PWS.pdf

DEPARTMENT OF THE AIR FORCE

OGDEN AIR LOGISTICS CENTER, HILL AFB, UTAH 84056-5820

PERFORMANCE WORK SPECIFICATION (PWS)

PR NO: FD2020-18-01640 DATE: 18 November 2019

1.0 SCOPE OF WORK: For the following end item(s), the contractor shall furnish all facilities, parts, materials, data, equipment and services, required to dissemble, (the process of breaking down item(s) into component parts that will be reworked, rehabilitated, altered, and/or replaced), inspect, repair as necessary (providing manufacturing processes that are similar to the original manufacturing process to totally rebuild items), upgrade, reassemble, align and functionally test each item(s), returning the item(s) to a serviceable condition. Electron tubes identified as MICAP (Mission

Incapable Awaiting Parts) repairs will follow the same scope of work processes identified in paragraph 1.1 and its subparagraphs.

1.1 ANALYSIS TEST: Visual, mechanical and electrical testing shall be accomplished to determine the condition of the tubes. Test requirements: Test procedures must be done in accordance with manufacturer’s original specification, utilizing test equipment: Upon completion of this task, tubes will fall into one of following categories:

1.1.1 Klystrons Categories: serviceable, minor repair, major repair, total rebuild, or

Beyond Economical Repair (BER). Serviceable falls under the Analysis Test category. If a tube falls into the major repair category after analysis test and it is found that the condition of the tube is actually a total rebuild, then it will fall into the total rebuild category with the major repair category acting as its analysis test.

1.1.1.1 MINOR REPAIR: Minor repair is a repair that does not require violation of the vacuum envelope. A minor repair candidate typically requires external adjustments or rework in order to meet all of the electrical specifications in accordance with the Test Performance Sheet

(TPS) and mechanical dimensions in accordance with the outline drawing. It would include repair or replacement of damaged or missing external parts as required. Test each electron tube IAW the specifications for P/N’s as listed in the contract schedule. In no case, shall minor repair consist of any tasks, which result in total disassembly of unit.

1.1.1.2 MAJOR REPAIR: Major repair is a repair that requires violation and/or repair of the vacuum envelope. A major repair includes the repair/replacement of the electron gun and ion pump. A major repair does not include the repair/replacement of the tube body or any other vacuum component. A tube body is defined as the RF interaction section or structure. A major repair is tested to ensure that it meets all of the electrical specifications in accordance with the Test Performance

Sheet (TPS) and mechanically inspected in accordance with the outline drawing. It would include repair or replacement of damaged or missing external parts as required. Remove all hardware and dissect the tubes, inspect all component parts, and major assemblies to ascertain their serviceability and conformance to specifications. Repair or replace all defective parts subject to end of life failure. Test each tube IAW specifications for P/N’s as listed in the contract schedule. If major repair is initiated and it is found that, in order to return the tube to serviceable condition that the level of repair must increase to a total rebuild the DCMA Government representative (ACO/PCO or QAR) will be notified and provide authorization to proceed to the total rebuild category. Tubes may be rebuilt (Major) three times before they are deemed a “Total Rebuild”. Whenever a given tube has had three or more Major Repairs the next Major Repair attempt for that tube must be moved to a Total Rebuild (see definition below).

1.1.1.3 TOTAL REBUILD: Defined as a tube that is beyond the major repair category to the extent that the tube is to be totally rebuilt or reconstituted. This could be due to the number of Major repairs already performed (three or more), cracked output window, extensive damage or low probability of repair in the Major Repair Category. A Total Rebuild consists of the repair or replacement of portions of the tube body as well as utilizing any portion of the tube deemed to be reusable to return the tube to serviceable condition IAW specifications for P/N’s as listed in the contract schedule. Test each tube IAW specifications for P/N’s and approved test plans as listed in the contract schedule. This category of repair meets all the requirements in FAR 22.1003 and is considered

“remanufacturing”. After a tube Total Rebuild is accomplished, then only three Major Repairs may be accomplished for that tube before another Total Rebuild is required.

1.1.2 Magnetron Categories: serviceable, minor repair, major repair (only for magnetrons operating under 5 GHz), total rebuild, or Beyond Economical

Repair (BER). Serviceable falls under the Analysis Test category. If a tube falls into the major repair category after analysis test and it is found that the condition of the tube is actually a total rebuild, then it will fall into the total rebuild category with the major repair category acting as its analysis test.

1.1.2.1 ANALYSIS TEST: Visual, mechanical and electrical testing shall be accomplished to determine the condition of the tubes. Test requirements: Test procedures must be done in accordance with manufacturer’s original specification, utilizing test equipment; in addition, test all thermal switches IAW spec drawings in Section 2.

Upon completion of these tasks, tubes will fall into one of following categories: Serviceable, minor repair, major repair, total rebuild, or

Beyond Economical Repair (BER). Serviceable falls under the Analysis

Test category.

1.1.2.2 MINOR REPAIR: Replace all defective mechanical and electrical parts that are outside the vacuum. Test each electron tube in accordance with the specification for PN’s as listed in the contract schedule. In no case shall minor repair consist of any tasks, which result in the total disassembly of the unit. Work includes, the repair or replacement of damaged or missing parts including but not limited to: broken leads, arc detector breakdown, tuner repair or adjustment, bearings, reprocessing to clear slight arcing, re-gauss of the magnets to increase power, replacement of thermal switches that are determined to be out of spec or faulty, etc.

1.1.2.3 MAJOR REPAIR (only for magnetrons operating under 5 GHz):

Remove all hardware and dissect the tubes, inspect all component parts and major assemblies within the vacuum envelope to ascertain their serviceability and conformance to the specification. Repair and replace all defective parts subject to end of life failure; namely, but not limited to: cathode, heater, end-hats and tuner assembly. In all cases of major repair, the cathode and pinched assemblies shall be replaced. (The use of repaired cathodes is not authorized). Test each tube IAW specifications for P/N’s as listed in the contract schedule. If a major repair is initiated and it is found that, in order to return the tube to serviceable condition that the level of repair must increase to a total rebuild, the DCMA Government representative (ACO/PCO or QAR) will be notified and give the notice to process to the total rebuild category. The magnetrons can be rebuilt (Major) three times before they are deemed a “Total Rebuild”. Whenever a given tube has had three or more Major Repairs the next Major Repair attempt for that tube must be moved to a Total Rebuild (see definition below).

