Cableway Improvement Program (CIP) Installation, Repair and Inspection

Outline of Instruction

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Overview / Introduction:

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The videotape “Wired for Disaster” gives the student an introduction to shipboard cable hazards and provides examples of existing and potential problems in electrical cables and cableways. This forms the basic building block on which the remainder of the course of instruction will be built.

Terminal Objective:

None.

Enabling Objective:

None.

Special tools and equipment:

This lesson presents the various tools and equipment and their use that will be required to properly remove dead end cable, install new cables and make repairs to disturbed cableways and equipment.

Terminal Objective:

Given the appropriate electrical tools and equipment, demonstrate their proper use in accordance with the guidelines specified in Electric Plant Installation Standard Methods DOD-STD-2003 (NAVY) EPISM.

Enabling Objectives:

Given a list of tools and their uses, match each tool with its appropriate use in accordance with the guidelines specified in Electric Plant Installation Standard Methods DOD-STD-2003 (NAVY) EPISM.

Stuffing of Tubes: This lesson presents the types, parts, proper installation and proper packing procedures for metal stuffing tubes.

Terminal Objectives:

Given an assignment to plan the installation of metal stuffing tubes to run electrical cables through a bulkhead or deck, sketch a layout plan showing proper tube sizes, hole dimensions, and spacing between adjacent tubes. The plan must be in accordance with the guidelines specified in the Electrical Plant Installation Standard Methods DOD-STD-2003 (NAVY) EPISM.
Pack a metal stuffing tube in accordance with the guidelines specified in the Electric Plant Installation Standard Methods DOD-STD-2003 (NAVY) EPISM, using proper tools and materials.

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Enabling Objectives:

Given drawings of different types of metal stuffing tubes, name each type.
Provided with a list of different size cables and a cable assignment chart, select the correct stuffing tube size for each cable.
Provided with a list of different stuffing tube sizes and a tube spacing chart, select the proper tube dimension for each stuffing tube mounting hole.
Given a list of stuffing tube sizes select the correct packing and metal tube blank for each tube.
Given a list of stuffing tube sizes and a hole spacing chart, determine the spacing required between adjacent tubes.
Given a list of stuffing tube sizes, a hole spacing chart, and a ruler, sketch a layout for the installation of the listed tubes.

Penetration of Equipment and Connection Boxes:

This lesson present information that will help personnel select and install watertight and non-watertight connectors penetrating equipment and seal holes in equipment when unused cables are removed.

Terminal Objective:

Given a list of cables and a cable assignment chart determine the size of nylon stuffing tube, nylon tube packing assembly, metal terminal tube or the correct size box connector required.
Given tools and material remove dead ended cable from equipment and seal all unused penetrations in accordance with guidelines specified in the Electric Plant Installation Standard Methods DOD-STD-2003 (NAVY) EPISM.

Enabling Objectives:

Given illustrations of cable penetrating pieces of equipment, determine if they are watertight or non-watertight.
Match the types of connectors with statements that best describe their uses.
Given an illustration of a nylon stuffing tube, label each part.
Provided with a list of different size cables and box connectors, determine the size plug required for the hole.
Provided with a list of different size cables and nylon stuffing tubes, determine the size plug required to seal the nylon stuffing tubes.
Provided with a list of different size cables and metal terminal tubes, determine the size plug required to seal the metal terminal tubes.
Provided with a list of different size cables and a cable assignment chart assignment chart for box connectors, determine the size connector and clearance hole size.
Provided with a list of different size cables and a cable assignment chart for nylon stuffing tubes, determine the size connector, clearance hole size and packing assembly for each cable.
Provided with a list of different size cables and a cable assignment chart for metal stuffing tubes, determine the size of tube and size of cable clearance hole.
Provided with a list of steps required to install a metal stuffing tube in a piece of equipment or connection box, arrange the steps in a sequence.

Multicable Penetrators:

This lesson presents the various types of multicable, penetrators, (MCP’s), their component parts, and application.

