KTM_Refurbishment_Statement_of_Work.pdf

STATEMENT OF WORK

FOR

WHITE SANDS MISSILE RANGE KINETO TRACKING MOUNT REFURBISHMENT

1.0 SCOPE

1.1 GENERAL

This Performance Work Statement (PWS) defines the requirements for the assessment and refurbishment of approximately five (5) Kineto Tracking Mounts (KTM) from White Sands Missile Range. The Customer, herein identified as White Sands Missile Range (WSMR), will supply original performance KTM specifications and/ or baselines and any other relevant maintenance history on the units to be processed by the Supplier. The Supplier shall refurbish those components not meeting, or marginally meeting specification. (“Marginal” performance implies that performance will soon degrade below specifications).

1.2 BACKGROUND

WSMR operates a fleet of optical tracking instruments. In order to provide high quality optical TSPI data, these instruments contain many precision subsystems that must be maintained in top condition. All of the subsystems require refurbishment and replacement of obsolete components in order to ensure the integrity of the TSPI data collected. Near factory delivery condition will be required to continue the reliable production of accurate TSPI information. Due to the age and harsh environments the instruments are experiencing severe deterioration. Many components of subsystems are obsolete and no longer readily supported by third party vendors. WSMR requires a refurbished fleet of optical mounts which support WSMR customers' requirements, to include providing optical TSPI data as well as event/attitude measurements.

1.3 QUANTITIES

The description and quantities of the components covered by this PWS follow.

(These quantities represent the total number of optical assets that may or may not be included in the final contract award)

Description Quantity White Sands Missile Range (WSMR) Kineto Tracking Mounts 5

1.4 SIZE AND WEIGHT SPECIFICATIONS

The physical dimensions of the KTMs with trailer and clamshell are 8’-5” W x 10’-0” H x 16’- 0” L. The combined weight of the mount, to include the trailer unit, is approximately 10,500 lbs.

2.0 APPLICABLE DOCUMENTS

2.1 GENERAL

Specific performance and manufacturing requirements may be difficult to obtain due to the extensive time since the mounts were originally delivered, the level of usage, and exposure to the environment. Current Government and industry best practices, standards, and specifications shall be applied to this task wherever applicable.

2.2 GOVERNMENT DOCUMENTS

None specified.

2.3 NON-GOVERNMENT PUBLICATIONS

Not applicable.

2.4 ORDER OF PRECEDENCE

In the event of a conflict between the text of this document and the references cited herein, the text of this document shall take precedence. Nothing in this document, however, shall supersede any applicable law and/or regulation unless a specific exemption has been obtained.

3.0 REQUIREMENTS

3.1 MEASURE AND TEST

KTMs will be made available to the Supplier for refurbishment and assessment as a package of five instruments to refurbish together.

Trailers are not considered as part of the basic refurbishment but are identified within the “Options” section.

3.2 REFURBISHMENT AND UPGRADE WORK FOR BASIC REFURBISHMENT A

1. The KTM pedestal, and the two outboard platforms, will be reconditioned and painted with the standard KTM paint color. The platform hardware will be replaced and the mounting surfaces will be de-burred.

2. The operator control console will be cleaned and painted. Repairs will be limited to replacing lights, switches, and gauges. Replacement of the joysticks is included.

3. The guide bridge and guide scope will be reconditioned and painted.

4. The operator seat will be replaced; the power mechanism will be inspected for proper functionality.

5. The azimuth and elevation axis bearings will be inspected and repaired or replaced as necessary. The bearings will be sent to the OEM for evaluation. The Supplier will notify WSMR contracting office of the estimated associated price and schedule impact prior to replacement or repair of the bearings. If replacement of the azimuth and elevation axis bearings is required, the costs for the repair or replacement will be reimbursed against a “Discovered Defects” contract line item.

6. The azimuth and elevation axis motors will be inspected and and repaired or replaced as necessary. The motors will be sent to the OEM for evaluation. The Supplier will notify WSMR contracting office of the estimated associated price and schedule impact prior to replacement or repair of the motors. If replacement of the azimuth and elevation motors is required, the costs for the repair or replacement will be reimbursed against the “Discovered Defects” contract line item.

