DNVGL-CP-0400 Edition December 2015

Transcription

1 CLASS PROGRAMME Type approval DNVGL-CP-0400 Edition December 2015 The electronic pdf version of this document, available free of charge from is the officially binding version.

2 FOREWORD DNV GL class programmes contain procedural and technical requirements including acceptance criteria for obtaining and retaining certificates for objects and organisations related to classification. December 2015 Any comments may be sent by to This service document has been prepared based on available knowledge, technology and/or information at the time of issuance of this document. The use of this document by others than DNV GL is at the user's sole risk. DNV GL does not accept any liability or responsibility for loss or damages resulting from any use of this document.

3 CHANGES CURRENT This is a new document. Changes - current Class programme DNVGL-CP Edition December 2015 Page 3

4 CONTENTS Changes current...3 Contents Section 1 General Introduction Documentation...5 Section 2 Product requirements Design requirements Test requirements... 9 Section 3 Test requirements Table of tests...11 Class programme DNVGL-CP Edition December 2015 Page 4

5 SECTION 1 GENERAL 1 Introduction 1.1 Objective Section 1 The objective of this class programme (CP) is to describe the type approval (TA) scheme for lightweight electric cables. For a description of the Society's type approval scheme in general and further information on general conditions and procedures for obtaining the Society's TA certificate, see the Society's document DNVGL CP 0338 Type approval scheme. The procedures and requirements described in this CP are applicable for obtaining the Society's TA certificate based on requirements given in: DNV GL rules for classification Ships RU SHIP Pt.4 Ch.8 Electrical installations the Society's document OS D201 Electrical installations Guidance note: This class programme is not applicable for obtaining EU Marine Equipment Directive (MED) certificates. Visit for information on MED certification. ---e-n-d---of---g-u-i-d-a-n-c-e---n-o-t-e Scope This CP gives a description of the procedures and requirements related to documentation, design and type testing applicable for TA of. This CP does not set the design requirements for the lightweight electric cables. TA is based on compliance with design requirements given in the rules and/or other regulations and standards. The CP describes the applicable design requirements and how to document compliance with the requirements in order to obtain a TA certificate for the equipment. This includes, where relevant, technical requirements for how the type tests shall be performed. 1.3 Application RU SHIP Pt.4 Ch.8 requires that lightweight electric cables are type approved by the Society Type approval in accordance with this CP is thus mandatory for equipment to be installed on vessels classed with the Society. A TA certificate in accordance with this CP will confirm compliance with the requirements given in the rules as specified in [1.1]. The TA certificate will not confirm compliance with requirements given in other parts of the rules. In case additional requirements given in other parts of the rules shall be covered by the TA certificate, this shall be specified in the application for TA and will be stated in the TA certificate. 2 Documentation For TA of the following documentation shall be submitted: 1) data sheet(s) 2) main drawings of all different cable construction covered by the type approval, showing conductors and the different layers. 3) references to design standards, rules, specifications etc. 4) specification of applied material. 5) test results (from tests already carried out, if any). 6) applicant s proposal to type test (TT) and routine test (RT). Class programme DNVGL-CP Edition December 2015 Page 5

6 7) documentation of reliability and endurance on board ships and mobile offshore units, if any. 8) special operational limitations. 9) field of application: general power and lighting control instrumentation and communication. 10) list of the cables covered by the type approval giving the following information for each variant: number of cores conductor cross-section (mm 2 ) and number of strands insulation thickness (mm) fillers/bedding thickness (mm) inner/outer sheath thickness (mm) braiding wire diameter (mm) overall diameter (mm). 11) construction details: voltage class: 0.6/1 kv or 150/250 V temperature class: 90 C conductors: Class 2 or class 5. Stranded plain or tinned copper insulation material fillers/bedding material inner/outer sheath material: SHF1, SHF2 metal covering: Braid or armour made of galvanised steel, bronze or copper material outer braid/armour if any. 12) special properties, if any (watertight, fire resistant etc.) Test programme, which as a minimum includes the elements for type testing, Sec.3. The test programme shall refer to the relevant standards for each test. 13) application for type approval form 90.01a. 14) for items 9), 10) and 11) above, application form no a shall be used. Section 1 Class programme DNVGL-CP Edition December 2015 Page 6

