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ATTACHMENT J-1

SPECIFICATIONS

FOR

Near Coastal Patrol Vessel

(NCPV)

FOREIGN MILITARY SALES

21 31 October 2016

Department of the Navy Program Executive Office, Ships Washington, DC 20376

Contract No: N0002417R2201 Contract No. N0002417R2201

MKV-PB Specifications Use or disclosure of data contained on this sheet is subject to restriction on the Title Page of this proposal.

TABLE OF CONTENTS

SECTION 042GENERAL ADMINISTRATIVE REQUIREMENTS11
042.1General11
042.2Definitions11
042.3Referenced Documents12
042.4Purchase Orders12
042.5Inspections12
SECTION 045CARE OF CRAFT13
045.1General13
045.2Machinery and Equipment13
045.3Running Aground13
045.4Mercury Restriction14
SECTION 070REQUIREMENTS FOR DESIGN AND CONSTRUCTION14
070.1Required Characteristics14
070.2Design Operational Profile15
070.3Environment15
070.4Craft Mission Requirements15
070.5Service Life15
070.6ABS Involvement16
070.7SOLAS and Safety Equipment16
070.8Weight and Stability Limits16
070.9General Requirements for Equipment, Machinery and Materials17
070.10Installation of Equipment, Machinery and Materials18
070.11Workmanship19
070.12Corrosion Control20
070.13Foundation Design21
070.14Tolerances21
SECTION 071ACCESS21
SECTION 073NOISE, VIBRATION AND RESILIENT MOUNTINGS22
073.1Noise Levels22
073.2Vibration23
073.3Resilient Mountings23
SECTION 074WELDING, CASTING AND ALLIED PROCESSES24
074.1 Structural Welding24
SECTION 075THREADED FASTENERS25
SECTION 076RELIABILITY AND MAINTAINABILITY25
SECTION 077SAFETY25
077.1General25
077.2System Safety Program Requirements26
077.3Safety Design Precedence27
SECTION 078MATERIALS27
SECTION 083ON-BOARD SPARE PARTS, TOOLS AND CONSUMABLES30
SECTION 084TRANSPORTATION AND HANDLING30
SECTION 085DRAWINGS AND CALCULATIONS30
085.1General30
085.2Drawing & Calculations Practices32
085.3Drawing Index33
085.4Arrangement Drawings33
085.5Structure and Structural Details Drawings36
085.6Machinery Drawings37
085.7Electrical, Electronic, and Interior Communications Drawings39
085.8Lines and Offsets Drawings42
085.9Curves of Form Drawings43
085.10Hoisting Drawing44
085.11Docking Drawing45
085.12Labels Drawing46
SECTION 091INSPECTIONS46
SECTION 092TEST AND TRIAL ADMINISTRATION47
092.1General Requirements for Testing and Trials47
092.2Testing and Trial documentation48
092.3Material, System, and Equipment Testing Requirements50
SECTION 094TRIALS60
094.1General60
094.2Safety During Trials62
094.3Dock Trials62
094.4Builders Trials63
094.5Propulsion Trials63
094.6Acceptance Trials64
SECTION 096WEIGHT72
096.1Definitions of Load Conditions72
096.2Weight Management Plan73
096.3Weight Control and Reporting74
096.4Determination of Weights74
SECTION 097INCLINING EXPERIMENT75
097.1General75
SECTION 100HULL STRUCTURE76
100.1General76
100.2Hull and Deckhouse Materials77
100.3Tolerances for Structure77
SECTION 117FRAMING FOR SHELL PLATING77
SECTION 130DECKS AND FLATS77
SECTION 150DECKHOUSE STRUCTURE78
SECTION 167DOORS, HATCHES, SCUTTLES, MANHOLE COVERS AND OTHER CLOSURES78
SECTION 170MASTS AND FLAGSTAFFS79
170.1Main Mast79
170.2Ensign and Jack Staff79
SECTION 200MACHINERY PLANT80
SECTION 233PROPULSION DIESEL FUELED ENGINES80
233.1General80
233.2Propulsion Plant Power Rating, Corrections and Reserve Capacity81
233.3Shields and Guards81
SECTION 241PROPULSION REDUCTION GEARS81
SECTION 242PROPULSION SYSTEM FLEXIBLE COUPLINGS82
SECTION 243PROPULSION SHAFTING82
243.1General82
243.2Mounting and Dismounting Equipment and Procedures82
SECTION 244PROPULSION SHAFT BEARINGS83
244.1General83
244.2Bearing Cooling and Purging83
SECTION 245PROPELLERS83
245.1General83
245.2Propeller Design84
245.3Propeller Material and Manufacturing84
SECTION 251COMBUSTION AIR SYSTEM85
SECTION 252PROPULSION CONTROLS AND MONITORING85
252.1General85
252.2Helmsman Controls and Monitoring85
252.3Local Control86
252.4Engine Diagnostic Laptop (If Option is Exercised)87
SECTION 256COOLING SYSTEM87
SECTION 259EXHAUST88
259.1General Requirements88
259.2Exhaust System Materials89
259.3Exhaust System Insulation90
259.4Generator Exhaust System90
SECTION 262LUBRICATION OIL CHANGE SYSTEMS90
SECTION 300ELECTRICAL PLANT92
300.1General92
300.2Protection of Personnel93
300.3Bonding Requirements93
300.4Equipment Enclosures and Protection94
300.5Electrical Equipment Installation94
300.6Load Analysis95
SECTION 303PROTECTIVE DEVICES FOR ELECTRIC CIRCUITS96
SECTION 304ELECTRIC CABLE AND WIRING96
304.1General96
304.2Selection of Cable and Wire97
304.3Installation98
304.4Connections100
SECTION 305ELECTRIC DESIGNATION AND MARKING101
305.1General101
305.2Equipment Designation and Marking102
305.3Power and Lighting Circuits104
305.4Control System Circuits105
305.5Interior Communications Circuits106
305.6Electronic Circuits107
305.7Label Plates107
305.8Cable Tags and Conductor Marking107
SECTION 310ELECTRICAL PLANT108
310.1Propulsion and Generator Engine Driven Alternators108
310.2Generator Sets109
SECTION 313STORAGE BATTERIES110
313.1General110
313.2Installation110
SECTION 314POWER CONVERSION EQUIPMENT111
314.1General111
