ufc_3_550_07_2017.pdf

UFC 3-550-07

19 January 2017

UNIFIED FACILITIES CRITERIA (UFC)

APPROVED FOR PUBLIC RELEASE; DISTRIBUTION UNLIMITED

OPERATION AND MAINTENANCE

(O&M): EXTERIOR POWER

DISTRIBUTION SYSTEMS

OPERATION AND MAINTENANCE (O&M): EXTERIOR POWER DISTRIBUTION

SYSTEMS

Any copyrighted material included in this UFC is identified at its point of use.

Use of the copyrighted material apart from this UFC must have the permission of the copyright holder.

U.S. ARMY CORPS OF ENGINEERS

NAVAL FACILITIES ENGINEERING COMMAND

AIR FORCE CIVIL ENGINEER CENTER (Preparing Activity)

Record of Changes (changes are indicated by \1\ ... /1/)

Change No. Date Location

FOREWORD

The Unified Facilities Criteria (UFC) system is prescribed by MIL-STD 3007 and provides planning, design, construction, sustainment, restoration, and modernization criteria, and applies to the Military Departments, the Defense Agencies, and the DoD Field Activities in accordance with USD (AT&L) Memorandum dated 29 May 2002. UFC will be used for all DoD projects and work for other customers where appropriate. All construction outside of the United States is also governed by Status of Forces Agreements (SOFA), Host Nation Funded Construction Agreements (HNFA), and in some instances, Bilateral Infrastructure Agreements (BIA.)

Therefore, the acquisition team must ensure compliance with the most stringent of the UFC, the SOFA, the HNFA, and the BIA, as applicable.

UFC are living documents and will be periodically reviewed, updated, and made available to users as part of the Services’ responsibility for providing technical criteria for military construction. Headquarters, U.S. Army Corps of Engineers (HQUSACE), Naval Facilities Engineering Command (NAVFAC), and Air Force Civil Engineer Center (AFCEC) are responsible for administration of the UFC system. Defense agencies should contact the preparing service for document interpretation and improvements. Technical content of UFC is the responsibility of the cognizant DoD working group. Recommended changes with supporting rationale should be sent to the respective service proponent office by the following electronic form: Criteria Change Request. The form is also accessible from the Internet sites listed below.

UFC are effective upon issuance and are distributed only in electronic media from the following source:

• Whole Building Design Guide web site http://dod.wbdg.org/.

Refer to UFC 1-200-01, DoD Building Code (General Building Requirements), for implementation of new issuances on projects.

AUTHORIZED BY:

GEORGE O. LEA, P.E. JOSEPH E. GOTT, P.E.

Chief, Military Engineering Branch Chief Engineer U.S. Army Corps of Engineers Naval Facilities Engineering Command

EDWIN H. OSHIBA, SES, DAF MICHAEL McANDREW Deputy Director of Civil Engineers DCS/Logistics, Engineering & Force Protection

Deputy Assistant Secretary of Defense (Facilities Investment and Management) Office of the Assistant Secretary of Defense (Energy, Installations, and Environment) http://www.wbdg.org/pdfs/ufc_implementation.pdf http://www.wbdg.org/ccb/browse_cat.php?o=29&c=4 http://dod.wbdg.org/

SUMMARY SHEET

Document: UFC 3-550-07, Operation and Maintenance (O&M) Exterior Power Distribution Systems

Superseding:

• AFJMAN 32-1082 (TM 5-684 and MO-200), Facilities Engineering Electrical Exterior Facilities.

• Air Force Handbook 32-1282 Volume 1, Field Guide for Inspection, Evaluation, and Maintenance Criteria for Electrical Substations and Switchgear.

• Air Force Handbook 32-1282 Volume 2, Field Guide for Inspection, Evaluation, and Maintenance Criteria for Electrical Transformers.

Description: UFC 3-550-07 provides guidance for the operation and maintenance of exterior power distribution systems.

Reasons for Document:

• Consolidate guidance;

• Provide technical requirements; and

• Incorporate new and revised industry standards.

Impact: There are negligible cost impacts associated with this UFC. However, standardized guidance will assist operators and maintainers in obtaining higher availability and design life from their installed systems.

Unification Issues: No unification issues noted.