1.1.2.4 TOTAL REBUILD: Defined as a tube that is beyond the minor repair category to the extent that the tube is to be totally rebuilt or reconstituted. A total rebuild consists of the replacement of the entire vacuum envelope of the magnetron and repair or replacement of defective final packaging material (magnet, external tuner, leads, etc.).

The repaired unit will be brought back to “like new condition”. Test each tube IAW specifications for P/N’s as listed in the contract schedule. This category of repair meets all the requirements in

FAR22.1003 and is considered “remanufactured”.

1.1.3 TWT Categories: serviceable, minor repair, total repair, or Beyond

Economical Repair (BER). Serviceable falls under the Analysis Test category.

1.1.3.1 MINOR REPAIR: Minor repair consists of any repairs or adjustments external to the vacuum envelope required to bring the unit into full compliance with the original specifications. Test each electron tube

IAW the specifications for P/N’s as listed in the contract schedule. In no case, shall minor repair consist of any tasks, which result in total disassembly of unit.

1.1.3.2 TOTAL REBUILD: The unit shall be completely remanufactured. All major components including the electron gun, tube body, collector, RF windows, and ion pump shall be brought to like new condition. The unit shall be completely tested, inspected, and labeled to the original requirement.

Below listed items will be shipped to the contractor for repair and return per negotiated schedules:

NSN Nomenclature MFR PART

NUMBER (CAGE)

System

5960-01-198-2244 Klystron VKC-7810H (99313) AN/MSQ-T43

5960-00-476-4750 Magnetron VMX1132 (88236), PM-325X (89146)

AN/MSQ-T43

5960-00-478-1167 Magnetron SFD369 (88236) AN/MPS-T1

5960-00-478-1168 Magnetron SFD385 (88236) AN/MPS-T1

5960-01-082-8571 Magnetron VMU-1359GD (88236) AN/MST-T1A

AN/MST-T1(V)

5960-01-083-8989 Magnetron VMC-1360GD (88236) AN/MST-T1A

AN/MST-T1(V)

5960-01-083-8990 Magnetron VMU-1361GD (88236) AN/MST-T1A

AN/MST-T1(V)

5960-01-084-7379 Magnetron VMX-1221GD (88236) AN/MST-T1A

AN/MST-T1(V)

5960-01-084-7380 Magnetron VMC-1223GD (88236) AN/MST-T1A

AN/MST-T1(V)

5960-01-086-6158 Magnetron VMC-1130GD (88236) AN/MST-T1A

AN/MST-T1(V)

5960-01-090-9291 Magnetron VMU-1301 (88236) AN/VPQ-T1

5960-01-307-2673 Magnetron VMS-1782 (88236) AN/TPT-T1

5960-01-307-2674 Magnetron VMU-1724D (88236), PM-250U (89146)

AN/TPT-T1

5960-01-353-3302 Magnetron VMU1222 (88236) AN/MSQ-T43

5960-01-391-1308 Magnetron 8811-2524-1 (12115) AN/TPT-T1

5960-01-526-3843 Magnetron PM-800S (89146) AN/TPT-T1

5960-01-550-2782 Magnetron VMC-1351D (88236) AN/TPT-T1

5960-01-098-1168 TWT L-5283-54 (80080),

VTS-5151 (99313),

240714 (99313)

AN/MST-T1A

NSN Nomenclature MFR PART

NUMBER (CAGE)

System

5960-01-098-1169 TWT L-5684-02 (80080),

VTJ6264F4 (99313)

AN/MST-T1A

AN/MST-T1(V)

5960-01-107-2549 TWT L-5714-50 (80080) AN/MST-T1A

AN/MST-T1(V)

5960-01-388-4951 TWT VTU-5690A3 (99313),

L-5649-03 (80080)

AN/MST-T1(V)

5960-01-058-6272 TWT L-4920 (89146) AN/FPQ-16

ESD: No

2.0 REFERENCE DOCUMENTS: See below for related reference documents, and Special

Packaging Instructions (SPI).

2.1 Klystron 5960-01-198-2244

1. T.O.s

a. 43D7-11-36-4, Figure 100, Index 195/10

2. Specification drawings

a. 600944 (CAGE 09017)

i. Engineering Order 10A0934-H (CAGE 98747)

b. 201027418 (CAGE 98747), OUTLINE DRAWING VKC-7810H

i. Engineering Order 12A0300-H (CAGE 98747)

3. Special Packaging Instructions (SPI)

a. F011982244 (REV-B)

2.2 Magnetron 5960-00-476-4750, 7.8 to 8.5 GHz

a. 43D7-11-36-4, Figure 17, Index 281/9

2. Specification drawings

a. 600951 (CAGE 09017)

i. Engineering Order 12A1064-H (CAGE 98747)

b. OD600951 (CAGE 09017), Electron Tube, Magnetron, H/I Band, Outline

Drawing

a. F000004XF1

2.3 Magnetron 5960-00-478-1167, 4.9 to 5.1 GHz

a. 43D7-11-21-4, Figure 201, Index 151

2. Specification drawings

a. 583Z1324 (CAGE 81755)

a. F004781168 (REV-D)

2.4 Magnetron 5960-00-478-1168, 2.9 to 3.1 GHz

a. 43D7-11-21-4, Figure 201, Index 151

2. Specification drawings

a. 583Z1325 (CAGE 81755)

a. F004781168 (REV-D)

2.5 Magnetron 5960-01-082-8571, 11.9 to 13.2 GHz

a. 43D7-19-2-4, Figure 158, Index 121

2. Specification drawings

a. 654VE00048 (CAGE 81755)

b. 654CE0004 (CAGE 81755)

a. F010847379 (REV-J)

2.6 Magnetron 5960-01-083-8989, 6.7 to 7.4 GHz

a. 43D7-19-2-4, Figure 141, Index 76/4

2. Specification drawings

a. 654VE00044 (CAGE 81755)

b. 654CE0004 (CAGE 81755)

a. F010838989 (REV-E)

2.7 Magnetron 5960-01-083-8990, 14.5 to 15.4 GHz

a. 43D7-19-2-4, Figure 151, Index 163/5

2. Specification drawings

a. 654VE00047 (CAGE 81755)

b. 654CE0004 (CAGE 81755)

