SHIP PRODUCTION COMMITTEE August 1988

FACILITIES AND ENVIRONMENTAL EFFECTS NSRP 0298

SURFACE PREPARATION AND COATINGS
DESIGN/PRODUCTION INTEGRATION
HUMAN RESOURCE INNOVATION
MARINE INDUSTRY STANDARDS
WELDING
INDUSTRIAL ENGINEERING
EDUCATION AND TRAINING

THE NATIONAL
SHIPBUILDING
RESEARCH
PROGRAM

1988 Ship Production Symposium

Paper No. 9A:

Wired for Disaster: Cableway
Improvement Program

U.S. DEPARTMENT OF THE NAVY

CARDEROCK DIVISION,
NAVAL SURFACE WARFARE CENTER
 Form Approved
Report Documentation Page OMB No. 0704-0188

Public reporting burden for the collection of information is estimated to average 1 hour per response, including the time for reviewing instructions, searching existing data sources, gathering and
maintaining the data needed, and completing and reviewing the collection of information. Send comments regarding this burden estimate or any other aspect of this collection of information,
including suggestions for reducing this burden, to Washington Headquarters Services, Directorate for Information Operations and Reports, 1215 Jefferson Davis Highway, Suite 1204, Arlington
VA 22202-4302. Respondents should be aware that notwithstanding any other provision of law, no person shall be subject to a penalty for failing to comply with a collection of information if it
does not display a currently valid OMB control number.

1. REPORT DATE 2. REPORT TYPE 3. DATES COVERED

AUG 1988 N/A -
4. TITLE AND SUBTITLE 5a. CONTRACT NUMBER
The National Shipbuilding Research Program: 1988 Ship Production
5b. GRANT NUMBER
Symposium Paper No. 9A: Wired for Disaster: Cableway Improvement
Program 5c. PROGRAM ELEMENT NUMBER

6. AUTHOR(S) 5d. PROJECT NUMBER

5e. TASK NUMBER

5f. WORK UNIT NUMBER

7. PERFORMING ORGANIZATION NAME(S) AND ADDRESS(ES) 8. PERFORMING ORGANIZATION

REPORT NUMBER
Naval Surface Warfare Center CD Code 2230 - Design Integration Tools
Building 192 Room 128 9500 MacArthur Blvd Bethesda, MD 20817-5700
9. SPONSORING/MONITORING AGENCY NAME(S) AND ADDRESS(ES) 10. SPONSOR/MONITOR’S ACRONYM(S)

11. SPONSOR/MONITOR’S REPORT

NUMBER(S)

12. DISTRIBUTION/AVAILABILITY STATEMENT

Approved for public release, distribution unlimited
13. SUPPLEMENTARY NOTES

14. ABSTRACT

15. SUBJECT TERMS

16. SECURITY CLASSIFICATION OF: 17. LIMITATION OF 18. NUMBER 19a. NAME OF
ABSTRACT OF PAGES RESPONSIBLE PERSON
a. REPORT b. ABSTRACT c. THIS PAGE
SAR 9
unclassified unclassified unclassified
 DISCLAIMER

These reports were prepared as an account of government-sponsored work. Neither the

United States, nor the United States Navy, nor any person acting on behalf of the United
States Navy (A) makes any warranty or representation, expressed or implied, with respect
to the accuracy, completeness or usefulness of the information contained in this report/
manual, or that the use of any information, apparatus, method, or process disclosed in this
report may not infringe privately owned rights; or (B) assumes any liabilities with respect to
the use of or for damages resulting from the use of any information, apparatus, method, or
process disclosed in the report. As used in the above, “Persons acting on behalf of the
United States Navy” includes any employee, contractor, or subcontractor to the contractor
of the United States Navy to the extent that such employee, contractor, or subcontractor to
the contractor prepares, handles, or distributes, or provides access to any information
pursuant to his employment or contract or subcontract to the contractor with the United
States Navy. ANY POSSIBLE IMPLIED WARRANTIES OF MERCHANTABILITY AND/OR
FITNESS FOR PURPOSE ARE SPECIFICALLY DISCLAIMED.
Wired for Disaster: Cableway Improvement
Program No. 9A
Verle Hendricks, Visitor, NAVSEADET (PERA CV), Bremerton, WA
Jim Pokrywka ViSitOr, and Cliff Creek, Visitor, American Systems Engineering Corp., Virginia Beach, VA

