J-1605000-03 NAVFACINT 11300-37A.pdf

NAVFACINST 11300.37A

09 DEC 1993

NAVFAC INSTRUCTION 11300.37A

From: Commander, Naval Facilities Engineering Command

Subj: ENERGY AND UTILITIES POLICY MANUAL

Ref: (a) OPNAVINST 11000.16A

1. Purpose. To provide updated policy and guidance on utilities management and engineering for shore activities.

2. Cancellation. This revision to NAVFACINST 11300.37 will replace in their entirety chapters 1, 2, 3, and 4 of the originating instruction.

3. Discussion. Recent changes to energy and utilities engineering policy has necessitated issuing a revision to NAVFACINST 11300.37. The revisions will be accomplished in two phases; utilities engineering policy changes to be issued as NAVFACINST 11300.37A and energy policy issued in the future as NAVFACINST 11300.37B. The utilities policy revisions include a new emphasis on integrated utility planning, revised clean steam and fuel selection criteria, as well as a more abbreviated utilities management chapter.

This revision is designed as a direct substitute for existing chapters 1 - 4.

4. Action. All Naval shore activities shall comply with the policy and guidance contained herein under the authority delegated to NAVFACENGCOM by reference (a).

Signed

J. P. KOVALCIK

Captain, CEC, U.S. Navy Director for Public Works Support

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TABLE OF CONTENTS

Page

CHAPTER 1. POLICY AND GENERAL RESPONSIBILITIES

1000 Scope 1- 1

Part 1. Energy and Utilities Assessment and Planning

1100 General 1- 1 1101 Utilities Master Plan 1- 1

Part 2. Energy and Utilities Management

1200 Policy 1- 2

Part 3. Energy Goals and Awareness

1300 Energy Goals 1- 3 1301 Energy Awareness 1- 3

Part 4. CNO, Claimant, and Public Works Support

1400 Policy 1- 4

Part 5. Economic Analysis

1500 Policy 1- 4

Part 6. Renewable Energy

1600 Scope 1- 4 1601 General 1- 4

CHAPTER 2. UTILITIES ENGINEERING PROGRAMS

Part 1. Utility Systems Assessments (USAs), Utility Technical Studies (UTSs), and Integrated Utility Development Plans (IUDPs)

2100 Purpose 2- 1 2101 Policy 2- 1 2102 Guidance 2- 1 2103 Responsibilities 2- 3

Part 2. Computer Aided Logistics Support

2200 Purpose 2- 4 2201 Guidance 2- 4 2202 Responsibilities 2- 6

Part 3. Waterfront Utilities

2300 Shore-to-Ship Power 2- 7 2301 Purpose 2- 7 2302 Policy 2- 8 2303 Guidance 2- 8 2304 Responsibilities 2-15 2305 Steam and Feedwater 2-16 2306 Discussion 2-16 2307 Criteria 2-16 2308 Responsibilities 2-17

Part 4. Energy/Fuel Source

2400 General 2-19 2401 Energy Source Selection 2-19

Part 5. Utilities Vulnerability

2500 Scope 2-21 2501 Responsibilities 2-22

Part 6. Cogeneration

2600 Scope 2-22 2601 Applications 2-23 2602 Basic Concepts/Definitions 2-24 2603 Technology Systems Overview 2-25 2604 Planning/Evaluation 2-25

Part 7. Coal

2700 General 2-28 2701 Requisition Procedures 2-28 2702 Military Service Control Points 2-28 2703 Requirements 2-29 2704 Coal Contracts 2-29 2705 Inspection and Acceptance 2-29 2706 Acceptance/Rejection 2-30 2707 Contract Waivers 2-30 2708 Transportation 2-31 2709 Standardization 2-31

CHAPTER 3. UTILITIES SYSTEMS OPERATIONS & MAINTENANCE

Part 1. Heating and Power Plants

3100 Purpose 3- 1 3101 Discussion 3- 1 3110 Operations and Maintenance Manuals 3- 1 3111 Discussion 3- 1 3112 Responsibilities 3- 3 3120 Boiler Water Treatment 3- 3 3121 Discussion 3- 3 3122 Guidelines 3- 4 3123 Prohibitions and Recommendations 3- 5 3124 Records 3- 6 3125 Responsibilities 3- 6 3130 Proprietary Devices and Chemicals 3- 6 3131 Discussion 3- 6 3132 General 3- 7 3133 Actions 3- 7 3140 Efficiency 3- 7 3141 Discussion 3- 7 3142 Criteria 3- 9 3143 Responsibilities 3-11 3150 Minimum Attendance 3-11 3151 Discussion 3-11 3152 Criteria 3-13 3153 Responsibilities 3-15 3160 Safety Inspection of Boilers and Unfired

Pressure Vessels 3-16 3161 Discussion 3-16 3162 Responsibilities 3-16 3170 Training 3-19 3171 Discussion 3-19 3172 Responsibilities 3-21

Part 2. Steam Distribution Systems

3200 Scope 3-21 3201 Applications and Systems 3-22 3202 Steam Distribution Methods 3-22 3203 Operation & Maintenance of

Steam Distribution Systems 3-23 3204 Operation & Maintenance of Steam

Traps and Pressure Reducing Stations 3-23 3205 Building Heating Systems 3-23

Part 3. Hot Water Distribution Systems

3300 Scope 3-23 3301 Applications and Systems 3-24 3302 High Temperature Water Distribution

Methods 3-25 3303 Operation & Maintenance of Hot Water

Distribution Systems 3-25 3304 Pumps 3-26

Part 4. Electrical Distribution

3401 Purpose 3-26 3402 Guidance 3-26 3403 Responsibilities 3-29

Part 5. Compressed Air Systems

3500 Scope 3-30 3501 Applications and Systems 3-30 3502 Compressed Air Distribution Methods 3-32 3503 Compressed Air Plants 3-32 3504 Maintenance and Operation of Compressed

