www.nasa.gov national aeronautics and space administration ares i-x statement of work (sow) overview...

National Aeronautics and Space Administration

www.nasa.gov

Ares I-X Statement of Work (SOW) Overview Ares I-X Statement of Work (SOW) Overview

Monica Hoffmann

Industry Day

14 November 2007

Monica Hoffmann

Industry Day

14 November 2007

2National Aeronautics and Space Administration

Ares I-X Statement of Work Overview

Procurement Details

Three Commercial procurements planned Procurement 1 – RFQ release on or about 11/16/07 – Parts- US-7, IS-1 and SA Procurement 2 – RFQ release on or about 12/21/07 – Parts- IS-1 and US-1 Procurement 3 – RFQ release on or about 11/16/07 – Flange Face Machining

Approximately two weeks to submit proposals.

Fixed Price Contracts

Delivery incentives 1%/day award based on delivery.

Best Value Selection Technical Quality = Meet Specifications + Schedule + Quality Assurance Price Past Performance

The government to provide: All NASA specifications and documents Weld wire material Option for providing segment transportation cart.



Procurements 1 and 2:

Ballast Support Structure Parts

Protuberances:

RCS Covers OML (US-1)

Ullage Motors OML (US-1)

Camera OML (US-7)

UHF Antenna OML (US-7)

Simulated flange OML

Systems Tunnel OML

Liquid Hydrogen OML

Ballast Segments US-7 and US-1



Protuberances


Ballast Segments US-7 and US-1

Ballast Support Structure Parts Overview



Service Module Segment

16.5 foot diameter

100 inches tall

approximate mass: 11,300 lbs

Procurements 2 and 3:

RCS thruster protuberances

SM Flange Face machiningOML protuberances for RCS thrusters



ECS Panel

I-beam support structure; A36 Steel

All Booster Deceleration Motors (BDMs), eliminated - moved to first stage.

RoCS Doublers (welded to IS-1 skin) Cutout size:52.56 high X 49.93in wide

T STRINGER(3 pieces)

www.nasa.gov

Access Door and internal Access Door Doubler (welded to IS-1 skin).

ECS Panel

IS-1 Floor (2 sections)

Ladders (4)

IS-1 Procurements 1, 2 and 3

Flange Face Machining

117” tall x 18’ diameter

Approx. mass = 28,000lbs


IS-1 Access Hatch Assembly

Welded halves

38 Self-locking nut plates, NASM21060-6W or –L6W



Spacecraft Adapter Conical Skin

Steel Grade A70, ½” thick skin Rolled and welded Conical Shape Skin-with diameter transition of18 ft (216.5”) to 16.5 ft (198 “) 114 inches tall approximate mass = 13,000lbs



Requirements The contractor shall develop a technical plan (schedule) laying out

tasks, durations, and dates for task completion with their proposal/quote. Updates to the schedule shall be provided for changes affecting the deliverables.

The contractor shall provide a Quality Plan with their proposal. The contractor shall machine the SM and IS-1 flange faces and provide

the parts per SOW Appendix D Parts Summary and Delivery Schedule and the following requirements: as specified on the NASA Drawings. Free of nicks, cuts, scratches, burrs, dirt, grease and/or oil prior to delivery Provide packing for the completed components to prevent any damage during all

phases of manufacturing and handling, including transportation from the Contractor’s plant to NASA Glenn Research Center

The contractor shall mark the parts as follows: The contractor shall identify all parts as specified on the NASA Drawings. The contractor shall prepare and paint the components as required per Appendix D

and as indicated on the drawing, on all surfaces in accordance with the SSPC SP6 preparation standard, a 2-3 layer (corrosion resistant primer and top coat as specified in the drawing at a minimum) paint system sufficient to withstand ~2 years use (GRC/KSC environment), and with FED-STD-595 and as specified on the NASA Drawings.



Requirements continued

The contractor shall prepare samples and submit inspection results of sample welds representing all Class A welds in accordance with ARES I-1-REQ-061, no later than 2 weeks prior to fabrication for government approval to proceed.

The contractor shall provide during fabrication the written weekly status based on their schedule electronically (email and/or Microsoft Word) including: Status on the purchasing and delivery of the materials and commercial items; and

status of obtaining any required permits. Percentage of completion of the fabrication. Brief summary of work completed during the week. Any problems or concerns with suggested resolutions and potential delays in the

Deliverable Items. Non conformance to specified inspections; non conformances shall be also

transmitted per verification requirements in SOW appendix A.