Terminal Objectives:

Given the task to plan a Multicable Penetrator (MCP) installation for running cables through a watertight bulkhead, sketch a layout on a multicable penetrator grid showing the numbers and types of installation blocks to use in accordance with guidelines specified in the Electric Plant Installation Standard Methods DOD-STD-2003 (NAVY) EPISM.
Given the proper tools and equipment and a completed MCP grid, pack a multicable penetrator in accordance with guidelines specified in the Electric Plant Installation Standard Methods DOD-STD-2003 (NAVY) EPISM.

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Enabling Objectives:

Given expanded drawings of MCP’s, label each part.
Match the parts of the multicable penetrator to the statement that best describes its function.
Given three groups of cable types to be installed in a bulkhead, select the proper MCP to use for each group.
Given a group of unidentified cables, determine the proper MCP block for each.
Provided with a list of different size cables and a Cable Assignment Chart, select the correct insert blocks for each cable type.
Given a Multicable Penetrator Grid, Multicable Penetrator Cable Assignment Chart, and a list of cable types, sketch a layout of the MCP. The MCP installation plan must be in accordance with guidelines specified in the Electric Plant Installation Standard Methods DOD-STD-2003 (NAVY) EPISM.
Discuss the application of the ROX system
Discuss the application of the Brattberg System
Discuss the application of the RISE system

OUTLINE OF INSTRUCTIONS

Hangers: This lesson presents the different types and sizes of cable hangers and their application

Terminal Objectives: Given illustrations of a single and multiple cable runs, plan the installation of hangers. The plan must show at a minimum the proper placement of the first hanger, proper bend radius, and spacing between each hanger. The plan must be in accordance with guidelines specified in the Electric Plant Installation Standard Methods DOD-STD-2003 (NAVY) EPISM

Enabling Objectives:

Given the illustrations of the hangers, write the name of each type.
Match the proper type of hanger with statements that best describe its uses
Provided with situations requiring the use of hangers, select the appropriate type(s).
Given illustrations of hangers that have been installed for a cableway, calculate the proper spacing for the first hanger, proper bend radius and proper spacing between each hanger.

Banding:

This lesson presents the banding tool, special equipment, and materials that are required to properly band cable in cableways.

Terminal Objective:

Provided with cable runs, banding tools, equipment and materials, band cable runs in accordance with guidelines specified in the Electric Plant Installation Standard Methods DOD-STD-2003 (NAVY) EPISM.

Enabling Objectives:

List places where cables must be banded to hangers in a cableway
Given statement’s describing the placement and banding of cables to hangers, select the proper arrangement.
Given a list of different size banding, select the ones to be used for banding cable runs in accordance with guidelines specified in the Electric Plant Installation Standard Methods DOD-STD-2003 (NAVY) EPISM.
Given a list of cable runs, select which runs should be banded with a buckle and a band assembly or with a hose clamp.
Given banding materials, proper tools and equipment, fabricate a buckle and band assembly.
Given cable-banding situations, the proper tools and equipment, secure the cables to the hangers with the proper banding materials.

Chafing Rings:

This lesson presents the purpose of chafing rings and the methods of determining whether additional cable can be passed through existing chafing rings.

Terminal Objectives:

Provided with a description of cables/cableway passing through a non-watertight bulkhead, determine if additional cable can be passed through the existing chafing ring in accordance with guideline’s specified in the Electric Plant Installation Standard Methods DOD-STD-2003 (NAVY) EPISM.
Given a description of cables to be passed through a non-watertight fire zone boundary bulkhead, determine if it is packed in accordance with guidelines specified in the Electric Plant Installation Standard Methods DOD-STD-2003 (NAVY) EPISM, to make the passage a fire-tight and fume-tight boundary.
Given a description of cables to be passed through a non-watertight bulkhead, design a chagin ring to accommodate each cable; allow for 20 percent unfilled space for future cable additions; and maintain a minimum clearance space around cables ¼ inch for single cables and 1 inch for multiple cables and I inch for multiple cables in accordance with guidelines specified in the Electric Plant Installation Standard Methods DOD-STD-2003 (NAVY) EPISM.

Enabling Objectives:

Provided with a description of cables/cableway passing through a non-watertight bulkhead, determine if additional cable can be passed through the existing chafing ring.
Given a description of cables to be passed through a non-watertight fire zone boundary bulkhead, determine if it is packed to make the passage a fire-tight and fume-tight boundary.