7 SECTION 2 PRODUCT REQUIREMENTS 1 Design requirements 1.1 General requirements The lightweight electric cables shall comply with the relevant requirements given in the latest edition of the following publications (including amendments): DNV GL rules for classification Ships RU SHIP Pt.4 Ch.8 (as applicable). DNV GL offshore standard DNVGL OS D201 as governed by applicable rules for offshore units requirements for insulation material as per Sec.2 and Sec : Insulating and sheathing materials for shipboard and offshore units, power, control, instrumentation and telecommunication cables. Section Special Properties : General construction and test methods of power, control and instrumentation cables for shipboard and offshore applications : Test for vertical flame propagation for a single insulated wire or cable - Apparatus : Test for vertical flame propagation for a single insulated wire or cable Procedure for 1 kw pre-mixed flame : Test for vertical flame spread of vertically-mounted bunched wires or cables - Apparatus : Test for vertical flame spread of vertically-mounted bunched wires or cables category A : Calculation of maximum external diameter of cables for indoor installations : Specification for flexible insulating sleeving. Methods of test : Determination of the amount of halogen acid gas : Determination of the degree of acidity of gases evolved during the combustion of materials taken from electric cables by measuring ph and conductivity : Methods for general application - Measurement of thickness and overall dimensions - Tests for determining the mechanical properties : Methods for general application Section Two: Thermal ageing methods : Methods for general application Section Four: Tests at low temperature : Methods specific to elastomeric compounds - Ozone resistance, hot set test and mineral oil immersion test : Methods specific to PVC compounds Section One: Pressure test at high temperature - Tests for resistance to cracking : Measurement of smoke density of cables burning under defined conditions Part Two: Test procedure and requirements : Test method for fire with shock at a temperature of at least 830 C for cables of rated voltage up to and including 0.6/1.0 kv and with an overall diameter exceeding 20 mm : Test method for fire with shock at a temperature of at least 830 C for cables of rated voltage up to and including 0.6/1.0 kv and with an overall diameter not exceeding 20 mm : Procedures and requirements Cables of rated voltage up to and including 0.6/1 kv ISO 5659, Part 2: Determination of optical density by a single chamber test. IMO: Res. MSC. 61(67) International Code for Application of Fire Test Procedures. British Standards BS 3G 230: General requirements for aircraft electrical cable (second series) EN 50305: Railway Applications Railway rolling stock cables having special fire performance test methods Class programme DNVGL-CP Edition December 2015 Page 7

8 EN : Cables, electrical, aircraft use Test methods Notch propagation NEK TS 606: Cables for Offshore installation, Halogen Free or Mud Resistant 1.3 details Table 1 Metric standard cores Section 2 Conductor nominal cross section Nominal conductor stranding no./ diameter Maximum conductor resistance at 20 C Minimum insulation thickness at any point Target insulation thickness Target core diameter (mm²) (mm) (ohms/km) (mm) (mm) (mm) / / / / / Valid for voltage class: 0.6/1 kv. Table 2 AWG Standard cores Conductor Nominal conductor stranding Maximum conductor resistance at 20 C Minimum insulation thickness at any point Target insulation thickness Target core diameter AWG No./ AWG (ohms/km) (mm) (mm) (mm) 22 19/ / / / / / Valid for voltage class: 0.6/1 kv. Table 3 Fire resistant cores 150/250 V Conductor nominal cross section Nominal conductor stranding no./ diameter Maximum conductor resistance at 20 C Minimum insulation thickness at any point Target insulation thickness Target core diameter (mm²) (mm) (ohms/km) (mm) (mm) (mm) / Class programme DNVGL-CP Edition December 2015 Page 8

9 Conductor nominal cross section Nominal conductor stranding no./ diameter Maximum conductor resistance at 20 C Minimum insulation thickness at any point Target insulation thickness Target core diameter (mm²) (mm) (ohms/km) (mm) (mm) (mm) / / Section / Table 4 Fire resistant cores 0.6/1 kv Conductor nominal cross section Nominal conductor stranding no./ diameter Maximum conductor resistance at 20 C Minimum insulation thickness at any point Target insulation thickness Target core diameter (mm²) (mm) (ohms/km) (mm) (mm) (mm) / / / / / / Braid wire Braiding wire diameter shall be specified in the individual cable construction tables. Braid Coverage shall meet the requirements given in Sec..3 Table 1 Test no Sheath dimensions: The fictitious diameter under the sheath (Df) is calculated using the rules specified in Clauses 1.3, 1.4, 1.5, 1.6 and 1.7, as required, except that the diameter of insulated conductor (di) shall be replaced with the appropriate target core diameter specified in Table 1 and Table 2. Target sheath thickness (Dt) and minimum sheath thickness (Dmin) are defined as follows: 2 Test requirements The testing is divided into: vsual inspection electrical/mechanical tests. 2.1 Visual inspection Target sheath thickness Dt = (0.04 Df) [mm]. Minimum sheath thickness Dmin = (0.85 Dt) 0.1 [mm]. By visual inspection, it shall be verified that the test sample is in conformity with the approved plans. Class programme DNVGL-CP Edition December 2015 Page 9

10 2.2 Electrical/mechanical tests The tests shall be according to the relevant parts of Sec.3 Table 1. Section 2 Class programme DNVGL-CP Edition December 2015 Page 10