314.2Transformers111
314.312 Volts Direct Current (VDC) Power (As Required)111
314.4Battery Charging112
314.5Installation112
SECTION 320ELECTRIC POWER DISTRIBUTION SYSTEM113
320.1General113
320.2Systems Reliability113
320.3AC Power Distribution System113
320.4DC Power Distribution System114
SECTION 324ELECTRIC POWER CONTROL AND DISTRIBUTION PANELS115
324.1Power Distribution Panels115
324.2Switchboards115
SECTION 330LIGHTING SYSTEMS117
330.1General117
330.2Illumination Requirements117
331.3Emergency Lighting118
331.4Darken Ship Lighting118
331.5Searchlights118
331.6Floodlighting118
331.7Deck Lighting119
SECTION 400NAVIGATION AND COMMUNICATIONS SYSTEMS120
SECTION 405ANTENNA INSTALLATION121
SECTION 420ELECTRICAL NAVIGATION SYSTEMS121
420.1General121
420.2Horn & Light122
SECTION 421NON-ELECTRONIC NAVIGATION AIDS122
SECTION 422NAVIGATION LIGHTING SYSTEM123
422.1General123
422.2Navigation Lights123
SECTION 428ANEMOMETER123
SECTION 430INTERIOR COMMUNICATIONS SYSTEMS123
430.1Interior Communications System123
430.2Loud Hailer System124
SECTION 436ALARM, WARNING AND SAFETY FEATURES124
436.1General124
436.2Monitoring, Alarm, and Warning Points125
436.3Alarm Control Panel125
SECTION 437TANK LEVEL INDICATING SYSTEMS125
SECTION 440EXTERIOR COMMUNICATIONS126
SECTION 450Electro-Optical Infrared Sensor (If Option is Exercised)126
SECTION 500AUXILIARY SYSTEMS127
SECTION 503PUMPS127
SECTION 504INSTRUMENTS AND INDICATORS127
SECTION 505PIPING127
505.1General Installation127
505.2Materials128
505.3Fittings (General)130
505.4Hoses and Flexible Piping Devices (General)131
505.5Valves (General)131
505.6Vents and Drains131
505.7Sealing Compound131
505.8Hull Connections for Water Discharge132
505.9Thermal and Anti-Sweat Insulation132
SECTION 508GUARDS133
SECTION 512FORCED AIR VENTILATION SYSTEMS133
512.1General133
512.2Engine Room Ventilation133
512.3Auxiliary Room Ventilation134
512.4General Unmanned Spaces Ventilation134
SECTION 514HEATING AND AIR CONDITIONING134
514.1General Design134
514.2Ducting135
514.3Galley Exhaust Hoods and Fans136
514.424 VDC Fans136
SECTION 521FIRE MAIN SYSTEM136
SECTION 528PLUMBING FIXTURES AND FITTINGS137
SECTION 529MAIN DRAINAGE SYSTEM137
529.1General Requirements137
529.2Bilge Alarms138
529.324 VDC Portable Electric Bilge Pump138
SECTION 533POTABLE WATER SERVICE SYSTEM138
533.1General138
533.2Potable Water Service138
533.3Water Maker139
533.4Potable Water Tank139
533.5Water Heater139
533.6Hose139
533.7Disinfection139
SECTION 541FUEL SYSTEM140
541.1General140
541.2Fuel Service System140
541.3Tanks141
541.4Valves and Emergency Fuel Shut-off141
541.5Fills, Vents, and Sounding Tubes141
541.6Tank Stripping142
541.7Transfer System142
SECTION 555FIRE FIGHTING SYSTEMS142
555.1General142
555.2Fixed Fire Extinguishing Suppression System142
SECTION 561STEERING SYSTEM144
561.1General Requirements144
561.2Steering Gear144
561.3Steering Angle Indicator System145
SECTION 562RUDDER145
562.1Rudders145
562.2Rudder Stop145
562.3Bearings145
SECTION 581ANCHOR STOWAGE AND HANDLING145
SECTION 582DECK FITTINGS146
SECTION 583BOAT BOARDING SYSTEM146
583.1RHIB146
583.2RHIB Trailer147
583.3Gasoline Stowage Rack149
583.4Launch and Recovery Winch149
SECTION 584TOWING149
SECTION 593ENVIRONMENTAL POLLUTION CONTROL SYSTEMS149
593.1Sewage Collection, Holding and Transfer System149
593.2Oil Pollution Prevention Measures150
593.3Garbage Pollution Prevention151
SECTION 600OUTFIT152
SECTION 602HULL & SYSTEM DESIGNATION AND MARKING154
602.1General154
602.2Label Plates, Warning Signs, and Operating, Instruction154
602.3Pipe Marking154
602.4Cable and Conductor Marking155
602.5High Voltage155
602.6Builder’s Plaque156
602.7Ship’s Identification156
602.8Compartment Identification156
SECTION 603DRAFT MARKINGS156
603.1General156
603.2Numerals156
603.3Bench Marks156
603.4Location157
603.5Painted Waterline157
603.6Establishment of Draft Marks157
SECTION 604LOCKS, KEYS AND TAGS157
604.1General157
604.2Padlocks157
604.3Key Tags157
604.4Safe158
SECTION 612RAILS, STANCHIONS, AND LIFE LINES158
SECTION 620BULKHEADS, PARTITIONS AND OTHER FINISHES158
SECTION 623LADDERS AND FLOOR PLATES159
SECTION 625WINDOWS AND AIRPORTS159
625.1General159
625.2Windshield Wipers159
SECTION 631PAINTING AND DECK COVERING159
631.1General159
631.2Boot top160
631.3Touchup painting160
631.4Steps and rungs160
SECTION 633CATHODIC PROTECTION160
SECTION 635INSULATION AND ACOUSTICAL TREATMENT OF COMPARTMENTS160
SECTION 640REQUIREMENTS FOR LIVING AND BERTHING SPACES161
640.1Officer Staterooms161
640.2Crew Berthing Spaces161
SECTION 644SANITARY SPACES AND FIXTURES161
SECTION 651GALLEY AND MESS SPACES162
651.1General162
651.2Galley162
651.3Mess Room163
SECTION 652MEDICAL LOCKERS163
SECTION 663PILOT HOUSE AND FLY-BRIDGE FURNISHING163
SECTION 671LOCKERS AND SPECIAL STOWAGES164
671.1General164
671.2Stowage Lockers164
671.3Damage Control Locker164
SECTION 700ARMAMENT INSTALLATION166
700.1General166
700.2Weapon Foundations166
700.3Ready Service Lockers166
700.4Weapon and Ammunition Stowage166
APPENDIX A – Exceptions and Clarifications to ABS HSNC168