2.8 Magnetron 5960-01-084-7379, 7.75 to 8.5 GHz

a. 43D7-19-2-4, Figure 155, Index 189/6

2. Specification drawings

a. 654VE00045 (CAGE 81755)

b. 654CE0004 (CAGE 81755)

2.9 Magnetron 5960-01-084-7380, 4.9 to 5.1 GHz

a. 43D7-19-2-4, Figure 155, Index 180/5

2. Specification drawings

a. 654VE00042 (CAGE 81755)

b. 654CE0004 (CAGE 81755)

a. F010847380 (REV-C)

2.10 Magnetron 5960-01-086-6158, 6.2 to 7.0 GHz

a. 43D7-19-2-4, Figure 158, Index 185/4

2. Specification drawings

a. 654VE00043 (CAGE 81755)

b. 654CE0004 (CAGE 81755)

a. F010866158 (REV-E)

2.11 Magnetron 5960-01-090-9291, 14.5 to 15.4 GHz

a. 43D7-9-7-14 (Change 7 – 24 May 1995), Figure 31, Index 74

2. Drawings

a. 667090 (CAGE 20418)

b. 667090 ECF 11-1166 (CAGE 20418)

c. 667090 ECF 11-1414 (CAGE 20418)

d. D7802 (CAGE 20418)

e. D7802 ECF 11-1411 (CAGE 20418)

f. D7802 ECF 11-1415 (CAGE 20418)

a. F000003XA4

2.12 Magnetron 5960-01-307-2673, 2.9 to 3.1 GHz

a. 43D7-11-40-4-1, Figure 66, Index 147/5

2. Drawings

a. SC5985-0100 (CAGE 12115)

b. 1006-4150 (CAGE 12115) [See 1006-4150-2]

c. PL1006-4150-2 (CAGE 12115)

d. 8811-4157-1 (CAGE 12115)

e. SC5970-0028 (CAGE 12115)

f. PL8811-4157-1 (CAGE 12115)

g. 8811-4158-1 (CAGE 12115)

h. PL8811-4158-1 (CAGE 12115)

a. F013072673 (REV-B)

2.13 Magnetron 5960-01-307-2674, 14.6 to 15.2 GHz

a. 43D7-11-40-4-1, Figure 36, Index 91

2. Drawings

a. SC5985-0097 (CAGE 12115)

a. F013072674 (REV-A)

2.14 Magnetron 5960-01-353-3302, 14.5 to 15.4 GHz

a. 43D7-11-36-4, Figure 36, Index 281/9

2. Drawings

a. 600950 (CAGE 09017)

i. Engineering Order 09A1103-H (CAGE 96341)

b. OD600950 (CAGE 09017)

a. F013533302 (REV-B)

2.15 Magnetron 5960-01-391-1308, 12.78 to 13.32 GHz

a. 43D7-11-40-4-1, Figure 86, Index 33

2. Drawings

a. 8811-2524 (CAGE 12115), Magnetron Assembly, Ku Band

i. Engineering Order 09A1767-H

b. PL8811-2524 (CAGE 12115), Parts List

c. SC5985-0098 (CAGE 12115), Magnetron Ku Band, Coaxial, Tunable

d. SC5935-0552 (CAGE 12115), Connector, High Voltage, Female

e. SC5935-0548 (CAGE 12115), Connector, High Voltage, Male

f. SC8040-0033 (CAGE 12115), Adhesive-Sealant, Silicone, RTV, Non-Corrosive

i. Engineering Order 11A1499-H

g. SC8040-0034 (CAGE 12115), Primer, Silicone

h. SC8040-0032 (CAGE 12115), Adhesive

i. SC5970-0028 (CAGE 12115), Sleeve, Marker, Heat Shrinkable

a. F000004XA4

2.16 Magnetron 5960-01-526-3843, 2.9 to 3.1 GHz

a. 43D7-11-40-4-1, Figure 66, Index 147/5

2. Drawings

a. 1006-4150 (CAGE 12115) [See 1006-4150-1], Magnetron Assembly

b. PL1006-4150-1 (CAGE 12115)

c. 1006-4157 (CAGE 12115), Cathode Lead, Magnetron

d. 1006-4157-1 (CAGE 12115), Parts List, Cathode Lead, Magnetron

e. 1006-4158 (CAGE 12115), Heater Lead, Magnetron

f. PL1006-4158-1 (CAGE 12115), Parts List, Heater Lead, Magnetron

g. SC5985-0269 (CAGE 12115), Magnetron, S Band, Coaxial, Tunable

h. SC5970-0028 (CAGE 12115), Sleeve, Marker, Heat Shrinkable

a. F013072673 (REV-B)

2.17 Magnetron 5960-01-550-2782, 4.965 to 5.175 GHz

a. 43D7-11-40-4-1, Figure 89, Index 176/5

2. Drawings

a. SC5985-0278 (CAGE 12115), Magnetron, C Band, Coaxial, Tunable

a. F015502782 (REV-A)

2.18 TWT 5960-01-098-1168

a. 43D7-19-2-4, Figure 130, Index 118/4

2. Specification drawings

a. 654VE4853 (CAGE 81755), Pulsed Traveling Wave Tube

i. Engineering Order 08A1948-H

ii. Engineering Order 12C2049-H

iii. Engineering Order 89C0230-H

iv. Engineering Order 92C0420-H

v. Engineering Order 96C0066-H

b. PL 654VE4853 (CAGE 81755), Pulsed Traveling Wave Tube

i. Engineering Order 92C0579-H

c. 240714 (CAGE 99313), Electron Tube

i. Engineering Order 14C0222-H

a. F000003E10

2.19 TWT 5960-01-098-1169

a. 43D7-19-2-4, Figure 172, Index 110/1

2. Specification drawings

a. 654VE4856 (CAGE 81755), CW Traveling Wave Tube

i. Engineering Order MM-0192

ii. Engineering Order MM-0316

iii. Engineering Order 08A1947-H

iv. Engineering Order 12C2050-H

v. Engineering Order 92C0134-H

vi. Engineering Order 92C1556-H

vii. Engineering Order 93C0056-H

b. 240481 (CAGE 99313), Outline Drawing VTJ-6264F4

i. Engineering Order 14C0221-H

a. F000003XE8

2.20 TWT 5960-01-107-2549

a. 43D7-19-2-4, Figure 172, Index 110/1

2. Specification drawings

a. 654VE0007 (CAGE 81755), TWT, E Band

i. Engineering Order 08A1913-H

ii. Engineering Order 12C0393-H

b. 654CE0007 (CAGE 81755), Specification for a 2.1 – 2.7 GHz Grid Pulsed TWT

a. F011072549 (REV-C)