The contractor shall support the following plant visits by the government: within two weeks after the award of the contract, to review inspection and

fabrication facilities and Quality Assurance processes. prior to final welding (at fit-up and tack phase) of parts with Class A welds. During SM and IS-1 segment handling at the contractor facility. Government inspections for part acceptance may take place at the contractor

facility.



Verification Requirements Inspection – Dimensional inspections of all hardware at the

contractor’s site and in accordance with AMSE Y14.5M-1994 “Geometric Dimensioning and Tolerancing.

Full volumetric nondestructive examination (NDE) of critical welds to follow requirements of GRC-ARES I – 1-REQ-061. All NDE reports are to be delivered to and reviewed by NASA GRC

prior to acceptance of the component.

Any non-conformances and disposition/corrective actions developed in accordance with GRC-ARES I-1-REQ-061 shall be included in the weekly status submitted to the government. Any non-conformances that are not correctable in accordance with REQ-061, shall be reported to NASA, GRC for reporting and disposition through Ares I –X Material Review Board.



Quality Assurance Requirements The contractor shall provide a quality plan with their proposal.

The contractor is not given Material Review Authority. All changes proposed by the contractor, as well as acceptance of any nonconforming product are at the discretion of the ARES-I-X project team alone.

NASA/GRC reserves the right to perform a Pre-award Survey at the contractor’s facility if deemed necessary.

NASA/GRC reserves the right to perform an on-site visit to review manufacturing operations and, or product status after notification of the contractor.

Acceptance shall be after verification of the finished product by NASA/GRC. This may be performed at the contractor’s facility prior to shipment to NASA/GRC, or at NASA GRC at NASA discretion.

For the purpose of this contract, any or all site visits may be performed by NASA or a NASA authorized third party contractor acting as NASA’s agent. If a NASA contractor is used, they shall be given the access to the contractor’s facility necessary to perform the function as required by NASA under this contract.



Flange Face Machining - Unique Requirements1. Service Module Simulator: a. Machine top flange and drill holes per drawing – 060213MFA701 b. Deliver CNC machine files for the flange bolt holes.

2. Interstage Simulator-1 Machine bottom flange per Drawing (TBD- to be made available

January, 2008) as follows: a. Flatness requirement : The IS-1 bottom flange will be machined with a maximum out-of-

flatness tolerance of 0.010” in the restrained condition. In addition, the machined flanges will have a local flatness tolerance of 0.005" over a 10º sector.

b. There will be 180 equally spaced holes, 120 will be for tension bolts and have a clearance hole .745 - .755 inches, the other 60 holes will be .000 - .005 inch clearance and .625 - .630 inch diameter on a 213.00 inch bolt circle.

c. Three alignment holes are required 1.120 - 1.130 in. diameter located on a 208 inch bolt circle at the 0°, 130°, and 230° positions.

d. Deliver: CNC machine files for the flange bolt holes.



Space Craft Adapter - Unique Requirements

1. As shown in NASA Drawing 060213MFA701, vendor shall quote only the rolled outer straight cone skin without the top and bottom flanges welded to the outer skin.

The vendor shall use the NASA Drawing 060213MFA931 for the weld prep of the outer straight cone skin welding and use NASA Drawing 060213MFA932 to prep the top and bottom edges of the outer skin. No gussets as shown in views “Detail E, F, G, and H shall be required.

Vendor shall fixture and/or brace the finished SA Assembly, so that during manufacturing, handling and shipping to NASA Glenn the SA Assembly shall conform to the dimensions as specified on the NASA Drawing.

All certification of conformance, inspection and NDT reports and weld documentation as specified on the drawings will be required.

The Vendor shall note the top diameter dimension of the SA Assembly as shown on NASA Drawing 060213MFA701 [198.00”] shall be changed to read, [198.125” – 197.875”]


Parts Procurement US-7 and IS-1 Delivery Schedule

Deliverables Date(s) (on or before)

Technical Plan / updates Initial with proposal; updates with changes affecting deliverables

Quality Plan With proposal

Certifications

1. Conformance for all type materials as specified on drawings; certified materials test report

2. Conformance for all type weld material as specified in contractor welding process and the ARES I-1-REQ-061

3. Conformance for all paint as specified in requirements

No later than 2 weeks prior to start of fabrication.

