40PB Flt2.2 Att J-1 Specification Rev (-)_Final.pdf

FY23CRF 40PB Flt 2.2 Specification Rev. - N00024-23-R-2275

NAVAL EXPEDITIONARY COMBAT COMMAND

Coastal Riverine Force (CRF)

40’ PATROL BOAT FLIGHT 2.2 (40PB Flt 2.2)

Solicitation Number: N00024-23-R-2275

SPECIFICATION

REV. -

Attachment J-1

5 July 2023

REVISION HISTORY

Date Summary Of Change Version

TABLE OF CONTENTS

SECTION 0: GENERAL GUIDANCE AND ADMINISTRATION

040 INTRODUCTION AND GENERAL DESCRIPTION

040-1 Background

042 GENERAL ADMINISTRATIVE REQUIREMENTS

042-1 General 042-2 Definitions 042-3 Referenced Documents 042-4 Alternate Items 042-5 Statement of Work 042-6 Contract Drawings

050 CRAFT PERFORMANCE

050-1 Craft Performance

070 GENERAL REQUIREMENTS FOR DESIGN AND CONSTRUCTION

070-1 Characteristics 070-2 Environmental Conditions 070-3 Operational Profile 070-4 Load Conditions 070-5 American Boat and Yacht Council (ABYC) Standards 070-6 Alterations to Equipment or Components 070-7 Seakeeping, Dynamic Stability and Maneuverability 070-8 Installation of Equipment, Machinery, and Materials 070-9 Workmanship 070-10 Tolerances 070-11 Configuration Management

071 ACCESS

071-1 Accessibility 071-2 Bilge Access

073 NOISE, VIBRATION, AND RESILIENT MOUNTINGS

073-1 Noise Levels 073-2 Sound Attenuating Materials 073-3 Resilient Mounts

074 WELDING AND ALLIED PROCESSES

074-1 General 074-2 Visual Inspections (VT) 074-3 Dye Penetrant Inspections (PT)

075 FASTENERS

075-1 Stainless Steel Fasteners

078 MATERIALS AND CORROSION CONTROL

078-1 General 078-2 Metal Materials 078-3 Fabric Materials 078-4 Bedding Compounds 078-5 Non-Biodegradable Materials 078-6 Interior Materials 078-7 Hazardous Materials 078-8 Corrosion Control 078-9 Dissimilar Metals

079 STABILITY

079-1 Stability Requirements 079-2 List Limits

084 TRANSPORTATION AND HANDLING

084-1 Air Transport 084-2 Road Transport

084-3 Marine Transport, Launch and Recovery 084-4 Boat Tiedowns Table 084-4.1. Tiedown Analysis Summary 084-5 Tiedown Straps

088 HUMAN SYSTEMS INTERFACE

088-1 Ergonomics

092 TESTING

092-1 General 092-2 Test Certifications 092-3 Seawater Piping Galvanic Isolation Test Certification

094 TRIALS

094-1 Builder’s Trials (BT) 094-2 Pre-Delivery Inspection and Trials (PDIT) 094-3 Steering and Maneuvering Trials Table 094 Qualitative Ride Severity Ratings

096 WEIGHT

096-1 Determination of Weights

SECTION 1: HULL STRUCTURE

100 GENERAL REQUIREMENTS FOR HULL STRUCTURE

100-1 General Structural Requirements 100-2 Limber Holes

114 HULL APPENDAGES

114-1 Directional Stability Fins

130 HULL DECKS

130-1 Deck Drains 130-2 Watertight Decks and Hull

150 DECK HOUSE STRUCTURES

150-1 Cabin

164 BALLISTIC PROTECTION (DIST. D – SEE ADDENDUM)

167 HULL STRUCTURAL CLOSURES

167-1 Doors and Hatches

169 SPECIAL PURPOSE CLOSURES AND STRUCTURES

169-1 Swim Platform 169-2 Mast 169-3 Aft Deck Overhead Canopy

SECTION 2: PROPULSION

200 GENERAL REQUIREMENTS FOR PROPULSION PLANT

200-1 Propulsion Plant 200-2 Arrangement of Machinery

233 INBOARD DIESELS

233-1 Inboard Diesel Performance 233-2 Starter 233-3 Alternator

241 PROPULSION REDUCTION GEARS

241 Marine Transmission

243 PROPULSION SHAFTING

243 Driveshafts and Seals

247 WATERJET PROPULSION

247-1 Waterjet Propulsion

252 PROPULSION CONTROL SYSTEM

252-1 Propulsion Instrument Marine Package

256 MACHINERY COOLING SYSTEMS

256-1 Strainer

259 ENGINE EXHAUST SYSTEMS

259-1 Main Engine Exhaust (wet) 259-2 Exhaust Risers

262 MAIN PROPULSION LUBE OIL SYSTEM

262-1 Electric Fast Lube Oil Change System (FLOCS)

SECTION 3: ELECTRIC PLANT

300 GENERAL REQUIREMENTS FOR ELECTRIC PLANT

300-1 Suitable for Marine Environment 300-2 Panel Covers 300-3 Switches 300-4 Bonding System

303 PROTECTIVE DEVICES

303-1 DC and AC 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 304-7 Cableways 304-8 Ignition Protection

313 BATTERIES

313-1 Batteries 313-2 Battery Charging (Alternator) 313-3 Battery Voltmeter 313-4 Shore Power Battery Charger 313-5 120 VAC Inverter

320 POWER DISTRIBUTION SYSTEMS

320-1 DC Power Distribution System 320-2 AC Power Distribution System 320-3 Outlets (12 VDC) 320-4 Outlets (120 VAC GFCI) 320-5 Shore Power System