ABSTRACT
INTRODUCTION
Throughout a Ship's lifecycle, as The objective of this paper is to
systems are installed, modified, or
removed, breaches of the technical introduce the cableway installation,
repair, and removal program currently
requirement for proper installation of being implemented on U.S. Navy aircraft
electrical and electronic cables occur. entitled
The majority of these deviations are a carriers. The program,
result of insufficient attention to "Carrier Life Enhancing Repairs (CLER)
cable installation requirements during Cableway Improvement Program (CIP)", is
ship design or production caused by a four phased program and was developed
shortcuts to reduce costs or meet considering the following objectives
schedules, and overall poor and goals:
workmanship.
Train and certify shipboard
personnel to inspect, install,
In January 1984 on the USS end repair cables and cableways.
TATTNALL (DDG-19) a fire originating in Increase shipboard personnel
a locked compartment spread through awareness of cableway safety
electrical cableways. Before being hazards.
contained, this fire caused loss of . Remove excess weight, especially
life, extensive damage to critical on main deck and above.
system and prevented the ship from . Clear cableway congestion.
completing her assigned mission. An Correct cable and cableway
investigation revealed that the fire hazards and discrepancies.
started as a result Of cableway . Train shipboard personnel to
discrepancies. Further Surveys perform quality assurance Of
performed on various ships revealed work accomplished by repair or
findings which included: modernization activities.
. Document work to be accomplished
The cableway discrepancies found and completed work in order to
on the USS TATTNALL (DDG-19) effectively track progress of
were not isolated, but common to the program.
the fleet in great numbers.
Fifteen to Twenty percent of all The four phases of the Program are as
dead-ended cables were found to follows:
be still electrically energized.
. Phase one - Ship's Force
TO develop a systematic and training and certification
program
discrepancies and reduce the risk of . Phase Two - Organizational Level
fire, Commander Naval Air Force, (Ship's Force, correction Of
Atlantic Fleet (COMNAVAIRLANT) tasked cableway discrepancies
American systems Engineering . Phase Three - Depot Level
Corporation (AmSEC) and Naval See (Industrial Activity) Correction
Systems Command Detachment (NAVSEADET) of cableway discrepancies
(PERA CV) to develop a program to . Phase Four - Documentation and
assist in correcting cableway Tracking
d i sic rse p ncc r ea ior c r
a a fnt c c air rei e rss .
The program since displayed great The first phase trains and
success evidenced by Navy wide certifies selected shipboard personnel
attention and expansion of the program to properly and safely remove and
to include aircraft carriers under install electrical cable and correct
Commander Naval Air Force, Pacific other associated electrical cableway
Fleet (COMNAVAIRPAC). adversities. It is conducted onboard
each ship with each student

9A-1
participating in both "hands-on" . Video tapes which introduce the
classroom lesson topics
instruction. In the second phase, . Lecturing by instructor with
shipboard personnel utilize the skills visual aids
learned in the training phase in the . Practice exercises located in
removal of unused cables and correction student guides
of associated cable and cableway . Instructor demonstrations
hazards, prior to the scheduled . Student "hands-on"
overhauls or availabilities. The
second phase work includes all cable classroom instruction consists of 16
runs up to the major cableways. The modules as follows:
third phase accomplished by
industrial activities during overhauls . Overview and introduction
or availabilities. In this phase, the . Special tools and equipment
discrepancies in the major cableways . Stuffing tubes
are removed. The fourth and final . Penetration of equipment and
phase is the documentation and tracking connection boxes
of completed or new work to be . Multicable penetrators
accomplished utilizing compartment- . Hangers
alization diagrams based on the ship's . Banding
Booklet of General Plans. . Chafing rings
. Cable pulling techniques
A multitude of cableway problems . Dead-ending cables
have bee" detected and corrected as a . Cable splicing
result of the program. The most common . Repairing insulation damage
types cableway discrepancies . Testing cables
identified for repair include: . Inspection of cables and
cableways
. Exposed or improperly end-sealed . Blueprint reading
dead-ended Cables . Cable Removal Plan of Action
. Improperly spliced cables
. Exposed conductors in junction Student participation during the
boxes, Power panels, fuse training is enhanced by "se of a
panels, and equipment student guide which contains the 16
. Violated firetight, smoketight modular 1essons with additional
and watertight boundaries practice exercise sections. Each
. Overcrowded cableways module, where applicable, is
. Overheated cables supplemented by excerpts from the EPISM
. Missing o r improper cable to heighten student understanding of
banding the subject matter as well as to
. Insufficient or improper cable encourage practical use of the EPISM.
hangers In addition, where specific equipment,
. Chafed or cut cables materials, or tools are addressed,
. Cables run outside of cableways supplements have been inserted giving
current noun name, manufacturer,
PHASE ONE - THE TRAINING AND national stock number (NSN), cost, and
CERTIFICATION PROGRAM quantity needed to perform. a given
task. In the event that specific tools
The first phase implemented in the and materials are not available through
cableway Improvement Program (CIP) is the Navy stock system, manufacturer's
the training and certification Of data is provided with the information
shipboard personnel to identify and necessary to procure the required
correct discrepancies associated with items.
the ship's electrical and electronic
equipment and cableways. The training T O fully ensure success of the
is composed of a NAVSEA approved formal training in Phase One, tools and
training course of instruction in materials associated with specific
modular form, developed from and modules are also included in the
adhering to the Electric training package. These tools and
Installation Standard Methods Manual materials allow instructor classroom
(EPISM) S9300-AW-EDG-010. demonstrations, and student hands-on
practical application of the lessons
Shipboard training involves 40 taught. I" some applications,
hours of formal classroom instruction classroom mock-ups are the only means
utilizing selected Ship's Force of student training due to
personnel with electrical and inaccessibility of equipment and time
electronic backgrounds. Class size is constraints imposed by numbers of
limited to a maximum of 20 students due students and training requirements.
to the extent of actual hands-on
participation of each student in At the conclusion of the training
various phases of the instruction. The phase, NAVSEA approved certification
training program is conducted in 5 forms are issued for each student
segments: completing the entire course of

