Attch_5_-_Specifications.pdf

Final (100%) Design Submittal

Design Lightning & Surge Protection Systems for Munitions Facilities 1544, 1545, 1546 and 1553

Project No. XUMU 08-1386E

Prepared for

30th Civil Engineering Squadron

Vandenberg AFB, CA

Prepared by Under Subcontract to

417 Montgomery St., Suite 700 250 Big Sur Drive San Francisco, CA 94104 Goleta, CA 93437 ( 415) 283-4970 (805) 685-6511

February 7, 2011

FA4610-15-R-0004

Attachment 5

Design Lightning & Surge Protection Systems for Munitions Facilities 1544, 1545, 1546 & 1553 February 7, 2011 Vandenberg AFB Project No. XUMU 08-1368E Final (100%) Design i

TABLE OF CONTENTS

1.0 Introduction

1.1 Scope of Work

2.0 Existing Lightning and Surge Protection System Conditions

2.1 Munitions Facility 1544 Lightning Protection System

2.2 Munitions Facility 1545 Lightning Protection System

2.3 Munitions Facility 1546 Lightning Protection System

2.4 Munitions Facility 1553 Lightning Protection System

2.5 Surge Suppression Systems

2.6 Lightning and Surge Protection Criteria Compliance Matrix

3.0 Lightning Protection System Alternative Evaluations

3.1 Mast-Type System

3.2 Overhead Ground-Wire (Catenary) Systems

3.3 Integral Systems

3.4 Metallic Cage System

4.0 Recommended Lightning and Surge Protection System Modifications

4.1 Lightning Protection System Modifications

4.2 Utility Line Bonding

4.3 Surge Suppression System Modifications

4.4 Enhanced Ground Rods

4.5 Construction Cost Estimate

List of Figures

Figure 1 Mast-Type System Lightning Protection Plan

Figure 2 Mast-Type System Zone of Protection Diagrams

Figure 3 Catenary System Lightning Protection Plans – Munitions Facilities 1544 and 1545

Figure 4 Catenary System Zone of Protection Diagrams – Munitions Facility 1544

Figure 5 Catenary System Zone of Protection Diagrams – Munitions Facility 1545

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List of Figures (Continued)

Figure 6 Catenary System Lightning Protection Plan – Munitions Facility 1546

Figure 7 Catenary System Zone of Protection Diagrams – Munitions Facility 1546

Figure 8 Catenary System Lightning Protection Plan and Zone of Protection

Diagrams – Munitions Facility 1553

Appendices

Appendix A Figures

Appendix B Basis of Design

Appendix C Construction Cost Estimate

Appendix D Specifications

Appendix E Calculations

Appendix F Catalog Cuts

Appendix G Review Comments and Responses

Appendix H CAD Project File List

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1.0 Scope of Work

Munitions Facilities 1544, 1545 and 1546 are above-grade reinforced concrete structures and Munitions Facility 1553 is an earth-covered steel arch igloo structure. All these buildings were constructed during the 1960’s.

This design is prepared under a sub-contract to Bengal Engineering, Inc., which holds indefinite delivery/indefinite quantity Contract No. FA4610-07-D-0003 with Vandenberg AFB.

The purpose of this effort is to provide a design package that upgrades or replaces the existing lightning protection and surge suppression system in each munitions facility to meet the following applicable codes and standards:

NFPA 70 (2011) National Electrical Code

NFPA 780 (2011) Standard for the Installation of Lightning Protection Systems

UL96 (2005) Manufacturing Standard for LPS Components

UL96A (2007) Master Label & 3rd Party Testing

AFI 32-1065 (1998) Grounding Systems

AFI32-1065, Supplement 1 (2003) Grounding Systems (Certified Current 1 October

2009.)

DoD 6055.9-STD (2008) DOD Ammunition And Explosives Safety Standards

AFMAN 91-201 (2008) Explosive Safety Standards

NEMA LS 1 (1992) Standard for Low Voltage surge Suppression

Devices (Rescinded in 2009 because document was determined to be out of date.)

MIL-HDBK-1004/6 (1988) Lightning Protection

UFC 3-501-01 (2010) Electrical Engineering

UFC 3-520-01 (2010) Interior Electrical Systems

AFSPCMAN 91-710 (2004) Range Safety User Requirements Manual, Volume 5 and Volume 6

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Site Investigation

Using the fall-of-potential method as described in AFI 32-1065, measure the resistance to ground at a down conductor (or at a test well, if available) of the existing grounding loop at each of the four munitions facilities.

Measure the resistance between existing air terminals to the ground ring electrode in each of the four munitions facilities.

Inspect the ground conductor connections of service entrance feeders at the point of building entry in each of the four munitions facilities.

Measure resistivity (ρ) of the earth near each of the four munitions facilities using the method as described in AFI 32-1065.

Measure depth of the earth covering on the roof of Munitions Facility 1553.

Inspect existing surge suppression systems installed on the incoming power supply at each of the four munitions facilities.

Inspect existing surge suppression systems installed on incoming telecommunications lines at each of the four munitions facilities.

Concept Study and Recommendations (30% Design)

Prepare a report that presents the results of the on-site investigations, including resistances to earth ground from the underground ground ring electrode for each of the four munitions facilities.

Evaluate alternative methods of providing effective lightning protection: Alternatives include (a) a mast-type system; (b) an overhead wire (catenary) system; (c) an integral system with verified bonding connections between floor, wall and roof rebar and between the structural rebar and the underground ground ring electrode; and (d) a metallic cage system.

