SM-2 BLK - SOW.pdf

STATEMENT OF WORK

FOR ORDNANCE ASSESSMENT TESTING OF STANDARD

MISSILE-2 BLOCK IIIB FLYAWAY COVER REMOVAL

PRESSURE CARTRIDGE ASSEMBLY, PART NUMBER L6668837

1 INTRODUCTION

1.1 Scope. This Statement of Work (SOW) defines the efforts to conduct non-destructive inspections, electrical tests, and destructive tests for sixteen (16) Government Furnished and two (2) Test Units of the STANDARD Missile-2 (SM-2) Block (BLK) IIIB Flyaway

Cover Removal Pressure Cartridge Assemblies (PRCARTs), Navy Part Number (P/N)

L6668837. Testing will occur at Pacific Scientific Energetic Materials Company (PSEMC) in Chandler, Arizona. The two (2) Test Units will be supplied by PSEMC. The PSEMC

P/N for this item is 103377-206.

2 APPLICABLE DOCUMENTS

2.1 Drawings.

2.1.1 Interface Description. Interfaces shall be in accordance with drawing L6668837.

Drawing No. L6668837, Rev L, Pressure Cartridge Assembly, Cover

Removal, Flyaway

Source Control Drawing No. 7539364, Cartridge, Pressure, Electrically-

Initiated

2.2 Test Procedures.

Pacific Scientific Energetic Materials Company (PSEMC) Acceptance Test

Procedure (ATP):

Document No. ATP103377-206 Rev G

Document No. ATP 105765 Rev B

3 REQUIREMENTS

3.1 On Site Visit and Coordination. Ordnance Assessment Testing. Technical representatives from the Government may witness testing. The Contractor shall provide the

Government at least twelve (12) calendar days advance notification prior to All-Fire Test activities required in Section 3.3.6 in order for representative(s) to make travel arrangements to for witnessing testing. The Contractor shall work with the Government to arrange reasonable accommodations.

3.2 Government Furnished Materials (GFM). The Government will furnish the following

Government Furnished Property (GFP) to the Contractor for use in performance of this contract:

ITEM: QUANTITY:

PRCART (Navy P/N L6668837/PSEMC P/N 103377-206) 16

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The material will be delivered at the Government’s expense to the Contractor’s facility.

Only the material listed above and on the GFM Attachment will be furnished by the

Government. All other material required for performance of this contract shall be furnished by the Contractor.

Within 30 days after GFM is determined by the Contractor to be lost, damaged, destroyed, no longer usable, or no longer needed for the performance of the contract, the

Contractor shall notify the Contracting Officer, in writing, thereof.

Disposition instructions for the GFM are as follows: Material will be destroyed by the

Contractor

3.3 Unit Testing. Unit Testing shall be performed on sixteen (16) Government Furnished

PRCARTs and two (2) Test Setup Units (TSUs) provided by PSEMC. Units with lot numbers are listed in Table 1. Testing shall be performed in accordance with ATP103377-

206 Rev G, ATP105765 Rev B, and in accordance with tests as shown in Table 2 on sixteen (16) PRCARTs total. If tests listed in Table 2 are not included in the Pacific

Scientific ATP, tests shall be conducted in accordance with Pacific Scientific local instructions and in accordance with drawings as Section 2. The test order shown in Table

2 must be maintained throughout the test program. The test work order should detail all test procedure requirements. The test work order shall be delivered to Naval Surface

Warfare Center Indian Head Division (NSWC IHD) in accordance with CDRL A001

(Test Work Order) for NSWC IHD technical representative’s approval prior to the start of testing.

3.3.1 Table 1. Pressure Cartridge Assembly (P/N L6668837) Test Sample

Test Item # Lot Number Serial Number

1 SEB98A001-007 0298

2 SDV99B001-008 0479

3 SDV00K001-010 0974A

4 SDV00K001-010 1012

5 SDV00A001-009 0707

6 SDV00A001-009 0750

7 SDV00A001-009 0769

8 ESD02F001-001 1327

9 ESD02F001-001 1548

10 ESD03G002-001 1626

11 ESD03G002-001 1629

12 ESD03G002-001 1729

13 ESD04L003-002 1948

14 ESD04L003-002 1979

15 ESD04L003-002 1994

16 ESD04L003-002 2068

TSU Supplied by PSEMC

TSU

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PRESSURE CARTRIDGE ASSEMBLY, PART NUMBER L6668837

3.3.2 Table 2. Test Matrix

Test* SOW Section

Requirement

Quantity

PRCARTs TSUs

Visual Inspection/Dimensional

Inspection

3.3.5.1 16 -

Electrostatic Discharge (ESD) 3.3.5.2 16 -

Radiographic, X-Ray Inspection 3.3.5.3 16 -

Insulation Resistance 3.3.5.4 16 -

Continuity Resistance 3.3.5.5 16 -

Shield Insulation Resistance 3.3.5.6 16 -

Dielectric Withstanding 3.3.5.7 16 -

Bridgewire Resistance 3.3.5.8 16 -

Thermal Transient Test (TTT) 3.3.5.9 16

Flexibility

Mating Interface

No-Fire 3.3.5.10 16 -

All-Fire Current @ +70ᵒF

-Peak Pressure

-Function Time

-Firing Current

3.3.6.1 16 2**

Pull-Test 3.3.6.2 7 -

Post-Function Visual Inspection 3.3.6.3 16 -

*Note: Testing shall be conducted in the sequence shown.