i

TABLE OF CONTENTS

CHAPTER 1 INTRODUCTION

1-1 BACKGROUND

1-2 PURPOSE AND SCOPE

1-3 APPLICABILITY

1-4 GENERAL BUILDING REQUIREMENTS

1-5 SAFETY

1-5.1 Minimizing Hazards

1-5.2 Qualifications of Electrical Workers

1-5.3 Certification of Electrical Workers

1-5.4 Public Safety

1-5.5 Personnel Safety

1-6 CYBER SECURITY

1-7 REFERENCES

1-8 GLOSSARY

CHAPTER 2 SYSTEM CONFIGURATIONS

2-1 DISTRIBUTION SYSTEM CONFIGURATIONS

2-1.1 Radial Feed

2-1.2 Loop Feed

2-2 SUBSTATION CONFIGURATIONS

2-2.1 Double Feed, Double Bus

2-2.2 Straight Bus

2-2.3 Ring Bus

2-2.4 Breaker-and-a-Half

2-2.5 Network Model

CHAPTER 3 DEVELOPING AN O&M PROGRAM

3-1 TRAINING

3-1.1 Qualifications of Test Operators

3-1.2 Electric Workers, Instruments, and Reports

3-1.3 Testing Agency Qualifications ii

3-2 TOOLS AND EQUIPMENT

3-2.1 Electrical Tools and Equipment Standards

3-2.2 Standard Tools and Equipment

3-2.3 Specialty Tools and Equipment

3-2.4 Care and Storage of Tools and Equipment

3-2.5 Electrical Inspecting and Testing Equipment

3-3 HAZARDOUS MATERIAL PROCEDURES

3-4 SYSTEM DATA, EQUIPMENT DATA, AND DOCUMENTATION

3-5 TESTING INTERVALS

3-6 RISK MANAGEMENT ANALYSIS

3-7 RELIABILITY AND AVAILABILITY

3-8 LIFE CYCLE COST ANALYSIS

3-9 RECORD DOCUMENTS - MANUALS, DIAGRAMS AND DRAWINGS. 20

3-9.1 Operation and Maintenance (O&M) Manuals

3-9.2 Electrical Drawings

3-9.3 Operating Instructions, Records, and Logs

3-9.4 Geospatial Information Systems

3-10 ENERGIZED WORK PROCEDURES

3-10.1 Work on Energized Circuits

3-10.2 Unique Procedures for an Energized Work Permit

3-11 LOCKOUT/TAGOUT PROCEDURES

3-12 CONFIRMATION OF ADEQUATE MAINTENANCE AND TESTING

3-12.1 Calibration Sticker Classification Codes

3-12.2 Test Reports

CHAPTER 4 OPERATION

4-1 DEMAND LOAD

4-1.1 Characteristics – Residential, Commercial, Industrial

4-1.2 Seasonal Behavior – Power Demand

4-1.3 Circuits with Minimal Seasonal Behavior

4-1.4 Metering Data as an Input to System Operation iii

4-1.5 Load Shifting

4-1.6 Peak Shaving/Load Shedding

4-1.7 Coincidence

4-1.8 Trend Analysis

4-1.9 Forecasting and Planning

4-1.10 Demand Management

4-2 RECLOSING PRACTICES AND FUSE SAVING

4-2.1 Reclosing Initiated at Substation or Switching Station Circuit Breakers.

4-2.2 Reclosing Initiated at Downstream Pole- or Pad-Mounted Reclosers. . 33

4-2.3 Maintenance Practices to Minimize Reclosing Events

4-3 POWER FACTOR CORRECTION

4-3.1 Power Factor Variation

4-3.2 Power Factor Evaluation

4-3.3 Operation

4-3.4 Automatic Operation

4-4 DISTRIBUTED GENERATION

CHAPTER 5 MAINTENANCE, INSPECTION, TESTING AND REPAIR

5-1 SYSTEM COMPONENTS AND MINIMUM REQUIREMENTS

5-1.1 Substations

5-1.2 Power Transformers Recommended Intervals and Requirements

5-1.3 Switching Equipment

5-1.4 Tap Changers/Voltage Regulators

5-1.5 Relays, Instruments and Controls

5-1.6 Stationary Batteries and Battery Chargers

5-1.7 Instrument Transformers

5-1.8 Capacitors and Inductors

5-1.9 Insulators

5-1.10 Bushings

5-1.11 Bus Structures

5-1.12 Terminations iv

5-1.13 Grounding

5-1.14 Fences

5-1.15 Lightning Protection

5-1.16 Structure Maintenance / Corrosion Control

5-1.17 Substation Yards

5-1.18 Wildlife Deterrents

5-1.19 Frequency Converters (Motor-Generator (MG) Sets) and Synchronous Condenser