9A-2
instruction. The certification forms Of unused cables.
are designed to allow partial • Open metal and nylon stuffing
certification for students not tubes
completing the entire 16 m o d u l e • Unpack chafing rings and multi-
training. The certification forms are cable penetrations.
in two parts, part one being the • Remove unused cable in 3 to 4
certification of having attended the foot sections to prevent damage
classroom training, part two of the to other installed cables.
certification form is for successful • Endseal all dead-ended cables
completion of the "hands-on" practical not removed.
application portion of the training. • Band all cables to installed
Certification forms once completed will hangers.
be forwarded to NAVSEA Code 07Q with a • Replace any missing or damaged
copy retained onboard the ship to cable hangers or cable hanger
become a permanent entry studs.
individual student's service record. • Plug all open metal and nylon
Certified shipboard personnel become stuffing tubes, box connectors,
part of a NAVSEA inspection team under multi-plugs, and multi-transits.
NAVSEAINST 9304.1A "Shipboard
Cableway • Pack all firestop chafing rings
Electrical Cable and with type HF sealant and
Inspection and Reporting Procedures". firestop caulk.
• Repair all insulation damage.
PHASE TWO - ORGANIZATION LEVEL (SHIP’S • Splice cables if extensively
FORCE) CORRECTION OF CABLEWAY damaged and continued use is
DISCREPANCIES required.

I" the second phase of the The formal statement of work is

program, shipboard personnel take an supplemented by specific technical
active and independent role in the guidance provided to assist shipboard
correction of cable and cableway personnel in a systematic method of
deficiencies, and the removal of unused discovery and correction of cableway
cables. These activities are related deficiencies. This technical
undertaken in preparation of Phase III guidance is first and foremost provided
which occurs during an industrial ship by the formal classroom training
availability e.g., Complex Overhaul received by the shipboard certified
Selected Restricted Availability inspection and repair team.
Extension guidance is provided by NAVSEA $9300
AW-EDG-010/EPISM; "Electric Plant
Installation Standard Methods" and by
Ship's Force personnel, use a" NAVSEAINST 9304.1A; "Shipboard
Engineered Maintenance Plan (EMP) for Electrical Cable and Cableway
systematic Cableway Improvement and Inspection and Reporting Procedures".
correction of ship's cable and cableway Strict compliance to procedure and
discrepancies. The EMP for Cableway documentation coupled with a quality
Improvement is a major element in a assurance program provides long term
successful shipboard effort. improvement to the material condition
provides all of the program and ship of electrical cables and cableways.
specific information required to
successfully implement and track the To facilitate the task of
progress of the program. Specifically, implementing and tracking the program,
the EMP contains background each aircraft carrier is broken into
information, a formal statement of well defined zones from the Booklet of
work, technical guidance far execution General Plans. Cable and cableway work
of the work and charts/diagrams for is usually concentrated on main deck
effective monitoring of program and above due to the fact that most of
progress. the ship's electronic equipment is
located in the upper decks. In
A comprehensive statement of work addition, the most favorable effects on
defines the work to be ship stability are generated by topside
accomplished by Ship's Force personnel weight removal. A zone is determined
as cable and cableway discrepancies are by three means, with the first
discovered. The general approach consideration being major or suitable
dictated by the Statement Of Work is as frames for boundaries. An additional
follows: consideration is the actual "umber of
compartments within the designated
• Electrically test all unused boundaries. The last consideration is
cables for applied voltage that a zone should not contain more
observing standard electrical compartments/work/area than is
safety precautions as outlined reasonable for a three man team to
in OPNAVINST 5100 series. complete the inspection and correction
• Remove banding from alternate procedures within 30 days. It should
hangers to maintain cables in be noted here that the inspection and
place but facilitate the removal correction team is only dealing with

