Tomahawk - SOW.pdf

SOW-20220506

STATEMENT OF WORK

FOR ORDNANCE ASSESSMENT TESTING OF

TOMAHAWK STANDARD INITIATORS (P/N 76Z2843-3) AND

TOMAHAWK 60% INITIATORS (P/N 2220343)

1. INTRODUCTION.

1.1 Scope. This statement of work (SOW) defines the efforts to conduct non-destructive, environmental, and functional (performance) testing of the following government furnished items: thirty-five (35) Tomahawk Standard Initiators (P/N 76Z2843-3, PacSci P/N 103377-32) and twenty-one (21) Tomahawk 60% Initiators (P/N 2220343, PacSci P/N 103377-432). Six (6) additional Tomahawk Standard Initiators (P/N 76Z2843-3, PacSci P/N 103377-32) will be provided for use as test setup units (TSUs) during functional testing.

1.2 Background. These initiators have been tested at Pacific Scientific Energetic Materials Company (PacSci) in April 2004, February 2006, May 2009, July 2010, October 2013, February 2015, August 2015, March 2016, February 2018 and February 2019. The last contract for ordnance assessment testing of these initiators was N00174-17-D-0024/ Task Order N00174-18-F-0316. The test data provided from non-destructive, environmental, and functional test results of fleet returned units furnished is used in an ordnance assessment evaluation of safety, performance, and reliability of the in-service aged parts.

2 APPLICABLE DOCUMENTS.

2.1 Drawings:

Dual Bridgewire Electrical Initiator - P/N 103377-32 (PacSci)

Electrical Initiator - P/N 103377-432 (PacSci)

2.2 Test Procedures:

Acceptance Test Procedure (ATP) for 103377-12, 103377-32, 103377-122, and 103377- 432 Initiator, Electrical - Document No. ATP103377-12, -32, -122, -432 (PacSci)

3 REQUIREMENTS.

3.1 Fleet Return Unit Testing. Fleet Return unit testing shall be performed as shown in Tables 1, 2, and 3. All inspections and test data in the below subsections shall be provided in accordance with SOW section 4.1 and CDRL A001 (Technical Report–Study/Services).

Table 1: Test Matrix

INITIATOR GROUPS & QUANTITIES

P/N 103377-32 P/N 103377-432

TEST REQUIREMENT* SOW SECTION A B C D E F

Visual Inspection 3.1.1.1 15 10 10 9 6 6 Leak Rate 3.1.1.2 15 10 10 9 6 6 Dielectric Withstanding Voltage 3.1.1.3 15 10 10 9 6 6 Insulation Resistance 3.1.1.4 15 10 10 9 6 6 Thermal Transient Test 3.1.1.5 15 10 10 9 6 6 Bridgewire Resistance 3.1.1.6 15 10 10 9 6 6 Radiographic Inspection (X-ray) 3.1.1.7 15 10 10 9 6 6 Radiographic Inspection (N-ray) 3.1.1.8 15 10 10 9 6 6 Shock 3.1.2.1 15 10 10 9 6 6 Vibration 3.1.2.2 15 10 10 9 6 6

TSHA 3.1.2.3 15 10 10 9 6 6

Leak Rate 3.1.1.1 15 10 10 9 6 6 Dielectric Withstanding Voltage 3.1.1.3 15 10 10 9 6 6 Insulation Resistance 3.1.1.4 15 10 10 9 6 6 Thermal Transient Test 3.1.1.5 15 10 10 9 6 6 Bridgewire Resistance 3.1.1.6 15 10 10 9 6 6 No Fire Current 3.1.1.9 15 10 10 9 6 6 Functional (Performance) Test

Ambient Temperature (70F) 3.1.3 15 9 Cold Temperature (-65F) 3.1.3 10 6 Hot Temperature (160F) 3.1.3 10 6

* Testing shall be conducted in the sequence as shown.

Table 2: Tomahawk Standard Initiator Test Sample (P/N 103377-32)

TCN Lot S/N Group Functional Test Temperature (F)

TS1 Test Setup ambient 1 A 70 2 A 70 3 A 70 4 A 70 5 A 70 6 A 70 7 A 70 8 A 70 9 A 70

10 A 70 TS2 Test Setup ambient 11 A 70 12 A 70 13 A 70 14 A 70 15 A 70 16 B -65 17 B -65 18 B -65 19 B -65 20 B -65

TS3 Test Setup ambient 21 B -65 22 B -65 23 B -65 24 B -65 25 B -65 26 C 160 27 C 160 28 C 160 29 C 160 30 C 160

TS4 Test Setup ambient 31 C 160 32 C 160 33 C 160 34 C 160 35 C 160

Table 3: 60% Initiator Test Sample (P/N 103377-432)

TCN Lot S/N Group Functional Test

Temperature (F) 1 D 70 2 D 70 3 D 70 4 D 70 5 D 70

TS5 Test Setup ambient 6 D 70 7 D 70 8 D 70 9 D 70

10 E -65 11 E -65 12 E -65 13 E -65 14 E -65 15 E -65

TS6 Test Setup ambient 16 F 160 17 F 160 18 F 160 19 F 160 20 F 160 21 F 160

3.1.1 Non-destructive Inspections and Electrical Tests. Non-destructive inspections and electrical test results shall be recorded and photographs shall be taken of each test setup.

