N6339424R0005 SSOV SOW.pdf

Statement of Work For

Short and Medium Range Sub-Orbital Vehicles and Launch Support

1.0 INTRODUCTION AND BACKGROUND

The Naval Surface Warfare Center Port Hueneme Division Detachment White Sands (NSWC PHD Det WS) has a requirement to provide Short and Medium Range Sub-orbital Vehicles and launch support services for customers. These vehicles are required to meet the needs of various programs including programs such as:

Aegis Ballistic Missile Defense (ABMD), Air and Missile Defense Radar (AMDR), Maritime Missile Defense, Fleet Training, and other programs needing rocket based vehicles.

1.1 Scope

The Statement of Work (SOW) defines tasks in support of the Short and Medium Range Sub-orbital Vehicle development programs to demonstrate the implementation of technologies in Army, Navy, Air Force, Missile Defense Agency (MDA), Foreign Military Sales (FMS), and Other Government Agency (OGA) development programs. The vehicle performance shall meet requirements of requested Performance Specifications, Vehicle Requirements Document, Target Mission Requirement Documents/Letter and Target Systems Requirements Document on standard vehicle configurations. This performance is dictated by the use of previously flown motor sets and hardware that is intended to be stable and of limited variability. The work shall include areas such as:

(a) The procurement of existing hardware designs

(b) Environmental testing

(c) Static and dynamic analysis of flight vehicles and dynamic flight interactions

(d) Sub-system testing for flight qualification and acceptance

(e) Vehicle sequence testing for verification of timing and events

(f) Qualification testing for unit buys to insure functionality and acceptance for flight under configuration control

(g) Identify plausible vehicle designs and analyze performance of existing and plausible designs deployed in various locations

(h) Predicted Performance Analysis

(i) Mechanical Design of housings, components and structures

(j) Mechanical, electrical, electronic component manufacture

(k) Ordnance and explosive systems work to include lethality assessment systems

(l) Provide and integrate deployed objects, debris, or associated objects for analysis of performance against various threat environments

(m) Provide interfacing of various launching systems and ground support equipment

(n) Provide ground launch and interface control equipment

(o) Fielding/launch support at various locations

(p) Performing pre and post mission field and flight data analysis

(q) Assist with configuration control and related procedural development

(r) Program planning, management and reporting, administration, Contract Data Requirements List

(CDRL A020)

(s) Quality assurance

(t) Provide engineering, design, and development of required hardware configurations considering specific mission requirements and parts obsolescence constraints.

(u) Design, modeling, and simulation of guidance and control systems for the Attitude Control Systems and single nozzle Thrust Vector Control System

(v) Signature Prediction analysis for Thermal, Radar Cross Section and radiometric definition

(w) Provide certified personnel as necessary for critical work areas and products such as certifications in accordance with OP-5, P-307, State licensing for Hazardous Materials, Range Commander

Council Documents for subsystems, and relevant Information Technology citations for protection of data

1.2 Objective

The Contractor shall provide support for the manufacturing, flight activity, and limited design support of Short and Medium Range Sub-orbital Vehicle configurations, with potential for limited design changes for these existing systems. This support shall include current design acceptance and qualification of systems and subsystems for the purpose of providing reliable flight systems. In addition, the Contractor shall provide support, including design changes, to mitigate and replace obsolete vehicle components. The Contractor shall support updating the obsolete parts list for all vehicle configurations in manufacturing and develop a sufficient replacement plan for parts. When required, the Contractor shall procure component parts according to the Government approved replacement plan to ensure minimal disruption of configurations. The Contractor shall define and recommend the scope of redesigns required to replace these obsolete parts and provide for acceptance of the redesigns for recurring flight and use, including cost and schedule, to NSWC PHD Det WS for concurrence. Particular attention shall be paid to prevent introduction of counterfeit parts into designs whether by procurement or manufacture from misrepresented components. Trade studies to ascertain the best method of approach and or recommended solutions shall be necessary to determine course of actions and alternatives.

The Contractor shall support all working groups, System Requirement Reviews (SRR), Preliminary Design Reviews (PDR), Critical Design Reviews (CDR), Failure Review Boards (FRB), Pedigree/Pre-Ship Reviews, quarterly reviews and planning meetings, as required in accordance with CDRL A020. Trade studies to ascertain the best method of approach and or recommended solutions shall be necessary to determine course of actions and alternatives.

The Contractor shall maintain a configuration management control program for the Short and Medium Range Sub-orbital Vehicles (CDRL A021). The contractor shall require subcontractors to adhere to their configuration management control program or require their subcontractor to have their own program that meets the same requirements. The Contractor shall participate in the data management and analysis functions and maintain a single, centralized system for management of data required under this Contract. The data shall include information such as: inventory, as built as designed (ABAD) documentation, travel logs, procedures, vehicle flight and day of test data, historical performance statistics, working group presentations, and all reports delivered.

The contractor shall maintain an integrated master schedule (IMS) and coordinate the IMS with all subcontractors to produce an IMS deliverable to NSWC. The IMS will be delivered to NSWC on a monthly basis.

Overall the Contractor is expected to be a Subject Matter Expert in the areas defined in Section 1.1 A-W above.

The meetings may take place in person, teleconference, video teleconference or other mediums as necessary.

