Att_1_65DS_Specification_03Oct2018.pdf

Attachment 1 – 65 FOOT DIVE SUPPORT (DS) BOAT SPECIFICATION 3 October 2018

Attachment 1

65 FOOT DIVE SUPPORT (65DS) BOAT

SPECIFICATION

3 October 2018

REVISION HISTORY

Date Summary Of Change Version

TABLE OF CONTENTS

TABLE OF CONTENTS

040 INTRODUCTION AND GENERAL DESCRIPTION

040-1 Background

042 GENERAL ADMINISTRATIVE REQUIREMENTS

042-1 General Requirements

042-2 Referenced Documents

070 GENERAL REQUIREMENTS OF DESIGN AND CONSTRUCTION

070-1 Vessel Characteristics

070-2 Builder Submitted Drawings

070-3 Environmental Conditions

070-4 Load Conditions:

070-5 ABYC Standards

070-6 Alterations

070-7 Installation of Equipment, Machinery, and Materials

070-8 Corrosion Control

070-9 Manned Spaces

070-10 Alternate Items

071 ACCESS

071-1 Accessibility

071-2 Bilge Access

071-3 Emergency Egress

071-4 Normal Access Below Deck

073 NOISE

073-1 Onboard Noise Levels

073-2 Hearing Conservation

075 FASTENERS

075-1 Stainless Steel Fasteners

078 MATERIALS

078-1 Structural Material/Aluminum

078-2 Non-Biodegradable Materials

078-3 Fabric Material

078-4 Fire Retardant Interior Materials

079 STABILITY

079-1 Stability

084 TRANSPORTATION AND HANDLING

084-1 Marine Transport

084-2 Boat to Ship Tiedowns

085 TECHNICAL DATA PACKAGE

085-1 Technical Design Analyses

085-2 Drawings

085-3 Bill of Materials (BOM)

085-4 Commercial Off the Shelf (COTS) Technical Manuals and Documentation

085-5 Boat Technical Manual

085-6 OEM Certifications

085-7 OEM Warranties Booklet

085-8 Tests and Trials Reports

085-9 Master Data Index

085-10 TDP Format

085-11 TDP Submittal

085-12 TDP Acceptance

092 TESTING

092-1 Test Certifications

092-2 Seawater Piping Galvanic Isolation Test Certification

092-3 Crane Testing

092-4 Noise Survey

094 TRIALS

094-1 Builder's Trials

094-2 Pre-Delivery Inspection and Trials (PDIT)

SECTION 1: HULL STRUCTURE

100 GENERAL REQUIREMENTS FOR HULL STRUCTURE

100-1 Structural Requirements

100-2 Scantlings Requirements

110 SHELL AND SUPPORTING STRUCTURE

110-1 Bow Reinforcement

130 HULL DECKS

130-1 Self-Bailing

150 DECK HOUSE STRUCTURES

150-1 Hull Style/Pilothouse and Main Cabin

167 HULL STRUCTURAL CLOSURES

167-1 Doors and Hatches

167-2 Equipment Removal

169 SPECIAL PURPOSE CLOSURES AND STRUCTURES

169-1 Swim Platform

169-2 Skegs

SECTION 2: PROPULSION

233 INBOARD ENGINES

233-1 Inboard Diesel

233-2 Starter

233-3 Alternator

243 PROPULSION SHAFTING

243-1 Shafting

244 PROPULSION SHAFT BEARINGS

244-1 Propeller Shaft Bearings

245 PROPELLERS

245-1 Propeller

252 PROPULSION CONTROL SYSTEM

252-1 Propulsion Instrument Marine Package

252-2 Propulsion/Propulsor Control (Tethered Remote)

256 SEAWATER COOLING SYSTEM

256-1 Strainer

256-2 Coolant Pre-Heater

259 EXHAUST SYSTEM

259-1 Main Engine Exhaust (wet)

262 MAIN PROPULSION AND GENERATOR LUBE OIL SYSTEM

262-1 Electric Fast Lube Oil Change System

SECTION 3: ELECTRIC PLANT

300 GENERAL REQUIREMENTS FOR ELECTRIC PLANT

300-1 Suitable for Marine Environment

300-2 Panel Covers

300-3 Bonding System

300-4 Switches

303 PROTECTIVE DEVICES

303-1 Overcurrent Protection

304 ELECTRICAL CABLE, WIRING, AND CONNECTIONS

304-1 Watertight Connections

304-2 Cable Supports

304-3 Marine Multi-Conductor Cable

304-4 Electrical Connections

304-5 Weatherproofed Connectors

304-6 Watertight Cable Penetrations (MCTs)

304-7 Cableways

310 GENERATORS

310-1 Generators (480 Vac / Three Phase)

310-2 Generator Paralleling and Load Management

313 BATTERIES

313-1 Batteries (Inboard Diesel 24 Vdc)

313-2 Battery Charging (24 Vdc)

313-3 Battery Voltmeter

313-4 Battery Charger (120 Vac to 24 Vdc)

320 POWER DISTRIBUTION SYSTEMS

320-1 24 Vdc Ungrounded Distribution System

320-2 AC Power Distribution (480 Vac)

320-3 AC Power Distribution (240/120 Vac)

320-4 Shore Power System (480 Vac/3-phase)

320-5 Shore Power System (120 Vac/1-phase)

320-6 Outlets (12 Vdc)

320-7 Outlets (24 Vdc)

320-8 Isolated Outlets (120 Vac)

320-9 Outlets (240 Vac)

320-10 Outlets (480 Vac)

