FAA-C-1391d.pdf

FAA-C-1391d

FAA-C-1391d September 2014

SUPERSEDING

FAA-C-1391c May 2012

DEPARTMENT OF TRANSPORTATION

FEDERAL AVIATION ADMINISTRATION

SPECIFICATION

INSTALLATION, TERMINATION, SPLICING, AND

TRANSIENT/SURGE PROTECTION OF UNDERGROUND

ELECTRICAL DISTRIBUTION SYSTEM POWER CABLES

This specification is approved for use by all Departments of the Federal Aviation Administration (FAA)

FAA-C-1391d September 2014

FOREWORD

1. This specification provides requirements for the installation of FAA-owned and maintained underground electrical line distribution (ELD) systems in support of FAA facilities. The ELD systems include power cable and associated components on the exterior, commercial power supply side of the circuit at the airfield or remote site through to the service entrance power panels of FAA facilities.

2. This specification applies only to FAA medium-voltage (MV) and low-voltage (LV) underground power cables, and to a limited extent to overhead lines that may form a part of an FAA-owned circuit. It does not apply to control, telecommunication, or facility service entrance (load side) wiring. For standards pertaining to these non-power cable and electrical systems, consult the appropriate office of primary responsibility for applicable standards.

3. Power for airfield lighting cables has a separate set of standards and procedures. Refer to the appropriate FAA Advisory Circular (AC) 150/5340 and associated governing standards.

4. This is an update to an existing specification. It assimilates recent utility industry knowledge concerning ELD systems, with the aim of providing safer, more reliable FAA underground MV and LV ELD systems.

5. Changes in this version of the document include (see change history, page iv):

a. Revised from “c” version to “d” version.

b. Miscellaneous updates collected from field comments.

c. Submittals section updated; submittals matrix added as an appendix.

d. Duct joining processes added, with special consideration of joining HDPE sections (see also appendix for sample bonding adhesives data sheet).

e. Product section updated (added power cable, transformers, switchgear/sectionalizers, service disconnects, terminations/splices, overcurrent devices, underground duct systems, and ducts and fittings, etc).

6. This specification is intended to ensure that minimum FAA requirements are met based on current commercial practices relating to safety, reliability, and restorability of FAA electrical line distribution systems. Contractors are encouraged to provide innovative, best-value solutions wherever possible within the bounds of these requirements.

Comments, suggestions, or questions on this document should be addressed to:

Federal Aviation Administration, AJW-22, Power Services Group, Power Cable Program, 800 Independence Ave., S.W., Washington, DC 20591, https://employees.faa.gov/org/linebusiness/ato/operations/technical_operations/atc _facilities/power_services/power_cable/ ii

Change History

1. Originator Name and Address AJW-22, Power Services Group

2. [] Proposed 3. Code Identification 4. Document No. FAA-C-1391c

Washington, DC [X ] Approved 5. Code Identification 6. DCN No.

7. System Designation 8. Related ECR/NCP No.

ATO0W-CABLE-1023

9. Contract No. 10. Contractual Activity N/A

11. Product Integration Plan 12. Effectivity

This notice informs recipients that the standard identified by the number (and revision letter) shown in block 4 has been changed. The pages changed by this DCN (being those furnished herewith) carry the same date as the DCN. The page numbers and dates listed below in the summary of changed pages, combined with non-listed pages of the original issue of the revision shown in block 4, constitute the current version of this specification.

13. DCN No. 14. Pages changed S* A/D* 15. Date Summary - general:

a. Deletion of requirements for non-electrical-line-distribution (non-ELD) systems, including communications and telecommunications cables (both copper and FOTS), control cables, and constant-current-regulated runway approach and edge lighting power cables. Basic separation requirements between ELD and non-ELD cables have been retained. Installation standards and specifications for the non ELD systems may be found by consulting the appropriate office of primary responsibility.

b. Emphasis on product changes in FAA ELD systems from the older 2.4 kV to 4.16 kV distribution circuits to the newer industry standard medium voltage systems, e.g., 3-phase/7200 V (phase to neutral). The Power Cable Program favors 15 kV rated cables and equipment to bring FAA ELD systems up to compatibility with the utility industry and to meet future FAA needs.

c. Increased attention to the protection of sensitive internal constituent parts of MV cable systems during installation, by (1) the imposition of stringent tests meeting IEEE criteria, and (2) using proper cable pulling, splicing, and terminating techniques.

d. Addition of power cable acceptance testing process for newly installed cables (text main body and Appendix C). Acceptance tests classified as destructive by the IEEE, such as the DC high potential (HIPOT) test, shall no longer be performed on in-service power cables.

e. Treatment of the qualifications of MV “qualified persons” during installations.

1/24/2012

Details – changes:

a. Non ELD systems, deletions from FAA-C-1391b version: pp. 1-4, 7-15, 17-19.

Sections/paragraphs affected: 2.1.2, 2.1.3, 3.1.2, 3.2.1, 3.2.2, 3.4, 3.4.1.1, 3.4.1.2, 3.4.2.2, Table I, 3.4.3, 3.4.3.1, 3.4.4, 3.4.5, 3.5.1, 3.5.2, 3.6, 4.2, 4.3, 4.5, 4.5.1, 4.5.2, 4.6, 4.6.1, 4.6.2, 4.6.3, App A.

1/24/2012

Details – changes:

b. Product changes, additions in FAA-C-1391c: cable 3.3.6.2; 15 kV surge protection 5.8.2; 15 kV splice kits 5.9.

1/24/2012

Details – changes:

c. Installation of cables, additions in FAA-C-1391c: splice procedures 5.9; cable pulling

5.5.12 and App B; cable end sealing 5.5.11; installer qualifications 3.3.3.2; 50/60 Hz offline partial discharge test 3.3.6.3, 3.3.6.4.

1/24/2012

Details – changes:

d. Acceptance testing procedures, additions in FAA-C-1391c: 3.3.6; Appendix C.