2.21 TWT 5960-01-388-4951

a. 43D7-19-4-4-1, Figure 35, Index 1

2. Specification drawings

a. 2001075 (CAGE 66948) [See 2001075-001], Traveling Wave Tube, High

Power Pulse, J-Band

i. Engineering Order 09A0335-H

a. F013884951 (REV-B)

2.22 TWT 5960-01-058-6272

1. Source Documents

a. 11260971 (CAGE 17773), Electron Tube – Traveling Wave

b. 11365057 (CAGE 17773), Electron Tube – Traveling Wave

i. 11317527 (CAGE 17773), Coupling Half, Self Sealing

ii. 11324916 (CAGE 17773), Line Section, Radio Frequency Transmission

Line-Rigid

1. 11258028 (CAGE 17773), Connector, Coaxial Interface

iii. 11263756 (CAGE 17773), Coupling Half, Self-Sealing

1. 11317525 (CAGE 17773), Coupling Half, Self-Sealing

a. 11317524 (CAGE 17773), Coupling Half, Self-Sealing

b. 11263757 (CAGE 17773), Coupling Half, Self-Sealing

2. 11317526 (CAGE 17773), Coupling Half, Self-Sealing

3. 11263754 (CAGE 17773), Coupling Half, Self-Sealing

4. 11263755 (CAGE 17773), Coupling Half, Self-Sealing

iv. 11256779 (CAGE 17773), Insulator Bullet Assembly for 3 1/8-inch

Nominal Diameter, RF, Coaxial Transmission Line

c. 11209550 (CAGE 17773), Transformer, Pulse

i. 01714-G302670-29 (CAGE 01714), Connector, Plug, Electrical

1. G396119 (CAGE 01714), Connector, Plug, Electrical

ii. 01714-G243222-2 (CAGE 01714), Cable, Special Purpose, Electrical

1. G231600 (CAGE 01714),

d. 11213776 (CAGE 17773),

e. 11259442 (Rev N), Part Number 11260971

f. 11366383 (Rev M), Part Number 11260971

2. Special Packaging Instructions (SPI)

a. In development

3.0 SERVICE DELIVERY SUMMARY (SDS): DCMA/ACO/Quality Assurance Representative

(QAR) is ultimately responsible for inspecting and accepting the repairable assets In Accordance

With (IAW) Federal Acquisition Regulation (FAR) Inspection Clause 52.246-4 & 52.245-1

Performance Objective PWS Para Performance Threshold Surveillance*

Return the assets to a serviceable condition.

5.2 Successful completion of

repair on all items not determined to be beyond economical repair.

DCMA QAR/DCMA ACO

Packaging IAW Special

Packaging Instructions (SPI)

2.0, 6.0 No more than one asset packaged incorrectly per delivery order; two (2) business days to make corrections upon identification.

DCMA QAR/DCMA

ACO/PCO/LMS

Acceptance Test Plan (ATP) 5.2, 5.5 All assets must meet form-fit-function-interface requirements of the applicable specification drawings and must pass performance acceptance testing per previously approved Acceptance Test

Plan (ATP).

DCMA QAR

Test Requirements 5.5, 9.4.1 All assets must pass performance acceptance testing and provide test report for each repair.

ENG/ES/DCMA QAR

Warranty 5.6, 8.6 Assets under warranty must be repaired and returned within greed upon schedule and have no impact on current delivery schedule.

ENG/ES/PM/DCMA

Reporting in Commercial

Asset Visibility Air Force

(CAV-AF)

DD250/Material/Inspection

Reporting and Receiving reports.

6.5 The contract must use

CAV-AF for asset repair data reporting, condition

Code changes must be processed no later than 7 days after change has taken place. All entries should be accurate with no more than

3-5 errors; 7 business days to make corrections upon identification. The DD

Form 1348 generated as a part of the shipping transaction shall be printed and used. NOTE: The DD

Form 1348 must be printed when prompted in CAV

AF.

CAV-AF POC/DCMA

Asset determined to be

Beyond Economical Repair

(BER)

7.0 No contested BERs

allowed.

DCMA QAR/DCMA

ACO/PCO

Delivery of repaired asset made IAW contract delivery schedule.

8.5 No more than one item

delivered after the scheduled due date.

DCMA QAR/ACO

Preservation of markings/

Item Unique Item Identifier

(IUID) marking

9.5

All assets must be marked with IUID labels per drawing. IUID information for all parts uploaded to

IUID database. DCMA has IUID inspection responsibility.

DCMA QAR

*All items will be inspected by the function listed on a periodic basis as described in the reference paragraph.

4.0 CDRL DELIVERY SUMMARY (CDS): Contractor is ultimately responsible for ensuring delivery of accurate and timely CDRLs.

Reporting in Commercial

Asset Visibility Air Force

(CAVAF)

DD250/Material/Inspection

Reporting and Receiving reports.

11.1 DD250 or CDRL Exhibit

A001 (DI-MGMT-

81838/T), A002 (DI-

MGMT-81995/T), and

(DI-MGMT-80441C/T).

CAV-AF POC/LMS

Item failures and component consumption data shall be documented and reported

11.2

Reporting shall take place according to contract schedule and CDRL

Exhibit B001 (DI-PSSS-

80386A).

ENG/ES

Counterfeit Prevention

Plan

11.3 CDRL Exhibit C001 (DI-

MISC-81832).

ENG/ES

Monthly Status Report 11.4 CDRL D001 (DI-MGMT-

80277) (see attachment A).

LMS/PMS

TEST PLAN 11.5 CDRL Exhibit E001 (DI-

NDTI-80603A).

ENG/ES

TEST REPORT 11.6 CDRL Exhibit F001 (DI-

NDTI-80809B).

ENG/ES

*All CDRL deliveries will be inspected per CDRL by the function listed as described in the reference paragraph.

