SHIIVER_MLI_vendor_SOW.docx

SHIIVER MLI STATEMENT OF WORK J-1

Large Scale Multilayer Blankets for Exploration Missions Requirements and Statement of Work

1. Background NASA is presently evaluating various types of multi-layered insulation (MLI) blankets, as well as the relative suitability of different fabrication and installation procedures. This endeavor is part of an effort to improve the fundamental understanding of multilayer insulation (MLI) systems. Extension of lessons learned to exploration upper stages is being investigated via design, fabrication, and installation of an MLI blanket onto a representative sub-scale tank, herein referred to as the Structural Heat Intercept, Insulation, and Vibration Experiment Rig (SHIIVER) tank. While the end application is a liquid hydrogen upper stage with a diameter of 8.4 m, the SHIIVER tank will be a 4 m diameter liquid hydrogen tank. As such, the MLI should be designed towards the 8.4 m tank and subsequently scaled to the 4 m tank. The tank will be tested in thermal vacuum chamber and in a reverberant acoustic environment. Following the reverberant acoustic testing, thermal vacuum testing will be repeated to determine whether damage to the MLI was caused by acoustic excitation.

The solicitation is for the design, fabrication, and installation of a MLI blanket system for the domes of a 4 m diameter liquid hydrogen tank (see the flow chart below). Domes and sidewalls of the hydrogen tank will be covered with Spray-On Foam Insulation (SOFI) of approximately one-inch thickness. The MLI insulation system design will include development of an attachment scheme for the MLI such that:

· MLI is not in physical contact with the SOFI

· MLI can be applied and removed without causing damage to the SOFI

· Attachment of the MLI will not cause unacceptable thermal shorting (in NASA’s judgment)

During the design phase of contracted activities, the vendor will deliver up to four MLI calorimeter coupons of different configurations. Said configuration(s) are subject to NASA’s review and approval. Results obtained in the course of testing the aforementioned coupons (i.e., by NASA) will be provided to the vendor, thereby affecting the final design of the MLI blankets prior to production of the test article. At the conclusion of the design, fabrication and installation effort, the vendor will provide a cost statement for identical builds of the same MLI blanket system.

This procurement will also delineate options for fabrication of an MLI curtain, capable of being raised and lowered to surround vertical faces of the test article, or an additional MLI blanket, similar in construction to the blankets used on the domes, to be affixed on the sidewall of the tank. Due to uncertainty about the ability of MLI to survive on the exterior of a launch vehicle during ascent, NASA will decide at the time of award whether to purchase: a) MLI for the side walls of the tank, b) curtains which can be removed during portions of the thermal vacuum and reverberant acoustic testing, c) or neither.

The scope of this procurement includes:

1. Design, fabrication, and installation of a MLI blanket system that conforms and attaches to the SHIIVER tank top and bottom domes (with TBD penetrations and plumbing).

2. Design, fabrication, and installation of MLI blankets that conform and attach to the inside of the top and bottom tank skirts (with TBD penetrations and plumbing).

3. Up to four cylindrical MLI coupons for testing on the GRC calorimeter (18.5 inch diameter, 48 inch long).

4. Cost statement corresponding to subsequent large-scale blankets, identical in design to the initial blanket.

5. An option (hereafter referred to as “Option 1”) for design, fabrication, and installation of MLI curtains that cover the sidewall of the tank barrel and skirts.

6. An option (hereafter referred to as “Option 2”) for design, fabrication, and installation of MLI for the sidewall of the tank barrel and skirts.

Respondents to this solicitation have the option of subcontracting any portion(s) of the work.

2. Reference Documents.

The following reference documents are provided as attachments.

2.1. eCryo-DOC-0102: SHIIVER MLI Materials Specification: Defines the requirements for materials to be used in all MLI systems procured

2.2. eCryo-SCM-0086: SHIIVER Tank Dimensions: Defines the size of the SHIIVER tank

2.3. eCryo-DOC-0103: SHIIVER Acoustical Test Profile: Defines the acoustic testing profile for the SHIIVER testing

2.4. eCryo-DOC-0104: SHIIVER Venting Profile: Defines the pressure profile the MLI blanket needs to be designed to withstand

2.5. eCryo-DOC-0105: GRC Calorimeter Dimensions: Defines the required size/dimensions of MLI coupons, to facilitate testing in the GRC calorimeter.