1/24/2012 Details – changes:

e. Qualified persons and contractors, change in FAA-C-1391c: 3.3.3 (all), 3.3.6.4, 5.9.

1/24/2012 Updated document from “c” version to “d” version. 4/4/2014

Miscellaneous updates collected from field comments. 4/4/2014 Submittals updated, products updated (added power cable, transformers, switchgear/sectionalizers, service disconnects, terminations/splices, overcurrent devices, underground duct systems, and ducts and fittings).

4/4/2014

Manhole cover wheel loading and guard wire grounding upgraded. 8/15/14 iv

CONTENTS

1. SCOPE

2. APPLICABLE DOCUMENTS

2.1 General

2.2 Order of precedence

2.3 Government documents

2.3.1 FAA orders, standards, specifications, and handbooks

2.3.2 Other Government documents, drawings, and publications

2.4 Non-Government publications

3. GENERAL

3.1 Definitions

3.2 Submittals

3.3 Quality assurance

3.3.1 Quality plan

3.3.2 Quality control

3.3.3 Qualifications of personnel

3.3.4 Receiving, storing, and protecting

3.3.5 Sequencing and scheduling

3.3.6 Cable testing

4. PRODUCTS

4.1 Product options and substitutions

4.2 Power cable

4.3 Transformers

4.3.1 High voltage transformers (>600 volts)

4.3.2 Low-voltage transformers (<600 volts)

4.4 Switchgear and sectionalizers

4.5 Service disconnecting means

4.6 Terminations and splices

4.6.1 Terminations

4.6.2 Splices

4.7 Overcurrent protective devices

4.8 Underground duct systems

4.8.1 Concrete-encased rigid nonmetallic conduit

4.8.2 Plastic-coated steel conduit

4.8.3 Direct buried rigid nonmetallic conduit

4.8.4 Rigid metal conduit (RMC)

4.9 Corrosion protection tape

4.10 Insulating bushings

4.11 Grounding bushings

4.12 Sweeps

4.13 Duct spacers

4.14 Duct plugs

4.15 Duct sealant and joint filler

4.16 Underground duct and cable warning tape

4.17 Pull wires and tape

v

4.18 Precast electrical manholes and hand holes, accessories

4.18.1 Manholes and hand holes

4.18.2 Manholes accessories

4.19 Grounding cables

4.20 Ground rods

4.21 Weather heads on risers, drip loops

4.22 Electrical equipment enclosures

4.23 Equipment vaults and pads

4.24 Bollards

5. EXECUTION

5.1 Scheduling of work

5.2 Existing FAA buried cable and ducts

5.2.1 FAA documentation

5.2.2 FAA marking of known buried cables and ducts

5.2.3 Other buried cables, ducts, piping and items

5.3 Safety during construction and testing

5.4 Excavation and trenching

5.4.1 Depth requirements

5.4.2 Survey requirements

5.5 Underground duct systems

5.5.1 Preparation and excavation for underground ducts

5.5.2 Backfilling

5.5.3 Restoration

5.5.4 Duct installation

5.5.5 Manhole and hand hole installation

5.5.6 Mandrel requirements

5.5.7 Spare ducts, preparation

5.5.8 Duct protection

5.5.9 Ducts without concrete encasement

5.5.10 Separation of cables

5.5.11 Installation of cables

5.5.12 Cable pulling

5.6 Medium-voltage direct earth buried cables

5.7 Cable installation in manholes

5.8 Cable terminations, connections, surge protection, and fault protection

5.8.1 Cable terminations and connections

5.8.2 Connections to a three-phase engine generator

5.8.3 Surge protection

5.8.4 Fault isolation

5.9 Splices

5.10 Equipment racks and disconnect switches

5.11 Grounding of ELD systems

5.11.1 Power cables, multigrounded neutral wires and shields

5.11.2 Cable guard wires

5.11.3 Manholes and hand holes

5.11.4 Equipment and equipment enclosures

vi

5.11.5 Surge arresters

5.11.6 Conduit and fittings

5.11.7 Low-voltage cable runs to facility service entrances

5.11.8 Installation details

5.12 Cable tagging, equipment markers and labels, and safety signs

5.12.1 Cable tags

5.12.2 Equipment markers and labels

5.13 Cable markers

5.13.1 Concrete markers for DEB cable

5.13.2 Special-purpose and near-surface markers

5.14 Acceptance and inspection procedures

APPENDIX A—Surge Arrester Performance Data

1. SCOPE

2. APPLICABLE DOCUMENTS

2.1 Non-government publications

3. REQUIREMENTS

3.1 Performance Requirements

3.1.1 General

3.1.2 Placement

3.1.3 IEEE Standard C62.11

3.1.4 Service conditions

APPENDIX B—Cable Pulling Calculations APPENDIX C—Acceptance testing of newly installed FAA power cables

SAFETY REQUIREMENTS, GENERAL

1. INSULATION RESISTANCE TEST

1.1 Theory of Operation

1.2 Parameters and Tolerance limits

1.3 Test Schedules

1.4 Safety and Test Procedure

1.4.1 Safety

1.4.2 Test Procedure

2. AC VLF FIELD TEST

2.1 Theory of Operation

2.2 Parameters and Tolerance Limits

2.3 Test Schedules

2.4 Safety and Test Procedure

2.4.1 Safety

2.4.2 Test Procedure

3. OFFLINE 50/60 Hz PARTIAL DISCHARGE TEST

3.1 Theory of Operation

3.2 Parameters and Tolerance Limits

3.3 Test Schedules

3.4 Safety and Test Procedure

3.4.1 Safety

3.4.2 Test Procedure

APPENDIX D—Acronyms/glossary vii

APPENDIX E--Submittals Matrix APPENDIX F—HDPE-to-HDPE and HDPE-to-PVC Conduit Adhesive - Sample Product viii

1. SCOPE

This specification defines the minimum requirements for the installation of medium voltage and low voltage (600 V) electrical line distribution (ELD) power cables buried directly in the earth or installed in underground duct or conduit. The industry definition of medium voltage is between 600 V and 34,500 V nominal voltage line to ground. The work includes surveying, trenching, and backfilling, installation of cables, conduits, concrete-encased ducts, hand holes, manholes, duct markers, joints and splicing, terminating, providing surge protection, and testing of cables for acceptability of the finished ELD. In addition, this specification defines the responsibilities of the contractor with respect to safety, quality assurance, and quality control during the installation and testing of ELD systems.