**PSEMC will provide 2 TSU units that operate in similar functional range to PN

L6668837 but do not require a harness

3.3.3 Failures. In the case of any failure or anomaly that may occur during testing, the

Contractor’s scope of work shall include validation of the test equipment and set up and photographing of the unit. The Contractor’s scope shall not include investigation or analysis should there be any type of anomaly during testing. Work will not be halted except to verify test equipment and set and photograph the unit. Units may be reallocated or removed per NSWC IHD technical representative’s direction. Units that are removed shall be disposed, retained for up to forty-five (45) days after completion of destructive testing in 3.3.6 or until direction is provided by Government. The Contractor will document any failure(s) with a notification of anomaly.

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3.3.4 Test Issues. In the event of a test issue that does not constitute a failure, but prohibits continuation of testing unit(s) (for example: inability to install unit(s) into fixture as required by this SOW), NSWC IHD technical representative shall be notified within 48 hours after issue is identified. Testing of the affected unit(s) shall resume per NSWC IHD technical representative’s permission. Unit(s) may be reallocated or removed per NSWC

IHD technical representative’s direction. Units that are removed shall be disposed, retained for up to forty-five (45) days after completion of destructive testing in 3.3.6 or until direction is provided by Government. Testing of units that are unaffected by any identified test issues may continue without NSWC IHD technical representative’s permission.

3.3.5 Non-Destructive Inspections and Electrical Tests. All test data shall be recorded.

Visual/Dimensional Inspection shall be conducted on sixteen (16) PRCARTs as specified in Table 2 in accordance with PSEMC ATP103377-206, Section 2.2.

Electrostatic Discharge (ESD) Testing shall be conducted on sixteen (16) PRCARTs as specified in Table 2 in accordance with PSEMC ATP 105765, except the connector pins shall be utilized instead of bridgewire pins. Pressure cartridge assemblies shall not be isassembled.

X-Ray Radiographic Inspections shall be conducted on sixteen (16) PRCARTs as specified in Table 2 in accordance with PSEMC ATP103377-206. Assemblies shall not be disassembled. Radiographic inspection report and copy of X-ray(s) shall be provided.

Insulation Resistance shall be conducted on sixteen (16) PRCARTs as specified in

Table 2 in accordance with PSEMC ATP103377-206. Actual readings for the data shall be included.

Continuity Resistance shall be conducted on sixteen (16) PRCARTs as specified in

Table 2 accordance with PSEMC ATP103377-206. Actual readings for the data shall be included.

Shield Insulation Resistance shall be conducted on sixteen (16) PRCARTs as specified in Table 2 in accordance with PSEMC ATP103377-206. Actual readings for the data shall be included.

Dielectric Withstanding shall be conducted on sixteen (16) PRCARTs as specified in

Table 2 in accordance with PSEMC ATP103377-206. Actual readings for the data shall be included.

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Bridgewire Resistance shall be conducted on sixteen (16) PRCARTs as specified in

Table 2 in accordance with PSEMC ATP103377-206. Actual readings for the data shall be included.

Thermal Transient Test (TTT) shall be conducted on sixteen (16) PRCARTs as specified in Table 2 in accordance with PSEMC ATP103377-206. Actual readings for the data shall be included.

Flexibility shall be conducted on sixteen (16) PRCARTs as specified in Table 2 in accordance with PSEMC ATP103377-206.

Mating Surface shall be conducted on sixteen (16) PRCARTs as specified in Table 2 in accordance with PSEMC ATP103377-206.

No-Fire Testing shall be conducted on sixteen (16) PRCARTs as specified in Table 2 in accordance with PSEMC ATP105765 except Units shall be left in their 103377-

206 configuration. Units shall be connected in electrical series string alongside the No-

Fire Tester and shall utilize connector pins A and C. No-Fire Traces for all units tested shall be included.

Non-Destructive Inspections and Electrical Test Results shall be recorded. A copy of test and inspection results, and, if necessary, associated notification of anomaly, shall be delivered to NSWC IHD in accordance with CDRL A002 (Test Data, Non-

Destructive and Destructive).