Classification level shall be consistent with applicable Security Classification Guidance but will be up to a SECRET level.

The Contractor shall procure materials for the fabrication of integrated tested systems and subsystems, fabricate integrated tested systems and subsystems, or procure fully integrated tested systems and subsystems for all short and medium range sub-orbital vehicles. The Contractor shall adhere to the drawings as provided in Exhibit B – Technical Data Package (TDP) unless otherwise specified by the Government. The Contractor shall provide a report of hardware delivery status in accordance with CDRL A006.

Hardware and components to be delivered under this Contract include items, as identified below by vehicle type, such as:

• Short Range (Group A) – One or two stage vehicles consisting of a Terrier Mk 12/Mk 70 first stage and either an improved Orion M112 or a Lynx Mk 104 second stage. Motor for single stage vehicles shall consist of either an improved Orion M112 or a Lynx Mk 104. The Contractor shall provide the following items with the exception of the items identified as Government Furnished Equipment (GFE):

- Mechanical components for delivery of defined nose tips in accordance with Government provided drawings

- Tail cans that interface to GFE motors

- Fins for all stages (all stages of vehicle)

- Ordnance control in the form of Vehicle Service Module (VSM) with channel minimal capability baseline of 2 trigger events and options to increase in groups of 2 additional event triggers to a maximum of 16 events per VSM.

- Payload skin sections supplied in increments of 1 inch with standardized, flight identifiable and qualified radial/axial, v-band joints in accordance with Government provided drawings.

Standard payload skin diameter ranges from 13.5 to 14 inches but may vary based on vehicle.

- Capability of providing roll stabilized Inertial Measurements Units (IMU) and instrumentation to include GLN-200 and Honeywell roll stabilized platforms.

- Power systems with rechargeable battery based and switched systems with flight heritage in similar or same suborbital vehicles

- Telemetry (TM) and instrumentation systems to include Global Positioning System (GPS) receivers and encryption based on flight qualified and flown systems from similar or same sub-orbital vehicles.

- Radar transponder systems based on flight qualified and flown systems from similar or same suborbital vehicles

- Flight performance analyses to include, basic performance metrics and plots up to 6 Degrees of Freedom (DoF) for each object in unitary or separated configuration, wind sensitivity and weighting, ground and flight safety data packages of sufficient qualified detail as defined by the Government Range Safety Organization of test location to satisfy executing range location missile flight safety or equivalent organizations.

- Analysis for applied environments to include thermal, shock, mechanical loads, dynamic interactions and flight induced phenomenology. This shall include ground launch environments induced as a function of launch, transport or recovery on occasion.

• Medium Range (Group B) – Generally a two or three stage vehicle consisting of a Terrier

Mk12/Mk70 first stage and an Alliant Tech Systems Graphite Epoxy Motor PN- 60474A20001 second stage with separating and non- separating nose tip and mid body sections or a Terrier Mk12/Mk70 first and second stage and an Alliant Tech Systems Graphite Epoxy Motor PN- 60474A20001 stage with separating and non- separating nose tip and mid body sections for the third stage. The Contractor shall provide the following items with the exception of the items identified as GFE:

- Nose Tips defined under a technical Instruction package

- Tail can for motors provided as GFE

- Fins for all stages (Terrier, GEM-22)

- Ordnance control in the form of VSM with channel minimum capability baseline of 2 redundant fixed time or commanded trigger events and options to increase in groups of 2 additional redundant event triggers to a maximum of 16 events per VSM. All ordnance considered for trigger with this system will be dual bridge wire 1 ohm 1 watt devices with exception of retro-motors defined as M-37A1 or E1 configurations configured as ¼ watt systems.

- Payload skin sections supplied in increments of 1 inch with standardized, flight identifiable and qualified radial/axial, v-band joints in accordance with Government provided drawings.

Standard payload skin diameter ranges from 22 to 25 inches but may vary based on vehicle.

- Capability of providing roll stabilized IMU and associated instrumentation.

- Additional instrumentation to define thermal, magnetometer based, shock, acceleration, video current loops, event capture, velocity measurement and other in-flight or ground based events. There will be explicit requirements to equip vehicles with detailed instrumentation for lethality / hit detection systems and appropriate feedback in-flight to reconstruct all phases of flight.

- Power systems with rechargeable battery based and switched systems with flight heritage in similar or same suborbital vehicles

- TM systems to include GPS receivers and encryption based on flight qualified and flown systems from similar or same sub-orbital vehicles

- Radar transponder systems based on flight qualified and flown systems from similar or same suborbital vehicles

- Separation systems consisting of manacle ring, ordnance driven separation at defined vehicle planes and joints, equipped with delta-velocity producing mechanical or ordnance systems between separated bodies, de-spinning systems of the mechanical centripetal type or cold gas attitude rate controlled or axis controlled roll type

- Flight performance analysis of all bodies from basic performance to generated trajectories to meet objective mission criteria Flight performance analyses will include, basic performance metrics and plots up to 6 DoF for each object in unitary or separated configuration, wind sensitivity and weighting, ground and flight safety data packages of sufficient qualified detail as defined by the Government

• The contract shall also be able to provide “beacon only” vehicles at a reduced cost from the fully instrumented vehicles detailed above.

