NAVFAC MO-200 Manual.pdf

ARMY TM 5-684

NAVY NAVFAC MO-200

AIR FORCE AFJMAN 32-1082

TECHNICAL MANUAL

FACILITIES ENGINEERING

ELECTRICAL EXTERIOR FACILITIES

APPROVED FOR PUBLIC RELEASE: Distribution is unlimited

DEPARTMENTS OF THE ARMY, THE NAVY, AND THE AIR FORCE

29 November 1996

TM 5-684/NAVFAC MO-200/AFJMAN 32-1082

REPRODUCTION AUTHORIZATION/RESTRICTIONS

This manual has been prepared by and for the Government and, except to the extent indicated below, is public property and not sub-ject to copyright.

Copyrighted material included in the manual has been used with the knowledge and permission of the proprietors and is acknowledged as such at point of use. Anyone wishing to make further use of any copyrighted material, by itself and apart from this text, should seek necessary permission directly from the proprietors.

Reprints or republication of this manual should include a credit sub-stantially as follows: “Joint Departments of the Army, the Navy and the Air Force, TM 5-864/NAVFAC MO-200/AFJMAN 32-1082.”

If the reprint or republication includes copyrighted material, the credit should also state: “Anyone wishing to make further use of copyrighted material, by itself and apart from this text, should seek necessary permission directly from the proprietor.”

Tables 13-l and 16-1 are reprinted from table 2 of IEEE Std 18-1992 and table 11.1 of IEEE Std 519-1992 respectively.

Copyright 0 1993 by the Institute of Electrical and Electronics Engi-neers, Inc. The IEEE disclaims any responsibility or liability resulting from the placement and use in this publication. Information is re-printed with the permission of the IEEE.

HEADQUARTERS

TECHNICAL MANUAL No. 5-684

DEPARTMENTS OF THE ARMY,

NAVY PUBLICATION NAVFAC MO-200 THE NAVY, AND THE AIR FORCE

AIR FORCE JOINT MANUAL No. AFJMAN 32-1082 WASHINGTON , D.C. 29 November 1996

ELECTRICAL EXTERIOR FACILITIES

CHAPTER 1. INTRODUCTION

SECTION I-PRIMARY CONSIDERATIONS

Purpose and scopee References Application of codes and publications Standardsofmaintenance Maintenance responsibilities Maintenance records Priority and scheduling

SECTION II-SAFETY

Minimizinghazards Qualification of electric workers Certification of electric workers Publicsafety Personnel safetyy Live-linemaintenance

SECTION III-AVOIDING PROBLEMS

Operating conditions Detecting potential trouble Electrical connections

CHAPTER 2. INSPECTION AND TESTS

SECTION I-PERFORMANCE

Determining equipment condition Reasons for inspections and tests Associated test guidance and records

SECTION II-REQUIREMENTS

Electric workers, instruments, and reports Frequencyofinspection

CHAPTER 3. TRANSMISSION AND DISTRIBUTION SUBSTATIONS

SECTION I-GOVERNING CONSIDERATIONS

Typeofsubstationscovered Electrical system relationships Substation safety concerns Substation security Periodic inspections of substations Visual inspections of substations Infrared inspections of substations

SECTION II-STRUCTURE MAINTENANCE

Importance of maintenance.... .1 Galvanized steel structures Painted steel structures Aluminumstructures Wood structures Concrete for structure foundations Structure connections and joints

SECTION III-SUBSTATION YARDS

Provisionofyards Fences for yards Warningsignsatyards Substation yardss

Paragraph Page l - l l-2 l-3 l-4 l-5 l-6 l-7 l - l l - l l - l l - l l - l l-2 l-2 l-8 l-9 l-10 l-11 1-12 1-13 l-3 l-3 l-3 l-3 l-3 l-3

1-14 l-4 1-15 l-4 1-16 l-4

2-l 2-l 2-2 2-l 2-3 2-l

2-4 2-2 2-5 2-2

3-l 3-l 3-2 3- l 3-3 3-l 3-4 3-l 3-5 3-l 3-6 3-l 3-7 3-l

3-8 3-2 3-9 3-2 3-10 3-3 3-11 3-3 3-12 3-3 3-13 3-3 3-14 3-3

3-15 3-3 3-16 3-3 3-17 3-3 3-18 3-3

This manual supersedes TM 5-684/NAVFAC MO-200/AFM 91-3, dated 20 April 1979

SECTION IV-INSULATORS

Function of insulators Testsofinsulators Inspection and repair of insulators Cleaningofinsulators

SECTION V-BUS STRUCTURES

Definitionofbus structures Maintenance of bus structures Cleaningofbus structures Testingofbus structures

SECTION VI-INSTRUMENT TRANSFORMERS

Definitions of instrument transformers Short-circuiting dangers Maintenanceofinstrumenttransformers Tests of instrument transformerss

SECTION VII-BUSHINGS

Definition of bushings Type of bushings covered Maintenanceofbushings Bushingpowerfactortests Bushing insulation resistance test

CHAPTER 4. OVERHEAD DISTRIBUTION

SECTION I-ASSOCIATED OVERHEAD DISTRIBUTION GUIDANCE

Relevant overhead distribution guidance General construction guidancee

SECTION II-DEFINING VOLTAGE NOMENCLATURE

Voltage terminology Voltagelevelclassification Voltagedeliveryusage Voltage origination point Voltage terminology usage in this manual

SECTION III-TYPES OF MAINTENANCE

Componentlinemaintenance Other types of line maintenance

SECTION IV-WOOD POLES

Lifespanofwoodpoles Supplementary data on wood poles Wood pole record keeping and inspections Wood pole maintenance crew instructions Wood pole spot inspection procedures Wood pole-by-pole inspection procedure Determination of wood pole adequacy Woodpolereplacement Woodpolereinforcement

SECTION V-CROSSARMS, BRACES, AND PLATFORMS

Polecrossarms Pole braces Pole platforms

SECTION VI-MAINTENANCE WOOD PRESERVATION

Initialwoodtreatment In-place wood treatment above ground Wood pole treatment at or below the ground line

SECTION VII-METAL POLES

Metalpoleusage Distribution line metal poles Transmission line metal towers Pole-linemetalhardware Paintingofmetalpoles