324 SWITCHGEAR AND PANELS

324-1 Electrical Circuit Breaker Panels

330 LIGHTING

330-1 Electronics Dimmer 330-2 NVIS Compatible Lighting 330-3 Interior LED Lighting 330-4 Deck Work Lights 330-5 Handheld Spotlight 330-6 Fixed Spotlight

SECTION 4: COMMAND AND CONTROL

400 COMMAND AND SURVEILLANCE, GENERAL

400-1 Tactical Communication and Navigation (TCAN) Systems 400-2 Communications Rack and Power Provisions

405 ANTENNA REQUIREMENTS

405-1 Antennas

420 NAVIGATION SYSTEMS

420-1 Electronic Chart System (ECS) 420-2 Integrated Electronic Navigation System

421 NON-ELECTRICAL/ELECTRONIC NAVIGATION AIDS

421-1 Magnetic Compass 421-2 Storage

422 ELECTRICAL NAVIGATION AIDS

422-1 Navigation Lights 422-2 Defense Advanced GPS Receiver (DAGR) Enhanced D3 (ED3) 422-3 Day Shape Mast

430 INTERIOR COMMUNICATIONS

430-1 Vehicle Intercom (TOCNET G4)

441 RADIO SYSTEMS

441-1 Commercial Marine Band Radio 441-2 Multi Band Mobile Radio (Motorola APX-8500) 441-3 SATCOM Radio System (Harris RF-300M-V250) 441-4 HF/VHF Radio system (AN/PRC-160)

443 VISIBLE AND AUDIBLE COMMUNICATION SYSTEMS

443-1 Navigation Horn 443-2 Law Enforcement Hailer/Siren System 443-3 Law Enforcement Light Kit 443-4 Infrared (IR) Strobelight

450 SURVEILLANCE SYSTEMS

450-1 Beacon Objective Lite (BOLT) 450-2 Automatic Identification System (AIS) 450-3 Electro-Optical/Infrared (EO/IR) Imaging System:

450-4 Video Distribution System

470 COUNTERMEASURE SYSTEMS

470-1 Long Range Hailing Device Provisions

SECTION 5: AUXILIARY SYSTEMS

500 GENERAL REQUIREMENTS FOR AUXILIARY SYSTEMS

500-1 Mechanical Components 500-2 Through-Hull Fittings and Valves

505 HOSES

505-1 Piping and Hose Materials 505-2 Pipe and Hose Installation 505-3 Hose Clamps

512 HEATING, VENTILATION, AND AIR CONDITIONING (HVAC)

512-1 Defogging System 512-2 Cabin Fans 512-3 Engine Room/Machinery Room Ventilation 512-4 Heavy Duty Cabin Heat and Air Conditioning

529 BILGE/DRAINAGE SYSTEM

529-1 Emergency Engine Space Dewatering System 529-2 Portable Manual Bilge Pump 529-3 Electric Bilge Pumps 529-4 Bilge Drainage

541 FUEL SYSTEM

541-1 General Requirements 541-2 Fuel Tank 541-3 Fuel Sounding 541-4 Fuel Level Gauge 541-5 Fuel Valves 541-6 Remote Fuel Shutoff 541-7 Fuel/Water Separator and Filter 541-8 Fuel Stripping Pump

555 FIRE FIGHTING

555-1 Engine Room Fixed, Clean Agent Fire Extinguishing System 555-2 Portable Fire Extinguishers

556 HYDRAULIC FLUID SYSTEM, CENTRALIZED

556-1 Hydraulics

561 STEERING CONTROL SYSTEMS

561-1 Hydraulic Steering

565 TRIM AND HEEL CONTROL SYSTEMS

565-1 Trim and Heel Control

581 ANCHOR HANDLING

581-1 Anchor Fittings 581-2 Fortress Anchor

582 MOORING AND TOWING

582-1 Towing Design Loads 582-2 Tow Posts 582-3 Bow Eye 582-4 Towing Hawser 582-5 Tow Pendant 582-6 Cleats

593 SEWAGE CONTROL SYSTEMS

593-1 Portable Toilet

SECTION 6: OUTFIT AND FURNISHINGS

600 OUTFIT

600-1 Onboard Spares 600-2 Boat Hook 600-3 Ring Buoy 600-4 U.S. Flag 600-5 Mooring Lines 600-6 Fenders 600-7 Air Horn 600-8 First Aid Kit 600-9 Emergency Positioning Indicating Radio Beacon (EPIRB)

602 LABELING

602-1 Hull Registry Number (HRN) 602-2 Label Plates (General) 602-3 Piping System Label Plates 602-4 Valve Label Plates 602-5 Instruction Label Plates 602-6 Operational Caution Label Plates 602-7 Hoisting Label Plates 602-8 Boat Information Label Plate 602-9 Boat Alteration Label Plate 602-10 Shipping Data Label Plate 602-11 In-Service Label Plate 602-12 Systems Label Plates 602-13 Stowage Label Plates 602-14 Unique Item Identification (UID) 602-15 Potential Noise Hazard Signs

603 LADDERS AND GRAB RAILS

611 HULL FITTINGS

611-1 Deck Cargo Tiedowns 611-2 Heavy Duty Fendering 611-3 Hoisting Fittings 611-4 Hoisting Sling 611-5 Hoisting Hardware

612 RAILS, STANCHIONS, AND LIFELINES

612-1 Grab Rails 612-2 Aft Deck Hand Rails 612-3 Life Lines

625 WINDOWS

625-1 Water Tight Windows 625-2 Windshield Wiper/Washer System

630 PRESERVATIVES AND COVERINGS

630-1 Bottom Paint 630-2 Draft Marks 630-3 Topside Paint 630-4 Anodes 630-5 Exterior Non-Skid 630-6 Anti-Fatigue Matting 630-7 Gratings