Range Safety Organization of test location to satisfy executing range location missile flight safety or equivalent organizations.

- Analysis for applied environments to include thermal, shock, mechanical loads, dynamic interactions and flight induced phenomenology. This shall include ground launch environments induced as a function of launch, transport or recovery on occasion.

- Flight performance analyses to include wind weighting, ground and flight safety data packages

- Third stage hardware configurations on occasion

The Contractor shall provide the materials, facility and field support necessary to support the repair of GFE for the Short and Medium Range Sub-orbital Vehicle program. This could include sections, assemblies, subassemblies, components and associated Test Equipment as directed under technical instruction by NSWC PHD Det WS. Systems shall be compatible with the existing Navy Government furnished equipment and ground support equipment, Remote Payload Ground Support Equipment (GSE) existing launcher systems and TM Data Acquisition System.

The Contractor shall deploy to support sub-orbital vehicle launch operations. Launches will occur at various locations but not limited to the following: the Pacific Missile Range Facility (PMRF), San Nicholas Island (SNI), White Sands Missile Range (WSMR), and Wallops Flight Facility (WFF). In addition, travel may be required to foreign countries. Work may include launches conducted in Broad Ocean Area (BOA), or other ranges and locations.

In the event there are design changes to the current designs, the Contractor shall provide design and analysis for all new proposed designs. The Contractor shall provide manufactured hardware and components for all new designs for all Short and Medium Range Sub-orbital Vehicles. Any new designs should be compatible with existing Navy ground support equipment. The new designs shall be Government owned and not to be considered Contractor proprietary.

2.0 APPLICABLE DOCUMENTS

The following documents are available online:

MIL-STD-1540D “Department of Defense Standard Practice: Product Verification Requirements for Launch, Upper Stage, and Space Vehicles” ISO 9001 “Quality Management Systems – Requirements” OPNAVINST 8023.24D “Navy Personnel Conventional Ammunition and Explosives Handling Qualification and Certification Program” NAVSEAINST 5000.9 “Virtual SYSCOM Naval SYSCOM Systems Engineering Policy, 2009” DFARS 252.227-7013 “Rights in Technical Data – Non-Commercial Items” NAVSEA OP-4 “Ammunition and Explosives Afloat” NAVSEA OP-5 “Ammunition and Explosives Safety Ashore” SECNAV Instruction 5510.30C “Department of the Navy Personnel Security Program” dated 24 January 2020 Homeland Security Presidential Directive 12 (HSPD-12) “Policy for a Common Identification Standard for Federal Employees and Contractors” United States Office of Personnel Management Memorandum “Final Credentialing Standards for Issuing Personal Identity Verification Cards under HSPD-12” dated 31 July 2008 SECNAVINST 5510.36B “Department of the Navy Information Security Program” OPNAVINST 5530.14E “Physical Security and Law Enforcement Program” NAVFAC P307 “Management of Weight Handling Equipment” Department of Defense Industrial Security Policy 5220.22 Latest Revision Launcher Documentation Manuals for SDD Model 956, Missouri Research Laboratories 7.3K, AML 4.3K, High Altitude Diagnostic, Thiokol 20K, Athena 25K, ANML V1, ANML V2, and NIKE M-35 NAVSEA Instruction 5100.12B System Safety Engineering (SSE) Manual January 2014

Contractors may request a copy of these documents from the Contracting Officer:

NSWC PHD Det WS Product Assurance Implementation Plan (PAIP) NAVSEAINST 2200.1A Portable Electronic Devices Policy dated 29 April 2019 NSWCPHDINST 3432.1C “Operation Security (OPSEC)”

Access to a Reference Library will be provided post-award. Reference Library includes documents such as:

reference material pictures, launcher manuals, operation procedure references, etc."

3.0 PROGRAM MANAGEMENT REQUIREMENTS

3.1 General Management

The Contractor shall provide all necessary personnel, facilities, materials, technology and services necessary to perform the tasks described in this SOW unless specified otherwise by Government. The Contractor may be required to provide transportation vehicles for general transport of personnel, tools, equipment and non-explosive hardware.

The Government will make provisions for up to 6,400 square feet to be available in NSWC PHD Det WS, Building N61, to include the following:

• Unfinished office space to be configured by Contractor

• 10 Department of Defense (DoD) NIPR system ports

• Mail service delivery

• Utilities accommodation

• Separated telephone lines (up to ten (10) lines)

• Janitorial services

• Access to development, test and integration laboratories at White Sands location for standardized processing qualification tasking

• Caged/theft deterrent storage for test articles managed by Contractor

• Work area for section assembly and component testing at selected locations during task specified assembly activity

The Government space described above is not to be considered full-time office space.

The Contractor will be granted access to Government facilities for the following activities:

• NSWC PHD Det WS, Building N99 for assembly, subassembly testing an integration of the short and medium range sub-orbital vehicles.

• Applied Environments Facility, WSMR, New Mexico, 300K site for environmental testing, to include vibration, shock, Moment of Inertia (MOI) measurements, center of gravity measurement, spin balance, and bend tests.