324 SWITCHGEAR AND PANELS

324-1 Electrical Circuit Breaker DC Panels and AC Sub-Panels

324-2 AC Switchboard

330 LIGHTING

330-1 Electronic Dimmer

330-2 Interior LED Lighting (24 Vdc)

330-3 Interior Lighting (120 Vac)

330-4 Deck Low Level Lighting

330-5 Deck Work Lights

SECTION 4: COMMAND AND CONTROL

421 NON-ELECTRICAL/ELECTRONIC NAVIGATION AIDS

421-1 Magnetic Compass

421-2 Storage

422 ELECTRICAL NAVIGATION AIDS

422-1 Navigation Lights

422-2 Integrated Electronic Navigation Package

422-3 Day Shape Mast

422-4 Spotlight, Handheld

422-5 Spotlight, Fixed Mount

433 ANNOUNCING SYSTEMS

433-1 Intercom/PA System

441 RADIO SYSTEMS

441-1 VHF Radio (Standard Horizon GX2000)

441-2 VHF Radio Hand Held (Standard Horizon HX400)

443 VISUAL AND AUDIBLE COMMUNICATION SYSTEMS

443-1 Navigation Horn

443-2 Close in camera monitoring system

SECTION 5: AUXILIARY SYSTEMS

500 GENERAL REQUIREMENTS FOR AUXILIARY SYSTEMS

500-1 Mechanical Components

500-2 Through-Hull Fittings and Valves

505 GENERAL REQUIREMENTS FOR PIPING SYSTEMS

505-1 Hose and Piping System Materials

505-2 Hose and Pipe Installation (General)

505-3 Hose Clamps

505-4 Fittings (General)

512 HEATING, VENTILATION, AND AIR CONDITIONING (HVAC)

512-1 Defogging/Defrosting System

512-2 Manned Compartment Fresh Air Ventilation

512-3 Pilothouse Fans

512-4 Machinery Room Ventilation

512-5 Manned Compartment Heat and Air Conditioning

512-6 Compartment Heater

523 RAW WATER SYSTEM

523-1 General Use Raw Water Washdown

523-2 Electric Seawater Pump for Cofferdam Eductor

523-3 Seawater Supply for Monkey Heater (see section 592-13)

528 PLUMBING FIXTURES

528-1 General

528-2 Head

528-3 Below Deck Shower

528-4 Aft Deck Shower

528-5 Galley Sink

529 BILGE/DRAINAGE SYSTEM

529-1 Portable Manual Bilge Pump

529-2 Electric Bilge Pump(s)

530 FRESHWATER SYSTEMS

530-1 Potable Water System

530-2 Water Heater

541 FUEL SYSTEM

541-1 Fuel Tank(s)

541-2 Fuel Sounding

541-3 Fuel Level Gauge

541-4 Fuel/Water Separator and Filter

541-5 Fuel Stripping Pump

541-6 Remote Fuel Supply Shutoff

555 FIRE FIGHTING

555-1 Engine Room Fixed, Clean Agent Fire Extinguishing System

555-2 Portable Fire Extinguishers

561 STEERING CONTROL SYSTEMS

561-1 Hydraulic Steering

568 STEERING CONTROL THRUSTERS

568-1 Bow Thruster

581 ANCHOR HANDLING

581-1 Anchor Windlass and Fortress Anchor

582 MOORING, TOWING, AND TIEDOWN FITTINGS

582-1 Tow Provision

582-2 Cleats/Bitts/Bollards

583 LIFEBOATS

583-1 Life Rafts

589 SPECIAL PURPOSE SYSTEMS

589-1 Articulating Knuckle (Folding and Telescoping) Boom Crane

589-1a General

589-1b Crane Design and Capabilities

589-1c Load Hook

589-1d Safety Systems

589-1e Hydraulic Power Unit

589-1f Location of System Components

592 DIVER SUPPORT SYSTEMS

592-1 Dive Compressor

592-2 Low Pressure Service Air Compressor System

592-3 Electric HPU

592-5 Wet Suit and Helmet Rack

592-6 SCUBA Tank Stowage

592-7 Dive Hose Rack Saddles

592-8 Vise

592-9 Navy Embarked Dive Systems Integration (Systems Embarked after delivery)

592-10a General Integration Requirements

592-10b Light Weight Dive System (LWDS) Specifics

592-10c Fly Away Dive System (FADS III) Specifics

592-11 Navy Embarked Electronic System

592-12 Navy Embarked Vidmar Tool Cabinets

592-13 Navy Embarked Welder

592-14 Navy Embarked Suit Heater

593 SEWAGE AND WASTE WATER POLLUTION CONTROL SYSTEM

593-1 Grey Water Holding Tank

593-2 Sanitation System

593-3 Garbage Pollution Prevention

593-4 Oil Pollution Prevention

SECTION 6: OUTFIT AND FURNISHINGS

600 OUTFIT

600-1 Boat Hook

600-2 Ring Buoy

600-3 U.S. Flag and Mast

600-4 Mooring Lines

600-5 Air Horn

600-6 Personal Flotation Devices

600-7 EPIRB

600-8 Dive Flags

600-9 Fenders

602 LABELING

602-1 Hull Registry Number

602-2 Label Plates (General)

602-3 Piping System Label Plates

602-4 Instruction Label Plates

602-5 Hoisting Label Plates

602-6 Boat Information Label Plate

602-7 Boat Alt Label Plate

602-8 Shipping Data Label Plate

602-9 In-Service Label Plate

602-10 Systems Label Plates

602-11 Stowage Label Plates

602-12 Crane Label Plates

602-13 Unique Item Identification (UID)

