AFI 32-1065.pdf

BY ORDER OF THE

SECRETARY OF THE AIR FORCE

AIR FORCE INSTRUCTION 32-1065

14 JUNE 2017

Civil Engineering

GROUNDING SYSTEMS

COMPLIANCE WITH THIS PUBLICATION IS MANDATORY

ACCESSIBILITY: Publications and forms are available on the e-publishing website at www.e-Publishing.af.mil for downloading or ordering.

RELEASABILITY: There are no releasability restrictions on this publication.

OPR: AF/A4C

Supersedes: AFI32-1065, 15 January 2015

Certified by: AF/A4CF

(Mr. Gerald Johnson)

Pages: 71

This instruction implements Air Force Policy Directive (AFPD) 32-10, Installations and

Facilities. It assigns maintenance responsibilities and requirements for electrical grounding systems on Air Force installations, including systems for equipment grounding, lightning protection, and static protection. This instruction also implements the maintenance requirements of DOD 6055.09-M, Volume 2, Ammunition Explosives Safety Standards, Enclosure 4, “Lightning Protection,” April 2012, for potentially hazardous explosives facilities. This instruction applies to all personnel, including Air Force Reserve Command (AFRC) units and the

Air National Guard (ANG). This instruction may be supplemented at any level, but all direct supplements must be routed to the office of primary responsibility (OPR) of this instruction for coordination prior to certification approval. The authorities to waive wing/unit level requirements in this publication are identified with a Tier number (“T-0, T-1, T-2, T-3”) following the compliance statement. See AFI 33-360, Publications and Forms Management, for a description of the authorities associated with the Tier numbers. Submit requests for waivers through the chain of command to the appropriate Tier waiver approval authority or to the publication OPR for non-tiered compliance items. Refer recommended changes and questions about this publication to the OPR using AF Form 847, Recommendation for Change of

Publication; route AF Forms 847 from the field through the appropriate functional chain of command. Ensure that all records created as a result of processes prescribed in this publication are maintained IAW Air Force Manual (AFMAN) 33-363, Management of Records, and disposed of IAW the Air Force Records Disposition Schedule (RDS) in the Air Force Records

Information Management System (AFRIMS). The use of the name or mark of any specific manufacturer, commercial product, commodity, or service in this publication does not imply http://www.e-publishing.af.mil/

2 AFI32-1065 14 JUNE 2017

endorsement by the Air Force. This AFI is intended for and applies to trained electrical personnel only.

SUMMARY OF CHANGES

This instruction has been substantially revised and must be completely reviewed. Major changes include the addition of Tier wavier authority requirements for added paragraphs, incorporated

Engineering Technical Letters, updated office symbols, updated glossary, updated references, revision of National Electrical Code (NEC) references to reflect current requirements, revision of current National Fire Protection Association (NFPA) references to reflect current and upcoming requirements for new facilities, and clarifications based on questions received from maintenance personnel. Also included are the incorporation of Engineering Technical Letter (ETL) 11-28:

Mandatory Review and Update of Record Drawings for Nuclear-Capable Weapons and

Munitions Storage and Maintenance Facilities, and Engineering Technical Letter (ETL) 12-9:

Personnel Certification Requirements for Inspection of Lightning Protection Systems (LPS) on

Nuclear Weapons Maintenance, Handling, and Storage Facilities.

Section A— Maintenance Policy 3

1. Responsibilities

Table 1. Scheduled Maintenance for Grounding Systems

2. Codes and Specifications

3. Required Maintenance

4. Recordkeeping and Review for Explosives Facilities

5. Forms

6. Personnel Qualifications

7. Developing Procedures

Section B— Grounding Resistance and Continuity Tests and Visual Inspections 21

8. Testing Requirements

9. Visual Inspections of Lightning Protection Systems

10. Visual Inspection of Facility Grounds

Section C— Grounding and Lightning Protection Requirements 22

11. Introduction

12. Testing and Inspecting Static and Lightning Protection Systems and Grounding. . 22

Figure 1. Example Sketch of Test Points (Typical)

13. Static Protection

AFI32-1065 14 JUNE 2017 3

Figure 2. Grounding Static Bus Bar on Interior Wall

14. Lightning Protection Systems

Figure 3. ECM With Center Conductor and Air Terminals

Figure 4. ECM Without Center Conductor and Air Terminals

15. Surge Protection

Attachment 1— GLOSSARY OF REFERENCES AND SUPPORTING INFORMATION 33

Attachment 2— BASIC REQUIREMENTS FOR GROUNDING SYSTEMS 39

Attachment 3— BASIC BONDING REQUIREMENTS 46

Attachment 4— LIGHTNING PROTECTION SYSTEMS 56

Attachment 5— MAINTENANCE SELF-CHECK FOR EXPLOSIVES FACILITIES 59

Attachment 6— TESTING REQUIREMENTS 60

Section A—Maintenance Policy

1. Responsibilities.

1.1. The Headquarters, United States Air Force, Deputy Chief of Staff for Logistics, Engineering and Force protection, Directorate of Civil Engineers (HQ AF/A4C) will ensure compliance with Statutory Law and will develop, maintain, clarify, approve, and publish Strategy, Doctrine, Policy, and Air Force Instruction for the Grounding System’s program. HQ AF/A4C will also develop Management Internal Control Toolset (MICT) Self-

Assessment Communicators as part of the oversight strategy for Grounding Systems.

1.2. Air Force Civil Engineer Center (AFCEC) will:

1.2.1. Establish standards and criteria for design, maintenance, repair, and management of grounding and bonding systems in accordance with mandatory requirements of UFC 3-

520-01, Interior Electrical Systems; UFC 3-550-01, Exterior Electrical Power

Distribution; UFC 3-575-01, Lightning and Static Electricity Protection Systems; and

UFC 3-580-01, Telecommunications Building Cabling Systems Planning and Design. (T-

0).

