4_Electrical_Shore_Tie_CSTO_-_May_11.pdf

Configuration Standard Technical Order

Electrical Shore Ties

SILC-CSTO-36-11 21 27 11-04 / 20110506

Include signed and dated authorizing memo here.

ELECTRICAL SHORE TIES

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RECORD OF CHANGES

CHANGE

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DATE OF

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DESCRIPTION

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BY WHOM

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Table of Contents

1. OVERVIEW ...................................................................................................................................... 1-1

1.A Intent .............................................................................................................................................. 1-1 1.B Referenced Directives .................................................................................................................... 1-1 1.C Development Team ........................................................................................................................ 1-1

2. SCOPE AND IMPACT .................................................................................................................... 2-1

2.A Scope .............................................................................................................................................. 2-1 2.B Impact ............................................................................................................................................. 2-1 2.C Process Links .................................................................................................................................. 2-2

3. REFERENCES ................................................................................................................................. 3-1

4. REQUIREMENTS ........................................................................................................................... 4-1

4.A Introduction .................................................................................................................................... 4-1 4.B Applicability ................................................................................................................................... 4-1 4.C Responsibilities .............................................................................................................................. 4-1 4.D Technical Requirements ................................................................................................................. 4-2

5. GLOSSARY ...................................................................................................................................... 5-1

6. APPENDICES

(A) Recommended Shore Tie Design PracticesError! Bookmark not defined.

A.1 General ........................................................................................................................................ A-1 A.2 Equipment ................................................................................................................................... A-3 A.3 Installation ................................................................................................................................... A-5 A.4 Resources ................................................................................................................................... A-10 A.5 Drawings ................................................................................................................................... A-13

a. A1.1 – Low Power Cutters (LPC) 450V, 3PH Electrical Characteristics A-15

b. A1.2 – Low Power Cutters (LPC) 230V, 3PH Electrical Characteristics A-16

c. A1.3 – High Power Cutters (HPC) 450V, 3PH Electrical Characteristics A-16

d. A2 – Small Boat Shore Power One Line Diagram A-18

e. A3 – LPC, 450V, 3PH One Line Diagram A-20

f. A4 – LPC, FRC – One Line Diagram: BSU Miami A-22

g. A4.1 – LPC, FRC - Power Mound Enclosure: BSU Miami A-24

h. A4.2 – LPC, FRC – Power Mound Enclosure: BSU Miami A-26

i. A5 – LPC – 230/240V, 3PH –One Line Diagram A-28

j. A6 – HPC – One Line Diagram – Single Mil-C-24368/2 A-30

k. A7 – HPC – One Line Diagram – Double Mil-C-24368/2 A-32

l. A8 – HPC – One Line Diagram – Multiple Mil-C-24368/2 A-34

m. A9 – HPC, WMSL – Power Mound Enclosure –BSU Alameda A-36

n. A9.1 – HPC, WMSL - Power Mound Enclosure - BSU Alameda A-38

o. A9.2 – HPC, WMSL – Insulation Resistance Monitor – BSU Alameda A-40

p. A10 – Mil-C-24368/2 Receptacle Details A-42

q. A11 – HPC – Shore Tie Cable Assembly A-44

r. A12 – DLO/RHW Cable Characteristics A-46 iii

(B) Shore-Tie Grounding Diagrams

B.1 Discussion…………………………………………………………….…...…………………….B-1 B.2 Drawings

a. B1 – Grounded WYE Service (RISK) - Shore-Tie Grounding Diagram…………………B-3

b. B2 – Ungrounded DELTA Service-450VAC- Shore-Tie Grounding Diagram…………..B-5

(C) Shore Power Standard Operating Instruction

C.1 Background…………………………………………………………… ......................... ……….C-1 C.2 Precautions……………………………………………………………… .............. …………….C-1 C.3 Boats……………………………………… .......... ……………………………………………..C-2 C.4 Cutters…………………………………………… ............ ……………………………………..C-2 C.5 Shore Power Operations………………… ........ ………………………………………………..C-3

(D) Transportable Shore Power Isolation Transformers

D.1 Background…………………………………………………………… ......................... ……….D-1 D.2 Operating Instructions……………………………………………………………… ..... ………D-2

a. 400kVA Portable Isolation Transformer Operator’s Manual............................................. D-3

b. 750kVA Portable Isolation Transformer Operator’s Manual............................................. D-9

D.3 Drawings

a. D1 – Transportable Shore Power Transformer Recommended Grounding Method ........ D-14

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1. OVERVIEW

1.A Intent This Configuration Standard Technical Order establishes standards for electrical shore ties for shore facilities applications. In conformance with logistics practices and to enhance home-porting interoperability, shore ties shall be standard for each cutter class and should be standard for each class of small boats. Standardization of shore-ties will normally occur during the acquisition phase with funding provided from the appropriation used to procure the new cutters/small boats.

This configuration standard addresses only the shore side facilities and equipment to provide electrical service to cutters and small boats. A companion configuration standard developed by the SFLC addresses the shipboard equipment necessary to connect and utilize the electrical shore tie services. An Interface Control Document has been prepared to highlight and clarify the interface between these two documents.

The boundary between this SILC Configuration Standard and that developed by the SFLC is the receptacle in the shore tie enclosure. For clarification purposes, the interface between the SILC and the SFLC configuration standards are identified below:

- SILC CSTO: The electrical distribution system and all associated equipment from the main utility transformer to the shore-tie receptacle on the pier.