9A-3
discrepancies within compartments and installations. These priorities are
areas peripheral to the ship's main therefore established by either the
cableways. Dead ended cables and ship's Maintenance Planner or the
related deficiencies which enter into ship's Maintenance Manager and
main cableways are tagged and recorded Electrical Officer.
for accomplishment during Phase III.
PHASE THREE - DEPOT LEVEL (INDUSTRIAL
The inspection procedure utilized ACTIVITY) CABLEWAY IMPROVEMENT
by the ship's team is aided by two
tools, NAVSEAINST 9304.1A and a NAVSEA The third phase of the program is
generated deficiency report. accomplished by industrial activities
NAVSEAINST 9304.1A defines cable and during a Complex Overhaul (COH)
cableway deficiencies into three Selected Restricted Availability (SRA),
distinct categories: or Service Life Extension Program
(SLEP). After Ship's Force p u r g e s
Immedlate Hazard Those items deficiencies from the peripheral
which are, or have the immediate compartments leading to the major
potential to be, personnel cableways, the industrial activity will
safety hazards, electrical fire open the main cableways, remove the
hazards, or which negate unused cable end correct miscellaneous
firebreak integrity. discrepancies. This work is generally
Potential Hazard Those items funded by NAVSEA (PMS 312) under "eight
which require corrective action removal ship alterations (SHIPALTS AVT
to ensure continued reliable and 0040, CV 3800K, or CVN 3801K) and is
safe performance or maintain normally concurrent with other cableway
watertight integrity but are not work being accomplished by other
of immediate danger to personnel SHIPALTS or modernization
or equipment. programs. The amount Of cable
Nonhazardous - Those items which (tonnage) removed is then reported to
are not hazardous to personnel the ship's planning yard to allow for
and equipment but are not in weight and moment computation. The
compliance with approved industrial activity accomplishing the
standard installation practices. work is then responsible for restoring
the cableways in accordance with the
Fleet Commander funded NAVSEA guidelines set forth in the Electric
certified inspection teams, using the Plant Installation Standard Methods
criteria es outlined above, conduct Manual (EPISM).
initial surveys on selected aircraft
carriers. The survey data is then During Phase Three, NAVSEA
compiled into a computer data base. certified shipboard personnel and
Deficiencies found are sorted by level Supervisors of Shipbuilding (SUPSHIPS)
and compartment end linked to each personnel perform the quality assurance
respective zone. The correction of functions for this work. Shipboard
these identified deficiencies, es well personnel must inspect all opened
as a thorough inspection procedure by cableways to be certain that all
Ship's Force, will restore the ship's electrical cableway deficiencies are
electrical and electronic systems and corrected prior to rebanding. In
cableways to a safe condition within particular, attention is given to the
the proper installation specifications. following es quality checks:
In addition, cableway space is made
available for new shipboard • All dead-ended cables are
installations. removed or properly end sealed
where they exit the established
A comprehensive tracking system work zone.
and completion checklist to be utilized l Unused stuffing tubes are
by Ship's Force to manage the cable and properly blanked.
cableway repair effort is also included l Chafing rings are packed with
in the EMP. These tracking aids are high temperature sealant (Type
used in conjunction with a detailed HF).
breakdown of the ship's zones. Each • channel rubber is used around
zone description contains information transmission, coaxial, or robber
relating to location and a complete jacketed cables prior to
listing, by compartment number, of all bending.
compartments located within the zone. • Cableways are arranged, "here
Lastly, the NAVSEA deficiency report possible, with the larger cables
for each zone is provided. in the center.
• Open multicable transits are
A removal schedule based primarily properly blanked.
upon weight removal is also included • Newly installed chafing rings
for management planning. The actual allow for an additional fifty
prioritization of zone work completion percent growth for new cable
is governed by criteria associated with installation.
ship alterations and modernization • At least every fourth horizontal