5-2 MEDIUM VOLTAGE (MV) DISTRIBUTION

5-2.1 Overhead Distribution

5-2.2 Underground

5-2.3 Ground Systems

5-2.4 Metering

5-2.5 Animal Control

5-3 ROADWAY/STREET/PARKING AREA LIGHTING

5-3.1 Voltage Level

5-3.2 Clearance Requirements

5-3.3 Multiple Street Lighting Circuits

5-3.4 Series Street Lighting Circuits

5-3.5 Climbing Space

5-3.6 Time Switches

5-4 DISTRIBUTED GENERATION

CHAPTER 6 WORKING ON OVERHEAD DISTRIBUTION

6-1 OVERHEAD DISTRIBUTION WORK

6-1.1 Working in Elevated Positions

6-1.2 Qualified Climber

6-1.3 Criteria for Qualified Climbers

6-2 POLE HANDLING OPERATIONS

6-2.1 General

6-2.2 Pole Contact Precautions

6-2.3 Receiving Pole Shipment v

6-2.4 Ground Handling

6-2.5 Long Term Pole Storage

6-2.6 Temporary Pole Storage

6-2.7 Hauling Poles

6-3 POLE INSTALLATION, REPLACEMENT, AND REMOVAL

6-3.1 Pole Holes

6-3.2 Digging Holes

6-3.3 Covering a Hole

6-3.4 Hole Casings

6-3.5 Setting Poles

6-3.6 Pole Setting Trucks

6-3.7 Setting Poles in Energized Lines

6-3.8 Backfilling the Hole

6-3.9 Dismantling Poles

6-4 CLIMBING AND WORKING ON POLES

6-4.1 General Rules

6-4.2 Pole Inspection Before Climbing

6-5 POLE CLIMBING EQUIPMENT

6-5.1 General Rules

6-5.2 Wooden Pole Climbing Equipment

6-5.3 Concrete and Steel Pole Climbing

6-6 POLE CLIMBING AND WORK PRECAUTIONS

6-6.1 General Pole Climbing Precautions

6-6.2 Wooden Pole Climbing Precautions

6-6.3 Concrete and Steel Pole and Tower Climbing Precautions

6-6.4 Working on Poles

6-6.5 Safety Straps

6-6.6 Hoisting or Lowering Materials

6-7 CROSSING STRUCTURES

6-8 STRINGING OR REMOVING DE-ENERGIZED CONDUCTORS AND

OVERHEAD GROUND WIRES

vi

6-8.1 Pre-Work Meeting

6-8.2 Work Adjacent to Energized Lines

6-8.3 Grounding

6-8.4 Handling and Stringing

6-8.5 Clipping-In or Tying Wires

6-8.6 Secondary Line Installation

6-8.7 Removing Lines

6-8.8 Guying

6-8.9 Insulators

6-9 ENERGIZED WORK

6-10 WORKING ON OR NEAR POLE-MOUNTED EQUIPMENT

6-10.1 Surge Arresters

6-10.2 Switches and Fuses

6-10.3 Capacitors

6-10.4 Power Transformers and Voltage Regulators

6-10.5 Fuses

6-10.6 Service Wires

6-10.7 Testing

6-11 AERIAL ROPE

6-11.1 Conductivity

6-11.2 Terminology of Rope Use

6-11.3 Knots and Splices

6-11.4 Hand Line and Rope Line Precautions

6-11.5 Tackle Blocks

6-12 TOOLS

6-12.1 Portable Power Tool Precautions

6-12.2 Miscellaneous Tool Precautions

6-13 AERIAL LIFTS AND INSULATED BUCKETS

6-13.1 Types of Aerial Lifts

6-13.2 Aerial Ladder vii

6-13.3 Insulating Versus Non-Insulating

6-13.4 General Requirements

6-13.5 Training

6-13.6 Driving Precautions

6-13.7 Setting Up and Knocking Down at the Job Site

6-13.8 Operating at the Job Site

6-13.9 Aerial Lift Equipment Operation near Energized Electrical Equipment.

