J2j FAA-C-1391F - ELD 2023.pdf

FAA-C-1391f

FAA-C-1391f September 15, 2023

SUPERSEDING

FAA-C-1391e May 2019

DEPARTMENT OF TRANSPORTATION

FEDERAL AVIATION ADMINISTRATION

SPECIFICATION

INSTALLATION, TERMINATION, SPLICING, AND

TRANSIENT/SURGE PROTECTION OF UNDERGROUND

ELECTRICAL DISTRIBUTION SYSTEM POWER CABLES

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

FAA-C-1391f September 15, 2023 ii

FOREWORD

1. This specification provides requirements for the installation of FAA-owned and maintained underground electrical line distribution (ELD) systems in support of FAA facilities.

2. ELD systems include power cable and associated components on the exterior, commercial power supply side of the circuit at the airfield or remote site through to the service entrance power panels of FAA facilities. These are medium-voltage (MV) and low-voltage (LV) underground power cables, and overhead lines. ELD systems typically do not include campus-wide underground cables close to buildings. In those instances, refer to FAA-C- 1217. Low-voltage systems such as MALSRs and ODALs, and high-voltage systems such as ALSF-2s, are considered part of the ELD Program, but are referred to as “system cables.”

3. This specification excludes facility service entrance (load side) wiring (except for ALSF, MALSR, and RWSL system power cables). It also excludes communication, control, and signal cables. For guidance pertaining to these types of cables, consult the appropriate office of primary responsibility for applicable standards.

4. For installation of communication, control, and signal cables, including fiber optic transmission systems (FOTS), refer to FAA-STD-061, Airport Fiber Optic Transmission Systems; FAA-E-2042, Cable, Electrical Control, Exterior; and FAA-E-2072, Electrical Cable, Telephone Exterior.

5. Power for airfield lighting cables has a separate set of standards and procedures. Refer to the appropriate FAA Advisory Circulars (AC) 150/5340-7 and -26, and associated governing standards.

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

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

a. Revised from “e” version to “f” version,

b. Miscellaneous updates collected from field comments.

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

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

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

Change History

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

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

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

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

ATO0W-CABLE-1023

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

11. Product Integration Plan 12. Effectivity

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

13. DCN No. 14. Pages changed S* A/D* 15. Date Summary - general: a. Deletion of requirements for non-electrical-line-distribution

(non-ELD) systems, b. Emphasis on product changes in FAA ELD systems from the older 2.4 kV to 4.16 kV distribution circuits to the newer industry standard medium voltage systems, e.g., 3-phase/7200 V (phase to neutral). c. Increased attention to the protection of sensitive internal constituent parts of MV cable systems during installation, by (1) the imposition of stringent tests meeting IEEE criteria, and (2) using proper cable pulling, splicing, and terminating techniques. d. Addition of power cable acceptance testing process for newly installed cables (text main body and Appendix C). Acceptance tests classified as destructive by the IEEE, such as the DC high potential (HIPOT) test, shall no longer be performed on in-service power cables.

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

1/24/2012

Details – changes: a. Non ELD systems, deletions from FAA-C-1391b version: pp. 1- 4, 7-15, 17-19. Sections/paragraphs affected: 2.1.2, 2.1.3, 3.1.2, 3.2.1, 3.2.2, 3.4, 3.4.1.1, 3.4.1.2, 3.4.2.2, Table I, 3.4.3, 3.4.3.1, 3.4.4, 3.4.5, 3.5.1, 3.5.2, 3.6, 4.2, 4.3, 4.5, 4.5.1, 4.5.2, 4.6, 4.6.1, 4.6.2, 4.6.3, App A.

1/24/2012

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

1/24/2012

Details – changes: c. Installation of cables, additions in FAA-C-1391c: splice procedures 5.9; cable pulling 5.5.12 and App B; cable end sealing 5.5.11; installer qualifications 3.3.3.2; 50/60 Hz offline partial discharge test 3.3.6.3, 3.3.6.4.