Paragraph Page

3-19 3-20 3-21 3-22

3-4 3-4 3-4 3-5

3-23 3-7 3-24 3-7 3-25 3-7 3-26 3-7

3-27 3-7 3-28 3-7 3-29 3-7 3-30 3 -8

3-31 3 -8 3-32 3-8 3-33 3-8 3-34 3-10 3-35 3-12

4-1 4-2

4 -3 4 -4 4-5 4 -6 4-7

4 -8 4 -9

4-4 4-4

4-10 4-4 4-11 4-4 4-12 4-4 4-13 4-6 4-14 4-6 4-15 4-7 4-16 4-9 4-17 4-10 4-18 4-10

4-19 4-11 4-20 4-12 4-2 1 4-12

4-22 4-13 4-23 4-13 4-24 4-13

4-25 4-14 4-26 4-15 4-27 4-15 4-28 4-15 4-29 4-15 ii

Paragraph

SECTION VIII-CONCRETE POLES

Concrete pole overvieww Concrete pole foundations

SECTION IX-OVERHEAD OPEN WIRE CONDUCTORS

Overhead conductor construction Overheadconductormaterial Overhead conductor covering Overheadconductorsag Overheadconductordamage Overheadconductorrepairs

SECTION X-OVERHEAD CABLE

Overhead cable construction Overhead cable repair requirements

SECTION XI-CONDUCTOR CONNECTIONS

Overhead line conductor requirements Overhead line conductor splices Overhead line connections Overheadline armor rods _

SECTION XII-POLE-LINE INSULATORS

Pole-line insulator related material Insulator operating performance Types of pole-line insulators Pole-line insulator class requirements

SECTION XIII-GUYS

Guy functional requirements Guy strand Anchor assemblies Guy attachments Guystraininsulators

SECTION XIV-TREE TRIMMING

Tree trimming objectivess Tree trimming clearances and climbing space Tree trimming tools Typesoftreetrimming Tree trimming instructions Treating a tree trimming wound Treeremovalmethods......, Tree killing chemicalss Poisonous plants

SECTION XV-LIVE-LINE MAINTENANCE

Live-line maintenance requirements Categories of energized-line maintenance Energized-linemethods Live-line operations

SECTION XVI-AERIAL LIFT REQUIREMENTS

Aerial lift construction Aerial lift specificss

CHAPTER 5. UNDERGROUND AND SUBMARIK E CABLES

SECTION I-ASSOCIATED GUIDANCE

Relevant cable guidance General construction guidance

SECTION II-SAFETY PRECAUTIONS

Cablesafety Structure safety

SECTION III-INSPECTION

Frequency of underground system inspections Structureinspections Cableinspections Underground equipment inspections

4-30 4-31

4-15 4-15

4-32 4-16 4-33 4-16 4-34 4-16 4-35 4-16 4-36 4-17 4-37 4-18

4-38 4-18 4-39 4-18

4-40 4-18 4-41 4-19 4-42 4-20 4-43 4-22

4-44 4-22 4-45 4-22 4-46 4-22 4-47 4-24

4-48 4-25 4-49 4-25 4-50 4-25 4-51 4-26 4-52 4-27

4-53 4-29 4-54 4-30 4-55 4-31 4-56 4-31 4-57 4-32 4-58 4-32 4-59 4-32 4-60 4-33 4-61 4-33

4-62 4-33 4-63 4-33 4-64 4-34 4-65 4-34

4-66 4-35 4-67 4-35

5-l 5-l 5-2 5-l

5-3 5-2 5-4 5-2

5-5 5-6 5-7 5-8

5-3 5-3 5-3 5-3

Page

TM 5-684/NAVFAC MO-2OO/AFJMAN 32-1082

SECTION IV-MAINTENANCE AND REPAIR OF DUCT SYSTEMS

Structure maintenance and repair Duct line maintenance and repair

SECTION V-CABLE FAULTS AND FAULT LOCATIONS

Cable faults Visual methods of cable fault locating Determining type of cable fault Cable fault locating test methods Simplifying cable fault locating Cable fault locating equipment Tracing the cable fault signal Selecting cable fault locating methods

SECTION VI-CABLE REPAIR

Undergroundcablerepairs Submarinecablerepairs Cablerepairsafety Makingcablerepairs Solid dielectric cable repairs Other cable insulation and covering repairs Othercablecomponentrepairs

SECTION VII-CABLE TESTING

Cabletests Cable insulation resistance tests Cable overvoltage testss Cable power factor testss Cablemoisturetests Cabletestrecords

SECTION IX-UNDERGROUND CORROSION CONTROL

Importanceofcorrosioncontrol Types of corrosionn Prevention of corrosionl

CHAPTER 6. OUTDOOR LIGHTING

SECTION I-LIGHTING AND CIRCUIT TYPES

Outdoorlightinguse Types of lighting circuits

SECTION II-MULTIPLE TYPE LIGHTING

Multiple type lighting system components Luminaires Lamp types Luminaire components Luminairemaintenance Multiple type lighting controls

SECTION III-LIGHT DISTRIBUTION

Light distribution standards Roadway lighting Floodlighting Airfield lighting

SECTION IV-SERIES TYPE AIRFIELD LIGHTING

Series type lighting system components Series type lighting control and protection Series type lighting power supply equipment Maintenance and troubleshooting series type lighting

CHAPTER 7. TRANSFORMERS AND REGULATORS

SECTION I-CONSIDERATIONS

Voltage provis ions covered. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .~ Defining transformer and regulator characteristics Transformerclassification

Paragraph Page

5-9 5-10

5-11 5-12 5-13 5-14 5-15 5-16 5-17 5-18

5-19 5-10 5-20 5-10 5-2 1 5-11 5-22 5-11 5-23 5-12 5-24 5-12 5-25 5-13

5-26 5-14 5-27 5-14 5-28 5-15 5-29 5-16 5-30 5-17 5-31 5-17

5-32 5-18 5-33 5-18 5-34 5-18

6-1 6-2

6 - l 6 - l

6-3 6 - l 6-4 6 - l 6-5 6 - l 6-6 6-2 6-7 6-2 6-8 6-3

6-9 6-10 6-11 6-12

6-13 6-14 6-15 6-16

6-6 6-6 6-7

7-1 7-2 7-3

7-l 7-l

7-l iv

TM 5-684/NAVFAC MO-200/AFJMAN 324082

SECTION II-MAINTENANCE

Transformer inspection and maintenance frequencies Transformer inspectionss Transformer testing guidance Solid (winding) insulation tests Transformer insulation liquids

