Tomahawk Electric Detonator - SOW dtd jul 27.pdf

SOW-20200127

27 January 2020

Attachment (I)

TITLE

STATEMENT OF WORK

FOR QUALITY EVALUATION (QE)

TESTING OF TOMAHAWK ELECTRIC

DETONATOR (P/N 76Z2737-7)

REVISION

CAGE Code ******

TOTAL PAGES

REVISIONS

EFFECTIVITY

AUTHORITY

LTR

DESCRIPTION

DATE

APPROVED

Initial Release

APPROVALS

PREPARED BY

Punit Dave, NSWC/IHEODTD E24AH

APPROVED BY

Sameh Lotfy, NSWC/IHEODTD E24TQ

Table of Contents

1. INTRODUCTION

2 APPLICABLE DOCUMENTS

3 REQUIREMENTS

4 DELIVERABLES

Summary of Tables Table 1: Test Matrix Table 2: Electric Detonator Test Sample Table 3: CDRL Submittals

1. INTRODUCTION.

1.1 Scope. This statement of work (SOW) defines the efforts to conduct non-destructive and functional testing of forty-two (42) government-furnished Tomahawk Electric Detonators (Raytheon P/N 76Z2737-7, -9 and PSEMC P/N 817447).

1.2 Background. Testing shall be conducted with the process, procedures, and equipment consistent with those used in Lot Acceptance Testing. The fleet-returned units will be furnished by the Naval Surface Warfare Center, Indian Head Explosive Ordnance Disposal Technology Division (NSWC/IHEODTD).

2 APPLICABLE DOCUMENTS.

2.1 Drawings: Pacific Scientific Energetic Materials Company Drawing No. 817447, Detonator, Electric. General Dynamics Drawing No. 76Z2737, Booster Separation System.

2.2 Specification. Specification No. 76Z2738, Product Fabrication Specification Separation System Booster

2.3 Test Procedure. Pacific Scientific Energetic Materials Company Acceptance Test Procedure TP-700169.

3 REQUIREMENTS.

3.1 Fleet Return Unit Testing.

3.1.1 Fleet Return unit testing shall be performed as shown in Table 1. Testing shall be completed in order indicated in Table 1.

3.1.2 Non-destructive Inspections and Tests.

3.1.2.1 Examination shall be conducted on units in Table 2 in accordance with Pacific Scientific TP700169 to check each unit for compliance with PSEMC drawing 817447.

True position of the detonator tip shall be measured and recorded. Examination report with true position data shall be provided in accordance with CDRL A001 (Technical Report–Study/Services).

3.1.2.2 The X-ray radiographic inspection shall be conducted on units in Table 2 in accordance with Pacific Scientific TP700169. If possible, all units shall be on one board for X-ray.

Radiographic inspection report and copy of X-ray(s) shall be provided in accordance with CDRL A001 (Technical Report–Study/Services).

3.1.2.3 Bridgewire resistance testing shall be conducted on units in Table 2 in accordance with Pacific Scientific TP700169. For the thirty-three (33) units not being subjected to environment testing and No-fire testing, bridgewire resistance testing shall be performed twice. Bridgewire resistance testing shall be performed four times on the ten

(10) units being subjected to environment testing and No-fire testing (as outlined in sections 3.1.3 and 3.1.4 of this SOW, respectively). Table 1 provides the sequence in which bridgewire testing shall be performed for each group of detonators. Bridgewire resistance test results, in ohms, shall be provided in accordance with CDRL A001 (Technical Report–Study/Services).

3.1.2.4 Insulation resistance shall be conducted on units in Table 2 in accordance with Pacific Scientific TP700169. Insulation resistance test results shall be provided in accordance with CDRL A001 (Technical Report–Study/Services).

3.1.2.5 Dielectric strength shall be conducted on units in Table 2 in accordance with Pacific Scientific TP700169. Dielectric strength test results shall be provided in accordance with CDRL A001 (Technical Report–Study/Services).

3.1.2.6 The Thermal Transient Test (TTT) shall be conducted on units in Table 2. Each detonator shall be subjected to TTT to measure the electro-thermal characteristics of the internal bridge circuit and the explosive interface. The TTT readings shall be between 5mv and 18 mV. Additionally, TTT shall be conducted a second time on ten (10) units after they have been subjected to environment testing and before No-fire testing as outlined in sections 3.1.3 and 3.1.4 of this SOW, respectively. TTT test results, in mV, shall be provided in accordance with CDRL A001 (Technical Report–Study/Services).