It is not the intent of this contract to provide for the following at the Contractor facility:

Vibration equipment Balance equipment Shock inducing equipment Bend test fixtures

If Contractor proposes use of existing Contractor facility equipment, the Government reserves the right to explicitly permit the use of said equipment and perform a cost based analysis of favorable expense to Government before use is sanctioned or permitted.

3.2 Program Management

The Contractor shall provide program management, including technical direction of Contractor staff, administration, planning and cost control for the tasks identified in this SOW (CDRL A001, A007). The Contractor’s Program Manager shall be responsible for the technical, financial and programmatic performance of the efforts performed under this SOW. The Contractor shall assign a staff of technical, financial, managerial, security, planning, assembly, and support personnel appropriate for the successful and efficient execution of the efforts identified in this SOW.

The Contractor shall provide technical engineering services by attending and supporting periodic management reviews specified herein. The purpose of these reviews shall be for the Government to monitor program progress and technical risk. The Contractor’s support may include hosting, conducting, creating agenda for, preparing minutes for, and responding to action items. As a result of these reviews, Conference and Trip Reports shall be delivered in accordance with CDRL A002 and CDRL A005.

• In Process Reviews (IPR)/Program Management Reviews (PMR): The Contractor shall conduct, at the Contractor’s facility, comprehensive Government-chaired IPR/PMR at approximately three (3) month intervals.

• Working Group Meetings: The Contractor shall participate in and support, at various Government/Contractor facilities, working group meetings.

• SRR/PDR/CDR Reviews: The Contractor shall participate in and support, at various Government/Contractor facilities, all formal Design Reviews.

• Pedigree/Pre-Ship Reviews: The Contractor shall support Government conducted hardware Pedigree/Pre-Ship reviews. The Contractor shall present appropriate data, reports, configuration lists, simulation results, hardware status, pedigree status, and other related information with sufficient time for review by the Government. This shall include defined testing at a component level, address of DoD issued counterfeit parts bulletins, failures and corrective actions taken for sibling and or related items from similar programs or hardware as well a quality control measures identified.

• FRB: The Contractor shall participate in and support FRB meetings, as required. FRB’s will be convened via official written request by the Government to the Contractor. An FRB will be held for reasons such as:

(a) Failure of a prototype or fundamental replacement or design during initial qualification process

(b) In-Flight failures that cause and contribute to a lack of having met primary objective(s) causing a mission failure during any segment of flight

(c) Loss of property and or damage to equipment

(d) Losses to the government exceeding $10,000 or 1 week of time caused by a failure

(e) Personnel Injury

The Contractor shall track and manage GFE. The Contractor shall provide a GFE electronic status report, in accordance with CDRL A008, describing the condition and usage status of GFE received under this Contract. In the report, the Contractor shall also document part numbers and National Stock Numbers (NSN), when available, and justify any requested changes in availability to the GFE schedule in the contract. The Contractor shall repair and test GFE items as required to support program test and flight hardware. The Contractor shall be responsible for managing GFE availability for different tests at different locations across the contract performance without conflicts. If conflicts arise, the Contractor shall notify the Government and provide a suggested plan of action to fulfill Government testing requirements.

The contractor shall turn over to the government any unused parts, electronics, and hardware that is built differently than the standard fully instrumented vehicles.

The contractor shall purchase any items that are required in the field in order to ensure the success of the mission. This includes but is not limited to electronics and electronic equipment, fiber, repeaters, instrumentation, launcher hardware, mechanical fixtures, etc.

3.3 Quality Assurance

The Contractor and its subcontractors shall be required to follow the NSWC PHD Det WS PAIP. The Contractor and its subcontractors shall have a Government approved Quality Assurance Program and maintain a historical archive of all configurations and test data, including qualification and acceptance data in accordance with CDRL A016.

The Contractor and its subcontractors shall document work processes and instructions to include hazardous and non-hazardous procedures, component testing, system testing, subsystem testing, and vehicle level testing.

Work processes and instructions shall identify flight qualified or accepted components, system and subsystems as follows:

• Document and provide signed copies of all work performed through work procedures/work instructions.

• Provide and maintain Qualification documents and specifications on all personnel.

• Provide vehicle assembly and log book. Log books shall include schematics, drawing packages, certification sheets, specification sheets, and conformance/non-conformance sheets. Documentation shall be provided as to disposition of all non-conformances.

• Provide source material specifications and certifications. This will be interpreted to be identification of sourcing to 3 levels ( Level 1 Section = Prime Contractor, Level 2 component or subsystem = Sub-contractor or vendor at direction of Prime Contractor, Level 3 = items making up a component or subsystem from 3rd party vendors under direction of Prime or Sub-contractors)

The contractor shall deliver procedures without their proprietary markings on them so as the government can turn these procedures into NSWC procedures with a NSWC cover.

The Contractor and its subcontractors shall document changes in work processes and instructions, and if change causes requalification or delta qualification of a system and/or subsystem, changes must be provided to the Government for approval in accordance with CDRL A011. The Contractor shall cite MIL-STD-1540D and industry specification traceable to the Institute of Environmental Management and Assessment, and others as applicable.

The Contractor and its subcontractors shall maintain ordnance report logs and hazardous material inventory system and to include destruction reports in accordance with CDRL A015. The Contractor shall document any anomalies with hazardous materials and provide reports to the Government.