1.2.2. Review emerging and evolving technologies and evaluates for applicability to the

Air Force.

1.2.3. Evaluate grounding and bonding training conducted internal to the Air Force, conducted by the Defense Ammunition Center (DAC), and conducted by the private sector. (T-1).

1.2.4. Assist direct reporting units (DRU) and Air Force installations with inspecting grounding and bonding systems and with troubleshooting electrical issues suspected to stem from grounding and bonding issues and discrepancies. (T-2).

4 AFI32-1065 14 JUNE 2017

1.2.5. Assists Air Force Safety Center (AFSEC) and Inspector General (IG) personnel with determining the equivalency of grounding and bonding protection systems. (T-1).

1.3. The Base Civil Engineer (BCE) will:

1.3.1. Maintain lightning and grounding systems specifically identified in Table 1 according to the procedures within, or procedures referenced by, this instruction. Wavier tiers per grounding system provided within table.

1.3.2. Ensure that user organizations identified in Table 1 are aware of their maintenance responsibilities. (T-2).

1.3.3. Train users to perform their responsibilities to inspect and maintain lightning and grounding systems as identified in Table 1 when requested. On installations where the electrical utility system is owned by a private entity, consult with the private/system owner. (T-2).

1.3.4. Review the lightning protection system record drawings on each facility at least annually or after repair actions (including facility repairs and construction additions by contractors) have been completed.

1.3.5. Ensure that, for all functions of the civil engineer squadron that are contracted

(e.g., base operations support [BOS] and contractors supporting government-owned/contractor-maintained facilities/installations), the responsibilities listed within this instruction are included in the contract, as applicable.

AFI32-1065 14 JUNE 2017 5

1.4. Users. Users will maintain and inspect lightning and electrical grounding systems as identified in Table 1.

Table 1. Scheduled Maintenance for Grounding Systems.

Facility or

System

Action

Required

Frequency of

Action

Responsible

Organization Reference Comments

Wavier

Authority

1. Exterior

Electrical

Distribution

a. Visual inspection of electrical distribution equipment fencing, pole grounds, pad-mounted equipment grounds, and neutrals.

5 years BCE

UFC 3-501-01

UFC 3-550-01

1. Any and all inspections should follow NETA MTS guidance

2. It is not necessary to perform the 5-year inspection of the system in a single year;

however, at the end of 5 years, documentation must show that the entire system has been inspected.

3. If utility is privatized, this does not apply; however, safety and operational discrepancies and damage should be reported when observed.

T-2

b. Physical continuity of grounds for separately derived systems

2 years BCE This AFI

Ensure ring currents are not established by the existence of grounds for multiple systems and equipment.

6 AFI32-1065 14 JUNE 2017

2. Electrical substation1

(if base-owned or totally/partia lly maintained by the base)

a. Continuity check across gate opening

(1 ohm or less)

5 years BCE NETA MTS

T-0

b. Ground resistance measuremen t of entrance gate (5 ohms or less)

T-0

3. Exterior lightning arrestors and/or surge protective devices on primary distribution lines (even if privately owned).

Visual

3-5 years

Critical systems 1-3 years

Upon revisions to a facility

BCE

Ensure reliability to the Air Force mission.

Discrepancies should be reported, in writing, to the owner if other than

Air Force, with cc to BCE

T-3

4. General

a. Facility service entrance -visual inspection

When electrical or communicati ons work is performed at facility service

BCE

NFPA 70

(NEC), Art.

NFPA 70

(NEC), B

UFC 3-575-01

Tag or mark in a conspicuous place to indicate visual inspection date and initials of inspector

T-3

b. Verify bonding of other systems to facility grounds

Upon new installation, installation or upgrade of other systems requiring grounding, and prior to contract acceptance

BCE

NFPA 70

(NEC)

Ensure the integrity of the single point facility ground

T-0

AFI32-1065 14 JUNE 2017 7

c. Visual inspection of lightning protection system and

Surge protective devices

(SPDs)

1-2 years, as determined by the base

AHJ, based on facility type.

BCE

This AFI

NFPA 780

UFC 3-575-01

UFC 3-520-01

Note mechanical damage, lightning damage, or discrepancies caused by repair, renovation, or addition

T-3

d. Facility ground resistance check (per

NEC Article

250, 25 ohms or less at service grounding electrode)

5 years BCE This AFI T-3

5. POL

facilities

a. Resistance measuremen t on static grounds

(10,000 ohms or less)

Upon installation and when observed to be physically damaged

BCE UFC 3-460-03 T-1

b. Visual inspection and mechanical check of ground conductor connections

(pull test)

Quarterly and when damaged

User

UFC 3-460-

03, para.

10.3.20

Annually BCE T-1

8 AFI32-1065 14 JUNE 2017

c. Inspection of connection to grounding electrode

Annually for other than thermal weld.

If thermal weld, inspect upon installation and when damaged.

BCE

UFC 3-460-

03, para.

10.3.20

T-1

d. Facility service entrance -visual inspection

When electrical work is performed at facility, including destructive inspection and any kind of electrical testing, by other than

BCE

BCE

NFPA 70

(NEC), Art.

NFPA 70

(NEC), B

Tag or mark in a conspicuous place to indicate visual inspection date and initials of inspector

T-0

6. Fuels lab

a. Visual inspection and continuity validation of equipment grounds

Monthly User

AFI 91-203,

paras.

36.5.4.2.2 and

36.5.4.2.3

BCE requirements are covered in Item

4, general facilities.

T-2

b. Visual inspection of facility grounds

Monthly User AFI 91-203

BCE requirements are covered in Item

4, general facilities.