- SFLC CSTO: The electrical system and all associated equipment from the plug on the shore side end of the shore-tie cable to the electrical system on the cutter/boat."

1.B Referenced Directives A. 64-CSTO-M2000.3-08, C4&IT Shore Tie Configuration Standard B. Recommended Waterfront Industrial & Contractor Power Design Practices.

C. SILC-CSTO-36-11 11 24 11-01/20100903, Shore Infrastructure Management Lexicon

1.C Development Team

Name Representing Unit Eric Tipping FDCC John Mathews FDCC Detachment Seattle Carl Lundquist SFLC Wade Williams SFLC David Robinson CEU MIAMI Al Boudreau BSU KODIAK

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2. SCOPE AND IMPACT

2.A Scope This technical order defines the requirements for providing acceptable facility/vessel (cutters and small boats) electrical shore-ties throughout the Coast Guard for both new and existing assets.

2.A.1 Who Performs The Shore Infrastructure Logistics Center (SILC) is responsible for executing this technical order for the shore side electrical system installation based upon the pier side power system requirements provided by Surface Forces Logistics Center (SFLC) for the particular classification of vessel to be serviced. The Facilities Design and Construction Center (FDCC) and the Civil Engineering Units (CEU) of the SILC are responsible for the technical content and executing the requirements of this technical order. The FDCC and the CEU organizations will execute this technical order through their contracting officers with appropriate AC&I or AFC-43 funding to bring facilities into compliance.

2.A.2 Applicable Assets All surface forces (cutters and boats) assets and their homeport facilities are covered under this technical order. Homeport locations will be documented by approved decision memos.

2.A.3 When to Perform Within three years of the date of this technical order, the PLMs will have established the baselines for electrical shore ties and will have completed a gap analysis. This establishes the basis for formulating a project funding plan to correct any deficiencies in existing facilities. Beginning with the date of this technical order, all new construction at piers and wharfs will comply with this technical order. All new cutters and boats will be delivered with an electrical shore tie conforming to this technical order.

Configuration validation shall be completed during Functional Configuration Audits and Physical Configuration Audits on a regular schedule.

2.A.4 To Whom (Customers) The technical order shall be used by all facility managers (CEU, BSU, Sector Logistic Officer or FDCC for new facilities) to plan, design and construct shore ties for all cutters and small boats. Coast Guard representatives at the shipyards building new cutters and small boats shall ensure compatible shore-tie cables have the appropriate matching plug for the shore receptacle as defined by the SFLC TWH for Naval Electrical Systems and SILC TWH for Electrical Shore Ties and required in the acquisition technical requirements."

2.A.5 Suppliers CEUs/BSUs shall be responsible for procuring replacement shore ties when required. Cutters and boats will not construct their own shore ties. Sole source contracts for the procurement of standardized electrical shore ties are directed.

2.B Impact Standardization of electrical shore-ties for cutters and small boats will significantly improve interoperability of surface forces.

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2.B.1 High Power Cutters (HPC) - (175’ and up) Electrical shore-ties for larger cutters are currently standardized using NATO compliant 400 amp receptacles, and are normally provided using AC&I funds to modify/upgrade the waterfront facilities to support the new cutters.

2.B.2 Low Power Cutters (LPC) (65’ to 175’) Electrical shore-ties for these cutters are currently non-standard and highly variable. Replacement of the existing shore-ties to meet this standard shall be accomplished as part of normal maintenance/ recapitalization actions. Electrical shore-ties to support new assets shall be constructed as part of the homeport preparation process using funds appropriated for the acquisition of the new vessel.

2.B.3 Small Boats (SB) (less than 65’) Electrical shore-ties for small boats are currently non-standard and highly variable. Replacement of the existing shore-ties to meet this standard shall be accomplished as part of normal maintenance/ recapitalization actions unless safety concerns require more immediate replacement. Electrical shore-ties to support new assets shall be constructed as part of the homeport preparation process using funds appropriated for the acquisition of the new vessel.

2.C Process Links To insure compliance with the principles of configuration management, electrical shore ties are established as a Configuration Item (CI). The as-built drawings for the shore-ties will document the Physical Baseline (PBL) of the CI. Changes to this Configuration Standard for electrical shore ties must be approved through a Configuration Control Board (CCB) with input from the Surface Forces Logistic Center (SFLC) using the Engineering Change Proposal (ECP) process. Waivers to this standard must also be approved by the CCB. Inspections will be conducted and documented through Functional Configuration Audits (FCA) and Physical Configuration Audits (PCA) to validate configuration compliance.

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3. REFERENCES

A. Naval Engineering Manual, COMDTINST M9000.6 (series) B. National Electrical Code (NEC), NFPA 70 C. Operation and Maintenance Policy for Shore-To-Ship Power, OPNAVINST 11310.3 (series) D. Connector Assemblies; Plugs and Receptacles, Electric Power Transfer, Shore to Ship and Ship to Ship, General Specification for, MIL-C-24368 E. Unified Facilities Criteria (UFC) 4-150- 02, Dockside Utilities for Ship Service F. Unified Facilities Criteria (UFC) 3-560-01, Electrical Safety, Operations & Maintenance, G. Interface Standard for Shipboard Systems, MIL-STD-1399 H. Naval Ships Technical Manual (NSTM) Chapter 320 – Electric Power Distribution Systems, NAVSEA S9086-KY-STM-010

I. Electric Plant Installation Standard Methods for Surface Ships and Submarines, DOD-STD-2003 J. National Electrical Safety Code (NESC) NFPA 70E

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4. REQUIREMENTS

4.A Introduction The shore facility electrical distribution system that provides shore-tie service to Coast Guard vessels shall be of a standard configuration with specific requirements identified herein for each class of HPC, LPC and SB.

