specification No: SP-FTDC-100.

6. TECHNICAL POINTS OF CONTACT

The technical points of contact for the Naval Surface Warfare Center, Indian Head Explosive Ordnance Disposal Technology Division (NSWC IHEODTD) are:

Mary H. Sherlock

NSWC IHEODTD

RDT&E Department

Detonation & Combustion Technology Branch, Code R33

2807 Strauss Ave, Suite 102, Bldg 695

Indian Head, MD 20640-5146

Phone:

301-744-1431

Email:

mary.sherlock@navy.mil Stephen J. Dolina

NSWC IHEODTD

RDT&E Department

Chemical and Material Analysis Branch, Code R14

5326 Whitman Court, Bldg 1864

Indian Head, MD 20640-5160

Phone:

301-744-4988

Email:

stephen.dolina@navy.mil