5.0 WORK PERFORMANCE REQUIREMENTS:

5.1 KICKOFF MEETING: The Contractor shall conduct a kickoff meeting with-in 30 days of contract award. This meeting will include the Contractor, the 415th Strategic Sourcing Team, DCMA and other Government Stakeholders deemed necessary. The Contractor will provide the

Point Of Contacts (POCs) that will be executing the contract requirements. All meeting participants will review and discuss issues/risks associated with in this PWS.

5.2 TECHNICAL OR PERFORMANCE REQUIREMENTS: Unit will meet all performance requirements of a new item. All repaired/retrofitted items will be configured and perform

IAW the latest requirements of the Specification Control Drawings listed in Para. 2.0 and the

Acceptance Test Plan approved by the 415th Engineer.

5.3 OBSOLETE COMPONENTS will be identified to the ACO/PCO after the Test and

Evaluation and before the level of repair is negotiated/defined.

5.4 FOREIGN DISCLOSURE RESTRICTIONS: These items contain critical technology and are export controlled. Distribution authorized to DoD and U.S. DoD Contractors only (Critical

Technology).

5.5 TEST REQUIREMENTS: The Contractor shall perform an acceptance test and checkout of each completed end-item to assure serviceability and full functionality prior to presentation to the Government. This testing will be performed IAW existing approved test plan or IAW developed test plans approved by the 415th Engineer (See paragraph 11.5).

5.6 QUALITY DEFICIENCY REPORTING: Any asset that fails to function within Government-

Contractor mutually agreed warranty period after date of repair, and the Government suspects failure is due to quality of workmanship, level of overhaul, or quality of replacement parts used by the contracted repair source, the asset shall be returned to the repair source for correction. This repair shall be accomplished at no additional cost to the government if deemed by DCMA to be the fault of the contractor and will be delivered back to the government under the terms of the original contract. The contractor may dispute Air Force determination of responsibility through the ACO to the PCO with DCMA providing evidence that the failure was not the fault of the contractor. This measure will be accomplished by customer reported deficiencies in the form of product quality deficiency or material deficiency reports according to T.O. 00-35D-54 titled USAF Deficiency Reporting Investigation and

Resolution.

6.0 PACKAGING, HANDLING, SECURITY AND TRANSPORTATION:

6.1 RECEIVING INSPECTION: Contractor shall notify the ACO/PCO along with the Quality

Assurance Representative (QAR) of all damages and shortages, or discrepancies (i.e. items not packaged in accordance with applicable Special Packaging Instructions (SPI)) discovered upon receipt of any item(s). All issues must be reported back to the originating organization for disposition. If items are damaged in transit or assets are found to be misidentified during the inspection process, the ACO/PCO will request disposition instruction from the 415 SCMS. The

415 SCMS will verify if additional assets are available to resubmit to the contractor. If no assets are available, ACO/PCO will address the required changes. The ACO or QAR shall initiate a

Supply Discrepancy Report (SDR). Access to Web-SDR can be found at https://www.daas.dla.mil/sar/warning.asp.

6.2 SECURITY REQUIREMENTS: N/A

6.3 REUSABLE CONTAINERS: Contractor shall handle and store reusable containers and materials used for packing and packaging in a manner, which shall assure that they are retained in a serviceable condition for reuse. If the contractor questions the serviceability/condition of the reusable containers, notify the ACO for repair/replacement instructions.

6.4 HANDLING: All items shall be handled and packaged in accordance with applicable Special

Packaging Instructions (SPI).

6.4.1 Electron tubes having permanent magnets shall be preserved in accordance with physical and mechanical protection methods of MIL-STD-2073-1 and MIL-

DTL-75K. The distance between the outer magnetic surfaces and the outside of the unit container shall be no less than the protective distance required in the precautionary handling or magnetic isolation instruction in the MIL-PRF-1 detail specification, or manufacturer's tube specification, as applicable. When special instructions are not available, a minimum protective distance of 4 inches shall be maintained.

Permanent magnets of tubes must be kept away from ferromagnetic items such as steel tools, tabletops, floors, etc. Each tube of this type must have a warning label on the magnet to indicate the minimum proximity permissible for ferromagnetic materials. The permanent magnet can be demagnetized by a severe mechanical shock or by being in close proximity to ferromagnetic materials. Forces exerted on a microwave tube structure as the result of dropping the tube or picking it up or setting it down roughly, can be destructive.

6.4.2 Care shall be exercised to prevent damage to Government Furnished

Property/Equipment while in the contractor’s possession.

6.4.3 All Government Furnished Property shall be stored in a secure area to provide protection against damage, pilferage, or loss. Storage areas shall provide protection against all adverse environmental conditions.

6.5 SHIPPING DOCUMENT REQUIREMENT: A DD Form 1348 shall be prepared and attached to any item or items that have been repaired and are ready to be shipped without exception. Under no circumstances shall a DD Form 250 or DD Form 1149 ever be sent with a shipment and/or used as a shipping document. If CAV AF is used by the contractor for repair data reporting, the DD Form 1348 generated as a part of the shipping transaction shall be printed and used. NOTE: The DD Form 1348 must be printed when prompted in CAV AF.

The DD Form 1348 cannot be printed after that point. If CAV AF reporting is not fully completed or used by the contractor for any reason, a manual DD Form 1348 shall be prepared and shall be annotated with the following statement: “Contract Repair; Receiving activities process as D6M receipt, __ Condition Stock.” (Enter appropriate condition code). When a manual DD Form 1348 is used, a copy must be sent to the Procuring

Contracting Officer (PCO) with a statement indicating that the DD Form 1348 is to be sent to the CAV AF POC for the contract.

6.6 OVER AND ABOVE PACKAGING REQUESTS: If it is determined, that over and above funding is required for packaging materials to meet the required Special Packaging

Instructions (SPI); this request must be coordinated through the PCO/ACO and the 415th for approval. Submit request via e-mail through the Strategic Contracting Office

(415SCMS.STRATEGIC.CONTRACTS@us.af.mil), the team will review and coordinate through the approval process. Once approved the PCO will complete a modification to the contract to reflect approved pricing and schedule.

7.0 CONDEMNATION: In general BER is not allowed / authorized as all repairs can be accomplished under the 'total re-build' category. Parts obsolescence may be a condition for BER.

