Statement_of_Work_SOW_E2D_Antenna_Assembly.pdf

Revision - A July 20, 2021

SOW – Page 1 of 5

STATEMENT OF WORK

For US NAVY E-2D PROGRAM - ROTODOME ANTENNA ASSEMBLY

PHASE II REPAIRS

L-3 Harris Randtron Antenna Systems (Randtron) E-2D Rotodome Antenna Assembly Phase II Overhaul efforts are as stated herein below and specifies the Baseline Repair Activities (in scope) and over and above (out of scope) work related to the forward, mid and aft sections. Randtron’s Phase II Overhaul effort includes inspection, repair and/or replacement of antenna hardware, incorporation of modification kits and full acceptance testing which will include high power testing to requirements as described below. Upon completion and shipment, Randtron shall provide, OBA tables, test data sheets, customer return material and acceptance test data files.

Unlike the E-2C program, an E-2D antenna repair will be a two-phased approach. The Phase I effort will be completed by FRC. FRC will conduct all of radome structural repairs and will paint the radome prior to shipping the unit to Randtron for execution of the Phase II effort. It is anticipated that the antenna will be shipped from FRC to Randtron and returned to FRC using the designated E-2D shipping trailer. The antenna provided for Phase II will be the Spare Rotodome configuration, p/n 123GSR36-3. The Spare Rotodome is the same as the production Rotodome Antenna Group Assembly, randtron p/n 59777, and NGC part number 123SCAV9301, except for the removal of the 3 GFE components; 1) the Rotary Coupler Assembly (RCA), 2) the Flight Shaft, and 3) the Lower Isolator.

Separately, a spare Rotary Coupler will need to be provided by the navy or alternatively the navy will contract Randtron to develop an RCA cable set in order to complete acceptance testing at Randtron.

The referenced CFE is listed in Table A within this SOW.

Upon successful completion of the Phase II effort, Randtron will ship the antenna with all CFE installed except for the rotary coupler and Lower Isolator. If applicable, FRC will receive the antenna, install the lightning diverters and store the antenna using the navy shipping and storage containers.

Radome - Incoming Inspection (Phase II)

FRC is responsible for completing the ‘Phase I’ overhaul effort, which entails stripping of the paint, conducting all necessary radome structural repairs and completing the painting of the radome surface. Since the radome will arrive from FRC repaired and painted, Randtron will be limited to a cursory visual inspection of the exterior surface. Randtron will not provide any additional NDI inspection. Our Baseline repair includes engineering structural analysis to support the FRC when a radome defect exceeds the limits as defined by the structural repair manual. Engineering analysis will exclude section replacement of Radome. FRC will also perform removal of any moisture entrapped in the radome shells. Moisture within the Forward Section will likely degrade electrical performance and preclude Randtron from meeting electrical performance requirements. Any unplanned Phase I radome work performed by Randtron, as may be authorized by the customer, will be charged as ‘over and above’ to this contract (see ‘over and above’ item list below). The customer shall respond to Randtron in a reasonable time (i.e. 2 weeks) with a written disposition subject to the limitations set forth herein below.

Antenna - Incoming Inspection (Phase II)

Randtron shall perform an incoming teardown and inspection of specified antenna components. Inspection of the antenna shall also include electrical VSWR testing and air leak testing as required per Randtron standard procedures. Inspection findings shall be documented per Randtron standard procedures using Randtron standard inspection report format. Any unplanned Phase I antenna work performed by Randtron, as may be authorized by the customer, will be charged as ‘over and above’ to this contract (see ‘over and above’ item list below). The customer shall respond to Randtron in a reasonable time (i.e. 2 weeks) with a written disposition subject to the limitations set forth herein below. Any structural damage to the dome that is sustained while in work at Randtron shall be repaired by Randtron prior to shipping the dome back to FRC.