4.B Applicability

4.B.1 The requirements of this section are mandatory for all new designs and retrofit projects. Waivers to deviate from any of these requirements may only be granted by the Configuration Control Board.

4.B.1.a Refer to Appendix (A) for recommended facility shore power design practices. Appendix A provides graphic representation of the standard electrical shore-tie configuration per classification of vessel, but doesn’t represent non-standard small boats as they are of various configurations and are not covered.

4.B.1.b Existing facilities that do not meet the requirements of this standard shall be upgraded to meet this standard when replaced or renewed for other reasons.

4.B.1.c System Deficiencies or limitations that are not obvious to the user, such as improper grounding, reduced or increased ampacity shall be listed on a permanently engraved warning plate that is conspicuously located immediately adjacent to the affected shore tie receptacle(s).

4.C Responsibilities

4.C.1 Afloat Units

4.C.1.a Afloat units shall be responsible for furnishing and maintaining shore-tie cables, plugs, and on board shore power equipment.

4.C.1.b Shore tie cables shall be continuous from the shore receptacle to the vessel receptacle without intervening connections, splices, plugs, or receptacles.

4.C.1.c Afloat units shall observe the procedures of Appendix (C) for connecting and disconnecting shore power.

4.C.1.d Afloat units shall promptly report problems with the dockside shore power infrastructure to the cognizant facilities engineering staff in accordance with standardized procedures.

4.C.1.e Afloat units shall notify shore facilities in advance of any testing or energizing of equipment not normally considered hotel loads. This is to ensure the shore power system can accommodate the additional load or whether to utilize shipboard generators, and to consider the cost implications of peak loads during times of high usage.

4.C.1.f Afloat units shall try to maintain balanced loading between phases where practical during shore facility connections, and notify the Facility Engineer of any phase deviations over 10%. Shall also provide additional information if requested.

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Afloat units shall provide protections for the shore-tie cables at the railings where the cables go overboard, a saddle cradle with minimum 2’ radius is one means of providing protection. Refer to Appendix (C) for further information.

4.C.2 Shore Facilities

4.C.2.a The shore facility shall be responsible for maintaining dockside receptacles and infrastructure, including any transportable isolation transformers (Appendix (D)).

4.C.2.b At publicly accessible waterfronts, shore power receptacles or their associated circuit breakers or disconnect switches shall be locked to prevent unauthorized access. A set of keys shall be provided to FE and ship.

4.C.2.c All shore power receptacles supplied with ungrounded power shall be so labeled and their usage restricted solely to U.S. Government vessels requiring such power.

4.C.2.d For cutters designed without shore power cable stowages, the shore facility shall be responsible for storing such cables in a protected location and transporting them to and from the cutter’s mooring.

4.C.2.e Shore facilities shall provide afloat units with advance notice of planned shore power outages or upgrades to the shore power installation.

4.C.2.f Shore facilities shall have designated personnel on duty or call back status to promptly respond to problems with the shore power infrastructure. Afloat units shall be furnished with a procedure or point of contact for requesting technical support.

4.C.2.g Local units shall not alter the design of their shore power infrastructure without the written technical approval of the servicing Civil Engineering Unit. One line electrical distribution and control system wiring diagrams shall be kept on file and maintained to reflect the installed as-built configuration.

4.C.2.h Facility Engineers should monitor the shore power system and be knowledgeable of the “Shore Power Standard Operating Instructions” Appendix C for each classification of ship under his jurisdiction.

FE and the ship EO/EPO along with the appropriate CEU shall coordinate to resolve problems that may arise.

4.C.2.i All renovations and new electrical service equipment shall have Arc Flash hazard identification warning labels. Whenever an interior access door is opened or a sheet metal cover is removed from energized shore power equipment, personnel within the arc flash protection boundary shall be qualified per NFPA 70E and properly outfitted with flame retardant clothing and personal protective equipment

(PPE).

4.D Technical Requirements

4.D.1 Design

4.D.1.a Shore power infrastructure (up to the dockside receptacles) shall be designed and installed in accordance with the latest edition of NFPA 70, except that circuits intended to supply ungrounded power to vessels shall not be grounded, and shall comply fully with the minimum requirements of Article 250.21(A) and (B).

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4.D.1.b Shore power voltage variations during operation of up to ±5% of 450V nominal, typical of most utilities, are permissible. Utilities provide grounded power for customer use with +/-5% voltage variations. To meet the 450V ungrounded delta power requirements for Coast Guard vessels particularly the cutters will require transformation of this service to ungrounded power. Refer to section 4.D.4 for these requirements and Appendix A for further clarification.

4.D.1.c The receptacle(s) serving a single vessel shall be on their own disconnect switch(es) or circuit breaker(s) to allow an afloat unit to disconnect and connect to shore power without affecting other vessels.

4.D.1.d The distance from the main electrical bus afloat to the separately derived service ashore should be minimized to prevent excessive voltage drop.

4.D.1.e Type LSTHOF and LSFHOF cable jackets are too soft for extra hard usage duty and should not be used for replacement shore tie cables; existing cables of these types may continue to be used until no longer serviceable. Shore-tie approved cable types for each vessel, determined by SFLC-ESD-NAME- ESS, are identified as follows: SB - 4.D.5.d.2, LPC - 4.D.6.h.5 and HPC - 4.D.6.i.4.