CHAPTER 8. OVERCURRENT PROTECTIVE AND SWITCHING DEVICES

SECTION I-CONSIDERATIONS

Circuit interrupting devices Location of protective and switching devices Protective and switching device instruction manuals Protective and switching device records

SECTION II-FUSES

Fuseusage Fuse operating safety considerations Fuse replacement Fuse maintenance

SECTION III-SWITCHES

Switchusage Operationofswitches Switch maintenance

SECTION IV-CIRCUIT BREAKERS

Circuitbreakerusage Frequency of circuit breaker maintenance Maintenance of nonmetalclad switchgear circuit breakers Maintenance of metalclad circuit breakers Maintenance of low-voltage power circuit breakers Repairofcircuitbreakers

SECTION V-MISCELLANEOUS DEVICES

.. Circuit switchers

Automaticcircuitreclosers

CHAPTER 9. OVERVOLTAGE PROTECTION

SECTION I-CONSIDERATIONS

Overvoltage protection Lightning-induced voltage surges System operating voltage disturbances Surge limiting protective device requirements

SECTION II-SURGE (LIGHTNING) ARRESTERS

Definition of a surge arrester Typesofsurgearresters Classification of surge arresters Maintenance of surge arresters

SECTION III-OTHER DEVICES

Surgeshieldingdevices Surge capacitors Surgeprotectivegaps Surgebypassresistors

CHAPTER 10. GROUNDING

SECTION I-CONSIDERATIONS

Basic principles of grounding Groundingprovisions

SECTION II-MAINTENANCE

Groundingmaintenancesafety Visual inspection of grounds Galvanic corrosion of grounds

SECTION III-TESTING

Ground resistance tests Groundvaluemeasurements

Paragraph Page

7-4 7-2 7-5 7-3 7-6 7-6 7-7 7-6 7-8 7-7

8 - l 8-2 8-3 8-4

8-1 8-1 8-1 8-1

8-5

8-7 8-8

8-1 8-2 8-2 8-3

8-9 8-10 8-11

8-3

8-12 8-13 8-l4 8-l5 8-16 8-l7

8-6 8-6 8-7 8-10 8-12 8-12

8-18 8-14 8-l9 8-14

9 - l 9-2 9-3 9-4

9-5

9-7 9-8

9-9 9-10 9-11 9-12

10-l 10-2

10-3 10-4 10-5

10-6 10-7

9-l 9-1 9- l 9 - l

9 - l 9 - l 9-2 9-2

9-2 9-3 9-3 9-3

10-l 10-l

10-l 10-l 10-2

10-2 10-2

V

Methods of measuring ground resistances Methods of reducing ground resistances

CHAPTER 11. RELAYS AND CONTROLS

SECTION I--RELAYS, ELECTRIC POWER APPARATUS

Relay functions Relay fundamentalss Relay constructionn Relaymaintenanceperiods Relaygeneralfieldinspection Relay performance testss Common electromechanical relay tests Relaytestequipment Relay repairs

SECTION II-CONTROLS

Control functions Preventive maintenance and inspections of controls Troubleshootingcontrols

CHAPTER 12. INSTRUMENTS AND METERS

SECTION I-CONSIDERATIONS

Electrical Instruments Electricalmeters Validity of electrical measurements Fixed installations of instruments and meters Portable instruments and meters Inspections of instruments and meters Tests of instruments and meters

SECTION II-PREVENTIVE MAINTENANCE

Mounting of instruments and meters Installation of instruments and meters Maintenance of instruments and meters

SECTION III-CALIBRATION AND ADJUSTMENT

Accuracy check of instruments and meters Adjustment of instruments and meters

SECTION IV-REPAIRS

Paragraph Page 10-8 10-2 10-9 10-4

11-l 11-l 11-2 11-l 11-3 11-l 11-4. 11-2 11-5 11-2 11-6 11-3 11-7 11-3 11-8 11-4 11-9 11-5

11-10 11-6 11-11 11-7 11-12 11-8

12-l 12-1 12-2 12-1 12-3 12-1 12-4 12-1 12-5 12-1 12-6 12-1 12-7 12-1

12-8 12-9 12-10

12-2 12-2 12-2

12-11 12-12

12-2 12-2

Field repairs of instruments and meters Shop repairs of instruments and meters

SECTION V-TROUBLESHOOTING

Temperature influence on instruments and meters Stray-field influence on instruments and meters Calibration of instruments and meters Other instrument and meter considerations

CHAPTER 13. POWER CAPACITORS

SECTION I-CONSIDERATIONS

Description of power capacitors Types of power capacitors Application of power capacitors Permissible power capacitors dielectrics

SECTION II-MAINTENANCE AND INSPECTION

Ensuring safe capacitor deenergizing Power capacitor inspection schedule Ventilation of power capacitors Temperature influence on power capacitors Exposure influence on power capacitors Voltage influence on power capacitors Fusesforpowercapacitors

SECTION III-TESTS

12-13 12-4 12-14 12-4

12-15 12-5 12-16 12-5 12-17 12-6 12-18 12-6

13-l 13-1 13-2 13-1 13-3 13-1 13-4 13-1

13-5 13-1 13-6 13-1 13-7 13-1 13-8 13-2 13-9 13-2 13-10 13-2 13-11 13-2

Field tests for power capacitors ........................................................... 13-12 13-2 Terminal tests of power capacitors ........................................................ 13-13 13-3 Leak tests of power capacitors ............................................................ 13-14 13-3

Vi

CHAPTER 14. STORAGE BATTERIES

SECTION I-CONSIDERATIONS

Battery usage Battery types Battery safetyy General battery maintenance procedures

SECTION II-FLOODED LEAD-ACID BATTERY MAINTENANCE

Visual inspections of batteries Measurements of battery condition Battery maintenance specifics Testingofbatteries