Major assembly items for inspection include:

• Antenna Box Elements

• UHF Antenna Transmission Lines

• IFF and SATCOM Transmission Lines

• Cooling and Exhaust System

• Moisture Purge Line System

• Forward, Mid, Aft Radome Assembly

• Gang Channel and Nut Plates

Forward Section Repair and Refurbishment (Phase II)

With the exception of upgrade kits as listed in Table B, all antenna hardware within the Forward Section is within the scope of the base repair price. The Forward section contains parasitics (or directors) for both the UHF and IFF system. The parts within the Forward section include the mounting hardware and the parasitics. Any unplanned Phase I Forward work performed by Randtron, as may be authorized by the customer, will be charged as ‘over and above’ to this contract (see ‘over and above’ item list below). The customer shall respond to Randtron in a reasonable time (i.e. 2 weeks) with a written disposition subject to the limitations set forth herein below.

Inspection and repair or replacement of components will be based on the following review:

• Condition of parasitics to shells

• Condition of parasitics to standoffs, standoffs to shells

• Condition of the IFF shingle panels

• Condition of IFF shingle elements to panels

• Foreign object material (FOM)

Mid Section Refurbishment (Phase II)

With the exception of any upgrade kits as listed in Table B, replacement of Box Elements and/or Power Splitters, all of the hardware and components within the Mid-Section are within the scope of the base repair price. Randtron will provide separate over and above pricing for box element or power splitter replacement which will be included as a contract line item in the event one is needed as indicated by after receipt inspection.

Any unplanned Phase I Mid Section work performed by Randtron, as may be authorized by the customer, will be charged as ‘over and above’ to this contract (see ‘over and above’ item list below). The customer shall respond to Randtron in a reasonable time (i.e. 2 weeks) with a written disposition subject to the limitations set forth herein below.

The Mid Section inspection and repair or replacement of components will be based on the following review of BFN, SATCOM and UHF an IFF Transmission Lines:

• Chafing conditions along transmission line runs

• Arcing

• Air leakage

• Condition of air flow section(s) of transmission line runs (Teflon beads)]

• Condition of plenum

• Bell mouthing connections

• Support bracket(s) and transmission line clamps

• BFN Hybrid mounting bracket, cables and box

• SATCOM cable mounting bracket and cables

• Foreign object material (FOM)

Aft Section (Phase II)

The Aft Section does not contain any hardware. Randtron will perform a cursory inspection for FOD or any damage internal to the radome shell. Any unplanned Phase I Aft Section work performed by Randtron, as may be authorized by the customer, will be charged as ‘over and above’ to this contract (see ‘over and above’ item list below). The customer shall respond to Randtron in a reasonable time (i.e. 2 weeks) with a written disposition subject to the limitations set forth herein below.

Upgrade Kits (Phase II)

Configuration changes or upgrades have been made throughout the history of the AHE antenna production. Based on the vintage of each antenna inducted for repair there may be several upgrades that are necessary in order to improve antenna performance. Since the various antennas can have different upgrade requirements, we have provided a configuration table shown in Table B that will determine by antenna serial number what upgrades are necessary. These items will be priced separately and will be over and above to the base contract base price.

Other Over and Above Items (Phase II)

Over and Above (out-of-scope) repair requirements shall require customer approval prior to commencement of such activities. Randtron teardown and inspection efforts include documenting out-of-scope repair conditions.

Disposition of all repair conditions will be performed by Randtron Engineering. Proof of customer Quality Assurance confirmation/verification of over and above items will be manifested in the form of a customer Quality Assurance Representative signature and/or stamp on Randtron’ s inspection report.

Items that are not included in the base repair contract are as follows:

• Box Elements - Replacement of this item – Randtron to price separately

• Power Splitters - Replacement of this item – Randtron to price separately

• Non Destructive Inspection (NDI) to support any additional radome investigation unless damaged occurred at Randtron during Phase II

• Corrosion on Transverse Beam, attach edge hardware and support brackets

• CFE items that are not operable will be required to be replaced in order to conduct the Phase II effort. The navy will be responsible to provide operational CFE. See CFE list of items in Table A with this document.

• Attach edge repairs including nut plates and gang channels

• Radome repairs or replacement including the shells, sheer plates, transverse beam or any internal radome repairs

• Radome moisture repairs or moisture removal

• It is assumed that all of the antenna components will be received at Phase II induction. Any “missing at induction” items that need to be replaced will be considered over and above to this contract.

• Flight shaft interface damage.

