NEW SOW CCU-148 Shell Assembly Glass FINAL.docx

Statement of Work First Article Testing (FAT)/Production Testing CCU-148 Shell Assembly

1. PURPOSE

The Naval Surface Warfare Center, Indian Head Explosive Ordnance Disposal Technology Division (NSWC IHEODTD) requires 100% hydrostatic and resistance testing for two FAT samples of the Shell Assembly, drawing number 3205AS236, in order to ascertain a suitable replacement for Schott S-8061. Once a suitable replacement is determined the government requires production quantities of Shell Assembly, 3205AS236, using the selected replacement material.

2. APPLICABLE DOCUMENTS

2.1 Drawings

2.2 Specifications

ASME Y14.5-2009 - Dimensioning and Tolerancing ASME Y14.100-2013 - Engineering Drawing Practices SAE AMS2700 - Passivation of Corrosion Resistant Steels ASTM A967/967M - Standard Specification for Chemical Passivation Treatments for Stainless Steel Parts ASTM A276/276M - Standard Specification for Stainless Steel Bars and Shapes ASTM F30-96 - Standard Specification for Iron-Nickel Sealing Alloys MIL-DTL-32245 – Cartridge, Impulse, CCU-148/B

2.3 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.

2.3.1. 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.

2.3.2. 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.

2.3.3. 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.

3. REQUIREMENTS

3.1 The contractor shall provide two FAT samples (quantities of 60 each). Both FAT samples shall adhere to the requirements of the drawing 3205AS238, with the following deviations. The first FAT sample shall replace the Schott S-8061 glass on drawing 3205AS245 with Richland Glass RG93 glass and the second FAT sample shall replace it with Electro-Glass M3-281. The FAT assemblies will be serialized to differentiate between the two possible replacements, Richland Glass RG93 and Electro-Glass M3-281.

3.2 The assemblies must be subjected to a pressure of 30,000±500PSI, in the location indicated by note #3 of DWG 3205AS238. Data traces should be correlated to be able to report observations, with photos of each serialized assembly before and after testing, as well as measurement of the glass surface, to ensure there is no movement.

Post pressure test, the assemblies must be leak tested IAW MIL-DTL-32245. Leakage may not be in excess of 10-5 cc/sec air ±0.1 atmosphere differential pressure, within 15 minutes of exposure to 27 mm Hg vacuum for 5 minutes then exposure to helium at 30 +2/-0 psia for 60 minutes.

3.3 The assemblies will also be subjected to a resistance test as indicated by note #4 of DWG 3205AS238. Specific measured resistance should be noted and traceable to each serialized assembly and delivered to the government.

3.4 Upon evaluation of the photos and measurement data listed in 3.2 and 3.3, the government will evaluate and approve either or both FAT quantities in order to build Shell Assembly 3205AS236.

3.5 Upon delivery of the two FAT samples of 3205AS236 and requested test documentation, the government will perform additional testing to verify the suitability of the replacement glass. The government will complete testing and approve a replacement glass within 60 days of FAT delivery.

3.6 Upon written approval of glass selection, the contractor will begin producing the final production units, according to the requirements of drawing 3205AS236 and 3205AS238, and this SOW.

3.7 A sample of the production quantity of 80 assemblies, per ANSI ASQ Z1.4 General Inspection Level II, must be tested IAW requirements 3.2. The sample quantity must be marked and segregated from the production lot shipment.

3.8 The production quantity of the assemblies are to be 100% subjected to a resistance test as indicated by note #4 of DWG 3205AS238.

4. PACKAGING AND SHIPPING

4.1 Please refer to Form 43 for packaging and shipping requirements.

5. QUALITY ASSURANCE

The contractor shall submit Certificates of Compliance/Analysis (Per 3205AS237, 3205A239, 3205AS238, 3205AS242, 3205AS244, 3205AS243 and 3205AS245 Form 16), including sub-vendor processes, certifying that each CCU-148 hardware component deliverable has been checked / visually inspected and meet the requirements of the individual drawings, as well as this SOW. The contractor shall maintain quality and process controls that will be used to ensure that the production parts will be in compliance with the applicable specifications and this SOW. The contractor shall maintain documentation and processes that will be used to identify, record, and disposition non-conforming material, in-process rejects/reworks and characteristic discrepancies. This documentation shall be kept by the contractor until further notified by the Government, at a minimum of one year after contract completion.

6. INSPECTION AND FINAL ACCEPTANCE

The contractor shall utilize best engineering practices and develop procedures to ensure that the each end item meets the requirements identified within the SOW. The contractor is responsible for the performance of in-house checks / visual inspections to ensure each CCU-148 hardware component (3205AS237, 3205A239, 3205AS238, 3205AS242, 3205AS244, 3205AS243 and 3205AS245) are in conformance with this SOW. Final acceptance will be determined by the Government at Government destination, at the conclusion of an engineering review.

Acceptance of each delivery / lot of hardware will only occur after all requirements specified within have been completed and passed. Notwithstanding the above, the Government may at its discretion, accept a defect on a waiver on a case-by-case basis. The Government may at its discretion increase inspection sample size if determined necessary as to validate any discrepancy variations/issues.

7. POINT OF CONTACT

NSWC IHEODTD Point of Contact:

Zelda Brown Zelda.Brown@navy.mil