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AMENDMENTS ISSUED SINCE PUBLICATION AMD NO DATE OF ISSUE TEXT AFFECTED SIGNATURE & DATE
Revision Note This Issue of this Standard has been prepared to incorporate changes to text and presentation. The technical content has been updated in line with current practice. Historical Record NES 512, Part 1, Issue 1 Def Stan 02-512, Part 1, Issue 1 Oct 91 Apr 00
PART 1 ISSUE 2
GENERAL
This Defence Standard is authorized for use in MOD contracts by the Defence Procurement Agency and the Defence Logistics Organization
Published by: Defence Procurement Agency An Executive Agency of The Ministry of Defence UK Defence Standardization Kentigern House 65 Brown Street Glasgow G2 8EX 1
SCOPE
1. This Part of the Defence Standard contains general information on categories, types, characteristics, application and selection of Electric Cables and Equipment Wires for use in HM Surface Ships and Submarines.
FOREWORD Sponsorship
1. 2. This Defence Standard is sponsored by the Defence Logistics Organization (DLO), Ministry of Defence (MOD). The complete Defence Standard 02512 comprises:
Part 4: Part 5: Part 6: Part 7: Part 8: Part 9: Part 10: Part 11: Part 12: Part 13: 3.
Any user of this standard either within MOD or in industry may propose an amendment to it. Proposals for amendments that are not directly applicable to a particular contract are to be made to the publishing authority identified on Page (i), and those directly applicable to a particular contract are to be dealt with using contract procedures. If it is found to be unsuitable for any particular requirement MOD is to be informed in writing of the circumstances. No alteration is to be made to this standard except by the issue of an authorized amendment. Unless otherwise stated, reference in this standard to approval, approved, authorized and similar terms, means by the MOD in writing. Any significant amendments that may be made to this standard at a later date will be indicated by a vertical sideline. Deletions will be indicated by 000 appearing at the end of the line interval. This standard has been reissued to reflect changes in Departmental Nomenclature due to the MOD reorganization.
4. 5. 6. 7. 8.
This document is Crown Copyright and the information herein may be subject to Crown or third party rights. It is not to be released, reproduced or published without written permission of the MOD. The Crown reserves the right to amend or modify the contents of this Defence Standard without consulting or informing any holder.
13.
14.
Related Documents
16. In the tender and procurement processes the related documents listed in each section and Annex A can be obtained as follows: a. British Standards British Standards Institution, 389 Chiswick High Road, London, W4 4AL Defence Procurement Agency An Executive Agency of the Ministry of Defence
b.
Defence Standards
UK Defence Standardization
Kentigern House 65 Brown Street Glasgow, G2 8EX. c. 17. Other documents Tender or Contract Sponsor to advise. All applications to the MOD for related documents are to quote the relevant MOD Invitation to Tender or Contract number and date, together with the sponsoring Directorate and the Tender or Contract Sponsor.
Prime Contractors are responsible for supplying their subcontractors with relevant documentation, including specifications, standards and drawings.
20.
Additional Information
21. To assist in the selection process reference is to be made to the following Parts of this standard: a. Parts 2 to 8 inclusive for Data sheets of individual cables and equipment wires, together with their appropriate terminations to suit conductor size and corresponding types and sizes of equipment glands/grommets, bulkhead glands and deck tubes. Part 4 Withdrawn. Part 10 for details of terminations and connectors. Part 11 for information on glands, grommets and deck tubes specified in the data sheets. Part 12 for list of NATO Stock Numbers (NSN) and associated cable specifications in NSN numerical order. Part 13 for determining the nearest equivalent metric cable for an obsolete/ obsolescent imperial cable.
b. c. d. e. f. 22.
In accordance with Ministry of Defence (MOD) policy to reduce the dangers to personnel and damage to equipment from smoke, toxic fumes and corrosive gases when electrical wires and cables are subjected to fire, an extended range of Limited Fire Hazard (LFH)wires, cables and ancillary components is now available. LFH components are to be used in all new construction MOD vessels and are also to be incorporated retrospectively in existing vessels when opportunities arise. A listing of a wire or cable does not in itself guarantee availability off-the-shelf from Naval Stores. Items that are low usage and, therefore, probably not readily available are shown in italics.
23.