2.6. Glenn Research Center Safety Manual: Defines the safety requirements and personnel training required for installation of the MLI system at Plumbrook Station.

http://smad-ext.grc.nasa.gov/shed/pub/gsm/gsm-manual.pdf (applicable chapters include 15 – 17).

3. Large Scale MLI System Requirements.

The contractor shall design, fabricate, and install one (1) MLI system in accordance with this Statement of Work and the attached Reference Documents (described in Section 2.).

3.1. Technical Reporting Requirements

3.1.1. Bi-weekly meetings shall be held between NASA and the vendor via teleconference with exception of times when minimal activity is occurring by agreement between NASA and the vendor.

3.1.2. Quarterly meetings shall be held face-to-face (instead of the bi-weekly meeting), alternating between NASA facilities and Vendor facilities as appropriate.

3.1.3. All materials presented at any meeting by either NASA or the contractor will be electronically shared between the two.

3.2. Design Requirements.

3.2.1. All materials shall be as specified in the attached MLI Specification referenced in 2.1.

3.2.2. MLI general requirements.

3.2.2.1. The MLI system shall be designed to cover both the top and the bottom domes and stay within the skirt boundaries (see section 2.2)

3.2.2.2. The total number of reflective (i.e., double-aluminized Mylar) layers shall be no less than 25.

3.2.2.3. The averaged heat load through the blanket including all seams, penetrations, and non-uniformities should be no more than 1.5 W/m2 at a warm boundary temperature of 300 K and a cold boundary of 20.4 K.

3.2.2.4. The MLI blanket shall be designed as if it were being installed on a 8.4 m diameter tank dome (configuration to be provided at kick-off meeting) and then scaled down to the tank domes described in Section 2.2

3.2.2.5. The MLI blanket shall be designed to survive acoustic loads as defined in Section 2.3.

3.2.2.6. The MLI blanket shall be designed to survive rapid depressurization on the profile defined in Section 2.4.

3.2.2.7. The MLI system shall be designed for pre-test predictions of all pertinent design details including (but not limited to): seams, attachment methods, penetration integration, and MLI system internal structural components.

3.2.2.8. NASA will provide the final tank (and Spray on Foam Insulation) dimensions 1 month prior to the final design review.

3.2.3. Attachments

3.2.3.1. The MLI system shall be supported by the tank and/or skirts only.

3.2.3.2. The MLI system shall not be attached to the spray on foam insulation (SOFI).

3.2.3.3. Attachments shall accommodate installation and removal of blankets without causing damage to the SOFI.

3.2.3.4. Any attachments directly to the tank wall shall be defined by the vendor at the Preliminary Design Review.

3.2.3.5. Contractor shall deliver any MLI attachments intended to attach to the SHIIVER tank under the SOFI to Marshall Space Flight Center (MSFC) within 60 days following PDR. Other attachments will be delivered to Plum Brook Station with the MLI blankets.

3.2.3.6. NASA will install these pre-defined attachments prior to foaming the tank.

3.2.4. Integration

3.2.4.1. The MLI system shall include design details for the integration of the MLI onto various tank features, including (but not limited to): the vent line, pressurization line, fill/drain line, vapor cooling line, and forward and aft skirts.

3.2.4.2. NASA will define all integration features no later than 30 days after the Kick-off meeting.

3.2.5. Seams and Venting.

3.2.5.1. Contractor shall provide thermal and venting performance prediction based on either analysis or test data as a part of the blanket design.

3.2.5.2. MLI system (in cooperation with other venting mechanisms, including seams, perforations, etc) shall be designed in a manner to allow venting of the system per the profile described in Section 2.4.