4.D.1.f Shore power to each cutter shall be separately metered. Individual metering of small boat shore power is not required. Small boats may be metered collectively per CG-4 Energy Program.

4.D.1.g The arc flash hazard associated with each newly installed or retro-fitted switchboard, transformer, and capacitor bank shall be analyzed and posted in a conspicuous location on the exterior of its enclosure in compliance with NFPA 70E and OSHA. Refer to 4.C.2.i.

4.D.1.h Phase rotation for shore power AC systems shall follow the NEC arrangement; for bus and cable connections, A-B-C, from front to back, top to bottom, left to right as viewed from the front of enclosure and for shore-tie receptacle phase rotation, “clockwise”, as viewed from the front of the receptacle. On multiple parallel receptacle installations, each pin location on each receptacle must be connected to the same phase.

4.D.2 Enclosures

4.D.2.a Outdoor enclosures shall be designed to exclude entry of the heaviest rain and wind blown spray expected at the site. Where practicable, locate non-submersible enclosures at elevations above the highest expected tide or storm surge.

4.D.2.b Outdoor enclosures exposed to sunlight shall be designed to resist degradation, both from prolonged exposure to ultraviolet radiation and solar heating. In warm climates, such enclosures shall be colored white or light gray to minimize solar heat absorption.

4.D.2.c Outdoor enclosures adjacent to bodies of salt water shall be of NEMA 4X construction with Type 316 stainless steel exterior hardware. All other outdoor enclosures shall be of NEMA 3R or better rating with exterior hardware treated to resist corrosion. Indoor enclosures may be rated for NEMA 1 if fluid leakage from overhead piping is unlikely.

4.D.2.d Where exposed to freezing weather enclosures shall be designed to retain strength and resistance to impact damage at temperatures as low as -20°C (-4°F).

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4. D.2.e When practicable, switchgear should be installed inside a building at an elevation above the 100 year flood level. In areas prone to storm surges from hurricanes or cyclones, outdoor electrical equipment should be installed on a tower or elevated platform above flood level.

4.D.3 Circuit Protection

4.D.3.a Remotely operated circuit breakers shall be of insulated case design with internal electrical operator and spring charging motor, a high current electro-mechanical contactor may also be used as a remotely operated solenoid or motor driven accessories shall not be installed over the operating handles of molded case devices.

4.D.3.b Programmable electronic trip units or over-current relays shall be installed as over-current protective devices in all shore power distribution circuits operating above 250 volts. Thermal-magnetic trip elements may be used in lower voltage shore power distribution systems and shall be rated for 40 degree C ambient.

4.D.3.c One or more relays shall be installed to protect the cutters with three phase power supply from phase loss. Such protective relays shall automatically secure shore power until satisfactory conditions are reestablished.

4.D.3.d Shore power systems shall be equipped with surge protective devices (SPD) to prevent damage to sensitive cutter electronic systems. Such devices shall be designed to clamp line to line voltages to the lowest values recognized by UL Standard 1449 and safely dissipate the maximum expected surge energy without damage. SPDs shall be self-testing to alert maintenance personnel of surge protection failure.

4.D.3.e For ungrounded power systems, the ground detectors required by NFPA 70 Article 250.21 shall be an electronic insulation resistance monitor. This primary function of the monitors is to measure the insulation resistance of the ungrounded shore facility electrical system from the isolation transformer to the shore-tie receptacles, but maybe extended to monitor the vessel electrical system under the conditions noted below. Monitor shall have adjustable pre-alarm and alarm level settings based upon insulation resistance leakage currents. Features are as follows:

4.D.3.e (1) Pre-Alarm: Shall be activated when insulation resistance leakage current exceeds 13 kilohm or 35ma level settings. Visual alarm shall consist of an amber strobe only.

4.D.3.e (2) Alarm/Strobe: Shall be activated when insulation resistance leakage current exceeds 9 kilohm or 40 ma level settings. Auto/visual alarm shall consist of a red strobe light and horn, mounted adjacent to the pre-alarm strobe. The horn shall have a pulse sound distinct from other alarms.

4.D.3.e (3) If either strobe is activated, local personnel (ship or shore) shall immediately notify the facility engineer for the unit.

4.D.3.f The Ground Fault Monitor connected to the system shall operate under the following conditions:

4.D.3.f (1) Condition 1 (Default): Will disconnect from the system whenever a shore-tie receptacle is engaged. Therefore, utilizing the ship ground detection system to monitor both the ship and shore facility systems. This is necessary to avoid conflicts between ground detection systems.

4.D.3.f (2) Condition 2: Monitor may be re-activated manually if ship system is a non-conflicting system. This is an unlikely scenario as there are only a few ships that have this level of monitoring. Note:

The alarm levels for the monitor may have to be reset to 100 kilohm (pre-alarm) and 50 kilohm (alarm) per NSTM Chapter 300.

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4.D.3.g Only qualified shore facility personnel are authorized to change settings on the monitoring system.

4.D.4 Transformers

4.D.4.a Shore power isolation, step up, or step down transformers shall be located as follows:

4.D.4.a.1 Standard small boats (see section 4.D.5.d below) – Afloat. Refer to 4.D.5.a.

4.D.4.a.2 Non-standard small boats (see section 4.D.5.e below) – Ashore unless the boat already has an onboard transformer installed.

4.D.4.a.3 Cutters (see section 4.D.6.g below) – Ashore.