635 HULL INSULATION

635-1 Thermal Insulation and Acoustical Treatment

662 WORKING SPACES AND SEATING

662-1 Seating-Crew 662-2 Console Ergonomics 662-3 Bow Gunner Station

670 STOWAGE SPACES

670-1 Stowage (General) 670-2 Stowage (Crew Gear) 670-3 Stowage (Misc)

SECTION 7: ARMAMENT

700 ARMAMENT

700-1 Heavy Machine Gun Foundations 700-2 Remote Weapons System Provisions 700-3 Ready Service Ammunition Storage

763 SMALL ARMS AND PYROTECHNIC STOWAGE

763-1 Small Arms Stowage Locker 763-2 M2HB Barrel Stowage

SECTION 0: GENERAL GUIDANCE AND ADMINISTRATION

040 INTRODUCTION AND GENERAL DESCRIPTION

040-1 Background

This specification is for the 40-ft Patrol Boat Flight 2.2 (40PB Flt 2.2). The 40PB Flt 2.2 is a nominally 40 foot long aluminum patrol boat with twin waterjet propulsion. The 40PB will operate day or night, in all-weather and will patrol green water littoral zones such as coastal water approaches, bays, major rivers, ports, and harbors. Specifically, the boat will support maritime security operation missions and tasks such as Harbor Approach Defense; High Value Unit Transit Escort Operations; Visit, Board, Search, and Seizure (VBSS) Operations and Over-watch; Critical Infrastructure Protection; Amphibious Operations Support; Riverine Operations; Mine Warfare Support; Embarked Forces Support (e.g., Special operations Forces (SOF), Explosive Ordnance Disposal (EOD), US Coast Guard Law Enforcement Detachment (LEDET)); and, Humanitarian Assistance/Disaster Relief (HA/DR) Support. A mission objective is "presence and deterrence”.

40PB shall have a 5 man crew including a coxswain, navigator, 2 gunners and an engineer/gunner. Boat crew rotations typically occur 2 to 3 times during a 24- hour duty cycle period. Patrol missions will include short transits of less than 1-hour, 25 nautical miles from base to the Operational Area (OPAREA). While patrolling an OPAREA a boat may be required to loiter at very slow/idle to speeds of 5-8 knots and/or sprint at 35 knots to intercept a Contact of Interest (COI). Escort missions require the boat to match the speed of the High Value Unit, which is usually between 15 to 20 knots. Individual missions will typically be limited to a 12 hour duration.

042 GENERAL ADMINISTRATIVE REQUIREMENTS

042-1 General

This Specification describes the general requirements of the 40PB Flt 2.2 (hereafter referred to as 40PB, “the craft” or “the boat”) and describes the essential features, functions, and arrangements, but not necessarily the details of the design. Together with the Contract Drawings, it defines the boat as to dimensions, structure, arrangement, systems, performance, and power.

With respect to components, this Specification in conjunction with the Contract Drawings indicates the quantity of each major component required, together with such data as size, capacity, rating or power, and applicable specifications and standards or other technical requirements, which will enable the Contractor to procure or build the component.

With respect to systems, this Specification, in conjunction with the Contract Drawings, defines the characteristics of each system to be provided. It contains additional data such as capacity of the systems under various conditions and the flexibility and segregation requirements, which will enable the Contractor to prepare construction drawings and build the systems.

With respect to materials of construction and items of machinery, equipment, and outfit, which by their nature may be manufactured or procured as distinct items; this Specification contains only the requirements and information that pertain to selection, installation, onboard performance, onboard inspection and tests, pre-installation handling, inspection and tests by the Contractor.

Requirements such as physical or chemical properties, manufacturer test and inspection requirements, or other requirements applicable only to manufacturers, are contained in specifications or standards, drawings, or in other documents referenced herein.

042-2 Definitions

As-built condition: The boat configuration after completion of construction.

Contract Drawing: a Government furnished drawing forming part of the Specification, which illustrates features of the boat that are mandatory requirements.

CONUS: inside the Continental United States.

Craft, Boat, or Vessel: Synonymous terms for the 40PB.

Cruise Speed: Fuel efficient transiting speed, 30 knots.

Government Representative: The Contract Administration Office or other designated representative specified in the contract. Where such terms as “as approved”, “for approval”, “as directed”, and “for review” are used without further qualification, the approval, direction, decision, or review of the Government Representative is intended.

Herein: Refers to this Specification (including any attachments), the Statement of Work, and the Contract. For example, a requirement that includes the qualifying statement “unless otherwise stated herein” refers to these Specifications, the Statement of Work, and the Contract.

Idle Speed: Speed of the craft with both engines engaged and operating at engine idle speed.

OCONUS: Outside the Continental United States.

Patrol Speed: Efficient displacement speed slightly before hump, 8 knots.

Readily Accessible: capable of being reached quickly and safely for effective use under emergency conditions without the use of tools.

Reduced Mission Capacity: Missions conducted at elevated sea states during which crew movement is restricted while transiting and maneuvering.

Significant Wave Height: the average wave height (measured from trough to crest) of the highest 1/3 of waves present.

Sprint Speed: Boat speed at 100% throttle setting (maximum engine RPM).