Specific requirements for the lightning protection and surge protection systems along with the applicable criteria document are listed as follows:

100-foot arc striking distance NFPA 780, DoD 6055.9

AFM 91-201

Adequate side flash protection NFPA 780, DoD 6055.9, AFMAN 91-201

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Air terminals, down conductors NFPA 780, AFI 32-1065 and ground loops

Grounding electrodes NFPA 780, AFI 32-1065, DoD 6055.9

Utility lines bonded upon DoD 6055.9 entering building

50-foot burial distance for DoD 6055.9, AFI 32-1065 conduits and shielded cables

Surge protection on all lines DoD 6055.9

Surge protection device testing IEEE C62.41.1 (Describes surge voltage and current environment in low-voltage AC power circuits)

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2.0 Existing Lightning and Surge Protection System Descriptions

2.1 Munitions Facility 1544 Lightning Protection System

2.1.1 As-Built Drawing Review: Neither original construction drawings nor modification project drawings of the lightning protection system are available.

2.1.2 Results of Site Investigation: Based on the site investigation, lightning protection for Munitions Facility 1544 is provided by an integral lightning protection system. An integral lightning protection system, as described in NFPA 780, consists of air terminals mounted directly on the roof, conductors that interconnect all air terminals, multiple down conductors bonded to a below-grade ground loop conductor (or counterpoise) and ground rods installed at the down conductor locations. All roof-top structures such as roof exhaust fans, flue pipes and air intake structures are protected with 4’ or 6’ long air terminals bonded to the grounding system.

Visual inspection of Munitions Facility 1544 revealed that the requirement for air terminals and down conductors has been met; however, no ground test wells are provided.

Results of resistance and earth resistivity measurements performed during the site investigation on 12 July 2010 through 16 July 2010 are presenting in the following table:

Measurement Description Point A Point B Ground Ring Electrode to Earth Ground (Ohms)

NA NA

Air Terminal to Ground Ring Electrode (Ohms)

0.01 0.01

Earth Resistivity (Ohm- Meters)

NA NA

Note: NA denotes Not Attainable.

Measurements were made with an Amprobe Model GP-2 GeoTest instrument with specified ranges, resolutions and accuracy shown in the following two tables:

Resistance Measurements

Range (Ohms) Resolution (Ohms) Accuracy

0.01 – 19.99 0.01 +-(2% reading + 3 digit)

20.0 – 199.9 0.1 +-(2% reading + 3 digit) 200 – 1,999 1 +-(2% reading + 3 digit)

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Resistivity Measurements

Range (Ohm-meters) Resolution (Ohm-meters) Accuracy

0.8 – 19.99 0.01 +-(2% reading + 3 digit)

20.0 – 199.9 0.1 +-(2% reading + 3 digit) 200 – 1,999 1 +-(2% reading + 3 digit)

2.00 k – 19.99 k 0.01 k +-(2% reading + 3 digit)

20.0 k – 125.6 k 0.1 k +-(2% reading + 3 digit)

2.2 Munitions Facility 1545 Lightning Protection System

2.2.1 As-Built Drawing Review: Neither original construction drawings nor modification project drawings of the lightning protection system are available.

2.2.2 Results of Site Investigation: Based on the site investigation, lightning protection for Munitions Facility 1545 is provided by an integral lightning protection system.

Visual inspection of Munitions Facility 1545 revealed that the requirement for air terminals and down conductors has been met; however, no ground test wells are provided.

investigation are presenting in the following table:

Measurement Description

Point A Point B Point C Point D

Ground Ring Electrode to Earth Ground (Ohms)

NA NA NA NA

Air Terminal to Ground Ring Electrode (Ohms)

Note 2 Note 2 0.03 0.01

Earth Resistivity (Ohm-

NA NA NA NA

Notes:

1. NA denotes Not Attainable

2. At two locations, the air terminals were not bonded to the down conductors.

Resistance between down conductor at base of air terminal and down conductor at grade was 0.01 ohm.

2.3 Munitions Facility 1546 Lightning Protection System

2.3.1 As-Built Drawing Review: Based on original construction and building modification drawings, an integral lightning protection system is installed at Munitions Facility 1546. According to as-built construction drawings for an addition constructed in 1968, reinforcing and lacing bars in all columns are bonded to copper ground conductors.

Additionally, a new grounding ring with ground rods was installed around the original building and bonded to the building addition grounding ring. No ground test wells appear

Design Lightning & Surge Protection Systems for Munitions Facilities 1544, 1545, 1546 & 1553 February 7, 2011

2-3 on the original construction or building addition lightning protection design drawings.

The original building lightning protection system consists of two-foot long air terminals spaced 40 feet on center: this combination does not provide 100-foot arc striking distance protection.

2.3.2 Results of Site Investigation:

Point A

Point B

Point C

Point D

Point E

Point F

Point G

Point H

Point I

Point J

Ground Ring Electrode to Earth Ground (Ohms)

0.06 Note

NA NA NA NA NA NA 0.10

Note

NA -

Air Terminal to Ground Ring Electrode (Ohms)

0.12 0.01 0.08 0.03 0.41 0.04 0.01 0.03 0.03 0.01

Earth Resistivity (Ohm-Meters)

Note

NA NA NA NA NA NA 513

Note

NA 496

Note

Notes:

1. NA denotes Not Attainable.

2. Resistance between down conductor at grade and grass lawn area on each side of the building.

3. Resistivity of the earth at the grass lawn area on the north side of the building.

2.4 Munitions Facility 1553 Lightning Protection System

2.4.1 As-Built Drawing Review: Based on inspection of as-built drawings, lightning protection for Munitions Facility 1553 is provided by metallic cage system—protection also known as a Faraday shield. According to as-built drawings, the earth-covered corrugated steel arch that forms the ceiling of the igloo is brazed to No. 2/0 AWG copper ground conductors in two places. The ground conductors extend to a below-grade counterpoise on one side of the igloo. The steel arch is bonded to reinforcing bar in the concrete floor. A single two-foot air terminal is bolted to the top of the concrete wall at each end of the storage igloo. A single No. 2/0 AWG bare copper ground conductor extends from each air terminal to the counterpoise; therefore, this installation does not meet current standards which require at least two paths to ground. An indeterminate number of ground rods are connected to the counterpoise.