T-2

7. Aircraft parking apron grounds and hangar floor static grounds

Resistance measuremen t on static grounds

(10,000 ohms or less)

When installed or repaired

BCE UFC 3-575-01 T-1

AFI32-1065 14 JUNE 2017 9

8. LOX

storage

Resistance measuremen t on static ground

(10,000 ohms or less)

When installed, physically damaged, or repaired

BCE This AFI T-2

9. Rail car off-loading spur

Visual inspection of rail bonding

Annually (If the rail car enters an explosive facility, test for continuity every 2 years)

BCE This AFI T-2

10.

Communicat ions (&

TEMPEST)

Facilities

Ground resistance measuremen t at service entrance

(Per NEC

Article 250, 10 ohms or less at the service grounding electrode is design objective. If

10 ohms cannot be obtained after compliant installation of a ground loop, resistance is recorded as is.)

Quarterly for first year after installation;

then every 21 months (see

Note for this item)

BCE

NFPA 70

(NEC)

This AFI

Communications facilities require tiered surge suppression – protection at the main distribution panel and any sub-panel serving sensitive communication s equipment, HVAC, and at communication s equipment.

Note: User has requested 21 months in order to comply with their references. User is responsible for trend analysis.

10 AFI32-1065 14 JUNE 2017

11.

Communicat ions

Equipment

Checks involving in-house electronic equipment ground

Determined by user from

T.O. and equipment manufacturer

User

MIL-HDBK-

419A

To prevent the effects of transients/surges on the electrical distribution, communications equipment contracts should include

SPDs on the load sides of sub-panels.

If surge protective devices are required by the equipment manufacturer, this is to be purchased and installed as part of the project.

T-3

12.

Hazardous2 explosives area

(weapons)

a. Visual inspection of static bus bars, grounding conductors, and bonds

Before using equipment and every 6 months

User

AFMAN 91-

201, para.

5.13.3.2 and

5.23.4.2.3.3.1

This AFI

NFPA 780,

Ch. 8

Explosives area governed by

DDESB

T-3

Annually for nuclear facilities

BCE T-0

b.

Resistance to ground for equipment bonding straps

(10,000 ohms or less)

When physically damaged or when frayed from use

User

AFMAN 91-

201, para.

5.13.1

T-3

c. Continuity across bonds, When physically damaged

User

AFMAN 91-

201, para.

5.24.2.1

AFI32-1065 14 JUNE 2017 11

between bus bars, conductors, and bonding straps (less than 1 ohm)

After system modification

BCE

DDESB

T-0

d. Facility ground resistance check (per

NEC Article

250, 25 ohms or less at service grounding electrode)

When repair or renovation is made to the facility

BCE

NFPA 70

(NEC)

This AFI governed by

DDESB

T-0 Per

NEC

T-1 for repair or renovation e.

Conductive floor grounding check

Upon installation and when damage is reported

BCE

AFMAN 91-

201, para

5.19.1

NFPA 780,

Ch. 8

Explosives area governed by

DDESB

T-1

f. Visual inspection of

SPDs

6 months and after a lightning strike

User

AFMAN 91-

201, para.

5.23.4.2.3.3.1

This AFI

Visual inspection may consist only of checking for an indicator lamp, denoting SPD operation

DDESB

Annually BCE T-0

g. See nonhazardou s explosives requirements

13e, 13f, 13g, and 13i

This block is intentionally blank

This block is intentionally blank

This block is intentionally blank

13. Non-hazardous2

a. Visual inspection of

Semi-annually User AFMAN 91-

201, para.

Intent of

“semiannually” is

12 AFI32-1065 14 JUNE 2017

explosives area

(weapons) static bus bar, conductor, and bonds Annually BCE

5.13.4 every 180 days, ±10 days

DDESB

T-0 b.

Resistance to ground for equipment bonding straps

(10,000 ohms or less)

When physically damaged or when frayed from use

User

AFMAN 91-

201, para.

5.13

Explosives area governed by

DDESB

T-3

c. Continuity check from equipment to static bus bar (1 ohm or less)

When physically damaged

User

AFMAN 91-

201, para.

5.13

NFPA 780,

Ch. 8

Explosives area governed by

DDESB

T-0

d. Facility ground resistance check (Per

NEC Article

250, 25 ohms or less at facility grounding electrode)

24 months BCE

NEC

This AFI

AFMAN 91-

201, para.

5.13.1

NFPA 780

AHJ

Explosives area governed by

DDESB

T-0

e. Visual inspection of lightning protection system components

12 months BCE

NEC

AFMAN 91-

201, para.

5.24.2.2

This AFI

NFPA 780

AHJ

AFMAN 91-201

refers to AFI 32-

AFI32-1065 14 JUNE 2017 13

f. Ground resistance measuremen t on LPS at grounding electrode

(per NEC

Article 250, 25 ohms maximum) measured diagonally opposite to electrical service

24 months BCE

NEC

AFMAN 91-

201, para.

5.24.2.2

This AFI

NFPA 780

AHJ

AFMAN 91-201

refers to AFI 32-

DDESB

T-0 g.

Continuity validation on air terminals, bonds, and conductor connections

(1 ohm or less)

24 months BCE

AFMAN 91-

This AFI

NFPA 780

AHJ

Explosives area governed by

DDESB

T-0

h. Visual inspection of

SPDs

6 months and after a lightning strike

User

AFMAN 91-

201, para.

5.23.4.2.3.3.1

This AFI

NFPA 780

AHJ

Visual inspection may consist only of checking for an indicator lamp, denoting SPD operation

DDESB

Annually BCE

i. Static bus bar continuity to ground (1 ohm or less)

24 months BCE

AFMAN 91-

This AFI

NFPA 780

AHJ

Explosives area governed by

14 AFI32-1065 14 JUNE 2017

14.