The Contractor and its subcontractors shall comply with the provisions of NSWC PHD Det WS Quality Assurance Inspection System Program Plan, Contractor ISO 9001 compliant processes, PAIP and Work Instructions in accomplishing the efforts performed under this Contract and CDRL A016.

3.4 Quality Certification Program

The Contractor and its subcontractors shall be in the Government’s QUAL/CERT program in accordance with

OPNAVINST 8023.24D.

1) The Contractor performing services involving Ammunitions and Explosives (AE) material on behalf of the Government shall have an established explosives handling personnel QUAL/CERT program.

2) All Contractor personnel performing AE tasks under the scope of this contract shall be included in the Contractor’s Government approved QUAL/CERT program.

3.5 Integrated Master Schedule

Develop and maintain an Integrated Master Schedule (IMS) by logically networking detailed program activities with critical path and delineated section level schedules in accordance with CDRL A007. IMS is intended to identify critical path to accomplishment of objective mission. The schedule shall contain the planning events and milestones, accomplishments, system, vehicle, and subsystem deliveries, and activities from Contract award to the completion of the Contract. The Contractor shall quantify risk in hours, days, or weeks of delay and provide optimistic, risk assessed and most likely during for each IMS activity and event. IMS shall include personnel, systems, components, GSE, maintenance and loaded costs.

3.6 Risk Management

Utilize a risk management process to rank and facilitate management of program risks for their subcontracted technical content in accordance with CDRL A019 and NAVSEA Instruction 5000.9, Naval SYSCOM Systems Engineering Policy. Risks shall be ranked according to a numerical rating scheme that uses the product of two or more equally weighted rating criteria (Probability of Occurrence and Seriousness of Consequence, as a minimum). Risks shall be classified as Low, Moderate or High.

3.7 Reports and Other Deliverables

Technical reports delivered by the Contractor in performance of this contract shall be considered Technical Data, as defined in DFARS 252.227-7013, Rights in Technical Data – Noncommercial Items.

The Contractor shall prepare and maintain the documentation identified in Exhibit B, Technical Data Package.

This documentation shall be made available to the Government in Contractor format, however, readable by MS products. The Contractor shall deliver the documentation in an unprotected format, version-controlled form, based on the following paragraphs for the short and medium range sub-orbital vehicles.

3.7.1 Provide a comprehensive interface control document/package in accordance with CDRL A017. This document shall contain the following basic information: mechanical diagrams, flow charts, assembly pictures, display examples, functional tests, and Interface Control Drawings (ICD). ICDs shall include any external mechanical, electrical, radio frequency and fiber optic or other interfaces to include vehicle, launcher, handling equipment, GSE and ordnance support and inflight/execution support. This shall include a top level assembly drawing to the third tier level and include critical fasteners, types and specifications. Safe-to-Mate procedures shall be provided for all electrical interfaces that involve multiple contractors.

3.7.2 Provide hardware listing of support components that will be populated or mounted in the TM mechanical sections in accordance with CDRLs A013 and A017. If hardware is mounted to the instrumentation deck, the Contractor shall be responsible for providing the wiring and assembly ICDs and wiring the hardware.

3.7.3 Provide technical inputs to assist developing operational requirements documentation at assigned ranges. Provide ordnance certification letters to NSWC PHD Det WS for all personnel who will be supporting ordnance work at NSWC PHD Det WS facilities and at other range facilities, in accordance with NAVSEA OP-4 and NAVSEA OP-5 requirements, as applicable. Provide technical input and documentation to support exchanges between Government and Contractor team members during development of vehicles as required. The Contractor shall provide proof of personnel ordnance certification and qualification. Contractor personnel shall obtain and maintain ordnance certifications and qualifications in accordance with Navy Instruction OP-4, Navy Instruction OP- 5, and

OPNAVINST 8023.24D.

3.7.4 The Contractor shall provide technical support to assist the Government in developing complete schematics for non-encrypted and encrypted TM systems. Encrypted TM systems shall be designed and provided in accordance with National Security Agency or designated representatives’ requirements as defined in each individual Delivery Order. Schematics will be required for each TM system individually (one individual schematic for a unitary payload and two individual schematics for the separating payload). Schematics shall include any GSE associated with encryption designed or built by Contractors. The Contractor shall provide a TM measurements list and TM matrix) for each TM system. The TM Measurements list shall include all items in the TM matrix, sample rate, resolutions and engineering unit conversions. In the event of a TM failure or anomaly, the failure or anomaly report shall include the frequency deviation and power measured at the antenna port. The Contractor shall provide mechanical and electrical system documentation and drawings in accordance with CDRL A010.

3.7.5 Procure spare GSE parts such as but not limited to antennas, circuit boards, fiber, telemetry racks, I- RIG timers, TM decoms, The GSE spare parts will be negotiated with NSWC.

3.7.6 The Contractor shall provide a T+45 calendar day report of overall vehicle performance, to include 3 and 6 DoF best estimate of trajectory dependent on instrumentation flown or data available, any high resolution instrumentation data, vehicle event timing and comparison to the 3 sigma bounds established by pre-flight performance Monte Carlo or root sum squared pre-flight analysis data set. The Contractor support shall include analysis and possible corrective actions when deviations from nominal trajectory or nominal instrumentation performance occur.