1/24/2012

Details – changes: d. Acceptance testing, additions in FAA-C-1391c: 3.3.6; App C. 1/24/2012 Details – changes: e. Qualified persons and contractors, change in FAA-C-1391c:

3.3.3 (all), 3.3.6.4, 5.9. 1/24/2012

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

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

4/4/2014

Manhole cover wheel loading and guard wire grounding upgraded. 8/15/2014 Miscellaneous updates as a result of field comments. 5/1/2019

Expanded the scope of ELD systems to include low-voltage systems cables such as for MALSR and ODALS, and high-voltage systems such as ALSF-2s. Added Section 6 to provide specific installation instructions for these systems. Added Appendix G.

5/1/2019

Submittals section updated; submittals matrix added as an appendix. 5/1/2019

Added duct joining processes, see also appendix for bonding adhesives data sheet. 5/1/2019

Product section updated. Installation processes updated. 5/1/2019

Revisions to Foreword and Scope to cover gray area between building premises (NEC) and airfield distribution (commercial or FAA utility) wiring. Load break elbows in lieu of splices in manholes not permitted. Manhole ID labels, stainless steel. Ground rod placement in rock or problematic soils. Hinged-on-hinged panel boards. Manhole sizing. ELD disconnect rack drawing updated to show SPD installation and lateral feeders note added. Product details for typical cables used for ELD. Prohibition of HV pole type or dry type transformers above ground. Updated definition of “Qualified Person.” Added reference to FAA Order JO 3900.64. Added definition of “System Cables.” Added EV charging station section. Misc updates from reviewer comments.

Repaginated document by section.

7/20/2023 iv

CONTENTS

1. SCOPE ................................................................................................................................................. 1-1

2. APPLICABLE DOCUMENTS .......................................................................................................... 2-1

2.1 General .............................................................................................................................. 2-1

2.2 Order of precedence ........................................................................................................ 2-1

2.3 Government documents ................................................................................................... 2-1

2.3.1 FAA orders, standards, specifications, and handbooks ........................................ 2-1

2.3.2 Other Government documents, drawings, and publications ................................ 2-3

2.4 Non-Government publications ........................................................................................ 2-4

3. GENERAL ........................................................................................................................................... 3-1

3.1 Definitions ......................................................................................................................... 3-1

3.2 Submittals ......................................................................................................................... 3-1

3.3 Quality assurance ............................................................................................................. 3-3

3.3.1 Quality control .......................................................................................................... 3-3

3.3.2 Qualifications of personnel ....................................................................................... 3-4

3.3.3 Receiving, storing, and protecting ........................................................................... 3-5

3.3.4 Sequencing and scheduling ...................................................................................... 3-5

3.3.5 Cable testing .............................................................................................................. 3-6

4. PRODUCTS ......................................................................................................................................... 4-1

4.1 Product options and substitutions .................................................................................. 4-1

4.2 Power cable ....................................................................................................................... 4-1

4.3 Transformers .................................................................................................................... 4-1

4.3.1 Medium voltage transformers (>1,000 volts) ......................................................... 4-1

4.3.2 Low-voltage transformers (≤600 volts) ................................................................... 4-3

4.4 Switchgear ........................................................................................................................ 4-3

4.5 Outdoor disconnecting means and exterior panel boards ........................................... 4-3

4.6 Terminations, Splices, and Separable Connectors........................................................ 4-5

4.6.1 Terminations ............................................................................................................. 4-5

4.6.2 Splices and Separable Connectors ........................................................................... 4-5

4.7 Overcurrent protective devices ....................................................................................... 4-5

4.8 Underground duct systems .............................................................................................. 4-5

4.8.1 Concrete-encased rigid nonmetallic conduit .......................................................... 4-5

4.8.2 Plastic-coated steel conduit ...................................................................................... 4-6

4.8.3 Direct buried rigid nonmetallic conduit ................................................................. 4-6

4.8.4 Rigid metal conduit (RMC)...................................................................................... 4-7

4.9 Corrosion protection tape ............................................................................................... 4-7

4.10 Insulating bushings ........................................................................................................ 4-7

