OA_Testing_Explosive_Bolt_-_SOW-rev3.docx

STATEMENT OF WORK

FOR ORDNANCE ASSESSMENT (OA) TESTING OF

MARK (MK) 9 MODIFICATION (MOD) 0 EXPLOSIVE BOLTS

1. INTRODUCTION

Scope: This statement of work (SOW) defines the efforts to conduct non-destructive inspections, electrical tests, and destructive tests for sixty (60) Mark (MK) 9 Modification (Mod) 0 Explosive Bolt, Navy Part Number (P/N) 7261266-001, Pacific Scientific Energetic Materials Company P/N 92115-08.

APPLICABLE DOCUMENTS

Drawings:

· Drawing No. 92115, “Explosive Bolt Assembly”

· Drawing No. 7261266, “Explosive Bolt Assembly”

· Interface Control Drawing No. 7261150, “Explosive Bolt Assembly” Specification:

· Weapon Specification (WS) 33306 Appendix XII, “Performance Specification for the Evolved SeaSparrow Missile (ESSM) Thrust Vector Control Section” Test Procedure:

Pacific Scientific Energetic Materials Company Acceptance Test Procedure

· Document No. TP852574, Rev A, “Acceptance Test Procedure, Explosive Bolt Assembly Part Number 92115-08”

REQUIREMENTS

On-Site Visit and Coordination. Technical representatives from the Government will witness testing. The contractor shall provide the Government at least 21 calendar days advance notification prior to inspections and tests required in SOW Sections 3.5.6 and 3.5.7.

The contractor shall provide planned Non-Destructive, Electrical, and Destructive test dates to the Government for concurrence. The government will confirm the dates or request different dates.

The contractor shall work with the Government to arrange reasonable accommodations.

The contractor shall answer questions by the technical representatives about the test set-ups and inspection/test techniques.

Government Furnished Materials (GFM). The Government will provide the contractor with sixty (60) explosive bolts as defined in Table I.

The Contractor will report the inventory of GFM in their possession to the Government in accordance with CDRL A001, until all GFM are either released for disposition or shipped back to the Government.

Table I: MK 9 Mod 0 Explosive Bolt Test Sample (PSEMC P/N 92115-08)

Notes:

Schedule. Function Firings shall be completed within 20 weeks after receipt of the contract and all Government Furnished Material (GFM).

Test Readiness Review (TRR). The contractor shall provide TRR with the government at least 14 days prior to Non-destructive inspections and tests required in SOW Section 3.5.6.

Testing.

General. Testing shall be performed in accordance with PSEMC TP852574 unless specified otherwise, and in accordance with the tests shown in Table II. If tests listed in Table II are not included in the contractor’s TP852574, tests shall be conducted in accordance with the contractor’s local instructions and with the drawings and specification listed in SOW Sections 2.1 and 2.2. The test order shown in Table II must be maintained throughout the test program.

Table II: Test Matrix

Group a

Notes:

a See Table I for samples selected per group b If a unit cannot be conducted in accordance with SOW Section 3.5.7.2 for No-Fire due to the electrical cable, the unit shall be conducted in accordance with SOW Section 3.5.7.2.1 c If a unit cannot be conducted in accordance with SOW Section 3.5.7.4 for Function Firing due to the electrical cable and/or thread, the unit shall be conducted in accordance with SOW Section 3.5.7.4.1

Failures. In the event of a failure, the contractor shall be limited to verifying the test setup, and taking a post-fire photograph (visual) and radiograph (x-ray) of the failed unit(s) alongside a successfully functioned unit. If possible, an unfired unit should also be included in the photograph and radiograph. The contractor shall retain any failed units for at least 45 days after test date or until released for disposition by the government representative, whichever occurs first. The contractor shall document any failure(s) with a notification of anomaly (NOA). No unit shall be removed from further testing in accordance with Table II as the result of a failure, except when either the unit fired or the technical representative requested for it.

Skipping Inspections/Tests. Any time before or during the testing in SOW Section 3.5, the technical representative specified in SOW Section 5 may request to have any of units listed in Table I to skip any of inspections and tests specified in Table II.

Test Samples and Packaging Materials Returning to Government. Any time during or after the testing in SOW Section 3.5 until those units are released for disposition by the government representative, the technical representative specified in SOW Section 5 may request any of units listed in Table I to be shipped back to NSWC IHEODTD after the Function Test (SOW Section 3.5.7.4) is completed. All packaging containers and supplies used by the Government to send the units to the contractor shall be returned to NSWC IHEODTD with or without the units unless requested otherwise by the technical representative specified in SOW Section 5.