NCPV Specifications ii Use or disclosure of data contained on this sheet is subject to restriction on the Title Page of the proposal.

SECTION 042GENERAL ADMINISTRATIVE REQUIREMENTS
042.1General

These Specifications describe the general requirements of the aluminum hull Near Coastal Patrol Vessel (NCPV) and describe the essential features, functions and arrangements, but not necessarily the details of the design.

When subcontractors and vendors are utilized by the Contractor, the Contractor shall remain responsible for compliance with all requirements of this Specification.

With respect to materials of construction and items of machinery, equipment and outfit items (which by their nature may be manufactured or procured as distinct items), these Specifications contain only the requirements and information that pertain to selection, installation, on board performance and tests by the Contractor.

042.2 Definitions

Drawings: Drawings prepared to commercial standards on Contractor’s Title Block to the level of detail required by the Contractor’s Production Department.

Specifications: These Specifications that describe the essential technical requirements of the NCPV, its materials or performance, including the procedures by which it will be determined that the requirements have been met.

The Contractor will be the Prime Contractor awarded the contract for design and construction of the NCPV.

The Purchaser, Customer or Buyer is NAVSEA.

The Technical Representative and ABS Naval Administrator is Naval Surface Warfare Center - Carderock Division (NSWCCD) Detachment Norfolk who represents NAVSEA on all technical matters.

Industry and commercial documents: Where industry standards are referred to for a specific item, the issue or revision in effect on the date of the contract shall apply. Where good shipbuilding standard is described, Contractor’s standards for construction of similar craft are acceptable, except where ABS requirements concerning this project prevail.

ABS and HSNC are abbreviations for American Bureau of Shipping and their Rules for Building and Classing High Speed Naval Craft.

042.3 Referenced Documents

In the event of a conflict between the text of this Specification and the references cited herein, the text of this Specification takes precedence. In cases where additional requirements in references cited herein constitute additional details or features, which violates the specified performance, then it shall be considered a conflict. Nothing in this Specification, however, supersedes applicable laws and regulations unless a specific exemption has been obtained.

In case of conflict between requirements in referenced documents at the same tier, the more stringent requirement shall take precedence.

042.4 Purchase Orders

A purchase order index and copies of all purchase orders and changes thereto shall be furnished. Purchase orders shall not incorporate requirement of these Specifications by reference but shall expressly quote the applicable requirements in the purchase documents.

042.5 Inspections

The Contractor shall allow designated Government representatives to monitor all aspects of construction of the boat for the purpose of ensuring compliance with the contract. During the life of the contract, the Purchaser or his Representative shall have access to the boat for inspection during working hours or outside of normal working hours when 24 hour notice is provided.

SECTION 045CARE OF CRAFT
045.1General

All parts of the craft shall be maintained in a satisfactory condition during the entire period the craft is in the Contractor’s possession. During construction all debris, refuse, dirt, and water shall be removed frequently. Tanks and voids shall be cleaned and pass Purchaser’s inspection before being closed. Rubbish shall be removed from places that are to be permanently closed or which may become inaccessible. Appropriate measures shall be taken to prevent wear and damage incident to construction and to prevent corrosion or other deterioration, especially to unpainted, polished and moving parts. Piping, machinery and equipment subject to freezing shall be kept drained during freezing weather, except during trials and tests.

Equipment, prefabricated parts, and furnishings shall be kept clean and protected from the environment when stored prior to installation.

045.2 Machinery and Equipment

The Contractor is responsible for the care of all machinery and equipment whether furnished by the Contractor or by the Purchaser. All parts, especially those having working surface, passage or piping for lubricating oil shall be kept clean and protected at all times. Electrical and electronic equipment and machinery shall at all times be protected against dust, moisture or other foreign matter and shall not be subjected to rapid temperature changes or extremes in temperatures.

All preservative applied by the manufacturer shall be left intact (or replaced if necessary) until installation of machinery or equipment on the craft. If removal of the preservative is necessary for testing of the machinery or equipment prior to installation, the Contractor shall re-preserved and protect the machinery or equipment until installed. All preservatives in working parts shall be thoroughly removed prior to operation of the machinery or equipment.

045.3 Running Aground

Precautions shall be taken to prevent the craft from going aground. Precautions shall include means to provide for safety of the crew if the craft is run aground. In the event the craft is grounded, the Government shall be notified promptly and a thorough inspection for damage shall be conducted. The craft shall be removed from the water for inspection if requested by the Government.

