Electric Plant Installation Standard Methods for Surface ...€¦ · Updates to MIL-STD-2003...

Updates to MIL-STD-2003

Electric Plant Installation

Standard Methods

for

Surface Ships and Submarines

Presented at the National Shipbuilding Research Program

Electrical Technologies Panel Meeting

Charleston, SC

March 9, 2017

Christopher Nemarich

NAVAL SEA SYSTEMS COMMAND

Electrical Systems Ships – SEA 05Z32

DISTRIBUTION STATEMENT A. Approved for public release. Distribution is unlimited.


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MIL-STD-2003

Details requirements for standard installation methods employed for

submarine and surface ship electrical distribution systems.

Application to new construction, conversion, repair, and alteration of ships.

Intended for use by all Navy installation activities, public and private yards,

repair/maintenance depots, ships, including MSC and USCG.

Divided into 5 Parts:

Cable

Equipment

Penetrations

Cableways

Connectors


MIL-STD-2003 has over 1,000 pages of procedures and methods


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Reasons for revision to MIL-STD-2003

• No comprehensive update since initial issue 24 June 1987.

• Updates for new electrical installation methods, ship design and construction

techniques developed over the past 30 years.

• To include practices selected from the 2013 NAVSEA Enterprise

Commonality Cost Reduction Review of Electrical Installation Standard

Methods.

• To eliminate references to cancelled specifications and standards.

• To eliminate inconsistencies across procedures.

• Evaluate and incorporate changes recommended through the Command

Standards change system.


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MIL-STD-2003 revisions additionally include:

• NAVSEA approved methods from shipyard standard electrical installation

methods drawings from:

• Newport News Shipbuilding

• Ingalls Shipbuilding

• General Dynamics Electric Boat

• Puget Sound Naval Shipyard

• SUPSHIP Gulf Coast

• Regional Maintenance and Repair Centers

• Implementation of current applicable versions of accepted commercial

standards and practices.




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Timeline

• Approval to proceed with development of MIL-STD-2003B - 2014

• Intermediate Review completed - 2015

• Final Review completed - October 2016

• Released for Standards Review Board (SRB) - November 2016

• Adjudication of comments - March – July 2017

• Issuance of MIL-STD-2003B (planned) – 30 Sept 2017


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• Significantly expanded list of reviewers for the SRB and included industry

suppliers that support electrical installation methods to maximize feedback.

• Received significant comments from NAVSEA codes, shipyards, and fleet

maintenance centers during intermediate review.

• Received over 500 comments to date from SRB.

• Comment adjudication with coordination across NAVSEA organizations and

field activities.

• Each comment will be addressed and adjudicated individually.



Goal

Ensure accuracy and broad acceptance of methods and practices to

be published in MIL-STD-2003B

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1B Cables

• Added a new method (1D7) for repair of insulation directly over cable

conductors if conductor is completely intact and NAVSEA approval is obtained.

This was not allowed before.

• Added cable shielding requirements from VIRGINIA Class Standard Methods

drawing, NAVSEA 803-7016612. New methods for cable shield grounding, for

splicing, and for cable repair. Based on newer technologies.

• Reinstated the use of thimbles for end sealing of existing connections to non-

water block cables with approval from the local authority. Based on input from

SSGC that removing thimbles during overhauls is costly and unnecessary.

• Added new, alternate, less labor intensive, method for insulating connections

for motors & transformers from SSGC drawing SP0002019 (1B10)

• Added methods for splicing 5kV cables (1E6)



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1B Cables

• Allows for cold shrink sleeving as a substitute for heat shrink sleeving per the

requirements of ASTM F1835 for splices of cables rated < 500 volts above the

ship waterline where watertight integrity is not required. (Enterprise

Commonality Cost Reduction item).



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Cold shrink tubing is a more efficient method in cable splicing and jacket repair (limited implementation)

Recommendation Detail

• Include industry standard cold shrink tubing

methods in MIL-STD

• Require all future cable splicing and jacket

repair methods employ lowest cost cold

shrink tubing technology

Rationale / Savings Estimate

• The use of cold shrink tubing generates

80% labor savings relative to heat shrink

tubing installation by eliminating the labor

time required for hot work area

preparations and the use of active heat

sources during jobs

Cold Shrink Comparison Process Review

Heat Shrink Tubing

• Traditional heat source is used to repair cable jackets

• Process must meet hot work area restrictions

• Average labor time = 15 min

Cold Shrink Tubing

• Open-ended rubber sleeves are factory expanded and assembled onto removable plastic cores

• Core is removed allowing the tube to shrink and form a water-resistant seal

Average labor time = 3 min


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2B Equipment

• Added methods for bulkhead clip mounting of smaller electrical boxes. From the

approved method 502-NG NNS Standard Methods Drawing NAVSEA 302-

7526370.

• Added detailed methods to illustrate bonding and grounding of equipment to meet

MIL-STD-1310 requirements. Based on lessons learned from a new construction

project.

• Added allowance to use junction boxes to extend power and signal cables to

replacement components to avoid replacing a cable if the replacement component

junction box is in a different location than the original junction box. The cabling

between the extension junction box and the replacement component shall meet all

requirements of the original cables.

• Updated fastener requirements, such as limiting the use of split ring lock washers.

Based on analysis, testing and field experience.



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3B Penetrations

• Added general methods for installation of bulkhead square frame back-to-back

MCTs for certain protected bulkheads and decks. Based on Newport News

Standard Methods Drawing.

• Added instructions for installing MCTs with the capability of providing EMC

grounding. Based on method 616-NG Newport News Standard Methods

Drawing.