Air Distribution Systems 3-32 3505 Evaluation of Losses in Compressed

Air Systems 3-32

CHAPTER 4. UTILITIES MANAGEMENT

4000 Scope 4- 1

Part 1. Operations Management

4100 Scope 4- 1

Part 2. Inspection and Maintenance

4200 Scope 4- 2

Part 3. Utilities Allocation

4300 Scope 4- 3 4301 Metering 4- 3 4302 Utility Estimates 4- 3 4303 Utility Sales to DOD Customers 4- 4 4304 Utility Sales to Private Parties 4- 4 4305 Automated Allocation and Billing Packages 4- 4

4400 Management Analysis 4- 5 4401 Utilities Cost Analysis Report (UCAR) 4- 5 4402 Management use of the UCAR 4- 6

FIGURES

4- 1 UCAR Utilities Management Indices 4- 9

CHAPTER 1

POLICY AND GENERAL RESPONSIBILITIES

1000 SCOPE

This manual consolidates CNO and NAVFAC policy and guidance on energy and utilities management and utilities engineering for Naval shore activities.

PART 1

ENERGY AND UTILITIES ASSESSMENT AND PLANNING

1100 GENERAL

Energy and utilities assessment and planning are ongoing functions performed by NAVFAC Engineering Field Divisions (EFDs), activities, claimants, and others. The purpose of NAVFAC energy and utilities programs is to assist activities and claimants to plan, build, modify, operate and maintain energy and utilities systems that satisfy mission requirements at the lowest life cycle cost.

1101 UTILITIES MASTER PLAN

a.PURPOSE The utilities section of an activity's Master Plan is an overview of the information developed in the Utility System Assessment (USA), Computer Assisted Utility System Evaluation (CAUSE), or integrated Utility Development Plan (IUDP) study. It is an important element in developing the Land Use Plan (LUP). It also serves to include important utility projects in an activity's Capital Improvement Plan (CIP). The LUP and the CIP are the key sections of an activity Master Plan.

b.POLICY Activity master plans should include a utility support section. The data, provided by the EFD's Utility Division, is based on USA, CAUSE, or IUDP studies.

IUDPs are long term development plans which, unlike USAs which look at the adequacy of the existing system, determine the optimum system which meets the needs of future missions. Our current utility systems were designed in the early 1900s to meet different mission requirements than we have today. Technologies have changed and our bases have become more spread out. Central, oil fired steam distribution systems may no longer be the most efficient and cost effective way to provide thermal energy to our buildings. Cogeneration, heat pumps, hot water heating systems in lieu of steam, and satellite or individual heating boilers may be the preferred way of providing electrical and thermal energy to our facilities.

An IUDP will provide a roadmap for an activity's development which will enable the activity to tailor infrastructure projects towards this more economical configuration rather than replacing old technology in kind.

c.GUIDANCE Since the USA, CAUSE, and IUDP programs are the primary sources for identifying utility requirements and deficiencies, the schedules for these studies and Master Plans need to be coordinated to ensure timely transfer of utility information into the activity Master Plan.

d.ACTION

(1)The Engineering Field Divisions shall use the USA, CAUSE, and IUDP programs to develop utilities data to support the activity Master Plan.

(2)Schedules for USAs, CAUSE, and IUDP studies and Master Plans shall be coordinated to ensure a timely transfer of utility information.

(3)Utility data shall be provided in the form of a utility support section for insertion into the Master Plan.

(4)Utility projects included in an activity Capital Improvement Plan shall include utility data provided for the Master Plan.

PART 2

ENERGY AND UTILITIES MANAGEMENT

1200 POLICY

Energy and utilities systems shall be operated and maintained at the lowest life cycle cost. To accomplish this, data on energy and utilities equipment performance, operation and maintenance costs, and other information must be collected and analyzed. The frequency of analysis depends on the cost of ownership of the system. In general, systems costing over $1 million a year to own and operate should be analyzed monthly. The purpose of the analysis is to determine areas where annual and life cycle costs can be reduced by capital improvement and changes in operation and maintenance procedures. Chapter 4 provides detailed guidance on utilities management. OPNAVINST

4100.5 provides guidance on energy management.

PART 3

ENERGY GOALS AND AWARENESS

1300 ENERGY GOALS

The following Navy energy goals were established by OPNAVINST 4100.5D. Fiscal year 1985 is used as the baseline year for comparison.

a. Existing buildings. Reduce adjusted energy consumption per thousand gross square feet (KSF) by 6 percent by the end of FY 1990, 12 percent by the end of FY 1995, and 20 percent by the end of FY 2000.

b. New buildings. Reduce the estimated annual design energy usage per gross square foot by 1 percent per year for new buildings, thereby achieving a 10 percent reduction for those buildings to be designed in FY 1995 over comparable buildings designed in FY 1985.

c. All shore activities. Support the following overall Navy FY 1995 goals to the extent that it is cost-effective and practical:

(1)Obtain 10 percent of total Navy shore facility energy from coal, solid fuels, and renewable energy sources; and

(2)Increase the miles per gallon efficiency of administrative vehicles (CESE A-N) by 12 percent, and increase the usage of alternative vehicle fuels.