611 HULL FITTINGS

611-1 Deck Equipment and Cargo Tiedowns

611-2 Heavy Duty Fendering

611-3 Bow Fendering

611-4 Hoist Fittings

612 RAILS, STANCHIONS, AND LIFELINES

612-1 Grab Rails

612-2 Life Lines

623 GANGWAY

623-1 Gangway

625 WINDOWS

625-1 Windshield Wiper/Washer System

630 PRESERVATIONS AND COVERINGS PAINTING

630-1 Bottom Paint

630-2 Topside Finish

630-3 Anodes

630-4 Exterior Non-Skid

630-5 Floor - Habitability and Work Spaces

643 BERTHING AND MESSING

643-1 Galley

644 SANITARY SPACES AND FIXTURES

644-1 Unisex Head

644-2 Diver's Dressing/Drying and Shower Room

653 THERMAL INSULATION AND ACOUSTICAL TREATMENT OF

COMPARTMENTS

662 WORKING SPACES AND SEATING

662-1 Console Ergonomics

662-2 Seating - Crew

662-3 Seating and Table - Passengers

670 STOWAGE SPACES

670-1 Stowage

670-2 Medical Stowage

670-3 Working Spaces

SECTION 0: GENERAL GUIDANCE AND ADMINISTRATION

040 INTRODUCTION AND GENERAL DESCRIPTION

040-1 Background

Dive operations are primarily conducted via surface support air to conduct underwater ships husbandry for surface ship and submarine availabilities and repairs. Basic underwater ships husbandry for surface ships include cofferdam installations to support internal work, hull inspections, propeller inspections and change-outs, underwater painting and epoxy repairs, photography (both still and video), and masker emitter belt cleaning. Submarine-specific jobs include shaft bearing change-outs, retractable bow plane cofferdams, secondary propulsion motor change-outs, security swims, arrival and departure swim-outs. Umbilical systems that are sourced from the dive support boat carry breathing air, hot water (to warm dive suits), voice and video communications, and air or hydraulic hoses for power tools. The aft deck crane is used for lifting cofferdams and other ship and submarine components weighing up to 4,000 lbs. in wind speeds up to 20 knots. For normal operations, the boat is underway in a harbor or transiting between operational sites, but spends most of its operational time moored alongside other vessels.

042 GENERAL ADMINISTRATIVE REQUIREMENTS

042-1 General Requirements

This Specification is for a nominal sixty-five (65) foot long by twenty-two (22) foot beam United States Navy (USN) aluminum Dive Support (65DS) boat.

NOTE: Builders are to fill in actual length and beam of proposed vessel in section Attachment 2, Spec Response Matrix.

This Specification includes information regarding USN diver embarked equipment described in Attachment 3 that the boat is required to support and will be installed by the Navy after delivery to the custodian’s site. The USN diver embarked equipment will not be available to the builder during the design or construction of the boat. Attachment 3 also illustrates some diver unique features (such as extensive hull and underwater fendering, umbilical hose racks, etc.) described in this specification.

A sketch showing the notional arrangement of the desired boat is provided in Attachment 4. The main compartments/areas illustrated in Attachment 4 are the Foredeck, raised Pilothouse, Main Cabin, Aft Work Deck, and below decks: Forepeak, Galley, Dive Equipment Room (DER), Engine Room (ER) and Lazarette (Note: Head and Diver’s Dressing/Drying and Shower Room not shown).

The walk-around Pilothouse and Main Cabin should be placed inboard to accommodate working under extreme bow flares of USN ships.

The Aft Work Deck shall have a minimum 350 square feet open area to support diving operations and payload. Other than the deck crane, equipment mounted on the Aft Work Deck shall be located outboard to allow clear deck space along centerline including at the transom. The Aft Work Deck shall include stowage area on deck which is out of direct sunlight for the wetsuit and helmet rack (see Section 592-5).

Mission duration is typically twenty-four (24) hours a day, seven (7) days a week dive operations with rotating dive teams.

The expected service life for the boat delivered under this specification is twenty-five to thirty (25-

30) years. Components shall be selected for reliability and ability to repair and return to service over a long life cycle with 24/7 operations.

The contractor shall adhere to best marine practices. Specifications identified in this section provide the minimum required general system characteristics and requirements for the selection, installation, onboard performance, onboard inspection of machinery, equipment and outfit, and pre-installation handling and inspections of materials for construction.

042-2 Referenced Documents

46 CFR Part 164, Materials

ABYC, Standards and Technical Information Reports for Small Craft

American Petroleum Institute (API) 2C Specification for Offshore Pedestal Mounted Cranes

ASME Y14.100, Engineering Drawing Packages

ASTM A182, Standard Specification for Forged or Rolled Alloy and Stainless Steel Pipe Flanges, Forged Fittings, and Valves and Parts for High-Temperature Service

ASTM A276, Standard Specification for Stainless Steel Bars and Shapes

ASTM A312, Standard Specification for Seamless, Welded, and Heavily Cold Worked Austenitic Stainless Steel Pipes

ASTM A351, Standard Specification for Castings, Austenitic, for Pressure-Containing Parts

ASTM B33, Standard Specification for Tin-Coated Soft or Annealed Copper Wire for Electrical Purposes

ASTM B466, Standard Specification for Seamless Copper-Nickel Pipe and Tube

ASTMB467, Standard Specification for Welded Copper-Nickel Pipe

ASTM B62, Standard Specification for Composition Bronze or Ounce Metal Castings

ASTM B88, Standard Specification for Seamless Copper Water Tube

ASTM B928, Standard Specification for High Magnesium Aluminum-Alloy Sheet and Plate for Marine Service and Similar Environments

ASTM F593, Standard Specification for Stainless Steel Bolts, Hex Cap Screws, and Studs

