1 of 14 ITEM NO: 009-73
FY-25
NAVSEA
STANDARD ITEM
FY-25
ITEM NO: 009-73
DATE: 01 OCT 2023
CATEGORY: I
1. SCOPE:
1.1 Title: Shipboard Electrical/Electronic Cable Procedure; inspect, test, install,
remove, and repair
2. REFERENCES:
|
2.1 MIL-STD-2003, Electric Plant Installation Standard Methods for Surface Ships and
Submarines
2.2 SE000-01-IMB-010, Navy Installation and Maintenance Book (NIMB), Section IX,
Installation Standards (Source CD: N0002400003)
2.3 MIL-STD-2042, Fiber Optic Cable Topology Installation Standard Methods for
Naval Ships
2.4 S9086-KC-STM-010/CH-300, Electric Plant - General
2.5 MIL-STD-1310, Shipboard Bonding, Grounding, and Other Techniques for
Electromagnetic Compatibility, Electromagnetic Pulse (EMP) Mitigation, and Safety
2.6 S9300-A6-GYD-010, Electrical Workmanship Inspection Guide for Surface Ships
and Submarines
2.7 S9AA0-AB-GOS-010, General Specifications for Overhaul of Surface Ships (GSO)
2.8 SE000-01-IMB-010, Navy Installation and Maintenance Book (NIMB), Section VII,
Industrial Electromagnetic Compatibility (IEMC) Work Process Instructions (Source CD:
N0002400003)
2.9 IA PUB-5239/31, Information Assurance Shipboard Red/Black Installation
Publication
2.10 CNSSAM TEMPEST/01-13, (U) RED/BLACK Installation Guidance
2.11 ANSI/TIA-568.2 – Commercial Building Telecommunications Cabling Standard –
Part 2: Balanced Twisted-Pair Cabling Components
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FY-25
2.12 NAVSEAINST 9304.1, SHIPBOARD CABLE AND CABLEWAY INSPECTION
AND REPORTING PROCEDURES
3. REQUIREMENTS:
3.1 Ensure only Qualified Personnel prepare electrical cable endings to receive
connectors, assemble connector parts on the cable endings, attach the connectors to the cable
endings, supervise, and inspect the execution of the process. (See 4.5 and 4.6)
3.1.1 Submit one legible copy, in hard copy or approved transferrable media, of
the credentials of the Qualified Personnel accomplishing connector fabrication, Supervision, and
QA Inspection to the SUPERVISOR prior to the start or continuation of work. Submit any
change as it occurs.
3.2 Inspect existing affected cable installations and interferences within the first 25
percent of contract completion. Inspect for conformance in accordance with 2.1, 2.3 and 2.12.
3.2.1 Submit one legible copy, in hard copy or approved transferrable media, of a
report listing inspection results including cable installation conditions not in compliance with
2.1, 2.3 and 2.12 to the SUPERVISOR, using Attachments A and B, within 4 days of completion
of inspections. (See 4.7)
3.3 Accomplish a shipboard electrical/electronic cable test on affected cables.
3.3.1 Accomplish an insulation resistance test of each electric cable conductor
using the appropriate direct current megger using Table 300-3-4 of 2.4 for guidance.
3.3.1.1 Disconnect low voltage equipment associated with circuits to be
tested to prevent damage during tests.
3.3.1.2 Ensure the minimum acceptable readings of each cable conductor
to ground and between conductors are:
Lighting Circuit 0.5 Megohm
Power Circuit 1.0 Megohm
Degaussing Circuit 0.1 Megohm
Interconnecting Control Circuit 1.0 Megohm
Interior Communication Circuit 0.2 Megohm
Sound Powered Telephone Circuit
(with telephone disconnected) 0.05 Megohm
Multiconductor Cables
(with circ mil less than 1700) 0.05 Megohm
3.3.1.3 Ensure the minimum acceptable reading of coaxial cable are in
accordance with Section 2.8.3.3 of 2.2:
3 of 14 ITEM NO: 009-73
FY-25
cable with Coax...
Length (feet)
Insulation resistance in megohms (To
equal or exceed)
Polyethylene or
polytetrafluorethylene
(Teflon) dielectric
100 (or less)
40,000
200
20,000
500
8,000
1,000
4,000
Synthetic rubber dielectric
Up to 1,000
1,000
Magnesium oxide
dielectric
Up to 1,000
10,000
Dielectric material
arranged in layers of
conducting and non-
conducting rubber
Up to 1,000
500
3.3.1.4 Discharge coaxial cable to ground following insulation resistance
test.