2.4.2 Results of Site Investigation: The measured minimum depth of the earthen covering over the steel igloo is two feet six inches, which exceeds the two feet minimum required by DoD 6055.09-STD, DOD Ammunition and Explosives Safety Standards.

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Therefore, only the exposed concrete walls at each end of the structure require lightning protection.

Point A Point B

Ground Ring Electrode to Earth Ground (Ohms)

NA NA

Air Terminal to Steel Arch (Ohms)

0.03 0.01

Door to Steel Arch (Ohms)

0.02 0.01

Earth Resistivity (Ohm-

NA NA

Notes:

1. NA denotes Not Attainable.

2.5 Surge Suppression Systems

2.5.1 Munitions Facility 1544 Surge Suppression: No transient voltage surge protection is provided on the incoming power service, telecommunications cables and security system cables.

2.5.2 Munitions Facility 1545 Surge Suppression: No transient voltage surge protection is provided on the incoming power service, telecommunications cables and security system cables.

2.5.3 Munitions Facility 1546 Surge Suppression: No transient voltage surge protection is provided on the incoming power service, telecommunications cables and security system cables.

2.5.4 Munitions Facility 1553 Surge Suppression: No transient voltage surge protection is provided on the incoming power service, telecommunications cables and security system cables.

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2.6 Lightning and Surge Protection Criteria Compliance Matrix

The following table summarizes the existing conditions of lightning and surge protection systems at each of the four munitions facilities:

Requirement Facility 1544 Facility 1545 Facility 1546 Facility 1553

100 Foot Arc Striking Distance Protection (Rolling Sphere)

Existing air terminals do not provide 100-foot arc striking distance protection over entire roof

Existing air terminals provide 100-foot arc striking distance protection over entire roof

Existing air terminals do not provide 100-foot arc striking distance protection over entire roof

Existing air terminals do not provide 100-foot arc striking distance protection over earth-covered magazine

Adequate Side Flash Protection

No bonding of metal doors and window frames to down conductors in evidence

No bonding of metal doors and window frames to down conductors in evidence

No bonding of metal doors and window frames to down conductors in evidence

Steel doors are bonded to door frames with braided copper straps which are bonded to the steel arch

Air Terminals 2’ long x 5/8” dia.

air terminals mounted at 25’ o.c. along roof perimeter; 4’ and 6’ air terminals mounted on all roof exhaust fans and flue pipes

2’ long x 5/8” dia.

air terminals mounted at 20’ on center over entire roof surface

First Increment: 2’ long x 5/8” dia. air terminals mounted at 40’ on center over entire roof surface Second Increment:

2’ long x 5/8” dia.

Air terminals mounted at 18’ to 22’ on center along roof perimeter; 4’ and 6’ air terminals mounted on all roof exhaust fans and flue pipes

One 2’ long x 1/2” dia. air terminal mounted on concrete wall at each end of igloo

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Requirement Facility 1544 Facility 1545 Facility 1546 Facility 1553

Down Conductors

No. 2/0 AWG bare copper down conductors from roof ground conductors to underground grounding loop

No. 2/0 AWG bare copper down conductors from roof ground conductors to underground grounding loop

First Increment: ½-inch galvanized steel down conductor attached to No. 2/0 AWG bare copper conductor with side-by-side connectors.

Second Increment:

No. 2/0 AWG bare copper down conductors from roof ground conductors to underground grounding loop

Separate No.

2/0 AWG bare copper down conductors from steel igloo and air terminals

Grounding Electrodes

Grounding electrodes are 8’ long, ¾”dia.

copper- clad steel

Grounding electrodes are 8’ long, ¾”dia.

copper- clad steel

Grounding electrodes are 8’ long, ¾”dia.

copper- clad steel

Grounding electrodes are 8’ long, ¾”dia.

copper- clad steel

Grounding Loop No. 2/0 AWG bare copper grounding loop

No. 2/0 AWG bare copper grounding loop

First Increment: ½-inch steel counterpoise abandoned; down conductors bonded to No. 2/0 bare copper ground loop.

Second Increment:

No 2/0 AWG bare copper grounding loop

No. 2/0 AWG bare copper grounding loop on one side of igloo

Utility Line Bonding Where Entering Building

Not provided for electric service, telephone or security system

Not provided for electric service, telephone or security system

Not provided for electric service, telephone or security system

Not provided for electric service, telephone or security system

50 Foot Burial Distance on Conduits and Shielded Cable

Meets requirements

Meets requirements

Meets requirements

Meets requirements

Transient Voltage Surge Protection

Not provided for electric service, telephone or security system

Not provided for electric service, telephone or security system

Not provided for electric service, telephone or security system

Not provided for electric service, telephone or security system

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3.0 Lightning Protection System Alternative Evaluations

3.1 Mast-Type System

3.1.1 Design Requirements: The zone of protection of a mast-type system is defined by a circular arc concave upward with a radius of 100 feet. The radius of the arc is the lightning striking distance and the arc must pass through the tip of the mast and be tangent to the ground. Where multiple masts are required, the arc must pass through the tips of adjacent masts. The protection of a structure or complex of structures by self-standing vertical masts requires that the distance from the center line of the structure or complex to the masts on the normal or the diagonal axis must not be greater than 100 feet.