OPNAVINST 4100.5C also established energy management standards for all shore activities. Chapter 5 provides detailed policy and guidance on Energy Goals and Reporting System. Chapter 7 provides additional detail on energy management standards for facilities.

1301 ENERGY AWARENESS

All Navy, Marine Corps, and civilian personnel in the Naval shore establishment use energy. All hands must be made aware of the significant cost of energy to the government and the significant cost reductions possible when energy is used efficiently.

PART 4

CNO, CLAIMANT AND PUBLIC WORKS SUPPORT

1400 POLICY

Reference (d) provides claimant support assignments for EFDs. In addition to these assignments, CHESNAVFACENGCOM will provide support for Headquarters Marine Corps.

Geographic EFDs will provide support for activities within their geographic areas and support CNO through NAVFACENGCOM Headquarters.

PART 5

ECONOMIC ANALYSIS

1500 POLICY

Economic analysis for all energy and utilities projects shall be based on methods outlined in NAVFAC P-442, Economic Analysis Handbook.

PART 6

RENEWABLE ENERGY

1600 SCOPE

The renewable energy program in the Navy was established to encourage the development of other than conventional or fossil fuel energy sources for the Navy and to reduce our dependence on foreign energy sources. The concept is not a new one, but due to the politics of energy within the last two decades renewable energy resources have gained new attention. The concept is that of using the supply of energy that surrounds us in the form of light, fluid motion, and renewable resources.

1601 GENERAL

a. Navy Funds. Renewable energy resources that are not able to be developed using Public/Private Venture contracts shall be developed using Navy funds where life cycle costs are effective.

b. Renewable Energy Resources. Renewable energy includes solar, wind, photovoltaics, wave power, biomass, trash, land-fill methane, geothermal, etc.

c. Payback. When renewable energy facilities are constructed using Navy funds, the project shall pay back within its life-cycle. Life-cycle cost analysis shall be conducted using the current discount rate and latest differential escalation rates for energy published by the Department of Energy.

d. Savings to Investment Ratio. Renewable energy projects must compete for Navy funds with other conservation technologies. The basis for project selection will be the Savings to Investment Ratio (SIR) described in Chapter 8, Part 1.

e. Solar Analysis. A solar analysis for a military construction project is not needed if:

(1)a solar analysis was conducted for a similar facility and location;

(2)that analysis shows solar is not cost effective; and

(3)energy costs have not substantially increased since the solar analysis was completed.

CHAPTER 2

UTILITIES ENGINEERING PROGRAMS

PART 1

UTILITY SYSTEMS ASSESSMENTS (USAs), UTILITY TECHNICAL STUDIES (UTSs) AND

INTEGRATED UTILITY DEVELOPMENT PLANS (IUDPs)

2100 PURPOSE

Utility Systems Assessments (USA) and Utility Technical Studies (UTS) identify utility deficiencies and recommend corrective actions to ensure that adequate utilities will be available to meet current and future mission requirements. Integrated Utility Development Plans are basewide studies which examine the most life cycle cost effective way to provide utilities in the future.

2101 POLICY

Commanding Officers are responsible for the adequacy of facilities in relation to readiness, effectiveness and responsiveness. Activity utilities engineering resources, however, are often not sufficient to maintain and upgrade the Navy's shore utility systems. As a result, many systems have deteriorated, are approaching capacity limits or are of questionable reliability. The EFDs, through the USA and UTS programs, in conjunction with the Utility Master Plan outlined in Chapter 1, Section 1101, provide utility engineering support to correct these deficiencies.

Certain activities have experienced major changes to their utility load distribution since the activity was constructed. These changes could include major changes in the size or density of the installation, mission changes with resultant changes in utility requirements, or the availability of new technology or fuel source. In these cases, evaluating the utility system for condition, capacity, and reliability may not be sufficient. In these limited cases an IUDP should be conducted to determine the most life cycle cost effective way to supply and distribute utilities. For example, an IUDP could determine that a base should ultimately convert from a steam system to a hot water system supplemented by individual building boilers.

An IUDP would evaluate new technology, and available fuels in determining the best system. The results would be a roadmap which an activity could follow in repairing and replacing its system. Following an IUDP, an installation can move from a utility system designed in the 1940s to one designed for the year 2000.

2102 GUIDANCE

a. In accordance with OPNAVINST 11000.16, EFDs provide USAs for Naval activities on a reoccurring cycle.

UTSs are accomplished by contracts funded by the activity, sub-claimant, or claimant and are administered by the geographic EFD.

b. A Utility System Assessment is an engineering evaluation of the condition, reliability, and quality of a utility system and of its capability to meet present and future requirements. It provides utility data for inclusion in an activity Master Plan. EFDs should schedule USAs to coordinate with Master Plan schedules. EFDs should identify not only utility systems that are deficient, but also utility systems or major components that have exceeded their useful life or are experiencing increasing maintenance costs or inefficiency. Specific deficiencies are identified and documented in sufficient detail to initiate corrective actions. Utility input into the Annual Inspection Summary (AIS) is reviewed to ensure that the AIS reflects all utility deficiencies. Utility systems include but are not limited to:

(1)Electricity generation and distribution (2)Steam production and distribution (3)High temperature hot water production and distribution (4)Chilled water production and distribution (5)Compressed air production and distribution (6)Natural gas supply and distribution (7)Potable water supply and distribution (8)Sewage collection and disposal (9)Salt water supply and distribution

c. Utility Technical Studies are investigations that focus on utility system deficiencies. Alternatives to correct the deficiencies are examined in enough detail to select and develop projects needed to implement the optimum solution. Funding for the UTS is provided by the claimant.