A copy of test and inspection results, and, if necessary, associated non-conformance reports, shall be delivered.

3.1.1.1 Each initiator shall be visually inspected for defects in workmanship, service related damage, and conformance to applicable drawings and specifications. Photographs shall be taken of each unit documenting the as received condition, to include, but is not limit to, condition of the output closure, condition of the interfacial seal, condition of the pins, and any damage or non-conformance.

3.1.1.2 Leak rate testing shall be conducted on units listed in Table 2 and Table 3 in accordance with PacSci ATP103377-12, -32, -122, -432 section 4.4. Additionally, leak rate testing shall be conducted a second time on units after they have been subjected to environmental testing (section 3.1.2 of this SOW) and before they are subjected to functional testing (section 3.1.3 of this SOW).

3.1.1.3 Dielectric withstanding voltage testing shall be conducted on units listed in Table 2 and Table 3 in accordance with PacSci ATP103377-12, -32, -122, -432 section 4.8.

Additionally, dielectric withstanding voltage will be conducted a second time on units after they have been subjected to environmental testing (section 3.1.2 of this SOW) and before they are subjected to functional testing (section 3.1.3 of this SOW).

3.1.1.4 Insulation resistance shall be conducted on units listed in Table 2 and Table 3 in accordance with PacSci ATP103377-12, -32, -122, -432 section 4.7. Additionally, insulation resistance will be conducted a second time on units after they have been subjected to environmental testing (section 3.1.2 of this SOW) and before they are subjected to functional testing (section 3.1.3 of this SOW).

3.1.1.5 Thermal Transient Testing (TTT) shall be conducted on units listed in Table 2 and Table 3 in accordance with PacSci local instructions (85mV 220mV 1A Reading @ 0.1). Additionally, TTT will be conducted a second time on units after they have been subjected to environmental testing (section 3.1.2 of this SOW) and before they are subjected to functional testing (section 3.1.3 of this SOW).

3.1.1.6 Bridgewire resistance testing shall be conducted on units listed in Table 2 and Table 3 in accordance with PacSci ATP103377-12, -32, -122, -432 section 4.6. Additionally, bridgewire resistance testing shall be conducted a second time on units after they have been subjected to environmental testing (section 3.1.2 of this SOW) and before they are subjected to functional testing (section 3.1.3 of this SOW).

3.1.1.7 The X-ray radiographic inspection shall be conducted on units listed in Table 2 and Table 3 in accordance with PacSci ATP103377-12, -32, -122, -432 section 4.9. If possible, all units shall be on one board for X-ray. Radiographic inspection report and digital copy of X-ray(s) shall be provided.

3.1.1.8 The N-ray radiographic inspection shall be conducted on units listed in Table 2 and Table 3 in accordance with PacSci ATP103377-12, -32, -122, -432 section 4.10. If possible, all units shall be on one board for N-ray. Radiographic inspection report and digital copy of N-ray(s) shall be provided. PNCI is acceptable.

3.1.1.9 No-fire testing shall be conducted on units as listed in Table 2 and Table 3 in accordance with Pacific Scientific ATP103377-12, -32, -122, -432 section 5.5. No fire testing shall only be conducted after environmental testing (section 3.1.2 of this SOW), and before they are subjected to functional testing (section 3.1.3 of this SOW)

3.1.2 Environmental Testing. Environmental test results shall be recorded and photographs shall be taken of each environmental test setup. A copy of test results, photographs and, if necessary, associated non-conformance reports, shall be delivered.

3.1.2.1 Shock testing shall be conducted on units listed in Table 2 and Table 3 in accordance with PacSci ATP103377-12, -32, -122, -432 section 5.1.

3.1.2.2 Vibration testing shall be conducted on units listed in Table 2 and Table 3 in accordance with PacSci ATP103377-12, -32, -122, -432 section 5.2.

3.1.2.3 Temperature Shock/Humidity/Altitude (TSHA) testing shall be conducted on units listed in Table 2 and Table 3 in accordance with PacSci ATP103377-12, -32, -122, -432 section 5.3.