Inspection results of sample welds No Later Than 2 weeks prior to start of fabrication.

Parts Per Appendix D

Final inspection results of parts 1 week prior to shipment of corresponding unit

Documentation of procedures / specifications No later than 2 weeks prior to the start of fabrication.

Status Weekly (Friday of each week)

Note: All documentation deliverables shall be in Microsoft Word


SM and IS-1 Flange Face Machining Delivery Schedule

Deliverables Dates) (on or before)

Technical Plan / updates Initial with proposal; updates with changes affecting deliverables

Quality Plan With proposal

Segment Handling and Lifting Plan SM segment: With ProposalIS-1 segment: within 1 week of IS-1 drawing receipt.

Permits as required Prior to Segment pickup from NASA GRC

SM Simulator Dec 21, 2007 SM available at GRCJan 11, 2008 SM complete - delivered to GRC

SM CNC Files Within 1 week prior to shipment of corresponding unit

IS-1 Simulator May 1, 2008 IS-1 available at GRCMay 13, 2008 IS-1 complete- delivered to GRC

IS-1 CNC Files Within 1 week prior to shipment of corresponding unit

Final inspection results of parts Within 1 week prior to shipment of corresponding unit

Status Weekly (Friday of each week)

Note: All documentation deliverables shall be in Microsoft Word


What Happens after Today?

Government will revise SOW based on feedback / discussions / questions

Drawing package to be updated (some parts in draft may not be included in the final package; may include some new parts that were not in the draft SOW.)

Anticipate a final request for quote go out at the end of this week or early next week.

Proposals due back in approximately 2 weeks (11/29/07).

Anticipate award by 12/7/07.

National Aeronautics and Space Administration

www.nasa.gov

ARES I-X Industry DayQuality RequirementsARES I-X Industry DayQuality Requirements

Tim Gaydos

November 14, 2007

Tim Gaydos

November 14, 2007


ARES I-X Quality Requirements

100% inspection with actuals recorded

No MRB authority – all nonconformances requiring repair or “use-as-is” disposition requires NASA approval

Material Traceability Starts with purchasing Certificate of Conformance – document signed by supplier affirming

product meets relevant specifications Manufacturer’s Test Report (MTR) – document produced by

manufacturer certifying information required by applicable specifications. Usually includes lot number, manufacturing date, lot quantity, raw material heat number, chemical composition (actuals), and mechanical/metallurgical test results (actuals).

Government Furnished Material (GFM) – needs segregation and control Traceability – documentation demonstrating solid chain from

manufacturer through all distributors to buyer. Must be specific to lot/material purchased.



Standard Quality Requirements

Independent quality function

Configuration Control – emphasis on control of customer changes and production process changes

Control of nonconforming material

Customer communication

Receiving inspection



Welding Requirements from ARES Qualified Welders Approved Welding Procedure Specifications traceable to an approved

Procedure Qualification Record

Weld Inspection NDE personnel shall certified per to NAS 410 Level II Level III for approved inspection procedures Certified Weld Inspector (CWI) per AWS QC1

Weld Inspections depend on weld Class Class A welds require volumetric, surface (per layer) and visual

inspections (per pass)



BACKUP SLIDES



Procurement Item Fabrication or Machining

Painting Required (Y or N)

Class A Weld (Y or N)

Drawing Number Part Quantity

Required Delivery Date

IS-1 ComponentsROCS DOUBLER WELDMENT FandM N Y

060213MFA103 22/23/2008

ACCESS HATCH DOUBLER WELDMENT

FandM N Y060213MFA105 1

2/23/2008

ROCS LIFT PLATE WELDMENT FandM N Y 060213MFA104 2 2/23/2008

ECS PANEL WELDMENT F N Y 060213MFA116 1 2/15/2008I BEAM (LONG) F N N

060213MFA108 12/1/2008

I BEAM (MEDIUM) F N N060213MFA109 2

2/1/2008

I BEAM (SHORT W/ CUTS) F N N060213MFA110 2

2/1/2008

I BEAM (SHORT W/O CUTS) F N N060213MFA111 2

2/1/2008

BULKHEAD, SHORT F N N060213MFA112 2

2/15/2008

BULKHEAD, LONG F N N060213MFA113 1

2/15/2008

ACCESS HATCH COVER ASSEMBLYF N N 060213MFA106 1 2/15/2008

SPACECRAFT ADAPTER SKIN F N Y 060213MFA701 1 1/25/2008

Ares1-X Fabrication Procurement 1

Parts Summary and Delivery Schedule



Procurement Item Fabrication or Machining

Painting Required (Y or N)