This specification covers installation and acceptance testing of FAA ELD systems only. For FAA power cable maintenance directives, refer to FAA Order 6950.22.

This specification applies to installation of medium and low voltage facility electrical supply power cables and associated equipment only. These systems provide facility power from the power supplier’s primary service to the service entrance power panels of FAA facilities.

For detailed information on the installation of non-ELD cable systems such as control cables, fiber optics telecommunication (FOTS) cables, communication cables, etc., consult with the office of primary responsibility (OPR) for guidance. The 2400-V shielded constant current power cables serving runway edge lighting fixtures have their own standards and are not the subject of this specification. Consult the appropriate office of primary responsibility and the airport circulars for guidance. For basic separation requirements of FAA utility power cable systems from non-electrical-power cable systems, consult the section of this specification entitled, “Separation of Cables” (5.5.10). When physically integrating non-ELD cables with power cables, do not assume all of the provisions of FAA- C-1391 apply without first coordinating with the appropriate OPR and the FAA onsite project engineer responsible for integration of multiple cable assets.

Non-ELD OPRs consist of:

a. AJW-45 Ground-Based Navaids Group,

b. AJW-46 Lighting Systems Group,

c. AJW-52 Communications Systems Engineering Group,

d. AJW-53 Telecommunication Services Group,

e. AJW-55 Air-Ground Data Communications Group,

f. AJW-56 Air-Ground Voice Communications Group,

g. Others (as applicable).

2. APPLICABLE DOCUMENTS

2.1 General

Due to the continuous updating of Government documents, the FAA Contracting Officer and/or the FAA Project Engineer must specify the document version and publication date current at the time of contract award or project design. The documents below form a part of this specification.

Some of the FAA documents listed are out of date but are still applicable; reference the notations next to each reference provided. FAA tailoring organizations should consult with the offices of primary responsibility to obtain the most recent applicable documentation.

2.2 Order of precedence

In the event of a conflict between the text of this document and the references cited herein, the text of this document takes precedence. Nothing in this document, however, supersedes applicable laws and regulations unless a specific exemption has been obtained.

2.3 Government documents

The following citations are government documents that are used as references in this specification.

2.3.1 FAA orders, standards, specifications, and handbooks

The following FAA orders, standards, specifications, and handbooks form a part of this document to the extent specified herein. Unless otherwise stated, requirements contained in these documents are as cited in the project solicitation or contract. (Copies of FAA orders, standards, specifications, handbooks, drawings, and other applicable FAA documents may be obtained from the Contracting Officer issuing the invitation-for-bids or request-for-proposals. Requests should fully identify the material desired; for example: specification, standard, amendment, drawing numbers [drawings possessing standard FAA signature block], and dates. Requests should cite the invitation for bids, request for proposals, the contract involved, or other source of the requested material.)

2.3.1.1. ORDERS

JO 3900.XX Air Traffic Organization Electrical Safety Program [Future]

JO 6750.16 Siting Criteria for Instrument Landing Systems

JO 6950.27 Short Circuit Analysis and Protective Device Coordination Study

[contact PSG Systems Engineering for arc flash calculations] https://employees.faa.gov/tools_resources/orders_notices/index.cfm/go/document.information/documentID/9901

2.3.1.2 STANDARDS

FAA-STD-XXX Underground Electric Line Distribution (ELD) Systems [Future]

FAA-STD-019 Lightning Protection, Grounding, Bonding and Shielding Requirements for Facilities

2.3.1.3 ADVISORY CIRCULARS AND SPECIFICATIONS

150/5300-13 Airport Design

150/5320 Surface Drainage Design

150/5370 FAA Standards for Specifying Construction of Airports

FAA-E-113 Poles, Wood, Treated

FAA-E-2793 Cable, Electrical Power, 2,000 to 35,000 Volts

FAA-E-2013 Cable, Electrical Power, Exterior 600 Volts

2.3.1.4 HANDBOOKS

FAA-HDBK-XXX Underground Electric Line Distribution (ELD) Systems [Future]

2.3.2 Other Government documents, drawings, and publications

The following Government documents, drawings, and publications form a part of this document to the extent specified herein. Unless otherwise specified, the issues of these documents are those cited in the solicitation or contract.

American Association of State Highway & Transportation Officials Specifications

AASHTO HB-17 Standard Specifications for Highway Bridges.

AASHTO HS-20 Standard Specifications for Highway Bridges

Occupational Safety and Health Administration Codes

Part 1926 Safety and Health Regulations for Construction.

Military Specifications

MIL-I-3825 Insulating Tape, Self-Fusing

DLA A-A-50563 Conduit Outlet Boxes, Bodies, and Entrance Caps, Electrical: Cast

Metal

DLA A-A-59213 Splice Connectors

DLA A-A-59214 Junction Box: Extension, Junction Box; Cover, Junction Box (Steel, Coated with Corrosion-Resistant Finish)

DLA A-A-59544 Cable and Wire, Electrical (Power, Fixed Installation)

DLA A-A-59551 Wire, Electrical, Copper (Uninsulated)

Navy A-A-59827 Topside Conduit (Flexible) and Conduit fittings, Electrical:

Composite Based (Non-metallic)

UFC 3-350-03FA Electrical Power Supply and Distribution

UFC 3-600-01 Fire Protection Engineering for Facilities

UFGS 26 12 19.20 Single-Phase Transformers

UFGS 26 12 19.10 Three-Phase Transformers

UFGS 33 70 02.00 10 Electrical Distribution System, Underground

Federal Specifications

W-C-375/3 Circuit Breakers, Molded Case; Branch Circuit and Service

W-S-865 Switch, Box (Enclosed), Surface Mounted

WW-C-566 Conduit, Metal, Flexible

WW-C-581 Class 1 Type A with Standard for Electrical Rigid Metal Conduit -

Steel, UL 6

2.4 Non-Government publications

The following documents form a part of this document to the extent specified herein. Unless otherwise specified, the issues of these documents are those cited in the solicitation or contract.