7. The azimuth and elevation axis seals will be replaced.

8. The azimuth and elevation axis brake assemblies will be replaced. The brake switches will be replaced.

9. The azimuth and elevation stow pins, stow pin switches, stow pin blocks, and shock assemblies will be replaced.

10. The azimuth and elevation stop assemblies will be replaced.

11. The azimuth and elevation resolver and potentiometer will be replaced.

12. The inductosyn will be inspected and tested to ensure compliance to original specifications. Supplier will notify the customer of the estimated associated price and schedule impact prior to replacement or repair of the inductosyn. If replacement of the inductosyns is required, the costs for the repair or replacement will be reimbursed against the “Discovered Defects” contract line item.

13. All pedestal bubble levels will be replaced and the levels calibrated.

14. Leveling screws will be replaced.

15. Basic mount cables only will be replaced (motor power cables, inductosyn feedback cables, and safety cables). No customer or signal cables are included in this effort – review below for DCS and customer cabling options.

16. All screws, bolts and other applicable hardware will be replaced with 316 Stainless Steel hardware where feasible.

17. Supplier will perform an Acceptance Test according to the coordinated Acceptance Test Procedure to verify acceptable performance of the refurbish KTM. The ATP will be performed on the KTM and witnessed by the Customer or their designated representative. The customer may also elect to attend and witness significant test events at the supplier’s facility.

During test execution, procedures, equipment, and results shall be monitored to verify adherence to requirements contained in the PWS. Two hard copies of the completed ATP with documented results will be provided with the mount upon completion.

3.3 REFURBISHMENT AND UPGRADE WORK FOR BASIC REFURBISHMENT B

1. The KTM pedestal, the two outboard platforms, and the center platform will be reconditioned and painted with the standard KTM paint color. The platform hardware will be replaced and the mounting surfaces will be de-burred. Additionally, early generation instruments (00 series) will be refitted to the same configuration as current (200 series) model KTMs.

2. The azimuth and elevation axis bearings will be inspected and repaired or replaced as necessary. The bearings will be sent to the OEM for evaluation. The Supplier will notify WSMR contracting office of the estimated associated price and schedule impact prior to replacement or repair of the bearings. If replacement of the azimuth and elevation axis bearings is required, the costs for the repair or replacement will be reimbursed against a “Discovered Defects” contract line item.

3. The azimuth and elevation axis motors will be inspected and repaired or replaced as necessary. The motors will be sent to the OEM for evaluation. The Supplier will notify WSMR contracting office of the estimated associated price and schedule impact prior to replacement or repair of the motors. If replacement of the azimuth and elevation motors is required, the costs for the repair or replacement will be reimbursed against the “Discovered Defects” contract line item.

a. Early series KTM Magnadyne elevation motors will be replaced with the current series Kollmorgen motors.

4. The azimuth and elevation axis seals will be replaced.

5. The azimuth and elevation axis brake assemblies will be replaced. The brake switches will be replaced.

6. The azimuth and elevation stow pins, stow pin switches, stow pin blocks, and shock assemblies will be replaced.

7. The azimuth and elevation stop assemblies will be replaced.

8. The azimuth and elevation resolver and potentiometer will be replaced.

9. The inductosyn will be inspected and tested to ensure compliance to original specs.

Supplier will notify the customer of the estimated associated price and schedule impact prior to replacement or repair of the inductosyn. If replacement of the inductosyns is required, the costs for the repair or replacement will be reimbursed against the “Discovered Defects” contract line item.

10. All pedestal bubble levels will be replaced and the levels calibrated.

11. Leveling screws will be replaced.

12. Basic mount cables only will be replaced (motor power cables, inductosyn feedback cables, and safety cables). No customer or signal cables are included in this effort – review below for DCS and customer cabling options.

13. All screws, bolts and other applicable hardware will be replaced with 316 Stainless Steel hardware where feasible.

14. Supplier will perform an Acceptance Test according to the coordinated Acceptance Test Procedure to verify acceptable performance of the refurbish KTM. The ATP will be performed on the KTM and witnessed by the Customer or their designated representative. The Customer may also elect to attend and witness significant test events at the supplier’s facility.

During test execution, procedures, equipment, and results shall be monitored to verify adherence to requirements contained in this PWS. Two hard copies of the completed ATP with documented results will be provided with the mount upon completion.

3.4 OPTIONS

1. The original KTM was powered by an analog servo amplifier and provided encoder feedback for closed-loop control. WSMR’s current control system is designed to interface with this configuration but efforts are on-going to transition to a full digital control system. In order to provide continued operational support during the transition, it is imperative that any replacement electronics in the KTM provide both digital and analog interfaces. This option will shall provide all control electronics and all necessary cabling. WSMR intends to exercise 5 of these options.

2. Center Platform. This includes the transition from an operator’s console to a center platform configuration or the addition of a center platform where none currently exists.