3.1.2.7 Hermetic seal (leak) testing shall be conducted on units in Table 2 in accordance with Pacific Scientific TP700169. Additionally, hermetic seal testing shall be conducted a second time on ten (10) units after they have been subjected to environment testing and before they have been subjected to No-fire testing as outlined in sections 3.1.3 and 3.1.4 of this SOW, respectively. Hermetic seal test results shall be provided in accordance with CDRL A001 (Technical Report–Study/Services).

3.1.2.8 The N-ray radiographic inspection shall be conducted on units in Table 2 in accordance with Pacific Scientific TP700169. If possible, all units shall be on one board for N-ray.

Radiographic inspection report and copy of N-ray(s) shall be provided in accordance CDRL A001 (Technical Report–Study/Services).

3.1.2.9 Electrostatic discharge (ESD) testing shall be conducted on units in Table 2 in accordance with Pacific Scientific TP700169. Additionally, ESD shall be conducted a second time on ten (10) units after they have been subjected to environment testing and before No-fire testing as outlined in sections 3.1.3 and 3.1.4 of this SOW, respectively.

Electrostatic discharge test results shall be provided in accordance with CDRL A001 (Technical Report–Study/Services).

3.1.2.10 Non-destructive inspections and test results shall be recorded. Non-conformance report(s) shall be provided for any unit(s) that does not meet the requirements for testing and inspections conducted under section 3.1.2 of this SOW. A copy of test and inspection results, and, if necessary, associated non-conformance reports, shall be delivered in accordance with CDRL A001 (Technical Report–Study/Services).

3.1.2.11 Photographs shall be taken of each test setup used in sections 3.1.2.3 to 3.1.2.7, and

3.1.2.9 of this SOW. Photographs shall be delivered in accordance with CDRL A001 (Technical Report–Study/Services).

3.1.2.12 In the event of a failure, the contractor shall be limited to photographing and verifying the respective test setup and notifying the Government representative. The Government representative shall provide concurrence to proceed forward with testing.

3.1.3 Environment Tests.

3.1.3.1 Temperature – Shock/Humidity/Altitude (TSHA) testing shall be conducted on ten (10) units as specified in Table 2 in accordance with Pacific Scientific TP700169. True position of the detonator tip shall be measured and recorded during the visual inspection. TSHA test results and true position data shall be provided in accordance with CDRL A001 (Technical Report–Study/Services).

3.1.3.2 Environment test results shall be recorded. Non-conformance report(s) shall be provided for any unit(s) that does not meet the requirements for testing and inspections conducted under section 3.1.3 of this SOW. A copy of test results, and, if necessary, associated non-conformance reports, shall be delivered in accordance with CDRL A001 (Technical Report–Study/Services).

3.1.3.3 Photographs shall be taken of the test setup for each environment test and copies shall be delivered in accordance with CDRL A001 (Technical Report–Study/Services).

3.1.3.4 In the event of a failure, the contractor shall be limited to photographing and verifying the respective test setup and notifying the Government representative. The Government representative shall provide concurrence to proceed forward with testing.

3.1.4 No-Fire Tests.

3.1.4.1 No-fire testing shall be conducted on ten (10) units as specified in Table 2 in accordance with Pacific Scientific TP700169.

3.1.4.2 No-fire test results shall be recorded. Non-conformance report(s) shall be provided for any unit(s) that does not meet the requirements for testing and inspections conducted under section 3.1.4 of this SOW. A copy of test results, and, if necessary, associated non-conformance reports, shall be delivered in accordance with CDRL A001 (Technical Report–Study/Services).

3.1.4.3 Photographs shall be taken of the test setup for No-Fire test and copies shall be delivered in accordance with CDRL A001 (Technical Report–Study/Services).

3.1.4.4 In the event of a failure, the contractor shall be limited to photographing and verifying the respective test setup and notifying the Government representative. The Government representative shall provide concurrence to proceed forward with testing.