Authorization to accomplish repair, condemnation, or disposition shall be obtained through the

415th Strategic Sourcing Office (415SCMS.STRATEGIC.CONTRACTS@us.af.mil) and

ACO/PCO for end items determined to be uneconomical to return to a serviceable condition. If

BER is approved the contract delivery schedule will be adjusted accordingly to relieve contractor delivery schedule on item. Contractor shall provide a “Death Certificate” for all assets deemed and approved by the government as BER.

8.0 GENERAL:

8.1 RELIABILITY AND MAINTAINABILITY (R&M): Additional R&M is not required;

however, existing R&M performance shall not be degraded during this work effort.

8.2 ENVIRONMENTAL IMPACT (EI) REQUIREMENTS: The Tubes may contain Beryllium

Oxide (BeO), Lead (Pb), or Cobalt (Co). Take appropriate Industry Standard precautions when working on tubes containing any of these materials.

mailto:415SCMS.STRATEGIC.CONTRACTS@us.af.mil

8.3 ROUTINE, MISSION IMPAIRED CAPABILITY AWAITING PARTS (MICAP), SURGE,

and ESSENTIAL DoD CONTRACTOR SERVICES: The Contractor shall be responsible for returning serviceable assets in the time set forth in this contract. In the event that the

Government requires an asset for coverage of a MICAP requirement, the Contractor agrees to enter into negotiations with the Government to expedite delivery of the needed asset(s).

8.4 ELECTROSTATIC DISCHARGE CONTROL: N/A

8.5 DISPOSITION: Repaired parts shall be shipped to the destination specified in the contract.

Disposition of any misidentified items shall be as stated in paragraph 6.1. Delivery shall be according to the delivery schedule in the contract. Early and partial shipments are acceptable.

8.6 WARRANTY: Warranty shall be 30 days for a Minor Repair, 60 days for a Major Repair, and

1 year for Total Rebuilds from the shipment data of the repaired unit.

8.7 TRIAGE CONCEPT IS AUTHORIZED: Cross utilization of components are authorized

ONLY after coordination with 415SCMS.STRATEGIC.CONTRACTS@us.af.mil .

8.8 ENGINEERING SERVICES: In the event an electron tube cannot be repaired due to the obsolescence issues; the government may provide an opportunity for contractor to provide engineering solutions to mitigate obsolescence issues and provide a form, fit, function, and interface solution.

8.9 SAFETY AND HEALTH: While performing work under this contract the contractor shall comply with all applicable federal, state and local regulations regarding occupational safety and health. The contractor shall notify the Contracting Officer, within eight (8) hours of any damage to government property where the dollar value exceeds $500,000.00 and within two workdays, for any damage to government property less than $500,000.00 during the execution of the contract.

Mishap notifications shall contain, as a minimum, the following information:

a. Contract, Contract Number, Name and Title of Person(s) Reporting

b. Date, Time and exact location of accident/incident

c. Brief Narrative of accident/incident (Events leading to accident/incident)

d. Cause of accident/incident, if known

e. Estimated cost of accident/incident (material and labor to repair/replace)

f. Nomenclature of equipment and personnel involved in accident/incident

g. Corrective actions (taken or proposed)

h. Other pertinent information

If requested by the designated Contracting Officer, the contractor shall immediately secure the mishap scene/damaged property and impound pertinent maintenance and training records, until released by the Procuring Safety Office.

9.0 SPECIFIC WORK REQUIREMENTS:

9.1 DISASSEMBLY: The Contractor shall disassemble each item only to the extent necessary to accomplish inspection, testing, fault isolation, and maintenance.

9.2 CLEANING: The end item shall be cleaned thoroughly prior to and after disassembly and maintain cleanliness during this maintenance effort IAW MIL-HDBK-454 and

TO 00-25-251.

9.3 CORROSION CONTROL AND TREATMENT: Accomplish corrosion control and treatment as required, using methods and materials IAW MIL-HDBK-1568, paragraphs 5.4 through 5.9 and TO 1-1-691 as applicable, and specification drawings.

9.4 MAINTENANCE: The contractor shall perform the required maintenance, inspection, reassembly of the reworked end item and components and calibration, if applicable, IAW T.O. 00-25-234.

9.4.1 The contractor shall perform an acceptance test and checkout of each completed end item to assure serviceability prior to presentation to the government IAW approved Test Plan.

9.4.2 Upon satisfactory completion of final test, the contractor shall cover and seal all ports, vents and electrical connection/plugs with suitable caps to prevent entry of foreign matter or damage during handling and shipment, IAW MIL-C-5501/11. Cap or seal all open flexible or rigid lines, hoses, and fittings at all times when not in use.

9.5 MARKING:

9.5.1 Preservation of Markings: The Contractor shall ensure nameplates and product markings are correct and accurate upon repair completion. The

Contractor shall replace damaged markings, identification, and decals

IAW drawings or equivalent best commercial practice. The assemblies, subassemblies, and parts that constitute this repair shall be marked for identification in accordance with existing style and format.

9.5.2 If not already marked, Item Unique Item Identifier (IUID) marking shall be accomplished according to MIL-STD-130 and MIL-STD-129 latest versions and per DFARS Clause 252.211.7003. All marking shall be placed in accordance with the technical data for the part.

9.5.2.1 Specification requirements for IUID marking will be contained in the applicable Air Force/OEM Technical Order, Specific Work

Requirements appendix, approved engineering drawing, or a

Government provided Engineering order as applicable. The government will provide IUID marking specifications.

9.5.2.2 In the event the government cannot provide or it is not feasible for the contractor to provide IUID marking specifications a determination and findings will be accomplished IAW DFARS

211.274-2 Policy for unique item identification.

9.5.2.3 IUID markings currently in place on items undergoing repair shall be protected from damage or removal during repair. Ensure 2-D matrix IUID markings are readable per TO 00-25-260. Should

IUID marking be rendered unreadable during repair, the contractor shall notify the PCO/ACO for determination.

9.5.2.4 Prior to government acceptance, the contractor shall submit the required and applicable contingent data to the IUID Registry per the data submission procedures at http://www.acq.osd.mil/dpap/pdi/uid/data_submission_informatio n.html. DCMA has IUID inspection responsibility.

