Statement_of_Work.docx

NAVAIR LAKEHURST

NAWCADLKE-SOW-

Engineering Statement Of Work FOR THE 2-Bend-over sheave Wire rope Fatigue Samples

Naval Air Systems Command Naval Air Warfare Center, Aircraft Division SE and ALRE Department SE and ALRE Systems Engineering Division Lakehurst, New Jersey 08733-5109

Prepared By:

ALRE Service Life Management IPT

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Table of Contents

Scope Purpose The purpose of this document is to provide contractual instructions for the design and construction of a 2-Bend-Over-Sheave Wire Rope Tester (2BOSWRT) and testing and delivery of Wire Rope Fatigue Samples (WRFS). Pre-fabricated wire rope samples will be furnished to the contractor as Government Furnished Material (GFM). All reference to “days” herein shall be considered calendar days.

Objectives The Contractor shall produce a testing product and testing samples that satisfy the requirements of this Statement of Work (SOW) and the Contractor Data Requirements List (CDRL).

Background The WRFS will be used in future analyses for wire rope used onboard the Navy’s aircraft carriers.

Post Award Orientation Conference Within 15 working days after contract award (DACA), the Contractor shall host a Post Award Orientation Conference (PAOC). The PAOC provides the Contractor with an introduction to the Integrated Product Team (IPT) and establishes formal and informal means of communication. The PAOC will also be used to ensure that the contractor understands all contractual timelines, requirements and administrative matters. This meeting shall include a full discussion and review of the required 2BOSWRT, GFM samples, WRFS, and the required contract deliverables. The Contractor shall provide meeting minutes NLT 10 days after the PAOC. (CDRL B001) Salient Characteristics – 2-Bend-Over-Sheave Wire Rope Tester NAWCAD Lakehurst is requesting engineering services with the capability to develop and test wire rope fatigue. Figure 1 is a notional depiction of the required method. Figure 1 is not an official engineering drawing or preliminary design. It is provided to demonstrate properties of the required test setup for wire rope fatigue testing.

Figure 1 Notional Depiction of a 2-Bend-Over-Sheave Wire Rope Tester

Design Characteristics – Wire Rope Tester The contractor shall complete a detailed design of the 2BOSWRT. The contractor shall design and fabricate a 2BOSWRT with the following requirements, at a minimum:

· WRFS’s shall be tested on 28” PD Steel Sheaves, Navy P/N: 524103-4 or 524103-1 (drawings provided)

· CSI requirements for the C87780-12 bearings are waived if steel sheaves are purchased as part of the 524103-1 Sheave Assembly

· Material Certs shall be provided

· Quality Assurance check list shall be provided verifying all dimension and material characteristics are within the drawing requirements

· Cycle stroke length of 62 inches

· Bi-directional cycling. A cycle is defined as a fixed point on the wire rope travelling its required stroke length, reversing direction, and returning to its original starting point. Cycle speed will be demonstrated and agreed upon at the demonstration review (Section 4.1).

· Maximum WRFS temperature, 100 degrees C

· Maximum cable tension, 100 kips, +/1 kip

· Recording of tension data for each WRFS.

· Recording of temperature data in the bend zone for each WRFS.

Test Readiness & Demonstration Review The contractor shall host a Test Readiness and Demonstration Review (TRDR) NLT 60 DACA at their facility. The contractor shall present a completely fabricated 2BOSWRT and perform a demonstration. The demonstration shall include the following:

· Inspection of the 2BOSWRT capability

· Installation of a WRFS

· Bi-directional cycling of the WRFS

· Display of maximum cable tension and temperature within required tolerance The contractor shall notify the Navy within 15 working days of scheduling the Test Readiness & Demonstration Review. The contractor shall compile and deliver documentation of the presented demonstrations in a Quality Test Report NLT 70 DACA (CDRL A001).

GFM – Wire Rope Fatigue Samples The Navy will supply the contractor with a total of eighty-two (82) GFM wire rope fatigue samples. Two of the GFM samples will be specifically identified as functional check samples and may be used by the contractor to functionally check and test the 2BOSWRT during development, fabrication, and pre-operational checks. All samples are carbon steel constructed with a multi-filament polyester core. They have die formed strands and are arranged in a right-hand lang lay orientation. The cross-section is Warrington Seale with 6 outer strands each composed of 31 wires. The wire rope is 1-7/16” minimum diameter, actual diameters usually measure 1.500” – 1.531”. Each provided sample will be 14’-1.5” long. Each sample will have both ends closed with seizing wire, the contractor shall terminate the ends for 2BOSWRT installation using their own preferred method.

Wire Rope Sample Testing The contractor shall fatigue test eighty (80) samples NLT 120 DACA. The samples shall be tested on the 2BOSWRT at a cable tension of 100 kips. Temperature of the wire rope cable samples shall be monitored and recorded during fatigue testing and not exceed 100 degrees Celsius. Upon sample failure, the sample shall be cut at approximately two feet on either side of the fatigue bend zone and the ends closed with seizing wire. Each modified fatigue sample shall be tagged with a metal identification and indicate the sample number. For planning purposes, wire samples that are new can typically last an average of 7,500 tension cycles prior to failure. With two samples tested at a time and an 8-hour test day this is approximately 5.2 days of testing. The GFM samples are already used and not expected to reach the average tension cycles for a new cable.

Sample Test Data The contractor shall record data for all WRFS and provide to the Navy in accordance with the requested deliverable NLT 140 DACA. (CDRL A002) Sample Delivery The contractor shall prepare, package and deliver the failed samples to NAVAIR Lakehurst upon completion of sample testing in accordance with the provided deliverable. A hard-copy of the sample test data shall be included with the packaged samples. (CDRL A003) Schedule Table 1 displays the overall 2-BOSWRT and WRFS Milestone/Deliverable Schedule

Table 1: Milestone/Deliverable Schedule

Safety The Contractor shall perform all work under this contract in full compliance with all applicable Federal, State, and local environmental and occupational safety and health regulations. In addition, the Contractor shall be responsible for ensuring that all vendors, suppliers, and subcontractors similarly perform all work under this contract in full compliance with all applicable Federal, State, and local environmental and occupational safety and health regulations.

Quality Assurance Best Commercial practices The contractor shall produce a 2BOSWRT and test WRFS in conjunction with best commercial practices for overall product quality and safety.

Contract Data Requirements List The Contractor shall deliver the required data as specified in the Contract Data Requirements List (CDRL). Data shall be delivered electronically (Microsoft Word for reports and Microsoft PowerPoint for presentations, except where otherwise specified) to the individuals identified in Block 14 of the CDRL as addressees. The Data Items on the CDRLs are cross-referenced thereon to the associated tasks in this SOW under which the basic information is generated. The list of associated CDRLS is summarized below.

CDRL A001: Qualification Test Report (QTR) CDRL A002: Wire Rope Fatigue Sample Test Data CDRL A003: Wire Rope Fatigue Samples CDRL B001: PAOC Meeting Minutes

Appendix A: Acronyms & Abbreviations The following list of Acronyms applies to both this Statement of Work and the accompanying CDRLS.

IAW In Accordance With

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