NAWCAD-2514-VH Draft SOW.docx

STATEMENT OF WORK

1.0 SCOPE

This Statement of Work defines tasks for design, hardware and software development, fabrication, installation, maintenance and technical services for support of the programs and laboratory facilities associated with the Avionics Department, “Avionics Architecture & Systems Engineering Division,” Code 4.5.1 of NAWCADPAX as follows:

Laboratories:

VH-3D/VH-60 Laboratory CH-53 / MH-53 Laboratory Other laboratories that Code 4.5.1 may support during the term of the contract

The tasks to be performed under this effort include: design, development, fabrication, installation, integration, testing, debugging, technical support services, documentation, and maintenance of aircraft avionics systems, ground systems, and laboratory electronic and electromechanical equipment to support the projects undertaken by the “Avionics Architecture & Systems Engineering Division.” This tasking may involve working with other DOD agencies.

2.0 REQUIREMENTS

2.1 TASK A - Avionics and Support Equipment Development and Fabrication

The contractor shall perform system design, hardware and software (or firmware) development, fabrication, installation, integration and testing for the development of new or upgraded avionics and its associated support equipment. The contractor shall be able to meet fast turnaround programmatic schedules for strategic DX-1 rated programs. The contractor shall provide on-site avionics troubleshooting support at HMX-1, Quantico Virginia and NAWC-AD Patuxent River Maryland within 24 hrs of notification. Multiple system upgrades shall be supported simultaneously. This includes, but not limited to, the planned upgrades and equipment listed in section 6.0. The contractor shall have available a cadre of personnel with expertise in the following areas: advanced avionics system design, integration of a variety of avionics equipment to form a system, detailed circuit design, avionics mechanical design, electrical and mechanical avionics fabrication, aircraft electrical and mechanical installations, software design, development and testing, avionics cable fabrication, installation and testing, and support services such as drafting, documentation control and material handling. The contractor shall have local purchasing authority for material purchases up to $100,000 dollars.

The Contractor shall have an in-house fabrication capability for avionics equipment and cabling for such tasks as: manufacturing internal and external avionics wiring harnesses in accordance with various Navy specifications and standards referenced in Section 6.0 of SOW, fabrication of avionics chassis from raw materials including metal cutting, bending, welding, plating and painting in accordance with appropriate Navy standards, aircraft installation kit development, limited production of avionics equipment, and electronic based documentation systems for automated electrical and mechanical fabrication design, and drawing generation, configuration control and archiving. The details of a particular project task will be specified in each Order. The contractor shall generate, maintain and deliver all documentation required to perform these tasks, such as system block diagrams, equipment design drawings, installation drawings, electrical schematics, aircraft avionics upgrade schematics, wire listings and test procedures as part of a complete data design data package, in accordance with associated Contract Data Requirements Lists, DD. Form 1423. All schematics and production drawings shall be delivered to the Government. The contractor shall update the maintenance manuals for all existing equipment and produce new maintenance manuals for any newly developed system.

2.2 TASK B - Facilities Development and Maintenance

The contractor shall perform system design, hardware and software development, fabrication, installation, integration and testing for the development and maintenance of new or upgraded NAWCAD “Avionics Architecture & Systems Engineering Division” project laboratories and other similar laboratory facilities including avionics test benches. This includes, but not limited to, the planned upgrades and equipment listed in section 6.0. The contractor shall perform engineering design, hardware electrical and mechanical fabrication, software design, development, integration and testing, equipment maintenance, and testing tasks necessary for the development, integration and operation of the various facilities systems. The contractor shall have available a cadre of personnel with expertise in the following areas: site preparation and modification, avionics installation and checkout, support equipment design, fabrication, integration and testing, simulation hardware and software design, development and integration, and long term facility maintenance. The contractor shall perform laboratory system maintenance, which shall be both preventative and corrective, in accordance with the equipment specifications and/or facility procedures. The contractor shall be responsible for the facility logistics, which includes equipment failure tracking, and maintaining inventory of spare parts, test equipment and facility consumables. The contractor shall provide on-site technical support to resolve any deficiencies associated with the NAWCAD “Avionics Architecture & Systems Engineering Division” within 4 hours of notification.