4.D.4.b Shore power transformers for all vessels shall be equipped with copper windings with 220°C or better insulation and 150°C average temperature rise at full load in a 40°C ambient environment. If located outdoors, the windings shall be varnished using the vacuum-pressure impregnation method and the frame treated to resist corrosion. If subject to salt water submergence 115 degree C epoxy encapsulated dry type transformer shall be used at the waterfront.

4.D.4.c For shore power transformers serving cutters: Each home port cutter shore tie service shall be fed from a dedicated voltage delta-delta isolation transformer with the follow characteristics:

4.D.4.c.1 Voltage adjusting taps on the primary shall be capable of supporting a range adjustment for (2) at 2.5% above normal (FCAN) and four (4) at 2.5% below normal (FCBN). Taps shall be adjusted to deliver the required nominal voltage of (paragraph 4.D.1.b) at the dockside receptacle when tested at 50% of rated load.

4.D.4.c.2 Dual electrostatic shields shall be installed between the primary and secondary windings, as well as between the windings and the core. All shields shall be joined together and bonded to earth ground.

4.D.4.d Shore power transformers are normally of the dry type, typically available in sizes up to 2500 kVA. Oil filled types may be preferable for large services; however, local environmental regulations may prohibit locating such units, even those filled with biodegradable vegetable oil, at sites where tank leakage could drain into navigable waters.

4.D.5 Small Boat Shore Power

4.D.5.a All vessels less than 65 feet in length are classified as small boats. They are identified solely by hull numbers and have no habitability features for the extended support of a permanently assigned crew.

4.D.5.b Shore power plugs shall be equipped with male pins that mate with the female receptacle ashore.

Shore power receptacles shall be equipped with a mechanical interlock that blocks insertion and removal of the plug when the receptacle is energized.

4.D.5.c Shore tie cables should be of round cross section with Type STOW, or SOOW construction.

Type G cable may be used for applications where an equipment grounding conductor is required. Type SOW cable may be used in applications where it is unlikely that the jacket will be exposed to gasoline, diesel fuel, or other organic solvents. Cables shall have colored jackets (other than standard black) for

4-6 better visibility and reduced solar heat absorption. Specific cable type application shall be a determination made by SFLC-ESD-NAME-ESS.

4.D.5.d Standard Small Boats

4.D.5.d.1 Nominal 100 ampere (80 ampere continuous rating), 120 VAC, single-phase, grounded service shall be provided to each standard boat (e.g., 41’ UTB, 45’RBM, 47’ MLB, and 49’ BUSL). The shore tie plug at the dockside end of the shore-tie cable shall be a Russellstoll DS1116MP000 which matches to a Russellstoll DBRS111610000 mechanically interlocked shore tie receptacle enclosure.

4.D.5.d.2 Standard boat shore tie cables should be fabricated from stranded copper, with two power conductors no smaller than #2 AWG (50 kcmil) and one equipment ground no smaller than #8 AWG (23 kcmil). Specific cable type application shall be a determination made by SFLC-ESD-NAME-ESS.

4.D.5.e Non-Standard Small Boats

4.D.5.e.1 Shore power services for non-standard small boats, including barges and landing craft, shall be provided as required to supply the in port loads. For boats not equipped with an on board shore power isolation transformer, such service shall be ungrounded with the same voltage and wiring configuration as the vessel’s main AC power distribution system. For all other boats, grounded or ungrounded power shall be provided with the same configuration and voltage as the onboard transformer primary windings.

4.D.5.e.2 Dockside plugs for non-standard small boats requiring 120 VAC single phase shore power service shall mate with standard boat receptacles unless any of the following are true:

4.D.5.e.2(a) A shore power isolation transformer is not installed aboard the boat.

4.D.5.e.2(b) The onboard transformer is smaller than 10 KVA and not protected against overload by an onboard circuit breaker, fusing, or other means.

4.D.5.e.2(c) Not all runs of portable (topside) and internal (up to the onboard shore power circuit breaker) shore tie cable meet the requirements of section 4.D.5.d.2 above.

4.D.5.e.2(d) Non-standard small boat shore tie cables should be fabricated from stranded copper with the appropriate number of conductors and ampacity. Shore tie cables should not contain an equipment grounding conductor unless it connects to the core of the onboard transformer and is insulated from the hull. Specific cable type application shall be a determination made by SFLC‐ESD-NAME-ESS.

4.D.5.e.2(e) Non-standard small boats not meeting 4.D.5.e.2 above shall be configured so that they cannot be powered from a standard boat receptacle.

4.D.5.e.2(f) Dockside shore power plugs and receptacles for non-standard small boats are not standardized; however, where several vessels of the same class operate within a geographical area, it may be advantageous to outfit all boats with the same dockside plug and all homeports with the same receptacle.

4.D.6 Cutter Shore Power

4.D.6.a Vessels 65 feet in length and longer are generally classified as cutters, which are further broken down into Low Power Cutters (LPC), Section 4.D.6.h; and High Power Cutters (HPC), section 4.D.6.i.

Each cutter has a name as well as a hull number. Cutters are assigned a permanent crew with an Officer

4-7 in Charge (OIC) or Commanding Officer (CO). The specific shore-tie technical requirements for each cutter class are available from the SFLC and summarized in Appendix (A).

4.D.6.b See Appendix (B) for a typical shore and cutter power distribution system grounding diagram.

4.D.6.c Shore-tie cables for connection between shipboard and dockside cutter shore-tie receptacles should be of round cross section and should not contain an equipment grounding conductor. Such cables should contain a neutral conductor only when the neutral is needed for proper operation of the shipboard electrical distribution system. Specific cable type application shall be a determination made by SFLC-

ESD-NAME-ESS.

