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
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Updates to MIL-STD-2003
2
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
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MIL-STD-2003 has over 1,000 pages of procedures and methods
Updates to MIL-STD-2003
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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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Updates to MIL-STD-2003
Updates to MIL-STD-2003
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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.
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Updates to MIL-STD-2003
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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Updates to MIL-STD-2003
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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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Updates to MIL-STD-2003
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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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Updates to MIL-STD-2003
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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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Updates to MIL-STD-2003
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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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Updates to MIL-STD-2003
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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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Updates to MIL-STD-2003
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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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Updates to MIL-STD-2003
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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.
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Updates to MIL-STD-2003
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
Updates to MIL-STD-2003
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Comments on revisions to MIL-STD-2003 should be sent
before 17 March 2017 to:
DISTRIBUTION STATEMENT A. Approved for public release. Distribution is unlimited.