American National Standards Institute (ANSI) Standards

ANSI 6 Standard for Rigid Metal Conduit. (Same as UL 6)

ANSI 467 Standard for Grounding and Bonding Equipment. (Same as UL 467)

ANSI 514 Fittings for Cable and Conduit. (Same as UL 514)

ANSI 651 Schedule 40 and 80 Rigid PVC Conduit. (Same as UL 651)

ANSI A14.3 Safety Code for Fixed Ladders

ANSI C2 National Electrical Safety Code (NESC). (Same as IEEE C2)

ANSI C62.11 IEEE Standard for Metal-Oxide Surge Arresters for AC Power

Circuits (>1 kV). (Same as IEEE C62.11)

ANSI C62.22 IEEE Guide for the Application of Metal Oxide Surge Arrester for

Alternating Current Power Circuits. (Same as IEEE C62.22)

ANSI C62.22.1 Guide for the Connection of Surge Arresters to Protect Insulated, Shielded Electric Power Cable Systems (Same as IEEE 1299/C62.22.1)

ANSI C62.41 Recommended Practice on Characterization of Surges in Low- Voltage (1000V and Less) AC Power Circuits. (Same as IEEE

C62.41)

ANSI C80 Rigid Steel Conduit – Zinc Coated. (Same as NEMA C80)

ANSI C119.1 Sealed Insulated Underground Connector System Rated 600 Volts.

(Same as NEMA C119.1)

ANSI FB 1 Fittings, Cast Metal Boxes, and Conduit Bodies for Conduit and

Cable Assemblies. (Same as NEMA FB1)

ANSI RN 1 Polyvinyl-Chloride (PVC) Externally Coated Galvanized Rigid Steel

Conduit and Intermediate Steel Conduit. (Same as NEMA RN 1)

ANSI S-97-682- Standard for Utility Shielded Power Cables Rated 5 through 46 kV 2007 (Same as ICEA S-97-682-2007)

ANSI TC 6 & 8 PVC Plastic Utilities Duct for Underground Installation. (Same as

NEMA TC 6 & 8)

ANSI Z535 Safety Alerting Standards. (Same as NEMA Z535)

American Society of Civil Engineers Standards

CI/ASCE 38-02 Standard Guideline for the Collection and Depiction of Existing

Subsurface Utility Data.

American Society for Testing & Materials (ASTM) Standards

ASTM A48 Standard Specification for Gray Iron Castings.

ASTM B8 Standard Specification for Concentric-Lay-Stranded Copper

Conductors

ASTM C267-97 Standard Test Methods for Chemical Resistance of Mortars, Grouts, Monolithic Surfacings and Polymer Concretes

ASTM C478 Standard specification for Precast Concrete Manhole Section (AASHTO No. M199)

ASTM C579-96 Standard Test Methods for Compressive Strength of Chemical-

Resistant Mortars, Grouts, Monolithic Surfacings and Polymer Concretes

ASTM C580-93 Standard Test Method for Flexural Strength and Modulus of

Elasticity of Chemical-Resistant Mortars, Grouts, Monolithic Surfacings and Polymer Concretes

ASTM C858 Standard Specification for Underground Precast Concrete Utility

Structures

ASTM C990 Standard Specification for Concrete Pipe, Manholes, and

Precast Box Sections Using Preformed Flexible Joint Sealants.

ASTM D422 Standard Test Method for Particle-Size Analysis of Soils

ASTM D698 Standard Test Methods for Laboratory Compaction Characteristics of Soil Using Standard Effort

ASTM D1056 Standard Specification for Flexible Cellular Materials - Sponge or Expanded Rubber

ASTM D2444-93 Standard Test Method for Determination of the Impact Resistance of Thermoplastic Pipe and Fittings by Means of a Tup (Falling Weight)

ASTM F512 Standard Specification for Smooth-wall PVC Conduit and Fittings for Underground Installation

ASTM 1962 Standard Guide for Use of Maxi-Horizontal Directional Drilling for

Placement of Polyethylene Pipe or Conduit under Obstacles

ASTM F2160 Standard Specification for Solid Wall High Density Polyethylene

(HDPE) Conduit

Institute of Electrical and Electronics Engineers (IEEE) Standards

IEEE C2 National Electrical Safety Code (NESC)

IEEE-48 Test Procedures and Requirements for Alternating-Current Cable

Terminations Used on Shielded Cables Having Laminated Insulation Rated 2.5 kV through 765 kV or Extruded Insulation Rated 2.5 kV through 500 kV

IEEE 80 IEEE Guide for Safety in AC Substation Grounding

IEEE-100 The Authoritative Dictionary of IEEE Standards Terms

IEEE-386 Standard for Separable Insulated Connector Systems for Power

Distribution Systems above 600V

IEEE-400.2 IEEE Guide for Field Testing of Shielded Power Cable Systems

Using Very Low Frequency (VLF)

IEEE-400.3 Guide for Partial Discharge Testing of Shielded Power Cables in a

Field Environment

IEEE-404 Standard for Power Cable Joints

IEEE-525 Cable Systems in Substations

IEEE-835 Power Cable Ampacity Tables

IEEE C62.11 IEEE Standard for Metal-Oxide Surge Arresters for AC Power

Circuits (>1 kV).