3.2.6. Electrical Grounding

3.2.6.1. No provision for electrical grounding needs to be provided. To be determined.

3.2.6.2. Any requirements for electrical grounding will be provided by NASA at the Kick-off and finalized by NASA at Preliminary Design Review (PDR).

3.2.6.3. Any electrical ground mechanisms provided shall not impact the thermal performance of the MLI system.

3.2.7. MLI for Inside of Skirts

3.2.7.1. MLI for the inside surfaces of the skirts shall cover the full circumference of the top skirt and bottom skirt (see section 2.2) for an approximate axial length of 4 ft. (typical roll width of aluminized Mylar), starting as close as practicable to the tank flange.

3.2.7.2. MLI for inside skirts shall be constructed of 10 layers of aluminized mylar separated by Dacron (or similar) netting.

3.2.7.3. MLI for inside skirts shall be structurally attached to the skirts such that the skirts can be removed from the tank without removing or substantially disturbing the installed MLI.

3.2.7.4. MLI for inside skirts shall be designed with venting capability adequate to survive vacuum chamber pumpdown without incurring damage.

3.2.7.5. NASA will provide the final skirt dimensions 1 month prior to Final Design Review.

3.2.8. Documentation

3.2.8.1. Vendor shall provide installation instructions and procedures at the final design review.

3.2.8.1.1. NASA reserves the right to include Government Mandatory Inspection Points (GMIPs) in the vendor’s installation instructions and procedures.

3.2.8.2. Vendor shall provide electronic versions (pdf) of drawings, cut sheets, materials of construction, material certifications, and other documentation encapsulating the final design.

3.2.8.3. Vendor shall define a mutually agreeable configuration control/change control process to be used during fabrication and installation of the MLI blankets.

3.3. Fabrication requirements

3.3.1. NASA will not take any measures to allow for fabrication onsite at Plum Brook Station.

3.3.2. No fabrication shall take place prior to the Final Design Review without NASA written consent.

3.3.3. Vendor shall use configuration/change control practices defined in section 3.2.7.3.

3.3.3.1. NASA shall be informed minimally within 1 week of any modifications of the design during the fabrication process.

3.3.4. NASA will schedule a one week period for the vendor to perform pre-installation check fits during the fabrication process.

3.3.4.1. The vendor shall work with NASA in scheduling the fit checks into the SHIIVER master schedule by the Final Design Review.

3.3.5. Fabrication shall be completed as described in the final design documentation provided in section 3.2.7.

3.3.6. After fabrication, the MLI blankets/sections shall be shipped to NASA Plum Brook Station (see Section 10) for Installation.

3.3.7. NASA reserves the right to visit the vendor’s facility at any time during blanket fabrication, with an expected minimum of one visit. Vendor will be given a minimum of 1 week notice prior to the NASA visit(s).

3.4. Instrumentation.

Silicon Diodes shall be embedded in the MLI System during prefabrication.

3.4.1. Silicon Diodes (model number to be specified at the PDR) shall be used for temperature measurement within each blanket (not on the inner or outer layer).

3.4.2. Silicon diode wiring shall be routed within a layer such as to thermally anchor it at that layer (a minimum of 6” of wiring attached to layer) prior to coming out of the blanket.

3.4.3. Silicon Diodes shall be attached using an epoxy adhesive compatible with the specified environmental conditions (see 2.1).

3.4.4. Wiring lengths shall extend more than 2’ (TBR - PDR) coming out of the MLI outer mold line.

3.4.5. Temperature instrumentation quantity, location, and attachment method will be approved by NASA at the PDR.

3.4.5.1. It is anticipated that there will be a minimum of 4 and maximum of 6 temperature profiles (or blanket cross-sections).

3.4.5.2. It is anticipated that there will be a minimum of 4 sensors in each profile.

3.5. Installation of Large Scale MLI

3.5.1. Installation of the blankets shall occur at NASA Plumbrook Station in either the B2 vacuum chamber or in other standard work areas.