4.11 Grounding bushings ...................................................................................................... 4-7

4.12 Sweeps ............................................................................................................................. 4-7

4.13 Duct spacers .................................................................................................................... 4-7

4.14 Duct plugs ....................................................................................................................... 4-8

4.15 Duct sealant .................................................................................................................... 4-8

4.16 Underground duct and cable warning tape ................................................................. 4-8

4.17 Pull wires and tape ......................................................................................................... 4-8 v

4.18 Precast electrical manholes and hand holes, accessories ............................................ 4-9

4.18.1 Manholes and hand holes ....................................................................................... 4-9

4.18.2 Manholes accessories ............................................................................................ 4-10

4.19 Grounding cables ......................................................................................................... 4-11

4.20 Ground rods ................................................................................................................. 4-11

4.21 Weather heads on risers, drip loops ........................................................................... 4-11

4.22 Electrical equipment enclosures ................................................................................. 4-11

4.23 Equipment vaults and pads ......................................................................................... 4-11

4.24 Bollards ......................................................................................................................... 4-13

4.25 Surge Protection Devices (SPD) .................................................................................. 4-13

5. EXECUTION ...................................................................................................................................... 5-1

5.1 Scheduling of work .......................................................................................................... 5-1

5.2 Existing FAA buried cable and ducts ............................................................................ 5-1

5.2.1 FAA documentation .................................................................................................. 5-1

5.2.2 FAA marking of known buried cables and ducts .................................................. 5-1

5.2.3 Other buried cables, ducts, piping and items ......................................................... 5-1

5.3 Safety during construction and testing .......................................................................... 5-2

5.4 Excavation and trenching................................................................................................ 5-2

5.4.1 Depth requirements .................................................................................................. 5-2

5.4.2 Survey requirements ................................................................................................. 5-4

5.5 Underground duct systems .............................................................................................. 5-5

5.5.1 Preparation and excavation for underground ducts ............................................. 5-6

5.5.2 Backfilling .................................................................................................................. 5-8

5.5.3 Restoration ................................................................................................................. 5-8

5.5.4 Duct installation ....................................................................................................... 5-9

5.5.5 Manhole and hand hole installation ....................................................................... 5-9

5.5.6 Mandrel requirements ............................................................................................ 5-11

5.5.7 Spare ducts ............................................................................................................. 5-11

5.5.8 Duct protection ....................................................................................................... 5-12

5.5.9 Ducts without concrete encasement ..................................................................... 5-12

5.5.11 Installation of cables ............................................................................................ 5-13

5.5.12 Cable pulling......................................................................................................... 5-14

5.6 Direct earth buried cables ............................................................................................. 5-18

5.7 Cable installation in manholes ...................................................................................... 5-20

5.8 Cable terminations, connections, surge protection, and fault protection ................. 5-20

5.8.1 Cable terminations and connections ..................................................................... 5-20

5.8.2 Connections to a three-phase engine generator ................................................... 5-20

5.8.3 Surge protection ...................................................................................................... 5-20

5.8.4 Fault isolation .......................................................................................................... 5-21

5.9 Splices .............................................................................................................................. 5-22

5.10 Power distribution racks, disconnect switches, junction boxes, and electrical cabinets.................................................................................................................................. 5-23

5.11 Grounding of ELD systems ......................................................................................... 5-23

5.11.1 Power cables, multigrounded neutral wires and shields ................................... 5-24

5.11.2 Cable guard wires ................................................................................................. 5-25

5.11.3 Medium voltage manholes and hand holes ......................................................... 5-27 vi

5.11.4 Equipment and equipment enclosures ................................................................ 5-31

5.11.5 Surge arresters (medium voltage systems) ......................................................... 5-31

5.11.6 Conduit and fittings .............................................................................................. 5-31

5.11.7 Low-voltage cable runs to facility service entrances ......................................... 5-31

5.11.8 ELD system grounding ........................................................................................ 5-32

5.12 Cable tagging, equipment markers and labels, and safety signs ............................. 5-33

5.12.1 Cable tags ............................................................................................................... 5-33