ASTM F1166, Standard Practice for Human Engineering Design for Marine Systems, Equipment, and Facilities

Authorization for Military Use (AMU), https://www.supsalv.org/00c3_AMU.asp?destPage=00c3 (NAVSEA 00C3 dynamic listing)

IEEE 45, Recommended Practice for Electric Installations on Shipboard

IEEE 45.7, IEEE Recommended Practice for Electrical Installations on Shipboard - AC Switchboards

IEEE 1580, Recommended Practice for Marine Cable for Use on Shipboard and Fixed or Floating Facilities

International Convention for the Safety of Life at Sea (SOLAS), Chapter II-2 https://www.supsalv.org/00c3_AMU.asp?destPage=00c3

International Regulations for Preventing Collision at Sea, 1972 (72 COLREGS) which are contained in “Navigation Rules, International Inland”, U.S. Coast Guard publication COMDTINST M166672.2 (U.S. Department of Transportation, United States Coast Guard, 2100 2nd Street S.W., Washington D.C. 20593-0001)

MIL-DTL-15562G Type III, Matting or Sheet, Floor Covering Insulation for High Voltage Application

MIL-DTL-24643, Cables, Electric, Low Smoke Halogen-Free, for Shipboard Use General Specification

MIL-PRF-24647E, Paint System, Anti-Corrosive and Anti-Fouling Ship Hull

MIL-STD-209K, Interface Standard for Lifting and Tiedown Provisions

MIL-STD-777F, Schedule of Piping, Valves, Fittings, and Associated Piping Components for Naval Surface Ships

MIL-STD-1366E, Interface Standard for Transportability Criteria

MIL-STD-1474D, Noise Limits

NAVMED P-5010-6, Manual of Naval Medicine

NAVSEA TO300-AU-SPN-010A

NAVSEA 0900-LP-060-4010

NAVSEA DWG 803 5184106, Standard Navy Docking Drawing Surface Ships

Naval Ship’s Technical Manual, Chapter 583, Volume I, Boats and Small Craft

NAVSEACOMBATSYSENGSTA Report No. 6660-99 Rev. A, Procedures Manual for Stability Analysis of U.S. Navy Small Craft

NSF/ANSI 61, Drinking Water System Components – Health Effects

NSWCCD-23-TM-2009/33 Rev B, Hoisting System Design and Certification Process Guidance

NSWCCD-23-TM-2012/58 Rev B, U.S. Navy Boat Electrical Practices

NSWCCD-23-TM-2009/59 Rev B, U.S. Navy Boat Ungrounded Electrical System Verification Test

NSWCCD-23-TM-2009/61 Rev A, U.S. Navy Boat Example Data Package

NSWCCD-23-TM-2009/64 Rev C, Transportability Design and Certification Process Guidance, NSWCCD-23-TM-2009/65 Rev C, Towing Fitting Design and Certification Process Guidance, NSWCCD-23-TM-2011/05 U.S. Navy Craft Mechanical Practices

NSWCCD-23-TM-2011/38 Rev A, Mooring Fitting Design and Verification Process Guidance

S6430-AE-TED-010, Technical Directive for Piping Devices and Flex Hose. Assemblies

SAE J516, Hydraulic Hose Fittings

SAE J1273, Recommended Practices for Hydraulic Hose Assemblies

SAE J1942, Hose and Hose Assemblies for Marine Applications

SNAME T&R Bulletin 4-16

070 GENERAL REQUIREMENTS OF DESIGN AND CONSTRUCTION

070-1 Vessel Characteristics

Length Overall (LOA): XX

Length (excluding swim platform): XX

Hull Length (Lhull): XX

Beam Overall (BOA) w/fendering: XX

Hull (hard) Beam: XX

Height, Keel to Fixed Structure: XX

Height, Keel to Moveable Structure: XX

Deadrise (if any): XX deg at transom; XX deg at midship

Total Installed Fuel Capacity: XX gal

Full Load: XX lbs. including X% build/design margin(s)

Full Load Longitudinal Center of Gravity (LCG): XX ft fwd of transom/keel intersect.

Full Load Vertical Center of Gravity (VCG): XX ft above baseline.

Full Load Draft to lowest extremity: XX ft

Maximum Speed: XX kts in Full Load

Range @ 10 knots: XX nautical miles (nm)

Notice to builders: Enter above parameters in Attachment 2 –Specification Response Matrix.

070-2 Builder Submitted Drawings

{{Notice to Builders: provide a list of the submitted drawings describing the proposed boat in Attachment 2 Specification Response Matrix.}}

070-3 Environmental Conditions

The boat shall be capable of operating in ambient air temperatures between zero (0) degrees Fahrenheit and one hundred twenty-five (125) degrees Fahrenheit and water temperatures between twenty-eight (28) degrees Fahrenheit and ninety-five (95) degrees Fahrenheit. The boat shall be capable of storage in air temperatures down to minus twenty (-20) degrees Fahrenheit. The boat shall be capable of underway, docking or moored operations in varying wind speeds and wave conditions.

The boat shall be capable of full operation (transiting) in three (3)-foot significant wave height and reduced operations in four (4)-foot significant wave height. Boat shall survive eight (8)-foot significant wave height at minimum headway.

070-4 Load Conditions:

The following load conditions are defined for reference throughout this specification. These definitions shall apply to the engineering design values for weight and moments of inertia of the vessel in the described condition:

Lightship: Boat complete in all respects, including Diver Support Systems to be installed following delivery (Section 592 and all subsections), and operating fluids in machinery at recommended levels, onboard spares in stowage location, with neither fuel nor liquids in tanks.