042-3 Referenced Documents

Unless otherwise stated all documents shall be the most current revisions at time of contract award.

a. ISO 2533:1975, “Standard Atmosphere”

b. Blount, Donald L., Performance by Design. 2014

c. NSWCCD-80-TR-2014/038, Weight Management Process Guidance for Boats and Craft

d. “Standards and Technical Information Reports for Small Craft”, American Boat and Yacht Council

e. NAVSEA TO300-AU-SPN-010, “Fabrication, Welding and Inspection of Small Boats and Craft, Aluminum Hulls”

f. MIL-STD-2035, “Nondestructive Testing Acceptance Criteria”

g. ASTM F593, “Standard Specification for Stainless Steel Bolts, Hex Cap Screws, and Studs”

h. ASTM F594, “Standard Specification for Stainless Steel Nuts”

i. ASTM B928, “Standard Specification for High Magnesium Aluminum-Alloy Products for Marine Service and Similar Environments”

j. MIL-STD-1623, “Fire Performance Requirements and Approved Specifications for Interior Finish Materials and Furnishings”

k. NAVSEA T9070-AL-DPC-020/077-2, “NAVSEA Hazardous Material Avoidance Process”

l. NSWCCD-23-TM-2011/05, “U.S. Navy Craft Mechanical Practices”

m. NAVSEACOMBATSYSENGSTA Report No. 6660-99 Rev. A, “Procedures Manual for Stability Analysis of U.S. Navy Small Craft”, 1988

n. NSWCCD-23-TM-2009/64 Rev C, “Small Craft Transportability Design and Certification Process Guidance”

o. MIL-STD-1366E, “Department of Defense: Interface Standard for Transportability Criteria”

p. 49 “CFR” 393.102, “What are the Minimum Performance Criteria for Cargo Securement Devices and Systems?”

q. MIL-STD-209K, “Interface Standard for Lifting and Tiedown Provisions”

r. MIL-STD-1791D, “Department of Defense Interface Standard: Designing for Internal Aerial Delivery in Fixed Wing Aircraft”

s. ASTM F1166, “Standard Practice for Human Engineering Design for Marine Systems, Equipment, and Facilities”

t. ASTM F1321-14, “Standard Guide for Conducting a Stability Test (Lightweight Survey and Inclining Experiment) to Determine the Light Ship Displacement and Centers of Gravity of a Vessel”

u. NSWCCD-23-TM-2011/38, “Mooring Fitting Design and Verification Process Guidance”

v. NAVSEA S6430-AE-TED-10, “Piping Devices and Flexible Hose Assemblies”

w. ISO 12215-6, “Small craft — Hull construction and scantlings — Part 6: Structural arrangements and details”

x. MIL A-A-55308, “Cloth and Strip, Laminated or Coated, Vinyl Nylon or Polyester, High Strength, Flexible”

y. NSWCCD-23-TM-2009/58, “U.S. Navy Boat Electrical Practices”

z. MIL-DTL-3950, “Switches, Toggle, Environmentally Sealed”

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

bb. UL 1426, “Standards for Safety Electrical Cables for Boats”

cc. MIL-STD-3009, “Department of Defense Interface Standard: Lighting, Aircraft, Night Vision Imaging System (NVIS) Compatible”

dd. MIL-STD-1310H, “Shipboard Bonding, Grounding, and other Techniques for Electromagnetic Compatibility, Electromagnetic Pulse (EMP) Mitigation, and Safety”

ee. Convention on the International Regulations for Preventing Collisions at Sea, 1972 (COLREGs)

ff. ASTM A276, “Standard Specification for Stainless Steel Bars and Shapes”

gg. SAE J1942, “Hose and Hose Assemblies for Marine Applications”

hh. SAE J1527, “Marine Fuel Hoses”

ii. SAE J2006, “Marine Exhaust Hose”

jj. SAE J517, “Hydraulic Hose”

kk. SAE J516, “Hydraulic Hose Fittings”

ll. SAE J3062, “Automotive Refrigerant Air-Conditioning Hose Requirements”

mm. SAE J1273, “Recommended Practices for Hydraulic Hose Assemblies”

nn. NSWCCD-23-TM-2011/39, “Anchoring System Design and Verification Process Guidance”

oo. NSWCCD-23-TM-2009/65, “Towing Fitting Design and Certification Process Guidance”

pp. MIL-DTL-15024, “Plates, tags, and bands for identification equipment”

qq. S9086-TX-STM-010, “Naval Ships’ Technical Manual Chapter 583 – Boats and Small Craft”

rr. NAVSEA DWG 602-5109421, “Boat Contact Information Label Plate”

ss. NSWCCD-23-TM-2009/33, “Hoisting System Design and Certification Process Guidance”, Rev A

tt. MIL-DTL-24779, “Anodes, Sacrificial Aluminum Alloy”

uu. MIL-PRF-24647, “Paint System Anti-Corrosive Ship Hull”

vv. NSWCCD-80-TR-2015/010, “Laboratory Test Requirements for Marine Shock Isolation Seats”

ww. MIL STD 1472, “Department of Defense Design Criteria: Human Engineering”

xx. ABCD-TR-15-001: Supplement, “High Speed Craft Human Factors Engineering Design Guide”

yy. DoD HDBK 743, “Anthropometry U.S. Military Personnel”

zz. NSWCCD-23-TM-2009/63, “Small Craft Crew Served Weapons Integration Guidance and Certification Process”

042-4 Alternate Items

Where boat components and equipment are specified by brand name or manufacturer and part number (p/n) and followed by “or equal”, such identification is intended to be descriptive, not restrictive, and is intended to indicate the required characteristics of the product. The Contractor 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:

a. 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.

b. The materials of construction of the alternate item shall be the same as those of the designated item unless the Contractor can demonstrate to the Government that the proposed alternate material will not adversely affect performance or service life of the item, the system within which it is installed, or the boat as a whole.

c. The reliability and maintainability of an alternate item shall be equal to or better than the specified item. The Contractor shall provide evidence of the reliability and maintainability of the alternate item. This evidence may include such things as results of testing, service histories, documentation of successful use in similar applications, planned maintenance requirements, etc. Where the reliability and maintainability of the specified item has been established by testing, the Government may require that the alternate item undergo similar testing to demonstrate its reliability and maintainability.