• Add requirements for spare MCP area to support future growth. “When installing

new MCPs, at least 20 percent of the MCP usable area shall be reserved for

future cable installations.”

• Added retest requirements for MCP installation. Retest requirements for all MCP

types changed to require airblast or vacuum box test for airtight, oiltight and

watertight penetrations. Based on input from PSNS and SSGC.

• Added requirements, methods and figures for the Expanded Sleeve Multi-Cable

Penetration Sealing System (RISE) system.



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The RISE system is an approved installation method for Multi-Cable Transits (MCTs)

RISE system components

Apply rubber sleeves

Cable RunsFill MCT with spare sleeve

Apply sealant

System Details

• RISE system utilizes specialized rubber sleeve that support various cables routed through MCT

• Spare sleeves are inserted in the MCT to allow for the quick installation of additional cables to a the MCT

• FIWA is a fire-resistant and water repellent sealant based on a single component silicone compound that expands to 10 times its original volume

Process Steps

• When exposed to fire or high temperatures, this rubber will expand to five times its original volume.

The RISE system allows for streamlined cable installation through MCTs that require fire resistant protection


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4B Cableways

• Eliminates requirement for channel rubber for cable banding in certain

circumstances as a labor and material cost savings.

• Specifies CRES 304 (nylon coated) or CRES 316 for cable bands for submarine

outboard cableways. Corrosion of CRES 304 occurs as they are electrically

isolated by channel rubber. Nylon coated CRES 304 is preferred due to

superior corrosion resistance.

• Added methods to allow cable hanger extensions to avoid adding new

cableways. Added methods for the use of Y-hangers. Based on Ingalls drawing

SP002109, Non-Standard Cableway Methods. (Enterprise Commonality Cost

Reduction Item)



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Including Y-Hangers in MIL-STD 2003 will allow for significant reduction in material cost (implemented)

Recommendation Detail

• Add Gulf Coast approved “Y – Shaped”

hanger as the primary method used for

creating multi-direction cableway

intersections

Rationale / Savings Estimate

• Average hanger installation currently

requires 2 hours of labor totaling 6 hours

• Reduction of 2 hanger installation will result

in 66% labor savings in time allocated to

cableway intersection installation

Y – Hanger Design Implications

Current cableway intersection components

• Intersection is created using either 2 or 3 hangers based on the nature of cable runs

Cableway Intersection

=

New cableway intersection components

Baseline Future Savings

Hangers Required 3 1 2

Average Material Cost Per Intersection $90 $60 $30

Average Labor cost per intersection $150 $100 $50

Total Intersection Cost $240 $160 $80


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4B Cableways

• Allows stud welding for major cableways. Based on NNS Standard Methods

Drawing for CVN’s. (Enterprise Commonality Cost Reduction Item)

• Allowed use of Panduit banding for larger cable bundles for non-weight bearing

applications with NAVSEA approval. Not approved for weight bearing

applications with larger cable bundles - not shock qualified. (Enterprise

Commonality Cost Reduction Item)



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Stud welding is NAVSEA approved installation method for hanger attachment that can be expanded to main cableways (implemented)

Stud Welding vs. Stick Welding Cost Opportunity

Stud Gun Welding Traditional Stick Welding

Process DetailsStud arc welding, joins a stud and another piece

of metal together using a capacitor discharge

Standard 360 degree weld for trapeze and inverted “T” hangers

Current ApplicationLimited to select applications in new construction

across the fleet except Virginia class

Main cableways during new construction and repair

Potential Future

State Application

90% of hull hanger connections where

technically feasible Extremely limited use in hanger connections

~Labor savings

relative to

traditional Welding

75% N/A

Source: Shipyard Workshops


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Employing the use of modern Panduit banding tools reduces labor required for cutting and securing banding material (implemented for main cableways)

Cable banding process

Source: Shipyard Workshops

Place strapApply buckle

Tighten band

Cut excess material

Close buckle

Panduit banding tools

Avg. Baseline Time

required with MIL-

STD tooling

2 min 2 min 10 min 2 min 2 min

Estimated time with

Panduit tools2 min 2 min 3 min 1 min 1 min

• Tools install extra-heavy .50" through super-heavy .63" cross section stainless steel metal locking ties

• Designed to reduce operator fatigue, promote worker safety, and improve productivity


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5B Connectors

• Added restrictions to use of hazardous connector material consistent with

NAVSEA letter Ser 05Z3/028 dated 06 December 2011 and MIL-STD-917.

• Acknowledges other connector types, other than the types specifically covered in

MIL-STD-2003-5, that may be called out for installation on drawings. “For other

connector types, such as RF, DB, and RJ connectors, class or specific ship

installation drawings, provided by the ship design activity, should be followed for

connector installation.”

• Provides SAE AIR1651 instructions for guidance to determine the proper torque

and tightness for assembling electrical connectors.



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5B Connectors

• Added new method for Multi-Cable Connector Assembly using grommets (Figure

5C3) Based on an Electric Boat drawing approved by NAVSEA letter 9300 Ser

397T1F/0693 dated 22 July 2016.



FIGURE XXXX. Multi Cable Connector Assembly - Connector.

CONNECTOR ADAPTERW/ O-RING

BACKINGPLATE

BACKSHELL MULTI-CABLE

GROMMET

GROMMETFOLLOWER

CLAMPASSEMBLY

BRANCHCABLES

1 2 3 4A 4 5 6

FIGURE XXXX. Multi Cable Connector Assembly - Grommet and Plug Views.

SEALING PLUG(S)

GROMMET

BACKING PLATE


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Comments on revisions to MIL-STD-2003 should be sent

before 17 March 2017 to:

[email protected]

[email protected]


mailto:[email protected]

mailto:[email protected]

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