4.D.6.d In order to obtain favorable utility rates, shore power systems may be equipped with static or automatic power factor correcting capacitors. Capacitor banks shall be equipped with discharge resistors that automatically reduce plate voltage to less than 50 volts within one minute of deenergization. For services intended for use by cutters with paralleling capability, the system shall be designed to prevent operation with a leading (capacitive) power factor.

4.D.6.e Shore power distribution systems may not contain any component that would permit more than 1 mA of current to flow when a 500 VDC potential is applied between any shore tie phase conductor and earth ground.

4.D.6.f For existing installations with shore power derived from a grounded wye transformer, a temporary transportable isolation transformer (if available), as shown in Appendix (D), shall be used until permanent ungrounded infrastructure is installed.

4.D.6.g Electrical Characteristics

4.D.6.g.1 Ungrounded delta 450 VAC, three-phase, three wire, 60 Hz power shall be the Coast Guard shore-tie standard for cutters operating in salt water or the Great Lakes. This category is further subdivided 4.D.6.i below into low power cutters and high power cutters. The desired hotel voltage as measured at the cutter switchboard with normal in port loads should be 450VAC, therefore the source voltage may be higher than 450VAC. Field adjusted by primary transformer taps per paragraph 4.D.4.c.1.

See Appendix (A) drawings A1.1 and A1.3.

4.D.6.g.2 Ungrounded delta 230 VAC, three-phase, three-wire, 60 Hz power shall be the Coast Guard shore-tie standard for river (WLR), inland waterway (WLI), and construction (WLIC) tenders operating predominantly in fresh water. See Appendix (A) drawings A1.2.

4.D.6.h Low Power Cutters (LPC)

4.D.6.h.1 Cutters that require less than 300 amperes of shore power shall be considered low power cutters. Such vessels generally include tugboats (WTGB, WYTL), patrol boats (WPB), craft (WPC) and fast response cutter (FRC).

4.D.6.h.2 Shore power plugs shall be equipped with male pins that mate with the female receptacle ashore. Shore power receptacles shall be equipped with a mechanical interlock that blocks insertion and removal of the plug when the receptacle is energized.

4.D.6.h.3 A Coast Guard hardware standard for electrical shore-ties is appropriate for patrol vessels because of their operational range and their potential for forward deployment. To this end, each patrol vessel mooring shall be equipped with either 100 ampere (non-continuous) or 200 ampere (continuous)

4-8 rated mechanically interlocked receptacle(s) with integral circuit breaker(s) or non-automatic switch (es).

The mating plug shall be a Russellstoll DS1404MP000 (100 amperes) or DS2404MP000 (200 amperes).

4.D.6.h.4 Where other low power cutters may share moorings with 87 foot patrol boats, the Russellstoll DS1404MP000 plug shall be used. In all other cases, standard hardware shall be used to permit sharing of shore-ties among cutters with similar shore power requirements.

4.D.6.h.5 New shore tie cables for low power cutters should be of three conductor Type SOOW construction. Conductors should be stranded copper and sized no smaller than shown in the table below.

Specific cable type application shall be a determination made by SFLC-ESD-NAME-ESS.

Service (A)

Conductor

AWG MCM

60 #6 23

100 #2 60

200 #000 150

4.D.6.i High Power Cutters (HPC)

4.D.6.i.1 Vessels requiring a shore power service of 300 amperes or more shall be considered high power cutters. Such vessels generally include icebreakers (WAGB, WLBB), National Security Cutters (WMSL), Offshore Patrol Cutters (OPC), high and medium endurance cutters (WHEC, WMEC), training ships (WIX), as well as coastal and sea going buoy tenders (WLM, WLB).

4.D.6.i.2 High power cutters shall be equipped with MIL-C-24368/2 receptacles (also known as Viking, Joy, or NATO type) at both the afloat and ashore connections. Shore receptacles shall be furnished with three individually factory potted SHOF-500 cable pigtails so that the assembly is rated for 500 ampere continuous loading. The number of receptacles located at each mooring shall be commensurate with the expected cutter class(es) to be served.

4.D.6.i.3 Dedicated grounded power for ship repair contractors and industrial maintenance activities shall also be provided and labeled. See referenced directive 1.B.D.

4.D.6.i.4 New shore tie cables for high power cutters should be three conductors 500 MCM enhanced THOF construction with factory vulcanized plugs on both ends. Cutters configured so that continuous shore power cable conductor current cannot exceed 365 amperes may use 400 MCM cable with M24368/4-33 cable size reducers at the plug bus lugs. Specific cable type application shall be a determination made by SFLC-ESD-NAME-ESS.

4.D.6.i.5 Shore power plugs may be the traditional straight type (MIL-C-24368/1) or the recently introduced 45° or 90° angled type manufactured by Cooper Crouse-Hinds. Where the vertical separation between the receptacle and deck or ground is sufficient, an angled plug should be used to reduce the strain on the backshell.

4.D.6.i.6 Existing Type LSTHOF or SOOW shore power cables may continue to be used until no longer serviceable. Field potting of plugs is no longer authorized except for temporary repair of existing cable assemblies due to annular cracking as a result of cable strain. Shore tie cable replacement with factory potted plug shall be a determination made by SFLC-ESD-NAME-ESS.