Protective aircraft shelter3 vault

a. Facility single point ground system resistance check

At construction and every 24 months

BCE This AFI Governed by

DDESB

T-0

b. Visual inspection of grounding system

12 months BCE This AFI Governed by

DDESB

T-0

c. Continuity between arch and ground (1 ohm or less)

At construction and every 24 months

BCE This AFI Governed by

DDESB

T-0

d. (HAS)

Validate door hinge continuity (1 ohm or less )

24 months BCE This AFI Governed by

DDESB

T-0

e. (HAS)

Continuity between vault lip

(flange) and ground (steel conduit) (1 ohm or less)

At construction and every 24 months

BCE This AFI Governed by

DDESB

T-0

f. Continuity of installed

(permanent) bonds between metal masses and steel support

When notified of damage

BCE This AFI Governed by

AFI32-1065 14 JUNE 2017 15

g. Visual inspection of permanent bonds between metal masses and steel support

Annually BCE This AFI Governed by

DDESB

T-0

15. Medical facilities4

a. Ground resistance validation

(Per NEC

Article 250, 25 ohms or less at service grounding electrode)

5 years BCE NFPA 99 T-3 b.

Effectivenes s of grounding system by voltage and impedance measuremen t s

Before acceptance of new facility or after service entrance modification

BCE NFPA 99 T-0

c.

Verification of continuity of receptacle grounding circuits

Annually

(semi-annually for critical care areas)

BCE NEC T-0

16. Airfield lighting vault single point facility ground

Ground resistance check (Per

NEC Article

250, 25 ohms or less)

2 years BCE This AFI T-2

16 AFI32-1065 14 JUNE 2017

17. EMP

hardened facilities

(These facilities may have special requirements

) Otherwise, resistance check (Per

NEC Article

250, 25 ohms or less at service grounding electrode)

2 years

User

BCE

DNA-A-86-

60, Vol 1-3

This AFI

18. PMEL

a. Visual inspection of equipment bonds

Before each use User This AFI T-3 b.

Continuity and resistance test of facility ground (Per

NEC Article

250, 10 ohms or less at service grounding electrode)

5 years BCE This AFI FC 4-218-01F T-2

19. Special intelligence, cyber, SCIF, UAS/RPA, launch and space, and other special-use facilities4

a. TBD by

AHJ

This block is intentionally blank

BCE

This block is

b. TBD by

AHJ

This block is intentionally blank

User

This block is

AFI32-1065 14 JUNE 2017 17

20. Surge protective devices

a. Visual inspection

After unscheduled power outages

(report outage to

BCE)

User This AFI

NFPA 780

User is onsite. A quick check and report to BCE may avoid additional damage until BCE can arrive.

T-0

b. Visual inspection

After unscheduled power outages and annually

BCE

This AFI

NFPA 780

T-0

1. If utility is privatized, this does not apply; however, safety and operational discrepancies and damage should be reported when observed.

2. As defined in NEC Article 500.

3. Also known as hardened aircraft shelter (HAS), as determined by current Security Forces

AFIs.

4. BCE will perform if separate medical facility maintenance branch does not exist, under memorandum of agreement (MOA) only.

5. T-0 requirements for explosives facilities and PAS/HAS is delegable from DDESB to

AFCEC/COSM.

Note: All incoming utility services should be verified for continuity of grounding and bonding by the service provider every 5 years (i.e., gas, telephone, signal lines, CATV), including government-owned facilities/systems.

2. Codes and Specifications. The BCE or user will follow applicable codes and specifications in Attachment 1 unless modified in this instruction, or deviations are justified due to local conditions. (T-1).

3. Required Maintenance. The BCE or user will perform required maintenance at the frequencies specified in Table 1. When possible, plan for and schedule maintenance when facility users will be least affected. (T-1).

4. Recordkeeping and Review for Explosives Facilities.

4.1. Inspectors and testers must compile and maintain records of their inspections and tests.

(T-1). Records should including the following (sample records are provided in Attachment

6, Figures A6.6, A6.7, A6.8, and A6.9):

4.1.1. A sketch of the grounding and lightning protection system showing test points and where services enter the facility. The sketch should also show the location of the probes during the ground resistance test. (Separate sketches are suggested for static, earth ground, and lightning protection systems on large complex facilities. (See Figure A6.8 and Figure A6.9 for examples of sketches or drawings that contain required information.)

18 AFI32-1065 14 JUNE 2017

4.1.2. Date action was performed.

4.1.3. Inspector's or tester’s name.

4.1.4. General condition of air terminals, conductors, and other components.

4.1.5. General condition of corrosion protection measures.

4.1.6. Security of attachment for conductors and components.

4.1.7. Resistance measurements of the various parts of the ground terminal system.

4.1.8. Variations from the requirements of this instruction.

4.1.9. Discrepancies noted and corrective actions taken.

4.1.10. Dates of repairs.

4.2. The BCE will review records for deficiencies; also analyze the data for undesirable trends. If test values differ substantially from previous or original tests obtained under the same test procedure and conditions, determine the reason and make necessary repairs. (T-1).

4.3. Inspectors and testers will keep test and inspection records in accordance with DODD

6055.09-M-V2, Ammunition and Explosives Safety Standards. (T-1).

4.4. Mandatory Review and Update of Record Drawings for Nuclear-Capable Weapons and Munitions Storage and Maintenance Facilities. Reproducible lightning protection system drawings are required to be included in record drawings and available for immediate use by AFSEC in initial and updated explosives site plans. The BCE will ensure the record drawings contain:

4.4.1. Dimensions and material sizes for all lightning protection systems (LPS) materials from top view and applicable elevations. (T-2).

4.4.2. Identification of test points. (T-2).

4.4.3. A 100-foot (30.5-meter) radius rolling sphere superimposed on elevations. (See

Figure A6.10 for a sample drawing.) (T-2).