Disposition of Test Samples. Upon Government acceptance of all CDRLs, the contractor shall dispose of fired test samples at their facility.

Non-Destructive Inspections and Electrical Tests. All test data shall be recorded.

Visual/Workmanship Inspections shall be conducted on all units in Table II in accordance with PSEMC TP852574 and the additional requirements in accordance with SOW Sections 3.5.6.1.1 – 3.5.6.1.6.

Unit(s) with damaged thread, which may affect the proper installation, shall be documented.

The electrical cable of each unit shall have no tear or damage. Unit(s) with visible damaged or torn cables shall be documented.

Units shall comply with the mechanical interface requirements in accordance with Interface Control Drawing no. 7261150. Location of Pin Numbers on the connector part of each unit shall be identified and documented at minimum.

Units shall be legibly and permanently marked. Each unit shall have a yellow band on the cable in accordance with Drawing no. 7261266. The identification of each unit shall be as specified in Drawing no. 92115.

Each unit shall have Electrostatic Discharge (ESD) identification marking indicated as ESD sensitive.

Units shall be weighted. Include weights for the data to be recorded.

Dimensional Inspections shall be conducted on all units in Table II in accordance with PSEMC TP852574. In addition, units shall comply with the dimensions as specified IAW Drawing no. 92115. Dimension measurements of bolt shank shall be taken and recorded.

Radiographic (X-Ray) examination shall be conducted on all units in Table II in accordance with PSEMC TP852574. Radiographic examination report and copy of X-ray(s) shall be provided. Units with visible damaged or torn cables shall be documented.

Bridgewire Resistance shall be conducted on all units in Table II in accordance with PSEMC TP852574. Include actual measurements for the data.

Insulation Resistance shall be conducted on all units in Table II in accordance with PSEMC TP852574. Include actual measurements for the data.

Dielectric Strength shall be conducted on all units in Table II in accordance with PSEMC TP852574. Include actual measurements for the data.

Electrostatic Discharge shall be conducted on all Group B units in Table II in accordance with PSEMC TP852574. Include ESD pulse charts for the data if available.

If five (5) unit failures occur during a single test in SOW Section 3.5.6 and those failures resulted in permanent loss of units (e.g. fired as the direct result of test), the contractor shall terminate the test and move on to the next test/inspection with remaining units. The contractor will document any failure(s) with a notification of anomaly (NOA).

Unit(s) that have damaged threads and/or cables, but have intact cartridge assembly remaining operational (unfired), are not considered as permanent-loss failures in accordance with SOW Section 3.5.6.8.

Photographs shall be taken of all anomalies, failures, test setups, and pre-test units.

Each anomaly/failure shall be documented and described.

Destructive Tests.

Bridgewire Resistance shall be conducted on all units in Table II in accordance with PSEMC TP852574. Include actual measurements for the data.

No-Fire Test shall be conducted on all Group C units in Table II in accordance with PSEMC TP852574, except the test shall comply with the no-fire current requirements from WS33306 Appendix XII (para. 3.2.1.17.7). If electrical cable is damaged to the point where normal electrical connections required for No-Fire Test in accordance with PSEMC TP852574 cannot be used, Alternative No-Fire Test shall be conducted on the unit in accordance with SOW Section 3.5.7.2.1 (only if PSEMC TP852574 cannot be used on this unit). Whether if Alternative No-Fire Test is being used or not shall be documented. Include the actual current readings for the data if available.

Alternative No-Fire Test shall be conducted on unit(s) in accordance with PSEMC TP852574, except the electrical connections specified by PSEMC TP852574 is not required. Procedure for Alternative No-Fire shall be provided through Test Work Order in accordance with SOW Section 4.2 for CDRL A002.

Post No-Fire Bridgewire Resistance shall be conducted on all Group C units in Table II in accordance with PSEMC TP852574. Include actual measurements for the data.

Functional Test shall be conducted on all units in Table II in accordance with PSEMC TP852574. If a unit cannot fit in any of test fixture(s) as specified in PSEMC TP852574 due to damaged thread, or if electrical cable is damaged to the point where normal connections specified in PSEMC TP852574 would not work, Alternative Functional Test shall be conducted on the unit in accordance with SOW Section 3.5.7.4.1 (only if PSEMC TP852574 cannot be used on this unit). Whether if Alternative Functional Test is being used or not shall be documented, and also document the reason if Alternative Functional Test is being used.