The UTS provides an investigation of each deficiency and an analysis, including life-cycle cost, for each alternative considered and the recommended alternative. Complete justification and project documentation is included.

d. An IUDP is not conducted on a regular cycle like a USA or UTS. Neither are all naval activities justified in requesting a IUDP. Because IUDPs are expensive and time consuming they should be limited to those installations who have experienced major changes to their load distribution and who will be budgeting for extensive utility system improvements.

e. NAVFACENGCOM encourages the use of Computer Aided Drafting & Design (CAD 2) in all areas of facilities engineering.

(1)The mapping capabilities of CAD 2 have particular application in support of USAs and UTSs.

Current and complete drawings of utility systems are a major requirement of engineering investigations.

(2)Expanded use of CAD 2 by utilities engineers is expected in the coming years. To assist in converting the shore establishment to CAD 2, USAs should include recommendations for UTSs to convert utility system drawings to digital format.

2103 RESPONSIBILITIES

a. NAVFACENGCOM. Provide policy and guidance for the USA/UTS and IUDP programs in accordance with OPNAVINST 11000.16.

b. Engineering Field Divisions.

(1)Accomplish USAs and IUDPs in accordance with OPNAVINST 11000.16 and this instruction.

(2)Provide the results of each study to the appropriate claimant via the activity.

(3)Use the study to develop a utility support section for incorporation into the activity Master Plan.

(4)Develop scope(s) of work and administer contracts to perform UTSs.

(5)Geographical EFDs shall provide claimant EFDs, by 1 December of each year, the status of recommended UTSs and a 6 year USA schedule for the claimant's activities.

The USA schedule should be coordinated with the Master Plan schedule. Claimant EFDs shall provide a consolidated status report of these requirements to the claimants prior to 1 January of each year.

c. Major Claimants.

(1)Prioritize and approve the six-year USA schedule by 1 March of each year in accordance with

OPNAVINST 11000.16.

d. Shore Activities. Provide assistance to EFDs and contractors in accomplishing USAs, UTSs, and IUDPs.

PART 2

COMPUTER AIDED LOGISTICS SUPPORT

2200 PURPOSE

Computer Aided Logistics Support (CALS) standardization will require that data prepared for CAD 2 and Computer Assisted Utility System Evaluation (CAUSE) be compatible with automatic machine to machine transfers and electronic telecommunications. The following CALS definition, scope and objectives were presented at a "SYMPOSIUM ON AUTOMATION OF THE NAVY" on 26 August 1986.

a. Definition. CALS is an integrating mechanism for a modernization process that is underway in the Navy today from design engineering to acquisition, to operational employment and support.

b. Scope.

(1)Mandated by Congress for DOD-wide implementation.

(2)Applies to all new major acquisitions advertising in 1990 and beyond.

(3)Development and implementation is a joint Industry-DOD process.

(4)Requires integration of existing "Islands of Automation" through standardization and coordinated architectures.

c. Objectives.

(1)Design more supportable facilities.

(2)Foster "Near Paperless" system of acquisition and support functions.

(3)Transition from paper based to digital logistics and technical information.

(4)Routinely acquire and distribute logistics and technical information in digital form for new facilities.

(5)Shorten the leadtime for more effective logistics support to the operating forces.

2201 GUIDANCE

a. The CAUSE program contains two major sub-programs, Computer Assisted Power Systems Engineering (CAPSE) and Computer Assisted Fluids Engineering (CAFE).

In-depth analyses of shore facility utility systems are needed to ensure that utility systems safely, adequately and reliably meet mission requirements. Additionally, good management practice dictates that optimum benefits be obtained from system improvements and that all utility systems work in concert at their optimum efficiencies.

Computer assistance in performing time consuming, complex calculations enables engineers to evaluate more alternatives and select the best overall solution. By freeing engineers of cumbersome calculations, the computer makes utilities engineers more productive. CAUSE studies provide utility data for inclusion in an activity Master Plan. EFDs should schedule CAUSE studies to coordinate with Master Plan schedules.

(1)The CAPSE series of computer programs permit the engineer to model the operation of electric power systems. Evaluations include: voltage, power factor, capacity, short-circuit, component characteristic and efficiency studies.

(2)The CAFE programs model the operation of mechanical utility systems, e.g., steam and water. They enable engineers to determine optimum configuration, system capacities, system efficiencies and improvements to system operation to optimize the effectiveness of these systems.

c. EFD Utilities Divisions use the CAUSE program to evaluate activities' utility systems.

(1)They conduct in-depth analyses on activities' utility systems in their geographic area to ascertain present and future operating conditions and identify deficiencies. These analyses evaluate utility system safety, reliability and efficiency. Immediate, short-term and long-term utility needs of the fleet can be met efficiently and effectively with maximum utilization of existing and planned resources. The data from this evaluation shall be summarized for inclusion in the utilities support section of an activity Master Plan.

(2)They coordinate analyses with planning for ship requirements using existing databases to model the future requirements. This ensures that activities can plan their utility system improvements to provide optimum benefits within existing funding constraints for time phased improvements.

(3)Computer aided analyses help to develop optimum system resolution for deficiencies identified by the Utility Systems Assessment Program, Energy Engineering Program Surveys and the activities Annual Inspection Summary.

d. Contractors are used to assist activities in their collection and preparation of data. The use of standardized (near paperless) electronic data handling will simplify gathering and transferring equipment characteristics, inventory and future load data. Improved activity utilization of mapping, one line diagrams and impedance diagrams will make the task of the utility analyst easier and will result in more effective use of the recommendations by the activity.