Such testing, if required, shall be at the Contractor's expense.

d. An alternate item shall conform to the same industry or Government specifications or standards as the specified item. Where a specified item has been approved or certified by a regulatory or testing agency, such as USCG or Underwriters' Laboratories, the alternate item shall also be approved or certified. The cost of demonstrating compliance with specifications or standards, or of obtaining approval or certification, shall be borne by the Contractor.

If the specified item is one with established logistic support any alternative item shall have equivalent logistic support. If equivalent logistic support has not been established for the alternate item, the Contractor shall bear the expense of establishing equivalent support. Logistic support shall include, as applicable: maintenance planning and analysis; training and training support, including training equipment, curricula, and instruction materials; supply support; support equipment such as special tools and test equipment; technical documentation including technical manuals, Product Technical Description (PTD), Planned Maintenance System (PMS), Technical Repair Standards (TRS), and software documentation; computer resource support; facilities for maintenance and training; unique packaging, handling, storage, and transportation requirements; and human engineering considerations.

042-5 Statement of Work

This specification is written to be used in conjunction with the Statement of Work.

Additional requirements such as training, testing, technical analyses, etc are defined in the Statement of Work.

042-6 Contract Drawings

The following Contract Drawings form a part of this Specification. Hereinafter, wherever a reference is made to "the drawings" without further identification, it shall be understood to apply to the following listed Contract Drawings.

CONTRACT DRAWINGS

Drawing Title NAVSEA Drawing Number Revision

Hull Lines and Offsets 40PB-100-5113121 -

Deck Lines and Offsets 40PB-100-5113122 -

Outboard Arrangement 40PB-100-5113123 -

General Arrangement 40PB-100-5113124 -

Hull Construction Arrangement and Details 40PB-100-5113125 -

Deck Construction Arrangement and Details 40PB-100-5113126 -

Cabin Construction Arrangement and Details 40PB-100-5113127 -

Control Console Arrangement and Details 40PB-100-5113128 -

Machinery Arrangement and Details 40PB-200-5113129 -

AC Electrical Systems 40PB-300-5113130 -

DC Electrical Systems 40PB-300-5113131 -

Tactical Comms and Nav Interconnection Diagram 40PB-400-5113132 -

Tactical Communications and Navigation Rack 40PB-400-5113133 -

Piping System Diagrams 40PB-500-5113134 -

Miscellaneous Details 40PB-600-5113135 -

Hoisting Arrangement and Details 40PB-600-5113136 -

Hull Insulation Arrangement 40PB-600-5113137 -

Weapons System Arrangement and Details 40PB-700-5113138 -

Ballistic Protection 40PB-100-5113139 -

In the development of construction drawings or construction of the boat by the Contractor, no departure from Contract Drawings is permitted unless such departure is specifically approved by the Government. The Contractor shall be responsible for developing the details necessary for the construction of the boat and correcting all interferences that may arise during development of construction drawings or construction of the boat. Quantities given on Contract Drawings are for estimating purposes only; the Contractor is required to ascertain the exact quantities required.

An arrangement drawing is a Contract Drawing used to depict a general understanding of the boat configuration. It is used to ensure interoperability across the fleet by defining the nominal placement of equipment in the boat and relative to adjacent components. Some arrangement drawings may contain dimensioned details that control critical sizes and interfaces that are defined by design points such as analyses or equipment installation.

A piping diagram is a Contract Drawing used to depict features, routing, functional relationships, relative locations, and nominal arrangements of the major components forming a fluid system without regard to actual physical size, shape or precise location of components.

A schematic or wiring diagram is a Contract Drawing used to depict features, routing, functional relationships, relative locations, and nominal arrangements of the major components forming an electrical system without regard to actual physical size, shape or precise location of components. In the development of construction drawings or construction of the boat, the Contractor shall complete details for the electrical system not depicted on the Contract Drawing such as, but not limited to: terminal boards, junction boxes, connectors, and systems described in this Specification but not included in the Contract Drawing.

050 CRAFT PERFORMANCE

050-1 Craft Performance

The 40PB is capable of the following performance parameters:

Sprint Speed: 35 kts

Cruise Speed: 30 kts

Range: 200 NM

Speed and Range are measured in Calm Water, Full Load condition (Section 070), ISO Standard 2533:1975 “Standard Atmosphere” conditions. Range is measured at cruise speed.

Navigational Draft: less than 3 ft

Minimum Payload : 5,350 lbs

Crew: 5 personnel at 285 pounds each 1,425 lbs.

Crew Served Weapons and Ammunition 1,240 lbs.

Miscellaneous Payload 500 lbs.

Remote Weapon System Reservation 570 lbs.

Service Life Margin 475 lbs.

4 Passengers 1,140 lbs.

Total Payload 5,350 lbs.

The craft meets all performance requirements in both fresh and salt water.

070 GENERAL REQUIREMENTS FOR DESIGN AND CONSTRUCTION

070-1 Characteristics

The 40PB has the following general characteristics:

Length Overall (LOA): 44’-0” feet

Beam Overall (BOA): 11’-11” feet

Chine Beam (maximum): 11’-8” feet

Total Installed Fuel Capacity: 340 gallons

The 40PB shall not exceed the following weight and center of gravity limits:

Light Ship (As-built condition): 25,500 lbs

Light Ship Longitudinal Center of Gravity (LCG) (As-built condition): 161.5 inches (+ 2 inches, – 4 inches) forward of transom-keel intersection.