5.12.2 Equipment markers and labels ............................................................................ 5-34

5.13 Cable markers .............................................................................................................. 5-34

5.13.1 Concrete markers for DEB cable ........................................................................ 5-34

5.14 Acceptance and inspection procedures ...................................................................... 5-36

5.15 FAA electric vehicle charging stations ....................................................................... 5-36

6. INSTALLATION OF SYSTEM CABLES .................................................................................. 6-1

6.1 MALSR/MALSF/MALS System Cables ........................................................................ 6-1

6.1.1 Power Cables Running from a Shelter to the Distribution Panel ........................ 6-1

6.1.2 Flasher Power Cables ............................................................................................... 6-1

6.1.3 Flasher Control Cables ............................................................................................. 6-1

6.2 ALSF System Cables........................................................................................................ 6-1

6.2.1 Flasher Power Cables ............................................................................................... 6-2

6.2.2 Flasher Control Cables ............................................................................................. 6-2

APPENDIX A—Surge Arrester Performance Data ........................................................................... A-1

1. SCOPE ................................................................................................................................................. A-1

2. APPLICABLE DOCUMENTS............................................................................................................ A-1

2.1 Non-government publications ........................................................................................ A-1

3. REQUIREMENTS ............................................................................................................................... A-2

3.1 Performance Requirements ........................................................................................... A-2

3.1.1 General ...................................................................................................................... A-2

3.1.2 Placement .................................................................................................................. A-2

3.1.3 IEEE Standard C62.11 ............................................................................................ A-3

3.1.4 Service conditions..................................................................................................... A-3

APPENDIX B—Cable Pulling Calculations ........................................................................................ B-1 APPENDIX C—Acceptance testing of newly installed FAA medium voltage underground power cables ....................................................................................................................................................... C-1 SAFETY REQUIREMENTS, GENERAL .............................................................................................. C-1

1. INSULATION RESISTANCE TEST .................................................................................................. C-2

1.1 Theory of Operation ....................................................................................................... C-2

1.2 Parameters and Tolerance limits .................................................................................. C-2

1.3 Test Schedules ................................................................................................................ C-2

1.4 Safety and Test Procedure ............................................................................................ C-3

1.4.1 Safety ......................................................................................................................... C-3

1.4.2 Test Procedure ......................................................................................................... C-3

2. AC VLF FIELD TEST ........................................................................................................................ C-4

2.1 Theory of Operation ....................................................................................................... C-4

2.2 Parameters and Tolerance Limits ................................................................................ C-5

2.3 Test Schedules ................................................................................................................ C-5

2.4 Safety and Test Procedure ............................................................................................ C-5

2.4.1 Safety ......................................................................................................................... C-5 vii

2.4.2 Test Procedure ......................................................................................................... C-6

3. OFFLINE 50/60 Hz PARTIAL DISCHARGE TEST ........................................................................ C-7

3.1 Theory of Operation ....................................................................................................... C-7

3.2 Parameters and Tolerance Limits ................................................................................ C-7

3.3 Test Schedules ................................................................................................................ C-8

3.4 Safety and Test Procedure ............................................................................................ C-8

3.4.1 Safety ......................................................................................................................... C-8

3.4.2 Test Procedure ......................................................................................................... C-8

APPENDIX D—Acronyms/glossary .................................................................................................... D-1 APPENDIX E—Submittals Matrix ....................................................................................................... E-1 APPENDIX F—HDPE-to-HDPE and HDPE-to-PVC Conduit Adhesive - Sample Product ........... F-1 APPENDIX G—Installation of Low-Voltage MALSR Systems and High-Voltage ALSF SystemsG-1

1-1

1. SCOPE

This specification defines the minimum requirements for the installation of FAA’s low voltage (typically 600 V, or 1000 V where listed) and medium voltage electrical line distribution (ELD) power cables buried directly in the earth or installed in underground duct or conduit. The industry defines medium voltage as between 1,000 V and 34,500 V nominal voltage line to ground and low voltage as 1000 V and below.

