SOW_-_ASD_TLX_DVT.docx

August 2019

STATEMENT OF WORK

Detonating Cord Assembly (DCA) / Thin Layer Explosive (TLX) Second Source Project Design Verification & Production Demonstration

1.0 Background

Detonating Cord Assemblies (DCA) or Thin Layer Explosive (TLX) components are designed to transmit a detonation signal from input action to output device in a wide variety of DoD aircraft and weapon system applications. The Naval Surface Warfare Center, Indian Head Explosive Ordnance Disposal Technology Division (NSWC IHEODTD) requires a Design Verification Test (DVT) effort and a production demonstration effort for a proposed new DCA/TLX line configuration, including a series of Non-Destructive Tests (NDT), and product certifications to support the evaluation of the proposed new DCA/TLX line configuration. The NDT for these lines includes dry gas leak tests and radiographic (X-ray) inspections.

The contractor shall design and produce new lines which will be evaluated for compliance with the technical requirements as presented in their DCA Detail Specification (MIL-DTL-82889A dated 25 Mar 04). The contractor shall also perform a series of environmental and functional tests on the new lines. The results of this study, in addition to the results of the previous NSWC IHEODTD functional testing efforts, will be utilized to determine the reliability of this new configuration to reliably function after exposure to various U.S. Navy, Air Force, Army aircraft operating environments.

2.0 Scope

The scope of this Statement of Work (SOW) defines the effort to be conducted by the contractor in support of the DCA/TLX Design Verification and Manufacturing Demonstration effort.

The contractor shall conduct an engineering study to verify the capability of the proposed High Energy (HE) component and to demonstrate the production capability to manufacture this new HE component that could potentially achieve all of the operational requirements as presented in the DCA Detail Specification (MIL-DTL-82889A dated 25 Mar 04). The contractor shall incorporate the enhanced DCA/TLX component design, utilizing the production manufacturing process, and fabricate forty (40) prototype DCA/TLX HE component lines, and conduct a series of environmental and functional tests on the lines.

3.0 Applicable Documents

DI-MGMT-80555A Program Progress Reports

DI-MISC-80771A Scientific and Technical Reports

MIL-DTL-82889A Detonating Cord Assembly (DCA)

ASTM E1742 Standard Practice for Radiographic Examination

DI-SESS-81495A Failure Modes, Effects, and Criticality Analysis Report

844AS292 Union, Inert Connector (SMDC)

841AS803 Dent Block

4.0 Requirements

4.1 The contractor shall submit Program Progress Reports (Monthly Reports) every thirty (30) days after contract award date CDRL A001. The contractor shall conduct a conference call twice per month.

The contractor shall submit the Scientific and Technical Final Report upon completion of the work per CDRL A002.

4.2 The contractor shall design and develop a High Energy (HE) component configuration that can achieve all of the requirements in the current DCA Detail Specification. The contractor shall document this proposed HE component design in accordance with their internal engineering procedures.

4.3 The contractor shall develop a pedigree for their proposed HE component design utilizing a series of functional tests to be conducted at their facility with CAD/PAD technical team participation.

4.4 The contractor shall develop production processes or manufacturing instructions to ensure that the proposed HE component design can be safely and reliably assembled at the Brownsville, TX facility.

4.5 The contractor shall conduct a pre-Production Readiness Review for their proposed HE component design, with participation by NSWC IHEODTD representatives, to review the production processes and manufacturing instructions.

4.6 The contractor shall utilize this proposed HE component design and production processes to assemble forty (40) complete DCA lines.

4.7 The contractor shall certify that these newly fabricated lines were assembled in accordance with the contractor’s manufacturing instructions.

4.8 The contractor shall conduct an internal Test Readiness Review (TRR) at their facility at least one (1) week prior to testing. The Contractor shall present to the Government a review of the environmental test procedure, test setups, the list of equipment and instruments to be used in the tests, and their calibration. The government will participate during the TRR.

4.9 The contractor shall manufacture sufficient quantities of Unions in accordance with drawing 844AS492 and Dent Blocks in accordance with 841AS803 to conduct all testing required for this contract. The contractor shall supply all other parts, materials, equipment, and facilities to conduct the testing per a developmental test plan to also include non-destructive tests x-ray and leakage, which shall be submitted to the government in accordance with CDRL A003 for review and approval.

4.10 The contractor shall conduct a series of environmental and functional tests (in accordance with MIL-DTL-82889A, Union Dwg. 844AS292, and Tables 1 and 2) on these forty (40) lines, with participation by NSWC IHEODTD representatives. Test results shall be submitted in the final report (CDRL A002).