Equations for calculating the required height of masts for catenary systems that provide lightning protection for ordnance handling facilities are provided in Appendix A of MIL- HDBK-1004/6, Lightning Protection. The height of masts installed in equally spaced pairs is determined by the following equation:

Equation (1): D = {(L + 2C)/N-2)2 + [(W + 2C )/2]2}1/2

Equation (2) M = S + 0.293 (2D2)1/2 + P

Where: M = height of the masts

D = mast spacing on the diagonal as determined by Equation (1)

S = height of the salient plane, or the highest point of the building

C = clearance distance between center of mast and building

P = an empirical value based on the value of “D” as follows:

P = 2 for values of D from 0 to 20 ft P = 3 for values of D from 20 to 50 ft P = 4 for values of D from 50 to 100 ft

3.1.2 Construction Requirements: Applying the mast-type system design calculation from MIL-HNBK-1004/6 to the munitions facility site yields a lightning protection system consisting of twelve (12) 115-foot long steel masts to protect Munitions Facilities 1544, 1545 and 1546 and two (2) 60-foot long wood masts to protect Munitions Facility 1553. All 14 masts are interconnected with a No. 2/0 AWG bare copper underground counterpoise;

and each existing lightning protection counterpoise is bonded to the new counterpoise in at least two locations.

Design Lightning & Surge Protection Systems for Munitions Facilities 1544, 1545, 1546 & 1553 February 7, 2011

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Refer to Figure 1 for a plan of a mast-type lightning protection system that protects all the munitions facilities on the site and to Figure 2 for zone of protection diagrams along two axes.

Refer to Appendix C for an estimate of the probable construction cost of a mast-type lightning protection system.

3.2 Overhead Ground Wire (Catenary) Systems

3.1.1 Design Requirements: The zone of protection of an overhead ground wire (or catenary) system is defined by a circular arc concave upward with a radius of 100 feet.

The radius of the arc is the lightning striking distance and the arc must (a) pass through the tip of a mast and be tangent to the ground and (b) pass through a pair of overhead ground wires while remaining above the protected structure.

Catenary lightning protection systems designs were performed graphically using zone of protection diagrams along two axes.

3.1.2 Construction Requirements: Applying the catenary system design requirements from NFPA 780 to the Munitions Facilities 1544 and 1545 yields lightning protection systems consisting of two pairs of wood masts supporting No. 2/0 bare copper catenaries. Down conductors from each pole are bonded to a No. 2/0 AWG bare copper underground counterpoise; and each existing lightning protection counterpoise is bonded to the new counterpoise in at least two locations.

Refer to Figure 3 for plans of catenary lightning protection systems for Munitions Facilities 1544 and 1545. Refer to Figure 4 for zone of protection diagrams along two axes of Munitions Facility 1544 and Figure 5 for zone of protection diagrams along two axes of Munitions Facility 1545.

Applying the catenary system design requirements from NFPA 780 to the Munitions Facility 1546 yields a lightning protection system consisting of two pairs of wood masts supporting No. 2/0 bare copper catenaries. Down conductors from each pole are bonded to a No. 2/0 AWG bare copper underground counterpoise; and each existing lightning protection counterpoise is bonded to the new counterpoise in at least two locations.

Calculated side flash distance from a mast is based on NFPA 780, 2011 Edition, paragraph 4.6.5.1. The side flash distance from a mast is:

Dmast = h/6 where:

Dmast = side flash distance from a mast, i.e., the distance between a grounded body and a down conductor at which a bond becomes necessary h = height of structure (or object being calculated)

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Calculated side flash distance from an overhead ground wire (catenary) is based on NFPA 780, 2011 Edition, paragraph 4.6.5.2. The side flash distance from an overhead ground wire is:

Dohgw = l/6n where:

Dohgw = side flash distance from an overhead ground wire l = length of lightning protection conductor between its grounded point and the point being calculated n = 1 where there is a single overhead ground conductor that exceeds 200 ft in horizontal length n = 1.5 where there is a single overhead conductor or more than one conductor interconnected above the structure to be protected, such that only two down conductors are located greater than 20 ft and less than 100 ft apart n = 2.25 where there are more than two down conductors spaced more than 25 ft apart within a 100 ft wide area that are interconnected above the structure being protected

Refer to Figure 6 for a plan of a catenary lightning protection system for Munitions Facility 1546. Refer to Figure 7 for zone of protection diagrams along two axes of Munitions Facility 1546.

Based on the above equations, calculated side flash distances from masts and overhead ground wires are summarized in the following table:

Munitions Facility Number

Side Flash Distance From Mast (Dmast)

Side Flash Distance From Overhead

Ground Wire (Dohgw) 1544 4.17 ft 6.24 ft 1545 4.17 ft 4.57 ft 1546 6.50 ft 16.19 ft 1553 2.08 ft 5.57 ft

However, the minimum recommended separation between the protected facility and the supporting mast is 6 feet, according to AFI32-1065.

3.3 Integral Systems

3.1.1 Design Requirements: An integral lightning protection system incorporates air terminals that are mounted directly on the structure to be protected. The existing lightning protection systems installed at Munitions Facilities 1544, 1545 and 1546 are integral systems. Air terminals installed on munitions facilities must be adequately spaced to provide a zone of protection defined by a 100-foot striking distance.

Design Lightning & Surge Protection Systems for Munitions Facilities 1544, 1545, 1546 & 1553 February 7, 2011

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3.4 Metallic Cage System

3.4.1 Design Requirements: According to NFPA 780, 2011 Edition, Chapter 8, Protection of Structures Housing Explosive Materials, paragraph 8.3.1, “where optimum protection for structures housing explosives is required (as determined by the AHJ), a grounded, continuously conductive enclosure, as shown in Figure 8.3.1, shall be used.