3.1.5 Functional (Dent Output) Tests.

3.1.5.1 The functional testing shall include the units as specified in Table 2. Functional testing is conducted in accordance with Pacific Scientific TP700169, except temperature conditioning at temperatures -65±5°F, 70±18°F, or 160±5°F is required as noted in Table 2. The detonator, dent block, and confining sleeve shall be temperature conditioned as an assembly. Temperature conditioning time, for the hot and cold conditions, shall be a minimum of 4 hours and no greater than 24 hours. The samples shall be removed from the conditioning chamber and functioned within 3 minutes. If units are out of conditioning for more than 3 minutes, they shall be reconditioned 2 minutes for every 1 minute out of conditioning time.

3.1.5.2 Rockwell hardness values shall be provided for each dent block used in the functional testing.

3.1.5.3 A tracking log that documents which dent block number was paired with each detonator, by serial number, during functional testing shall be provided.

3.1.5.4 Test data, which includes dent depth, function time, and current vs. time and audio vs.

traces shall be recorded. Non-conformance report(s) shall be provided for any unit(s) that does not meet the requirements for testing and inspections conducted under section

3.1.5 of this SOW. A copy of test results (data and current time traces), and, if necessary, associated non-conformance reports, shall be delivered in accordance with CDRL A001 (Technical Report–Study/Services). A compact disc containing a digital copy of the current vs. time and audio vs. time data traces, in a file format that is compatible with Excel spreadsheets (e.g., .csv files), shall be delivered in accordance with CDRL A001 (Technical Report–Study/Services).

3.1.5.5 Photographs shall be taken of test setup and post fired units. For post fired units, photographs of both the pin side and output side shall be taken to document any hot gas leakage through the pins/insulator and complete booster tip functioning. Photographs shall be delivered in accordance with CDRL A001 (Technical Report–Study/Services).

3.1.5.6 In the event of a failure, the contractor shall be limited to verifying the test setup and taking a post-fire x-ray of the unit(s) alongside a successfully functioned unit. The contractor must retain any failed units for at least 45 days after testing or until released for disposal by a government representative, whichever comes first. The contractor shall ship failed unit(s) back to the government only upon request.

3.1.6 Test Dates. Functional testing per section 3.1.5 shall be completed at least by 9 weeks after receipt of hardware.

3.1.7 On-Site Visit and Coordination. Pacific Scientific shall notify the NSWC/IHEODTD at least ten (10) working days prior to functional testing (section 3.1.5 of this SOW), so representatives can make travel arrangements to witness testing. The NSWC/IHEODTD technical representative is Punit Dave at 301-744-2329.

3.1.8 Disposal of Test Sample. Any unit(s) that does not meet requirements in SOW sections

3.1.2.4 and 3.1.2.5 shall be shipped back to NSWC/IHEODTD after functional testing in section 3.1.5 is complete. All other units can be disposed at the vendor after 60 days after all CDRLs have been accepted by NSWC/IHEODTD.

Table 1: Test Matrix

DETONATOR GROUPS

(Number of units per group)

TEST

SOW SECTION

REQUIREMENT A B C D TOTAL

Examination 3.1.2.1 10 10 10 10 40 Radiographic Inspection (X-ray)* 3.1.2.2 10 10 10 10 40 Bridgewire Resistance* 3.1.2.3 10 10 10 10 40 Insulation Resistance* 3.1.2.4 10 10 10 10 40 Dielectric Strength* 3.1.2.5 10 10 10 10 40 Thermal Transient Test* 3.1.2.6 10 10 10 10 40 Hermetic Seal* 3.1.2.7 10 10 10 10 40 Radiographic Inspection (N-ray)* 3.1.2.8 10 10 10 10 40 Electrostatic Discharge* 3.1.2.9 10 10 10 10 40

TSHA* 3.1.3.1 10 10

Bridgewire Resistance* 3.1.2.3 10 10 Thermal Transient Test* 3.1.2.6 10 10 Hermetic Seal* 3.1.2.7 10 10 Electrostatic Discharge* 3.1.2.9 10 10 Bridgewire Resistance* 3.1.2.3 10 10 No-Fire Current* 3.1.4 10 10 Bridgewire Resistance* 3.1.2.3 10 10 10 10 40 Functional (Dent Output) Test*

Cold Temperature (-65 °F) 3.1.5 10 10 Ambient Temperature (70 °F) 3.1.5 10 10 20 Hot Temperature (160 °F) 3.1.5 10 10

* Testing shall be completed in order indicated in Table 1.