The contractor shall have an in-house fabrication capability for laboratory equipment and cabling such as: manufacturing internal and external wiring harnesses, fabrication of electronics chassis from raw materials including metal cutting, bending, welding, plating and painting, and electronic based documentation systems for automated electrical and mechanical fabrication design, and drawing generation, configuration control and archiving. The details of a particular project task will be specified in individual Orders. The contractor shall generate and maintain all documentation required to perform these tasks, such as equipment design drawings, installation drawings, electrical schematics, wire listings and test procedures, in accordance with Contract Data Requirements List, DD. Form 1423.

2.3 TASK C - Avionics Testing and Repair

The contractor shall perform testing and repair of avionics and equipment listed in section 6.0 and associated support equipment. This task shall require the contractor to maintain, operate and upgrade special purpose test systems, including the Common Avionics Test Bench (CATB) and VH Automatic Test Equipment (VH-ATE) Test Bench, to verify the operation of the avionics equipment. This includes both hardware and firmware. The contractor shall have a tracking system that identifies the status, configuration, and location of the project avionics equipment. The contractor shall have a dedicated storage area at the contractor's facility. Cryptographic Control Item Communication Security Key material (CCI-COMSEC) will be required to test some of this equipment. The contractor shall have available personnel with expertise in the following areas: avionics equipment testing and repair, operation of special purpose test systems, documentation control, and material handling/storage. This may include the requirement to ship various materials.

The contractor shall have an in-house capability for avionics diagnosis, repair, and storage including COMSEC equipment. The contractor shall have the capability to induct, test and provide root cause failure analysis of failed avionics components within 24 hours of receipt. The details of a particular project task will be specified in individual Order. The contractor shall generate and maintain all documentation required for performing these tasks, such as individual equipment status sheets and avionics inventory in accordance with Contract Data Requirements List, DD. Form 1423. Personnel who work on VH-60N and VH-3D Presidential Helicopter avionics may be required to have special security clearances.

2.4 TASK D - Technical Services

2.4.1 System Engineering

The contractor shall provide technical support in the generation and review of system requirements, using a MIL-STD top-down hierarchical approach per NAVAIRINST 4355.19B. In addition to system level requirements, requirements shall include control, and man-machine interface, as well as those for aircraft integration and installation. The contractor shall develop and deliver design documentation.

2.5 TASK E - Documentation Control

The contractor shall provide the following services to maintain configuration control and storage of project documentation for the “Avionics Architecture & Systems Engineering Division.”

2.5.1 Project Library

The contractor shall maintain a physical location that shall be designated as the Project Library and identify a custodian of that library. The contractor shall ensure that copies of all relevant hardware and software documentation items associated with any in-house developed avionics and facility equipment are available in this library and are replaced with updated copies as modifications are made. The documentation items to be included shall include, but are not restricted to the following: logic diagrams, schematic diagrams, firmware listings, software listings, software tape/disk archives, maintenance manuals, user's manuals, mechanical drawings, cable lists, and wire connection lists.

2.5.2 Drafting System

The contractor shall operate and maintain a computerized drafting system that supports drafting and graphic presentation activities both at the contractor's facility and at NAWCADPAX. The contractor shall maintain the drafting system and perform the following procedures in accordance with prudent operation of a data storage system: automatically backup the system every twenty-four hours so that drawings that are updated during the course of a day are backed up before the next business day. Weekly and monthly complete system backups are required. The contractor shall maintain an up-to-date listing of all drawings stored on the system and make the lists and drawings available to the government engineers upon request. The stored drawing listing shall be updated on a weekly basis. Removal of drawings from the system shall not be performed without the written authorization of the Contracting Officer Representative (COR). All documentation generated in support of the Presidential Helicopter Program shall be marked with Distribution Statement F. “Distribution Statement F: Further dissemination only as directed by the Presidential Helicopters Program Office (PMA-274), Patuxent River, MD 20670, April 2005, or higher authority. Specific authority: In-Service Presidential Helicopters (VH) Program Protection Plan (PPP) of 17 September 2004.” All documentation developed under this contract shall be stored locally at the contractor’s facility.

