53711-8580071 _Pulse_Power_Specefication_120814.pdf

NAVSEA Number: 53711-8580071

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SPECIFICATION, CABLE, ELECTRICAL,

POLYURETHANE JACKETED FOR OUTBOARD USE

DISTRIBUTION STATEMENT A: Approved for public release; distribution is unlimited.

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REVISION RECORD

ECP# SCN REV DATE DESCRIPTION OF CHANGE APPROVED

SAS-E0084 - 8 December 2014 INITIAL RELASE 14060 PMS415C

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TABLE OF CONTENTS

Paragraph Page

1.0 Scope -------------------------------------------------------------------------------------- 5

2.0 Applicable Documents ---------------------------------------------------------------- 5

2.1 Order of Precedence ------------------------------------------------------------------ 5

2.2 Issues of Documents ------------------------------------------------------------------ 5

2.2.1 Government Documents ------------------------------------------------------------- 5

3.0 Requirements --------------------------------------------------------------------------- 5

3.1 General Requirements ---------------------------------------------------------------- 5

3.1.1 Bulk Requirements -------------------------------------------------------------------- 5

3.1.2 Classification ---------------------------------------------------------------------------- 5

3.1.3 NAVSEA Material Approval ---------------------------------------------------------- 6

3.1.4 Materials unique to this specification -------------------------------------------- 6

3.2 Detailed Requirements --------------------------------------------------------------- 6

3.2.1 Design ------------------------------------------------------------------------------------- 6

3.2.2 Construction ---------------------------------------------------------------------------- 6

3.2.2.1 Conductors ------------------------------------------------------------------------------ 6

3.2.2.2 Conductor Insulation ------------------------------------------------------------------ 6

3.2.2.3 Filler and Water Blocking ------------------------------------------------------------ 6

3.2.2.4 Binder Strand --------------------------------------------------------------------------- 6

3.2.2.5 Outer Cable Jacket --------------------------------------------------------------------- 6

3.2.2.6 Bend Radius ----------------------------------------------------------------------------- 7

3.2.3 Electrical ---------------------------------------------------------------------------------- 7

3.2.3.1 Dielectric Withstanding Voltage ---------------------------------------------------- 7

3.2.3.2 Insulation Resistance ------------------------------------------------------------------ 7

3.2.3.3 Conductor Resistance ----------------------------------------------------------------- 7

3.2.4 Physical ----------------------------------------------------------------------------------- 7

3.2.4.1 Visual and Dimensional --------------------------------------------------------------- 7

3.2.4.2 Water Tightness ------------------------------------------------------------------------ 7

3.2.4.3 Cold Bending (-20°C) ------------------------------------------------------------------ 7

3.2.4.4 Cold Working (-20°C) ------------------------------------------------------------------ 7

3.2.4.5 Cable Filler Removability ------------------------------------------------------------- 7

3.2.4.6 Pressure Integrity ---------------------------------------------------------------------- 7

3.2.4.7 Cable Aging and Compatibility ----------------------------------------------------- 8

3.2.4.8 Permanence of Jacket Printing ----------------------------------------------------- 8

3.2.4.9 Conductor Insulation (Unaged) ---------------------------------------------------- 8

3.2.4.10 Jacketing (Unaged) -------------------------------------------------------------------- 8

3.2.5 Marking ---------------------------------------------------------------------------------- 8

4.0 Quality Assurance Provisions ------------------------------------------------------- 8

4.1 General ----------------------------------------------------------------------------------- 8

4.2 Qualification and Quality Conformance ------------------------------------------ 8

4.3 Quality Products List (QPL) ---------------------------------------------------------- 8

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4.4 Vendor Qualification ------------------------------------------------------------------ 8

4.5 Qualification Inspection -------------------------------------------------------------- 9

4.6 Extension of Qualification ----------------------------------------------------------- 9

4.7 Quality Conformance inspection --------------------------------------------------- 9

5.0 Packaging -------------------------------------------------------------------------------- 9

5.1 General ----------------------------------------------------------------------------------- 9

6.0 Notes -------------------------------------------------------------------------------------- 9

6.1 General ----------------------------------------------------------------------------------- 9

Table 1 Bulk Cable Test Requirements ------------------------------------------------------ 10 Table 2 Qualified Vendors List ---------------------------------------------------------------- 11 Figure 1 Cable Cross-section -------------------------------------------------------------------- 12

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1.0 Scope:

This specification covers the detail requirements for 3 AWG, four conductor Submarine Outboard Cable. The cable consists of four 3 Awg High Density Polyethylene (HDPE) insulated conductors, that are helically twisted, water blocked and jacketed with Polyurethane.

2.0 Applicable Documents:

2.1 Order of Precedence: Unless otherwise noted in the event of a conflict between the requirements of this specification and those referenced herein, this specification shall take precedence. Nothing in the specification, however, shall supersede applicable laws and regulations.