2202 RESPONSIBILITIES

a. NAVFACENGCOM. Provide policy and guidance for the CAUSE and Utilities CAD 2.

b. Engineering Field Divisions. Use the CAUSE program to assist activities in evaluating utility systems under their cognizance by developing a utility support section for incorporation into the activity Master Plan.

(1)Collect all necessary system data, including equipment characteristics and inventory and present and future loads, to conduct a thorough analysis and prepare system component connection (one-line) diagrams. Activity and A&E resources shall be used to augment EFD efforts to collect and prepare system data.

(2)Conduct periodic in-depth analyses of utility systems to ascertain present and future operating conditions and identify deficiencies. Analyses shall evaluate utility system safety, reliability and efficiency.

They shall ensure that utility systems provide the quantity and quality of service necessary to meet all mission requirements. Coordinate analyses with planning, ship requirements, and MILCON Program development to ensure shore facilities have adequate utilities to meet requirements ten years into the future. Immediate, short-term and long-term needs shall be met efficiently and effectively with maximum utilization of existing and planned resources.

(3)Recommend actions necessary to ensure that system improvements provide optimum benefits and are time phased with system requirements. Also, provide recommendations regarding changes to O&M procedures and system configurations.

(4)Initiate follow-up action to ensure that all recommendations involving system capacity, reliability, and/or safety are being implemented.

(5)Coordinate a continuing education program for their utility system analysts.

(6)Work closely with activities to have utility maps, diagrams and site survey drawings converted to CAD 2.

c. Atlantic Division, Naval Facilities Engineering Command, Code 16. Responsible for the technical management of the CAUSE program. Specific duties include:

(1)Maintain existing computer programs/software supporting CAUSE.

(2)Optimize the operation of computer programs/software including all computer instructions needed by engineers using the programs.

(3)Develop and/or adapt new computer programs (software) to enhance the capabilities of CAUSE.

(4)Train EFD personnel in the use and application of the program packages and necessary time-sharing computer operating instructions.

(5)Ensure hardware and software requirements are inc consonance with program objectives.

(6)Prepare and publish technical documentation required to support CAUSE.

(7)Provide technical advice to the NAVFAC program manager of the impact of any proposed hardware, software or central processor changes.

(8)Coordinate all technical problems directly with the EFDs and government or commercial time-sharing service organizations.

d. Activities

(1)Assist EFDs in collecting and preparing data for studies.

(2)Use CAUSE to monitor and plan changes for utility systems.

PART 3

WATERFRONT UTILITIES

2300 SHORE-TO-SHIP POWER

2301 PURPOSE

OPNAVINST 11310.3A provides minimum operation and maintenance procedures for electrical systems which provide shore-to-ship power.

2302 POLICY

Applies to all Navy-owned components of electrical distribution systems between each power source (commercial utility metering point or Government owned generator) and each shore power connection point on board ships.

Electrical components that are not directly involved in supplying power to ships, but can affect the reliability of these circuits, are also included. This instruction does not apply to electrical components aboard ships or components used exclusively to deliver 400 Hertz, supershore, or direct current power or any other power for major ship repair or overhaul. All shipyards are excluded.

2303 GUIDANCE

The safe and reliable operation of shipboard electrical equipment is critical in port as well as at sea. A malfunction or misapplication of shore-to-ship power equipment could cause at least an inconvenient interruption of electrical service to a ship at berth; at worst, it could threaten the lives of personnel, damage critical shipboard and shore power equipment, or completely disable a ship. Problems with shore-to-ship power systems are frequent and may become more common as ships' power requirements increase in the future. Investigations by NAVSEASYSCOM and NAVFACENGCOM have shown that improperly trained ship and shore personnel and inadequately maintained shore-to-ship power equipment are the major causes of problems. Because the requirements are critical and the waterfront environment is harsh for electrical equipment, it is imperative to apply the highest standards to the operation and maintenance of electrical distribution systems that supply shore-to-ship power to the fleet.

a. Training. Training programs should be developed by each ship and shore activity for all ship and shore based personnel involved in the operation and maintenance of shore-to-ship power systems. The program should include the installation, fabrication, assembly and testing of low and medium voltage cable, splices, terminations, connectors, portable substations, switchgear and receptacles, where applicable. NFPA 70B, Electrical Equipment Maintenance, can be used as a guide for local training programs. NFPA 70B may be obtained from:

National Fire Protection Association, Battery March Park, Quincy, MA 02269. Navy sponsored training courses and manufacturers' training shall be used to the maximum extent possible to supplement local training. Activities and Fleet Commanders should establish standards for personnel working on shore-to-ship power systems. Activities should maintain training records and conduct periodic refresher training programs.

b. Shore-to-Ship Power System Operating Procedures.

Basic power system operating guidelines are published in NAVFAC MO-201, Operation of Electric Power Distribution Systems. The following additional procedures shall be applied to all shore-to-ship power systems.

(1)Standard Operating Procedures (SOPs). SOPs shall be prepared by each activity and distributed to all personnel involved with the operation and maintenance of shore-to-ship power systems. These SOPs shall address, as a minimum, the following areas:

(a)Organization (b)Responsibilities (c)Priorities (d)Normal Procedures (e)Emergency Procedures (f)Safety and Health Requirements and

Considerations

(2)Critical Component Identification. Activities shall identify as critical components of shore-to-ship power systems, all electrical components whose failure could effect the reliability of the electrical distribution system supplying power to the ships. Critical components shall be placed under the maintenance program defined in this section.