Class A Weld (Y or N)

Drawing Number Part Quantity

Required Delivery Date

US-7 Components

RIGHT ANGLE CLIP F N N 060213MFA604 8 11-Jan-08OD ROLLED ANGLE F N N 060213MFA612 10 11-Jan-08ID ROLLED ANGLE F N N 060213MFA613 8 11-Jan-08OD ROLLED ANGLE SHORT F N N 060213MFA642 4 11-Jan-08

Gratings for US-7 and US-1 F 11-Jan-08GRID PLAIN PLATFORM CHANNEL F N N 060213MFA622 4 11-Jan-08GRID PLATFORM SUPPORT TAB A F N N 060213MFA623 4 11-Jan-08GRID PLATFORM SUPPORT TAB BF N N 060213MFA624 4 11-Jan-08

GRID THRU PLATFORM CHANNEL F N N 060213MFA627 4 11-Jan-08GRID CHANNEL A F N N 060213MFA628 12 11-Jan-08GRID CHANNEL B F N N 060213MFA629 4 11-Jan-08GRID CHANNEL C F N N 060213MFA630 4 11-Jan-08 GRID PLATFORM ANGLE F N N 060213MFA631 8 11-Jan-08

STEEL GUSSET SIDE F N N 060213MFA632 8

11-Jan-08

STEEL GUSSET WALKWAY TOPF N N 060213MFA633 2 11-Jan-08 STEEL GUSSET DFI WALKWAY TOPF N N 060213MFA634 1 11-Jan-08 STEEL GUSSET ECS WALKWAY TOPF N N 060213MFA635 1 11-Jan-08 STEEL GUSSET PLATFORM ANGLE AF N N 060213MFA636 16 11-Jan-08 STEEL GUSSET PLATFORM ANGLE BF N N 060213MFA637 16 11-Jan-08 STEEL GUSSET ECS WALKWAY BOTTOMF N N 060213MFA638 1 11-Jan-08 STEEL GUSSET WALKWAY BOTTOMF N N 060213MFA639 2 11-Jan-08 STEEL GUSSET DFI WALKWAY BOTTOMF N N 060213MFA640 1 11-Jan-08 BALLAST BEAM CLOSEOUT PLATE THRUF N N 060213MFA644 4 11-Jan-08

Ares1-X Fabrication Procurement 1Parts Summary and Delivery Schedule


GFE

Dual Shield Certified FCAW Weld Wire, E71T-1M / E71T-12M Each Spool weighting 33 lbs. Wire diameter .045

Segment Cart may be provided Approximately 12, 000 lbs; 27 inches tall and 18 ft diameter Equipped with single- or dual-wheel casters, depending on the weight

of the segment that will be mounted to it. cart with single-wheel casters weight limit = 24,000 lb, cart with dual-wheel casters weight limit = 48,000 lb.



Quality Assurance Requirements The contractor shall provide a quality plan detailing the processes and procedures that

will be used in the performance of this procurement. If the contractor is ISO 9001 or AS9100 certified, the certification detailing approved operations should be included with the plan. The contractor may use existing Quality Plans/Quality Manual or procedures, as appropriate, already in place to meet this requirement.

As a minimum, the plan shall address the following: Configuration Management including control of customer changes Nonconforming control, corrective and preventive actions Material identification and traceability including Material Test Reports or Certificates of

Conformance, as required. Calibration control of measuring and test equipment including traceability of standards to

the National Institute of Standards and Technology for applicable tolerances measuring 0.010” and smaller

Control of Government Furnished Material Inspection planning Initial Quality planning Subcontractor controls Receiving inspection All final inspection shall be 100% and actual inspection results shall be recorded for each

unit unless directed otherwise. Special process procedures Preservation, packaging, handling and shipping procedures Training records of special processes certified employees

www.nasa.gov national aeronautics and space administration ares i-x statement of work (sow) overview...

Documents

parts us

camera oml us

high x

ullage motors oml us

uhf antenna oml us

delivery schedule

nasa specifications

nasa drawings