3.7.7 The Contractor shall provide anomaly and non-conformance reports as follows: 1) for hardware if the impact is greater than $1K and/or 3 days schedule; 2) for flight performance any requirement exceeding or performance outside 1.5 sigma. Non-conformance Reports (NCR) are required for a variety of reasons (e.g. as-built mechanical hardware delivered does not meet drawing specifications or fit/form/function, electrical systems not delivered in accordance with electrical ICD or function) re-work or other corrective address and shall include: anomaly noted, cause and corrective action, and corrective action plans, as necessary, in accordance with CDRL A009. Government approval of corrective action plan is required prior to implementation. A database of all NCRs shall be maintained.

Additionally, parts and components that are suspected or confirmed as counterfeit or non-conforming to “as purchased” requirements shall be reported immediately to the Contracting Officer Government representative and Contracting Officer’s Representative (COR). If a part is confirmed as counterfeit, the Contractor shall support the Government in implementation of DoD policy on counterfeit parts.

3.7.8 The Contractor shall provide electronic or hard copy of completed relevant logs and procedures or work instructions, as proof of completion. Procedures shall include Government signature after critical completion points. The Contractor shall retain the completed original of documents in the mission records. Documents shall be delivered to NSWC PHD Det WS at mission completion (T+45 days).

3.7.9 The Contractor shall provide monthly progress reports (A001) to include incurred and expenditure costs (labor, material, travel, shipping and Sub-contractor costs), available balance, man-hour expenditure, and system and subsystem percent of completion, expected expenditures for the next 30 days, and system, subsystem and vehicle deliveries.

3.7.10 The Contractor shall provide technical papers and presentation material in support of technical exchange with Government and other Contractor team members, as required in accordance with CDRL A020.

3.7.11 The Contractor shall provide as-built drawing packages for both electrical and mechanical systems and subsystems in accordance with CDRL A022.

3.7.12 The Contractor shall provide a Management Plan in accordance with CDRL A018. The goal of the

Management Plan is to assist with the initiation, monitoring, and reporting of programs, projects, tasks, material related items (procurement and assembly), test and verification, and reporting. The plan shall consist of the following:

- Organizational structure,

- Assignment of functions, duties and responsibilities,

- Procedures and policies,

- Established reporting requirements for the initiation, monitoring, material control task progress and completion, test and verification, and reporting of contractual tasks, projects, and programs.

4.0 TECHNICAL REQUIREMENTS

4.1 Systems Engineering

The Contractor shall establish a system engineering process and use it to perform system analysis and documentation to meet the requirements of the Performance Specifications. When directed by the Government, the Contractor shall conduct system engineering analysis and perform technical studies in support of the short and medium range sub-orbital vehicle interface requirements with other systems. The analysis and studies shall address system concepts and requirements for existing functionality and upgrades required to meet objective missions. The Contractor shall submit a final report for each study performed under each Technical Instruction (TI), describing the problem, approach taken to solve, alternatives considered and results. The report shall include recommendations, objectives, expected outputs, cost and schedule analysis, alternatives investigated and recommendations (to support decision rationale) in sufficient detail to allow evaluation by stakeholders.

The final report shall not contain proprietary data. The technical studies shall be delivered in accordance with CDRL Item A004.

• The Contractor shall perform overall system design analysis as defined in the following paragraphs and Table 1 below.

Flight Readiness/Qualification Process (Phase 1)

Vehicle Systems Functional (Pre-Vibration)

• System Level Functional

Checkout

• Pre-Vibration Sequence

Testing

- All-Fire Sequence Test

- No-Fire Sequence Test

Environmental (Vibration)

• Installation Match Squibs or Breakers

• Random Vibration Testing

• In-family behavior

(vibration signature resonance)

• Workmanship screen

Functional (Post-Vibration)

• System Level Functional

Checkout

• Post-Vibration Sequence

Testing

- All-Fire Sequence Test

- No-Fire Sequence Test

- Power Back-up Tests • Foreign objects/debris, integrity of mechanical sys.

- Power Back-up Tests

Telemetry System

• Component-Level

Functional Checkout

• System-Level Functional

Checkout Section Level Assembly (N99)

Flight Readiness Process (Phase 2) All-Systems Integration

Functional (Pre-Vibration)

• System Level Functional

• Checkout

• Safe-to-Mate Checks

• All Systems Integration

• Pre-Vibration Sequence

Testing

- All-Fire Sequence Test

- No-Fire Sequence Test

- Power Back-up Tests

Environmental

• Vibration Testing

- Thrust Sine

- 3-Axis Random

• Install IMU

• Functional Check

• Complete Vibration

Testing

• Static Load “Bend” Test

• Mass Properties

• Dynamic Spin Balance

• Install Balance Weights

• Dynamic Check Spin

Functional (Post-Vibration)

• Post-Vibration Sequence

Testing

- All-Fire Sequence Test

- No-Fire Sequence Test

- Power Back-up Tests

• Post-Vibration Functional Checkout

Vehicle Preparations (Phase 3) Launch Preparations

Functional Checks

• System Level Functional

Checkout

• All-Systems Integration

• Horizontal Test

- GPS Roll-Out

- All-Fire Sequence Test

- No-Fire Sequence Test

- Power Back-up Tests

GSE Functional (Post- Assembly/ Pre-Rail)