[Figure 8.3.1 depicts a metallic (Faraday-like) cage.]

According to DoD 6055.9, OD Ammunition and Explosives Safety Standards, at least two feet of earth cover is required over munitions storage magazines.

A metallic cage lightning protection system protects Munitions Facility 1553. An earth-covered corrugated steel arch forms the ceiling of the igloo.

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4.0 Recommended Lightning and Surge Protection System Modifications

4.1 Lightning Protection System Modifications

4.1.1 100-Foot Arc Striking Distance Protection – Munitions Facilities 1544 and 1545: To fully comply with the 100-foot rolling sphere concept as described in NFPA 780, it is recommended that new catenary lightning protection systems be installed at these two buildings. The two new overhead-wire lightning protection systems will consist of two pairs of l60-foot hollow steel poles supporting No. 2/0 bare copper catenaries. Two conductors bonded to the base of each pole will be bonded to new No. 2/0 AWG bare copper underground counterpoises; and the existing lightning protection counterpoises will be bonded to the new counterpoises in two locations.

4.1.2 100-Foot Arc Striking Distance Protection – Munitions Facility 1546: To fully comply with the 100-foot rolling sphere concept as described in NFPA 780, it is recommended that a new catenary lightning protection system be installed at this building The new overhead-wire lightning protection system will consist of two pairs of 70-foot long hollow steel poles supporting No. 2/0 bare copper catenaries. Two conductors bonded to the base of each pole will be bonded to a new No. 2/0 AWG bare copper underground counterpoise; and the existing lightning protection counterpoise will be bonded to the new counterpoise in two locations.

4.1.3 100-Foot Arc Striking Distance Protection – Munitions Facility 1553: To fully comply with the 100-foot rolling sphere concept as described in NFPA 780, it is recommended that a new catenary lightning protection system be installed at this building The new overhead-wire lightning protection system will consist of one pair of 45-foot long steel poles supporting No. 2/0 bare copper catenaries. Two conductors bonded to the base of each pole will be bonded to a new No. 2/0 AWG bare copper underground counterpoise; and the existing lightning protection counterpoise will be bonded to the new counterpoise in two locations.

4.1.4 Mast-Type Lightning Protection System: A mast-type lightning protection system that protects Munitions Facilities 1544, 1545, 1546 and 1553 is not recommended because of the estimated probable construction cost. The estimated construction cost for a steel mast-type system is $578,000, which exceeds the estimated construction cost of catenary systems using wood poles by $143,000 or 33 percent. Refer to Appendix C for estimates of probable construction cost.

4.2 Utility Line Bonding

4.2.1 Electric Service Bonding: No bonding of the incoming electrical service ground conductor and conduit to the lightning protection grounding system is provided in Munitions Facilities 1544, 1545, 1546, and 1553. It is recommended that a No. 8 AWG bare copper bonding conductor be installed from the existing service entrance disconnect switch to the new lightning protection underground grounding loop conductor at each of the four magazines.

4.2.2 Telephone Service Bonding: No bonding of the incoming telephone pair conduit to the lightning protection grounding system is provided in Munitions Facilities 1544, 1545, 1546, and 1553. It is recommended that a No. 8 AWG bare copper bonding conductor be installed from

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4-2 the existing telephone conduit to the new underground lighting protection grounding loop conductor at each of the four magazines.

4.2.3 Security System Bonding: No bonding of the incoming security system conduit to the lightning protection grounding system is provided in Facilities 1544, 1545, 1546, and 1553. It is recommended that a No. 8 AWG bare copper bonding conductor be installed from the existing security system conduit to the new underground lightning protection grounding loop conductor at each of the four magazines.

4.3 Surge Suppression System Modifications

4.3.1 Electric Service Entrance: No secondary transient voltage surge suppressors (TVSS) are installed at the service entrance main distribution panel in Facilities 1544, 1545, 1546 and 1553. It is recommended transient voltage surge suppressor with a minimum rated maximum surge current of 250 kA per phase be installed on the service entrance main distribution panel in each of the four munitions facilities. Surge current per phase is the maximum amount of discharge current that can be shunted through each phase of the device based on IEEE Standard C62.41.1 8x20 microsecond test waveform.

4.3.2 Telephone Service Entrance: No telecommunication transient voltage surge suppression is installed on telephone cables at the incoming terminal boards in Munitions Facilities 1544, 1545, 1546 and 1553. It is recommended telecommunication transient voltage surge suppressor with a minimum rated maximum discharge current of 40 kA be installed on each existing telephone pair adjacent to the existing telephone terminal cabinets in each of the four munitions facilities.

4.3.3 Security System Service Entrance: No telecommunication transient voltage surge suppression is installed on the incoming security system data cables. It is recommended that a data communication transient voltage surge suppressor with a minimum rated maximum discharge current of 40 kA be installed on incoming data lines to each existing security system control cabinet in each of the four munitions facilities.

4.4 Enhanced Ground Rods vs. Conductive Concrete Encasement

Due to the high resistivity soil conditions encountered at the construction site, two methods are available to reduce the contact resistance of the grounding electrode with the surrounding soil:

(a) enhanced ground rods in lieu of standard ground rods and (b) conductive concrete encasement of the underground grounding loops.

An enhanced ground rod is a conductive, hollow tube rod manufactured from copper or stainless steel. The rod contains hygroscopic, electrolytic salts that form a saline solution by absorbing moisture out of the atmosphere. The saline solution leaches out of the bottom of the rod, which gradually lowers the resistivity of the surrounding soil, thus forming electrolytic “roots.”