4.5. Engineering Technical Letter (ETL) 11-28, Mandatory Review and Update of Record

Drawings for Nuclear-Capable Weapons and Munitions Storage and Maintenance Facilities, required completion of this review of LPS drawings meeting the requirements in paragraphs

4.4.1 through 4.4.3 for existing system drawings by 15 June 2012.

4.6. No ongoing or currently active project (awarded or under design) on nuclear, nuclear-capable, or munitions storage areas (WSA and MSA) shall be accepted until drawings are delivered to and approved by the BCE or his/her written designated representative. Drawings must meet American National Standards Institute (ANSI), Architectural Graphic Standards

(AGS), and Architectural Engineering and Construction (AEC) standards for content, abbreviations, reproducibility, and graphics. A signature by the BCE or his/her designated representative is required as proof of receipt and approval of as-built drawings. (T-2).

4.7. The contract for a lightning protection system project, or for any project on a facility containing a lightning protection system, shall require an LPS inspection by other than the designer and installer, prior to acceptance of the project. This may be accomplished by compliance with UFC 3-575-01, paragraph 3-1, third-party inspection requirements, or by

AFI32-1065 14 JUNE 2017 19

advanced government training, as outlined in paragraph 6.2, this AFI. Projects calling for a facility addition, with or without addition to the existing LPS, shall consider the configuration of the overall facility LPS in the design. Projects of this type shall ensure the final LPS as a whole is compliant with AFI 32-1065 and NFPA 780, in that priority order.

(T-2) Paragraph 12 of this AFI applies for facilities housing explosives, whether permanent or temporary. See AFMAN 91-201 for testing requirements. (T-0).

5. Forms. Inspectors and testers will provide copies of completed forms to the facility user, for munitions facilities maintained by host nation civil engineers, the using agency must receive a copy of the completed forms. (T-1). Sample forms for inspection and test records are provided in Attachment 6, Figures A6.6 and A6.7. Either the sample forms or the Air Force General

Purpose Form (3100 series) may be used to record test results for other-than-explosives facilities.

6. Personnel Qualifications.

6.1. General Qualifications. Workers maintaining, repairing, modifying, and testing grounding systems must be thoroughly familiar with test equipment operation, lightning protection, grounding, bonding theory, practices, referenced codes, standards, specific requirements, and procedures in this instruction. DAC course number 4E-F37 645-F21

(formerly referred to as AMMO-47), AMMO-48, or an official on-the-job (OJT) program, If

OJT is selected, the trainee must be instructed and mentored by a worker who has completed

AMMO-47 or AMMO-48 within the last three years, and training milestones comparable to those in formal training must be tracked and documented by the electrical superintendent.

Minimum OJT program is 6 months. Workers will renew maintenance training every three years, +/- one month. One person with completion of AMMO-47 or AMMO-48 within the past three years must be part of the electrical shop at all times. (T-2). Attachments 2 through

6 provide information suitable for use in training and familiarization.

6.2. Advanced Qualifications. In addition to general qualifications, government personnel may meet the third party inspector requirements in paragraph 4.7 with additional training.

Government personnel responsible for inspection and acceptance of contracts, including

SABER contracts, on facilities with LPS installation have the following requirements. For official (designated in writing by the BCE) CE inspectors, advanced qualifications shall be renewed every three years. Air Force Reserve Command (AFRC) units and the Air National

Guard (ANG) may comply with UFC 3-575-01, Lightning and Static Electricity Protection

Systems, in lieu of these advanced qualifications, by complying with paragraph 3-1, for a third-party inspector. (T-1).

6.2.1. Qualifications in paragraph 6.1 as a pre-requisite.

6.2.2. Attendance and completion of the Senior Inspector AMMO-50 course, or equivalent, with completion certificate. AFCEC/CO must approve the equivalent course, based on content, prior to participation. An equivalent course would be one in which all topics in AMMO-50 are covered, all codes and references in AMMO-50 are addressed, a class field inspection is conducted for the purpose of identifying real-world common discrepancies, and “certification” must be conditional upon passing a graded, four-hour examination, which includes an LPS design, essay questions, and code/ Air Force criteria

(with focus on this AFI) based questions. A certificate of completion and competency within three years prior to the inspection is required.

20 AFI32-1065 14 JUNE 2017

6.2.3. Air Force Specialty Code (AFSC) 3E0X1, 7-level, with training commensurate with that level of expertise and experience or, for civilians, training and experience equivalent to this AFSC.

6.2.4. Proficiency using test equipment required to obtain test readings for inspections referenced in this instruction.

6.3. Project Acceptance Qualifications. Air Force-approved inspectors, with authority to recommend acceptance of LPSs that protect explosives facilities and communications facilities, are limited to:

6.3.1. Nationally recognized inspection agencies who have a minimum 10 years of experience in inspection of LPS for explosives facilities on DOD or Department of

Energy (DOE) installations and have exhibited accuracy in identifying discrepancies, evidenced by no modifications having been required for the system during the warranty period (see UFC 3-575-01). Discrepancies must not be listed on any database with public access. (T-1).

6.3.2. Air Force personnel with a minimum six years of experience in LPS maintenance and have taken an advanced lightning protection systems senior inspector course approved by the Air Force. (T-2).

6.3.3. Air Force-contracted maintenance personnel (BOS or other contracted maintenance to government-owned facilities) shall meet the experience levels of paragraph 6.3.2. (T-2).

6.4. IG and Nuclear Surety. Qualifications required for Nuclear Surety Inspections (NSI), Nuclear Surety Staff Assistance Visits (NSSAV), and Initial Nuclear Surety Inspection

(INSI) of nuclear facilities:

6.4.1. Military must:

6.4.1.1. Attend and complete the initial Air Force Inspection Agency inspector’s course. (T-1).

6.4.1.2. Attend and complete the AMMO-47, AMMO-48, or equivalent experience, with completion certificate or supervisor memorandum of qualification on file. (T-1).