IEEE C62.22 IEEE Guide for the Application of Metal Oxide Surge Arrester for Alternating Current Power Circuits

IEEE 1299/C62.22.1 Guide for the Connection of Surge Arresters to Protect Insulated, Shielded Electric Power Cable Systems

IEEE C62.41 Recommended Practice on Characterization of Surges in Low- (Formerly IEEE Voltage (1000V and Less) AC Power Circuits 587)

Insulated Cable Engineers Association (IECA) Standards

ICEA S-94-964 Concentric Neutral Cables Rated 5-46 kV

ICEA S-97-682-2007 Standard for Utility Shielded Power Cables Rated 5 through 46 kV

International Electrotechnical Commission (IEC) Standards

IEC 60071-2 Insulation coordination Part 2: application guide.

National Electric Manufacturers Association (NEMA) Standards

RN 1 Polyvinyl-Chloride (PVC) Externally Coated Galvanized Rigid Steel

Conduit and Intermediate Steel Conduit

FB1 Fittings, Cast Metal Boxes, and Conduit Bodies for Conduit and

Cable Assemblies

TC 2 Electrical Polyvinyl Chloride (PVC) Tubing (EPT) and Conduit

(EPC-40 AND EPC-80)

TC 3 PVC Fittings for Use with Rigid PVC Conduit and Tubing

TC 6 & 8 PVC Plastic Utilities Duct for Underground Installation

TC 7 Smooth-Wall Coilable Electrical Polyethylene Conduit

TC 9 Fittings for PVC Plastic Utilities Duct for Underground Installation

TC 14 Filament-Wound Reinforced Thermosetting Resin Conduit and

Fittings

NECA/NEMA 605 Recommended Practice for Installing Underground Nonmetallic

Utility Duct

Underwriters’ Laboratories (UL) Inc. Standards

UL 6 Standard for Rigid Metal Conduit

UL 467 Standard for Grounding and Bonding Equipment

UL 514 Fittings for Cable and Conduit

UL 651 Schedule 40 and 80 Rigid PVC Conduit

National Fire Protection Association (NFPA) Standards

NFPA-70 National Electric Code (NEC)

NFPA-70E Electrical Safety in the Workplace

NFPA-780 Standard for the Installation of Lightning Protection Systems

NEC Hdbk Art. 110.16, Flash Protection

NEC Hdbk Art. 344.10, Rigid Metal Conduit: Type RMC

NEC Hdbk Art. 280, Surge Arrestors, Over 1 kV

3. GENERAL

3.1 Definitions

Unless otherwise specified, electrical and electronics terms used in this specification, and on the drawings, shall be as defined in IEEE 100, The Authoritative Dictionary of IEEE Standards Terms.

In the text of this specification, the words “conduit” and “duct” are sometimes used interchangeably and have the same meaning.

In the text of this specification, "medium voltage cable splices" and "medium voltage cable joints" are used interchangeably and have the same meaning.

For the purposes of this specification, “FAA electrical line distribution systems (ELD)” shall be defined as:

FAA owned and operated electrical power distribution systems (underground or overhead) running from a power source to FAA facility load(s). An ELD may include some or all of the following: power cable; transformers; sectionalizers; switchpads; disconnect switches; manholes;

hand-holes; utility poles; direct earth buried (DEB) cables; and underground duct banks. Intra-facility wiring, runway edge lighting cables, and FOTS and system cables, such as MALSR or ALSF loop cables are not included as part of ELD.

The demarcation point between an FAA ELD system and FAA facility premises wiring on an airport can be ambiguous. When in doubt, consult AJW-22, Power Services Group, Power Cable Program.

3.2 Submittals

Submittals are limited to those necessary for quality control (see Appendix E). Submittals marked A are required. For submittals marked B or C, the FAA task or contract specifier shall evaluate the contract for each kind, voltage, or type of submittal used on the project and make a determination as to whether the submittal is required. Examples given are not limited to those shown in parentheses:

“A” indicates that the submittal is required.

“B” indicates that the submittal is required, unless specifically deleted by the contract specifier.

“C” indicates that a submittal is not generally required because it is expensive and/or time consuming (i.e., a special case). If the submittal is required, the contract specifier shall show the required submittal on the submittals matrix (Appendix E) and in the contract documents (as a CLIN item).

a. Contractor-generated design data (ANSI C2 and FAA-STD-032, Para 3.1.13)

1. Code analysis (e.g., voltage drops, clearance calculations, design arc flash study, etc)

(ANSI C2) [A]

2. Design assumptions and parameters (FAA-STD-032) [B]

3. Test reports and findings (e.g., soil resistivity, load bearing, frost analysis, etc) [C]

4. Design calculations (FAA-STD-032) [A]

5. Contractor-generated design drawings or sketches. [A]

b. Cost estimates [A]

c. Medium voltage cable [A]

d. Medium voltage cable splices and joints* [A]

e. Medium voltage cable terminations* [A]

f. Conduits [A]

g. Duct construction materials (e.g., concrete, alternatives to concrete where approved, fills and layers, etc) [A]

h. Switch pads and sectionalizers [A]

i. Transfer switches (automatic and manual) [A]

j. Transformers [A]

k. Surge arresters [A]

l. Live end caps or protective caps [A]

m. Precast concrete structures [A]

n. Sealing Material [B]

o. Manhole frames and covers [A]

p. Hand hole frames and covers [A]

q. Cable supports (racks, arms and insulators) [A]

r. Protective devices and coordination study [A]

s. As-built arc flash hazard study. Required when an existing study is not available, or if modifications are being made to the existing ELD system. [A]

t. Electrical equipment factory test reports [A]

1. Medium voltage cable factory certified test result report as per FAA-E-2793, Section 4.2 (includes meeting ICEA S-94-649, Sections 4.3.2.1 and 9.13). [A]

2. Transformers [A]

3. Switchgear, sectionalizers [A]

4. Disconnects [A]

5. Other applicable components [B]

u. Field acceptance checks and tests (see Appendix C) [A]

v. Arc-proofing test for cable fireproofing tape [C]

w. Cable installation plan and procedure (use cable installation plan only when pulling cable between manholes; do not use for pulling from pole riser to manhole only):