CONTENTS Page No TITLE PAGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SCOPE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . FOREWORD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Sponsorship . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Conditions of Release . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Categories of Naval Defence Standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Related Documents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Health and Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Additional Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CONTENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SECTION SECTION SECTION SECTION 1. 2. 3. 4. 4.1 4.1.1 Table 4.1 4.1.2 Table 4.2 4.1.3 4.1.4 4.1.5 4.1.6 4.1.7 4.1.8 SECTION ANNEX A ANNEX B ALPHABETICAL INDEX 5. PERFORMANCE SPECIFICATION . . . . . . . . . . . NATIONAL/INTERNATIONAL REGULATIONS MILITARY STANDARDS/REQUIREMENTS . . . . DESIGN REQUIREMENTS/GUIDANCE . . . . . . . Cables Categories, Types, Characteristics, Application and Selection . . . . . . . . . . . . . . . . . . . . . Naval Shipwiring Cable Categories . . . . . . . . . . . . . Cable Categories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Cables Cable Insulation/Sheath Materials . . . . . . Cable Insulation/Sheath Materials . . . . . . . . . . . . . . Cable Selection Procedure . . . . . . . . . . . . . . . . . . . Cable Selection General . . . . . . . . . . . . . . . . . . . . . Cable Selection Use of Fire Resisting Cable . . . . . Cable Selection Special Cables (see Clause 4.1.1) Cable Selection Radio Frequency (RF) Cable . . . Cable Selection Submarines . . . . . . . . . . . . . . . . . . CORPORATE EXPERIENCE & KNOWLEDGE . RELATED DOCUMENTS . . . . . . . . . . . . . . . . . . . . ABBREVIATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . ........................................... 6 1 2 3 3 3 4 4 5 5 6 7 7 7 7 7 7 7 8 8 9 10 10 10 10 10 11 12 14 15
1.
2.
3.
4.
4.1
4.1.1
Insulation
Silicone Rubber EPR/LFH Thin Wall Polymer Polyethylene PTFE Polyolefin/ Polyethylene -
Sheath
LFH LFH LFH LFH FEP Glass Braid LFH LFH
Operating Temperature
up to 105_C up to 85_C up to 85_C up to 50_C
Construction Specification
DEF STAN 02-527 DEF STAN 02-526 DEF STAN 61-12 Part 25
Group
1 and 2 1 1 and 2
>85_C
up to 50_C up to 85_C
3 DEF STAN 61-12 Part 9 NES 517 Part 3 Manufacturer's own DEF STAN 60-1 Part 2 3 3
Submersible* Polyethylene
Polyethylene up to 50_C
Table 4.1 Cable Categories * For use outside hull of pressure hull
Definition of Groups: 1. Power Cable 2. Signal Cable 3. Special Cable Conductor cross section 4 mm2 or greater, used for power supply to equipments, or for degaussing. Conductor cross section 2.5 mm2 or less used for information transfer or minor power lighting circuits. Co axial or data cables with defined electrical characteristics at high fre quencies.
4.1.2
Cables Cable Insulation/Sheath Materials a. Cable materials in common use are listed in Table 4.2, together with some materials that may be found on older vessels. Materials are selected to give the best compromise in electrical characteristics, environmental resistance to fluids and temperature, and low hazard in case of fire or accident. Material
CSP (also CSP[LFH]) EPR
b.
Use
Sheath
Name/Characteristics
Chlorosulphonated Polyethylene tough, oil resistant rubber.
Remarks
Does not meet smoke and toxicity requirements for shipboard materials. No longer acceptable for shipboard use. Meets smoke and toxicity requirements when coated with LFH compound. Meets smoke and toxicity requirements. There are various proprietary formulations, depending on the cable type and manufacturing process. MI cable. Used only where fire or extreme temperature resistance is required. Best material for water resistance. Used only in special cables inboard, due to limited fire performance. Fails toxicity requirement. Only to be used where its properties are essential, e.g. gearbox instrumentation or GT module wiring. Fails smoke and toxicity requirements. No longer acceptable for shipboard use. Forms insulating ash when burnt. Used for highly loaded cable or for fire survival. Meets smoke requirement when combined with LFH sheath. Meets smoke and toxicity requirements. Various proprietary formulations. Used as equipment wire or as cores in cable.