3.3.2 Test each cable conductor for continuity and complete circuit. Ensure
terminal connections are tight.
3.3.3 Test each cable for conductor continuity, complete circuit, all swept
electrical parameters, and bandwidth per 2.11 using a SCAT 4465 cable tester. Ensure cable
connectors are tight.
3.4 Install each new cable, cableway, penetration, sleeving, lug, and connector in
accordance with 2.1, 2.2, 2.5 and referenced drawings, to support work required by the
individual Work Items. (See 4.2.1)
3.4.1 Ensure new cable conforms to MIL-DTL-24643 (low smoke) and MIL-DTL-
24640 (lightweight). New Radio Frequency (RF) cables must conform to MIL-DTL-17 (low
smoke).
3.4.2 Use existing cableways and penetrations wherever possible.
3.4.3 Ensure penetrations are the correct size in accordance with 2.1.
3.4.4 Install new cable conductor identification sleeving conforming to SAE
AS23053, Class One, white, marked with indelible ink. Mark in accordance with the referenced
drawings and/or equipment technical manual.
3.4.5 Install new lugs of correct size and shape conforming to MIL-T-16366 or SAE-AS7928.
Do not cut off strands of copper to reduce size of lead to fit lug. Use correct barrel and hole size.
3.4.6 Accomplish the requirements of 009-25 of NAVSEA Standard Items for
conducting a local air hose test after the installation, removal or relocation of cables of each new
and disturbed multi-cable transit device, multi-cable penetration, stuffing tube, kick pipe, and
cable penetration of tightness boundaries.
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FY-25
3.4.7 Band disturbed cable in accordance with Part 4 of 2.1.
3.4.8 Bond and ground cable in accordance with 2.5.
3.4.9 Accomplish the requirements of 3.3 through 3.3.1.4 immediately prior to
conductor or cable termination.
3.4.10 Accomplish requirement 3.3.2 immediately prior to conductor or cable
termination except for cables conforming to MIL-DTL-24643/59 - 77.
3.4.11 Accomplish requirement 3.3.3 for cables conforming to MIL-DTL-24643/59
- 77 after cable termination.
3.4.12 Connect each cable using referenced drawings.
3.4.13 Install new cable identification tags in accordance with 2.1 and 2.2.
3.5 Disconnect and remove each cable to be replaced in its entirety. Record and retain
electrical hook-up data. (See 4.2.7)
3.5.1 Accomplish the requirements of 3.4 through 3.4.11.
3.6 Identify, disconnect and isolate each cable to be pulled back, reused, rerouted,
relocated, or repurposed. Record and retain electrical hook-up data. (See 4.2.2 through 4.2.5)
3.6.1 Inspect each cable end to be disconnected for correct conductor identification
sleeving, including size, type, and legible lettering in accordance with referenced drawing.
Ensure lugs are secured to leads and are of correct size and type, and the insulation is not
damaged. Accept and reject criteria for lugs and sleeving for cables must be in accordance
with Chapters 3 and 4 of 2.6.
3.6.2 Accomplish the requirements of 3.3 through 3.3.1.4 for disconnected cables.
3.6.3 Accomplish requirement 3.3.2 for disconnected cables except for cables
conforming to MIL-DTL-24643/59 - 77.
3.6.4 Accomplish requirement 3.3.3 for disconnected cables conforming to MIL-
DTL-24643/59 - 77.
3.6.5 Remove each cable from equipment and pull back to predetermined
locations. Coil each cable and secure to prevent damage. Protect disconnected connectors and
wiring from the industrial environment and weather.
3.6.6 Accomplish the requirements of 3.4.2 through 3.4.11. Use
retained electrical hook-up data.
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FY-25
3.7. Identify, disconnect, isolate and remove each cable designated for removal. (See
4.2.6)
3.7.1 Blank each bulkhead, deck penetration, and multi-cable transit device from
which cable was removed and which will not be reused, in accordance with Part 3 of 2.1.
3.7.2 Blank each unused hole in equipment, in accordance with 2.1.
3.7.3 Remove unused hangers from which cable was removed and which will not
be reused, in accordance with Section 070a of 2.7.
3.7.4 Install new banding for cableways affected by cable removals, in accordance
with Part 4 of 2.1.