Alternative Functional Test shall be conducted on unit(s) in accordance with PSEMC TP852574, except the test fixture or electrical connections specified by PSEMC TP852574 is not required. In addition, a secondary monitoring and recording method may be provided in place of separation time measuring instrument(s) that required the test fixture specified by PSEMC TP852574. Procedure for Alternative Functional shall be provided through Test Work Order in accordance with SOW Section 4.2 for CDRL A002.

In addition to the test setups and data recording in both Functional Test, SOW Section 3.5.7.4, and Alternative Functional Test, SOW Section 3.5.7.4.1, both tests shall also capture the “audio break” separation time using microphone circuit as additional data recording instrument, with audio break time measured between application of firing pulse and an indication of “break” separation from audio recording. Record approximate distance between microphone and firing unit(s).

Photographs shall be taken of all anomalies, failures, test setups, and pre- & post-fired units.

Those following shall be documented for Function Test, SOW Section 3.5.7.4 and Alternative Function Test, SOW Section 3.5.7.4.1: Temperature and humidity of the bay the function firing conducts in, date and time of test, separation at the breakline, torque measurement (if torqued into a test fixture), trace charts of currents with time if applicable, bolt separation times, audio break times, and test equipment used and calibration dates.

Full billing may be submitted upon submittal of all destructive test data in accordance with Sections 4.3 for CDRL A003.

Radiographic Reports and Films Delivery. Radiographic reports and films shall be provided in accordance with CDRL A004. When deliver the film, the film shall be placed in film envelopes or sleeves. Radiographic film shall be place into an appropriate shipping container that will not damage the film. The film envelopes shall be placed in either a fiberboard, cardboard, or wooden box. X-rays films shall not be placed directly into a shipping container (i.e. FedEx or UPS box). X-ray films shall not be rolled up and place in a shipping tube. The film should be flat, and not folded, bent, or otherwise mutilated.

DELIVERABLES

Reporting of Government Inventory Held Under Product Support Contractual Arrangements (CDRL A001). Inventory of GFM provided by the Government for this SOW shall be reported to the Government until all GFM are either released for disposition or shipped back to the Government. Inventory shall be provided in file format compatible with MS Excel (e.g. .xls or .xlsm files). Contractor format is acceptable.

First Submission – Initial submission due 6 months after award of contract or 60 days after receipt of modification incorporating this CDRL.

Subsequent Submission – Due 6 months after initial submission, and semiannual thereafter. Until all GFM are either released for disposition or shipped back to the Government.

Test Work Order (CDRL A002). A copy of the work order(s) detailing the procedures for No-Fire (3.5.7.2), Alternative No-Fire (3.5.7.2.1), Functional (3.5.7.4), and Alternative Functional (3.5.7.4.1) shall be provided for Government review/approval at least 21 days prior to the start of nondestructive testing. Contractor format is acceptable.

Technical Report- Study/Services (CDRL A003).

First Submission - A copy of all destructive test results and associated current and time traces, non-destructive inspection results, electrical test results, test equipment list and calibration information, conditioning chamber temperature profiles, pulse charts, and photographs shall be provided to NSWC IHEODTD within 5 days after the completion of the destructive testing. A notification of anomaly shall be provided for any unit that does not meet the non-destructive, electrical, or destructive test requirements. Contractor format is acceptable.

Subsequent Submission – Final report and electronic copies of current and time traces in a digital file format compatible with MS Excel (e.g. .csv or .xls files), and photographs shall be provided to NSWC IHEODTD within 30 days of completion of destructive testing. Radiographic inspection reports and copy of x-ray also shall be provided to NSWC IHEODTD within 30 days after completion of testing. Contractor format is acceptable.

Radiographic Report and Film (CDRL A004). Radiographic inspection reports and copy of x-ray films shall be provided to NSWC IHEODTD within 30 days after completion of testing. Contractor format is acceptable.

Contractor may be required to handle Controlled Unclassified Information (CUI). There are numerous types of CUI, e.g. documents with limited distribution statements, documents marked as For Official Use Only (FOUO), etc. The minimum level of protection for all CUI is adherence to FOUO protection standards. Distribution Statements (DS) and warning labels, such as the Arms Export Control Act Warning, identify additional protection requirements for a given document. Minimum FOUO protection requirements/controls applicable to the performance of this contract for CUI are listed below. Additional protection requirements, as marked on a given CUI document, are in addition to the standards listed.