4-9

4.D.6.i.7 Over-current protection and feeder ampacity of each dockside MIL-C-24368/2 receptacle shall be designed for a 400 ampere continuous load capacity. Where multiple receptacles are installed to provide power to a single cutter, consideration needs to be given to providing larger frame circuit breakers, as necessary, to coordinate with cutter circuit breaker trip settings and to protect dockside circuit breakers from catastrophic failure in overload conditions when a single circuit breaker could be exposed to the entire cutter load due to cascading trips of other dockside circuit breakers.

4.D.6.i.8 The MIL-C-24368/2 receptacle cover interlock switch shall be connected so as to de-energize the receptacle whenever the cover is open without a plug installed or an attempt is made to remove an inserted plug.

4.D.6.i.9 Shore power circuit breaker closed and power available indicator lights (high brightness light emitting diode type preferred) and related control switches shall be provided near each receptacle. Cables feeding LED indicators shall be shielded to prevent false indications from induced voltages.

4-10

Straight MIL-C-24368/1 plugs, field potted`

Below: Angled plugs, factory vulcanized

5-1

5. GLOSSARY

Alphabetized glossary of some of the important terms and definitions used or introduced in this technical order. Refer to National Electrical Code Article 100 for definition of terms not included in this list.

• Ambient Temperature: The highest air temperature to which a cable or component is exposed

• Arc Flash: An electric current that passes through air when insulation or isolation between electrified conductors is no longer sufficient to withstand the applied voltage.

• AWG: American Wire Gage – A wire diameter specification. Increasing the gauge value decreases the wire size.

• Berth: A specific, marked-off length, along a pier or wharf, containing ships services appropriate for the ship classes which may be assigned to it.

• Bollard: A single-post fitting to which mooring lines from vessels are attached.

• Cold Iron: Used to describe the condition of a ship when all shipboard boilers, engines, and generators are inoperative during repairs and can furnish none of the required ships services.

• Conductor size: The cross sectional area of electrical wire, normally expressed as American Wire Gauge (AWG) or thousands of circular mils (kcmil).

• Demand Factor: The ratio of the maximum loads, averaged for a period of minutes, to the total connect load on the cable.

• Double banking: Installation of two rows of cable within a cable hangar tier.

• FCAN: Primary transformer tap indicating “Full Capacity Above Normal” voltage.

• FCBN: Primary transformer tap indicating “Full Capacity Below Normal: voltage.

• Floating: A circuit which has no connection to ground.

• Hotel Service (Load): Dockside utilities provided for a ship at berth (also called services, utility services, and cold iron services).

• Insulation Resistance: Characteristic of an insulating material that being subject to voltage indicates a resistance such that the value of leakage current which flows through it stays within acceptable limits.

• Insulation Monitoring Device: Monitors the ungrounded AC system between an active phase conductor and earth. It is intended to sound an alert (audio/visual) or disconnect the power supply when the impedance between two conductors drops below a set value.

• Information Plate: A label listing the equipment manufacturer, model number, and key design data.

• Label Plate: A label identifying the function of the equipment and its unit number (if two or more units with similar function are installed.)

• Nesting: When a second vessel berths outboard of existing vessel at the single pier berth.

• Mechanical Interlock: A physical action which directly de-energizes a circuit or enables a circuit as a safeguard. Mil-C-24368 receptacle comes with a mechanical plug below the

5-2 receptacle which activates a micro switch (DPDT) when the cover is closed or plug fully inserted.

It is also used with an interlock switch/receptacle assembly used of SB or LPC which de-energizes circuit for insertion of shore tie plug or removal of same.

• Percent Voltage drop: The difference in voltage between any two points in a circuit, expressed as a percentage of the rated voltage at the power source (switchboard bus or transformer secondary.

• Reactive: The component of an AC voltage, current, or impedance that is 90 degree out of phase with the “real” or in phase component. Reactive components are associated with capacitive or inductive circuits.

• Resultant load current: The product of the total connected load current and a demand factor applicable to the total connected load.

• Power Mounds: A single enclosure which houses the shore tie receptacles for a vessel which includes power and telecommunication and industrial receptacles for a berth.

• Tag: A label bearing identification or data pertinent to the item to which it is attached.

• Total connected load current: The vectorial sum of the identification plate or rated currents of a connected loads and the specified spare (growth) current allowance.

ELECTRICAL SHORE TIES APPENDIX A

A-1

APPENDIX A

RECOMMENDED SHORE POWER DESIGN PRACTICES

A.1 General

A.1.1 Objective

This appendix provides recommended design practices based upon mandatory requirements of section 4 and lessons learned. They are to be utilized in the development of electrical shore power systems to service SB, HPC and LPC class Coast Guard vessels. Compliance with the statements containing the word “shall” is mandatory unless a deviation is approved by the CCB.

A.1.2 Drawings

A.1.2.1 Attached drawings provide clarification of the elements of a shore tie installation and will be referenced throughout this appendix. They include the minimum recommended configurations as well as examples of existing installations that comply with this document.

A.1.2.1.1 Vessel Electrical Characteristic: Drawings A1.1, A1.2 and A1.3 provides tables listing LPC and HPC vessels per voltage (paragraph 4.D.6.g) and by hull number, with reference to the associated one line diagrams herein.

A.1.2.1.2 Standard Small Boats (SB): Drawing A2 is the one line diagram with different enclosure options based upon the Russellstoll “mechanically interlocked” receptacle enclosures and associated plugs which is the standard for these boats.

A.1.2.1.3 Low Power Cutters (LPC) 450V, 3Ø: Drawing A3 represents the Russellstoll “mechanically interlocked" receptacle enclosure and associated plug for 200A and 100A circuits. Drawing A4 is based upon the proposed installation at BSU Miami which utilizes a fabricated power mound enclosure that will service 2-153’ FRC’s and one 87’ WPB per berth, and includes telecommunication plus industrial outlets.