The installation work includes surveying, trenching, and backfilling, installation of cables, conduits, concrete-encased ducts, manholes, hand holes, duct markers, joints and splicing, terminating, providing surge protection, and testing of cables for acceptability of the finished ELD. In addition, this specification defines the responsibilities of the contractor with respect to safety, quality assurance, and quality control during the installation and testing of ELD systems.

This specification covers installation and acceptance testing of FAA ELD power cable systems only. For other design, maintenance, and technical details for general ELD systems not covered in this specification, refer to other documents referenced in this specification.

This specification applies to installation of medium and low voltage facility electrical supply power cables and associated equipment. These systems provide facility power from the power supplier’s primary service to the service entrance power panels of FAA facilities, to include low-voltage systems cables that feed MALSRs and ODALs, and high-voltage systems supplying power to ALSF-2 equipment.

For detailed information on the installation of non-ELD cable systems such as control cables, fiber optics telecommunication (FOTS) cables, communication cables, etc., consult with the office of primary responsibility (OPR). Consult also the applicable airport circulars for guidance.

For basic separation requirements of FAA utility power cable systems from non-electrical-power cable systems, consult the section of this specification entitled, “Separation of Cables” (5.5.10).

When physically integrating non-ELD cables with power cables, do not assume all of the provisions of FAA-C-1391 apply without first coordinating with the appropriate OPR and the FAA onsite project engineer responsible for integration of the various types.

For detailed installation requirements for low-voltage systems such as MALSRs and ODALs, and high-voltage systems such as ALSF-2, see Section 6 and Appendix G.

Non-ELD OPRs consist of:

a. Control Cables – Telecommunications Services Group, AJM-313,

b. Fiber Optics Transmission Systems (FOTS) – Air-Ground Data Communications Group, AJM-313,

c. Voice Communications – Air-Ground Data Communications Group, AJM-313,

d. Runway Status Lights (RWSL) – Lighting Systems Group, AJW-46, 1-2

e. Others (as applicable).

For outdoor campus underground electrical work away from buildings, this document takes precedence over FAA-C-1217. FAA-C-1217 is not to be used for outdoor ELD underground electrical requirements beyond buildings. However, for the secondary low-voltage services as they pass into buildings, shelters, or building campuses, the exceptions in FAA-C-1217 may be applied.

2-

2. APPLICABLE DOCUMENTS

2.1 General

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

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

2.2 Order of precedence

Requirements of ELD installations are based on the National Electrical Code (NEC); FAA-STD- 019, Lightning and Surge Protection, Grounding, Bonding, and Shielding Requirements for Facilities and Electronic Equipment; and the content outlined in this document.

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

2.3 Government documents

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

2.3.1 FAA orders, standards, specifications, and handbooks

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

2.3.1.1. ORDERS

3900.19 FAA Occupational Safety and Health Program

JO 3900.57A Chg 1 EOSH Requirements in the Planning and Execution of Construction and Maintenance Activities at NAS Facilities.

JO 3900.64 Air Traffic Organization Electrical Safety Program

JO 6750.16 Siting Criteria for Instrument Landing Systems

JO 6950.27 Power System Analyses: Load Flow Calculations, Short Circuit

Analysis, Protective Device Coordination Studies, and Arc Flash Risk Assessment

JO 6950.28 Underground Electrical Distribution System Power Cables Policy

2.3.1.2 STANDARDS

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

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

FAA-STD-061 Airport Fiber Optic Transmission Systems (FOTS)

2.3.1.3 SPECIFICATIONS

FAA-E-113 Poles, Wood, Treated

FAA-C-1217 Electrical Work, Premises Wiring

FAA-E-2042 Cable, Electrical Control, Exterior

FAA-E-2072 Cable, Telephone Exterior

FAA-E-2171 Cable, Coaxial Armored, M17/6-RG-11

FAA-E-2271 Cable, Coaxial, 50-Ohn, Foam Dielectric, 1/2 and 7/8 Inch

FAA-E-2524 Cable, Radio Frequency, Foam Dielectric, 1/2 and 7/8 Inch, Corrugated Type