Handling/Storage: Access to FOUO is limited to those needing it to conduct official business for the Department of Defense (DoD). FOUO information is not classified information, but requires extra precautions to ensure it is not released to the public. During business hours, reasonable steps shall be taken to minimize risk of access by unauthorized personnel. After business hours, FOUO information shall be stored in unlocked containers, desks, or cabinets if Government or Government-contracted building security is provided. If it is not, store in locked desks, file cabinets, bookcases, locked rooms, or similar items.

Transporting/Transmitting/Release/Destruction: FOUO information shall be transported in a manner that prevents disclosure of the contents. FOUO information may be sent via USPS first-class mail, parcel post, or – for bulk shipments – 4th class mail. Electronic transmission of FOUO information (voice, data, or facsimile) shall be by approved secure communications systems. Transmission via unsecure fax is acceptable if an authorized person is standing by on the receiving end to take custody. All emails containing FOUO or attachments with FOUO must be digitally signed and encrypted when transmitted within a Navy network or to an approved contractor email address. Transmission of FOUO (i.e. any CUI) to personal email accounts (e.g. AOL, Yahoo, Hotmail, Comcast, etc.) is strictly prohibited. FOUO sent out of the contractor’s facility electronically must be encrypted (DoD FIPS 140-2 standard). FOUO material shall not be released outside the contractor’s facility except to representatives of DoD. When no longer needed, destroy FOUO by a method that precludes its disclosure to unauthorized individuals.

Markings: Unclassified documents (paper or electronic) generated in support of this contract which contain FOUO are to be marked “For Official Use Only” at the bottom on the outside of the front cover (if any), on each page containing FOUO information, and on the outside of the back cover (if any). Each paragraph containing FOUO information shall be marked as such. Within a classified document, an individual page with both FOUO and classified information shall be marked at the top and bottom with the highest security classification of information appearing on the page. Individual paragraphs shall be marked at the appropriate classification level, as well as unclassified or FOUO, as appropriate. Within a classified document, an individual page that contains FOUO information but no classified information shall be marked “For Official Use Only” at the top and bottom of the page, as well as each paragraph that contains FOUO information. Other records, such as photographs, films, tapes, or slides, shall be marked “For Official Use Only” or “FOUO” in a manner that ensures that a recipient or viewer is aware of the status of the information therein. DS on technical documents identify access restrictions. DS “B” through “D” preclude public release and while not marked as FOUO, are subject to all FOUO protection requirements, including the prohibition on unencrypted transmission over the public Internet.

Enterprise-Wide Contractor Manpower Reporting Application (ECMRA)

The Contractor shall report Contractor labor hours (including subcontractor labor hours) required for performance of services provided under this contract for (OA) Testing of Mark (MK) 9 Modification (MOD) 0 Explosive Bolts via a secure data collection site. Contracted services excluded from reporting are based on Product Service Codes (PSCs). The excluded PSCs are:

1) W, Lease/Rental of Equipment;

2) X, Lease/Rental of Facilities;

3) Y, Construction of Structures and Facilities;

4) D, Automatic Data Processing and Telecommunications, IT and Telecom-Telecommunications Transmission (D304) and Internet (D322) ONLY;

5) S, Utilities ONLY;

6) V, Freight and Shipping ONLY.

The Contractor is required to completely fill in all required data fields using the following web address www.ecmra.mil

Reporting inputs will be for the labor executed during the period of performance during each Government fiscal year (FY), which runs October 1 through September 30. While inputs may be reported any time during the FY, all data shall be reported no later than October 31 of each calendar year. Contractors may direct questions to the help desk, at DoD.ECRMA.Support.Desk@mail.mil

Summary.

Table III: CDRL Summary

CDRL

NUMBER

(SOW Paragraph

(SOW Paragraph 4.1)

(SOW Paragraph 4.2)

(SOW Paragraph 4.3) Within thirty (30) days of completion of destructive testing

POINT OF CONTACT

Technical Representative:

Kyle Brossoit, Code E14KB Work: (301) 241-8992 kyle.brossoit@navy.mil

Technical Representative’s Manager:

Deidre Cunningham, Code E14DC Work: (301) 744-1101 Mobile: (301) 221-4735 deidre.cunningham@navy.mil Shipping Address for Documentation only:

System Engineering Division

NSWC IHEODTD

3703 Benson Road, Bldg. 3157 Indian Head, MD 20640 Attn: Kyle Brossoit, E14KB