Attachment A - CONSOL Station Requirement Final.docx

Attachment (A) - CONSOL

1. Vessel must be equipped within six months of delivery to perform Replenishment at Sea (RAS) operations (CONSOL only).

2. A total of three (3) RAS fueling stations shall be installed on the vessel. Two (2) RAS stations that can receive a fueling rig with a ROBB or NATO coupling during CONSOL operations are to be installed forward of the house on the starboard side in the fore and aft positions. The capability to perform the simultaneous transfer of up to two (2) different fuel products shall be met. Each station on the starboard side shall be capable of accepting two (2) ROBB or NATO coupling during Refueling at Sea (RAS). The port side station shall have one (1) Fuel Delivery Station (FDS) installed on the port side per Attachment (C).

3. Stations will be forward of the manifold (no more than half way between the forward tanks and manifold) and about similar distance between the manifold and the house (allowing sufficient room for safe working of cargo hoses, installation of hard points to accept span wire, etc.). Exact location, and either port or starboard, would be based on specific vessel configuration and in cooperation with Military Sealift Command (MSC) and Naval Surface Ware Center, Port Hueneme Division (PHD).

4. Reference CONSOL drawings 2227933A (attached), Standard RAS Receiving Station Arrangement and Requirements, shall be used as guidance for installing RAS stations. Only rigging and fittings for the ROBB and NATO coupling configuration shall be installed. Since the probe receiver will not be required onboard, item numbers 1,2,5,6, and 7 listed on the reference drawing are not required to be sourced or installed. Appropriate reference drawing number for swivel joint assembly, Item 3 and reference drawing 3 is 803-2213159G.

5. Swivel joint assembly shall be installed so that centerline of pivot is positioned iaw general notes 2 and 9 of drawing 2227933. Easing out line padeye, staple and cleat shall fabricated and installed/tested iaw general note 4 and drawing 6695696A. Eight-inch cleat shall be iaw drawing 804-2276338B. Riding line and jigger tackle fittings shall be installed per general note 7 and procedures/views on sheet 4 of drawing 2227933. Riding line and jigger tackle cleats, items 19 & 22, shall be iaw drawing 803-2554187A. Jigger tackle and link, item 21, shall be iaw drawing 571-2227936D, Detail M.

6. All ships structure, including deck handrails, must be clear of the space defined as the CONSOL station maximum holding range: 45 degrees forward and aft, measured from the receiving station swivel joint center line, plus 15 inch side clearance (past the +/- 45 degrees). This requirement is documented in NAVSEA S(AA)-AB-GOS-10/GSO, Section 571d holding range. Means to provide temporary lifelines are removed during operations must be provided iaw drawing 2227933A general note 8. Amount of removable handrail required for CONSOL operations determined by Plan View for ROBB fueling on sheet 4 of drawing 2227933A.

7. Design and install CONSOL station risers that meets the interface and location requirements shown in NAVSEA 2213794 Rev D. Interface flange to be 8 inch IPS in accordance with ASME B16.5. Location of flange face to be in accordance with “Locating Curve Plan View”, sheet 2 of NAVSEA drawing 2213794 Rev D. Riser height to be in accordance with NAVSEA drawing 2213794 Rev D sheet 1, Side Elevation; 48 +/- ½ inch from CL spanwire swivel assembly to CL of riser. Riser shall be designed to withstand a 24,000 lbs. pull without damage, as demonstrated through FEA. Engineering design and analysis shall be reviewed by PHD and/or MSC N7 Engineering representatives. Each rise shall be outfitted with a pressure gauge that can shall have a range a minimum range of 0-200psi and be visible to where the rigging team can safely see during operations.

8. Testing: Spanwire attachment point (NATO long link), connect a test wire and fairlead outboard at 30 degrees forward and 30 degrees above horizontal. Apply a test load of 36,000 pounds to the test wire. Repeat for 0 degrees forward and 0 degrees above horizontal, as well as for 30 degrees aft and 15 degrees below horizontal. All messenger inhaul padeyes to be tested to 9,000 pounds. Test easing out line padeye, staple and cleat to 5,300 lbs. as an assembly, use-drawing 6695696 as guidance. Test riding line and jigger tackle padeyes and cleats to drawing 2556869. All static test loads shall be applied for 10-minute duration. After testing is complete, all components shall be inspected to ensure no damage or permanent distortion has taken place. All testing to be witnessed by PHD and/or MSC N7 Engineering representatives. After testing is complete, engraved stainless steel test label plates shall be installed near the tested component. Label plates shall provide name of fitting tested, static test load, drawing number which test was accomplished iaw, test date and location of test. Label plates shall be mechanically installed to ship’s structure with a silicone sealant barrier between the plate and structure to prevent corrosion. Copies of test documents shall be kept on board the ship. Shipyard/contractor pull testing procedures should be sent to PHD for review and approval.

9. Develop and provide station specific, detailed rigging drawings with written procedures. Drawing shall provide views documenting how and where to connect all rigging components, and describe in procedures how to receive an UNREP fuel delivery rig in accordance with NTTP 4-01.4, Underway Replenishment. The rigging drawing shall contain a detailed list, with part numbers, of all required components to perform CONSOL operations. All drawings will be submitted for review by PHD and MSC N7 Engineering personnel.

10. Night lighting shall be provided at each CONSOL station with illumination levels as specified in DOD-HDBK-289 Lighting on Naval Ships, paragraph 4.6.4 and Table XVII, RAS Illumination Levels. Lights to be installed with amber lenses; ship to be provided with a set of interchangeable red lenses for darkened ship conditions. Additionally, 25 Watt hull blue contour lights be provided located at the fore and aft extremes of that portion of the side parallel to the keel and a third light located at the mid-point of the other two lights. Capable of being visible at a distance of 3000 FT and not more than 24,000 FT. If permanently mounted and wired to the ship, contour lighting system must have an emergency power source. If not permanently mounted to the ship, battery power is acceptable and a SMS procedure shall be provided to install and remove contour and station lighting.

11. Ships will provide means to pull over the UNREP messenger with a variable speed of up to 150 fpm (if two speed motor is used a minimum speed of 75 fpm) with rated load of 4,000 lbs. If messenger line is not a direct pull to winch, additional tested anchorage points shall be installed and tested for use. Messenger line padeyes can run to the mooring winch or a designated approved unrep messenger winch.

12. The owner provides actual RAS stations (hard point for the span wire, piping to the cargo system, etc.).

13. Reference NAVSEA S9AA0-AB-G0S-10/GSO, Section 571d for design criteria - Components associated with rigging such as pad eyes, fittings, blocks, sheaves, equipment, foundations, securing bolts, and supporting structure of each CONREP station shall withstand the combination of the design loads applied at the angles within the working or holding range that result in the most severe stresses. The design loads specified are the tensions in the lines as rigged for station operation. The combined stresses in components shall not exceed 35 percent of the yield strength of the material under rated load and subject to maximum ship actions resulting from Sea State 5 (moderate seas). The combined stresses in components shall not exceed 70 percent of the yield strength of the material under static test load. Under tight line conditions occurring with CONREP, design load is the wire rope breaking load, the factor of safety shall not be less than 2.25 based on the ultimate strength of the material used.”

14. All design criteria should be developed and provided to PHD for review and approval PRIOR to final design and or fabrication. Any stations that are pre-existing shall be subject to PHD inspection of the station layout and condition, as well as associated test/FEA documentation and station shall be modified, repaired, or re-tested as required by PHD.