045.4 Mercury Restriction

Mercury, either undiluted or in solution in as small a proportion as one part per million, will cause severe corrosion of aluminum. The Contractor shall protect the craft and the materials used in its construction from contamination. Mercury and mercury compounds shall not be stored or carried aboard the craft. The Contractor shall restrict the use of mercury aboard the craft to mercury or mercury compounds contained in components and which are required for the component to operate properly. Components containing mercury that may be used include florescent lights, mercury batteries and permanently installed instruments, sensors and controls specifically required by these Specifications.

SECTION 070REQUIREMENTS FOR DESIGN AND CONSTRUCTION
070.1Required Characteristics
Length, Overall (molded)Nominally 23-26m (75-85 ft)
Beam, MaximumNominally 5.8-6.7m (19-22 ft)
Range*,500 NM
Speed, Max (calm water)**25 knots
Speed, Minimum Cruise**12 knots
Endurance4 days
PropulsionTwo (2) fixed pitch propellers
Diesel Engines, Mains and GeneratorsCaterpillar
Electrical System24 volt DC & 220 volt AC Three Phase, DELTA, 60 Hz
CrewSix Enlisted in 1 room, Four Officers in 2 rooms

*Range is measured at cruise speed with a 10% fuel reserve.

**In the Full Load Condition

070.2 Design Operational Profile

The craft and systems shall be designed for the following operational profile. This operational profile shall be within the limits of the engines based on engine manufacturer recommendations:

Slow Speed/Loitering
50%
Cruise Speed
35%
Maximum Speed
15%

070.3 Environment

The Craft shall operate in the following environment.

· Salt and/or fresh water

· Air Temperature: 0 to 38º C Dry Bulb, 28º C Wet bulb with 90% relative humidity

· Seawater temperature: 10 to 30º C

· Operational in Sea State 3 (Significant Wave Height 1.37m (4.5ft), Significant Wave Period 4.6 sec)

· Survive Sea State 5 (Significant Wave Height 3.66m (12 ft), Significant Wave Period 6.3 sec). Survive means maintain best heading

· ABS HSNC Coastal Naval Craft wave height and speed requirements shall be used for structural design.

070.4 Craft Mission Requirements

The NCPV shall be capable of performing patrol, interdiction, search and rescue, and small boat logistics support operations.

The NCPV shall be built to accommodate a stern ramp launch and recovery of a Rigid Hull Inflatable Boat (RHIB).

The NCPV shall provide for MOGAS refueling of small boats at sea.

070.5 Service Life

When selecting materials, based on material properties or any special calculations, a 15 year system service life shall be required.

The craft shall be designed with a service life margin of five percent growth on lightship weight and .33 m (one foot) growth on lightship vertical center of gravity at craft delivery.

070.6 ABS Involvement

The boat will not be classed by the American Bureau of Shipping (ABS). The Contractor however shall design the craft as if it were to be classed to the following classification notation in the ABS Rules for Building and Classing High Speed Naval Craft 2016 and its corrigenda with the exceptions and clarifications listed in Appendix A:

A1-HSNC-Coastal Naval Craft- AMS The Contractor shall have ABS perform plan review and construction survey as if the craft is going to receive classification. Contractor shall obtain a letter of findings from ABS stating that the craft meets the specified ABS requirements except in areas as identified in Appendix A.

070.7 SOLAS and Safety Equipment

SOLAS 1978-79 and its amendments for safety equipment shall be followed only as it applies to safety and lifesaving equipment.

The Contractor shall ensure that the boat is equipped with all USCG required safety equipment for a boat of this size and purpose. Such safety equipment shall be USCG certified. Horn shall be a permanent installation with controls from the helmsman’s station. USCG requirements are mandatory even if not specified. If any item is specified to be in accordance with the standards of ABS or these Specifications and that item exceeds USCG requirements, the most severe requirement shall be met.

070.8 Weight and Stability Limits

The boat shall meet the intact stability requirements of Manual for Stability Analysis of U.S. Small Navy Craft, Report #6660-99, Rev. A, dated May, 1988 with the following clarifications and exceptions.

(1) Wind heel speed of 70 knots

(2) Roll back angle of 25 degrees

(3) Free to trim in analysis

(4) No “Lifting Heavy Weights over the Side” requirements

(5) High speed turn calculations are not required for hydrodynamically supported vessels which bank in on a turn.

The boat shall meet the meet the one compartment standard of subdivision criteria of Procedure Manual for Stability Analysis of U.S. Small Navy Craft, Report #6660-99, Rev. A, dated May, 1988 with the following clarifications.

(1) Wind heel speed of 30 knots

(2) Roll back angle of 14 degrees

(3) Free to trim in analysis In no event shall the list in the Full Load Condition exceed onehalf degree to port or starboard.

The values used in determining that these requirements have been met shall be the displacement, VCG, list, and trim at Full Load based on the inclining experiment performed in accordance with Section 097.

The use of ballast is not acceptable as a corrective measure to deliver the boat within the required values.

070.9 General Requirements for Equipment, Machinery and Materials All material, equipment, and machinery regardless of by who furnished or procured shall be installed or stowed, as appropriate, by the Contractor.

If applicable, the Contractor shall provide all necessary engineering services required for the installation of Government Furnished Material.

All material, equipment, and machinery installed in the boat shall be new.

Asbestos shall not be used.

All mercury or mercury compounds shall be potted or otherwise sealed and secured to prevent contamination of the atmosphere or other material or equipment. Mercurybearing devices must be contained within a double boundary of confinement, i.e., primary and secondary seals or barriers, the second to prevent contamination in the event of rupture of the primary.

Selection and installation of equipment for the boat shall be suitable for the following general conditions of marine service:

· Conditions of roll, pitch, list, trim, vibration and pounding to be expected of the boat in service to include all dynamic aspects to which the boat is capable of exhibiting (i.e. high speed turns, crashbacks (emergency stops)).

· Continuous conditions of exposure to salt spray for equipment exposed to the weather.

· Exposure to the design impact loading of the craft. The design impact loading of the NCPV shall be calculated in accordance with ABS HSNC.

