Tomahawk Tsi - SOW dtd jul 27 (1).pdf

SOW-20200303

3 March 2020

Attachment (I)

TITLE

STATEMENT OF WORK

FOR QUALITY EVALUATION (QE)

TESTING OF TOMAHAWK STANDARD

INITIATORS (P/N 76Z2843-3) AND

TOMAHAWK CLS INITIATORS (P/N

JCM-14175-001)

REVISION

CAGE Code ******

TOTAL PAGES

REVISIONS

EFFECTIVITY

AUTHORITY

LTR

DESCRIPTION

DATE

APPROVED

Initial Release

APPROVALS

PREPARED BY

Punit Dave, NSWC/IHEODTD E24AL

DATE

APPROVED BY

Sameh Lofty, NSWC/IHEODTD E24TQ

DATE

Table of Contents

1. INTRODUCTION

2 APPLICABLE DOCUMENTS

3 REQUIREMENTS

4 DELIVERABLES

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

1. INTRODUCTION.

1.1 Scope. This statement of work (SOW) defines the efforts to conduct non-destructive, environment, and ballistic testing of thirty-five (35) Government Furnished Tomahawk Standard Initiators (P/N 76Z2843-3, PSEMC P/N 103377-32) and twenty-one (21) Electric Initiator (P/N JCM-14175-001, PSEMC P/N 103377-12).

1.2 Background. Similar initiators have been tested at Pacific Scientific in April 2004, February 2006, May 2009, July 2010, October 2013, February 2015, February 2016, and February 2019. The testing has provided non-destructive, environments, and ballistic test results of fleet returned units furnished by NSWC Indian Head Explosive Ordnance Disposal Technology Division (NSWC/IHEODTD).

2 APPLICABLE DOCUMENTS.

2.1 Drawings: Pacific Scientific Energetic Materials Company P/N 103377-32, Dual Bridgewire Electrical Initiator. Pacific Scientific Energetic Materials Company P/N 103377-12, Electrical Initiator.

2.2 Test Procedures: Pacific Scientific Energetic Materials Company Acceptance Test Procedure (ATP) Document No. ATP103377-12, -32, -122, -432

3 REQUIREMENTS.

3.1 Fleet Return Unit Testing.

3.1.1 Fleet Return unit testing shall be performed as shown in Table 1.

3.1.2 Non-destructive Inspections and Electrical Tests.

3.1.2.1 Leak rate testing shall be conducted on 35 units in Table 2 and 21 units in Table 3 in accordance with Pacific Scientific 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 environment testing and before they have been subjected to No-fire testing as outlined in sections 3.1.3 and 3.1.2.9 of this SOW, respectively.

3.1.2.2 Electrostatic discharge (ESD) testing shall be conducted on 35 units in Table 2 and 21 units in Table 3 in accordance with Pacific Scientific ATP103377-12, -32, -122, -432 section 4.5. ESD testing shall only be conducted after environment testing, under section 3.1.3 of this SOW, and before No-fire testing, per section 3.1.2.9 of this SOW, is conducted.

3.1.2.3 Dielectric withstanding shall be conducted on 35 units in Table 2 and 21 units in Table 3 in accordance with Pacific Scientific ATP103377-12, -32, -122, -432 section 4.8.

Additionally, dielectric withstanding will be conducted a second time on units after they have been subjected to environment testing and before No-fire testing as outlined in sections 3.1.3 and 3.1.2.9 of this SOW, respectively.

3.1.2.4 Insulation resistance shall be conducted on 35 units in Table 2 and 21 units in Table 3 in accordance with Pacific Scientific 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 environment testing and before No-fire testing as outlined in sections 3.1.3 and 3.1.2.9 of this SOW, respectively.

3.1.2.5 The Thermal Transient Test (TTT) shall be conducted on 35 units in Table 2 and 21 units in Table 3 in accordance with Pacific Scientific local instructions: “85mV 220mV 1A 10ms Reading @ 0.1”. Additionally, TTT will be conducted a second time on units after they have been subjected to environment testing and before No-fire testing as outlined in sections 3.1.3 and 3.1.2.9 of this SOW, respectively.

3.1.2.6 Bridgewire resistance testing shall be conducted on 35 units in Table 2 and 21 units in Table 3 in accordance with Pacific Scientific 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 environment testing and before they are subjected to No-fire testing as outlined in sections 3.1.3 and 3.1.2.9 of this SOW, respectively.

3.1.2.7 The X-ray radiographic inspection shall be conducted on 35 units in Table 2 and 21 units in Table 3 in accordance with Pacific Scientific ATP103377-12, -32, -122, -432 section 4.9. X-ray radiographic inspection shall be only conducted prior to environment testing, under section 3.1.3 of this SOW. 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).