1. Site layout drawing with cable pulls numerically identified [B]

2. A list of equipment used, with calibration certifications [A]

3. The manufacturer, type, and quantity of lubricant used on pull [B]

4. The cable manufacturer and type of cable [A]

5. The dates of cable pulls, time of day, and ambient temperature [C]

6. The length of cable pull and calculated cable pulling tension (calculated value, not maximum value). A single generic table cable pulls may be submitted. [A]

7. The actual cable pulling tensions encountered during pull [A]

8. Certificates (tensiometer calibration, VLF tester calibration, etc) [A]

x. Cable splicer/terminator qualifications* [A]

y. Cable installer qualifications* [A]

z. Project design drawings [A]

*Note: The contractor shall provide the product drawings showing details of the connecting methods to be used, and a statement of the experience of the contractor in making connections on underground systems with the proposed product. Cable splicing/terminating personnel shall have a minimum of three (3) years continuous experience in terminating/splicing medium voltage cable. Products shall meet the latest editions of applicable standards as follows:

APPLICATION STANDARD (USE LATEST ISSUED) LEVEL OF ACCEPTANCE

IEEE-404 Standard for Power Cable Joints Meet or Exceed IEEE-48 Standard for Cable Terminations Meet or Exceed

ANSI C119.1 Sealed Insulated Underground Connector System Rated 600 Volts

Meet or Exceed

IEEE – 386 Standard for Separable Insulated Connectors Meet or Exceed

3.3 Quality assurance

All work shall comply with the National Electrical Code (NEC) and IEEE C2/National Electrical Safety Code (NESC) for components and installation. To the maximum extent practicable, furnish products that are listed and labeled by a nationally recognized testing laboratory (NRTL) for the application, installation condition, and the environment in which the products are installed. Use of nonlisted components will not be allowed unless (1) it is demonstrated that listed components are not available, and (2) the FAA preapproves such components before installation. Approval shall be at the discretion of the FAA.

3.3.1 Quality plan

The contractor shall submit a Quality Plan in compliance with ISO 9001, Quality Management Systems Requirements. This plan will allow the FAA to identify the stages at which the FAA requires carrying out an inspection or witnessing a test. The plan shall cover all relevant stages of personnel qualification, design, coordination, supplier selection, manufacturers’ acceptance testing, site inspection, site quality control testing, and commissioning. The plan shall identify relevant suppliers by name, components supplied, country of origin, and whether suppliers and supplied components are quality assurance certified.

3.3.2 Quality control

The quality of the equipment installed shall be controlled at the manufacturers’ plants and at the project site to ensure that it meets the required specifications. The quality of civil engineering work, such as trenching, ducting, and other operations, shall be inspected by the FAA and approved after each major construction step. The contractor shall inform the FAA of manufacturing/shipping schedules and shall offer representatives of the FAA the opportunity to witness acceptance tests. These tests shall be performed on a statistically meaningful number of samples, as specified by FAA engineers. After receipt of equipment shipment and prior to installation, the contractor shall subject equipment to a thorough visual inspection. An FAA representative shall be notified in advance and afforded the opportunity to be present and witness this step. Nameplates and markers shall be checked against the required specifications, and deviations brought to the FAA’s attention. At the FAA’s request, quality control checks, including acceptable electrical measurements (such as cable insulation resistance tests and surge protection leakage current measurements) shall be performed and reported. After the installation of cable systems is completed, acceptance/commissioning tests shall be performed.

All equipment and materials shall be subject to acceptance through the manufacturers’ certification of compliance with applicable requirements when so requested. The requirements of this standard shall be considered as minimum requirements and shall not relieve the contractor of the responsibility to furnish and install higher grades of materials than specified when so required by the contract drawings and specifications. The installation shall conform to the most stringent requirements of the National Electrical Code (NEC), the local electrical codes, NFPA- 70E, and applicable ANSI and IEEE standards, e.g., the National Electrical Safety Code (NESC), as well as other relevant guides and standards as listed in Section 2.

3.3.3 Qualifications of personnel

3.3.3.1 Designers

The design team shall have at least one engineer with significant experience in medium voltage design, review, and construction management. The engineer shall have worked with electrical power systems, and shall have designed electrical distribution systems whose reliability, maintainability, availability, and fault tolerance are of a similarly high level to those found in campus environments such as hospitals, life safety systems, and/or large computer and telecommunication facilities. The design engineer shall have the ultimate responsibility for the construction set (specifications, drawings, and cost estimates) and installation quality control.

Drawings and engineering documents published by a non-FAA entity shall be signed by a registered professional engineer with knowledge and qualifications tailored to underground medium-voltage and low-voltage electrical distribution systems. Drawings and engineering documents published by a non-FAA entity shall be signed as approved by FAA Engineering Services or a representative of the PSG ELD/Power Cable Program upon design acceptance.

Drawings ready for release for construction shall incorporate the project’s design acceptance drawings by reference.

3.3.3.2 Installation Crew

Experienced personnel regularly engaged in underground electrical distribution system work shall perform the installation. Personnel exclusively or mainly trained in overhead line work, or low voltage facility wiring work, are not sufficiently qualified to install FAA medium-voltage underground electrical distribution systems. Workers shall be properly licensed where required by law. Only qualified personnel may work on electric circuit parts or equipment being installed.

A qualified person is one who has skills and knowledge related to the construction and operation of the FAA’s electrical equipment and installations, and has received safety training to recognize and avoid the hazards involved. Management personnel shall be responsible for authorizing the qualified personnel to perform a task. Besides completion of Occupational and Safety and Health

Administration (OSHA)/FAA required electrical safety training for qualified personnel, those persons authorized to work on FAA ELD systems shall meet the requirements of a Qualified Person as mandated by OSHA and as discussed in NFPA 70E.