SECTION III-FLOODED LEAD-ACID BATTERY CHARGING

Battery charging precautions Battery charging considerationss Normal floating battery charge Equalizing battery charge

SECTION IV-VALVE-REGULATED LEAD-ACID CELL BATTERIES

Valve-regulated cell differences Charging or valve-regulated cells Temperature compensation for valve regulated cells

SECTION V-Nickel-cadmium cell batteries Description of nickel-cadmium batteries Requirements for nickel-cadmium batteries

SECTION VI-CHECKS AND TROUBLESHOOTING

Inspectionsofbatteries Troubleshooting batteries

SECTION VII-BATTERY CHARGING EQUIPMENT

Batterychargingrequirement Rectifier type battery chargers Accessories for battery chargers Maintenanceofbatterychargers

SECTION VIII-PLACING A NEW BATTERY IN SERVICE

Placing lead-acid batteries in service Placing nickel-cadmium batteries in service Connections for batteries

SECTION IX-PUTTING A BATTERY IN STORAGE

Batterystorageprocedure Periodic check of a stored battery

SECTION X-REPLACEMENT AND DISPOSAL

Replacementofa battery Disposal of batteries

CHAPTER 15. TOOLS AND EQUIPMENT

SECTION I-USE

Electrical tools and equipment standards Tools and equipment classification Tools and equipment safe use

SECTION II-HAZARDOUS MATERIAL PROCEDURES

Hazardous substances Asbestos containing materials Polycholorinated biphenyl (PCB) insulated equipment Sulfur hexifluoride (SF,) insulated equipment Chemicals used for outside maintenance

SECTION III-PROTECTIVE EQUIPMENT

Protective electrical rubber goods Helmets for electrical work Barrier protection for electrical work Visual warnings for electrical work Protective grounding of deenergized lines

Paragraph Page

14-1 14-2 14-3 14-4

14-1 14-1 14-3 14-4

14-5 14-4 14-6 14-6 14-7 14-7 14-8 14-8

14-9 14-10 14-11 14-12

14-9 14-9 14- 10 14-10

14-13 14-14 14-15

14-11 14-11 14-11

14-16 14- 12 14-17 14-12

14-18 14-14 14-19 14- 14

14-20 14-14 14-21 14-15 14-22 14-15 14-23 14-15

14-24 14-16 14-25 14-16 14-26 14-16

14-27 14-17 14-28 14-17

14-29 14-30

14-17 14-17

15-1 15-1 15-2 15-1 15-3 15-1

15-4 15-1 15-5 15-1 15-6 15-2 15-7 15-2 15-8 15-2

15-9 15-2 15-10 15-3 15-11 15-3 15-12 15-3 15-13 15-3 vii

SECTION IV-CLIMBING EQUIPMENT

Body belts, climber straps, and safety straps Climber gaffs Ladders for electrical work

SECTION V-LIVE-LINE TOOLS

Certification of live-line tools Careoflive-line tools Repairs of live-line tools

SECTION VI-HAND TOOLS

Handtoolsafety General requirements for hand tools Power tool electric shock hazard avoidance

SECTION VII-ROPE

C a r e o f r o p e . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15-23 15-8 Splicingrope . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15-24 15-8

SECTION VIII-LARGE PORTABLE AND MOBILE EQUIPMENT

Large portable and mobile equipment covered Large portable and mobile equipment maintenance

SECTION IX-ELECTRICAL INSPECTING AND TESTING EQUIPMENT

Minimum facility field test equipment requirements Maintenanceoftestequipment

CHAPTER 16. ELECTRICAL SERVICE INTERFERENCE

SECTION I-DISTURBANCE PRODUCERS

Electrical power quality . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16-l 16-1 Electromagnetic interference (EMI) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16-2 16-1 Harmonic interference . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16-3 16-1

SECTION II-ELECTROMAGNETIC INTERFERENCE

Electrical distribution system interference Electrical noise origin Electrical interference during bad weather conditions Methods of electrical interference location Instrument requirements for checking electrical interference Communication interference from electrical lines

SECTION III-HARMONIC INTERFERENCE

Harmonic causing devices and their effects Electric power quality responsibilities Electric power quality data Electrical distribution system interference

CHAPTER 17. MAINTENANCE SCHEDULES

SECTION I-CONSIDERATIONS

M a i n t e n a n c e p l a n n i n g . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17-l 17-l Maintenance priorities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17-2 17-l

SECTION II-SCHEDULES

Maintenance frequency guides . . . . . . . . . . , Revisions to maintenance frequencies

APPENDIX A-REFERENCES

APPENDIX B-BIBLIOGRAPI-IY

APPENDIX C-ADDITIONAL WOOD POLE DATA

INDEX

Paragraph Page

15- 14 15-4 15-15 15-5 15-16 15-5

15-17 15-6 15- 18 15-6 15-19 15-7

15-20 15-7 15-21 15-7 15-22 15-7

15-25 15-10 15-26 15-10

15-27 15-11 15-28 15-11

16-4 16-1 16-5 16-1 16-6 16-3 16-7 16-3 16-8 16-3 16-9 16-4

16-10 16-11 16-12 16-13

16-4 16-4 16-4 16-5

17-3 17-4

17-l 17-l

Figure 3- l .

3-2.

4- l .

4-2.

4-3.

. . .v i i i

LIST OF FIGURES

Page Connections for ungrounded specimen power factor test Connections for hot- and cold-collar tests Details showing various horizontal dimensions necessary to provide recommended climbing space Details showing various vertical dimensions necessary to provide recommended climbing space Sample format for recording pole inspection and maintenance data

3-12 3-12 4-2 4-3 4-5

4-4.

4-5.

4-6.

4-7.

4-8.

4-9.

4-10.

4-11.

4-12.

4-13.

4-14.

4-15.

4-16.

4-17.

4-18.

4-19.

4-20.

4-21.

4-22.

4-23.

4-24.

4-25.

4-26.

5-1.

5-2.

5-3.

6-1.

10-l.

10-2.

10-3.

10-4.

10-5.

11-1.

11-2.

11-3.

11-4.

11-5.