To achieve ready replacement of parts, the Contractor shall standardize the selection of equipment, fittings, and fabrication methods within each and between all boats under the contract. Components and equipment that are functionally interchangeable shall be identical. The Contractor shall use the least practicable variety of types and sizes of items with multiple applications.

070.10 Installation of Equipment, Machinery and Materials

Foundations and brackets for equipment shall be configured to provide access for cleaning, painting, preservation, and maintenance, and to prevent accumulation of water, dirt, and foreign material.

Connecting piping and wiring shall be run to allow only minimum exposure to weather. Bulkhead and deck penetrations shall be as close as practicable to the equipment being served, preferably by direct connection through the adjacent deck or bulkhead.

Wiring and piping to equipment mounted on spars shall be contained within the spar structure to the maximum extent possible.

Systems, equipment, and components shall be installed to facilitate accessibility for operating efficiency and for inspection, adjustment, and repair. Permanent fittings and structure shall be kept clear of routes required for the removal of machinery and equipment. The space behind certain equipment may be inaccessible after installation. This factor shall be considered in providing proper preservation in way of such equipment and in selecting the location of pipes, ducts, wireways, and other permanent fittings behind such equipment. Nooks, cracks, and openings where water, dirt, dust, or foreign material can accumulate shall be avoided.

Protection of personnel against operating hazards shall be provided. Shafting, couplings, gears, flexible shafts, and similar items shall have adequate guards installed for protection of personnel. Such protective guards shall be removable without dismantling the machinery surrounded. Guards shall be as light as is consistent with required protection and strength. Guards shall be of sufficient strength to be used as steps or hand holds if located where such use may be anticipated. Protective guards shall also be installed as barriers to prevent personnel from inadvertently contacting energized and exposed electrical circuits, components, and terminals.

Equipment shall be protected against the hazard of personnel brushing against or being thrown against the equipment, particularly under heavy sea conditions, and inadvertently causing damage to exposed components or resulting in maladjustment of exposed functional controls such as push buttons, knobs, and switches. Protection shall be provided by equipment arrangement or design or by installation of enclosures, screens, or guardrails.

Except as specified, the area around the magnetic compass shall be clear of magnetic objects and sources of electrical fields as much as practical. All items in the vicinity of the magnetic compass shall be either nonmagnetic or sufficiently separated from the compass to preclude any uncorrectable deviation. To the extent practicable, electronic equipment, electrical instruments, electric motors and similar devices shall be kept away from the magnetic compass.

Contractor shall comply with Original Equipment Manufacturer (OEM) component design and installation recommendations.

070.11 Workmanship

Quality of work throughout the craft shall reflect the best marine practices.

All joints are to be neatly and accurately made. Faying surfaces shall be free from gaps, hollows or warping. Shims or filling compounds shall not be used to correct improper fit.

All sharp edges exposed to personnel shall be dressed, ground or radiused to avoid injury to personnel.

All exterior aluminum surfaces, except where painting is specified, shall receive a nondirectional silica sandblast to achieve a uniform, clean, matte finish. This finish shall remove all heat treat films, surface corrosion and oxidation byproducts, weld spatter, paint and ink identification marks, and foreign matter from the aluminum.

Pipe, cable and other penetrations through decks and through watertight bulkheads shall be watertight, shall reduce the transmission of heat, and shall prevent the transfer of machinery vibration and noise through the hull structure. Pipe and cable penetrations through bulkheads above the main deck shall minimize the transmission of heat through the penetrated structure and prevent the transfer of machinery vibration and noise through the hull structure.Piping, wiring leads and vent ducts shall penetrate the bulkhead as close to the top of the bulkhead as practicable unless otherwise specified.
070.12Corrosion Control

All items used in the construction of this boat shall be fabricated of noncorroding materials or shall be suitably protected against corrosion for service in a marine environment. Ferrous metals other than stainless steel shall not be used except where specifically required by these Specifications.

Dissimilar metals, with the exception of stainless steel fasteners, shall not be joined directly except as specifically allowed herein. Galvanic corrosion shall be prevented by insulating dissimilar metals from each other with suitable gaskets, washers, sleeves, bushings and hose of insulating material; insulating materials shall be nonporous, with mechanical properties suitable for the application. In order to exclude moisture from the joint, faying surfaces between mechanically fastened metal components, except machinery foundation shims, shall be protected by the use of bedding compound or structural adhesive, as applicable.

070.13 Foundation Design

The Contractor shall design the foundations (i.e. load bearing or equipment supporting structure or members) to withstand the weight of the equipment and any dynamic operational loads that may be applied to it due to predicted motions during all required operations.

070.14 Tolerances

Where tolerances are not otherwise specified the following tolerances shall apply:

1) U.S. customary units (inch-pound) Dimensions given decimally in inches:

.X0.06 in (1.524 mm)
.XX0.03 in (0.762 mm)
.XXX0.005 in (0.127 mm)

Dimensions given in feet, whole inches and fractions: 1/8 in (3.175 mm)

2) Angles and tapers:

length of shorter leg (mm)

up toover 10over 50over
10to 50to 120120
in whole degrees1°1°1°1°
in decimal degrees1°0.5°0.3°0.1°
in degrees and minutes1°0° 30'0° 20'0° 10'
in mm per 100 mm1.8 mm0.9 mm0.6 mm0.3 mm
in milliradians18963

The tolerances shall apply to all fabrication performed from Contractor developed drawings except where other tolerances are specified. In the preparation of drawings by the Contractor the above tolerances shall be applicable except where special requirements exist. Drawings deviating from these tolerances shall reflect the variant tolerances designated and the justification for the variance noted.

SECTION 071 ACCESS

Interior spaces, except inaccessible voids, shall be provided with practical and convenient access. Two means of access and egress shall be provided to all compartments.