Note: For the Lightship and all derived load conditions, assume the Fly Away Dive System (FADS), Section 592-10c, is embarked. With the FADS, the combined weight for all Navy Embarked Equipment to be included in Lightship is 4,682 lbs. per Table 1, in section 592.

Minimum Payload Capacity: The boat shall be capable of supporting a minimum of 7,990 lbs.

total payload, including personnel and mission gear/cargo. The notional breakdown of payload is twelve (12) divers at 285 lbs. each and two (2) crew at 285 lbs. each and 4,000 lbs. of mission gear/cargo (7,990 lbs. total).

Note: This Minimum Payload Capacity is in addition to the Navy Embarked equipment list in Section 592 of this specification, which is included in the Lightship weight, as specified above.

Full Load Condition: Lightship plus Minimum Payload Capacity, full fuel, and full potable water tank.

PDIT Load Condition: Full Load Condition.

Boat Design Hoisting / Transport: Full Load Condition, less fourteen (14) personnel (285 lbs.

each), and a 10% margin for growth.

070-5 ABYC Standards

As a minimum, the boat in all respects shall meet American Boat and Yacht Council (ABYC) standards and recommended practices.

070-6 Alterations

Alterations to Original Equipment Manufacturers’ (OEM) products by the builder or distributor are highly discouraged. If alterations are necessary, documentation of the change shall be submitted for Government approval and shall be provided with the Technical Data Package (TDP).

070-7 Installation of Equipment, Machinery, and Materials

Unless otherwise specified, OEM recommendations for design and installation of their products into the boat shall be followed. Systems and components shall be selected for durability, longevity, safety, and ruggedness. Components shall be selected to maximize the use of Commercial-off-the-shelf (COTS) products and commonality between hulls. Systems and components shall be installed with proper tools and aligned with best industry practices.

All systems should be free from leaks and safety hazards. Workmanship shall be in accordance with industry best practices.

Galvanically dissimilar metals (copper compounds or stainless steels, aluminum) shall be isolated using insulating materials to prevent any path for electrical current (see Section 070-9).

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 minimize 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.

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 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 or insulation shall be installed to prevent contact with equipment where surface temperatures exceed 160°F. Protective guards, insulation, or caution signs shall be installed to prevent contact with equipment where surface temperatures exceed 140°F, up to 160°.

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

070-8 Corrosion Control

All items used in the construction of this craft shall be fabricated of non-corroding 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 this specification.

Where ferrous metals other than stainless steel are required by this specification, they shall be galvanized or coated; the protective coating shall be applied after fabrication; zinc plating shall not be considered an acceptable protective coating. Alternatively, ferrous metal items may be replaced with stainless steel items, or items of other non-corroding materials.

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, pipe/hose hangers, and hose of insulating material; insulating materials shall be non-porous, 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.

Copper-nickel/Bronze seawater systems shall be installed with replaceable sacrificial aluminum spool pieces for all aluminum interfaces (e.g. thru-hulls, bulkhead penetrations, etc.). All spool pieces shall include cathodic protection (i.e. anodes). See Section 092-1 for certification requirements for seawater systems.

070-9 Manned Spaces

The Pilothouse, Main Cabin, Head, Diver’s Dressing/Drying and Shower Room, and Galley shall be considered manned spaces.

070-10 Alternate Items

Where boat components and equipment are specified by brand name or manufacturer and model number, such identification is intended to be descriptive, not restrictive, and is intended to indicate the required characteristics of the product. The Builder may propose the use of other products which are equal to the specified make and model products. The following general requirements shall form the basis for determining the equality of alternate products unless additional specific or alternate requirements are designated within the applicable sections of these Specifications.

The major attributes of form, fit, function, interface, and material of an alternate item shall not degrade the performance of the system within which it is used, nor the boat as a whole. The alternate item shall require no more space or volume than the designated item for installation, operation, or maintenance. The alternate item shall weigh no more than the designated item. The connection fittings required to incorporate the alternate item into a system shall be identical to those necessary to incorporate the specified item. The principles of operation of the alternate item shall be the same as those of the designated item (i.e., hydraulic cylinders shall not be used in lieu of springs, etc.).

Input power, capacity, and other operating requirements for the alternate item shall be no greater than those required by the designated item. Output power, capacity, and other performance parameters of the alternate item shall be no less than those required for the designated item and not so much greater than those of the designated item as to require an increased capacity of the system within which the item is installed.

071 ACCESS

071-1 Accessibility

Electrical and mechanical components shall be accessible for maintenance and repair. All items requiring operation or maintenance (e.g. hydraulic steering reservoir, washer fluid tanks, switches, valves, filters, strainers, seacocks, etc.) shall be readily accessible while at the dock or underway.

Stowage and securing of arches, antennas, masts or other items shall not prevent access to critical items such as battery switches, fuel shut off valves or other items that need to be checked, secured or operated for any of the required transport modes.

071-2 Bilge Access

All bilges and voids shall have removable plates or hatches for bilge access/inspection. The access and inspection openings shall be of sufficient size and locations to allow personnel visual access to the entire bilge and void area.

071-3 Emergency Egress

All spaces shall have multiple egress points clearly labeled and sized for a person wearing a lifejacket.

071-4 Normal Access Below Deck

Below decks, centerline watertight doors with viewports shall allow passage from the galley to the DER, from the DER to the Engine Room and from the Engine Room to the Lazarette. The below deck spaces shall have a six and a half (6.5) foot minimum head height clearance that is free of all structure, cabling, and equipment. Any localized area with equipment protruding from the overhead below this height clearance shall be marked and guarded as a personnel hazard.