9.5.2.5 Enter logistical data into database. See MIL-STD-130N

CHANGE 1 [3.2 Item unique identification (IUID)]. The registry is maintained by the Defense Logistics Agency Logistics

Information Service (DLIS) (see http://www.acq.osd.mil/dpap/pdi/uid/).

IUID REGISTRY

To access the IUID Registry website, please use the following link:

https://iuid.logisticsinformationservice.dla.mil

9.5.3 Serial Numbers: Electron Tubes shall have the letters “RX” (where X is a number described in the following paragraphs) appended to the Serial

Number.

9.5.3.1 When an electron tube receives a Total Rebuild the base Serial

Number is to have the letters “R0” appended to the number, or if the last two letters of the Serial Number are already “RX” (where

X is any number) the last two letters of the number are to be changed to “R0”.

9.5.3.1.1 Example: VKC7810H Serial Number 2076 becomes

2076R0 following a Total Rebuild.

9.5.3.1.2 Example: VKC7810H Serial Number 2076R2

becomes 2076R0 following a Total Rebuild.

9.5.3.2 Minor repairs do not change the “RX” number in the serial number.

http://www.acq.osd.mil/dpap/pdi/uid/ https://iuid.logisticsinformationservice.dla.mil/

9.5.3.2.1 Example: VKC7810H Serial Number 2076R2 remains

2076R2 following a Minor Repair

9.5.3.3 Each Major Repair increments the “RX” number in the Serial

Number by 1.

9.5.3.3.1 Example: VKC7810H Serial Number 2076R2

becomes 2076R3 following a Major Repair

9.5.3.4 If the initial Serial Number of the Electron Tube has no “RX” number appended to it, append “R0” to the Serial Number for any

Total Rebuilds or “R1” for any other evaluations or repairs.

9.6 REFINISHING: Refinish only to the extent necessary to assure adequate protection of all surfaces. Touch-up minor scratches, chipped, or scaled surfaces. Refinish severely marred surfaces to provide adequate protection and smooth even surface.

Blend all spot painting to avoid unsightly mismatches. Use only approved paint per

OEM specifications.

9.7 COUNTERFEIT PREVENTION PLAN (CPP): Contractors that supply electronic parts or systems that contain electronic parts shall establish policies and procedures to avoid, detect, mitigate and dispose of counterfeit electronic parts to prevent such parts from entering the USAF/DoD supply chain. These policies and procedures shall be documented in a CPP for submission and approval in accordance with CDRL C001 (DI-

MISC-81832) and accomplished for all specified contract items. DI-MISC-81832 is applicable to Parts, Material and Processes Selection (PMPS) associated with delivery of systems and assemblies to the USAF and DoD. The requirements established by DI-

MISC-81832 also apply to electronics components procured in sustainment of such systems and assemblies. The requirements of the recently DoD-adopted SAE 5553, Aerospace Standard, Counterfeit Electronics Parts; Avoidance, Detection, Mitigation, and Disposition shall also apply.

9.7.1 At a minimum, the CPP shall address:

9.7.1.1 Applicability. The Contractor shall identify all Business locations and programs to which the CPP applies. The CPP shall address materials, hardware, electronic parts, and procured assemblies.

9.7.1.2 Definitions. The Contractor shall utilize definitions per AS 5553 to ensure consistency. Any contractor-derived definitions must be included in an appropriate CPP appendix or annex. (Ref. AS5553, Section 3)

9.7.1.3 Parts Availability and Use of Parts Brokers. The Contractor shall not procure materials, systems, assemblies, subassemblies or parts from parts Brokers when available from Original Manufacturers (OM) or their

Authorized Distributors. In cases where materials, systems, assemblies, subassemblies or parts are no longer available from the OM or their

Authorized Distributors, procurement from Brokers may be authorized as defined by the Contractor’s policy and their CPP. (Ref. AS5553, Section

3.1)

9.7.1.4 Procurement Policies. The Contractor shall provide and implement policy directing development and implementation of business practices and procedures, and processes to prevent procurement of

Counterfeit materials and parts. The Contractor shall identify the appropriate office(s), business units, functional organizations, and programs, who shall have responsibility for development, maintenance and implementation of the CPP. The CPP shall identify the specific roles and responsibility for each. (Ref. AS5553, Section 3.1.3, 3.1.4)

9.7.1.5 Risk Assessment. The contract shall address the risk of using unknown sources and or unauthorized suppliers in the CPP. Application or technical risk assessments shall establish the effect that counterfeit parts may have on performance. Vendor or source of supply risk assessments shall establish the potential for obtaining counterfeit parts. Using any risk analysis tool acceptable to the Government, the Contractor shall conduct a risk assessment based upon item characteristics and how likely it is that a counterfeit part will be received. The contractor shall identify and describe in the CPP how parts are selected for assessment and what risk is acceptable based upon the parts design, construction, material and functional requirements. As a minimum, analysis shall be completed for flagging high risk items, such as items that are obsolete, discontinued, rare, etc. The contractor shall require completion of a trade study, documented within the

CPP that shall facilitate determining whether 100% testing of parts procured from after-market sources is more cost effective than qualification or requalification of a manufacturer. (Ref. AS5553, Section 3)

9.7.1.6 Detection and Avoidance Responsibilities. The Contractor shall establish processes for the review and approval of contractor and applicable subcontractor systems for the detection and avoidance of counterfeit electronic parts and suspect counterfeit electronic parts, which processes shall be comparable to the processes established for contractor business systems under section 893 of the Ike Skelton National Defense

Authorization Act for Fiscal Year 2011 (Public Law 111–383; 124 Stat.