Whenever possible, machinery, piping, brackets, and other items that impede passage or are a source of danger to personnel, shall be kept clear of normal routes of access. Where such installations cannot be avoided, guards or protective padding shall be provided.

Inclined ladders shall be provided for normal and frequent access between both interior and exterior decks.

Vertical ladders shall be provided to access infrequently used areas or where inclined ladders are not practical.

Access shall be provided for required shipboard maintenance, test, repair, adjustment, and checkout of systems, machinery, and equipment without having to dismantle adjacent machinery, piping, or structure. Ancillary equipment, panels, gages, controls, sensors, and other equipment mounted on machinery shall be located to facilitate access and monitoring and not interfere with the machinery servicing, maintenance, and component replacement. Pipes, ducts, wireways, and other permanent fittings shall be installed in spaces that are accessible.

SECTION 073NOISE, VIBRATION AND RESILIENT MOUNTINGS
073.1Noise Levels

Acoustic insulation shall be installed on Engine Room and Auxiliary Machinery Space overheads. In addition acoustic insulation shall be mounted on bulkheads separating machinery and personnel spaces.

The Aweighted sound level at all speeds shall not exceed 84 dB at the Helmsman's Station and in passenger or crew compartments.

Table 0731 gives the maximum Aweighted sound level for various spaces aboard the boat. In addition to meeting the Aweighted limits of Table 0731, the low frequencies shall be limited to the levels given in Table 0732.

TABLE 073-1
ALLOWABLE AWEIGHTED SOUND LEVELS (dB)
SPACESOUND LEVEL
Maximum Speed Cruise Speed
Pilothouse84NA
Berthing & living spaces8478
Fly bridge (if applicable)84NA
Messing spaces8478
Engineer’s Monitoring Station (EMS)*84NA

*As applicable

TABLE 0732
ALLOWABLE OCTAVE BAND SOUND LEVELS (dB re 20 Pa)
AWEIGHTED LEVELSOCTAVE BAND CENTER FREQUENCY, HZ
FROM TABLE 073131.563125250

70 90 84 79 76

78 100 95 90 85

84 105 100 95 90

073.2 Vibration

The boat and all associated components shall be free from excessive vibration. Vibration is excessive when it interferes, or threatens to interfere, with the proper operation of the boat or components.

Means shall be provided to prevent rattling of removable plates, ladders, gratings, and similar items.

073.3 Resilient Mountings

To reduce structure borne vibration induced noise, Main Engines, Generators, HVAC condenser units and fan-coils and air handlers, and hydraulic power units and their associated equipment installations shall include manufacturers’ furnished resilient mounts. Piping connections to resiliently mounted equipment shall be flexible. All exhaust piping systems shall have flexible expansion joints and resilient hangars / mounts. Ventilation fans and pumps greater than 3 hp shall be mounted on isolation gaskets.

Sufficient clearance shall be provided to prevent the unit from striking structure, adjacent fixed or resiliently mounted units, or other fixed objects during maximum deflections of the unit.

SECTION 074 WELDING, CASTING AND ALLIED PROCESSES

074.1 Structural Welding

Welding for the craft shall be made by welders with welder certificates in accordance with AWS or ASME. Weld procedures shall be in accordance with AWS or AMSE codes. All welding procedures and their supporting documentation and welder certificates shall be on site and available to the Government.

Fabrication, welding, records and inspection shall be subject to the following:

(1) All welding shall receive visual inspection by a certified NDT inspector.

(2) Nondestructive testing in accordance with ABS Rules for Nondestructive Inspection of Hull Welds shall be as follows:

(a) Nondestructive (NDT) including radiographs, on up to one and one half percent (1.5%) of the structural welding (based on the length of welding) at the discretion of the Government.

(b) Ultrasonic Testing (UT) shall be performed on areas selected by the designated Government representative not to exceed fifteen (15) checkpoints. These UT areas shall not apply toward the one and one half percent (1.5%) NDT requirement.

(c) Dye Penetrant Testing (PT) shall be conducted on 100% weapon foundations, crane foundation, and towing fittings. PT shall be performed on these areas after load tests as applicable. These PT areas shall not apply toward the one and one half percent (1.5%) NDT requirement. 074.2 Piping Welding Pipe welding shall be incompliance with ASME Boiler Pressure Vessel Code or AWS D10.11 (Root Pass welding for pipe) D10.12 (Pipe Welding – Mild Steel), D10.13 (Tube Brazing copper), D10.18 (Pipe welding stainless steel) where ABS Rules are silent.

SECTION 075 THREADED FASTENERS

All threaded fasteners shall be type 316 stainless steel. All nuts shall be the prevailing torque elastic self-locking type. One stainless steel flat washer shall be used under each bolt and machine screw head, except countersunk types, and under each nut. Mechanical thread locking devices shall be used for installations where temperature exceeds elastic self-locking type fastener allowance.

Male threads on threaded fasteners, after being installed and tightened, shall protrude at least two and not exceed five threads beyond the top of the nut or plastic locking element and shall not violate clearances, accessibility, or safety requirements. Where both sides of a joint are accessible, nuts and washers shall be used to secure bolts or machine screws. In blind connections, stainless steel countersunk head threaded inserts shall be used to secure bolts or machine screws.

SECTION 076 RELIABILITY AND MAINTAINABILITY

The boat shall provide for ease of maintenance (i.e., preventive service actions, fault/failure resolution, restoration, and continuous operation) such that its components and ancillary features can be readily serviced. The emphasis of maintenance shall be on “routine” actions to avoid, reduce, or eliminate the consequences of failures.

SECTION 077SAFETY
077.1General

These requirements define the Contractor's role in the system safety program. They have been tailored to meet the objectives of MIL STD 882, System Safety Program Requirements. The objective of system safety is to optimize the safety of the craft within the constraints of operational effectiveness, time, and cost. Safety is defined in this context as freedom from those conditions that can cause death, injury, occupational illness, or damage to or loss of equipment or property.