3.5.1.1. Vendor shall indicate at the Preliminary Design Review where the preferred installation is.

3.5.1.2. Vendor shall indicate at the Final Design Review (FDR) special facility requirements (such as scaffolding)

3.5.1.3. Vendor shall provide all structures and machines required for MLI installation and inspection not currently available (decided at FDR).

3.5.1.4. Vendor shall comply with all safety requirements with use of equipment as needed in section 3.5.1.3 (see GLM-QS-1700.1, section 2.6).

3.5.1.5. Vendor shall be responsible for properly training appropriate vendor personnel to perform all operations necessary for installation of the blankets.

3.5.1.6. Security Requirements:

3.5.1.6.1. Contractors shall have a valid picture ID and are required to watch a 20 minute safety video on their first day of work, if they have not worked on the station in over 1 year.

3.5.1.6.2. Contractor employees shall obtain an identification badge prior to entry onto the Station. Contractor employees shall wear these identification badges at all times.

3.5.1.7. Safety Requirements:

3.5.1.7.1. Any work at the Plum Brook station, if required, shall be accomplished in accordance with the latest revisions of the Occupational Safety and Health Association (OSHA) codes and related reference materials as applicable.

3.5.1.7.2. Any work after normal business hours (7 to 3:30) must be coordinated with NASA Plum Brook personnel at least one week prior to the anticipated after hours work date.

3.5.2. Vendor shall work with NASA to plan for MLI installation and ensure it is adequately accounted for in NASA’s schedule by the FDR.

3.5.3. Vendor shall install blankets per documentation produced in section 3.2.7

3.5.4. NASA will perform final acceptance of the MLI system.

3.5.4.1. Vendor shall provide to NASA all installation and close out pictures taken during the MLI installation process.

3.5.5. NASA reserves the right to record video of the installation.

4. Thermal Coupons for Calorimeter As a part of the design review process, the vendor is expected to provide a minimum of 3 and a maximum of 4 coupons to be thermally tested at GRC.

4.1. Vendor shall supply minimum of three coupons for thermal testing at GRC

4.2. Coupons shall conform to the Glenn Calorimeter as described in Section 2.5

4.3. One of the coupons shall be a “seamless” blanket to serve as a baseline.

4.4. The other 2-3 coupons shall incorporate blanket design details for minimizing the pre-test thermal prediction uncertainty of the SHIIVER installation.

4.5. Coupon approach and design will be approved at the Preliminary Design Review.

5. Pricing of Subsequent Builds

5.1. Following the fabrication and installation of all portions of the MLI blanket, the vendor shall provide a fixed price quote, good for 180 days for the procurement of a subsequent identical blanket for the SHIIVER test article.

5.2. Vendor shall list all assumptions made in the cost analysis.

6. Option 1: Design, Fabrication, and Installation of MLI for Curtains Vendor designed and built MLI curtains for incorporation into the Plumbrook Station B2 facility

6.1. Design Requirements

6.1.1. All materials shall be as specified in the attached MLI Specification referenced in 2.1.

6.1.2. The MLI curtain shall have an inner diameter no more than 6 inches and no less than 3 inches greater than the maximum outer diameter on the tank (including SOFI).

6.1.3. The MLI curtain shall run from the bottom edge of the bottom skirt to the top edge of the top skirt (see tank drawing, section 2.2).

6.1.4. The MLI curtain shall have a minimum of 40 layers.

6.1.5. The vendor shall provide a weight estimate for the MLI curtain as a part of the curtain design at PDR.

6.1.6. The MLI system shall interface with the B2 hoop rings,

6.1.7. NASA will provide to the contractor a curtain interface drawing/document no later than PDR.

6.1.8. The MLI curtain shall not require external support other than the provided B2 interfaces.

6.2. The MLI curtain shall be fabricated in time for initial SOFI testing. (see Section 9.10)

6.3. The vendor shall provide step-by-step installation instructions for installing the MLI curtain.

6.4. The MLI curtain will be installed by NASA.

7. Option 2: Design, Fabrication, and Installation of MLI for Sidewall This option is for the fabrication of MLI for the sidewall of the tank should it be desired.