A.1.2.1.4 Low Power Cutter (LPC) 230/240V, 3Ø: Drawing A5 represents the Russellstoll “mechanically interlocked" receptacle enclosure and associated plug for 200A and 100A circuits.

A.1.2.1.5 High Power Cutters (HPC) 450V, 3Ø: Drawings A6-A8 represents single and multiple Mil- C-24368/2 receptacle combinations.

A.1.2.1.6 Shore tie component: Drawing A10 – A12 provides information on the Mil-C-24368 NATO receptacle, shore tie cable assembly options, and DLO cable characteristics, respectively.

A.1.3 Equipment Standards

Unless reusing existing Government owned materials, all electrical cable, conduit, and components shall be new and constructed in accordance with nationally and internationally recognized industrial electrical equipment manufacturing standards. Such standards are issued by Underwriters Laboratories (UL), the National Fire Protection Association (NFPA), the National Electrical Manufacturers Association (NEMA), the American National Standards Institute (ANSI), the Institute of Electrical and Electronic Engineers (IEEE), and the International Electrotechnical Commission (IEC).

A.1.4 Site Conditions

A-2

A.1.4.1 Geographic locations of Coast Guard facilities vary; therefore, differing site conditions need to be considered in the design process. Climatic conditions effect the type of loads a ship utilizes while tied up to the pier. Pier arrangements and configuration along with the type of home ported and visiting vessels and whether nesting of vessel occurs shall be considered in the layout of the shore tie installation.

A.1.5 Utility Service

A.1.5.1 It is extremely important to verify that the source transformer has achieved the required grounding impedance by testing with a fall-of-potential meter. UFC-4-150-02 requires a ground system at piers, wharves, and other waterfront structures that measure not more than five (5) ohms. If the ground impedance is not within these parameters then additional ground electrodes will need to be added. All ground systems shall be tied together and tested for compliance with UFC-4-150-02.

A.1.6 Accessibility

A.1.6.1 Clearances shall be provided in the immediate vicinity of electrical equipment (NEC Article 110) and machinery to permit complete accessibility for operation, maintenance, repairs, renewal of fuses, and testing.

A.1.6.2 Dockside receptacles shall be arranged so that shore tie plugs can be connected and disconnected without a significant risk of falling overboard. Cables connected to such receptacles should not block access to dockside utility service pits or pass over steam piping. Adequate space for cable slack, not subject to vehicular traffic, shall also be provided

A.1.7 Human Factor

A.1.7.1 The design of new systems and equipment shall conform to the capabilities and limitations of the operator to run and maintain the equipment. Accordingly, design-induced workload, accuracy, time constraints, mental processing, and communications requirements shall not exceed the operator’s capabilities. Design shall also foster effective procedures, work patterns, and personnel safety, while minimizing factors that degrade human performance.

A.1.7.2 Commercial off the shelf (COTS) equipment need not be modified solely to improve the operator interface. Whenever practicable, however, new instrumentation and controls designs shall incorporate the human engineering principles of MIL-HDBK-759

A.2 Equipment

A.2.1 Location

A.2.1.1 Electrical equipment shall be located and/or of construction and coating system to provide maximum protection from vehicle impacts, storm surge, flooding, and windblown or floating debris.

A.2.1.2 Electrical equipment susceptible to vehicle impacts shall be protected by 6 inch diameter concrete filled RGS bollard spaced at 3 foot intervals. Such bollards should project 5 feet above ground and be set into a 24 inch diameter concrete base to a depth of at least 6 feet. If the equipment is to be located on the pier the post shall be welded to a 12” square steel plate anchored to the concrete or steel pier deck.

Bollards shall be painted bright yellow with optional black striping or provided with a commercial manufactured identification cover assembly

A-3

A.2.2 Enclosure

A.2.2.1 Equipment enclosures shall be designed and fabricated such that the internal components will perform their intended function satisfactorily in the environment to which the enclosure is exposed.

Enclosures for electrical equipment shall be in accordance with NEMA or IEC standards. Paint coating system must meet the minimum requirements of IEEE C57.12.29 unless noted otherwise herein.

A.2.2.2 Equipment enclosure exposed to the weather should be fabricated from inherently corrosion resistant materials, such as stainless steel, brass, bronze, or fiberglass. Aluminum or steel, whether coated or not, typically degrade rapidly as a result of corrosion and are not recommended in salt water locations.

A.2.2.3 Watertight stuffing tubes and terminal boxes of MIL-T-24558 design, rated for 15 feet of water submersion (NEMA 6P), are recommended for all exposed connection box applications, particularly those subject to flooding.

A.2.2.4 Enclosure options for the small boats and low power cutters are identified in one line diagrams on drawings A2 and A3 respectively.

A.2.1.5 Examples of enclosures for the multiple outlets are shown in drawings A4.1, A4.2, A9.1 and A9.2. and are also addressed below.

A.2.3 Power Mound

A.2.3.1 Power mounds are single enclosures which house all shore tie power and telecommunication receptacles, and pier industrial receptacles. Where more than one vessel is being nested outboard at a pier berth, consolidation of all outlets in a single enclosure shall be provided to reduce foot print on the pier.

Refer to drawings A4 and A9 as examples of such enclosures. Industrial power receptacle requirements vary and shall be determined for each site and require separate service transformers from ship power.

Refer to the 64-CSTO-M2000.3-08 “C4&IT SHORE TIE” for the…