6.4.1.3. Attend and complete an advanced commercial lightning protection course per paragraph 6.2.2. (T-1).

6.4.1.4. AFSC 3E0X1, 7-level, with training and experience commensurate to that intended level of expertise. (T-1).

6.4.1.5. Proficiency using test equipment required to obtain test readings for inspections referenced in this instruction, validated in writing by a supervisor. (T-1).

6.4.2. Civilian must:

6.4.2.1. Attend and complete AMMO-47, AMMO-48, or equivalent experience, with completion certificate or supervisor memorandum of qualification on file. (T-1).

6.4.2.2. Attend and complete an advanced commercial lightning protection course per paragraph 6.2.2. (T-1).

AFI32-1065 14 JUNE 2017 21

6.4.2.3. Have 10 years of experience in maintenance and inspection of LPS in a field equivalent to AFSC 3E0X1, 7-level. (T-1).

6.4.2.4. Proficiency using test equipment required to obtain test readings for inspections referenced in this instruction, validated in writing by a supervisor. (T-1).

7. Developing Procedures. The organization performing inspections and tests must develop standard procedures based on the requirements in this instruction. To avoid potential security issues, inspection information providing the facility name, facility number, street address, and/or base on which the facility is located must not be posted to any site available for public access.

(T-0).

Section B—Grounding Resistance and Continuity Tests and Visual Inspections

8. Testing Requirements. See Attachment 6 for resistance and continuity test requirements for typical systems. Instruments must be able to measure 10 ohms +10 percent for ground resistance tests and 1 ohm +10 percent for continuity testing. Only instruments designed specifically for earth-ground systems are acceptable for ground resistance testing. Follow the manufacturer’s instruction manual except as modified herein when using the instruments. Earth-ground resistance should be less than 25 ohms at the service grounding electrode unless otherwise specified in this instruction. Note. The National Electrical Code (Articles 250.52 and 250.53) does not require 25 ohms to ground for a ground ring (counterpoise), therefore, ground rings are not required to be tested for resistance; resistance test requirements are for the grounding electrodes bonded to the ground ring. Continuity testing is required for the ground ring

(counterpoise). Periodic tests should be made at approximately the same time each year to minimize distortions to readings resulting from seasonal changes (see Attachment 2). If the resistance measured during continuity tests is greater than 1 ohm, check for deficiencies, repair, then retest. When performing a continuity test over very long lengths of conductors (more than

65 feet [20 meters] with no parallel paths), readings above 1 ohm but less than 3 ohms may occur. This can be due to the added resistance of the test wire and is acceptable. Documentation is required for the file. The base electrical engineer may modify the test procedures to compensate for local conditions as long as the intent of the test is still met.

9. Visual Inspections of Lightning Protection Systems. Inspector will inspect all visible parts of the system. (T-1). Pulling or tugging on conductors and connections to ensure soundness is a necessary part of these inspections, but be careful not to damage the system in the process.

Visual/physical inspection must determine if:

9.1. The system is in good repair.

9.2. Loose connections might be causing high-resistance joints.

9.3. Corrosion or vibration has weakened any part of the system.

9.4. Down conductors, roof conductors, ground terminals and all other components are intact, air terminals exceeding 24 inches in length are supported at a point not less than one-half their length, and no components or fasteners are missing.

9.5. Braided bonding wires or straps are excessively frayed (cross-sectional area reduced by half).

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9.6. Ground wires/down conductors, air terminals (for earth-covered magazines [ECM]), masts, or poles are/have been damaged by mowers, equipment, or vehicles.

9.7. Conductors and system components are securely fastened to mounting surfaces. Position connections to better protect against accidental displacement. Adhesive-type fasteners are not allowed.

9.8. Project additions or alterations to the protected structure require additional protection.

See UFC 3-575-01.

9.9. Surge protective devices (SPDs) supporting facilities and facility service appear damaged or indicator lamps signal an operation has occurred. Note: Inspection, repair, and replacement of SPDs protecting equipment are the responsibility of the equipment owner or user.

9.10. The system complies with the intent of applicable sections of the most recent version of NFPA 780, Standard for the Installation of Lightning Protection Systems, unless otherwise noted in this AFI. (T-1).

10. Visual Inspection of Facility Grounds. Unless otherwise specified by references in Table

1, conduct visual inspections as follows. Inspect all visible and accessible parts of the facility grounding system. Validate satisfactory condition and verify the installation meets NEC requirements (T-1). Typical items to check include:

10.1. The system is in good repair.

10.2. No loose connections are visible.

10.3. The system neutral is grounded at the service entrance. This may be achieved either by bonding the neutral bus to the ground bus in the main distribution panel or by connection to the grounding electrode (single point ground) for the facility.

10.4. Separately derived systems are properly grounded.

10.5. Flashover protection (bonding) is installed on insulating fittings on underground metallic pipelines entering the facility.

10.6. Grounding systems and static systems within the facility are bonded together at floor level or at or below ground level outside the building.

Section C—Grounding and Lightning Protection Requirements

11. Introduction. This section covers requirements for grounding and lightning protection systems, including systems installed on or in areas such as explosives buildings, magazines, operating locations, and aircraft shelters. Use these requirements when inspecting to determine compliance and when repairing or modifying systems. See AFMAN 91-201, Explosive Safety

Standards.

12. Testing and Inspecting Static and Lightning Protection Systems and Grounding.

12.1. Procedures. Use Attachment 4 and Attachment 5 as a guide for establishing proper maintenance procedures and as a self-check prior to inspections.