System safety design requirements include but are not limited to the following:

(1)Eliminate identified hazards or reduce the associated risk through design.
(2)Ensure that details of equipment installation minimize exposure of personnel and equipment to hazards such as sharp edges, points, moving parts, high temperatures, noise, vibration, acceleration, toxicity, high voltage, and electro-magnetic radiation.
(3)Ensure that details of design and construction minimize the consequences of human error in the operation and support of the craft.
(4)Ensure that warning, caution and instruction markings are provided as necessary to identify hazards and reduce the associated risk.
(5)Minimize the severity of personnel injury or damage to equipment in the event of a mishap.

In developing the details of design and construction, the Contractor shall review these Specifications, referenced documents, and standards for safety impact. Any hazards identified shall be reported to the Government.

Where the Contractor is given latitude on details of design, arrangements or construction, the Contractor shall ensure that the details used do not degrade system safety.

077.2 System Safety Program Requirements

The contractor shall establish and maintain a system safety program. The program shall be designed to meet safety objectives in a timely and cost efficient manner. All decisions made by the builder shall be made with impact to system safety in mind. As part of the System Safety Program the Contractor shall:

(1)Perform an analysis of each request for configuration change in order to determine any safety impact. The results of each analysis shall be included in the applicable Safety Assessment Report and shall become part of each request for configuration change.
(2)Ensure that suitable "DANGER", "WARNING" and "CAUTION" statements are provided as required to protect personnel and equipment.
(3)Prepare a Final Safety Assessment Report which clearly states those safety issues which remain unresolved.
077.3Safety Design Precedence

The order of precedence for resolving identified hazards shall be as follows:

(1)Design for minimum risk. From the first, design to eliminate hazards. If an identified hazard cannot be eliminated, reduce the associated risk through design selection so that serious injury or major material loss would not result from a mishap.
(2)Incorporate protective devices. Where identified hazards cannot be eliminated or their associated risk adequately reduced through design selection, fixed, automatic protective devices shall be used to prevent the mishap form occurring. Provisions shall be made for periodic functional checks of these devices.
(3)Incorporate warning devices. Where design selection and safety devices cannot effectively eliminate the hazard or reduce the associated risk, devices shall be used to detect the hazardous condition and to produce a warning designed to alert personnel of the hazard.
SECTION 078MATERIALS

All metals shall be of material and composition as specified herein. Internal corners shall be filleted and external corners shall be rounded off. Counter sinking for fasteners shall be as specified by the fastener manufacturer. Fastening patterns shall be well arranged and consistent.

Where galvanizing is required, it shall be done by hot dip process and shall meet the requirements of ASTM Specification A-153. The zinc shall be at least 98 percent pure.

Joiner hardware shall be brass, bronze or corrosion resisting steel and of rugged design and shall prevent latches from coming adrift due to vibration.

When materials are referred to in these Specifications without further identification, they shall confirm to the following material Specifications as applicable.

Bronze, Silicon

Sand Cast
ASTM-B584, alloy C87200
Bars, plates, sheets and shapes
ASTM-B97, alloy C65500 or
ASTM-B98, alloy C65500

Brass, Naval

Rods, bars, and shapes
ASTM-B21, alloy C46400

Copper-Nickel Alloy

Rod and flat products
ASTM--B122, alloy C71500
Tube/Pipe
ASTM B-466, alloy 9010

Nickel-Copper Alloy (Monel)

Rods and bars
ASTM-B164

Plate and Sheet

ASTM-B127

Aluminum

Sand cast
ASTM-B26, 356.0-T6
Tube/ Seamless Pipe
5086-H111 or 5086-H32 or
Alloy 6061-T6
Plate & Sheet
5086-H116 or 5086-H117
B928M–H112 or B928M-H32
Shapes
Extruded, 5086-H111 or
Alloy 6061-T6 or Alloy 6063-T5

Corrosion resistant steel (CRES)

Wrought
A1S1 type 304, 316, or 316L or Aquatech 17
Castings
For applications exposed to sea water (underwater)
ASTM-A744, grade CF-8, CF-8M, CF-3. Castings are to be heat
treated as required by ASTM-A744. In addition, the castings
must be heat treated following any weld repairs.
Castings
For above water applications
ASTM-A743, grade CF-8, CF-8M, CF-3, or CF-3M. Heat
treatment required.
Pipe or Tubing
MIL-P-1144, grade 304L or 316L
ASTM-A312, grade 304L or 316L
or UNS S31254

Marine Steel Sheet

ASTM-A36

Castings

MIL-S-15083, or
ASTM-A27, grade 60-30
Forgings
ASTM-A668, Class C
Bars and shapes
MIL-S-20166 grade M or
ASTM-A131 or
ABS Hull, grade A or B
Steel pipe
ASTM-A53 or
ASTM-A-106, grade B

Plastic Pipe PVC (ASTM F441-84, Ex: D-1785)

Bedding Compound Woolsey 2005N

Gaskets Unless otherwise specified herein, gaskets for mechanically attached fittings shall be neoprene rubber

Materials used to fabricate the structure, systems, and equipment shall have material properties and behavior suitable for the manufacturing and installation processes selected, in-service environment, and function performed. Selected materials shall support the boat’s required service life without degrading the performance of structure, systems, and equipment during the specified operational profile. Asbestos, polychlorinated biphenyl (PCB), and lead paint shall not be used. Mercury shall not be used in applications where a functionally equivalent substitute is available. Direct contact of electrolytically dissimilar metals is prohibited unless electrolytic corrosion precautions are used.

SECTION 083 ON-BOARD SPARE PARTS, TOOLS AND CONSUMABLES

Space, weight, and storage onboard the craft shall be provided for on-board spare parts, tools and consumables needed for a duration of one (1) mission.