• Complete Flight Assembly

• All-Systems Pre-Rail

Functional Status Check

• GSE Pre-Rail Functional

Checkout (BH/LEB)

• Range Horizontal Test

Pad Checks/Closeout

• Boom Test

• All-Systems Vertical Test

• Readiness Closeout

• IMU Initialization and verification

• GPS Performance Time of

Day

TABLE 1 – FLIGHT READINESS PROCESS

• The Contractor shall develop a test plan for environmental testing, in accordance with CDRL A014, for environmental testing such as: vibration testing, joint compliance bend test, static and dynamic spin balance, Total Indicated Run-Out (TIR), MOI, and Product of Inertia (POI) for payloads.

The Contractor shall provide the following as a single data package or as individual data items:

• TM requirements

• TM mapping and matrix with engineering units

• power requirements

• electrical interface requirements

• Timing and critical triggers tolerance and interrelated events

• Dynamic behavior interactions

The Contractor shall prepare and submit a comprehensive listing of data available for use derived from the instrumentation. This shall be delineated as those elements that can be provided at T+4 hours post flight and those elements that can be provided with post mission reduction at up to T+30 days. The Contractor shall perform data reduction of high resolution data in sufficient detail to allow body attitude at a specified rate, assuming availability of data given flight and instrumentation performance and limitations.

The Contractor shall support TM turn on checks and generate a TM flight record for up to three (3) TM signals for a single vehicle. This record will be used for playback purposes and test range setup of the project and range graphical user interface displays.

The Contractor shall prepare the GFE rocket motors for flight, to include pre-flight preparations such as: but not limited to visual inspections, pressure tests, electrical checks and reconfiguration from a tactical asset to a sounding rocket asset, installation of tail can and fins (where applicable) and setting of fin cant based on flight performance requirement. These tasks shall include replacement of soft parts and wiring as well as removal of tactical systems.

The Contractor shall prepare all subsystems to support System Level Integration and Test, as well as final assembly and flight test, such as: separation systems, de-spin systems, deployed objects, high pressure systems and ordnance systems. The Contractor shall be responsible for purchasing, testing, storage, installation and service life extension of small ordnance (initiators, pressure cartridges, etc). If in the Government’s best interest and at the Government’s discretion, the WSMR location and facility may be used for inspection of small ordnance. The Contractor shall store Hazard Classification 1.4 ordnance at the approved Contractor facility.

• The Contractor shall develop performance charts as a function of launch elevation angle and payload weight in accordance with CDRL A014 and A022.

The Contractor shall develop and maintain mathematical and aerodynamic models of the sub-orbital vehicles for use in six (6) DoF simulations and Monte Carlo analyses.

The Contractor shall generate static and dynamic stability analyses of each stage to confirm the adequacy of the static stability margins and to define the burnout roll rates for each stage.

The Contractor shall conduct aero flight loads, aero-thermal, wind-weighting, and dispersion analyses for each stage and article ejected or separated from vehicle.

The Contractor shall conduct TM system analysis to include: link margin, battery margin, frequency de-confliction and Electro- Magnetic Compatibility and Interference.

The Contractor shall develop trajectory profiles compliant with individual mission and safety objectives, launch elevation, vehicle mass properties, event timing (e.g. separation timing, stage coast times, attitude control system events, deployed items, camera switching). Trajectory profiles shall include all deployed hardware (e.g. manacle rings, ejectable lugs).

The Contractor shall provide post-flight analysis of vehicle, system, and sub-system performance and provide a comparison to pre-mission predicted behavior. The Contractor shall also assess the mission critical parameters from the Mission Documentation as part of the post-flight analysis.

The Contractor shall conduct investigations of flight anomalies that detail the cause, effect, and possible solutions and submit reports to NSWC PHD Det WS in accordance with CDRL A009. The Contractor shall also support FBRs, as required.

The Contractor shall support wind-weighting analysis prior to and during launches of the vehicles. The Contractor shall provide a wind weighting package no less than 90 days, or earlier as specified by the Government, prior to deployment to the field in support of launch operations, including wind related launch restrictions. The Contractor will be provided with meteorological services consistent with this task. The package shall be delivered in accordance with CDRL A014.

The Contractor shall provide a flight safety data package and a ground safety data package for each test event, prior to field deployment, at a time determined by the Government. This shall be flight-mission T-60 days, or earlier, unless otherwise specified by the Government. The package shall be delivered in accordance with CDRL A014.

• The Contractor shall maintain a database of and provide access to the mechanical drawings prepared for vehicle design. The Contractor shall deliver the mechanical drawings at the end of contract performance in accordance with CDRL A017, A021, and A022. Provide Finite Element Analysis (FEA) models of mechanical flight systems and structures. Develop and analyze flight loads on vehicle structures. Provide a comprehensive load case analysis for each applied environment – thermal, vibration, shock, acceleration, rolling or other.

4.2 Government Furnished Equipment

The Contractor shall have access to and maintain GFE as specified in Attachment 1. The Contractor shall track, manage and provide an electronic status report, in accordance with CDRL A008, describing the condition and usage of GFE received under this contract. In the report, the Contractor shall also document part numbers and NSN, when available, and justify any requested changes in availability to the GFE schedule in this contract.