FAA-E-2619 Cable, Coaxial, RG-35/U, Armored

FAA-E-2761 Cable, Fiber Optic, Multimode and Single Mode, Multifiber

FAA-E-2793 Cable, Electrical power, Exterior, 2000 to 35,000 Volts

2.3.1.4 ADVISORY CIRCULARS

150/5300-13 Airport Design

150/5320 Surface Drainage Design

150/5370 FAA Standards for Specifying Construction of Airports

150/5345-7 Specification for L-824 Underground Electrical Cable for Airport

Lighting Circuits

150/5345-26 Specification for L-823 Plug and Receptacle, Cable Connectors

2.3.1.4 HANDBOOKS

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

2.3.2 Other Government documents, drawings, and publications

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

American Association of State Highway & Transportation Officials Specifications

AASHTO HB-17 Standard Specifications for Highway Bridges

AASHTO HS-20 Standard Specifications for Highway Bridges

Occupational Safety and Health Administration Codes

Part 1926 Safety and Health Regulations for Construction

29 CFR 1910 Occupational Safety and Health Standards (General Industry)

Military Specifications

MIL-C-38359 Cable, Power, Electrical, Airport Lighting, Cross-Linked, Polyethylene XLP

MIL-I-3825 Insulating Tape, Self-Fusing

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

Metal

DLA A-A-59213 Splice Connectors

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

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

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

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

Composite Based (Non-metallic)

UFGS 26 12 21 Single-Phase Pad-Mounted Transformers

UFGS 33 71 02 Underground Electrical Distribution

Federal Specifications

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

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

WW-C-566 Conduit, Metal, Flexible

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

Steel, UL 6

2.4 Non-Government publications

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

American National Standards Institute (ANSI) Standards

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

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

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

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

ANSI A14.3 Safety Code for Fixed Ladders

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

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

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

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

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

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

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

C62.41)

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

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

(Same as NEMA C119.1)

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

Cable Assemblies. (Same as NEMA FB1)

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

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

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

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

NEMA TC 6 & 8)

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

American Society of Civil Engineers Standards

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

Subsurface Utility Data.

American Society for Testing & Materials (ASTM) Standards

ASTM A48 Standard Specification for Gray Iron Castings.

ASTM B8 Standard Specification for Concentric-Lay-Stranded Copper

Conductors

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

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

ASTM C579-96 Standard Test Methods for Compressive Strength of Chemical- Resistant Mortars, Grouts, Monolithic Surfacings and Polymer Concretes

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

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

ASTM C858 Standard Specification for Underground Precast Concrete Utility

Structures

ASTM C990 Standard Specification for Concrete Pipe, Manholes, and

Precast Box Sections Using Preformed Flexible Joint Sealants.

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

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

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

ASTM D2444-93 Standard Test Method for Determination of the Impact Resistance of

Thermoplastic Pipe and Fittings by Means of a Tup (Falling Weight)

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

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

Placement of Polyethylene Pipe or Conduit under Obstacles

ASTM F2160 Standard Specification for Solid Wall High Density Polyethylene

(HDPE) Conduit

Institute of Electrical and Electronics Engineers (IEEE) Standards

IEEE C2 National Electrical Safety Code (NESC)

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

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

IEEE 80 IEEE Guide for Safety in AC Substation Grounding

IEEE-100 The Authoritative Dictionary of IEEE Standards Terms

IEEE-386 Standard for Separable Insulated Connector Systems for Power Distribution Systems above 600 V

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

Using Very Low Frequency (VLF)

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

IEEE-404 Standard for Power Cable Joints

IEEE-525 Cable Systems in Substations

IEEE-835 Power Cable Ampacity Tables

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

Circuits (>1 kV).