Insulation
Ethylene Propylene Rubber. Good mechanical strength and electrical properties. Limited Fire Hazard sheathing compound to DEF STAN 61-12 Part 31. Tough, resistant to oil and other fluids. Usually magnesium oxide. Excellent fire resistance, needs copper sheath for water resistance. Polyethylene. Excellent electrical properties and moderate mechanical strength. Polytetrafluoroethylene. Excellent high temperature insulation (260_C) Highly resistant to oil and other fluids. Polyvinyl chloride. Tough, with moderate electrical properties and temperature resistant. Silicone rubber. Moderate electrical properties, good temperature resistance.
LFH
Sheath
`Mineral'
Insulation
PE
PTFE
PVC
Silicone
Insulation
Thin Wall
Insulation
Shorthand for insulation to DEF STAN 61-12 Part 18. Good electrical properties. Radial thickness nominally 0.2 mm.
4.1.3
Cable Selection Procedure a. Many factors are to be considered in selecting a cable for a particular application and the following stages are to be assessed: (1) Number of Cores (a) (b) Initially the number of cores required is to be established with spare cores allocated to give total number of cores required; As a guide for main run signal cables the spare cores normally are to be within the range of 10 to 20 per cent of the total at the completion of installation.
(2)
Conductor Size (a) The conductor size will depend on the loading and the volt drop limitations (transient and steady state). To determine the latter it is necessary to know the final calculated length of cable. In high power installations, full load, allowable overload margin, starting currents, maximum prospective fault current, diversity factor, maximum permitted temperature rise and possible growth are to be taken into account. Minimum cable sizes for services from Moulded Case Circuit Breaker (MCCB) are given in DEF STAN 08-109. Excessive sizes of cables are to be avoided in order to minimize cost, weight and bulk. There are exceptions to this general rule however, e.g. supply cable to motors having thermistor protection may require a larger cable than that indicated by the power rating of the motor. DEF STAN 08-109 gives further details.
(3)
External Influences (a) (b) Fixed glands and terminals will influence the type and sizes of cable to be used in certain circumstances; The physical conditions involved, e.g. type of bends, movement, twisting motion etc. may require the use of flexible or specially flexing cables; The type of insulation and sheathing will depend on the service, ambient temperatures and physical conditions.
(c) (4)
Special Conditions (a) EMC and RF requirements may dictate that screened cables/cores or twisted pairs/triples are to be used. Guidance is given in DEF STAN 59-41 Part 7; Where connectors are to be used, cables are to be selected from the preferred list of cables and connector combinations (see BR 4596); It is imperative that Equipment and System Designers specify in the Installation Documentation the permissible losses and characteristics for interconnecting cables, together with any other special requirements, e.g. circuit integrity in a fire.
(b) (c)
4.1.4
Cable Selection General a. Cables are to be selected from the range detailed in DEF STAN 02-512 Parts 2 to 8. Whenever possible, cables constructed to DEF STAN 02-526, DEF STAN 02-527 or DEF STAN 61-12 Part 25 are to be specified for shipwiring, as these have been developed to give greatly reduced levels of toxic fumes, smoke and corrosive products if burnt while retaining properties of toughness, fluid resistance and long life in normal service.
4.1.5
Cable Selection Use of Fire Resisting Cable a. Cable with silicone rubber insulation to DEF STAN 02-527 has some degree of circuit integrity in fire test situations and has a higher current rating due to the greater capability of the material. Because of their higher cost, silicone insulated cables are to be restricted in use to the following services: (1) (2) (3) Permanently run emergency cables. Degaussing cables. Cables for services essential to float and move the ship. (This includes cable connecting generators and electrical load centres to the main switchboards). Cables in areas where the ambient temperature would lead to an unacceptable derating of a cable to alternative specifications.
b.
(4) 4.1.6
Cable Selection Special Cables (see Clause 4.1.1) a. Some circuit requirements lead to cable designs which are not covered in the standard range. In this case, special cables shall have halogen free internal materials appropriate to their characteristics, with an LFH sheath complying with the requirements of DEF STAN 61-12 Part 31.
4.1.7
Cable Selection Radio Frequency (RF) Cable a. RF cables are to be selected from DEF STAN 02-512 Part 5. Screened coaxial (i.e. tri axial) cables are not to be used for sync and video circuits carrying pulses in the intermediate voltage range up to 30 volts, since normal coaxial cables are adequate in this region. Where additional screening is required, either for sensitive or high power circuits, then solid metal outer cables are preferred. Advice and guidance on the selection of these cables is to be obtained from WSA/MLSIPT/MLS2.
NOTE
b. 4.1.8
For rigid co-axial transmission lines, select in accordance with the instructions in DEF STAN 59-6.