3.1.2.8 The N-ray radiographic inspection shall be conducted on 35 units in Table 2 and 21 units in Table 3 in accordance with Pacific Scientific ATP103377-12, -32, -122, -432 section 4.10. N-ray radiographic inspection shall be only conducted prior to environment testing, under section 3.1.3 of this SOW. 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 No-fire testing shall be conducted on units as specified in 35 units in Table 2 and 21 units in Table 3. The initiator shall not fire or dud within five minutes when subjected to a DC current of 1.0 Amperes minimum per bridgewire with a power of 1.0 Watt minimum applied to each bridge simultaneously at ambient conditions. A direct current of not less than one ampere supplying a minimum of one watt shall be applied to both bridgewires simultaneously for a period of at least five minutes to verify compliance with the requirements. No fire tests shall be conducted in accordance with Pacific Scientific ATP103377-12, -32, -122, -432 Rev E, section 5.5.

3.1.2.10 Non-destructive inspections and electrical test results shall be recorded. 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 In the event of a failure, the contractor shall be limited to photographing and verifying the respective test setup and notifying the Government representative.

3.1.3 Environment Tests.

3.1.3.1 Shock testing shall be conducted on 35 units in Table 2 and 21 units in Table 3 in accordance with Pacific Scientific ATP103377-12, -32, -122, -432 section 5.1.

3.1.3.2 Vibration testing shall be conducted on 35 units in Table 2 and 21 units in Table 3 in accordance with Pacific Scientific ATP103377-12, -32, -122, -432 section 5.2.

3.1.3.3 Temperature – Shock/Humidity/Altitude (TSHA) testing shall be conducted on 35 units in Table 2 and 21 units in Table 3 in accordance with Pacific Scientific ATP103377-12, -32, -122, -432 section 5.3.

3.1.3.4 Environment test results shall be recorded. A copy of test results, and, if necessary, associated non conformance reports, shall be delivered in accordance with CDRL A001 (Technical Report–Study/Services).

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

3.1.3.6 In the event of a failure, the contractor shall be limited to photographing and verifying the respective test setup and notifying the Government representative.

3.1.4 Ballistic (Function) Tests.

3.1.4.1 The ballistic testing shall include 35 units in Table 2 and 21 units in Table 3.

Functional testing is conducted in a 10.0 to 10.2 cc closed bomb and in accordance with Pacific Scientific ATP103377-12, -32, -122, -432 section 5.6, except temperature conditioning at temperatures -65 °F, 70 °F, or 160 °F 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.

3.1.4.2 Test data, which includes maximum pressure and function time, 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 in accordance with CDRL A001 (Technical Report–Study/Services). 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 in accordance with CDRL A001 (Technical Report–Study/Services).

3.1.4.3 Photographs shall be taken of test setup and the exterior of the post fired units, including photos of the output cavity and hot gas leaks around the threads and o-ring.

Photographs 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 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.

3.1.5 Test Dates. Ballistic testing shall be completed at least by 18 weeks after receipt of hardware.

3.1.6 On-Site Visit and Coordination. Pacific Scientific shall notify the NSWC/IHEODTD at least ten (10) days prior to both environment tests listed in section 3.1.3 and ballistic testing section 3.1.4, so representatives can make travel arrangements to witness testing.

The NSWC/IHEODTD technical representative is Punit Dave at 301-744-2329.

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

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

Table 1: Test Matrix

NUMBER OF INITIATORS

(GROUPS)

TEST

SOW SECTION

REQUIREMENT A B C TOTAL

Leak Rate 3.1.2.1 16 24 16 56 Dielectric Strength* 3.1.2.3 16 24 16 56 Insulation Resistance* 3.1.2.4 16 24 16 56 Thermal Transient Test* 3.1.2.5 16 24 16 56 Bridgewire Resistance* 3.1.2.6 16 24 16 56 Radiographic Inspection (X-ray)* 3.1.2.7 16 24 16 56 Radiographic Inspection (N-ray)* 3.1.2.8 16 24 16 56 Shock* 3.1.3.1 16 24 16 56 Vibration* 3.1.3.2 16 24 16 56

TSHA* 3.1.3.3 16 24 16 56

Leak Rate* 3.1.2.1 16 24 16 56 Electrostatic Discharge* 3.1.2.2 16 24 16 56 Dielectric Strength* 3.1.2.3 16 24 16 56 Insulation Resistance* 3.1.2.4 16 24 16 56 Thermal Transient Test* 3.1.2.5 16 24 16 56 Bridgewire Resistance* 3.1.2.6 16 24 16 56 No-Fire Current* 3.1.2.9 16 24 16 56 Ballistic (Function) Test*

Cold Temperature (-65 °F) 3.1.4 16 56 Ambient Temperature (70 °F) 3.1.4 24 56 Hot Temperature (160 °F) 3.1.4 16 56

* Testing must be complete in order indicated in Table 1.