3.7.5 Accomplish the requirements of 3.4.6.
3.8 Weatherproof and seal connectors exposed to the weather in accordance with 2.8.
3.9 Remove, install, and relocate cables which are part of the secure electrical
information processing systems or are located within a secure processing space in accordance
with 2.9 and 2.10.
3.10 Accomplish the requirements of 009-32 of NAVSEA Standard Items for each new
and disturbed surface.
3.11 Submit one legible copy, in hard copy or approved transferrable media, of a report
listing results of the requirements of 3.4.9 and 3.6.2, including circuit numbers, lead numbers,
and readings obtained, to the SUPERVISOR within 3 days of completion of tests. Record data
in Attachment C or equivalent form that contains the requirements of “Attachment C”.
4. NOTES:
4.1 The requirements in this Standard Item apply to installation, repair, disconnect,
connect, removal, relocation, test, and inspection of electrical/electronic cables affected by the
work required by individual Work Items on Naval surface ships and submarines and personnel
supporting these tasks. This Standard Item applies to the following cable usages; new, removed,
replaced, pulled back, reused, rerouted and repurposed.
4.2 Cable Definitions
4.2.1 New Cable – a cable not previously installed.
4.2.2 Pulled Back Cable – a cable disconnected and physically removed from a
wireway, conduit, or cableway to protect the cable from industrial use.
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FY-25
4.2.3 Reused Cable – a cable disconnected from the equipment to facilitate
equipment removal.
4.2.4 Rerouted Cable – a cable disconnected from equipment and physically
moved to a new wireway, conduit, or cableway and then reconnected in the new location to the
same equipment.
4.2.5 Repurposed Cable – a cable with termination points changed.
4.2.6 Removed Cable – a cable disconnected from equipment and physically
removed in its entirety and not being replaced.
4.2.7 Replaced Cable – a cable disconnected from equipment and physically
removed to install with a new cable.
4.3 Cable installations consist of cable, banding, boxes, equipment, penetrations,
cableways, hangers, cable separation and connection(s) and associated components.
4.4 Electrical connector fabrication is the preparation of cable endings to receive multi-
pin connectors, coaxial connectors, and securing connectors to cables.
4.5 A Qualified Person is defined as a person who has successfully completed connector
fabrication training and meets the qualification requirements stated below.
4.5.1 Emphasizes the importance of connector fabrication to the performance and
long-term reliability of shipboard systems.
4.5.2 Uses 2.1, 2.2, and 2.6 for basic instructional material supplemented by
connector manufacturer's instructional material as desired.
4.5.3 Requires classroom lecture, study, and demonstration of each topic in
Appendix A of Part 5 of 2.2.
4.5.4 Requires individual student practice in the use of specified tools and
performance of connector fabrication techniques and procedures described in Appendices B
through H of Part 5 of 2.1 and Paragraph 2-20.2 of 2.2.
4.5.5 Requires a minimum of 32 hours of combined classroom lecture and
laboratory practice in the type of connectors to be fabricated.
4.6 Connector fabrication qualifications consist of:
4.6.1 Connector Fabricator Qualification requirement: Successful completion of
the training course required in 4.5.5 followed by successful completion of 40 hours on-the-job
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FY-25
training under the tutelage of a qualified connector fabricator or a qualified connector fabrication
supervisor in the type of connectors to be fabricated.
4.6.2 Connector Fabrication Supervisor Qualification requirement: Successful
completion of the classroom training required in 4.5.5 plus be the incumbent of a supervisory
electrical or electronic mechanic position.
4.6.3 Connector Fabrication Quality Assurance Inspector Qualification
requirement: Successful completion of the classroom training required in 4.5.5 plus be the
incumbent of a quality assurance specialist or inspector position.
4.7 Attachment B is provided as an aid to completion of Electrical Cableway Inspection
Form.
SER #
COMPT
DECK
FRAME
P/S
POS
CABLE
CIRCUIT
DESIG
CABLE
TYPE
*CAT
*NAVSEA
DWG NO.
EQUIPMENT
DESCRIPTION
DESCRIPTION
DESCRIPTION
DESCRIPTION
Criteria
Category
Reference(s)
Surface
Submarine
Aircraft Carrier
1/
I. Cables
A. Installation
1. Bend radius less than minimum, causing visible damage
to cable.