2.6 PROPERTY ACCOUNTABILITY

The contractor shall institute a documented property accountability system and procedures whereby all government furnished property is tracked and shall include all pertinent information about the property, including item nomenclature, serial number, and location. The contractor shall make property reports available to the COR.

2.7 DELIVERABLE PRODUCT

Deliverable Products will be set forth in individual orders, with data to be delivered in accordance with Contract Data Requirements List DD 1423.

2.8 SCHEDULE

All work required hereunder shall be performed, completed, and delivered to meet the schedule constraints associated with Department of Defense DX Rated Program and contract shall have the expertise, capacity and facilities to perform avionics design, prototyping and upgrade of avionics integration labs via concurrent engineering methodology.

3.0 TRAVEL

Contractor personnel shall travel to perform tasks in accordance with each order to provide needed tasks through off-site training, conferences, design, fabrication, installation, integration, maintenance, or system test.

4.0 PROGRESS REPORTS

Per Contract Data Requirements List, DD Form 1423.

5.0 AVIONICS UPGRADES AND EQUIPMENT LISTING

List of planned avionics upgrades, technical services and typical equipment to be maintained and/or supported by this effort.

Note: Individual orders will specify avionics upgrades and equipment to be maintained and/or supported. These lists represent some of the planned avionics upgrades and types of equipment found in the various labs and facilities the contractor shall be required to maintain and/or support. These lists are not all inclusive but are provided to show the contractor what type of avionics design and equipment will be expected to be developed, maintained and/or supported.

The following is partial list of planned Avionics Upgrades:

Crypto Modernization Upgrade: The following avionics may be upgraded under the Crypto Modernization Program.

SATCOM Integrated Mount (SIM) (P/N: VH70201): Mechanical and Electrical redesign of SIM mount to replace legacy SATCOM Radio with ARC-210 GEN 5 radios. SIM redesign shall support installation of either ARC-210 High Power Amplifier (HPA) or legacy SATCOM HPA. SIM Mount shall maintain existing Clear and Secure Full Duplex, Half Duplex and DAMA operating modes and provide a growth path to meet future MUOS Satellite Communication Requirements.

Communication Interface Unit (CIU) (P/N VH83001-1): The CIU modification shall provide for the control of clear and secure voice and data switching, crypto fill and zeroize for both legacy and ARC-210 GEN 5 radios. Existing VH-3D or VH-60N CUP platform specific functionality currently supported by the CIU should not be impacted as a result of the Crypto Modernization upgrades.

Common Fill Port (CFP) (P/N VH85601): The CFP design will be modified to provide single fill port device to load both legacy platform CCI equipment and upgrade crypto modernization radios. The CFP should support both DS-101, DS-102 and TIA-102.AACD key fill protocols.

VH-3D Cockpit Upgrade Program: The following VH Avionics will be upgraded under a VH-3D Cockpit Upgrade Program.

Navigation Interface Unit (NIU) (SA-HS-54140-1H): The NIU design will be modified to support pilot selection of either Inertial EGI#1 or Inertial EGI#2 as attitude and heading source for the VH-3D Automatic Stabilization Equipment (ASE) Flight Control. The NIU design should provide the interface between platform unique sensors, including but not limited to Engine Torque, Rotor Speed and Oil Pressure, and Mission Computer software resources.