6-14 TREE TRIMMING AND BRUSH REMOVAL

6-14.1 Training Qualifications

6-14.2 Public Safety

6-14.3 Tool Safety

6-14.4 Work Near Energized Lines

6-14.5 Climbing and Working on Trees

6-14.6 Felling Trees

6-14.7 Power Trimming Equipment

6-14.8 Right-Of-Way Brush Removal

6-15 WORKING NEAR COMMUNICATIONS ANTENNAS

CHAPTER 7 OUTAGES

7-1 TROUBLESHOOTING AND FAULT DETECTION METHODS

7-2 FAULT ANALYSIS

7-3 DOCUMENTING/REPORTING

7-4 SCHEDULING AND PLANNING

CHAPTER 8 POWER SYSTEM STUDIES AND COMPUTER MODELS

8-1 TOOLS, DATA AND DEVELOPMENT

8-1.1 General Process

8-1.2 UFC 3-501-01 Requirements

8-1.3 Software Requirements

8-1.4 Periodic Updates

8-2 MODELING

8-2.1 Equipment Naming Conventions viii

8-2.2 Equipment Modeling

8-3 POWER FLOW

8-3.1 Overview

8-3.2 Metering Data

8-3.3 System Electrical Measurements

8-3.4 Power Flow Analysis

8-3.5 Cross-Connect Analysis

8-4 SHORT CIRCUIT ANALYSIS

8-4.1 Overview

8-4.2 Short Circuit Results

8-4.3 Equipment Duty Evaluation

8-5 ARC FLASH ANALYSIS

8-5.1 Analysis Criteria

8-5.2 Arc Flash Labels

8-5.3 Maintenance and Testing Requirements

8-6 ELECTRICAL COORDINATION

8-6.1 Overview

8-6.2 Coordination System Study Documentation and Criteria

8-6.3 Coordination System Study – Substations and Switching Stations

8-6.4 Circuit Breaker Instantaneous Trips

8-6.5 Feeder Circuit Breaker Relay Settings for Underground Distribution. 147

8-7 AURORA ANALYSIS

CHAPTER 9 POWER AVAILABILITY/RELIABILITY/RESILIENCY

9-1 METRICS

9-2 POWER QUALITY

9-2.1 Monitoring

9-2.2 Harmonics

9-2.3 Voltage Unbalance

9-2.4 Phase Current Imbalance

9-3 PERFORMANCE AND EVALUATION

ix

9-4 PREDICTIVE ANALYSIS

CHAPTER 10 PHYSICAL SECURITY

10-1 PHYSICAL SECURITY

10-2 LESSONS LEARNED

APPENDIX A REFERENCES

APPENDIX B IEEE COLOR BOOKS

APPENDIX C PRIMARY DISTRIBUTION SYSTEM FUSING

C-1 OVERHEAD DISTRIBUTION FUSING

C-2 PAD-MOUNTED SWITCHGEAR FUSING

APPENDIX D VACUUM FAULT INTERRUPTER (VFI) TRIP SETTINGS

D-1 GENERAL CRITERIA

D-2 S&C VISTA PAD-MOUNTED SWITCHGEAR

D-3 G&W VFI PAD-MOUNTED SWITCHGEAR

D-4 COOPER VFI PAD-MOUNTED SWITCHGEAR

D-4.1 Overview

D-4.2 Trip Unit Characteristics

D-4.3 Example Trip Settings

D-4.4 Recommended Settings

D-5 COMPARISON OF S&C, COOPER, AND G&W TRIP SETTINGS

APPENDIX E STANDARD OPERATING PROCEDURES FOR ENERGIZED WORK

PERMITS

E-1 OVERVIEW

E-1.1 OSHA Criteria

E-1.2 SOP Limitations

E-1.3 Items to Address in an SOP

E-2 SAMPLE SOP – FUSED CUTOUTS: OPENING, CLOSING, OR

REPLACING FUSES

E-3 SAMPLE SOP – CONNECTING/DISCONNECTING LOADBREAK

ELBOWS

APPENDIX F SAMPLE MAINTENANCE PROGRAM CHECKLISTS

APPENDIX G SAMPLE LIFE CYCLE COST MAINTENANCE WORKSHEET

x

APPENDIX H SAMPLE MAPCO MAINTENANCE DOCUMENT

APPENDIX I RECOMMENDED TESTING INTERVALS

APPENDIX J GLOSSARY

J-1 ACRONYMS

J-2 DEFINITION OF TERMS

xi

FIGURES

Figure 2-1 Radial Feed Figure 2-2 Primary Loop System Figure 2-3 Double Feed, Double Bus System Figure 2-4 Straight Bus System Figure 2-5 Ring Bus System Figure 2-6 Breaker and a Half System Figure 2-7 Network Model Figure 4-1 Power Demand Variation – Northern Base Figure 4-2 Power Demand Variation – Southern Base Demand Figure 4-3 Daily Power Demand Variation Figure 4-4 Data Center Power Demand Variation Figure 4-5 Typical Recloser Control Unit Settings Figure 4-6 Typical Power Factor Variation Figure 6-1 Pike Pole Method Figure 6-2 Winch Line Method Figure 6-3 Honing a Gaff Figure 8-1 Aurora Vulnerability Assessment Flowchart Figure C-1 Various Fuse Link Type Time-Current Response Figure D-1 S&C Vista Switchgear Figure D-2 G&W VFI Switchgear Figure D-3 Cooper VFI Switchgear Figure D-4 Factory Default Settings Figure D-5 Example Tri-Phase Trip Settings – Higher Trip Values Figure D-6 Comparison of S&C Vista and G&W Switchgear VFI Settings xii

TABLES

Table 3-1 Availability and Downtime Table 5-1 Electromechanical Relay Test Intervals Table 5-2 Electronic Relay Test Intervals Table 5-3 Qualified Worker Minimum Approach Distances – DC Systems Table 5-4 Arc Flash PPE Categories for DC Systems Table 5-5 Battery Monitor System Maintenance Table 5-6 Time-Based Preventive Tests Table 5-7 Time-Based Predictive Tests Table 6-1 Average Crew Size Required to Raise Poles by Piking Table 6-2 In-Use Check of Pole Climber Gaffs Table 6-3 Insulating Device Categories Table 6-4 Application and Uses of Aerial Devices Table 6-5 Periodic Electrical Test Values for Insulating Aerial Devices with a Lower Test

Electrode System (Category A and Category B) Table 6-6 Insulating Aerial Devices without Lower Test Electrode System (Category C)

Table 6-7 Insulating Aerial Ladders and Insulating Vertical Aerial Towers Table 6-8 In Field Tests for Insulating Aerial Devices – ANSI/SIA A92.2 Section 5.4.3.2

Item 10(c) Table 8-1 Electrical Protection and Coordination Criteria Table B-1 IEEE Color Books Table B-2 IEEE 3000 Standards Collection Table C-1 Type K or T Fuse Link Sizing for Individual Transformers – 2.4 kV Table C-2 Type K or T Fuse Link Sizing for Individual Transformers – 4.16 kV Table C-3 Type K or T Fuse Link Sizing for Individual Transformers – 11 kV Table C-4 Type K or T Fuse Link Sizing for Individual Transformers – 11.5 kV Table C-5 Type K or T Fuse Link Sizing for Individual Transformers – 12.47 kV Table C-6 Type K or T Fuse Link Sizing for Individual Transformers – 13.2 kV Table C-7 Type K or T Fuse Link Sizing for Individual Transformers – 13.8 kV Table C-8 Type K or T Fuse Link Sizing for Individual Transformers – 22 kV Table C-9 Fuse Link Sizing for Individual Transformers – 34.5 kV Table C-10 Type H or QA Fuse Link Sizing for Individual Transformers – 12.47 kV ... 174 Table C-11 Fuse Sizing for Individual Transformer Primary Protection – 2.4 kV Table C-12 Fuse Sizing for Individual Transformer Primary Protection – 4.16 kV Table C-13 Fuse Sizing for Individual Transformer Primary Protection – 11 kV Table C-14 Fuse Sizing for Individual Transformer Primary Protection – 11.5 kV Table C-15 Fuse Sizing for Individual Transformer Primary Protection – 12.47 kV Table C-16 Fuse Sizing for Individual Transformer Primary Protection – 13.2 kV Table C-17 Fuse Sizing for Individual Transformer Primary Protection – 13.8 kV Table C-18 Fuse Sizing for Individual Transformer Primary Protection – 22 kV Table C-19 Fuse Sizing for Individual Transformer Primary Protection – 34.5 kV xiii