12-l.

12-2.

13-1.

13-2.

14-1.

15-1.

15-2.

15-3.

15-4.

c-1.

c-2.

c-3.

Table 3-l.

3-2.

3-3.

3-4.

4- l .

4-2.

4-3.

4-4.

4-5.

5-l.

6-1.

7-1.

TM 5-684/NAVFAC MO-200/AFJMAN 32-1082

Typical pole branch and key The increment borer . . .

Sealing a test hole with a treated wooden

Wood stub pole Steelreinforcingforawoodpole Nozzle for application of a compound preservative Measuring sag on line conductors Measuring sag on service drop conductors Single-sleeve compression splice Double-sleeve compression splice Automatictensionsplice Clamp connectors Internally-firedtapcomponents Types of insulators commonly installed Steepness and flatness limits for guy strands Typesofpatentanchors Loganchor Wood-polepushbrace Sideanchor Self-supporting, hog-guyed pole Recommended minimum clearances for tree trimming Tree trimming to clear electric wires Removing a limb overhanging wires. . . . . .,....* Terminal equipment and cable connection diagrams Cable fault waveform reflections Insulation power factor equivalent circuit and vector diagram Light distribution patterns for roadway lighting Direct-reference or two-point ground test Auxiliary ground method Ground resistance measurement, three-point method Field setup and curve for fall-of-potential method Methods of soil treatment for lowering of ground resistance Typical test connection for a nondirectional overcurrent relay Typical test connections for directional overcurrent relays Typical test connections for a differential relay Typical test connections for reactance distance relays Typical test connection for a pilot wire relay Method of connecting a phantom load for a field test, if on a single-phase, two-wire watthour meter Method of connecting a phantom load for field test, if on a three-phase, three-wire watthour meter Terminal-to-terminal voltage test circuit Terminal-to-case insulation test circuit Battery warning sign Methodsoffinishingropeends Makinganeyesplice Makingashortsplice Making a long splicee Twelve-inch (300-millimeter) pole with l-inch (25-millimeter) surface decay Twelve-inch (300-millimeter) pole with 2-inch (50-millimeter) surface decay Twelve-inch (300-millimeter) pole with 4-inch (l00-millimeter) radial heart-rot

Infrared hot spot gradients . . . . . .* Cleaning ceramic insulators and bushings .

LIST OF TABLES

Temperature correction factors for power factor Insulation resistance tests on electrical apparatus and systems Sapwood thickness in poles Pole setting depth Tiewirerequirements Relation of the NESC voltage levels to ANSI C29 class ratings Numberofguywireclamps Typical power factor ranges for various cable insulating materials Floodlight beam descriptionss Transformer inspection and maintenance checklist

Page 4-6 4-8 4-8 4-11 4-12 4-14 4-17 4-17 4-19 4-19 4-20 4-20 4-21 4-23 4-25 4-26 4-27 4-28 4-29 4-30 4-30 4-3 1 4-32 5-8 5-9 5-16 6-5

10-3 10-3 10-4 10-5 10-6 11-3 11-4 11-4 11-5 11-6 12-3 12-3 13-3 13-4 14-2 15-8 15-8 15-9 15-9 c-3 c-3 c-4

Page 3-2 3-6 3-11 3-13 4-8 4-10 4-24 4-24 4-30 5-17 6-5 7-3 ix

7-2.

7-3.

8- l .

8-2.

11-l.

11-2.

12-l.

12-2.

13-1.

13-2.

14-1.

14-2.

14-3.

14-4.

15-1.

16-1.

17-l.

Insulation resistance conversion factors to 20°C Satisfactorypowerfactors Troubleshooting chart for oil problems Troubleshooting chart for power circuit breakers Typical laboratory relay test equipment Troubleshooting chart for general control equipment Troubleshooting chart for indicating instruments Troubleshooting chart for recording instruments and meters Maximum ambient temperatures for continuous operation Capacitor bank oil switch maintenance Battery room warning notice Suggested test accessory list for battery maintenance Equalizingcharge Charging of nickel-cadmium batteries Suggested list of minimum facility-wide field test equipment Harmonic distortion limits Maintenance frequencies

Page 7-6 7-8 8-12 8-13

11-6 11-8 12-6 12-6 13-2 13-3 14-2 14-9 14-11 14-13 15-11 16-5 17-l

_.--.-I

CHAPTER 1

INTRODUCTION

Section I - PRIMARY CONSIDERATIONS

1-1. Purpose and scope.

This manual provides guidance for the maintenance and repair of exterior electrical distribution sys-tems. New construction of exterior electrical facil-ities, even when funded from maintenance appro-priations, should comply with the appropriate design criteria. These systems include substations, overhead and underground electrical distribution systems, exterior lighting systems, and electrical apparatus and components. Guidance for genera-tors and interior electrical systems (600 volts and less) are covered in the following publications:

a. TM 5-683/NAVFAC MO-ll6/AFJMAN 32-1083.

b. TM 5-685/NAVFAC MO-912.

c. MIL-HDBK-1003A/ll.

1-2. References.

Appendix A contains a list of references used in this manual.

1-3. Application of codes and publications.

The information in this manual should not super-sede equipment manufacturers’ instructions and re-quirements. When conflicts exist the most rigorous requirement should be followed. A11 maintenance and repair of electrical systems should be performed in such a manner that the completed work will conform to the publications listed below to the de-gree indicated.

a. Codes. The listed codes and standard contain rules (both mandatory and advisory) for the safe installation, maintenance, and operation of electri-cal systems and equipment.

(1) The National Electrical Code (NEC), NFPA 70.

(2) The National Electrical Safety Code

(NESC), ANSI C2.

(3) Occupational Safety and Health (OSHA), General Industry Standards, 29 CFR 1910.

b. Nongovernment publications. Other nongov-ernment publications referenced in this manual ex-pand guidance in line with recognized industry standards. The most extended coverage on recom-mended practices for electrical equipment mainte-nance, and one that should be used in conjunction with both the NEC and the NESC, is NFPA 70B.

Publication NFPA 70B is recommended as a useful reference in preparing contract requirements for maintenance to be done by outside service agencies.

1-4. Standards of maintenance.