Photographs shall be taken of all test setups, test units, post-fired units, failures, and anomalies. Photographs shall be delivered to NSWC IHD in accordance with CDRL

A002 (Test Data, Non-Destructive and Destructive).

3.3.6 Destructive Tests

All-Fire Testing shall be conducted on sixteen (16) PRCARTs and two (2) TSUs as specified in Table 2. The testing shall be conducted in 10 cc closed bomb and in accordance with PSEMC ATP105765 except units shall be left in their 103377-206 configuration. Firing leads shall be connected to connector pins A and C.

Pull (Mating Interface) Test shall be conducted on one sample unit per lot for a total of seven (7) PRCARTs as specified in Table 1 and Table 3 and in accordance with

PSEMC ATP103377-206.

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Table 3. PRCART (P/N L6668837) Test Sample

TCN Lot SN Non-Destructive

Inspections &

Electrical Testing

(SOW section

3.3.5.13)

All-Fire

Testing

(SOW

section

3.3.6.1)

Ambient

Temperature

Pull

Testing

(SOW

section

3.3.6.2)

1 SEB98A001-007 0298 X X X

2 SDV99B001-008 0479 X X X

3 SDV00K001-010 0974A X X X

4 SDV00K001-010 1012 X X

5 SDV00A001-009 0707 X X X

6 SDV00A001-009 0750 X X

7 SDV00A001-009 0769 X X

8 ESD02F001-001 1327 X X X

9 ESD02F001-001 1548 X X

10 ESD03G002-001 1626 X X X

11 ESD03G002-001 1629 X X

12 ESD03G002-001 1729 X X

13 ESD04L003-002 1948 X X X

14 ESD04L003-002 1979 X X

15 ESD04L003-002 1994 X X

16 ESD04L003-002 2068 X X

TSU1 TBD TBD

X

TSU2 TBD TBD

X

Post-Function Visual Inspection shall be conducted on sixteen (16) Units as specified in Table 2 and consist of visual examination of ALL PRCARTs after All-Fire testing, as outlined in Section 3.3.6.1, is complete. Each unit shall be inspected for any obvious signs of damage or other anomalies. Any of the following conditions shall be noted on the data sheets:

Discoloration

Evidence of closure remaining intact

Newly identified cracks, nicks, burrs, and/or contamination that were not previously noted during Visual Inspection, Section 3.3.5.1.

Additional detail(s) on mode(s) of failure for any Pull Test failures as captured in Section 3.3.6.2

Any additional anomalous observations

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Test Data, which includes peak pressure output and function time, temperatures from conditioning chamber, and current and pressure time traces, shall be recorded. A copy of test results (data and current and pressure time traces), and, if necessary, associated non-conformance reports, shall be delivered to NSWC IHD in accordance with CDRL

A002 (Test Data - Non-Destructive and Destructive). A compact disc containing a digital copy of the current and pressure time data traces, in a file format that is compatible with Excel spreadsheets (e.g., .csv files), shall be delivered to NSWC IHD in accordance with CDRL A002 (Test Data - Non-Destructive and Destructive).

Photographs shall be taken of all anomalies, failures, test setups, and post-fired units.

Photographs shall be delivered to NSWC IHD in accordance with CDRL A002 (Test

Data – Non-Destructive and Destructive).

4 DELIVERABLES

See all deliverables in Table 4

4.1 Test Work Order (CDRL A001). A copy of the work order(s) detailing the procedures for No-Fire (3.3.5.12) and All-Fire (3.3.6.1) assembly level shall be provided for

Government review/approval at least ten (10) days prior to the start of testing for NSWC

IHD technical representative’s approval.

4.2 Test Data, Non-Destructive and Electrical (CDRL A002). A copy of all non-destructive and destructive test results shall be provided to NSWC IHD within thirty (30) days of completion of destructive testing. Non-destructive test results shall be inclusive of inspection results, electrical test results, test equipment list and calibration information, any conditioning chamber temperature profiles, x-rays, and photographs. Destructive test results shall be inclusive of associated current and pressure time traces, photographs, test equipment list and calibration information, and conditioning chamber temperature profiles.

Current and pressure time data shall also be submitted in digital file format compatible with Microsoft Excel (e.g. .csv or .xls).

4.3 CDRL Summary

Table 4. CDRL Submittals

CDRL

NUMBER

TITLE FIRST SUBMISSION SUBSEQUENT

SUBMISSION

CDRL A001 Test Work Order (Section

4.1)

Ten (10) days prior to the start of testing

Revision

CDRL A002 Test Data, Non-

Destructive and

Destructive (Section 4.2)

Within thirty (30) days of completion of destructive testing

None

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4.4 Deliverable Address

NSWC IHD CAD/PAD Division

4393 BENSON ROAD SUITE 108

INDIAN HEAD, MD 20640-5092