3.1.3 Functional (Performance) Testing.

3.1.3.1 The functional testing shall be conducted on units listed in Table 2 and Table 3.

Functional testing is conducted in a 10.0 to 10.2 cc closed bomb and in accordance with PacSci ATP103377-12, -32, -122, -432 section 5.6, except temperature conditioning at temperatures -65F, 70F, or 160F is required as noted in Tables 2 and 3. Temperature conditioning time, for the hot and cold conditions, shall be a minimum of 4 hours and no greater than 24 hours. Photographs shall be taken of the test ready setup with unit installed and delivered.

3.1.3.2 The Kistler gauges shall be re-greased after every tenth firing. The six initiators (P/N 76Z2843-3, PacSci P/N 103377-32), identified in Table 2, will be TSUs for conditioning the closed bomb and checking the test equipment after Kistler gauges are re-greased.

3.1.3.3 Test data, which includes maximum pressure and function time, and current-time and pressure-time traces shall be recorded. Test results, data traces, and, if necessary, associated non-conformance reports, shall be delivered.

3.1.3.4 A digital copy of the current-time and pressure-time data (raw data), in a file format that is compatible with Excel spreadsheets (e.g., .csv files), shall be delivered.

3.1.3.5 Photographs shall be taken of the exterior of the post fired test setup and post fired units, including photos of the output cavity showing condition of charge cup and evidence of hot gas leaks around the threads and o-ring. Photographs shall be delivered.

3.2 Government Furnished Material (GFM). The Government will provide the following GFM to the contractor for use in performance of this contract:

Tomahawk Standard Initiators (P/N 76Z2843-3, PacSci P/N 103377-32) 41 each

Tomahawk 60% Initiators (P/N 2220343, PacSci P/N 103377-432) 21 each

3.2.1 The property will be delivered at the Government’s expense to the contractor’s facility.

3.2.2 Only the property listed above and on the GFM Attachment will be furnished by the Government. All other property required for performance of this contract shall be furnished by the contractor.

3.2.3 Within 30 days after GFP 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.

3.2.4 Disposition instructions for the GFM test samples are as follows: All units shall be disposed of by the vendor after NSWC IHD has accepted all CDRLs.

3.2.5 The contractor’s GFP inventory shall be provided in accordance with non-sustainment

CDRL A002.

3.3 Test Dates. Functional testing shall be completed at least by 18 weeks after receipt of GFM hardware.

3.4 On-Site Visit and Coordination. The contractor shall notify the NSWC IHD at least ten

(10) business days prior to functional testing, so government representative(s) can make travel arrangements to witness testing.

3.5 Test Failures. In the event of any failure, the contractor shall be limited to verifying the respective test setup and photographing test item and test setup. Contractor shall notify the Government representative before proceeding with testing.

4 DELIVERABLES.

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

First Submission – Contractor shall submit non-destructive inspection and functional test data sheets, electrical test data sheets, environment test data sheets, photographs, and non-conformance reports to NSWC IHD within ten (10) business days after the completion of the functional testing.

Subsequent Submission – Contractor shall submit current-time and pressure-time traces, radiographic inspection reports, digital copies of X-rays and N-rays, test equipment and calibration list, conditioning chamber temperature profile, and electronic copies of current-time and pressure-time raw data in a file format compatible with Excel spreadsheets (e.g., .csv files) to NSWC IHD within 45 business days of completion of testing.

4.2 Government Property Inventory Report. The contractor shall submit a report of government inventory held under product support contractual arrangements for the GFP requirements of section 3.1 (CDRL A002).

Table 4: CDRL Submittals

CDRL

Number

Title First Submission Subsequent Submission

A001

Technical Report -Study/Services (SOW sections 3.1 (in its entirety) and 4.1)

Within 10 business days of completion of functional testing

Within 45 business days of completion of functional testing

A002 Government Property Inventory Report

Within 30 business days of completion of functional testing

4.3 Deliverable Address.

NSWC IHD

Attn: Chrissy Fish-DeAtley, Code E24CF 4393 Benson Rd, Suite 101

Indian Head, MD 20640-5092 christina.m.fishdeatley.civ@us.navy.mil

4.4 Points of Contact.

Tony Quebral, Code E24TQ 301-744-2312 anthony.p.quebral.civ@us.navy.mil

Chrissy Fish-DeAtley, Code E24CF 301-744-2313 WAWF email notifications shall be sent to:

christina.m.fishdeatley.civ@us.navy.mil mailto:christina.m.fishdeatley.civ@us.navy.mil mailto:anthony.p.quebral.civ@us.navy.mil mailto:christina.m.fishdeatley.civ@us.navy.mil

3.5 Test Failures. In the event of any failure, the contractor shall be limited to verifying the respective test setup and photographing test item and test setup. Contractor shall notify the Government representative before proceeding with testing.