Conductive concrete, otherwise known as ground enhancement material, is a highly conductive material designed to reduce the contact resistance of a grounding electrode with the

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4-3 surrounding soil. The material is placed into the counterpoise trench in a dry state and solidifies by absorbing moisture from the surrounding soil. The material will not leech chemicals into the ground and will inhibit corrosion of copper grounding electrodes. Two products available on the market are San-Earth manufactured by Sankosha Corp. and Contact.GM manufactured by Thermoweld.

4.5 Construction Cost Estimate

An estimate of the probable construction cost of the recommended catenary lightning protection systems is included in Appendix C. The construction cost estimate is based on providing a new overhead wire (catenary) lightning protection system at each of the four munitions facilities.

Improvements will include:

New catenary lightning protection systems to protect Munitions Facilities 1544 and 1545 each consisting of two pairs of 60-foot long steel pole, catenary conductors, and an underground grounding loop encased in conductive concrete.

New catenary lightning protection system to protect Munitions Facility 1546 consisting of two pairs of 80-foot long steel poles, catenary conductors, and an underground grounding loop encased in conductive concrete.

New catenary lightning protection system to protect Munitions Facility 1553 consisting of one pair of 45-foot long steel poles, a catenary conductor and an underground grounding loop encased in conductive concrete.

Climbing steps installed on all hollow galvanized steel poles.

New lightning protection system bonded to the existing lightning protection counterpoise in two locations.

New secondary transient voltage surge suppressors (TVSS) installed on incoming power feeders.

Telecommunications transient voltage surge suppressors installed on all incoming telephone pairs within the existing telephone terminal cabinets and backboards.

Communications surge suppressors installed on the incoming security system data cable adjacent to the existing security system control cabinets.

Design Lightning & Surge Protection Systems for Munitions Facilities 1544, 1545, 1546 & 1553 February 7, 2011

Appendix A

Figures

Design Lightning & Surge Protection Systems for Munitions Facilities 1544, 1545, 1546 & 1553 February 7, 2011

List of Figures

Figure 1 Mast-Type System Lightning Protection Plan

Figure 2 Mast-Type System Zone of Protection Diagrams

Figure 3 Catenary System Lightning Protection Plans – Munitions Facilities 1544 and

Figure 4 Catenary System Zone of Protection Diagrams – Munitions Facility 1544

Figure 5 Catenary System Zone of Protection Diagrams – Munitions Facility 1545

Figure 6 Catenary System Lightning Protection Plan – Munitions Facility 1546

Figure 7 Catenary System Zone of Protection Diagrams – Munitions Facility 1546

Figure 8 Catenary System Lightning Protection Plan and Zone of Protection Diagrams

– Munitions Facility 1553

Design Lightning & Surge Protection Systems for Munitions Facilities 1544, 1545, 1546 & 1553 February 7, 2011

Appendix B

Basis of Design

Winzler & Kelly 1 Design Lightning & Surge Suppression Systems for Munitions Project No. XUMU 08-1386E Facilities, Basis of Design, 4 March 2010 (Rev. 12 March 2010)

BASIS OF DESIGN

Design Lightning & Surge Protection Systems for Munitions Facilities

1544, 1545, 1546 & 1553 Vandenberg AFB Project No. XUMU 08-1386E

Munitions Facilities 1544, 1545 and 1546 are above-grade reinforced concrete structures and Munitions Facility 1553 is an earth-covered steel arch igloo structure.

All these buildings were constructed during the 1960’s.

This design is prepared under a sub-contract to Bengal Engineering, Inc., which holds indefinite delivery/indefinite quantity Contract No. FA4610-07-D-0003 with Vandenberg AFB.

The purpose of this effort is to provide a design package that upgrades or replaces the existing lightning protection and surge suppression system in each munitions facility to meet the following applicable codes and standards:

NFPA 70 National Electrical Code

NFPA 780 Standard for the Installation of Lightning Protection Systems

UL96 Manufacturing Standard for LPS Components

UL96A Master Label & 3rd Party Testing

AFI 32-1065 Grounding Systems

AFI32-1065 Grounding Systems Supplement 1

DoD 6055.9-STD OD Ammunition And Explosives Safety Standards

AFMAN 91-201 Explosive Safety Standards

NEMA LS 1 Standard for Low Voltage surge Suppression Devices

MIL-HDBK-1004/6 Lightning Protection

Winzler & Kelly 2 Design Lightning & Surge Suppression Systems for Munitions

UFC 3-500-01 Electrical Engineering

UFC 3-520-01 Interior Electrical Systems

AFSPCMAN 91-710 Range Safety User Requirements Manual, Volume 5

No references to lightning protection were found in AFSPCMAN 91-710, Range Safety User Requirements Manual, Volume 3.

2.0 Existing Lightning and Surge Protection Systems Conditions and

Deficiencies

2.1 Lightning Protection Systems – Munitions Facilities 1544, 1545 and 1546: Based on a site walk conducted on 18 February 2010 and a review of the original construction drawings, the lightning protection for Munitions Facilities 1544, 1545 and 1546 is provided by an integral lightning protection system. An integral lightning protection system, as described in NFPA 780, consists of air terminals mounted directly on the roof, conductors that interconnect all air terminals, multiple down conductors bonded to a below-grade ground loop conductor (or counterpoise) and ground rods installed at the down conductor locations. All roof-top structures such as roof exhaust fans, flue pipes and air intake structures must be protected with air terminals bonded to the grounding system. In addition, all structural steel must be bonded to the building grounding system. According to as-built construction drawings for the addition to Munitions Facility 1546 constructed in 1968, reinforcing and lacing bars in all columns are bonded to copper ground conductors.