Communications Interface Unit (CIU) (VH83001-1): To capitalize on power, weight and space savings associated with VH-3D Cockpit upgrade, the CIU design shall incorporate, to maximum extent possible VH functionality currently performed by dedicated LRUs. The CIU should, at a minimum, incorporate the functionality to allow removal of the existing VH-3D Direction Finding Switching Unit (DFSIU P/N SA-2464/A), System Control Unit 1 (SCC-830E), System Control Unit 2 (SCC-830F) and Emergency Control Panel (ECP) (C-11480/A). Existing VH-60N CUP platform specific functionality currently supported by the CIU should not be impacted as a result of the VH-3D Cockpit Upgrade modifications.

Iridium Airborne Data Communication System AN/ARC-245 The Contractor shall provide depot test, diagnostic and repair facilities for the ADCS AN/ARC-245 avionics system. The Contractor shall maintain sufficient spare parts to facilitate rapid repair of returned ADCS avionics hardware. The Contractor shall provide engineering support as required to address software and hardware problems and requirements updates developed during fleet integration and crew indoctrination and training. The Contractor shall develop and submit a data-log payback plan for mission tracking data stored in ADCS memory.

Obsolescence and Weight Reduction Program: The following avionics will be redesigned as a part of the Obsolescence and Weight Reduction Program:

ARC-209(B) Digital VHF/FM Radios (VH77001-1): Due to parts obsolescence and weight reduction initiatives the existing ARC-209(B) Digital VHF/FM radio will be re-designed to reduce size/weight. Existing ARC-209(B) weight is 28 lbs. The goal of the redesign effort is to limit the weight to 15 lbs. Redesign effort will maintain existing ARC-209(B) functionality (APCO-25 Compliance, Transmit power, Over-The-Air-Rekeying and frequency agile tuning). The re-design effort should not result in any impact to existing aircraft wiring or mission computer software.

The following is a partial list of VH unique avionics test benches, automatic test equipment and avionics:

The VH Program maintains a closed loop supply/inventory system requiring all avionics equipment to be inducted into Yankee White controlled environment. To meet security requirements the program maintains a Common Avionics Test Bench (CATB) to test commercial off the shelf avionics as well as VH specific Automatic Test Equipment rack to test VH unique Avionics. The tasking will maintain and upgrade the avionics test bench and automatic test equipment to perform full functional test for all current and planned avionics systems.

ILS CATB Avionics Test Bench (VH49701) will be maintained and upgraded to perform automated functional testing of commercial avionics (to include but not limited to: IFF, TCAS, ICS, AHRS, Doppler, VOR/ILS, GPS, etc.)

VH Specific Automated Test Equipment (VH84728B) will be maintained and upgraded to perform automated LRU assembly level testing as well as final system level testing of all current and planned VH unique avionics (to include but not limited to:

Navigation Interface Unit (NIU) ( SA-HS-54140-1H) Communication Interface Unit (CIU) (VH83001-1) VHF-FM Radios (VH77001-1) Direction Finding Switching Unit (DFSIU) (SA/2464/A) Remote Fill Panel (RFP) (VH62401) Milaide Panel (MAP) (VH62201) DAMA SATCOM Integrated Mount (SIM) (VH70201) DAMA SATCOM Fill Panel (SFP) (VH72601) Common Fill Panel (CFP) (VH85601)

The following is a partial list of NAWC-AD Laboratories:

The VH program maintains an Avionics Integration Station (AIS) (fully representative of current VH-3D and VH-60N avionics architectures) to support development of mission computer operational flight program software. The contractor shall maintain and upgrade the AIS to incorporate new avionics upgrade programs planned for the VH-3D and VH-60N.

VH Avionics Integration Station Roof-top antenna farm Survivability Test Rack

The H-53 program maintains an Avionics Integration Station (AIS) (representative of current CH-53 and MH-53 avionics architectures) to support development of mission computer operational flight program software. The contractor shall maintain and upgrade the AIS to incorporate new avionics upgrade programs planned for the CH-53 and MH-53.

CH-53 Avionics Integration Station MH-53 Avionics Integration Station

Generic Avionics Systems that shall be able to be installed, maintained and/or supported: Communication Systems (including encryption devices), Survivability Systems, Navigation Systems, Display Systems, and Flight Planning Systems.