7.1. The MLI for the tank side wall shall meet all requirements in section 3.2, 3.3, and 3.5 in addition to those in section 7.

7.2. General MLI sidewall requirements are defined below:

7.2.1. The MLI shall cover the length from the top of the forward skirt to the bottom of the aft skirt.

7.2.2. The MLI shall encompass the flanges between the tank and the skirts.

7.2.3. Attachment points shall be defined as in section 3.2.3.

7.3. Instrumentation

7.3.1. Silicon Diodes (model number to be specified at the PDR) shall be used for temperature measurement within each blanket (not on the inner or outer layer).

7.3.2. Silicon diode wiring shall be routed within a layer such as to thermally anchor it at that layer (a minimum of 6” of wiring attached to layer) prior to coming out of the blanket.

7.3.3. Silicon Diodes shall be attached using an epoxy adhesive compatible with the specified environmental conditions (see 2.1).

7.3.4. Wiring lengths shall extend more than 2’ (TBR - PDR) coming out of the MLI outer mold line.

7.3.5. Temperature instrumentation quantity, location, and attachment method will be approved by NASA at the PDR.

7.3.5.1. It is anticipated that there will be a minimum of 2 and maximum of 3 temperature profiles (or blanket cross-sections).

7.3.5.2. It is anticipated that there will be a minimum of 4 sensors in each profile.

8. Product Assurance.

8.1. Responsibility for Product Assurance.

The Vendor shall have quality assurance (QA) procedures subject to NASA review and approval in place that ensure compliance with these requirements and specifications. Except where explicitly stated, the responsibility for product QA resides with the Vendor. The contractor shall submit a Quality Plan, due as a deliverable for Preliminary Design Review (See section 9.2), which outlines/defines the specific quality activities which will be implemented for this contract. This can be satisfied by referencing the contractor’s existing quality manual and specific procedures to describe the quality control system which will be utilized.

8.2. Procured Materials Acceptance Testing and Traceability.

8.2.1. The Vendor shall comply with in-house standards and procedures for procured materials acceptance testing and traceability, subject to NASA review and approval. The contractor shall submit a brief outline/overview of these standards and procedures for NASA review prior to the start of their procuring materials for this contract.

8.2.2. Vendor shall supply all materials and lot test results to NASA with MLI documentation (see Section 9.5).

8.2.3. Vendor shall supply results of any internal acceptance testing to NASA with MLI documentation (see Section 9.5).

9. Milestones and Deliverables Schedule.

8.

9.

9.1. MLI System Kick-Off Meeting: No later than 3 weeks after Date of Award.

The Kick-Off meeting will be held at the vendor location as the first quarterly meeting.

At the kick-off meeting, NASA will provide an update on the SHIIVER project and expectations of the MLI system design and the vendor will provide a general design philosophy and initial coupon test concepts.

9.2. MLI System Preliminary Design Review: No later than 15 weeks after Date of Award.

The Design Review will be held at NASA GRC (NASA will also provide dial-in information for those unable to attend) and include a visit to NASA Plumbrook Station as the second quarterly face-to-face meeting.

During the Design Review, delivery of the following will be considered success criteria:

1. A preliminary design is provided that can be shown to meet requirements and key technical performance measures.

2. Other technical products for hardware elements have been made available to the cognizant participants at least one week prior to the review:

a. Subsystem design specifications (hardware), with supporting trade-off analyses and data, as required, that are ready to be baselined after review comments are incorporated.

b. Technical plans that are ready to be baselined after review comments are incorporated (technical performance measurement plan, contamination control plan, quality assurance plan, including implementation of software assurance).

c. Preliminary instrumentation list and location.

d. Applicable standards that have been identified and incorporated.

e. Preliminary hazard analysis Mil-STD-882, Rev E or equivalent with initial Hazard Likelihood/Consequence matrix, and initial hazard mitigations for installation specific hazards.

f. Preliminary Interface Control Document.

g. Verification/validation plan that is ready to be baselined.

h. Preliminary compliance matrix.

i. Preliminary technical resource utilization estimates and margins.

j. Schedule update for hardware (fabrication and installation).

k. Baseline operations (installation) concept.

l. Copy of contractor’s Quality Plan.

m. Coupon test plan (in conjunction with NASA).

n. Any other information that the Contractor deems worthy of mention.