Trailer Weight: 7,100 lbs

Trailer Longitudinal Center of Gravity: 21’- 5” feet forward of t/k intersect

Trailer Vertical Center of Gravity: 0’- 0” feet above boat baseline, 2’ - 0” above the ground

070-2 Environmental Conditions

The boat shall be capable of operating in ambient air temperatures between 10oF and 125oF and water temperatures between 28oF and 95oF. See Section 512 for specific environmental conditions for HVAC performance.

The boat shall be capable of full operations in Full Load condition in up to 3 foot Significant Wave Height (SWH) waves. The boat is capable of Reduced Mission Capacity operations in up to 5 foot SWH waves. Wave characteristics are defined by Wilbur Marks Scale per Table A1-H of reference (b), Performance by Design.

The primary areas of operation shall consist of seawater and brackish waters. 40PB shall be capable of conducting fresh water operations.

The boat materials shall be capable of withstanding ambient temperatures up to one 150oF during full exposure to ultraviolet (UV) rays when onboard ships in open stowage areas.

070-3 Operational Profile

40PB shall operate up to 3,000 hours a year when deployed OCONUS and 1,000 hours/year when stationed CONUS. Normal lifecycle maintenance and emergent equipment or systems repairs will be accomplished at their CONUS homeports, or in deployed locations OCONUS, as appropriate. Boats typically forward deploy for 3-4 year rotations before returning CONUS. Crews typically rotate every 6-8 months, training on boats CONUS then operating forward deployed boats.

Given the high annual number of operational hours on the water, a simple, reliable and easy to maintain design is required.

The 40PB will have a mission duration up to 12 hours with two primary mission profiles defined as follows:

Speed Mission Profiles

Harbor Patrol HVU Escort Idle: 82% 56% Patrol: 11% 19% Cruise 5% 15% Sprint: 2% 10%

The expected service life for the boat delivered under this Specification is 15 years. The service life may be extended for up to 20 years with major overhauls including replacement of propulsion systems (engines, water jets), mechanical systems (fuel, bilge), electrical systems, collars/fendering, and cosmetic hull repair.

070-4 Load Conditions

The following load conditions are provided for reference throughout this specification. These definitions apply to the engineering design values for weight and moments of the vessel in the described condition. Weight Management Process Guidance for Boats and Craft, NSWCCD-80- TR-2014/038 shall be used for guidance.

Light Ship: The boat is complete in all respects including outfit (defined in Section 600), Government Furnished Equipment (defined in Section 400) and ready for service with liquids in machinery at operating levels, but no payload, personnel, fuel, or other variable loads.

Full Load Condition: Light Ship plus payload as defined in Section 050 and full fuel.

Fuel weight shall be calculated using a density of 7 lbs/gallon.

Minimum Operating (MinOp) Condition: Light Ship plus crew and 10% fuel.

PDIT Load Condition: Full Load Condition

Boat Over-the-Road (OTR): Light Ship plus full fuel, plus 3,310 lbs of mission gear and a 5-10% margin for growth. Note the 5-10% margin is used for sizing of the trailer.

The trailer axles and components shall support the boat/trailer within the 5-10% margin range.

Trailer Curb Weight: Trailer complete in all respects, including all tools/stowages on trailer, OTR tiedown straps, and misc. material required for OTR transport (e.g. boat covers, tiedown strap chafe protection, etc), and a 5-10% margin for growth.

Gross Vehicle Weight (GVW): Combined Boat OTR and Trailer Curb Weight.

Trailer Design Hoisting: Trailer Curb Weight using a 10% margin for growth.

Combined (Boat and Trailer) Design Hoisting: Combined Boat OTR using a 10% margin for growth (weight and moment) and Trailer Design Hoisting (weight and moment), including any additional material needed for hoisting trailer beneath boat (e.g.

additional tiedown straps, ballast (if necessary) and deck tiedowns, etc).

Boat Only Internal Air Transport (IAT): Boat OTR, reduced to have no more than 25% fuel, without mission or personnel gear, rounded up to the neared 1000 pounds (minimum)

Trailer Only IAT: Trailer curb weight, rounded up to the nearest 1000 pounds (minimum)

Boat Design Hoisting at Sea: Full Load plus a 10% margin for growth.

070-5 American Boat and Yacht Council (ABYC) Standards

Unless otherwise defined, the boat in all respects shall meet ABYC standards and recommended practices.

070-6 Alterations to Equipment or Components

Alterations to Original Equipment Manufacturer's (OEM) products by the Contractor or distributors are strongly discouraged unless alternations are specifically referenced in the drawings.

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 Seakeeping, Dynamic Stability and Maneuverability

In Full Load and MinOp Condition and at all speeds defined herein, the 40PB shall be able to maintain a straight course. Without coxswain action for 10 seconds, the boat shall not deviate course by more than 5 degrees in calm, flat conditions.

Dynamic Stability: The 40PB shall be dynamically stable (oscillatory and non-oscillatory) at all operational loading conditions and speeds.

The astern performance shall be such that the 40PB can be maneuvered in reverse at speeds of at least 3 knots in a straight course and perform backing turns to port and starboard.

070-8 Installation of Equipment, Machinery, and Materials

All equipment and materials shall be new. 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.

Unless otherwise approved by the Government, OEM recommendations for design and installation of their products into the boat shall be followed. Connecting piping and wiring shall be run to minimize exposure to weather and bilge water. 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.

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

All piping shall be cleaned to a degree of cleanliness that results in a surface that is reasonably free of contamination and any remaining residue on the surface does not interfere with system operation or damage system components.

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. Equipment shall be removable without the removal of adjacent equipment unless otherwise approved by the government.

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 200°F. If surfaces exceed 140°F in the proximity of controls or manual actuators requiring manipulation by personnel during normal operation, protective guards or insulation shall be installed to prevent contact. For other surfaces exceeding 140°F, caution signs shall be installed.