Electrical systems will be regularly maintained to ensure continued compliance with the codes and publications referred to in appendix A. Such main-tenance will prevent system and equipment failures and ensure maximum safety and efficiency in the utilization of the facilities. At each installation, a program for proper maintenance should be estab-lished and effectively followed. This program should include the scope of work, intervals of performance, and methods of application including safety require-ments, practices and procedures. When a number of items require servicing or renewal over a period of years, a proportionate number should be main-tained each year. For instance, if there are 100 transformers on the system, requiring maintenance at 5-year intervals, the work should be performed on 20 transformers each year.

a. Predictive maintenance. A predictive mainte-nance program is more desirable than routine re-curring maintenance. Predictive testing should oc-cur periodically but actual maintenance or replacement should take place only when necessary.

An automated testing and record management sys-tem should be utilized where available. Where such a system is not available, its acquisition is recom-mended.

b. Sample testing formats. Testing formats for cable, circuit breakers, switchgear, and transform-ers are provided in NFPA 70B. These formats can be revised as needed for local requirements.

1-5. Maintenance responsibilities.

An adequate supply of dependable electrical energy is essential for the accomplishment of the installa-tion mission. Adherence to a well planned and well organized maintenance program, including the es-tablishment of specific goals and follow-up proce-dures will ensure the proper functioning of the equipment in the electrical distribution system.

a. Electrical supervisor. As used in this manual, the title electrical supervisor indicates the indi-vidual assigned the responsibility for maintenance of electrical distribution systems and equipment.

The maintenance of electrical distribution systems is the responsibility of the installation’s commander and a specific duty of an Army director of public

1-1 works, a Navy public works officer, or an Air Force base engineer. Operation and maintenance are a single staff responsibility, and frequently the same personnel will perform both functions.

b. Electrical supervisor trical supervisor will:

responsibilities. The elec-

(1) Initiate positive action to remove, or reduce to a minimum, the cause of recurrent maintenance problems.

(2) Carry out maintenance inspections and ser-vices so there is a minimum of interference with user activities.

(3) Provide for the accomplishment of as much work as possible during each maintenance visit, and ensure that spot checks, inspections, and repairs are made on all components of the electrical facil-ities.

(4) Ensure that an adequate set of up-to-date records are maintained for each major component of all systems.

(5) Develop standard operating procedures which are in compliance with applicable safety re-quirements.

(6) Train maintenance personnel to improve their efficiency and to observe safety requirements.

1-6. Maintenance records.

One of the most important sources of information for aiding inspections, maintenance, or tests is a comprehensive file of equipment and service records. In addition to indicating basic information required for proper inspection of the equipment, these records will indicate where trouble has been experienced and where special procedures may be warranted.

a. Equipment documents. There are a variety of documents which indicate the equipment provided and how to keep it operating properly. These docu-ments should be provided when new facilities are built, or existing facilities modified. These records should be obtained from the construction agency as soon as possible, preferably before the electrical su-pervisor accepts maintenance responsibility. These documents should address any warranty provisions applicable to the equipment. Equipment documents determine maintenance practices and should be in-cluded as a part of the maintenance records of the facility. The most common documents are listed be-low.

(1) Instruction leaflets and manuals. Each piece of major electrical equipment purchased should be accompanied by an instruction leaflet or manual outlining the desired methods of installa-tion, operation, and maintenance. These instruc-tions contain valuable information on maintenance practices, part designations, and ordering proce-dures. Spare parts lists are a vital part of these records.

(2) Installation drawings. Maintenance is often affected by the manner in which the equipment is installed. For convenience, and as a means of expe-diting maintenance, as-built installation drawings should be readily accessible to maintenance and inspection personnel.

(3) Wiring diagrams. Adequate and up-to-date wiring diagrams are important for proper mainte-nance. Diagrams facilitate locating troubles, which otherwise may require extensive probing and test-ing procedures. Such diagrams should be readily available to maintenance personnel.

(4) Distribution maps. Maps showing locations of distribution lines, wire sizes, transformer sizes, pole numbers, voltage classes, and sectionalizing devices are vital. Up-to-date distribution maps mounted on the maintenance or electrical shop wall are very useful.

b. Service records. Service records constitute a history of all work performed on each item of equip-ment and are helpful in determining the overall condition and reliability of the electrical facilities.

Service records should show type of work (visual inspection, routine maintenance, tests, repair), test results (load, voltage, amperes, temperature), and any other remarks deemed suitable. It is highly recommended that service records should include a log of incidents and emergency operating proce-dures.

(1) Logs of incidents. Logs of incidents, such as power failures, surges, low voltage, or other system disturbances are very useful in planning and justi-fying corrective action.

(2) Emergency operating instructions. Emer-gency work on electrical facilities is safer and quicker when instructions are prepared and posted in advance. Instructions should be prepared for each general type of anticipated emergency, stating what each employee will do, setting up alternatives for key personnel, and establishing follow-up proce-dures. Instructions should be posted in the electri-cal shop, security guard office, substations, operat-ing areas, and such other locations as the responsible supervisor deems advisable. Employees should be 1isted by name, title, and official tele-phone number. These instructions should empha-size safety under conditions of stress, power inter-ruptions, and similar emergencies.

1-7. Priority and scheduling.

a. Priority. In regard to the support of the instal-lation physical plant, it is the policy of the military l - 2 departments that, in order of priority, maintenance manders to meet local requirements. Service in-should be second only to operations. It must be tervals may be lengthened only when justified by systematic, and it must be timely. extenuating circumstances. Whenever service inter-

b. Scheduling. The following chapters provide vals or other guidance in this manual differs from data on service intervals, procedures, and practices. information supplied by the manufacturer, the more Modifications may be made by installation com- stringent procedure should be followed.

Section II - SAFETY

1-8. Minimizing hazards.

Material specifications, construction criteria, instal-lation standards, and safe working procedures have been developed to minimize hazards. All work and materials should conform to the latest accepted pro-cedures and standards, as defined in publications listed or referred to in this manual.

1-9. Qualification of electrical workers.

Due to the inherent hazards encountered in the maintenance of electrical distribution systems and equipment, it is essential that all electrical workers be thoroughly trained and be familiar with the equipment and procedures to be followed.