Table D-1 S&C VFI Settings to Provide Primary Protection for Individual Transformers –

2.4 kV

Table D-2 S&C VFI Settings to Provide Primary Protection for Individual Transformers –

4.16 kV

Table D-3 S&C VFI Settings to Provide Primary Protection for Individual Transformers – 11 kV

Table D-4 S&C VFI Settings to Provide Primary Protection for Individual Transformers –

11.5 kV

Table D-5 S&C VFI Settings to Provide Primary Protection for Individual Transformers –

12.47 kV

Table D-6 S&C VFI Settings to Provide Primary Protection for Individual Transformers –

13.2 kV

Table D-7 S&C VFI Settings to Provide Primary Protection for Individual Transformers –

13.8 kV

Table D-8 S&C VFI Settings to Provide Primary Protection for Individual Transformers – 22 kV

Table D-9 S&C VFI Settings to Provide Primary Protection for Individual Transformers –

34.5 kV

Table D-10 G&W VFI Settings to Provide Primary Protection for Individual Transformers

– 2.4 kV

Table D-11 G&W VFI Settings to Provide Primary Protection for Individual Transformers

– 4.16 kV

Table D-12 G&W VFI Settings to Provide Primary Protection for Individual Transformers

– 11 kV

Table D-13 G&W VFI Settings to Provide Primary Protection for Individual Transformers

– 11.5 kV

Table D-14 G&W VFI Settings to Provide Primary Protection for Individual Transformers

– 12.47 kV

Table D-15 G&W VFI Settings to Provide Primary Protection for Individual Transformers

– 13.2 kV

Table D-16 G&W VFI Settings to Provide Primary Protection for Individual Transformers

– 13.8 kV

Table D-17 G&W VFI Settings to Provide Primary Protection for Individual Transformers

– 22 kV

Table D-18 G&W VFI Settings to Provide Primary Protection for Individual Transformers

– 34.5 kV

Table D-19 Cooper VFI Settings to Provide Primary Protection for Individual Transformers – 2.4 kV

Table D-20 Cooper VFI Settings to Provide Primary Protection for Individual Transformers – 4.16 kV

Table D-21 Cooper VFI Settings to Provide Primary Protection for Individual Transformers – 11 kV xiv

Table D-22 Cooper VFI Settings to Provide Primary Protection for Individual Transformers – 11.5 kV

Table D-23 Cooper VFI Settings to Provide Primary Protection for Individual Transformers – 12.47 kV

Table D-24 Cooper VFI Settings to Provide Primary Protection for Individual Transformers – 13.2 kV

Table D-25 Cooper VFI Settings to Provide Primary Protection for Individual Transformers – 13.8 kV

Table D-26 Cooper VFI Settings to Provide Primary Protection for Individual Transformers – 22 kV

Table D-27 Cooper VFI Settings to Provide Primary Protection for Individual Transformers – 34.5 kV

Table E-2-1 Qualified Worker Minimum Approach Distances – AC Systems Table E-3-1 Qualified Worker Minimum Approach Distances – AC Systems Table E-3-2 Rubber Insulating Equipment Voltage Requirements

CHAPTER 1 INTRODUCTION

1-1 BACKGROUND.

This UFC updates the requirements of and replaces AFJMAN 32-1082 /TM 5-684 /MO- 200, and AFH 32-1282 V1 & V2.

1-2 PURPOSE AND SCOPE.

This UFC provides guidance for operations and maintenance of electrical power and distribution systems. Electrical systems need regular maintenance to ensure continued compliance with the codes and publications referred to in this document. Such maintenance will prevent system and equipment failures and ensure maximum safety and efficiency in the utilization of the facilities. At each installation, establish a program for proper maintenance and effectively follow it. Include in this program the scope of work, intervals of performance, and methods of application including safety requirements, practices and procedures, and operations and maintenance (O&M) of electrical power and distribution systems.

The information provided applies to the plans and procedures to operate and maintain installation electrical distribution systems. Specific installation conditions may dictate the need for procedures that exceed these minimum requirements.

These systems include substations, overhead and underground electrical distribution systems, exterior lighting systems, and electrical apparatus and components. Guidance for generators is covered in the following publications:

• UFC 3-540-01;

• UFC 3-540-07 (future UFC); and

• UFC 3-520-01.

1-3 APPLICABILITY.