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

Alternating Current Power Circuits

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

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

Insulated Cable Engineers Association (IECA) Standards

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

ICEA S-95-658 Power Cables Rated 2000 Volts or Less for the Distribution of

Electrical Energy

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

International Electrotechnical Commission (IEC) Standards

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

National Electric Manufacturers Association (NEMA) Standards

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

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

Cable Assemblies

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

(EPC-40 AND EPC-80)

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

TC 6 & 8 PVC Plastic Utilities Duct for Underground Installation

TC 7 Smooth-Wall Coilable Electrical Polyethylene Conduit

TC 9 Fittings for PVC Plastic Utilities Duct for Underground Installation

TC 14 Filament-Wound Reinforced Thermosetting Resin Conduit and

Fittings

NECA/NEMA 605 Recommended Practice for Installing Underground Nonmetallic

Utility Duct

Underwriters’ Laboratories (UL) Inc. Standards

UL 6 Standard for Rigid Metal Conduit

UL 467 Standard for Grounding and Bonding Equipment

UL 514 Fittings for Cable and Conduit

UL 651 Schedule 40 and 80 Rigid PVC Conduit

National Fire Protection Association (NFPA) Standards

NFPA-70 National Electric Code (NEC)

NFPA-70E Electrical Safety in the Workplace

NFPA-780 Standard for the Installation of Lightning Protection Systems

3-

3. GENERAL

3.1 Definitions

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

In the text of this specification, the term “conduit” refers to a single pipe through which cable passes. The term “duct” refers to one or more conduits connected through a manhole or hand hole system.

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

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

Electrical Line Distribution (System). An FAA owned and operated electrical power distribution system (underground or overhead) running from a power source to FAA facility load(s). Low-voltage systems such as MASLRs and ODALs, and high-voltage systems such as ALSF-2s are also included in ELD systems. An ELD may include some or all of the following: power cable;

transformers; sectionalizing switchgear; switchpads; disconnect switches; manholes; hand-holes;

utility poles; direct earth buried (DEB) cables; and underground duct banks. Runway edge lighting cables, fiber optic communication cables, and control and signal cables are not included as part of ELD.

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

3.2 Submittals

Submittals are required for quality control (see Appendix E), unless otherwise directed.

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

“A” indicates that the submittal is required.

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

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

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

1. Code analysis (e.g., load flow study, voltage drop calculations, short circuit analysis, clearance calculations, design arc flash study, etc) (ANSI C2) [A]

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

3. Test reports and findings (e.g., soil resistivity) [C]

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

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

b. Cost estimates [A]

c. Medium voltage cable [A]

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

e. Medium voltage cable terminations* [A]

f. Conduits [A]

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

h. Switch pads and sectionalizing switchgear [A]

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

j. Transformers [A]

k. Surge arresters [A]

l. Live end caps or protective caps [A]

m. Precast concrete structures [A]

n. Sealing Material [B]

o. Manhole frames and covers [A]

p. Hand hole frames and covers [A]

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

r. Protective devices and coordination study [A]

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

t. Power cable manufacturer’s factory certification [A]

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

ii. Low voltage cable factory certification meeting ICEA S-95-658. [A]

u. Field acceptance checks and tests (see Appendix C), including demonstrating the adequate performance of the circuit breakers. [A]

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

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

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

2. The manufacturer, type, and quantity of lubricant used on pull [C]

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

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

5. The length of cable pull, calculated maximum cable pulling tension, and calculated maximum sidewall pressure. For cable pulls, a single generic table of cable pulls may be submitted. [A]

6. The actual cable pulling tensions encountered during pull [C]

7. Certificates (tensiometer/dynamometer calibration, VLF tester calibration, etc) [C]

x. Cable splicer/terminator qualifications* The PMO shall assist with the designation of “qualified.”[A]

y. Cable installer qualifications* The PMO shall assist with the designation of “qualified.”

[A]

z. Project design drawings [A]

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

APPLICATION STANDARD (USE LATEST ISSUED) LEVEL OF ACCEPTANCE

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

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

Meet or Exceed

IEEE – 386 Standard for Separable Insulated Connectors Meet or Exceed

3.3 Quality assurance

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

3.3.1 Quality control

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

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

3.3.2 Qualifications of personnel

3.3.2.1 Designers

The design team shall have at least one engineer with significant experience in medium voltage design, review, and construction management.