Along with training, personnel performing medium voltage work on FAA ELDs shall have: (1) the skills and techniques necessary to distinguish exposed live parts from other parts of electric equipment, including wire and cables, (2) the skills and techniques necessary to determine the nominal voltage of exposed energized electrical conductors or parts, (3) knowledge of the safe approach boundaries, work clearances, and voltages involved, (4) familiarity with construction and operation of equipment and the hazards involved, (5) familiarity with electrical safety related work practices and precautionary techniques, (6) familiarity with proper use of personal protective equipment (PPE), arc flash, insulating and shielding materials, (7) familiarity with the proper use of insulated tools and test equipment, (8) ability to make good decisions in determining the degree and extent of the hazard and the PPE and job planning necessary to perform the task safely, (9) familiarity with safety precautions associated with confined spaces,

(10) knowledge of skills and techniques regarding how to select and use a voltage detector and phase meter, (11) familiarity with mechanical aspects of ELD installation work such as trenching, boring, excavation around existing utilities and structures, manhole rigging, and pulling cable, and (12) CPR training and basic training for emergency dispatch if an electrocution or confined spaces injury occurs.

Cable termination and splicing shall be performed only by experienced and qualified medium/high voltage electricians experienced in underground distribution systems. Before cable splices/terminations are made, the FAA may request an example splice and/or termination be made to demonstrate the electricians’ qualifications. In order to qualify the splicer, this example splice and/or termination shall comply with the requirements of accessory manufacturers, and pass the requirements of IEEE standards 48, 386, and 404 with respect to partial discharge.

3.3.3.3 Inspectors and Testing Personnel

Inspectors of the FAA ELD distribution systems shall have knowledge and experience in quality control activities related to the inspection of cables laid in trenches such as are found at large campus environments such as hospitals, life safety systems, and/or large computer and telecommunication facilities; shall perform quality control activities during installation and preacceptance of medium and low-voltage switchgear and sectionalizers, protective devices, power distribution transformers, surge arrestor equipment, and motor control centers; shall review functional tests of electrical equipment and conduct inspection and preacceptance of electrical drawings, termination drawings, and cable schedules; and shall interpret the various drawings used in the projects for executing and recording the work.

Test personnel shall be qualified persons meeting the requirements stipulated in Appendix C.

3.3.4 Receiving, storing, and protecting

The contractor shall receive, store, protect, and handle products according to National Electrical Contractors Association NECA 1, Standard Practices for Good Workmanship in Electrical

Construction, and NECA/NEMA 605, Recommended Practice for Installing Underground Nonmetallic Utility Duct.

3.3.5 Sequencing and scheduling

The contractor shall:

1) Notify the FAA resident engineer to schedule inspection of each duct bank or duct bank segment before concrete is placed.

2) Provide the FAA resident engineer with reasonable notification before the anticipated date of acceptance testing of the newly installed replacement ELD system so that arrangements can be coordinated with the testing contractor.

3.3.6 Cable testing

3.3.6.1 Government-furnished cable

If government-furnished power cable is delivered to the contractor, the contractor shall test the cable on the reel and report electrical or physical cable defects within two weeks of cable receipt.

If adequate cable lengths are unavailable for testing on the reel, a visual inspection shall be made and damage reported to the FAA. The required tests shall then be made immediately after unreeling. Defects discovered when installing the cable shall be reported to the FAA in accordance with the contract provisions.

3.3.6.2 Contractor-furnished cable

Single and multi-conductor power cables furnished by the contractor shall conform to the FAA specifications given in the Products section of this specification.

Cable shall meet the following minimum requirements:

a. Copper conductors.

b. Thermoplastic, thermosetting, or silicon rubber insulation.

c. Neoprene, polyethylene, or vinyl jacket for normal areas, and polytetrafluoroethylene

(PTFE) (Teflon®) jacket in areas exposed to fuel, oil, solvent or chemical leakage, excessive groundwater, or extremely acidic soil.

d. For cables with rated voltages to 8 kV, cable insulation shall have a minimum continuous voltage withstanding capability of four times rated voltage (but not less than 150 volts).

For rated voltages above 8 kV, insulation shall have a minimum continuous voltage withstanding capability of three times rated voltage. Cable voltage surge capabilities shall be 15 times rated voltage for voltages to 8 kV, nine times rated voltage for voltages above 8 kV through 15 kV, and seven times rated voltage for voltages above 15 kV through 25 kV. Whenever a cable is covered by applicable ICEA/NEMA specifications, the cable shall pass the test requirements for such cable. In addition, the installed cable shall satisfy after-installation acceptance tests as specified below, and in Appendix C.

e. The pull strength of the completed cable(s) shall exceed the expected installation forces by a minimum of 50 percent.

3.3.6.3 Acceptance testing of new cable

Following installation, the contractor shall perform cable testing in the presence of the FAA. The contractor shall furnish necessary test instruments except where otherwise indicated in the project plans. Only currently calibrated instruments shall be used for cable testing. A laboratory approved by the measurement instrument manufacturer shall have performed instrument calibration. When conducting FAA-authorized third-party testing, offline partial discharge testing shall constitute the final acceptance test after completion of the installation.

Testing shall be completed on contractor-installed cable before connection is made to existing cables. If warranted, the FAA will test existing cables and provide the results to the contractor through the contracting officer prior to the contractor splicing or connecting cables he has installed to existing cables.

Certain acceptance tests classified as “destructive” by the IEEE shall only be conducted on newly installed cables. Such tests shall only be conducted within the test constraints given in Appendix C. Destructive tests shall not be performed on in-service (five years or older) power cables.

3.3.6.4 Acceptance testing of new power cables above 2000 volts

CAUTION

Zero-energy verification shall be accomplished before doing any work on de-energized medium-voltage equipment. In preparing for, and conducting, power cable tests, follow electrical safety procedures as outlined in FAA Order 6950.22.

New FAA underground, shielded, medium-voltage power cables rated 2000 volts and above shall be subjected, after installation but before connection to terminal equipment, to the following acceptance tests:

a. Continuity test for cable conductor, shield, and armor, using an ohmmeter type instrument.