The guidance and standards contained within are the minimum requirements acceptable for military installations for efficiency, economy, durability, maintainability, and reliability of electrical power supply and distribution systems. The provided guidance does not automatically supersede equipment manufacturers’ instructions and requirements. When conflicts exist, follow the most rigorous requirement. The guidance and standards herein are not intended to be retroactively mandatory. Provide, as a minimum, the level of maintenance required to meet the critical mission reliability goals.

• Comply with the requirements of Occupational Safety and Health (OSHA), General Industry Standards, and 29 CFR 1910;

• Comply with UFC 3-550-01 for minimum system and component design standards;

• Comply with UFC 3-560-01 for electrical safety requirements applicable to the installation and operation of electrical systems;

• Comply with UFC 4-010-01 and UFC 4-020-01 for security requirements related to exterior electrical distribution systems; and

• Comply with UFC 3-540-07 for operations and maintenance (O&M) of generators (future UFC).

Note: for privatized utilities, this UFC is for guidance only and compliance is not mandatory.

1-4 GENERAL BUILDING REQUIREMENTS.

Comply with UFC 1-200-01. UFC 1-200-01 provides applicability of model building codes and government unique guidance for typical design disciplines and building systems, as well as for accessibility, antiterrorism, security, high performance and sustainability requirements, and safety.

1-5 SAFETY.

Safety must always be top priority when working on or near any piece of electrical equipment. The electrical safety requirements for all electrical work activities on DoD utilities are provided in UFC 3-560-01, which provides implementation criteria for the various regulations, codes, and standards that apply to electrical safety activities.

Note: For Army installations, also comply with Army Pamphlet DA PAM 385-26.

1-5.1 Minimizing Hazards.

Material specifications, construction guidance, installation standards, material procedures, and safe working procedures have been developed to minimize hazards.

Ensure all work and materials conform to the latest accepted procedures and standards, as defined in publications listed or referred to in this manual.

1-5.2 Qualifications 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.

1-5.3 Certification of Electrical Workers.

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

1-5.4 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.

1-5.5 Personnel Safety.

Any work on or close to electrical equipment of any kind is 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. If an agency has a detailed labeling program or reliability program, comply with its requirements.

1-5.5.1 Safety First.

Two safety rules are mandatory as follows:

• Consider all electrical equipment is energized until it is known positively under LOCKOUT/TAGOUT (as by the presence of grounding clamps) that it is not energized. Comply with UFC 3-560-01, the applicable departmental publications, and special publications issued by the local command; and

• Work may be done only by personnel qualified by their job descriptions for that voltage level. Job descriptions to require actual hands-on work service periods to meet local utility approval. All tools and equipment must be maintained in proper operating order, be suitable for the maximum voltage level involved, and be periodically tested for compliance with all safety requirements. Consult departmental publications for specific requirements in each voltage level.

1-5.5.2 Service Safety Requirements.

This UFC addresses some safety requirements, but users must also be familiar with the service specific safety requirements.

1-5.5.3 Personal Protective Equipment.

Personal protective equipment (PPE) is equipment worn to minimize exposure to serious workplace injuries. These injuries may result from contact with electrical, chemical, physical, mechanical, or other workplace hazards. PPE may include items such as gloves, safety glasses and shoes, earplugs or muffs, hard hats, respirators, or coveralls, vests and full body suits. If PPE use is required, implement a PPE program.

Address in the PPE program the hazards present; the selection, maintenance, and use of PPE; the training of employees; and monitoring of the program to ensure its ongoing effectiveness. Refer to OSHA standards and UFC 3-560-01 to become familiar with PPE requirements.

1-5.5.4 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; “The Lineman’s and Cableman’s Handbook;” and UFC 3-560-01.

1-6 CYBER SECURITY.

All control systems (including systems separate from an energy management control system or a utility control system) must be planned, designed, acquired, executed and maintained in accordance with UFC 4-010-06, DoD Instruction 8500.01 and DoD Instruction 8510.01, and as required by individual Service Implementation Policy.

1-7 REFERENCES.

Appendix A contains a list of references used in this document. The publication date of the code or standard is not included in this document. In general, the latest available issuance of the reference is used.

1-8 GLOSSARY.

Appendix J contains acronyms, abbreviations, and terms.

CHAPTER 2 SYSTEM CONFIGURATIONS

2-1 DISTRIBUTION SYSTEM CONFIGURATIONS.

2-1.1 Radial Feed.

Radial feed systems (Figure 2-1) are defined as having a single source and single load with no interconnections to other sources.

Figure 2-1 Radial Feed

2-1.1.1 Benefits and Limitations.

Benefits: Radial feed systems are the least expensive to build and limit losses when there is a problem as only the loads on that feed are affected.

Limitations: Radial feed systems have the highest outage impact due to being unable to feed load from other sources of power. Overhead systems typically employ fuse saving methods using reclosers and sectionalizers to minimize the impacts of the majority of faults that are self-clearing see Section 4-2.

2-1.1.2 Reliability.

System redundancy requires having identical components available and in a usable configuration so that the replacement of a failed component will not result in a long-term outage. Outages / repairs may be able to extend longer based upon the loads being served. In general, redundancy is required to meet a requirement for long-term outage sustainment. The reliability is established by the backup generator.

2-1.1.3 Maintenance Implications.