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

TCN Lot S/N Group

Non-destrutive Inspections &

Electrical Testing (SOW section

3.1.2 excluding

3.1.2.2 and

3.1.2.9)

Environment Testing

(SOW section 3.1.3)

Post Environment

Electrical Testing

(SOW

sections

3.1.2.1 to 3.1.2.6)

No-Fire Testing

(SOW section 3.1.2.9)

Ballistic Testing (SOW section 3.1.4) Temperature

(°F)

1 ESD07C025-001 A X X X X 70

2 ESD07C025-001 A X X X X 70

3 ESD07C025-001 A X X X X 70

4 ESD07C025-001 B X X X X -65

5 ESD07C025-001 B X X X X -65

6 ESD07C025-001 C X X X X 160

7 ESD07C025-001 C X X X X 160

8 SEB89G003-035 A X X X X 70

9 SEB89G003-035 A X X X X 70

10 SEB89G003-035 A X X X X 70

11 SEB89G003-035 B X X X X -65

12 SEB89G003-035 B X X X X -65

13 SEB89G003-035 C X X X X 160

14 SEB89G003-035 C X X X X 160

15 ESD08A026-012 A X X X X 70

16 ESD08A026-012 A X X X X 70

17 ESD08A026-012 A X X X X 70

18 ESD08A026-012 B X X X X -65

19 ESD08A026-012 B X X X X -65

20 ESD08A026-012 C X X X X 160

21 ESD08A026-012 C X X X X 160

22 SEB93B002-001 A X X X X 70

23 SEB93B002-001 A X X X X 70

24 SEB93B002-001 A X X X X 70

25 SEB93B002-001 B X X X X -65

26 SEB93B002-001 B X X X X -65

27 SEB93B002-001 C X X X X 160

28 SEB93B002-001 C X X X X 160

29 ESD02H008-003 A X X X X 70

30 ESD02H008-003 A X X X X 70

31 ESD02H008-003 A X X X X 70

32 ESD02H008-003 B X X X X -65

33 ESD02H008-003 B X X X X -65

34 ESD02H008-003 C X X X X 160

35 ESD02H008-003 C X X X X 160

TS1 SDV01A005-014 - - - - ambient TS2 SDV01A005-014 - - - - ambient TS3 SDV01A005-014 - - - - ambient TS4 SDV01A005-014 - - - - ambient TS5 SDV01A005-014 - - - - ambient TS6 SDV01A005-014 - - - - ambient

Table 3: Initiator Test Sample (P/N 103377-12)

4 DELIVERABLES.

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

First Submission - Copy of ballistic test data sheets, and associated current and pressure time traces, non-destructive inspection results, electrical test results, environment test results, test equipment list and calibration information, and conditioning chamber temperature profile shall be provided to NSWC/IHEODTD within 2 days after the completion of the ballistic testing. Any non-conformance report shall be provided for any unit(s) that does not meet the non-destructive inspections, electrical, environment, or ballistic test requirements.

Subsequent Submission - Electronic copy of current and pressure time traces, in a file format compatible with Excel spreadsheets (e.g., .csv files), and photographs shall be provided to NSWC/IHEODTD within 30 days of completion of testing. Radiographic

TCN Lot S/N Group

Non-destrutive Inspections &

Electrical Testing

(SOW section

3.1.2 excluding

3.1.2.2 and 3.1.2.9)

Environment Testing

(SOW section 3.1.3)

Post Environment

Electrical Testing

(SOW sections

3.1.2.1 to 3.1.2.6)

No-Fire Testing

(SOW section 3.1.2.9)

Ballistic Testing

(SOW

section 3.1.4)

Temperature (°F)

1 ESD07M008-001 A X X X X 70

2 ESD07M008-001 A X X X X 70

3 ESD07M008-001 A X X X X 70

4 ESD07M008-001 B X X X X -65

5 ESD07M008-001 B X X X X -65

6 ESD07M008-001 C X X X X 160

7 ESD07M008-001 C X X X X 160

8 SEB97G001-012 A X X X X 70

9 SEB97G001-012 A X X X X 70

10 SEB97G001-012 A X X X X 70

11 SEB97G001-012 B X X X X -65

12 SEB97G001-012 B X X X X -65

13 SEB97G001-012 C X X X X 160

14 SEB97G001-012 C X X X X 160

15 SDV01A001-018 A X X X X 70

16 SDV01A001-018 A X X X X 70

17 SDV01A001-018 A X X X X 70

18 SDV01A001-018 B X X X X -65

19 SDV01A001-018 B X X X X -65

20 SDV01A001-018 C X X X X 160

21 SDV01A001-018 C X X X X 160

inspection reports and copy of X-rays and N-rays shall be provided to NSWC/IHEODTD within 30 days of completion of testing.

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, and 3.1.4)

Within 2 days of completion of ballistic tests

Within 30 days of completion of ballistic tests

4.3 Deliverable Address.

The address for data is:

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 Repsentative:

Punit Dave, CODE E4PD 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:sameh.lotfy@navy.mil