(3)One-Line Diagrams. One-line diagrams illustrating the equipment ratings and system configuration of all critical components shall be prepared and kept current by the activities. Plot plans shall be annotated to show the location of all shore-to-to-ship power system components. See NAVFAC MO-204, Electric Power System Analysis, for additional information.

(4)Power System Study. An activity power system study, including load flow, fault current analysis and coordination of protective devices, shall be reviewed and updated at least once every 5 years of sooner, if required by major modifications to the activity's or utility company's electrical distribution system. The study evaluates the adequacy of all critical components of the shore-to-ship power system.

(a)All protective devices which could directly or indirectly cause a ship power failure shall be evaluated to determine compliance with the American National Standards Institute (ANSI) standards and the National Electrical Code.

(b)EFDs shall perform USAs to assist activities in evaluation changes to the shore-to-ship power systems and recommend, as appropriate, a power system load flow, fault current and/or protective device coordination study to be performed either by the EFD, using their Computer Assisted Utility Systems Engineering (CAUSE) facilities, or by contract.

(5)Voltage Requirements. Voltages available at the ship's shore-to-ship power receptacles shall be within +/-15 percent of rated voltage under full load conditions.

(6)Transportable Substations. Transportable substations or other portable equipment used to supply power to ships are included in the maintenance program defined in this section.

(7)Paralleling Transformers. If a ship is supplied by two or more shore transformers, the ship's operating forced should be directed, through standard ship operating procedures, not to parallel the transformers through the ship's bus unless the senior ship's electrician verifies correct phase orientation between power sources and the supplying activity authorizes the parallel operation. If shore transformers are paralleled through the ship's bus, short circuit currents may be increased to unsafe levels and circulating currents may overheat and destroy cables, transformers and switchgear on board ship and on shore.

(8)Paralleling Shipboard Generation with the Shore Power System. Paralleling of ship's service generators with the shore power system is prohibited except for the shortest time necessary to transfer to or from shore power.

c. Shore-to-Ship Power System Maintenance Standards

(1)General. The basic electrical equipment maintenance guidelines, as outlined in National Fire Protection Association (NFPA) Publication 70B, Electrical Equipment Maintenance, shall be used as minimum maintenance standards. Additionally, NAVFAC MO-200, Facilities Engineering, Electrical, Exterior Facilities, NAVFAC MO- 322, Inspection of Shore Facilities and manufacturers maintenance recommendations shall be used as supporting guidelines for all shore-to-ship power system equipment.

Maintenance schedules listed shall be adjusted so as not to interfere with normal waterfront operations, e.g., schedule maintenance when critical components are not required for ship support.

(2)Continuous Inspection Schedules

(a)Inspection checklists shall be prepared by each activity and used for all shore-to-ship power system critical components. A checklist shall be prepared for each type of preventive maintenance if there is more than one type, e.g., semi-annual, annual, etc. These checklists shall include everything that is to be done during the scheduled maintenance. Signed off copies of checklists shall be filed with maintenance records.

(b)Inspection schedules shall be prepared and followed for all shore-to-ship power system critical components. Maintenance intervals published in NFPA 70B, NAVFAC MO-200 and NAVFAC MO-322 may be adjusted based upon local conditions and experience. However, maintenance intervals shall not exceed the times listed in NFPA 70B.

(3)Maintenance Records

(a)Maintenance records shall be established and maintained covering each shore to ship power system.

Critical component records must indicate completed work and by whom. Testing and test records shall be part of each critical component's maintenance record.

(b)Maintenance records shall also be used to identify excessive unscheduled maintenance so that problems may be diagnosed and corrected.

(4)Switchgear Operations. Switchgear devices included on the critical component list which operate because of an overload, overcurrent, or short-circuit shall be evaluated for damage. Air circuit breakers shall be carefully inspected for damage to contacts, arc chutes frame and operating mechanism and oil circuit breakers shall be inspected and maintained as outlined in MO-322.

Shipboard operational requirements may require that maintenance other than visual inspections be temporarily deferred but deferrals shall not exceed the times listed in NFPA 70B for maintenance intervals.

(5)Testing. Critical components shall be tested during regular maintenance intervals in accordance with the requirements of NFPA 70B.

d. Portable Shore-to-Ship Electric Power Cables

(1)Low Voltage Cables (Rated 600 Volts and Below). Portable cables used in the shore-to-ship power system shall be supplied in accordance with MIL-C-915E and MIL-C-915/6. Cable shall be three conductor, flexible, unshielded type THOF-500 construction. Cable shall be rated for at least 600 volt service and should be ordered from the Defense Industrial Supply Center, Philadelphia, Pennsylvania. The stock number for the cable is THOF-500

NSN 6145-01-008-5468.

(2)Medium Voltage Cables (Rated 601 Volts to 5000 Volts). The portable cables used for the 4160 volt shore-to-ship power system shall be three conductor, flexible, braided shield type SHD-350GC, 8,000 volt insulated, with PVC jacket. Insulation shall conform with Insulated Power Cable Engineers Association (IPCEA) S-66-524. Jacket materials shall comply with IPCEA S-19-81. Medium voltage cables are available only from commercial sources.

(3)Low Voltage Cable Overcurrent Protection.