1-10. Certification of electric workers.

Properly trained electric workers will be certified in accordance with applicable publications.

1-11. Public safety.

All necessary precautions will be taken to warn the public of electrical hazards or other conditions which may constitute a danger. This is especially true of temporary hazards due to work in progress.

1-12. Personnel safety.

Any work on or close to electrical equipment of any kind should be considered dangerous and proper safety precautions will be taken. All personnel who perform work of any kind on or near electrical equipment must be familiar with and observe all safety precautions.

a. Safety first. Two safety rules are mandatory as follows:

(1) Consider all electrical equipment to be en-ergized until it is known positively (as by the pres-ence of grounding clamps) that it is not energized.

Comply with regulations and safety instructions contained in NEC and NESC, the applicable depart-mental publications, and special publications issued by the local command.

(2) Work may be done on energized lines and equipment only by personnel qualified by their job descriptions for that voltage level. Job descriptions should require actual hands-on work service periods which meet local utility and the International Brotherhood of Electrical Workers approval. All tools and equipment must be maintained in proper operating order, be suitable for the maximum volt-age level involved, and should be periodically tested for compliance with all safety requirements. De-partmental publications should be consulted for specific requirements in each voltage level.

b. Service safety manuals. This manual addresses some safety requirements, but users should also be familiar with the service safety manuals TM 5-682, NAVFAC P-1060, and AFMAN 32-1078.

c. Personal protective temporary grounding. This is temporary grounding installed to protect workers engaged in de-energized line maintenance. The grounds are provided to limit the voltage difference between any two accessible points at the work site to a safe value. An expanded discussion of protective grounding principles and practices is contained in IEEE 1048, NFPA 70B and “The Lineman’s and Cableman’s Handbook”.

1-13. Live-line maintenance.

Aerial live lines are energized lines that are being tested, repaired, and maintained more and more by electrical utilities to reduce the number of outages or service interruptions. The use of such procedures on DOD installations requires that good practice be followed and that there is no conflict with local facility rules.

a. Good practice. Personnel doing live-line work should have satisfactorily completed a formal train-ing course of instruction and be examined periodi-cally. Live-line maintenance usually means any maintenance activity performed on energized elec-trical conductors or equipment with a phase-to-phase voltage exceeding 600 volts. It usually does not include such activities as switching, hardware tightening, climbing, hole digging, pole setting, con-ductor stringing, etc. The performance of this work requires equipment and tools that meet applicable industry standards for energized-line maintenance.

b. Local facility rules. Two considerations affect facility rules on the type and extent of live-line maintenance permitted: availability of qualified fa-cility personnel and equipment versus the facility’s requirement for uninterrupted operation. If local missions prevent electrical power shutdowns and local facilities are not qualified to perform live-line l-3 work, then a live-line contractor may need to be and are not intended to substitute for training or hired on a scheduled and/or a nonscheduled basis. operating procedures; for meeting specific industry General energized-line maintenance practices cov- guidelines; or for meeting federal, state, local, or ered in chapter 4, section VI, serve only as a guide facility regulations and rules.

Section III - AVOIDING PROBLEMS

1-14. Operating conditions.

Always observe the four cardinal rules of electrical maintenance.

a. Keep the equipment clean.

b. Keep the equipment dry or lubricated as ap-propriate to the part.

c. Keep screwed parts tight.

d. Prevent friction on moving parts.

1-15. Detecting potential trouble.

Diagnostic devices, where available, allow checking the system for potential trouble before it occurs.

Potential problems may also be detected by the use of four of our five senses: see, hear, touch, and smell.

a. See. Many abnormal conditions can be de-tected by visual inspection: some of the patterns identifiable by sight are cleanliness, distortion, color, misalignment, size, and position.

b. Hear. Changes in the intensity of noise, pitch, or frequency are significant clues to operational changes and possible malfunctions. Some of the sound patterns that may indicate malfunctioning are squeaking, rattling, knocking, and whistling.

c. Touch. Among the damaging characteristics which may be identified by touch are vibration, wet-ness, and heat. Caution should be exercised in touching components which are normally hot enough to burn personnel on contact or live parts with hazardous potentials.

d. S m e l l . Burning insulation and battery fumes provide distinctive odors which signal component deterioration.

1-16. Electrical connections.

Connections are an essential part of any electric circuit. Good electrical contact is essential. Dirt is the enemy of good contact. Whenever an electrical connection is to be made, extreme care must be taken to ensure all dirt, rust, corrosion, insulation, oil, and other contaminants are removed. The con-tact surfaces should be bright, clean metal. This requirement applies to connections made by solder-ing, clamps, twisted sleeves, compression fittings, or any other method.

a. Aluminum. Connections of aluminum items should always include the application of a joint com-pound which will ensure metallic contact by dissolv-ing the aluminum oxide which is always present on aluminum and aluminum alloy surfaces in air. The contact surfaces of aluminum conductors and con-nectors should first be vigorously cleaned with a stainless steel wire brush to a bright finish and then immediately coated with the aluminum-oxide inhibiting compound.

b. Copper. Copper contact surfaces should be cleaned, but not connector barrels. The barrels should be cleaned on the inside.

c. Dissimilar metals. Only connectors designed for the purpose should be used to connect aluminum and copper items.

d. Testing. Accessible connections may be tested using an infrared detector only if the connection is under load as covered in chapter 3, section I.

l-4

TM 5-684/NAVFAC MO-200/AFJMAN

CHAPTER 2

INSPECTION AND TESTS

32-1082

Section I - PERFORMANCE

2-1. Determining equipment condition.

The ability of equipment to perform its function, or to continue its function for its normal life cycle, must be determined if the distribution system is to operate dependably and economically. The condition of equipment can be determined by two methods:

inspection and tests. Such things as broken insula-tors or oil leaks can easily be determined by inspec-tions, but other details such as the condition of transformer oil or a trip setting for a circuit breaker can be determined only by tests. The scope of in-spection and tests is dependent on the type and complexity of the equipment, and the results de-sired. Inspections are normally visual, but hearing, touching, and smelling can also indicate problem areas. Tests can be electrical, physical, or chemical, or combinations of these. The selection of the test to be made may be at least partially determined by the availability of test equipment and of personnel ca-pable of using it.