2.2 Issues of Documents: The following documents form a part of this specification to the extent specified herein.

2.2.1 Government Documents:

MIL-DTL-915G; Cables and Cord, Electrical, For Shipboard Use, General Specification for

MIL-W-81381; Wire, Electric, Polyimide-Insulated, Copper or Copper Alloy PMO450-0008; Pollution Prevention Strategy for the New Attack Submarine Program; Figure 1. NSSN Hazardous

Substance Avoidance List SEA 05P5 Ltr 5090; Ser 05P/374; dtd 19 Sep 2012; The Prohibited and

Controlled Chemical List (PCCL); Enclosure (1) NAVSEA S932-AM-PRO-020/MLDG, Rev 2; Technical Manual, Underwater Cable Assembly and Encapsulated Components, Fabrication, Repair and Installation Manual, Volume II PPD 802-6337554, Rev B; Fiber Optic, Fiber Optic/Electrical Hybrid Hull

Penetrator Project Peculiar Document NAVSEA 53711-8580072; Drawing, AN/WSQ-9(V) Pulse Power Outboard Cable Assembly

3.0 Requirements

3.1 General Requirements

3.1.1 Bulk requirements: The requirements for acquiring the cable described herein shall consist of this specification and MIL-DTL-915, Revision G, with Supplement 1A and Notice 1.

3.1.2 Classification: The finished cable provided under this specification shall meet the following construction, service and application requirements.

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3.1.2.1 Construction Outboard Use and unarmored

3.1.2.2 Service Non-Flexing

3.1.2.3 Application Special purpose

3.1.3 NAVSEA Material Approval: NAVSEA approval of materials used in the construction of the cable furnished under this specification is not required.

3.1.4 Materials unique to this specification: All high level components which are incorporated in this cable shall comply with documents as listed in 2.2.1 of this specification. Materials and chemicals used during the manufacturing process of these components that are not present in the final high level of said components shall not to be considered.

3.2 Detailed Requirements

3.2.1 Design: Unless otherwise specified herein, the cable provided in accordance with this specification shall be designed in accordance with the following requirements.

3.2.2 Construction: (See Figure 1)

3.2.2.1 Conductors: Four conductors, AWG No. 3 (37 X 0.0403) bare copper conductor O.D. 0.280 ±0.010 inches. DC Resistance @ 20°C ≤ 0.23 Ohms / 1000 Ft. Inside and outside diameter interstices water blocked with fibrous filaments impregnated with water blocking compound.

3.2.2.2 Conductor Insulation: High Density Polyethylene, Nominal Thickness 0.040 inches. Voltage Rating, 1000 Vrms, Color: Black, White, Red, Green.

3.2.2.3 Fillers and Water Blocking: All fillers shall be fibrous filaments and/or tape impregnated with water blocking compound.

3.2.2.4 Binder Strand: A binder strand shall be impregnated with water blocking compound and helically wound.

3.2.2.5 Outer Cable Jacket: The Outer Cable Jacket shall be Black Polyurethane, Lubrizol Corp. Estane 58887 Thermoplastic Polyurethane, (TPU). Nominal thickness to be 0.125 inch. Outer Diameter to be 1.180 ±

0.030 inches. Circularity of jacket to be within 0.020 inches. The jacket shall be easily removable without damage to other cable component members. The jacket shall be dry and free from coatings, films or treatment that would tend to interfere with the bonding of it to encapsulating or molding materials approved by NAVSEA S932-AM-PRO-

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020/MLDG Rev 2. The jacket shall be free of pinholes, blowouts and bumps. No Jacket repairs allowable.

3.2.2.6 Bend Radius: Minimum Bend Radius of the finished cable to be

6.0 inches.

3.2.3 Electrical:

3.2.3.1 Dielectric Withstanding Voltage: 5000 Vrms, Conductor to Conductor. Test in accordance with paragraph 4.6.5 of MIL-DTL-915G.

3.2.3.2 Insulation Resistance: 200 Megohms minimum per 1000 ft when measured at 500 VDC. Conductor to Conductor. Test in accordance with paragraph 4.6.4.2 of MIL-W-81381.

3.2.3.3 Conductor Resistance: ≤ 0.23 ohms per 1000 ft. @ 20°C. Test in accordance with paragraph 4.6.4 of MIL-DTL-915G.

3.2.4 Physical:

3.2.4.1 Visual and Dimensional: The finished cable shall have no failures when inspected according to paragraph 4.5.16 of MIL-DTL-915G.

3.2.4.2 Water tightness: 13 in³ maximum water leakage permitted when tested in accordance with paragraph 4.5.17 of MIL-DTL-915G, hydrostatic pressure shall be 25 psig.

3.2.4.3 Cold Bending (-20°C): The finished cable shall not suffer damage or degradation of performance when tested in accordance with paragraph

4.5.5 of MIL-DTL-915G. Mandrel diameter shall be 14.0 inches.