Table 2: Electric Detonator Test Sample (P/N 76Z2737-7)

TCN Lot S/N

Non-Destructive Testing

(SOW section 3.1.2)

Environment Testing

(SOW section 3.1.3)

Post Environment NDT (SOW sections 3.1.2.3, 3.1.2.6, 3.1.2.7, & 3.1.2.9)

No-Fire Testing (SOW section

3.1.4)

Ballistic Testing (SOW section 3.1.5)

Temperature (°F)

1 MSV84A006-001 X X X X 70

2 MSV84A006-001 X 70

3 MSV84A006-001 X -65

4 MSV84A006-001 X 160

5 MSV85C007-001 X X X X 70

6 MSV85C007-001 X 70

7 MSV85C007-001 X -65

8 MSV85C007-001 X 160

9 MSV87A010-001 X X X X 70

10 MSV87A010-001 X 70

11 MSV87A010-001 X -65

12 MSV87A010-001 X 160

13 MSV87G012-001 X X X X 70

14 MSV87G012-001 X 70

15 MSV87G012-001 X -65

16 MSV87G012-001 X 160

17 MSV88C013-001 X X X X 70

18 MSV88C013-001 X 70

19 MSV88C013-001 X -65

20 MSV88C013-001 X 160

21 MSV89A015-001 X X X X 70

22 MSV89A015-001 X 70

23 MSV89A015-001 X -65

24 MSV89A015-001 X 160

25 MSV90A016-001 X X X X 70

26 MSV90A016-001 X 70

27 MSV90A016-001 X -65

28 MSV90A016-001 X 160

29 MSV90C018-001 X X X X 70

30 MSV90C018-001 X 70

31 MSV90C018-001 X -65

32 MSV90C018-001 X 160

33 MSV91J020-001 X X X X 70

34 MSV91J020-001 X 70

35 MSV91J020-001 X -65

36 MSV91J020-001 X 160

37 MSV97C028-001 X X X X 70

38 MSV97C028-001 X 70

39 MSV97C028-001 X -65

40 MSV97C028-001 X 160

4 DELIVERABLES.

4.1 Technical Report–Study/Services (CDRL A001).

First Submission - Copy of dent block Rockwell Hardness, dent block and detonator tracking log, performance test data sheets, and associated current vs. time and audio vs.

time traces, non-destructive inspection results, electrical test results, environment test results, no-fire test results, test equipment list and calibration information, conditioning chamber temperature profiles, and any required non-conformance report(s) shall be provided to NSWC/IHEODTD within 2 days after the completion of the functional testing in section 3.1.5.

Subsequent Submission - Electronic copy of current time and audio time traces, in a file format compatible with Excel spreadsheets (e.g., .csv files), photographs, radiographic inspection reports, and copy of X-rays and N-rays shall be provided to NSWC/IHEODTD within 30 days of completion of functional testing in section 3.1.5.

4.2 CDRL Summary.

Table 3: CDRL Submittals

CDRL

NUMBER

TITLE FIRST

SUBMISSION

SUBSEQUENT

SUBMISSION

CDRL A001 Technical Report -Study/Services (SOW paragraphs 3.1.2, 3.1.3, 3.1.4 and 3.1.5)

Within 2 days of completion of functional tests

Within 30 days of completion of functional tests

4.3 Deliverable Address.

NSWC/IHEODTD

Attn: Punit Dave, E24PD

4393 BENSON ROAD SUITE 101

INDIAN HEAD, MD 20640-5092

Punit.Dave@navy.mil

4.4 Points of Contact

NSWC/IHEODTD Technical Representative:

Punit Dave, CODE E24PD 301-744-2329 Punit.Dave@navy.mil

NSWC/IHEODTD Technical Representative:

Sameh Lotfy, CODE E24SL 301-744-2312 sameh.lotfy@navy.mil

WAWF email notifications shall be sent to: rosemary.hodgson@navy.mil mailto:Punit.Dave@navy.mil mailto:sameh.lotfy@navy.mil