Group

Group Notes

Pressure Cycling

DCAs will be subjected to 100 cycles (50 each at -65° F and 350° F) iaw MIL-DTL-82889A, Para. 4.6.4

Temperature Cycling

DCAs will be subjected to 100 cycles from -65° F to 350° F iaw MIL-DTL-82889A, Para. 4.6.5

Solvent Resistance

DCAs subjected to 70 exposures at 10 sec. each of submersion into Cleaner iaw MIL-DTL-82889A, Para. 4.6.9

Table 1: DVT Test Matrix

Notes:

1. DVT matrix includes a total of 40 lines manufactured and certified to ASD’s manufacturing process and design.

2. The short family is represented by a 8.7” long line – B-1B aircraft application.

3. The medium family is represented by a 49.27” long line – T-45 aircraft application.

4. The long family is represented by a 112.8” long line – F-18 aircraft configuration.

(System Compatibility)

49.27”→Union→112.8”→Dent Block

(System Compatibility)

8.7” (Min. Bend)→Union→112.8”→Dent Block

(System Compatibility)

49.27”→Union→8.7”→Dent Block

(System Compatibility)

49.27”→Union→112.8”→Dent Block

Table 2: Specific Test Conditions and Configurations

Notes:

1. Function times will be recorded for all tests.

2. PC – Lines exposed to MIL-DTL-82889A Pressure Cycling.

3. TC – Lines exposed to MIL-DTL-82889A Temperature Cycling.

4. SR – Lines exposed to MIL-DTL-82889A Solvent Cycling.

4.11 The contractor shall prepare an initial Failure Mode, Effects and Criticality Analysis (FMECA). DI-SESS-81495A may be used for guidance. The FMECA shall be submitted in the final report (CDRL A002).

4.12 The energetic materials shall be compatible with each other and materials they may come into contact. The contractor shall evaluate the compatibility of the energetic materials with each other and materials they may come in contact with by conducting compatibility testing using two separate methodologies per STANAG 4147, 2nd edition. Any dynamic work, including calibration, shall be done at 2°C/min. Provide the results of the tests to the Navy using the templates in STANAG 4147 for each method. Chemical Analysis (Test 5) shall not be used. If the material is a pyrotechnic, the Vacuum Stability Test (Test 1) shall not be used, since pyrotechnics do not appreciably out-gas. At the conclusion of the compatibility testing the contractor shall submit a Chemical Compatibility Report to the government for review and approval. Data and analysis report shall be submitted in the monthly report (CDRL A001).

Samples of all energetic materials, including a sample of the cord (shock tube) and samples of the energetic materials in the HE tips, and any adhesives and sealants used, shall be delivered to NSWC IHEODTD.

5.0 Deliverables

5.1 The contractor shall submit Monthly Reports detailing their efforts over each thirty (30) day period after contract award date. (CDRL A001). Included in these Monthly Reports, the contractor shall submit all design or configuration changes, and results of environmental and functional test used to establish product pedigree. Also included in these Monthly Reports, the contractor shall submit the pre-Production Readiness review minutes, the preliminary results of environmental and functional testing (paragraph 4.8), and compatibility data and analysis (paragraph 4.10).

5.2 The contractor shall deliver samples of the energetic materials, including a sample of the cord (shock tube), samples of the energetic materials in the HE tips, and any adhesives and sealants used.

Delivery address:

N00174 Explosives Scales Facility 5021 Safe Haven Way Indian Head, MD 20640-5173

5.3 The contractor shall submit a draft Final Report (CDRL A002) to the NSWC IHEODTD team no later than 30 days after the completion of Task 4.8. The NSWC IHEODTD team will review and comment on the contractor’s Final Report no more than 30 days after submission.

5.4 The contractor shall submit a design verification test plan per CDRL A003

5.5 The contractor shall submit a Final Report 30 days after NSWC comments are received.

6.0 Administrative Requirements

This procurement includes controlled unclassified technical information assigned a restricted distribution statement which is export controlled. To receive this unclassified controlled technical information, the Contractor must be currently certified through the United States/Canada Joint Certification Program.

6.1 Controlled Unclassified Information (Includes For Official Use Only Information)

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.

6.2 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.

6.3 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 ( e.g. 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.

6.4 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.

7.0 Operations Security

7.1 For Official Use Only (FOUO) Information and Controlled Unclassified Information (CUI). The contractor shall be capable of accessing, handling, receiving, and storing UNCLASSIFIED documents, equipment, hardware, and test items using the applicable standards of FOUO Information.

7.1.1 Physical Security Standards for Sensitive Items. The contractor shall provide property storage and accountability of sensitive conventional Arms, Ammunition, and Explosives (AA&E). These standards are set forth in Department of Defense (DoD) 5100.76-M entitled “Physical Security of Sensitive Conventional Arms, Ammunition, and Explosives.” The contractor facility storing or handling AA&E shall pass a pre-award Physical Security Inspection of the facility.

7.1.2 Transportation Security Requirements. Supplies procured or furnished under this contract/subcontract, which are qualified as sensitive in accordance with DoD 5100.76-M (Physical Security of Sensitive Conventional Arms, Ammunition, and Explosives), or are shipped as DOT Hazard Class 1 Explosives 1.4C, require special Transportation Protective Service (TPS) during shipment from all points of origin to all destinations. TPS will be equivalent to the DOD security standard for the applicable sensitive category or explosive class identified under DOD 5100.76-M and DOD 4500.9R, Defense Transportation Regulation, parts II and III, as added to or amended by applicable military service policies in accordance with guidance provided by Defense Logistics Agency (DLA)/Defense Contract Management Agency (DCMA). Shipper's Defense Contract Management District/Area Operations (DCMD/DCMAO) transportation offices will furnish assistance in providing the sensitive category of items to be shipped, determining the TPS required, and obtaining the TPS from commercial carriers as necessary.

8.0 Technical point of contact:

Name: Mr. Bobby Abraham Phone: (301) 744-2303 Email: Bobby.abraham@navy.mil