A bulkhead hatch or door from the galley to the forepeak shall be provided for access and stowage.

073 NOISE

073-1 Onboard Noise Levels

Sound treatment shall be installed as required in all manned spaces (defined in Section 070-10) to ensure sound levels are below 84 dBA for eight (8) hour exposure durations while underway at full RPM and below 77.5 dBA with main engine(s) secured and generators running for twenty-four

(24) hour exposure durations. Aft Work Deck and manned space noise level shall permit conversation at normal talking level (Speech Interference Level – 4, SIL-4, Category E from MIL STD 1474) with generators on and main engines secured.

073-2 Hearing Conservation

Based on Noise survey results required in Section 092, warning signs in accordance with Figure 1 of MIL STD 1474 shall be installed at entrance ways to any space where steady-state noise levels were recorded at 84 dBA or greater, to warn occupants of hazardous noise levels when machinery is operating.

Hangers for hearing protection earmuffs shall be provided adjacent to the entrance to DER and Engine Room.

075 FASTENERS

075-1 Stainless Steel Fasteners

Fasteners shall be Stainless Steel. Fasteners used for structural applications shall be ASTM F593, type 316. At a minimum, structural applications shall be defined as mounting of equipment greater than 50 lbs., strength fittings, hatches, and soft patches. For bolts with high strength requirements, non-stainless steel bolts may be used with Government approval and preserved in accordance with Section 070-9. Self-locking hardware shall be used unless otherwise specified.

Component mounting shall be through-bolted with ASTM F594 nylon locknuts and flat washers wherever practical to suit fastener reinstallation during maintenance and repair. Threaded fasteners shall fully engage nuts with thread protrusion. For blind connections, stainless steel threaded inserts shall be used to secure bolts or machine screws. Self-tapping screws shall not be used without government approval, which will only be considered for non-structural applications where threaded inserts are impractical or not desired for reasons of appearance.

Exceptions to the requirement for stainless steel threaded inserts in blind connections and approval of self-tapping screws shall be limited to the following:

• For the installation of sheathing/paneling in living spaces, except where access is necessary for equipment operation and maintenance. Examples where access is necessary for equipment operation and maintenance include operating valves, removal or servicing HVAC equipment, battery chargers, etc.

• For the installation of label plates throughout the craft.

• Any removable pins used for folding, removable, or stowable features shall be secured with a lanyard to prevent loss.

078 MATERIALS

078-1 Structural Material/Aluminum

Metal structure shall generally be of welded aluminum construction. Except as otherwise specified or approved by the Navy, structural aluminum materials shall be used and conform to the following specifications:

Sand cast (3560 T6)

Plate and sheet (5086 H116 or 5086-H117 both ASTM B928)

Extrusions (5086 H111)

Drawn tube (5086 H32)

Non-structural components such as handrails, small component brackets, and wire ways may include extruded 6061 material.

Stainless Steel (if used) shall be:

Cast for general applications (J92800 or J92500; for non-welded applications UNS J92900 or J92600 may be substituted.)

Cast for underwater applications (J92800; for non-welded applications UNS J92900 may be substituted.)

Plate/sheet, bars/shapes, tubing, pipe (S31603; for non-welded applications S31600 may be substituted.)

Component materials (e.g. piping, fasteners, etc.) are defined in their respective Specification Sections.

078-2 Non-Biodegradable Materials

Use of wood and other hygroscopic or biodegradable materials anywhere on the boat is prohibited.

All materials shall be marine grade and resistant to corrosion and Ultraviolet (UV) exposure.

078-3 Fabric Material

All boat fabric shall be marine grade as well as fade-, stain- and mildew-resistant and a near match in color as the surface it is mounted to or covering unless otherwise noted. Fabrics shall be easy to maintain and waterproof and/or breathable where required. All seams, edges, grommets, fastening points and areas of chafe shall be reinforced. Venting is acceptable to ventilate covers, but must minimize or eliminate the intrusion of water. Seats, seat fabric and foam shall be durable, provide comfort and be flame retardant.

078-4 Fire Retardant Interior Materials

All interior materials shall be fire retardant in accordance with 46 CFR 164.

079 STABILITY

079-1 Stability

The craft shall meet the following stability criteria of NAVSEACOMBATSYSENGSTA Report No. 6660-99 Rev. A, Procedures Manual for Stability Analysis of U.S. Navy Small Craft with the craft free to trim for all analysis:

• Beam Winds Combined with Rolling for a roll back angle (ƟR) of 25 degrees and a wind speed of 60 knots.

• Topside Icing for the default ice thickness of 3 inches.

• Damaged Stability for single compartment damage, a roll back angle of 14 degrees, and a wind speed of 30 knots. The permeability of the engine compartment shall be 0.85. The permeability of all other compartments shall be 0.95. Margin line and floodable length criteria need not be met.

• Lifting Heavy Weights Over the Side for the limit design load (See Section 589-1) of the crane at all crane boom and jib positions.

After Navy equipment installation, the boat shall float at an even heel (less than 0.2 degrees) and aft trim. Builders shall position organic and embarked equipment to achieve this requirement.

Permanent ballast shall not be required to correct the trim or heel of the craft.

See Section 085 for technical analysis requirements.

084 TRANSPORTATION AND HANDLING

084-1 Marine Transport

The boat shall be designed for marine transport and logistical launch and recovery (e.g. crane, well deck, or deck cargo transport) for Commercial shipping.

084-2 Boat to Ship Tiedowns

Tiedown provisions shall be provided for securing boat to the ship. Provision and adjacent structure shall be sized for applicable load (Boat Design Hoisting/Transport), per MIL-STD-1366E Section

5.1.6 with boat designed to be arranged longitudinally and athwartship on the transport ship.