3.2.4.4 Cold Working (-20°C): The finished cable shall not suffer damage or degradation of performance when tested in accordance with paragraph

4.5.6 of MIL-DTL-915G using a 14 inch diameter sheave as shown in figures 3 and 4 of MIL-DTL-915G.

3.2.4.5 Cable Filler Removability: The finished cable shall experience no failures when tested in accordance with paragraph 4.5.4 of MIL-DTL-915G.

3.2.4.6 Pressure Integrity: The finished cable’s physical, mechanical and electrical properties shall not be degraded when the cable is continuously or intermittently subjected to external pressures (air, water and/or seawater media) in the range of 0 to 1000 psig. This requirement shall be verified by a separate connectorized cable assembly constructed in

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3.2.4.7 Cable Aging and Compatibility: No failures permitted when tested in accordance with paragraph 4.5.3 of MIL-DTL-915G. The Test shall be conducted at 80 +3/-0 deg. Celsius

3.2.4.8 Permanence of Jacket Printing: No failures permitted when tested in accordance with paragraph 4.5.13 of MIL-DTL-915G, 250 cycles.

3.2.4.9 Conductor Insulation (Unaged): The High Density Polyethylene conductor insulation shall have the following physical properties: Tensile Strength: 2000 PSI minimum, Elongation: 250 % minimum.

3.2.4.10 Jacketing (Unaged): The Polyurethane TPU Jacketing shall have the following physical properties: Tensile Strength: 4000 PSI minimum, Elongation: 500% minimum.

3.2.5 Marking: The finished cable jacket shall be permanently marked every one

(1) to three (3) feet in accordance with the requirements of MIL-DTL-915G.

Marking shall consist of the following information: manufacturer’s name, part number of cable (53711-8580071), week and year of manufacture (WW/YY).

4.0 Quality Assurance Provisions

4.1 General: Quality assurance requirements shall be in accordance with the requirements of this specification and MIL-DTL-915G as applicable.

4.2 Qualification and Quality Conformance: Cable provided under this specification shall be subjected to, and meet, the acceptance criteria of all test and inspections specified in section 4 of this specification. The cable shall not be degraded by any test or combination of tests.

4.3 Quality Products List (QPL): Listing of cables on the applicable qualified products list as specified in MIL-DTL-915G is not required. Table 2 lists all qualified vendors who are approved to manufacture the cable specified in this document.

4.4 Vendor Qualification: Manufacturer’s seeking “Qualified Vendor” status shall manufacture cable and pass the Qualification tests listed in Table 1.

4.5 Qualification Inspection: A production First Article Test sample shall be subjected to, and satisfactorily pass, all of the Qualification and Quality Conformance tests of Table 4 for vendor qualification.

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4.6 Extension of Qualification: When assemblies, sub-assemblies and parts/materials are identical or similar to those utilized in designs previously qualified to MIL-DTL-915G, extension of qualification for a given test may be requested from the procuring activity based upon previous test results. Any internal cable component substitution requires a complete article one re-test.

4.7 Quality Conformance Inspection: All cables supplied under this specification shall be subjected to, and satisfactorily pass, all of the quality conformance tests of table 1.

5.0 Packaging

5.1 General: The packaging requirements for cable furnished under this specification shall be in accordance with the requirements of MIL-DTL-915G.

6.0 Notes

6.1 General: The notes of MIL-DTL-915G shall be adhered to as defined in this specification.

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Table 1 Bulk Cable Test Requirements

Test

Test Paragraph No. Qualification Testing

Quality Conformance

Testing

Remarks

Visual & Dimensional 4.5.16

MIL-DTL-915G

X X

Conductor Resistance 4.6.4

MIL-DTL-915G

X X

DWV 4.6.5

MIL-DTL-915G

X X

Insulation Resistance 4.6.4.2 MIl-W-81381

X X

Water Tightness 4.5.17

MIL-DTL-915G

X 25 Psig

Cold Bend (-20°C) 4.5.5

MIL-DTL-915G

X Mandrel Dia.14.0 “

Cold Working (-20°C) 4.5.6

MIL-DTL-915G

X Sheave dia. 14.0”

Pressure Integrity 4.3.14

PPD802-6337554

X Specimen constructed in accordance to NAVSEA 53711-

8580072

Cable Aging & Compatibility

4.5.3

MIL-DTL-915G

X

Permanence of Jacket Printing

4.5.13

MIL-DTL-915G

X 250 cycles

Conductor Insulation (Unaged)

4.5.14

MIL-DTL-915G

X

Jacketing (Unaged)

4.5.14

MIL-DTL-915G

X

Marking MIL-DTL-915G X

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Table 2 Qualified Vendors List

Cable Type Manufacturer Vendor Part Number

Cage Code

53711-8580071 South Bay Corp. SB-48116 Rev A 51173

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Figure 1 Cable Cross-section