11 SECTION 3 TEST REQUIREMENTS 1 Table of tests Table 1 Required test types Section 3 Test No. Examination or test Test basis Requirements Test on Type test Routine test General properties 1. Dimensions details , Braid wire , Sheath dimension , Cable 2. Concentricity % Minimum (50% for FR cores) Insulation Sheath 3. Workmanship By inspection Material free of cracks, splits, irregularities and foreign material Insulation Sheath 4. Braid coverage 90% Minimum coverage density Cable 5. Metallic coating of copper conductors (By inspection) Conductor surface will be smooth and uniform. Insulation will not adhere to the conductor. Conductor Physical properties 6. Tensile strength & ultimate elongation MPa minimum, 150% minimum (insulation) (speed 50 ± 10 mm/min) Insulation 7. Scrape abrasion resistance EN50305 cl cycles minimum (5N load, 0.45mm diam. rod, 20 C, 55 cycles/minute) 8. Dynamic cut through EN50305 cl N minimum ( mm radius blade, 20 C, 100g/s load) No dielectric breakdown 9. Notch propagation EN (0.05mm notch, 6 mandrel, 1.5kV AC for 1 minute) 10. Mechanical/particular characteristic of sheathing compounds, SHF1 or SHF2 Sheath Table 6 & 8 Class programme DNVGL-CP Edition December 2015 Page 11

12 Test No. Examination or test Test basis Requirements Test on 10a. SHF2 mud resistance NEK TS 606, Tensile and elongation ±25% Volume swell 20% max Weight increase 15% max (IRM C, 7 d Calcium bromide brine 70 C, 56 d Sheath (SHF 2 cables only) Type test Routine test Section 3 EDC (oil based), 70 C, 56d) Thermal properties 11. Lifetime BS 3G 230 >20 000h at 105 C 12. Accelerated ageing No cracks, no dielectric breakdown (168h at 150 C, 1.5kV AC for 5 minutes) 13. Insulation blocking EN s must be easily separated (6h at 150 C) No cracks, no dielectric breakdown 14. Cold bend (Where outer diameter <12.5mm) (-30 C, 10 mandrel, 1.5kV AC for 5 mins for 1m core) (-30 C, 10 mandrel, 3.5kV AC for 5 min. sample of cable) Cable 15. Current overload BS 3G 230 No cracks, no dielectric breakdown (30s at 250 C, 10 mandrel, wind as in test 11, 1.5kV AC for 5 minutes) Electrical properties 16. Conductor resistance per Appendix 1 No dielectric breakdown (2.5kV AC/4.5kV DC for 5 minutes for 1m of core ) 17. AC and DC voltage tests (1.5kV AC / 5 minutes for each delivery length of cable) (150v rated: 1.5kV a.c /3.6kV DC for 5 mins for 1m core) Cable (600v rated: 3.5kV AC /8.4kV DC for 5 mins for 1m core) Class programme DNVGL-CP Edition December 2015 Page 12

13 Test No Examination or test Test basis Requirements Test on Insulation - continuity proof test Insulation resistance at 20 C No dielectric breakdown At least 8kV impulse, 8kV DC or 5.3kV AC 500MΩkm min. at 20 C (5m length, quote actual IR) Type test Routine test 100% Section Insulation resistance at 90 C 1.5MΩkm min. at 90 C (5m length, quote actual IR) 21. Increase in AC capacitance after immersion in water C 14 -C C 1, C 14 -C C 7 (14 days at 50 C in tap water) Environmental properties 22. Ozone resistance No crazing or cracking ( ppm, 25 C, 30h) 23. Fluid immersion: 72h at 70 C IRM 902, IRM 903 Diesel(F-76), 3.5% salt water BS 3G 230 No cracking or dielectric breakdown 7.5% max. swell (6 mandrel, soak in water, 1.5kV AC for 5 minutes) Fire hazard properties 24. Flammability - small scale Charring confined between 50mm and 540 mm from lower edge of top support (single vertical wire) 25. Flammability - large scale Category D, designation F Cable 26. Halogen content cl. 45 Less than 0.5% for each non-metallic component Cable 27. Toxicity index IMO FTPC Annex 1, Part 2 I t of less than 2, report L c value Cable 28. Smoke emission - small scale ISO D s max. and D max 150 max. VOF4 300 max. 29. Smoke emission - large scale % Minimum transmittance Cable 30. Fire resistance / C with shock, at rated voltage, min. 2 hrs (fire resistant cables only) Cable All samples shall be conditioned for greater than 16 hours at room temperature prior to test (Routine test excluded). Where sheath tests are performed at elevated temperatures, control samples may be conditioned at 70 C for 24 hours. Class programme DNVGL-CP Edition December 2015 Page 13

14 TT = Type Test RT = Routine Test Section 3 Class programme DNVGL-CP Edition December 2015 Page 14

15 DNV GL Driven by our purpose of safeguarding life, property and the environment, DNV GL enables organizations to advance the safety and sustainability of their business. We provide classification and technical assurance along with software and independent expert advisory services to the maritime, oil and gas, and energy industries. We also provide certification services to customers across a wide range of industries. Operating in more than 100 countries, our professionals are dedicated to helping our customers make the world safer, smarter and greener. SAFER, SMARTER, GREENER