Electrical equipment shall have non-conductive guards, screens, protective barriers or be insulated to protect personnel from contacting hazardous voltages or exposed terminals. Male plug and receptacle connectors shall be wired to the load side of the circuit to ensure that no voltage is present when not connected.

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

070-9 Workmanship

The Contractor shall adhere to best marine practices.

Plating shall be fair, closely fitted, and free from buckling or uneven edges. Filler shall not be used to correct improper fit. Warpage and distortion of the hull below the sheer line shall not exceed limits stated in NAVSEA TO300-AU-SPN-010. Fairing compounds shall not be used.

Permissible unfairness above the sheer, including main deck and cabin plating, shall not exceed 1/4” between longitudinal stiffeners. Heat forming and flame straightening shall not be used.

All sharp edges shall be dressed, ground, or radiused to avoid injury to personnel or damage to equipment, and to promote adhesion of coatings.

Pipe, cable and other penetrations through decks and through watertight bulkheads shall be watertight using a multi-diameter sealing system with removable layers, shall reduce the transmission of heat, and shall 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.

070-10 Tolerances

a. Where tolerances are not otherwise indicated by OEM guidance or on the drawings the following tolerances shall apply:

i. Dimensions given decimally:

in inches (inch-pound);

.X - ±0.06 inch

.XX - ±0.03 inch

.XXX - ±0.005 inch

ii. Dimensions given in inches and fractions:

linear - ± 1/16 diameters - ± 1/16 radii - ± 1/16

iii. Dimensions given in feet and whole inches - ±1/8 inch

iv. Angles:

Whole degrees - ±1/2 degree

Degrees and minutes - ±5 minutes

v. Construction tolerance. Cumulative departure from the lofted dimensions shall be held within the following limits:

Length Overall - ± 3/4 inch

Beam Overall - ± 3/8 inch

b. The tolerances shall apply to all fabrication performed from the Contract Drawings and the Contractor developed Construction Drawings, except where deviation to either relax or tighten the tolerance is noted on the drawings or required elsewhere in this Specification.

c. The finished lines of the completed hull and deck shall be maintained to ± 0.188 inch for transverse and height dimensions and to ± 0.375 inch for longitudinal dimensions when compared to the hull lines lofted from the Contract Drawings table of offsets.

070-11 Configuration Management

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

071 ACCESS

071-1 Accessibility

Electrical and mechanical components shall be accessible for maintenance and repair. All items requiring operation or maintenance (e.g. switches, valves, filters, strainers, seacocks, etc.)

shall be readily accessible while at the dock, on the trailer, or underway. Stowage and securing of antennas or other items, with the exception of the mast in the stowed position, 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.

Where accessibility for operation or maintenance is not evident during Pre-Delivery Inspections and Trials (PDIT) the Contractor shall be prepared to demonstrate accessibility by operating, removing, or otherwise manipulating the necessary components under realistic conditions.

071-2 Bilge Access

All bilges and voids shall have removable, mechanically fastened plates or hatches for bilge access and 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. Components in the bilge that need to be regularly accessed such as bilge pumps, strainers, valves, etc. shall be readily accessible by hatches requiring no tools to open. Access panels, plates or hatches shall not compromise the rating of the deck in which they are installed.

073 NOISE, VIBRATION, AND RESILIENT MOUNTINGS

073-1 Noise Levels

The 40PB cabin is designed to avoid requirements for hearing protection for a 12 hour time weighted averaged not to exceed 82 dBA. To achieve these noise levels in the cabin, insulation shall be installed as per contract drawings to achieve the following objectives.

Speed Noise Limit dB(A)

Idle: 73

Patrol: 77

Cruise 88

Sprint: 91

Wind noise on the aft deck and in the gun tub is 85dBA or greater at speeds greater than 12 knots. Appropriate labels (Section 602) shall be provided on the access to the aft deck, fore deck and in the gun tub advising personnel of the potential noise hazard.

073-2 Sound Attenuating Materials

Any sound attenuating material shall: (1) permit inspection of the interior hull and hull structure; (2) be resistant to absorbing any type of liquid or vapors; (3) not cause any corrosion to the hull material; and (4) be noncombustible.

073-3 Resilient Mounts

The boat and all boat components shall be free from excessive vibration. Vibration is excessive when it interferes, or threatens to interfere, with the proper operation of any boat component. Mounts for removable components and accessories subject to vibration, including items moved for towing or transport, shall be provided with resilient material as necessary to prevent rattling.

074 WELDING AND ALLIED PROCESSES

074-1 General

Welder and weld procedure qualification - weld procedures and welder qualification, including the associated record keeping requirements, shall be in accordance with the American Society of Mechanical Engineers (ASME), the American Welding Society (AWS), or NAVSEA TO300-AU-SPN-010 A, dated 5 October, 1992 (NAVSEA SPN-10).

The Contractor shall select one of these welding codes and adhere to all requirements of the selected document for each welding procedure specification. The Contractor may select different regulating codes for different weld procedures; however, all documentation, welding and welder requirements for each procedure (for example, the Welding Procedure Specifications (WPSs), the Procedure Qualification Records (PQRs) and the welder qualification and testing of the welds) must follow the same code.

All documentation pertaining to welder, weld procedure, and weld standard qualification shall be maintained by the Contractor and shall be available for inspection by the Government. If a subcontractor is used, the Contractor shall include these requirements in the subcontracting agreement and be responsible for assuring they are fulfilled.

Joint design, fabrication requirements, repairs to welds and pipe welding and brazing shall be in accordance with the American Society of Mechanical Engineers (ASME), the American Welding Society (AWS), or NAVSEA TO300-AU-SPN-010.