Maintenance tasks require components de-energizing prior to testing. Therefore, any testing must have an outage unless there are redundant feeds or redundant circuit breakers, then one component may be taken out of service and another will feed the load. Outages will be short and quick, as components can be switched out as required.

2-1.2 Loop Feed.

Loop systems (Figure 2-2) loop through the service area and then return to the source.

Alternate sources or paths for the service feeder may be installed.

Figure 2-2 Primary Loop System

2-1.2.1 Benefits and Limitations.

Benefits: This is the next lowest cost system. The loop system gives another backup for the primary power feed. If a failure of the system is noted, power can be redirected through a re-configuration of the loop automatically, or manually as the system is set up.

Typically, DoD installations are operated in an open loop configuration that only provides a “hot stand-by” for the system. If you operate a loop-feed closed, it can reduce the events that the entire system sees when the downstream protective devices are properly coordinated. However, more fault current is available due to the paralleling effect, which is not desirable. Limitations: By operating it open-looped, you are removing some of the benefits of building the loop. However, in the event of a typical outage caused by a blown splice on a feeder cable, the outage will take down the entire loop. Furthermore, troubleshooting may be more difficult, depending upon how the loop is installed.

2-1.2.2 Reliability.

Depending on how it is operated this system is more reliable than the radial system as current has two paths to reach the loads.

2-2 SUBSTATION CONFIGURATIONS.

2-2.1 Double Feed, Double Bus.

In a double bus system (Figure 2-3), two identical busses are used in such a way that any outgoing or incoming feeder can be taken from any of the bus. Every feeder is connected to both of the buses in parallel through individual feeds. With double feeds, only the loads are individual. The system is able to have a failure of any individual feed and have a spare component substituted into its place.

Figure 2-3 Double Feed, Double Bus System

2-2.1.1 Benefit and Limitations.

Benefit: Double bus configuration increases flexibility for maintaining service through outages and performing maintenance in substations.

Limitations: Any large fault on the system will affect both buses. This is also the most expensive system, and has a lower reliability than a ring bus due to the fact that the radial feeds are not able to be maintained or replaced without taking the end load down.

2-2.1.2 Fault Tolerance.

Fault tolerance is the philosophy that states a system should survive faults with minimal downtime and if possible, automatically reconfigure itself to isolate the fault and mark it for repair. A double feed, double bus will have high fault tolerance due to the ability of the system to have alternate paths from the power source to the loads served, except to local loads. Relative fault tolerance – 3.

2-2.1.3 Maintenance Implications.

System maintenance is contained within the overcurrent device portion, relays, and in the cable testing.

2-2.2 Straight Bus.

A straight bus (Figure 2-4) is one where there is one source, and individual feeds to the loads. This is the same as the radial feed described above for connectivity purposes.

Figure 2-4 Straight Bus System

2-2.2.1 Benefit and Limitation.

Benefit: Straight bus/radial feed systems are the least expensive to build and radial feeds limit losses when there is a problem as only the loads on that system are affected.

Limitation: Straight bus/radial feed systems have the highest outages and highest mean time to repair due to the entire load being unable to be fed from other sources of power.

2-2.2.2 Fault Tolerance.

Straight bus systems have a very low tolerance of faults, as any one fault on the bus will take down the entire system. Relative fault tolerance – 1.

2-2.2.3 Maintenance Implications.

Maintenance tasks require the entire bus de-energized to work on without safety concerns. Outages will occur for all maintenance functions, such as insulation testing, breaker testing, etc.

2-2.3 Ring Bus.

A ring bus (Figure 2-5) is identical to a loop feed on the distribution side. This allows switching components to feed any load based upon faults anywhere on the bus structure. Loop systems must be carefully applied, as tying the two systems together, or completing the loop, will result in a future fault taking down both sides of the loop, rather than just one side. A loop system is fault tolerant to the extent that the faulted portion of the loop can usually be isolated and the entire ring placed back into service while the damaged portion is repaired.

Figure 2-5 Ring Bus System

2-2.3.1 Benefits.

A loop system loops through the service area and then returns to the source.

Sometimes there are alternate sources for the power, sometimes just alternate paths.

2-2.3.2 Fault Tolerance.

This system is more expensive that a single bus, however reliability is increased based upon the ability to move feeds to loads from any direction on the bus. Relative fault tolerance – 2.

2-2.3.3 Maintenance Implications.

Maintenance tasks are easier as portions of the bus can be taken down systematically and outages required to perform them don’t affect the entire system.

2-2.4 Breaker-and-a-Half.

The breaker and a half system (Figure 2-6) is an improvement on the double breaker scheme as costs are lowered by reducing the number of required circuit breakers. For every two circuits, only one spare breaker is provided. The protection is however complicated since it must associate the central breaker with the feeder whose own breaker is taken out for maintenance. Because of the high costs of equipment, even this scheme is not very popular. As shown in the figure that it is a simple design, two feeders are fed from two different buses through their associated breakers and these two feeders are coupled by a third breaker which is called tie breaker. Normally all the three breakers are closed and power is fed to both the circuits from two buses which are operated in parallel. The tie breaker acts as coupler for the two feeder circuits.

Figure 2-6 Breaker and a Half System

2-2.4.1 Benefits and Limitation.