Fittings design limit loads shall be as follows, applied to the Design Hoisting/Transport condition at the center of gravity of the craft: 1.0 times the acceleration due to gravity in the longitudinal direction (fore and aft), and 1.0 times the acceleration due to gravity in the lateral direction (port and starboard) assuming a 45 degree down angle from horizontal of the tiedown strap or chain.

Each tiedown provision shall be designed to a safety factor of 1.5 on the yield strength of the material in each direction of the design load. Labeling of the fittings shall include load ratings of the fittings in lbs. Up to 50% of the lateral and longitudinal load may be designed to be taken by a shipping cradle, if used. If a shipping cradle is assumed to take any of the lateral or longitudinal load, the preliminary design of the shipping cradle must also be provided with the Boat to Ship Tiedown calculations.

See Sections 085 and 092 for technical analysis and testing requirements. The Transportability Design and Certification report shall be used as guidance.

085 TECHNICAL DATA PACKAGE

The Technical Data Package (TDP) shall include all information essential for acceptance, operation/training, maintenance, repair, modification and supply support for the delivered boat. The TDP shall include, but not be limited to:

1. Technical Design Analyses;

2. As-built boat drawings including or cross referenced to:

3. a Bill of Materials (BOM) to the line replaceable unit (LRU) level;

4. Commercial Off-the-Shelf (COTS) manuals;

5. Boat Technical Manual;

6. OEM certifications;

7. OEM warranty durations for major systems;

8. Test and Trials Reports;

9. A Master Data Index.

085-1 Technical Design Analyses

Technical Design 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.

A sample calculation is included as an Appendix to NSWCCD-23-TM-2009/33 Rev A, Hoisting System Design and Certification Process Guidance, October 2009, US Navy Boats Hoisting Guidance document.

The contractor shall provide the following Technical Design Analyses:

a) Boat Stability: The analysis shall demonstrate that the integration of intact and damage stability standards in the boat design meets the required criteria in Section 079 following the procedures and assumptions outlined in NAVSEACOMBATSYSENGSTA Report No.

6660-99 Rev. A, Procedures Manual for Stability Analysis of U.S. Navy Small Craft.

b) Tow Provision Design: The analysis shall demonstrate that the design of the tow provisions meets the required criteria in Section 582-1.

c) Hoisting Fitting Design: The analysis shall demonstrate that the design of the hoisting fittings meets the required criteria in Section 611-3.

d) Tiedown Provision Design: The analysis demonstrates that the design of the tiedowns/restraints, fittings, and straps have the appropriate minimum factor of safety based on the weight and design loads in Section 084-2.

e) Electrical Load Analysis: An AC Electrical Load Analysis (ELA) shall be performed for both summer and winter conditions described in Attachment 5 for each of the following conditions: shoreside, transit and dive operations. AC ELA usage factors are provided in the ELA sample. A DC Electrical Load Analysis shall be performed in accordance with ABYC E-11 paragraph 11.8.1.

f) HVAC Sizing Analysis: The analysis shall be performed in accordance with the guidelines of SNAME T&R Bulletin 4-16 and shall demonstrate all installed HVAC equipment, components and systems will meet the required design criteria and environmental conditions in Section 512-5.

g) Submarine Fendering Protection: The analysis shall demonstrate the location and extent of fendering necessary to protect a submarine hull from incidental impact with the boat, based on the criteria in Section 611-2.

h) Structural Design: The analysis shall demonstrate that the craft structure meets the requirements of Section 100-2.

i) Crane integration: The following information shall be submitted as part of the crane analysis:

• Structural calculations showing that the crane foundation and supporting structure meets the requirements of Section 589b.

• Crane load and information charts, including all derating based on operating conditions

• List of all critical crane components in accordance with API 2C section 5.2 and certification that these components meet the API 2C material, traceability, welding (as applicable), and nondestructive examination requirements

• Crane operations, parts, and maintenance manuals in English

• Confidential access to crane manufacturer’s design calculations, associated drawings, and other pertinent information necessary to verify calculations in accordance with API 2C. The manufacturer shall certify that the crane meets the material and dimensional specifications used in the calculations.

• Wire rope manufacturer’s certification indicating the nominal breaking strength and actual breaking strength of a sample from the reel

• Nondestructive test report and proof test certificate on load hook from manufacturer

• Crane HPU operations, parts, and maintenance manuals in English

• List of all lubricants and fluids used on crane including Safety Data Sheets (SDS)

• Design criteria used for crane electrical components

Analysis documentation for items in Section 085 shall be provided in electronic format (native analysis format).

085-2 Drawings

Drawings and drawing revisions shall be prepared in accordance with the guidance of ASME Y14.100 and all referenced documents. Drawing level of detail shall be sufficient for acceptance, operation/training, maintenance, repair, modification and supply support for the delivered boat. The drawings shall reflect the accepted configuration for the first boat of the initial delivery order and shall be considered part of the boat’s baseline documentation for all subsequent delivery orders.

The Builder shall validate the construction drawings during the construction process by building all craft to the drawings. Drawings shall first be validated against the initial boat. 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. Drawings shall include a list above the title block of the applicable hull numbers for the given contract. All drawings shall be marked as ‘Rev 1’, ‘Rev 2’, etc. during the draft process through final approval. Upon final approval, the drawings shall be marked ‘Rev –‘. Any changes made after final approval will receive a ‘Rev A’, ‘Rev B’, etc. marking with revision history.