See FAA Order 6950.22 for parameters and test equipment.

b. Limited-voltage DC insulation resistance test using a Megger ™ type instrument. This test is formulated to apply and hold a DC voltage on the cable for a specified time, while measuring insulation resistance. See Appendix C for test description and processes.

c. One of the following tests:

a. Very low frequency (VLF, 0.1 Hz) AC high-potential withstand “pass/fail” test. The purpose of this type of test is not to ensure cable system future performance but simply to reassure the construction team that the line is not grounded/shorted before energization. The test shall be performed after cable system installation, including terminations and joints, but before the cable system is placed in normal service. See Appendix C for test description and procedures.

b. If third-party partial discharge acceptance testing is authorized, a diagnostic 50/60 Hz, off-line partial discharge test. This test can localize and determine the severity of any defects in the new installation. Due to its requirements for specialized test equipment, signal processing software, and diagnostic skills, the test must be conducted by a third-party testing firm. The testing firm shall be a qualified contractor preauthorized by the FAA. See Appendix C for test description and procedures.

3.3.6.5 Acceptance testing of new power cables 600 volts and below

CAUTION

Zero-energy verification shall be accomplished before doing any work on de-energized medium-voltage equipment. In preparing for, and conducting, power cable tests, follow electrical safety procedures as outlined in FAA Order 6950.22.

All low-voltage (≤ 600 V) power cables shall measure not less than 50 megohms resistance between conductors, and between conductors and ground (see FAA Order 6950.22, Maintenance of Electrical Power Cables, Chapter 3, Standards and Tolerances, Paragraph 301, Table (see column heading labeled “NEW CABLE”). Measurements shall be taken at not less than 500 volts DC and not more than 1000 volts DC. This test does not constitute proof that the system is free from insulation defects but rather supplies evidence that the insulation was not damaged during the installation process.

3.3.6.6 Failure of cable under test

If the contractor-furnished cable fails to meet test requirements after installation, the contractor shall repair or replace, at his expense, the sections of cable proven defective.

If the government-furnished cable fails to meet test requirements after installation due to contractor’s faulty installation practices, the contractor shall repair or replace the defective sections of cable at contractor’s expense.

The installation contractor shall be responsible for retest costs if components are found to be substandard during acceptance test(s) as a result of contractor faulty installation practices.

4. PRODUCTS

4.1 Product options and substitutions

Alternative products may be substituted for product types that do not apply to the project.

Consult with the airport authority and the local FAA project engineer.

4.2 Power cable

Single and multi-conductor power cables shall conform to the following FAA specifications:

a. FAA-E-2013 for single-and multi-conductor power cables used in exterior 600 volt applications.

b. FAA-E-2793 for single and multi-conductor power cables used in exterior 2,000 to

35,000 volt applications. Reference Section 4.2 for product factory certified test result reporting requirement.

4.3 Transformers

4.3.1 High voltage transformers (>600 volts)

4.3.1.1 Transformer design

ELD transformers are normally installed outdoors with proper clearance from structures.

Transformers shall be “enviro-friendly” mineral-oil-filled or biodegradable electrical insulating and cooling-liquid filled. Choose less-flammable transformer liquids unless there is a specific requirement to do otherwise.

If the local site stipulates less flammable transformer liquids, the following section shall apply, use NFPA 70 for liquids having a fire point not less than 300 degrees C tested per ASTM D92 and a dielectric strength not less than 33 kV tested per ASTM D 877. Provide identification of transformer as "non-PCB" and "manufacturer's name and type of fluid" on the nameplate. The fluid shall be a biodegradable electrical insulating and cooling liquid classified by UL and approved by FM Approvals® as "less flammable" fluids. The fluid shall meet the following properties:

• Pour point: ASTM D 97, less than -15 degree C,

• Aquatic biodegradation: EPA 712-C-98-075, 100%,

• Trout toxicity: OECD Test 203, zero mortality of EPA 600/4-90/027F, pass.

Silicon-filled and R-temp filled transformers shall not be used for less-flammable applications.

Transformers shall be pad mounted and of dead front design. If two-compartment transformers are required, obtain preapproval from the lead Engineering Services engineer or the Power Services Group, AJW-22. Aluminum core construction is acceptable. Due to associated safety hazards, transformers of the pole-mounted style shall not be used for ground-level FAA ELD applications.

4.3.1.2 Transformer bases and cabinets

Use stainless steel bases and cabinets in most applications, unless otherwise specified. The manufacturer's standard construction material is acceptable only in noncoastal and noncorrosive environments. For coastal/corrosive environments, ensure that front sill, hood, and tank base of single compartment transformers are corrosion resistant and constructed of stainless steel of not less than No. 13 U.S. gage, conforming to ASTM A167, Type 304 or 304L, unless otherwise indicated on the drawings. Base shall include any part of the pad-mounted transformer that is within 1.5 inches of the concrete pad.

In highly corrosive environments, the addition of totally stainless steel tanks and metering is required.

4.3.1.3 Warning signs and arc flash/shock hazard labels

For the enclosures of pad-mounted transformers having a nominal rating exceeding 600 volts, provide warning signs. After completion of arc flash hazard and shock analyses, label transformers with arc flash hazard and shock hazard warning information suitable to the particular installation.

4.3.1.4 Transformer losses

Transformers should meet the efficiency standards set forth in DOD’s Unified Facility Guide Specification (UFGS) 26 12 19.20, Single Phase Transformers, Section 2.2.3.

4.3.2 Low-voltage transformers (<600 volts)

In FAA ELD systems, dry-type distribution transformers are used for buck boost applications or for short point-to-point distances for small loads of 600 volts or less. When used indoors, refer to FAA Specification FAA-C-1217, Electrical Work, Interior.

Transformers shall be mounted to allow for adequate ventilation (suitable for the local ambient temperatures).

4.4 Switchgear and sectionalizers

FAA ELD systems contain two types of switchgear: switch pads and sectionalizers. Both are fused devices used to de-energize equipment to allow work to be done and to clear faults downstream. More importantly, they isolate faulted line segments from a distribution system.

These units shall be dead front-type units.

• Low-profile switch pads are typically used for single-phase applications.

• Sectionalizers are typically used for…