Shore-to-ship cables are rated to carry maximum continuous load of 400 amperes. The 450 volt pier substation circuit breaker long time overcurrent protection shall be adjusted to trip at continuous loads of 440 amperes to prevent overload damage to the cables of ship's electrical system.

(4)Medium Voltage Cable Overcurrent Protection.

4160 volt ship-to-shore cables are rated to carry a maximum continuous load of 360 amperes. The 4160 volt pier substation circuit breaker long time overcurrent protection shall be set to trip at a maximum of 400 amperes to prevent overload damage to the cable or ship's electrical system.

(5)Standard Cable Lengths. Activities should maintain an inventory of portable shore-to-ship electric power cables in lengths required for serving the ships.

Lengths are selected and constructed to minimize the requirements for in-line connections. All of the cables serving a ship from a pier mounted 450 volt turtleback must be of equal length to minimize the unequal sharing of loads.

(6)Cable Storage. Cables not in use should be stored in a dry, weatherproof location. Covered off pier storage locations are highly desirable. Cable ends, terminations and plugs shall be protected against contamination and moisture when not in use.

(7)Number of Shore-to-Ship Circuits

(a)The number of shore-to-ship circuits using three conductor cables required to supply power to a particular ship depends on the estimated power requirements of the ship. Power requirements vary depending on the ship's activity while in port. MIL-HDBK-1025/2, table 10, gives the Shore Power Requirements for various classes of ships. Each low voltage cable is limited to 400 amps steady state at 450 volts. The medium voltage cables are limited to 360 amps at 4.16 KV.

(b)The ship's force should provide estimated ampere load requirements to the shore operators. When the available shore power is less than the estimated ship load, the ship's force shall be notified of the available capacity of shore-to-ship power system. When more than one circuit is required all cables shall be the same length and conductor sizes shall be matched to minimize unequal load distribution in accordance with OPNAVINST 11310.3A. Shore power mounds should have sufficient number of receptacles so that splice boxes, which negate the safety features built into the shore power system, are not used in paralleling widely separated power mounds.

(8)Cable Terminations

(a)All low voltage cables should be terminated with a MIL-C-24368/1 plug at each end of the cable. The connectors are assembled onto the cable using approved methods as detailed in NAVSEA drawing 803-5001027, section 2, group E, sheet 15, which is available from Naval Sea Systems Command, SEA 563Z, Washington, DC 20362. This drawing is also available in hardbound copy as publication number S9300-AW-EDG-010/EPISM from the Commanding Officer, Naval Publications and Forms Center, 5801 Tabor Avenue, Philadelphia, PA 19120.

(b)Portable shore power cable jumpers, supplied by the ship, may be used only where piers do not have MIL- C-24368/2 type receptacle and plug assemblies.

(c)Cables serving submarines shall have a MIL-C- 24368/5 outboard plug connection permanently attached to the shipboard end.

(d)All medium voltage cables shall be terminated at the shore end with a three phase 5000 volt, 400 ampere plug. The shipboard end of the cables shall be terminated with MIL-E-16366, 2 hole bolted lug type terminals.

(9)Low Voltage System In-Line Connections. In-line connections are used only if operationally necessary.

The in-line connection shall use MIL-C-24368/4 connectors or an equivalent method of connection that is watertight, oil resistant and ensures proper phase orientation. The following three pole connectors may also be used:

CAGE CONNECTOR ASSEMBLY COG FED SUPPLY CLASS

90129 X 8998-1 Male 1H 0099-LL-H28-0067 90129 X 8998-2 Female 1H 0099-LL-H28-0067

(10)Shore-to-Ship Power System Service Connections

(a)Connecting the shore-to-ship power system cables to the pier receptacles shall be accomplished only by qualified shore electricians in direct coordination with an electrical supervisor from the serviced ship. A checklist with detailed, sequential step-by-step connection procedures shall be developed by the activity providing the cold iron electrical service. The checklist shall show the date, ship, pier and outlet number and shall be signed by both the shore electrician and the shipboard electrician in charge when the hookup is completed. This checklist should be retained by the Public Works Department or Center for at least one year.

(b)This checklist shall address at least the following items:

- Visual inspection of the cable terminations to insure they are clean, free from salt, moisture, and corrosion, and are undamaged.

- Inspection of the cable terminations to insure they are clean, free from salt, moisture, and corrosion, and are undamaged.

- Electrical insulation resistance tests of each cable assembly showing actual values measured. Cables having insulation readings below 1,000,000 ohms for 450 volt cables and 5,000,000 ohms for 4160 volt cables shall not be placed in service; shop testing and repair shall be initiated.

- Shore power outlets are de-energized before connecting the cables.

- Connect the cables to the pier shore power outlets.

- If the ship is supplied by more than one shore transformer, the electrician shall instruct the ship's operating force that paralleling of shore transformers through the ship's bus is prohibited unless authorized by the cognizant activity based on a fault current analysis.

- Energize the cables only after the ship grants permission to transfer to shore power.

- Ship's forces are responsible for rigging the cables on board the ship, verifying phase rotation on each cable and for completing the connection on board the ship.

The shore activity will assist in rigging cable in some cases.

(11)Maintenance of Portable Shore-to-Ship Power Cable

(a)Shop Tests. The shop test procedures given in NAVFAC MO-200 shall be performed on all cables and connectors which fail insulation resistance tests or pre-installation inspections. These tests can be used to locate cable faults and to verify cable integrity after repairs are completed. Cables which fail shop tests and cannot be economically repaired shall be removed from service permanently.