Cable Selection Submarines a. The criteria for the selection of cables in Submarines is to be the same as for HM Surface Ships. Particular requirements are: (1) Power cables in the main ac and dc systems down to load centre level, and cables for degaussing coils shall be silicone rubber insulated as specified in DEF STAN 02-527;
10
NOTE 1. Some special cable designs also defined in DEF STAN 02-525 and DEF STAN 02-643. 2. Pressure tight cable was used to transit bulkheads in some older Submarine designs. Details of this obsolescent cable can be obtained from WSA/MLSIPT/MLS2.
5.
11
DEF STAN 02-512 Pt 5 DEF STAN 02-512 Pt 6 DEF STAN 02-512 Pt 7 DEF STAN 02-512 Pt 8 (NES 512 ) DEF STAN 02-517 Pt 2 DEF STAN 02-517 Pt 3 (NES 517) DEF STAN 02-524 Pt 1 DEF STAN 02-524 Pt 2 DEF STAN 02-524 Pt 3 (NES 524) DEF STAN 02-525 (NES 525) DEF STAN 02-526 (NES 526) DEF STAN 02-527 (NES 527) DEF STAN 08-109 (NES 532) DEF STAN 02-643 (NES 643) DEF STAN 59-6 DEF STAN 59 41
DEF STAN 60 1
12
DEF STAN 61 12
Wires, Cords and Cables, Electrical - Metric Units: Part 9: Cables, Radio Frequency including Limited Fire Hazard (LFH) Variants Part 18: Equipment Wires, Limited Fire Hazard (LFH); Part 25: Cables Electrical Limited Fire Hazard (LFH) up to 10 mm 2 (cross sectional area); Part 31: Sheaths Limited Fire Hazard (LFH). Electrical Connectors Pattern 608. MOD Ship Safety Management System Handbook
13
ANNEX B. ABBREVIATIONS
B1. For the purposes of this standard the following Abbreviations apply: BR CSP DEF STAN DLO DPA EMC EP EPR JSP LFH MOD NSN NATO NES MCCB MLSIPT PE PTFE PVC RF WSA Book of Reference Chlorosulphonated Polyethylene Defence Standard Defence Logistics Organization Defence Procurement Agency Electromagnetic Compatibility Ethylene Propylene Ethylene Propylene Rubber Joint Services Publication Limited Fire Hazard Ministry of Defence Nato Stock Number North Atlantic Treaty Organization Naval Engineering Standard Moulded Case Circuit Breaker Marine Electrical Systems Integrated Project Team Polyethylene Polytetrafluorethylene Polyvinyl Chloride Radio Frequency Warships Support Agency
14
C
Cable categories, 7 external to pressure hull, 10 insulation/sheath materials, 8 penetrators, 10 Selection, conductor size, 9 Selection, external influences, 9 Selection, general, 10 Selection, non pressure tight, 10 Selection, number of cores, 9 Selection, polyethylene, 10 Selection, pressure tight, 10 Selection, procedure, 9 Selection, radio frequency, 10 Selection, silicone rubber insulated, 10 Selection, special conditions, 9 Selection, submarines, 10
15
Defence Standards are Published by and Obtainable from: Defence Procurement Agency An Executive Agency of The Ministry of Defence UK Defence Standardization Kentigern House 65 Brown Street GLASGOW G2 8EX
DStan Helpdesk Tel 0141 224 2531/2 Fax 0141 224 2503 Internet e-mail enquiries@dstan.mod.uk
File Reference The DStan file reference relating to work on this standard is D/DStan/69/02/512 Pt 1. Contract Requirements When Defence Standards are incorporated into contracts users are responsible for their correct application and for complying with contractual and statutory requirements. Compliance with a Defence Standard does not in itself confer immunity from legal obligations. Revision of Defence Standards Defence Standards are revised as necessary by up issue or amendment. It is important that users of Defence Standards should ascertain that they are in possession of the latest issue or amendment. Information on all Defence Standards is contained in Def Stan 00-00 Standards for Defence Part 3 , Index of Standards for Defence Procurement Section 4 Index of Defence Standards and Defence Specifications published annually and supplemented regularly by Standards in Defence News (SID News). Any person who, when making use of a Defence Standard encounters an inaccuracy or ambiguity is requested to notify the Directorate of Standardization (DStan) without delay in order that the matter may be investigated and appropriate action taken.