1
1
1 (96 hours)
(f), (i)
2. Bend radius less than minimum, no visible cable
damage, cable rings out and meggers satisfactorily.
2
2
2
(b), (c), (g), (h), (i)
3. Equipment connector supporting weight of cable (more
than 32” of cable from last support to end use equipment) (18”
from shock mounted motors).
2
2
1 (90 days
2/
)
(b), (i)
4. Cables run on or near hot objects (steam or exhaust
pipes, griddles, ovens, etc.).
1
1
1 (96 hours)
(b), (g), (h), (i)
5. Cables run outside of hangers.
3
3
3
(b), (c)
6. Lack of slack at expansion joints.
2
2
2
(b)
7. Excess slack between hangers (minimum distance of
6’4” between deck and cables).
3
3
3
(b), (g), (h), (i)
8. Excess cable slack stored in wireway.
3
3
3
(b), (g), (h), (i)
9. Missing, damaged, or illegible cable tags.
3
3
3
(b), (c)
B. Damage
1. Bulging, bubbling, or discoloration of cable jacket
(evidence of overloading, overheating, or hot spots).
1
1
1 (96 hours)
(g), (h)
2. Bulging, bubbling, or discolored cable jacket, but cable
rings out and meggers satisfactorily.
1
1
1
(g), (h)
3. Cable chafed or cut through outer jacket only.
2
2
2
(b), (c)
4. Cable chafed or cut through, inner wire insulation
damage.
1
1
1 (96 hours)
(b)
5. Cable pulled out of equipment/junction box penetrations
and bare conductor exposed.
1
1
1 (96 hours)
(b), (g), (h)
Criteria
Category
Reference(s)
Surface
Submarine
Aircraft Carrier
1/
6. Cable pulled out of equipment/junction box penetrations
and inner insulation exposed.
1
1
1
(b), (c), (g), (h)
7. Armored and unarmored cables in contact at an oblique
angle causing chafing of unarmored jacket.
2
2
2
(b)
C. Dead-Ended
1. Cable dead-ended, not end sealed properly at known end.
1
1
1 (96 hours)
(b), (g), (h), (i)
2. Cable dead-ended, properly end sealed, but not labeled
(serialized) at known end(s).
2
2
2
(b), (c), (g), (h), (i)
3. Cable dead-ended, end sealed, and labeled (serialized)
properly at known end.
3
3
3
(b), (c), (g), (h), (i)
4. Cable for future use or other cables where both ends are
known, properly end sealed and labeled (serialized).
3
3
3
(b), (c), (g), (h), (i)
D. Spliced
1. Improper materials/methods used for splicing or
evidence of loose joints.
1
1
1 (90 days
2/
)
(b), (c)
2. Splice located in bend of cable.
2
2
2
(b)
II. Banding
A. All Cable Runs
1. Banding or other restraints cut cable outer jacket.
1
1
1 (96 hours)
(b), (c)
2. Banding compressing outer jacket (banding too tight, but
not cutting jacket).
3
3
3
(b), (c)
3. Plastic tie wraps used in place of banding straps (metal
banding strap required).
3
3
3
(b), (c)
4. Cables secured to hanger with bailing wire or rope.
2
2
1 (90 days
2/
)
(b), (c)
5. Bands cut and left in wireway.
3
3
3
(b), (c)
6. Channel rubber not installed where required.
2
2
2
(b), (c)
7. Cable saddles missing where required.
3
3
3
(c)
NAVSEAINST
9304.1E
DRAFT
Criteria
Category
Reference(s)
Surface
Submarine
Aircraft Carrier
1/
B. Horizontal Cable Runs
1. Banding not installed at breakout hangers before and
after penetrations or at change of direction of wireway.
2
2
2
(b)
C. Vertical Cable Runs
1. No banding or loose banding (banding required on every
hanger).
2
2
2
(b), (c)
III. Cableways
A. Cableways
1. Cable hangers or hardware cutting into the cable jacket.
1
1
1 (96 hours)
(b), (c)
2. Improper hanger spacing. Required at least every 32”
(16” for hangers for multiple tier overhead aluminum decks).
2
2
2
(b), (i)
3. Inadequate cableway support (hangers, hardware, tiers,
or cable straps missing) or welds cracked.
2
2
2
(b)
4. Overloaded/Overcrowded cable hangers.
3
3
3
(b), (i)
5. Maximum number of tiers exceeded.
3
3
3
(b)
6. Inadequate fastener length.
3
3
3
(b)
7. ½” clearance not maintained between cable run and
hangers or structure above.