9A-4
 hanger and every vertical hanger
is banded. Upon completion of the removal/
repair work, the accomplishing activity
. Any damaged cable is either Conducts a final inspection in the
replaced or properly spliced. applicable zones. The inspection
serves to document the completed
The supervisors of shipbuilding removal/repair work and complete the
(SUPSHIPS) are also required to perform Pre-prepared Ship's Maintenance Action
certain quality assurance functions es Form or Automated Work Request (AWR),
follows: utilizing the ship's SNAP computer
system, indicating the number of feet
. Periodically audit contractor of cable removed from the applicable
practices end conduct onboard zone. The size or type of cable is not
inspections to ensure compliance identified, es NAVSEA engineers have
with NAVSEAINST 9304.lA. developed a formula for computing
. Establish a formal quality approximate weight removed. This
assurance program to ensure that formula is based on the average size
the work done by private sector cable know" to be installed in aircraft
facilities conforms to the carriers in corresponding areas.
EPISM, NAVSEA S9300-AW-EDG-010.
. Conduct a final cableway RESULTS
inspection in the areas affected NAVSEADET (PERA CV), es Cableway
by the work package prior to Improvement Program manager for
final ship acceptance and/or end COMNAVAIRLANT, COMNAVAIRPAC, and NAVSEA
of repair availability. (PMS 312) is successfully providing
designated shipboard personnel the
These two activities, Ship's Force training, tools and materials required
and SUPSHIPS, working as separate and to implement NAVSEAINST 9304.1A
independent entities have assured a "Shipboard Electrical Cable and
successful quality assurance inspection Cableway Inspection and Reporting
program for all aircraft carriers Procedures". Since ninety percent of
during a depot level availability. a11 cableways on aircraft carriers
contain unused cables, removal of these
PHASE FOUR - PROGRAM DOCUMENTATION AND cables by Ship's Force make it more
TRACKING cost effective to install new cables
without having to construct new
Phase Four, the final phase of the cableways. Cable weight removal costs
program, entails the documentation and are approximately eight to ten thousand
tracking of completed or new work. The dollars per ton, or about half the
tracking system c o n s i s t s of three normal fifteen to thirty thousand
distinct elements as follows: dollars per ton for other weight
removal items. The Carrier Life
. Color coded Booklet of General Enhancing Repairs (CLER) Cableway
Plans. Improvement Program has integrated Type
. Tracking Matrix/Completion Check 'Commander repairs and NAVSEA (PMS 312)
List "Weight and Moment Compensation'
. Automated Work Requests (AWR's)/ S HIPALTS to accomplish the removal of
Ship's Maintenance Action Forms these cables.
(2-KILO)
To date, certification training
Copies of the Booklet of General has been completed on fifty percent of
Plans are color coded to track work -the Navy's aircraft carriers and
completed in each zone. They aid Cableway Engineered Maintenance Plans
cableway inspection teams to quickly have been developed and implemented on
identify compartments and zones where ‘about twenty percent of the carriers.
outstanding work remains to be The remaining carriers are scheduled to
accomplished. The tracking matrix/ commence the implementation of the
completion check list used to record program in the near future.
work already accomplished, or work yet
to be completed is included in the In addition, students who attended
Engineered Maintenance Plan (EMP) and the cable and cableway training course
serves the following functions: of instruction have returned to their
respective work centers with useful
. Determines if the work was knowledge for future application. In
accomplished in accordance with passing the training received to their
the EMP peers, a higher degree of professional-
. Provides a means of documenting ism is realized by the ship and the
and updating of work Navy. Work center supervisors,
accomplished on the plan division officers, and other ship's
. Provides a means of feedback to officers attest to the quality o f
monitor the effectiveness of the workmanship generated by Ship's Force
work prescribed in the EMP in personnel having participated in the
order to make adjustments to the Cableway Improvement Program.
plan if required.

9A-5
Additional copies of this report can be obtained from the
National Shipbuilding Research and Documentation Center:

http://www.nsnet.com/docctr/

Documentation Center
The University of Michigan
Transportation Research Institute
Marine Systems Division
2901 Baxter Road
Ann Arbor, MI 48109-2150

Phone: 734-763-2465
Fax: 734-763-4862
E-mail: [email protected]