Final Acceptance Test and Customer Acceptance (Phase II)

Randtron will perform an acceptance test including high power operation at its test site. This is necessary to ensure that the antenna performs to electrical acceptance criteria and meet high power requirements. Electrical acceptance criteria will be established with a mutually agreeable compliance table. The table will be used to demonstrate that the test data taken falls within the historical acceptance levels. This table will be established within the contract. In addition, weight and CG data will not be applicable and will not be included as an ATP requirement. Finally, after successful completion of the Acceptance Test Procedure (ATP), Randtron shall perform clean-up and quality operations with final sell-off with the customer’s Quality Assurance Representative, DCMA. Acceptance Test Procedure (ATP) data with compliance table, OBA tables and calibration files will be provided to the Navy.

Summary

This SOW defines Randtron’ s E-2D Rotodome Antenna Assembly “Phase II” Baseline Repair Effort which includes teardown, inspection, testing, repair and replacement of antenna components. The SOW also provides an upgrade kit by serial number table and describes what is to be considered as “over and above” within the contract.

Lastly, the SOW provides the distinction between FRC and Randtron responsibilities during the Phase I and Phase II efforts.

Table B

Description Part Number Provided Note

BFN 123SCAV9358-1 Yes Will be installed in antenna when delivered to Randtron

BFN Hybrid 123SCAV9359-1 Yes Will be installed in antenna when delivered to Randtron

BFN Cables 123SCAV9304-1 Yes Will be installed in antenna when delivered to Randtron

Flight Shaft 123BM52104-301 No Randtron will supply a non-flyable shaft for testing. FRCSW will return to Randtron after shipment

Lower Isolator 123SCAM9603-1 Yes Not provided with shipped antenna but will need a supplied spare for testing with Coupler

Check Valves 123SCEC5212-1 Yes Will be installed in antenna when delivered to Randtron

Rotary Coupler 123SCAV1303-1 No

Not provided with shipped antenna to Randtron. Randtron will however require a supplied spare rotary coupler for testing or alternatively will uti l ize a cable set that would need to be developed for testing.

Table A

Kit Type Description Original Cut-In Upgrade Applicability Benefit A Antenna Upgrade Updated BFN hybrid bracket AHE012 AHE 001 to 009 & 011 Features better nutplates that are at less risk of causing the Hybrid mounting hardware to seize during Hybrid servicing.

B Antenna Upgrade Updated plenum design AHE012 AHE 001 to 011 The original threaded housing design in the early antenna builds is prone to galling, making it difficult to impossible to inspect / service the orficies without removing the Aft Section. The updated plenum housing design will greatly facilitate any future servicing / inspection of the orifices.

C Radome Upgrade Updated nutplates/gang channel assemblies for the Forward Attach Edge, New nutplate rings for access holes in Bays 1L/1R/2L/2R, MS21083C8 (Nylocks) on the titanium shear panels.

AHE021 AHE 001 to 020 The original nutplates used in the early radome builds are prone to galling during hardware removal resulting in fastener seizer, damage to the nutplate cage, and/or breakage of the rivets used to retain the nutplates to the gang channel. The updated nutplate designs will greatly facilitate in bolt/fastener removal/installation in the areas of: Forward Attach Edge, Access Covers - Bays 1L/1R/2L/2R, Flight Shaft Hardware that is secured into the shear panels.

D Radome Upgrade Updated guide pins for titanium shear panel AHE031 AHE 001 to 030 The longer guide pins greatly help the maintainer during installation of the shear panels during depot maintenance of the antenna.

E Radome Upgrade Install borescope holes in Bays 1, 2 and 3, Forward Section AHE060 AHE 001 to 009 & 011 to 059 The borescope holes facilitate in allowing the maintainer to making borescope inspections in an assembled antenna, in the area of the antenna aperture adjacent to the Bays 1-3 high power UHF and IFF elements.

F Antenna Upgrade Modification of High Power UHF Flared Notch Elements AHE034 AHE 001 to 033 Modifying the high power UHF flared notch elements to minimize the risk of high power breakdown. The modification consist of breaking a sharp inner edge and applying dielectric paint in the area of rework.