The following is a partial list of typical technical services system engineering support The contractor shall generate and update detailed point-to-point avionics integration drawings for both the VH-60N Cockpit Upgrade (Drawing VH80110) and VH-3D Upgrade (Drawing VH90110). Drawing shall include point to point wiring for entire avionics system and include wire type, wire gauge and shielding requirements.

To meet the schedule requirements of a DOD DX Rated Program, the contractor shall have the expertise, capacity and facilities to perform the avionics design, rapid prototype, upgrades of automatic test equipment and Avionics Integration station identified in this section via concurrent engineering methodology.

6.0 CONTRACTOR’S FACILITY

The contractor shall provide a facility consisting of drafting, laboratory, electrical fabrication, mechanical fabrication, and storage spaces to fulfill the requirements of this effort. To meet the 24 hour turnaround requirements for onsite aircraft troubleshooting support, test and diagnostics of critical avionics and maintenance of the VH-60N / VH-3D avionics integration laboratory, the contractor facilities shall reside within 15 miles of the Naval Air Warfare Center located in Patuxent River Maryland.

For mechanical fabrication, the contractor shall provide capability to perform the following operations:

Metal Welding: Aluminum and Steel .050 to .375 mat'l thickness

Metal Shearing: Up to 10 gage mild steel by 6 ft long or .190 thick 6061-T6 aluminum alloy.

Metal Bending: Up to .125 thk Aluminum 5052-H32 alloy w/ .187 radius by 4 ft. wide Up to .090 thk Aluminum 6061-T6 alloy w/ .187 radius by 4 ft wide Up to .090 thk Mild Steel w/ .187 radius by 4 ft wide

Plating and Painting: Mil quality 2 Part Polyurethane Enamels - Industrial Maintenance Coatings P.C. Board Conformal Coating - Textured or Smooth Finish. All Spray equipment to be HVLP. Local and State of Maryland Environmental Compliance with Valid Permit Required.

Hardware and Fastener: Experienced in the application, appropriate use, and installation of proven fastening systems such as Pem, Dzus, Camloc, Southco, Deutsch, ESNA, Dimco Gray, Helicoil, Unicorp, MS, AN, and Hardware.

For electrical fabrication, the contractor shall provide capability to perform the following operations:

Soldering: Done in accordance with ANSI J-STD-001, IPC-S-815, or Equivalent Commercial Standard.

PC Boards: Assembled & repaired in accordance with MIL-STD-275 Sect. 6.2, and MIL-C-28809 or Equivalent Commercial Practice. Conformal Coated in accordance with MIL-STD-275 Sect. 6.3, MIL-C-28809, MIL-I-46058, IPC-CC-830 or Equivalent Commercial Standards.

Component Testing, Solderability IAW MIL-STD-202, IPC-S-805 or Equivalent Commercial Standards.

ESD Protection: In accordance with MIL-STD-1686 or Equivalent Commercial Standards.

Markings: Marking of Assemblies, Chassis’, Cables, etc. meet MIL-STD-130 or Equivalent Commercial Standards.

Chassis Assembly / Wiring: Chassis’ assembled, components mounted and marked, discrete wiring & wire harnesses installed and terminated.

Other Requirements: Contractor shall maintain tooling and expertise to perform wire-wrap and speed-wire terminations.

7.0 GOVERNMENT FURNISHED EQUIPMENT

7.1 COMPUTER SYSTEMS

The Government will provide physical space for the contractor to perform tasks specified in each order. The contractor shall request laboratory and computer time to perform tasks with the responsible Government personnel.

The Government will provide the computer-based drafting and documentation systems, and project unique computer systems for the contractor's use as specified in each order. The contractor shall provide general purpose office computer to perform the tasks in a timely and efficient manner.

7.2 PROJECT EQUIPMENT

The NAWCAD will provide project specific avionics equipment as necessary to perform the tasks specified in each order.