The Contractor shall provide the materials, facility and services necessary to support the repair of GFE for the short and medium range sub-orbital vehicle program. The Contractor shall repair and test GFE items as required to support program test and flight hardware and screen for counterfeit parts and domestic traceability of parts. This shall include sections, assemblies, subassemblies, components and associated Test Equipment as directed by NSWC PHD Det WS.

4.3 Configuration Management

The Contractor shall implement a Configuration Management plan to include all Short and Medium Range Sub-orbital Vehicle hardware. The plan shall provide for the configuration identification, control and status accounting of all major items in accordance with CDRL A021.

4.4 Technical Reviews and Meetings

The Contractor shall maintain communication to ensure Government approval is obtained for any flight, test, manufacturing, or design changes or decisions. The Contractor shall support technical interchange meetings and formal reviews, including SRRs, PDRs and CDRs, and other reviews as requested. These are formal reviews, requiring approval from a panel consisting of Government and Contractor personnel. The review panel will weigh the briefing material content against defined entrance/exit criteria to assess a “pass”, “conditional pass” or “fail” grade. Formal action items will be captured and approved by the panel, and will be released with the review documentation. The Contractor shall report Action Item status monthly along with quad charts. Closure of action items will be approved by panel direction. At the discretion of the Government, the results of attendance at these meetings shall be delivered as trip reports in accordance with CDRL A002 and CDRL A005 for Conference/Meeting Action Items.

4.5 On-Site Support

4.5.1 On-Site Support at WSMR, NM. The Contractor shall support integration and test of the sub-orbital vehicles and systems to include personnel, electrical interfaces, ground support equipment, and data analysis. GSE and support equipment used to support System Level Integration and Test will be for final assembly and test in the field for launch preparations and support, as much as practical. The government maintains the right to change integration facility location if it is beneficial to the government.

The System Level Integration and Test period is generally no less than two weeks for a single vehicle payload at WSMR, provided no anomalies occur. If anomalies present themselves, the Government and Contractor will adjust operations in order to resume schedule as soon as possible.

• The Contractor shall provide GSE laptop computers for instrumentation local display and communications. The GSE laptop assigned to perform data logging shall not be capable of writing data to a CD/DVD. GSE laptop computers are not deliverables under this Contract. Data as supplied must be compatible with policies for Information Assurance and restricted use of data devices inside government controlled areas.

• The Contractor shall provide cabling, cradles, and support equipment as required for instrumentation GSE support. These items are provided to test the instrumentation while external to the payload.

• The Contractor shall perform the mechanical installation and electrical connection and field verification of the instrumentation. This includes internal system wiring and connectivity to a defined interface on the vehicle.

• Laptop computers shall be required to be classified up to SECRET. This includes stipulation that such items must be compatible with policies for Information Assurance and restricted use of data devices inside government controlled areas.

4.5.1.1 In the event that instrumentation mass simulators are not available as GFE, the Contractor shall provide instrumentation mass simulators for use during vibration testing, fit qualification and mechanical integration.

4.5.1.2 The Government will provide a document defining environments and test levels. The Contractor shall provide the loads to be applied with corresponding location to apply the loads, and acceptable deflections for the bend test. The Contractor shall define the balance planes for each payload section (or payload sub-sections for separating payloads) requiring spin balance, as well as the allowable limits for static and dynamic balancing. For separating payload configurations, the Contractor shall also define the allowable limits for static and dynamic balancing of the entire payload (payload sub-sections joined together as a single payload unit). For items interfacing onto tables, vibration heads, spin balance rotary planes etc., the Contractor may be required to assess the current adapter and interface structures and provide a manufactured adapter to maintain ability to interface to said units.

4.5.1.3 The Contractor shall be required to provide all the sub-systems necessary between the vehicle subsections and GSE, such as: interface cables (i.e. umbilicals).

4.5.1.4 The Contractor shall ensure that all flight hardware and GSE is on-site at WSMR or a location designated by the government prior to travel and start of System Level Integration and Test.

4.5.1.5 The Contractor shall provide and maintain specialized lifting equipment to include periodic calibration, weight test and inspection reports. Lifting equipment shall be required to be part of Navy Ordnance Handling Equipment/Weight Handling Equipment (OHE/WHE) Program in accordance with NAVFAC

P307 “Management of Weight Handling Equipment”, NAVSEA OP-4 “Ammunition and Explosives Afloat” and NAVSEA OP-5 “Ammunition and Explosives Safety Ashore”

4.5.1.6 The Contractor shall provide support for rocket motor inspection and modification for rocket motors. The

Contractor shall provide specialized tools for support of same.

4.5.2 On-Site Support at PMRF, SNI, WSMR, WFF or other locations including foreign countries (Continental United States (CONUS)/Outside the Continental United States (OCONUS)) and BOA. The Contractor shall provide visit requests for all sites and may be required to obtain State Department requirements for work in foreign countries. At the discretion of the Government, the results of this support shall be delivered as trip reports in accordance with CDRL A002.

The Contractor shall provide coordination and on-site support to Government personnel during operations at the…