4311; 10 U.S.C. 2302 note). The Contractor shall flow down such requirements and processes to their subcontractors per ODASD Memo titled

“Overarching DoD Counterfeit Prevention Guidance”, dated 16 March

2012. (Ref. AS5553, Section 3)

9.7.1.7 Testing and Verification. The Contractor shall establish and accomplish testing and verification processes for items not received from an original equipment manufacturer, original component manufacturer, or authorized distributor that are identified as having high risk for counterfeit potential. These processes apply to prime contracts, and to subcontracts or suppliers below the prime contracts. The Contractor shall provide a list of acceptable test facilities if the subcontractor or supplier does not have the capability to perform required testing. Submittal of Certificates of

Compliance indicating the parts are not counterfeit shall be acceptable for verification of testing. (Ref. AS5553, Section 3.1.5)

9.7.1.8 Configuration Identification and Traceability. The Contractor shall identify and control the configurations of all systems, assemblies, subassemblies and parts, and enable mechanisms to provide traceability of parts. The Contractor shall report to the Government when control of the configurations of all systems, assemblies, subassemblies and parts, and mechanisms to provide traceability of parts are not possible. The

Contractor shall identify the specific systems, assemblies, subassemblies and parts beyond the Contractors’ control. The Contractor shall be responsible for detecting and avoiding the use or inclusion of counterfeit materials and parts, to include procured assemblies and subassemblies, in such products and shall be responsible for the rework or corrective action that may be required to resolve the use or inclusion of counterfeit materials and parts. The cost of counterfeit electronic parts and suspect counterfeit electronic parts and the cost of rework or corrective action that may be required to remedy the use or inclusion of such parts are not allowable costs under Department contracts , unless: a) the contractor has established a counterfeit avoidance/detection system approved by the DoD, b) the counterfeit parts were procured from a DoD-accredited trusted supplier or provided as government property, and c) the contractor has provide timely notification to the government. (Ref. AS5553, Section 3.1.7)

9.7.1.9 Counterfeit Notification and Reporting. The Contractor shall report in writing to the Procuring Activity within 30 days of determining any end item, component, part, or material contained in supplies purchased by the Department of Defense, or purchased by a contractor or subcontractor for delivery to, or on behalf of, the Department, contains counterfeit electronic parts or suspect counterfeit electronic parts for the purpose of investigation and notification of the Air Force Office of Special

Investigations (AFOSI). The Procuring Contracting Officer (PCO) shall coordinate reporting to the appropriate Program Management/Item

Management, System Engineering Management, the AFMC Discrepant

Materiel Reporting Program (DMRP) Office in 406 SCMS/GULAB, and the AFOSI. Additionally, the Contractor shall within the same 30 day period ensure all suspected or confirmed counterfeit items are entered into the Government-Industry Data Exchange Program (GIDEP) system, which will serve as the DoD central reporting repository. (Ref. AS5553, Section

3.1.8)

9.7.1.10 Counterfeit Prevention Training. The Contractor shall provide appropriate training and shall require all personnel working procurement within their company, to include at a minimum their supply chain management specialists, receiving inspectors, and engineers, to complete said training. The Contractor shall determine the appropriate training required. Training may be developed in-house or may be other Industry accepted training. The CPP shall describe and list the training provided by the contractor to their personnel. (Ref. AS5553, Section 3.1.1)

10.0 DISCREPANCIES: In case of conflict between this document and any referenced document, contact ACO & PCO for resolution of discrepancy.

11.0 DATA DELIVERABLES:

11.1 CAV AF: Contractor shall provide the status of maintenance production, asset management, and condemnations IAW Contract Data Requirements List (CDRL)

Exhibit A001 (DI-MGMT-81838/T), A002 (DI-MGMT-81995/T), A003 (DI-

MGMT-80441C/T) and all requirements of this PWS. Contractor shall be ready to report in CAV-AF before receipt of assets. The Contractor shall provide a CAV-

AF Point of Contact (POC) and their scheduled availability to maintain and resolve all reporting discrepancies. The Contractor CAV-AF POC shall complete all required CAV-AF production/repair data reporting as required in paragraph

Error! Reference source not found. of this PWS.

11.2 REPAIRED ITEM INSPECTION REPORT: All item failures and component consumption data shall be documented and reported to OO-ALC 415 SCMS IAW with the Repairable Item Inspection Report, CDRL B001 (DI-PSSS-80386A).

11.3 COUNTERFEIT PREVENTION PLAN: The contractor shall provide a

Counterfeit Prevention Plan (CPP) per CDRL C001 (DI-MISC-81832), including the identified items of SAE AS5553 per section 9.7.

11.4 MONTHLY STATUS REPORTS: The Contractor shall be ready to report in

CAV-AF before receipt of assets. The Contractor shall provide a CAV-AF Point of

Contact (POC) and their availability to maintain and resolve all reporting discrepancies. The contractor shall document and provide the status of all efforts within this task in monthly status reports in accordance with (IAW) Contractor's

Progress, Status, and Management Report CDRL, Exhibit D001. IAW Section

10.3p of DI-MGMT-80227 the Contractor shall include as part of the Monthly

Status Report a Microsoft Excel 2010 Spreadsheet (Save as Type: Excel

Workbook) that provides a cumulative status of the categories shown in the attached example spreadsheet. The contractor shall submit the monthly status reports to the LMS within 24 hours of the due date with no more than five (5) significant errors; seven (7) days to make corrections upon identification.

11.5 TEST PLAN: The contractor shall provide a Test Plan for each of the NSNs listed in Section 1 per CDRL Exhibit E001 (DI-NDTI-80603A).

11.6 TEST REPORT: The contractor shall provide a Test Report for each repair attempt per CDRL Exhibit F001 (DI-NDTI-80809B).

PREPARED BY: 448 SCMW/415 SCMS

Attachment A

Monthly Status Reports

Electron Tube Status

Electron Tube Cumulative Status Categories shall include:

1. Shipment #

2. (Contractor) PN

3. NSN

4. CLIN

5. Orig Serial #

6. New (Contractor) Serial #

7. Cust Serial #

8. Date Asset Rec'd

9. T& E Date Competed

10. Contract Due Date

11. Repair Classification

12. Invoice Amount

13. Date (sold off) in WAWF

14. "EZ" Ship Doc #

15. Date (Physically) Shipped From (Contractor)

16. Date (Physically) Received at Barstow

17. Comments

Electron Tube Cumulative Status Spreadsheet Example

Shipment

(Contractor)

PN NSN CLIN

Orig

Serial #

New

(Contractor)

Serial #

Cust

Serial #

Date Asset

Rec'd

T& E Date

Competed

Contract

Due Date

Repair

Classif ication

Invoice

Amount

Date (sold off) in WAAF "EZ" Ship Doc #

Date (Physically)

Shipped From

(Contractor)

Date (Physically)

Received at

Barstow Comments

PRODUCTION (OPEN / COMPLETE)

Note:

Note:

Hill AFB Contract Number