The Contractor shall develop, maintain and follow a weld sequencing and distortion control plan. The plan shall be available for inspection by the Government. Distortion reduction techniques shall be employed on assemblies of light plating 1/4 inch thick or less, particularly flat panels. Generally welding shall be started in the center of the boat or craft and progress to outboard, keel to shear, forward, and aft. Prefabricated units (subassemblies, assemblies) should be welded in the same manner, starting in the center and welding progressively outward. These should be externally stiffened as necessary and such stiffening left intact until the assembly is welded into the main structure. Distortion shall be minimized by use of a backstep sequence, weighting (with lead or clean steel), external temporary stiffening or a combination of these techniques.

Acceptance criteria for workmanship shall be as specified in NAVSEA TO300-AU-SPN- 010, Section 11.

074-2 Visual Inspections (VT)

All welds shall be visually inspected.

Surfaces to be welded shall be cleaned to remove oil, grease, wax, oxide, scale, rust and other contaminants. In the case of aluminum, the oxide film shall be removed within 8 hours prior to welding.

Welds shall be free of slag, weld splatter, cracks, sharp irregularities, craters, and incomplete fusion.

The weld edge shall not form a reentrant angle with the base metal less than 90 degrees due to lack of fusion, undercut or excessive convexity.

Fillet welds dimensioned 3/8 inch or less shall not vary below the specified size by more than 1/16 inch for a total distance greater than 25% of the joint length. Fillet welds dimensioned 7/16 inch and larger shall not be less than the specified size. Fillet welds in excess of the required dimensions shall be avoided; however, oversized welds will be acceptable provided they meet the contour requirements and do not interfere with proper operation of the boat or its components.

Undercut shall not reduce the base metal thickness by more than 1/32 inch.

Welds shall not exhibit porosity or worm holes in excess of two indications 1/16 inch or larger in any 6 inch length of weld, exclusive of weld crater porosity.

Grinding to correct the weld profile shall not reduce the base metal thickness by more than 1/32 inch.

074-3 Dye Penetrant Inspections (PT)

PT methods shall be in accordance with American Society of Mechanical Engineers (ASME), American Welding Society (AWS), or NAVSEA TO300-AU-SPN-010 requirements.

The bow eye, forward tow post, aft tow post, hoisting fittings, crew served and remote weapons foundations, including any supporting insert plates; and boat and trailer tiedown fittings are critical welded assemblies. Critical welded assemblies, in addition to visual inspection, shall be dye penetrant inspected (PT) prior to painting or other finish treatment as follows:

1. Visually inspect completed critical welded assembly per Section 074-2. If passing, proceed to step 2.

2. Before load testing, PT welds and 1/2 inch of base metal on either side of the weld for linear indications greater than 1/16 inch. If passing, proceed to step 3.

3. Pull test to the load required by Section 092.

4. After load test, visually inspect fittings and boat structure for signs of failure or permanent deformation. If passing, proceed to step 5.

5. After visual inspection, PT welds and 1/2 inch of base metal on either side of the weld for linear indications greater than 1/16 inch.

075 FASTENERS

075-1 Stainless Steel Fasteners

Fasteners shall be type 316 Stainless Steel (UNS S31600). Fasteners used for structural applications shall be ASTM F593, Alloy Group 2 (type 316 stainless steel), Condition A or CW.

Where required for high strength application (e.g. engine shaft coupling), non-stainless, high strength fasteners with corrosion protection (e.g. paint corrosion inhibitor, etc.) may be used with Government approval.

Component mounting shall be through-bolted with ASTM F594 (type 316 stainless steel) nylon insert lock nuts and flat washers wherever practicable to facilitate fastener reinstallation during maintenance and repair. Threaded fasteners shall fully engage nuts with thread protrusion.

Excessive thread protrusion that poses a personnel hazard shall be avoided.

Fasteners may be threaded into structural or non-structural materials only with Government approval.

Any removable pins used for folding, removable, or stowable features shall be secured to the craft with stainless steel lanyards to prevent loss. Spring-loaded ball bearing type locking pins shall not be used.

The Contractor shall supply all fastening hardware for the Government Furnished Equipment (GFE).

078 MATERIALS AND CORROSION CONTROL

078-1 General

Materials referred to in this Specification without further identification shall comply with this section. Other materials, which are acceptable for use in specific applications, will be defined in the relevant Specification section or reference document that requires their use.

No plastic, polyvinyl chloride (PVC), chlorinated polyvinyl chloride (CPVC), or high-density polyethylene (HDPE) shall be used without explicit Government approval except OEM components (e.g. electric bilge pump, NEMA Boxes).

All materials shall be marine grade and resistant to corrosion. All materials normally subjected to sunlight shall be highly resistant to degradation caused by ultraviolet radiation.

Joining surfaces between mechanically fastened metal components and between metals and laminates shall be protected by the use of bedding compound.

078-2 Metal Materials

Aluminum shall be:

Sand cast: 3560 T6, Plate and sheet: 5086 H116 or 5086 H117 both ASTM B928, Extrusions: 5086 H111, Drawn tube: 5086 H32.

Non-structural non-welded components such as handrails, small component brackets, and wire ways may include extruded 6061 material. Non-structural 6061 components in welded applications shall be approved by the Government prior to fabrication.

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.

078-3 Fabric Materials

All boat fabric shall be marine grade as well as fade, stain and mildew resistant and as near a match in color as possible to 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 Bedding Compounds

Polysulfide and polyurethane sealants may be used above and below the waterline. Where waterproof adhesive bonds are required, a polyurethane compound shall be used. Bedding compound shall be highly elastic, non-corrosive, paintable, solvent-free, with high adhesion properties and be suitable to the intended environment.

078-5 Non-Biodegradable Materials

The use of wood and other hygroscopic or biodegradable materials anywhere on the boat is prohibited, except where provided within OEM…