-- 2-2. Reasons for inspections and tests.

Inspections and tests are performed for several rea-sons.

a. Preventive maintenance. This includes routine testing of operating equipment and periodic testing of nonoperating components to anticipate and cor-rect possible equipment failure before it occurs.

b. Maintenance proof testing. This is testing to ensure that maintenance/repair was done properly.

This should be done when maintenance and/or re-pair are complete, and to show whether the equip-ment is operable and properly connected.

2-3. Associated test guidance and records.

Tests are ordinarily used in the field to determine the condition of various elements of an electrical power-distribution system. The data obtained in these tests provide information that is used to de-termine whether any corrective maintenance or re-placement is necessary or desirable. The ability of the element to continue to perform its design func-tion adequately can be ascertained. Also the gradual deterioration of the equipment over its service life can be charted. Records must include factory test data provided with shop drawing submittals, accep-tance testing data, and each routine maintenance test, so that the history of the equipment may be available for future reference. Records should be maintained to indicate what test data are required and what means are to be used to provide this data.

Nondestructive maintenance tests can cause insula-tion breakdown with no warning. A plan for coping with this possibility should be included in the test procedures.

a. Qualifications of test operators. If a testing pro-gram is to provide meaningful information relative to the condition of the equipment under test, then the person evaluating the test data must be assured that the test was conducted in a proper manner and that all of the conditions that could affect the evalu-ation of the tests were considered and any pertinent factors reported. The test operator, therefore, must be thoroughly familiar with the test equipment used in the type of test to be performed, and also sufficiently experienced to be able to detect any equipment abnormalities or questionable data dur-ing the performance of the tests.

b. Test equipment. It is important to have the proper equipment for performing the required tests in any test program. In general, any test equipment used for the calibration of other equipment should have an accuracy at least twice the accuracy of the equipment under test. The test equipment should be maintained in good condition and should be used only by qualified test operators. All test equipment should be calibrated at regular intervals to ensure the validity of the data obtained. In order to get valid test results, it may be necessary to regulate the power input to the test equipment for proper waveform and frequency and to eliminate voltage surges.

c. Use of forms. To provide optimum benefits, record all testing data and maintenance actions on test circuit diagrams and forms that are complete and comprehensive. Recording both test data and maintenance information on the same form is rec-ommended. A storage and filing system should be set up for these forms that will provide efficient and rapid retrieval of information regarding previous testing and maintenance on a piece of equipment. A well-designed form will also serve as a guide or a checklist of inspection requirements. Samples of typical forms that can be used are included in NFPA 70B, appendix G.

2 - l

Section II - REQUIREMENTS

2-4. Electric workers, instruments, and re-ports.

Tests of electrical equipment should be performed under the supervision of qualified electric workers.

If in-house personnel are not available for these tests, the services of a qualified electrical testing agency may be used.

a. Testing agency qualifications. The testing agency should submit proof that it is a corporately independent testing organization which can func-tion as an unbiased testing authority, professionally independent of the manufacturers, suppliers, and installers of equipment or systems evaluated by the testing firm. The testing agency should meet OSHA criteria for accreditation of testing laboratories, Title 29, Part 1910-7; or be a full member company of the InterNational Electrical Testing Association (NETA) and be regularly engaged in the testing of electrical equipment devices, installations, and sys-tems. The lead technical agency member on-site should be currently certified by NETA or the Na-tional Institute for Certification in Engineering Technologies (NICET) in electrical power distribu-tion system testing.

b. Test instrument calibrations. Instruments should have been calibrated within the last 12 months except that analog instruments should have been calibrated within the last 6 months. Calibra-tion should provide the full-scale accuracy based on the manufacturer’s data, usually 1 percent for switchboard instruments and 0.25 percent for por-table instruments. Dated calibration labels should be visible and up-to-date calibration records, in-structions, and procedures should be maintained for each instrument which should have had a calibrat-ing standard of higher accuracy than that of the test instrument.

c. Test reports. A dated test report should include, as a minimum, the following data:

(1) Summary of project findings and recom-mendations, if required for additional work.

(2) Description of equipment tested.

(3) Description of test.

(4) Test results.

2-5. Frequency of inspection.

The intervals given in this manual and/or by manu-facturer’s maintenance recommendations should be considered an initial interval for normal conditions.

Intervals should be shortened where adverse condi-tions exist and may be lengthened only where expe-rience under better-than-normal conditions show this can be done safely. The frequency of inspection may vary for similar equipment operating under different conditions. Critical equipment, heavily loaded apparatus, operator handled, and intermit-tently operated units are examples of different op-erating conditions.

2-2

CHAPTER 3

- TRANSMISSION AND DISTRIBUTION SUBSTATIONS

Section I - GOVERNING CONSIDERATIONS

3-1. Type of substations covered.

This chapter includes a transmission and distribu-tion substation which is an assemblage of equip-ment for purposes other than generation or utiliza-tion, through which electrical energy in bulk is passed for the purpose of switching or modifying its characteristics.

3-2. Electrical system relationship.

A substation is an integral and vital part of an electrical system. It does not exist independently of the rest of the system, though it is usually designed so that a failure of a single component will not interrupt loads, except for switching times. Such interruption may force greater than normal loads to be carried by other components of the station while repairs are being made. Most substations are de-signed so they do not require attendant personnel on a continuous basis. Supervisory control and data acquisition (SCADA) systems, where provided, al-low monitoring at a central point.

3-3. Substation safety concerns.

Substations present a potential safety hazard, ow-ing to the large amount of energized conductor sur-face concentrated in a relatively small area. In gen-eral, only portions of an entire substation can be de-energized, although scheduled outages may be required for equipment which can not be bypassed or worked on while energized. All inspecting and repairing personnel must be thoroughly trained.

The following requirements are minimum:

a. Familiarity with operating procedures, protec-tive and interlocking schemes, and the equipment capabilities at the specific substation.

b. Knowledge of the proper use of safety equip-ment, first aid procedures and equipment, and equipment grounding techniques.

c. Access to safeguards such as danger signs, tem-porary barriers, protective clothing, tools and…