Presentation materials (e.g., Power Point charts) shall be considered deliverables.

9.3. MLI Coupon Delivery: As below:

MLI coupon delivery to the designated address in Section 10.

Baseline coupon at PDR.

Other coupons no later than 30 calendar days after PDR.

9.4. On-Tank MLI Attachments:

Any MLI attachments required to be installed under the SOFI shall be delivered to MSFC no later than 60 calendar days after PDR.

9.5. MLI Final Design Review: No later than 32 weeks after Date of Award.

The Final Design Review will be held at the vendor location as the third quarterly meeting.

During the Final Design Review, the following will be considered success criteria, with emphasis on any changes made following the Initial Design Review:

1. Previous planned milestone reviews have been completed, action items have been closed, and plans to complete open work have are defined.

2. The following primary products are ready for review:

a. A baselined detailed design that can be shown to meet requirements and key technical performance measures.

3. Other technical products for hardware elements have been made available to the cognizant participants at least one week prior to the review:

a. Product build-to specifications along with supporting trade-off analyses and data that are ready to be baselined after review comments are incorporated.

b. Fabrication, assembly, integration, and installation procedures are developed and are ready to be baselined after review comments are incorporated.

c. Technical data package (e.g., integrated schematics, spares provisioning list, interface control documents, engineering analyses, and specifications).

d. Instrumentation list and location.

e. Updated Interface Control Document.

f. Updated verification/validation plan and updated compliance matrix.

g. Updated technical plans.

h. Operations safety analyses that identifies interface issues and any Operational hazards not incorporated in prior Hazard Analyses.

i. Fabrication and Installation Plans, documentation, and acceptance criteria.

j. Updated technical resource utilization estimates and margins

k. Schedule update.

l. Any other information that the Contractor deems worthy of mention.

9.6. Shipment of MLI: No later than 18 weeks after Final Design Review The MLI will be shipped to NASA Plumbrook (Sandusky, OH).

The shipment of MLI shall include the following documentation:

1. Initial Installation Procedure/Documentation (in Word and pdf format).

2. As-built drawings, templates, or other fabrication documentation (in pdf format).

9.7. Cost of Subsequent blankets: No later than 30 days after MLI Installation A Technical Interchange Meeting to discuss the costing of subsequent blankets will be held at NASA GRC.

9.8. MLI Installation Kick-off: Two weeks prior to the start of installation.

Installation Kick-off will be held at Plumbrook Station.

9.9. Completion of MLI Installation: No later than 10/21/2017 (TBR).

Included installation of MLI developed in Baseline and Option 2 (if exercised) After the installation of the MLI the following documentation shall be provided within 10 work days:

1. As-performed Installation Procedure/Documentation (in Word and pdf format).

2. As-installed drawings, templates, or other fabrication documentation (in pdf format) (if any changes).

3. Any photographic documentation of installation performed by vendor.

9.10. Design Review/Fabrication (Option 1).

The Design and Fabrication Reviews for Option 1 will be held in conjunction with those for the baseline.

9.11. Curtain Installation (Option 1): No later than 8/1/2017 (TBR).

Installation to be completed prior to SHIIVER baseline testing.

9.12. Design Review/Fabrication/Installation (Option 2).

The Design, Fabrication, and Installation Milestones for Option 2 will be held in conjunction with those for the baseline.

10. Mailing addresses

10.1. Glenn Research Center

NASA Glenn Research Center 21000 Brookpark Rd, M/S: 86-12 Cleveland, OH 44135

10.2. Plumbrook Station

NASA Glenn Research Center Plum Brook Station 6100 Columbus Avenue Sandusky, OH 44870

10.3. Marshall Space Flight Center

NASA Marhshall Space Flight Center

MS ZP-30

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