12.2. Inspection and Testing. Visually inspect and test the static, grounding, and lightning protection systems for buildings and facilities in accordance with Section A, Maintenance

AFI32-1065 14 JUNE 2017 23

Policy, and Section B, Grounding Resistance and Continuity Tests and Visual Inspections, and the special requirements in this section. (T-1).

12.3. Records. Inspectors and testers will keep test and inspection records in accordance with DODD 6055.09-M-V2, Ammunition and Explosives Safety Standards for a minimum of six inspection cycles. (T-1). Figure 1 is an example sketch of a grounding and lightning protection system with test points.

Figure 1. Example Sketch of Test Points (Typical).

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13. Static Protection.

13.1. Static Protection for Electronics and Electrical Equipment. The best methods to eliminate or reduce the hazard from static electricity are bonding and grounding. Bonding minimizes potential differences between conductive objects. Grounding minimizes potential differences between objects and the ground. Inspectors will inspect and test facilities for compliance with NFPA 77, Static Electricity, which contains the minimum acceptable static grounding and bonding requirements for Air Force activities, except as modified in this AFI.

(T-0). See Attachment 3.

13.1.1. Bonding conductors shall be large enough to withstand mechanical damage.

Minimum size for existing bonding conductors is AWG No. 8. If bonding conductors are in areas of high use or are subject to physical damage, make repairs with wires no smaller than AWG No. 6 copper. Static grounds for portable or movable equipment must be of braided cable for added flexibility. (T-0).

13.1.2. Static grounds shall be 10,000 ohms to ground or less, unless otherwise stated.

Static electricity creates extremely small (on the magnitude of milliamps) currents, so even this large resistance is small enough to bleed off static charges. But because the static grounding system must be connected to the facility grounding system, resistances of less than 25 ohms are common. (T-0).

13.2. Static Bus Bars. Static bus bars are usually 2-inch by 0.25-inch copper bars installed on the interior wall of the facility. The length will vary for new facilities but design the bar itself to be no closer than 12 inches from the intersection of an interior wall with an exterior wall for side-flash reasons. See Figure 2 for bus bar end and for transition at floor level, around windows, and doorways (requires depression for ground wire). Design the down conductor location so that it does not “cross” an interior static bus bar. For existing facilities at which this condition exists, perform side-flash calculations to ensure that the wall thickness exceeds the side flash distance. Typically, the side flash distance through the wall, using the basic bonding formula (BBF), exceeds the calculated side-flash distance at the normal static bus bar height up to 48 inches (1.2 meters). If installed within side flash distance, relocate either the down conductor or discontinue the static bus bar 1 foot (0.3 meter) either side of the exterior down conductor location and bond the two sections of the static bus bar at floor level, using a 1/0 copper conductor. Note: For structures exceeding 250 feet (76 meters) in perimeter, if relocating the down conductor results in a separation distance of greater than 100 feet (30.5 meters) between down conductors, an additional down conductor may be necessary. The grounding conductor from the static bus bar shall be connected directly to the facility grounding electrode system. See Attachment 6 for testing requirements. Use static bus bars only for static grounding. Communications systems, electrical conduit, intrusion detection systems, and other permanently installed systems shall not use the static bus bar as a system ground. As a general rule, do not connect a static bus to any facility metal body or use this bus to ground structural components of a facility;

however, coincidental connections of the bus bar through its anchoring/mounting system are acceptable, as is the mounting of the static bars on the skin of a metal structure. Portable grounding straps from equipment to the static grounding bus are not real property; therefore, visual inspections and continuity checks for these straps are the responsibility of the user. (T-

0).

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Figure 2. Grounding Static Bus Bar on Interior Wall.

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13.3. Belting Requirements. On equipment such as belt-driven compressors and conveyor belts, if static electricity is a hazard, use non-static-producing belting. Belting must have a resistance not exceeding 1,000,000 ohms when measured according to IEEE Standard 142, IEEE Recommended Practice for Grounding for Industrial and Commercial Power Systems

(Green Book), Chapter 3. (T-0).

13.4. Conductive Floor Grounds. If the electronic equipment within a facility requires a resistance of the floor-to-ground of less than 1,000,000 ohms, a conductive floor is required.

This resistance value is the sum of the resistance of the floor plus a person, added together.

Static dissipative footwear (PPE) will ensure protection for personnel from electric shock hazard and will allow bleed-off of static buildup in personnel and equipment. Testing requirements are in the appendices of this document. Using agency must keep a record of test results. (T-1).

14. Lightning Protection Systems. The following requirements will be used as a guide for facilities that require or possess lightning protection. (T-1).

14.1. General. Systems must comply with NFPA 780 and UFC 3-575-01, whichever is more restrictive (except as modified herein). (T-0). See Attachment 4. Early streamer emission systems, charge dissipation systems, or other unconventional systems are not permitted. Parts and materials must carry the Underwriters Laboratories (UL) label or equivalent, and must be listed for use on lightning protection systems. (T-0). Components not carrying a UL label or equivalent, or components carrying a UL label or equivalent and not listed for use on lightning protection systems, must be approved by the BCE or designated representative. (T-2). Facilities in foreign countries may use host nation codes and standards if they offer equivalent protection, as determined by the BCE, with concurrence from

AFCEC/COSM and, for facilities housing explosives, approval of the DOD Explosive Safety

Board (DDESB). (T-0). Otherwise, the status of forces agreement (SOFA) must specifically permit the use of host nation codes. Where the SOFA requires compliance with host nation codes, translate those required codes into English, make them available to all appropriate personnel, and conduct necessary training. Maintain all installed systems in accordance with this instruction. If an existing lightning protection system is no longer required, coordinate with the facility manager to remove the LPS. Test records of the LPS must remain with the facility for six inspection cycles. (T-1).