Dead Ending Cables:

This lesson presents various end sealing methods, selection of proper end caps for each conductor and cable, and end sealing procedures.

Terminal Objectives:

Provided with an end cap chart and the proper tools and equipment, end seal a dead ended cable in accordance with the guidelines specified in the Electric Plant Installation Standard Methods DOD-STD-2003 (NAVY) EPISM.

Enabling Objectives:

Given different cable types and a copy of the Electric Plant Installation Standard Methods DOD-STD-2003 (NAVY) EPISM, select the method for end sealing dead-ended cables.
Given pieces of different cable types, and end cap chart, ruler, wire gage, and an AWG &C/M Cross Reference Chart, select the proper end caps for each conductor and cable.
Given a piece of cable, proper end caps, and a heat gun, seal the end caps to conform to the diameter of the conductor.

Splicing Cables:

This lesson presents the basic splicing materials and proper procedures for splicing armored and unarmored cables used in power, control, and communication systems.

Terminal Objective:

Provided with the proper tools and supplies, splice electrical cable in accordance with the guidelines specified in the Electric Plant Installation Standard Methods DOD-STD-2003 (NAVY) EPISM.

Enabling Objectives:

Provided with proper tools and supplies, prepare cable ends for splicing.
Provided with proper tools and supplies, restore cable jacket to meet or exceed original electrical specifications.

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Cable Jacket Repair:

This lesson presents the basic tools, materials, and procedures for repairing damaged armored and unarmored cable jackets.

Terminal Objective:

Given the proper tools and supplies, restore damaged cable jacket insulation of electrical cables (armor and /or sheath damage only) to meet or exceed original electrical specifications, with conductors and water-sealing compounds being intact in accordance with the guidelines specified in the Electric Plant Installation Standard Methods DOD-STD-2003 (NAVY) EPISM

Enabling Objective:

Given damaged electrical cables (armored and unarmored), identify the damage in each, and the procedure to repair cable jacket damage.

Testing Cables:

This lesson presents the basic test instruments to required to check cables for opens, shorts, and grounds.

Terminal Objectives:

Given the test instrument (megger), measure insulation resistance to ensure that two or more electrical conductors or cables are properly separated from each other or from ground by an insulating material.
Given test instrument (multimeter), perform a continuity check to ensure there are no shorts, opens, grounds, or leads incorrectly connected.

Enabling Objective:

Given a list of test instruments and their uses, match each test instrument with its appropriate use.

Cable ID and Marking:

This lesson presents the methodology used for the numbering of electrical systems and equipment for locating and identifying purposes, and the proper use of shipboard Isometric Wiring Diagrams.

Terminal Objective:

Given various circuit numbers, students will be able to identify electrical cables to include terminations, equipment type and type of service.
Students shall be able to state the requirements for cable identification tags.
Given a cable tags obtain the correct Isometric Wiring Diagrams; determine cable route and location of nearest connection box.

Cable pulling Techniques:

This lesson presents information on planning, preparation, and proper procedures to remove and install cables and cableways.

Terminal Objective:

Pull dead ended cable from ship’s cableways using proper tools and materials, observing all standard electrical safety precautions in accordance with the guidelines specified in the Electric Plant Installation Standard Methods DOD-STD-2003 (NAVY) EPISM
Install cable in ship’s cableways using proper tools and materials, observing all standard electrical safety precautions in accordance with the guidelines specified in the Electric Plant Installation Standard Methods DOD-STD-2003 (NAVY) EPISM.
Install cable in ships cableways using proper tools and materials, observing all standard electrical safety precautions in accordance with the guidelines specified in the Electric Plant Installation Standard Methods DOD-STD-2003 (NAVY) EPISM

Cableway Inspection:

This lesson presents information that will help personnel look for discrepancies and problems in cables and cableways and necessary steps to correct them.

Terminal Objective:

Given illustrations of electrical cable and cableway deficiencies, identify each deficiency and assign the proper category type using the information provided in the Cable Inspection Criteria NAVSEA INST. 9304.1C

Enabling Objective:

Match the category deficiency to the statement that best describes its definition.