Visual inspection of Munitions Facilities 1544, 1545 and 1546 revealed that the requirement for air terminals and down conductors has been met. There are no ground test wells installed at the three facilities.

Electrical Shop personnel reported that recent continuity measurements made on the grounding systems of Munitions Facilities 1544 and 1545 yielded bonding resistances less than one ohm. However, resistance of the ground loop to earth ground has not been measured. Electrical Shop personnel reported that there are a number of locations in the Munitions Facility 1546 lightning protection system where the bonds do not meet the resistance requirement.

2.2 Lightning Protection Systems – Munitions Facility 1553: Based on a site walk conducted on 18 February 2010 and inspection of as-built drawings, lightning protection for Munitions Facility 1553 is provided by metallic cage system—protection also known as a Faraday shield. According to as-built drawings, the corrugated steel arch that forms the ceiling of the igloo is brazed

Winzler & Kelly 3 Design Lightning & Surge Suppression Systems for Munitions to No. 2/0 AWG copper ground conductors in two places. The ground conductor extends to a below-grade counterpoise on one side of the igloo. An indeterminate number of ground rods are connected to the counterpoise.

A single air terminal is bolted to the top of the concrete retaining wall at each end of the storage igloo. A single No. 2/0 AWG bare copper ground conductor extends from each air terminal to the counterpoise.

2.3 Surge Suppression Systems: Surge suppression systems will be inspected during the during the site investigation phase of the design.

3.0 Proposed Basis of Design for Electrical System

3.1 List of Existing Deficiencies: It is unknown whether or not the existing lightning and surge protection systems that protect Munitions Facilities 1544, 1545, 1546 and 1553 meet all the requirements specified in the applicable National Fire Protection Agency (NFPA), Underwriters Laboratories (UL), Department of Defense (DoD), U.S. Air Force and National Electrical Manufacturers Association (NEMA) publications.

Refer to paragraph 2.0 of this document for a description of lightning protection system deficiencies for each of the four munitions facilities.

3.2 List of Design (Construction) Requirements: The existing systems will require site investigation and study to delineate appropriate remedies. The recommended study includes:

SITE INVESTIGATION

1. Using the fall-of-potential method as described in AFI 32-1065, measure the resistance to ground at a down conductor (or at a test well, if available) of the existing grounding loop at each of the four munitions facilities.

2. Measure the resistance between existing air terminals to the ground ring electrode in each of the four munitions facilities.

3. Inspect the ground conductor connections of service entrance feeders at the point of building entry in each of the four munitions facilities.

4. Measure resistivity (ρ) of the earth near each of the four munitions facilities using the method as described in AFI 32-1065.

Winzler & Kelly 4 Design Lightning & Surge Suppression Systems for Munitions

5. Measure depth of the earth covering on the roof of Munitions Facility 1553.

6. Inspect existing surge suppression systems installed on the incoming power supply at each of the four munitions facilities.

7. Inspect existing surge suppression systems installed on incoming telecommunications lines at each of the four munitions facilities.

CONCEPT STUDY AND RECOMMENDATIONS (30% DESIGN)

1. Prepare a report that presents the results of the on-site investigations, including resistances to earth ground from the underground ground ring electrode for each of the four munitions facilities.

2. Evaluate alternative methods of providing effective lightning protection:

Alternatives include (a) a mast-type system; (b) an overhead wire (catenary) system; (c) an integral system with verified bonding connections between floor, wall and roof rebar and between the structural rebar and the underground ground ring electrode; and (d) a metallic cage system.

3. Specific requirements for the lightning protection and surge protection systems along with the applicable criteria document are listed as follows:

• 100-foot arc striking distance NFPA 780, DoD 6055.9

AFM 91-201

• Adequate side flash protection NFPA 780, DoD 6055.9, AFMAN 91-201

• Air terminals, down conductors NFPA 780, AFI 32-1065 and ground loops

• Grounding electrodes NFPA 780, AFI 32-1065, DoD 6055.9

• Utility lines bonded upon DoD 6055.9

• 50-foot burial distance for DoD 6055.9, AFI 32-1065 conduits and shielded cables

Winzler & Kelly 5 Design Lightning & Surge Suppression Systems for Munitions

• Surge protection on all lines DoD 6055.9

4. Due to the high resistivity soil conditions expected to be encountered at the construction site, it is recommended that enhanced ground rods be incorporated into the lightning protection system designs. An enhanced ground rod is a conductive, hollow tube rod manufactured from copper or stainless steel. The rod contains hygroscopic, electrolytic salts that form a saline solution by absorbing moisture out of the atmosphere.

The saline solution leaches out of the bottom of the rod, which gradually lowers the resistivity of the surrounding soil, forming electrolytic “roots” over time.

3.3 Pre-Design Construction Cost Estimate: An estimate of the probable construction cost is included in Attachment A. The construction cost estimate is based on the assumption that improvements in the existing lightning protection system will be required for each of the four munitions facilities. Improvements will include:

• New catenary lightning protection systems to protect Munitions

Facilities 1544 and 1545 each consisting of two pairs of wood poles with air terminals, catenary conductors, down conductors, grounding loop and enhanced ground rods.

• New catenary lightning protection system to protect Munitions Facility 1546 consisting of four pairs of wood poles with air terminals, catenary conductors, down conductors, grounding loop and enhanced ground rods.

• New catenary lightning protection system to protect Munitions

Facility 1553 consisting of one pair of wood poles with air terminals, catenary conductors, down conductors, grounding loop and enhanced ground rods.

• New secondary surge arresters installed on incoming power feeders.