14.2. Bonding Requirements. Adequate bonding is more important than grounding.

Bonding ensures all metallic objects are at equal potentials to protect personnel against dangerous arcs or flashovers. Inspectors will inspect and test facilities for compliance with

NFPA 780 and Attachment 3 (T-0).

14.3. Resistance to Ground. Low resistance is desirable but not essential for lightning protection. For most facilities and per NEC Article 250.53, resistance to ground should be less than 25 ohms at the service grounding electrode. If 25 ohms cannot be achieved with the addition of a grounding electrode, a supplemental electrode may be necessary, depending upon the magnitude of resistance obtained and the contents of a facility being protected. The resistance to ground of a ground loop conductor is acceptable even if greater than 25 ohms.

See Attachment 2.

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14.4. Lightning Protection for Explosives Facilities. AFMAN 91-201 identifies explosives facilities that require lightning protection systems. Use the basic practices in

Attachment 4, with the following additions:

14.4.1. The system shall be designed for a 100-foot (30.5-meter) striking distance. (T-0).

Note: an administrative, educational, or other non-explosives-type facility located within a weapons or munitions storage area may be designed for a 150-foot (45.7-meter) striking distance.

14.4.2. Installation of test wells or hand holes at corner grounding electrodes for existing connections to grounding electrodes is recommended to aid with access for testing unless conductors are exothermically welded to the grounding electrode and the exothermic weld is shown on record drawings.

14.4.3. Replace existing bolted connectors on down conductors and roof conductors, when in need of repair, with high compression or exothermic-weld type connectors.

Connections to air terminals are an exception, but they must be tight and in good repair.

Bolted connections to aluminum bodies (such as vents) and to metal bodies for the purpose of bonding are also acceptable. Brazing to metal bodies is not allowed for new construction due to the possibility of a cold weld with inadequate strength. (T-0).

14.4.4. The metal framework of a structure shall be permitted to be utilized as an air terminal and main conductor of a lightning protection system if it is equal to or greater than 3⁄16 (0.188) inch (4.8 millimeters) in thickness and is electrically continuous, either inherently or made. (T-0).

14.5. Explosives Facility with Large Perimeter. New explosives facilities with a perimeter over 300 feet (91.4 meters) that require lightning protection and do not use the structural steel as an air terminal equivalent shall use either a mast system or an overhead wire system. See Attachment 4 for requirements. Such indirect air terminal designs are intended to provide lightning attachment away from the facility and not directly to the facility. It also reduces maintenance and installation costs. The BCE may waive this requirement (overhead or mast system). ECMs are not required to carry air terminals from headwall to headwall (for drive-through ECMs) or from headwall to air vent. (T-2).

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Figure 3. ECM With Center Conductor and Air Terminals.

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Figure 4. ECM Without Center Conductor and Air Terminals.

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14.6. Sunshades. The metal framework of a sunshade structure shall be permitted to be utilized as an air terminal and main conductor of a lightning protection system if structural members are equal to or greater than 3⁄16 (0.188) inch (4.8 millimeters) in thickness and structural members are electrically continuous (either inherent or made) to ground.

Grounding requirements depend upon the footing of the vertical support units (columns).

Vertical support units with full footers require no further grounding. The flight line (to include sunshade areas) is evacuated once lightning is at a distance (in nautical miles [NM]) determined by the base; therefore, step potential is not considered for sunshades. Vertical support units bolted to the apron concrete make it necessary to, as a minimum, install one grounding electrode at two diagonally opposite corners. Roof material, whether metallic or fabric, is of no consequence when considering the steel structure as a lightning protection system.

14.7. Protective Aircraft Shelters (PAS) (also known as Hardened Aircraft Shelter

[HAS]). Aircraft shelters with continuous interior steel arches, either visible or validated by record drawings, provides a Faraday-like shield and therefore requires no air terminals.

Exterior metallic ventilators with an enclosure at least 3/16 (0.188) inch (4.8 millimeters) in thickness do not require air terminals if properly bonded to the steel arch. Metallic ventilators less than 3/16 (0.188) inch (4.8 mm) in thickness must be protected by an air terminal bonded to the steel arch in accordance with NFPA 780. All metal bodies mounted to the steel arch shall be bonded and grounded in accordance with this instruction and NFPA 780. The facility grounding system shall also comply with this instruction and NFPA 780. Since the floor is designed to be separable from the walls, the walls and the floor shall be permanently bonded to a single grounding point or series of connected grounding points identified on record drawings. If no record drawings are available, continuity shall be validated by a minimum of four shell-to-ground tests interior to the facility. A sketch will be made, indicating test points, and this shall become the record drawing. Visual inspection will be conducted every 12 months and testing will be conducted every 24 months. (T-0).

15. Surge Protection. Surge protection is required on electrical service entrances and on some interior distribution panels in accordance with NFPA 780. (T-0). SPD, formerly referred to as

TVSS (transient voltage surge suppression), protect facilities and facility contents from transient voltages resulting from lightning surges, switching surges, and surges internal to the facility caused by mechanical and user-owned electronic devices and equipment, and may protect the upstream distribution system from the rapid switching effects of user-owned electronics. For large facilities, SPDs are most effective when used in the form of tiered protection. Tiered protection means providing protection at main distribution panels, at secondary or sub-panels, and at the equipment point of use. For protection of non-real property installed equipment, refer to the equipment manufacturers’ requirements for surge protection (the equipment users fund purchase, installation and maintenance of any surge protective devices required for the protection of communications and other equipment or desired by the user for additional protection of communications and other equipment). In facilities such as dormitories and other facilities with basic/minimal electronics, low-dollar contents, and/or minimal occupants, surge protection may meet the requirement for a lightning protection system.

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15.1. WSAs, MSAs, and Communications Facilities:

15.1.1. Standard, published, minimum 10-year unlimited replacement warranty on product (SPD).