(b)Repair. Insulation repairs entailing damage to outer cable jacket with conductor insulation intact should use approved materials only. An approved materials or kit will provide abrasion resistance and will remain flexible over a wide range of temperature. The completed insulation repair must have a moisture seal and the seal must be permanently bonded to the cable insulation. Repair kits and materials which carry a Bureau of Mines approval number or use a vulcanized rubber molding for insulating are the only materials which are approved for use on portable shore-to-ship power cables. Procedures for repairs to cables with damage outer jacket and conductor insulation shall be as required for cable splicing.

(c)Splicing. Splicing of portable shore-to-ship power cables is not recommended. However, if splices cannot be avoided, low voltage cables may be spliced when the spliced connections are insulated with an insulating material which conforms to the requirements of paragraph 11(b) above and NCEL Technical Note N-1503, copies of which may be obtained from the Commanding Officer, Naval Civil Engineering Laboratory, Code L07, Port Hueneme, CA 93043.

Medium voltage power cables shall not be spliced under any conditions.

2304 RESPONSIBILITIES

a. NAVFACENGCOM Public Works Centers and Engineering Field Divisions

(1)Issue shore-to-ship power operation and maintenance policy and procedures.

(2)Evaluate shore-to-ship electrical power outages and recommend corrective actions for design, operation and maintenance of shore-to-ship power systems.

(3)Provide support to NAVSEASYSCOM for the identification and solution of interface problems between ships' electrical distribution systems and shore-to-ship power systems.

b. Major Claimants and Sub Claimants

(1)Ensure that subordinate shore activities and applicable fleet units develop shore-to-ship power operation and maintenance programs.

(2)Ensure that projects necessary to correct identified waterfront deficiencies involving shore-to-ship power support are submitted.

c. Commanders of Forces Afloat

(1)Establish standards for shipboard personnel for the checkout and connection of the power cables on board ship and ensure that subordinate units apply these standards.

(2)Develop required changes to shipboard operating procedures in support of the shore-to-ship power operating procedures established by this instruction.

d. Activities. The following apply to shore activities and Public Works Centers providing electrical cold iron power:

(1)Establish shore-to-ship power operation and maintenance program.

(2)Assess waterfront facilities as they relate to shore-to-ship power, and submit projects to correct identified deficiencies.

2305 STEAM AND FEEDWATER

2306 DISCUSSION

a. Background. The Navy spends millions of dollars annually to repair ship boiler corrosion and damage. Part of this damage is the result of impurities found in steam and feedwater supplied to ships for "cold iron" support and steam blanketing of ships' boilers. To ensure that impurities do not enter ships NAVSEASYSCOM has prohibited ships from accepting shore-to-ship steam and feedwater unless the supplying activity certifies that the steam and feedwater meet NAVSEASYSCOM standards.

b. Standards. Shore-to-ship steam and feedwater sampling and testing shall be conducted in accordance with Naval Ships Technical Manual, NAVSEA S9086-GX-STM-020/CH- 220 V2. PACNAVFACENGCOM Manual P-200, Shore to Ship Steam and Feedwater Manual for Naval Facilities, provides further guidance and information.

2307 CRITERIA

Shore-to-ship steam must be generated from feedwater which is either treated with a chemical oxygen scavenger or mechanically deaerated to a maximum dissolved oxygen content of 15 parts per billion. When shore steam condensate or feedwater is provided, a 100 mesh Y type strainer shall be installed in the feed line to the ship to preclude resin contamination of the ship's system. The quality requirements are:

a. Shore Steam and Condensed Steam Constituent or Property Requirement pH 8.0 to 9.5 Conductivity 25 uS/cm max Dissolved Silica 0.2 ppm max Hardness 0.10 epm max

b. Feedwater Supplied to Ships Constituent or Property Requirement

Conductivity 2.5 umho/cm max Silica 0.20 ppm max

Facilities providing shore steam to Navy ships are required to sample and test shore steam and provide certification to the ships as follows:

(1)Sampling and analysis requirements:

(a)Shore boiler discharge shall be sampled daily.

(b)Each pier and quay shall be sampled quarterly.

(2)Shore steam certification requirements:

(a) Documentation of the most recent daily and quarterly analysis results shall be provided to each ship prior to shore steam hookup.

(b) Daily steam analysis results shall be made available to each ship by telephone. Telephone numbers shall be provided to each ship at the time of shore steam hookup.

(c)Each ship shall be notified any time shore steam does not meet the specified requirements.

2308 RESPONSIBILITIES

a. Engineering Field Divisions

(1)Assist activities to ensure that shore-to-ship steam requirements and feedwater requirements are met and maintained. Shore-to-ship steam meeting the NAVSEASYSCOM quality requirements is known as Clean Steam.

(2)Monitor the success of activities in meeting the NAVSEASYSCOM quality standards and report such monitoring to NAVFACENGCOM biannually. Activities meeting the NAVSEASYSCOM Clean Steam and feedwater standards at the time of the biannual report are considered "certified".

(3)Provide periodic assessments of Clean Steam production and distribution facilities to insure the quality requirements are met and maintained; and to recommend improvements to equipment and procedures.

b. NAVFEC. Provide as requested:

(1)Troubleshooting, metering and equipment testing services on a reimbursable basis.

(2)MUSE steam plants as required to support cold iron services.

c. Activities. The supplying activity is responsible for providing steam and feedwater of sufficient quality to meet NAVSEASYSCOM requirements. Activities are advised of the following:

(1)Daily laboratory tests to certify that steam purity at the shore boiler discharge and quarterly laboratory tests to certify that steam quality at each pier/or quay…