2
2
2
(b), (i)
8. EMI separation not maintained.
2
2
2
(b)
9. Fiber optic cables not installed on top layer of cableway.
3
3
3
(c)
IV. Equipment
A. Covers
1. Junction box or equipment covers loose or missing.
1
1
1 (96 hours)
(g), (h)
B. Mounting
1. Cable supporting the weight of equipment (power
junction boxes, lighting fixtures switch boxes, etc.).
1
1
1 (96 hours)
(b), (g), (h)
2. Missing loose or improperly installed mounting
hardware on equipment.
2
2
2
(b), (c), (g), (h)
Criteria
Category
Reference(s)
Surface
Submarine
Aircraft Carrier
1/
C. Cable Entrance
1. Watertight penetrators not utilized for entrance to
watertight equipment enclosures.
2
1
1 (90 days
2/
)
(b), (c), (i)
2. Drip loops, drip shields plastic sealer, or bottom
penetration not utilized for entrance to non-watertight drip proof
equipment.
2
1
1 (90 days
2/
)
(b), (i)
3. Cable can be moved in and out of tube. Improperly
packed or not packed.
2
1
1 (90 days
2/
)
(b), (c)
4. Nylon tube base loose in enclosure (O-ring missing).
2
1
1 (90 days
2/
)
(b), (c)
V. Deck/Bulkhead Penetrations
A. Non-Watertight Deck or Bulkhead Cable Penetration
1. No plastic sealer around cables through collars where
required.
2
2
1 (90 days
2/
)
(b), (g), (h)
2. Chafing protection not installed at non-watertight deck
or bulkhead cableway penetrations.
2
2
2
(b)
3. Chafing ring overloaded.
3
3
3
(b)
4. Inadequate chafing protection and damage evident.
1
1
1 (90 days
2/
)
(b), (i)
B. Watertight Deck or Bulkhead Single Cable Penetrations
1. No plastic sealer around cable at stuffing tubes that are
exposed to the weather. Note: If plastic sealer is installed at
locations other than those exposed to the weather, it is not
required to be removed.
2
1
2
(b)
2. Stuffing tube or kickpipe not utilized (cable installed
without tube).
2
1
1 (90 days
2/
)
(b), (g), (h), (i)
3. Unused stuffing tube or kickpipe not plugged.
2
1
1 (90 days
2/
)
(b)
4. Stuffing tube or kickpipe assembly incomplete (missing
gland nut, packing, or pipe connector).
2
1
1 (90 days
2/
)
(b)
5. Stuffing tube assembly incorrect (improper packing).
2
1
2
(b)
6. Stuffing tube or kickpipe too large for size of cable.
3
1
3
(b)
Criteria
Category
Reference(s)
Surface
Submarine
Aircraft Carrier
1/
7. Multiple cable in a single stuffing tube or kickpipe.
2
1
2
(b)
8. Stuffing tube or kickpipe damaged to point where
complete assembly not possible (cracked welds, damaged
threads, out-of-round, etc.) if fire stop material is installed.
2
1
2
(b)
C. Watertight Deck or Bulkhead Penetrations Utilizing Multiple Cable Penetrations (MCPs)
1. Insert blocks, compression bolts, or filler blocks missing.
2
1
1 (90 days
2/
)
(b), (g), (h)
2. Improper size blocks used for size cable installed
violating watertight integrity.
2
1
2
(b)
3. Incorrect type or missing fire stop caulk used to seal
armored cable through MCP blocks.
2
1
1 (90 days
2/
)
(b)
4. RISE
®
type MCP not properly sealed with a soft-seal
sealant (FIWA Catalog #80-0900, or equivalent) or missing soft-
seal sealant.
2
N/A
3/
1 (90 days
2/
)
(b)
NOTES:
1/
Information in parentheses is the no-later-than time to repair/downgrade.
2/
90 days or prior to deployment, whichever occurs first.
3/
The use of RISE
®
is not permitted on submarines.
CABLE TYPE
CIRCUIT ID
CONDUCTOR
ID
LEAD
COLOR
CABLE
START
TERM PT
CABLE END
TERM PT
Megger Readings
Continuity
Cable Condition
Cable
Length *
Disconnect
Reconnect
Term
Lug
Insulation
Sleeving