3. Fabricate 2 new Outboard platform and installation on a KTM pedestal. WSMR intends to exercise one of this option.

4. Azimuth slip-ring configuration, that allows continuous azimuth rotation of the mount.

5. Fiber Optic Rotary Joint (FORJ), 6 channel single mode fiber. (Requires option 4)

6. The outboard mounting plates (2) will be replaced.

7. Spare control electronics for trailer only, no cables or other electronics.

8. Spare electronics for pedestal, not to include those in trailer.

3.5 Over and Above Items

1. Discovered defects for pedestal, trailer, motors, bearings, and inductosyns (items will be defined in a discovered defects report).

2. Modification of the operator console provided by the customer with azimuth and elevation encoder displays driven by the DCS.

3. Misc. engineering analysis or unknowns.

4. Shipping Costs.

3.6 ASSESSMENT AND RECOMMENDATIONS

The Supplier shall perform those tasks identified, negotiated, and scheduled in accordance with paragraphs 3.1 - 3.5, above.

3.7 CONDITIONS AND ASSUMPTIONS

KTM pedestals will be generally refurbished to the original specifications for the instrument unless instructed otherwise. Any wiring changes or cable configuration from those noted above will be quoted separately and may affect the proposed delivery date. Any defects that are identified with the incoming inspection or throughout the refurbishment/upgrade efforts, outside the scope of the PWS will be quoted separately. Option pricing is contingent upon the procurement of a standard KTM refurbishment/upgrade (Basic Refurbishment A or Basic Refurbishment B).

VERIFICATION PROGRAM The Customer shall verify performance under this contract by the means identified in the following paragraphs.

3.9 GENERAL PROVISIONS

Unless otherwise specified in this purchase order, the Supplier is responsible for the performance of all inspections. The Supplier may utilize his own facilities or any other facilities suitable for the performance of the inspection unless disapproved by the Customer. The Customer reserves the right to witness any of the inspections, if such inspections are deemed necessary, to assure that supplier and services conform to prescribed requirements. Customer reviews will be scheduled to not impede the Supplier from completing the required work in the targeted schedule.

3.10 TEST OVERSIGHT

The Customer may attend a significant test event (ATP) at the Supplier’s facility. During test execution, procedures, equipment, and results shall be monitored to verify adherence to requirements contained in this PWS. Customer reviews will be scheduled to not impede the Supplier from completing the required work in the targeted schedule.

3.11 MONITOR REPORTS

The Customer shall monitor performance of the contract through the review of monthly reports.

The Supplier will provide the Customer photographs to document the refurbishment progress.

4.0 DELIVERABLES

Defined by the final customer requirements and CLINS exercised.

4.1 STATUS REPORTS

Per unit Discovered Defects report will be generated after the initial baseline of each KTM describing cost and schedule recommendations. A monthly report will be provided to the Customer to include current technical progress, problems encountered, man-hours expended during the month, and schedule information. Reports shall be submitted electronically in Contractor formatted PDF Files.

4.2 FINANCIAL REPORTS

Monthly reports providing funds expenditure will not be required, since the contract is FFP.

4.3 TEST AND ANALYSIS REPORTS

Supplier will perform an Acceptance Test according to a coordinated Acceptance Test Procedure to verify acceptable performance of the refurbish KTM.

4.4 RECOMMENDATIONS, COST ESTIMATES, SCHEDULE

Cost and schedule estimates shall be completed on a unit by unit basis, as they are defined in paragraph 4.1.

4.5 REFURBISHED KTMS

The Supplier shall deliver refurbished KTMs in accordance with this PWS. Components that are removed from their host systems/chassis by the Supplier, to complete component refurbishment, will be reinstalled and realigned prior to final delivery.

5.0 SCHEDULE

Each refurbished KTM will be completed and ready for shipment in approximately nine (9) months after receipt of the KTM at the Supplier’s facility.

6.0 PAYMENT TERMS

Payments will be made upon completion of each KTM Refurbishment.

7.0 RESIDUAL MATERIAL

Following completion of the refurbishment process, i.e., upon completion of ATP and shipment, title to and ownership of any residual materials, not otherwise dispositioned by the Customer at such time, will vest in the Supplier.

8.0 WARRANTY

The Supplier shall provide a limited warranty for a period of twelve (12) months from date of acceptance of the KTMs. Supplier agrees to rework any goods found to contain harmful defects in material or workmanship, provided Supplier is notified of such defects within thirty (30) days of delivery of the KTMs.