• New surge arresters installed on incoming voice and data telecommunications cables.

Winzler & Kelly 6 Design Lightning & Surge Suppression Systems for Munitions

3.4 List of Drawing Sheets

CONCEPT (30%) DESIGN STUDY

Figure 1 Munitions Facility 1544 – Zone of Protection Diagram, Side Elevation

Figure 2 Munitions Facility 1544 – Zone of Protection Diagram, End Elevation

Figure 3 Munitions Facility 1545 – Zone of Protection Diagram, Side Elevation

Figure 4 Munitions Facility 1545 – Zone of Protection Diagram, End Elevation

Figure 5 Munitions Facility 1546 – Zone of Protection Diagram, Side Elevation

Figure 6 Munitions Facility 1546 – Zone of Protection Diagram, End Elevation

Figure 7 Munitions Facility 1553 – Zone of Protection Diagram, Side Elevation

Figure 8 Munitions Facility 1553 – Zone of Protection Diagram, End Elevation

FINAL DESIGN DRAWINGS

G001 Title, Area and vicinity Maps and List of Drawings G002 Symbols, Legends, Abbreviations and General Notes E101 Munitions Facility 1544 Lighting Protection Plan E102 Munitions Facility 1544 Lighting Protection Elevations E103 Munitions Facility 1545 Lighting Protection Plan E104 Munitions Facility 1545 Lighting Protection Elevations E105 Munitions Facility 1546 Lighting Protection Plan E106 Munitions Facility 1546 Lighting Protection Elevations E107 Munitions Facility 1553 Lighting Protection Plan E108 Munitions Facility 1553 Lighting Protection Elevations E601 Pole Details E602 Miscellaneous Details

3.5 Project Schedule

Winzler & Kelly requests that the performance period for preparation of the Concept Design Study (30% Submittal) be increased from 28 days to 75 days to allow flexibility in scheduling the field work and to allow sufficient time to prepare analyses of the three alternative lightning protection schemes.

Winzler & Kelly 7 Design Lightning & Surge Suppression Systems for Munitions

All other performance periods in the Scope of Work dated February 9, 2010 are acceptable.

Design Lightning & Surge Protection Systems for Munitions Facilities 1544, 1545, 1546 & 1553 February 7, 2011

Appendix D

Specifications

Design Lightning & Surge Protection Systems for Munitions Facilities 1544, 1545, 1546 & 1553 February 7, 2011

List of Specification Sections

Section 01000 General Requirements

Section 01001 Contractor Project Management System

Section 01010 Environmental Requirements

Section 01440 Contractor Quality Control

Section 16671 Telecommunication Line Surge Suppression

Section 26 20 00 Interior Distribution System

Section 26 41 01.00 10 Lightning Protection System

AF Form 66 Schedule of Material Submittals

XUMU 08-1368E 01000-1

SECTION 01000

GENERAL REQUIREMENTS

PART 1 - GENERAL

1.01 PROJECT DESCRIPTION

A. The project consists of furnishing all labor, materials, and equipment in connection with

Design Lightning & Surge Protection Systems for Munitions Facilities 1544, 1545, 1546 and 1553, Project XUMU 08-1386E at Vandenberg Air Force Base, California.

B. The work is briefly described as follows, but is not the entire scope of the project:

1. Lightning Protection System Modifications: Provide new catenary lightning protection systems for Munitions Facilities 1544, 1545, 1546 and 1553 consisting of (a) pairs of steel poles supporting overhead ground wires, (b) conductors from hollow steel pole bonded to new underground counterpoises and (c) bonding of existing lightning protection counterpoises to the new counterpoises in two locations for each facility.

2. Utility Line Bonding: Provide a bare copper grounding conductor from the existing electric service entrance main circuit breaker or disconnect switch to the new lighting protection system counterpoise at each of the four munitions facilities. Provide a copper bonding conductor between (a) the existing incoming telephone conduit(s) and (b) the existing incoming security system conduit(s) and the new lightning protection system counterpoise at each of the four munitions facilities

3. Surge Suppression System Modifications: Provide a transient voltage surge suppressor with a minimum rated maximum surge current of 250 kA at the service entrance main distribution panel at each of the four munitions facilities. Provide a transient voltage surge suppressor with a minimum rated discharge current of 40 kA for (a) each existing incoming telephone pair and (b) each existing security system incoming data line at each of the four munitions facilities.

1.02 OCCUPANCY:

A. The project site(s) will be occupied by base personnel during construction operations.

1.03 WORK SCHEDULE

A. Working hours will normally be between the hours of 7:15 a.m. and 4:15 p.m., excluding Saturdays, Sundays, and federal holidays. If the Contractor desires to work during periods other than above, he shall make his request to the Contracting Officer three workdays in advance. If Government inspection forces are not required or such forces are reasonably available, the Contracting Officer may authorize the Contractor to perform work during periods other than normal duty hours/days; however, if Government inspectors are required to perform in excess of their normal duty hours/days solely for the benefit of the Contractor, the actual cost of inspection at overtime rates will be charged to the Contractor. These adjustments to the Contract price may be made periodically as directed by the Contracting Officer.

XUMU 08-1368E 01000-2

B. All Contractor work schedules shall be coordinated with Munitions leadership to facilitate mission accomplishment and escort with the controlled area.

1.04 MANDATORY WORK STOPPAGES

A. A mandatory work stoppage occurs whenever the Contractor is restricted from working a full workday and is unable to reallocate work forces to other locations. All costs associated with five mandatory work stoppages must be included in the bid price. No additional compensation or extension to the Contract performance period will be given as a result of five mandatory work stoppages.

B. The Contractor may be required, without advance notice, to move work to a different location.