Drawings shall include, but are not limited to:

a) Boat Drawing Index

A boat drawing index shall be developed. This drawing shall list, in tabular form, all final construction 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.

b) Arrangements

The construction drawings shall include general arrangement, inboard profile, and outboard profile drawings that convey, without controlling dimensions, a general understanding of the craft 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 depict the external components, equipment and configuration of the craft. These drawings shall include external fittings such as:

Anchors Antennas Awnings Bell Canopy Capstans Compasses Console Control stations Crane Doors Draft marks Fire fighting 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 Rails Rigging Rub Rails / Fendering Rudders Scuppers Scuttles Searchlights Sewage connections Shafting Sheer guard Shore power connections Signal lights Skegs

Stanchions Station numbers Stowage locations Struts Water connections

Winches Windows Windshields Windshield-wipers

Inboard arrangements shall consist of plan and profile 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. Additional plan, longitudinal, and transverse section views shall be used as necessary to fully describe the craft. These drawings shall include internal fittings such as:

Auxiliary machinery Batteries Bulkheads Compartments identification and use Compasses Console Control stations showing all controls Doors location and swing Ducts Electronic equipment Fans Fire-fighting equipment Food service equipment Frames Generators Grab rails Hatches

Interior communication equipment

Ladders Lighting Lockers Longitudinals Power panels, electrical Propulsion machinery Scuttles Seating Stanchions Station numbers Stowage locations Switchboards; generator, distribution, and load center Tanks Vents Water closet showing fixtures Windows

c) Structure and Structural Details

The construction drawings shall include structure and structural details drawings that depict the craft structure and construction details, with controlling dimensions. Materials, scantlings, parts and other information necessary to construct the craft shall be specified.

The construction drawings shall include plan views of the bottom, decks, platforms, and flats; profile views of hull and superstructure, sides; and section views of the transom, bulkheads, frames, superstructure front and back, and longitudinals.

For structure that is symmetrical about the centerline, only one side need be shown. Minor exceptions to symmetry may be shown on the side drawn and designated port only or starboard only, as applicable. Groups of bulkheads or of frames that share identical scantlings and differ only in those overall dimensions that are determined by the lofted lines may be represented by a single typical section for each group.

Welding symbols, showing size and design, shall be shown for metal fabrications.

These drawings shall show the locations and details of hull construction and components, such as, but not limited to:

Access plates Aft Work Deck Frame / Canopy Brackets Bulkheads Bulwarks Coamings Collar plates Crane Support Structure Deck house intersections Doors, watertight and non-tight Doublers and inserts Flag staffs Flats Foundations Frames Gangways/Brows Hatches Hull penetrations Ladders

Lifting fittings Longitudinals Manholes Masts Mooring fittings Overboard discharges Pad eyes Patches Plating Rudder ports Scuttles Sea chests Shaft logs Shaft struts Skeg Stanchions Stiffeners Towing-fittings

d) Machinery Drawings

Machinery drawings shall be provided for each system. The machinery drawings shall depict the arrangement and details of all machinery and associated systems. The relationship of machinery and system components to each other and to the craft structure shall be shown with controlling dimensions and tolerances. Parts, materials, processes and other information necessary to construct the craft shall be specified.

Machinery drawings shall show piping, ventilation and electrical equipment as necessary to expose interferences between components and other undesirable conditions. The construction drawings shall also show other features such as component removal space outlines, ladders, accesses, and structural members necessary to indicate machinery clearances, obstructions and accessibility for maintenance.

A diagram which delineates the features and functional relationships of system components by means of symbols and lines shall be provided in each system drawing. The diagram shall provide a graphic explanation of the manner by which the system performs its intended function. The diagram shall show the interconnection of components. Applicable details, such as routing of fluids; types of valves and fittings; design pressures, temperatures, and flow rates; cleaning and testing requirements; interfaces with other systems; and all required warning, caution, or instruction labels shall be specified. System arrangement and diagrammatic drawings may be combined provided there is no loss of clarity.

The machinery drawings shall include the arrangements, details and diagrams for machinery, systems and their components such as:

Air conditioning system Bilge pumping system Combustion air system Crane Crane Hydraulic Systems Drain system

Engines Exhaust system Fans Fire extinguishing system Fresh water system Fuel system

Generators Hangers Heaters Hydraulic system Instruments and indicators Insulation Lagging Lubrication system

Navy embarked equipment and supporting systems

Piping Plumbing fixtures and fittings Propellers Propeller nozzles Propulsion control system

Pumps Reduction gear Resilient mounts Rudder Seawater systems Sewage system Shaft bearings Shaft couplings Shafting Steering system Structural penetrations Tank vents Tank sounding Ventilation system Washdown system

e) Electrical

Electrical drawings shall depict the arrangement and details of all electrical equipment, wiring and related hardware. The relationship of equipment, wiring, components, devices and parts to each other and to the craft structure shall be shown with controlling dimensions. Equipment, parts, materials, processes and other information necessary for installation and testing of electrical systems shall be specified.

A wiring or connection diagram shall be shown for each system. Electrical and electronics drawings and diagrams shall be in accordance with the IEEE-45 section 1.4.

Equipment designations, electrical circuit designations, and cable and conductor designations and markings shall be shown. Drawings shall show the change of conductor designations at changeover points from the craft numbering system to the numbering system of equipment as provided by the equipment manufacturer. Each conductor shall be identified on each side of the changeover point.

Electrical drawings shall specify applicable details, such as routing of wires; wiring devices; design voltage, current, power and temperature; testing requirements; interfaces with other systems; and all required warning, caution, and instruction labels.

The electrical drawings shall include the arrangements, details, and diagrams for electrical equipment, systems, and their components such as:

A.C. power system Alarm systems…