SECTION 084 TRANSPORTATION AND HANDLING

Contractor shall provide all handling gear, attachment fittings, permanent lifting fittings, belly bands, spreaders, etc. necessary to accomplish lift of boat from a single point. The factor of safety for all lifting components (lifting pads, wire rope, thimbles, etc.) shall be five on ultimate strength. Testing results shall be permanently marked/banded on the gear and testing label plates provided on the slings.

The design, testing, and marking of the lifting slings shall be in accordance with ASME B30.9c.

Lifting gear shall be provided to support the shipping arrangements of the boats.

SECTION 085DRAWINGS AND CALCULATIONS
085.1General

The Contractor shall prepare all drawings and calculations required for ABS approval and Contractor’s construction requirements.

Detailed design and engineering work and related drawings shall precede construction so that problems are discovered and resolved prior to construction. Detailed accurate drawings which define the NCPV shall be developed prior to construction and shall be used as a quality assurance and configuration control tool by the Contractor and by the Purchaser.

The Contractor is required to develop a complete set of drawings adequate for the construction of the craft. Drawing level of detail shall be sufficient for acceptance, operation/training, maintenance, repair, modification and supply support for the delivered boat. The construction and testing requirements of these Specifications are to be incorporated into the construction drawings such that the drawings are self-sufficient and fully describe construction and testing of the craft without reference to these Specifications. These requirements do not apply to drawings depicting tooling or manufacturing processes.

During detailed design and development of drawings the Contractor shall verify the availability of all material and components required for the construction of the craft.

Drawings shall be checked for accuracy and completeness and approved by the Contractor prior to transmittal to the Government. No portion of the craft is to be built until after drawings applicable to that portion of the craft have been provided to the Government.

The Contractor shall validate the drawings during the construction process by building all craft to the drawings. Drawings shall first be validated against the lead craft. The original drawings shall be revised to show the actual construction if discrepancies are found. Subsequent craft shall be checked against the revised drawings to validate the revision. The drawings shall be revised so that they are maintained up to date. The latest revision shall accurately reflect all craft as constructed and the current status of changes, deviations and waivers.

At the completion of the contract, the final drawings shall accurately and completely describe each craft. Drawings may include alternate details applicable to different craft within the contract. The applicability shall be clearly indicated. No alternate detail applicable to any craft shall be erased or crossed out.

If the correction of defects by the Contractor during the warranty period requires an engineering change, the Contractor shall revise the final drawings to reflect the change. The revised final drawings shall be provided to the Government.

Design calculations shall be performed to support verification of the design and Specification requirements. Design calculations shall support all drawing content as required and calculations shall be delivered with the drawings that they support. Design calculations shall include:

(1) Stability Calculations

(2) Resistance and Powering Calculations

(3) Electrical Load Analysis

(4) Structural Calculations

(5) Range and Endurance Calculations

(6) HVAC Calculations

(7) Auxiliary System Calculations

(8) Hoisting Calculations

(9) Docking Calculations

085.2 Drawing & Calculations Practices

All drawings shall be drawn to full size in model space and shall be in Metric units. The scale shall be indicated on drawings. As-built drawings shall be dimensioned in Metric and English units.

Parts lists shall be included on the drawings. The parts lists shall list materials, components and equipment for the drawing. The parts list shall contain the item number, quantity required, manufacturer, nomenclature or description, material or Specification or other identifying information.

Design calculations and analyses shall be clear and complete. No steps shall be skipped or presumed. Any descriptive information needed to completely describe the calculations and their methods shall be included. For repetitive calculations, a full example calculation describing methodology, assumptions and any additional descriptive information shall be provided. Subsequent repetitive calculations may be placed in a matrix or tabular form that includes all inputs and outputs to these calculations.

Calculations shall be clear and complete and include the following:

· Clear, complete and concise assumptions presented in a neat, legible manner.

· Any necessary diagrams to fully describe the design situation and its associated calculations.

· Pertinent information from all references, standards and guidelines cited including appropriate excerpts.

· All symbols and acronyms fully defined Calculations shall be submitted in the electronic format in which they were created such that all formulas are identified.

085.3 Drawing Index

A drawing index shall be developed. This drawing shall list, in tabular form, all final drawings by drawing number, revision and title. The list shall be in numerical order according to the drawing number. The drawing number assigned to the boat drawing index shall be the first number in the series.

085.4 Arrangement Drawings

The drawings shall include general arrangement, inboard, and outboard drawings that convey, without controlling dimensions, a general understanding of the boat configuration. The scale and number of views used shall be sufficient to clearly depict the relationship of all major components. All major components shall be identified on the drawing.

Outboard arrangements shall include plan, profile, and transom views to depict the external components, equipment and configuration of the boat. These drawings shall include external fittings such as:

Anchors Antennas Anti-fatigue matting

Armament
Awnings
Bell
BERP and WERP
Boats
Canopy
Capstans
Compasses
Control stations
Deck Drains
Doors
Draft marks
Firefighting equipment
Flag staffs
Frame numbers
Fuel fills and vents
Grab rails
Hatches
Horn
Intake and exhaust openings
Ladders
Life lines
Life rafts
Life saving gear
Lifting fittings
Lighting
Masts
Mooring fittings
Navigation lights
Pad eyes
Propellers
Pyrotechnics lockers
Rails
Ready service lockers
Rigging
Rubbing beads
Rudders
Scuppers
Scuttles
Searchlights
Sewage connections
Shafting
Sheer guard
Shore power connections
Signal lights
Spars
Stanchions
Station numbers
Stowage locations
Struts
Through hull fittings

Tiedown fittings Trim Tabs Tow fittings

Ventilators
Water connections

Weapons and foundations

Winches
Windows
Windshields

Windshield wiper / washer system Inboard arrangements shall consist of plan, profile, and section views of the interior of the craft. They will show only the internal components, equipment and configuration of the craft. The sections for the plan views shall be taken at each deck, platform or flat. The section for the profile view shall be taken through the centerline.

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