Benefits: During any fault on any one of the buses, that faulty bus will be cleared instantly without interrupting any feeders in the system since all feeders will continue to feed from other healthy bus; however, it is cheaper than the double breaker configuration.

Limitation: This scheme is very expensive due to investment for third breaker.

http://www.electrical4u.com/electrical-circuit-breaker-operation-and-types-of-circuit-breaker/

2-2.4.2 Fault Tolerance.

This scheme is fairly highly tolerant for faults, as the third breaker allows a short time for switching. Relative fault tolerance – 5. Highest tolerance.

2-2.4.3 Maintenance Implications.

System maintenance is of a comparable level to the double breaker scheme.

2-2.5 Network Model.

A Network model (example provided in Figure 2-7) is a configuration using several of the above mentioned configurations. This allows many options and many configurations. However, this flexibility, because of complexity, requires a cybersecurity certified SCADA (Supervisory Control And Data Acquisition) system and highly trained operators to control feeders, monitor status, control breakers, and report maintenance issues.

Figure 2-7 Network Model

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CHAPTER 3 DEVELOPING AN O&M PROGRAM

3-1 TRAINING.

3-1.1 Qualifications of Test Operators.

Test operators must be thoroughly familiar with the test equipment used in the type of test being performed, and sufficiently experienced to detect any equipment abnormalities or questionable data during the performance of the tests.

All qualified inspecting and repairing personnel must be thoroughly trained to perform such activities required. The following requirements are minimum:

• Familiarity with operating procedures, protective and interlocking schemes, and the equipment capabilities at the specific substation;

• Knowledge of the proper use of power distribution and utility systems control systems to ensure efficient O&M;

• Knowledge of general cybersecurity concerns and protection protocols for net-centric operations;

• Knowledge of the proper use of safety equipment, first aid procedures and equipment, and equipment grounding techniques;

• Access to safeguards such as danger signs, temporary barriers, protective clothing, tools and protective equipment, and all safety manuals and rules.

Procedures to clearly indicate insulating requirements and working clearances for any category of energized-line maintenance employed; and

• Keeping proper inspection records and checklists so that observed defects or improper conditions will be promptly corrected.

3-1.2 Electric Workers, Instruments, and Reports.

Perform electrical equipment tests 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.

3-1.3 Testing Agency Qualifications.

Require the testing agency to submit proof that it is a corporately independent testing organization which can function independent of the manufacturers, suppliers, and installers of equipment or systems evaluated by the testing firm. The testing agency must 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 systems. The lead technical agency member on-site to have a current certification by NETA or the National Institute for Certification in Engineering Technologies (NICET) in electrical power distribution system testing.

3-2 TOOLS AND EQUIPMENT.

3-2.1 Electrical Tools and Equipment Standards.

Industry standards describe the requirements for electrical protective equipment and for tools. These standards were developed so that the tools, equipment, materials, and test methods used by electrical workers will provide protection from electrical hazards.

Electrical protective equipment is included in the ASTM F18 series specifications. Tool and equipment terminology and in-service maintenance and electrical testing are included in ANSI/IEEE 935 and 516 and IEEE 978 respectively. UFC 3-560-01 also contain tool and equipment requirements. In case of conflict, always use the most stringent safety requirement.

3-2.2 Standard Tools and Equipment.

For simplicity and convenience, the tools and equipment required for electrical inspection and maintenance are classified as follows:

• Tools: Tools include hand tools, digging tools, hot line tools, miscellaneous and special tools, and tackle;

• Protective equipment: Protective equipment includes rubber gloves, helmets, lie hose, matting, blankets, insulator hoods, sleeves, barricades and warning devices;

• Climbing equipment: Climbing equipment includes body belts, safety and climber straps, climbers, and ladders;

• Electrical inspecting and testing equipment: Electrical inspecting and testing equipment includes electrical and mechanical devices used to test the operation of electrical equipment, such as voltmeters, ammeters, ohmmeters, tachometers, and similar devices;

• Large portable and mobile equipment: Large portable and mobile equipment includes relatively large and easily transportable equipment for use in maintenance work, such as line trucks, aerial lift trucks, motor-generator sets, posthole diggers, and similar apparatus;

• All hand and mechanically operated tools must be used in a manner to comply with all applicable safety rules. Each worker is responsible for observing safety rules and preventing accidents;

• Energized lines: The methods used when working on energized lines, such as gloving, use of hot line tools, and provision of electrically insulated buckets, will be in accordance with the applicable services’ safety manuals. Safety rules governing the use of such tools and equipment are given in these manuals and in applicable OSHA regulations, 29 CFR 1910 and 29 CFR 1926; and

• Material use: An insulating type hydraulic fluid is required in all hydraulic hand tools used on or near energized lines and in insulated sections of aerial lift trucks. Hazardous material procedures must be followed when dealing with such substances.

Apply ANSI/IEEE Std 935 for the identification of tools and equipment used in live line work. Use tools in accordance with Chapter 6 in ANSI/IEEE Std 935. Maintain live line tools and rubber goods in accordance with UFC 3-560-01. Manufactured tools must meet ASTM F18 series specifications, as appropriate to the device and material. Refer to Chapter 6 for tools and equipment associated with overhead distribution.

3-2.3 Specialty Tools and Equipment.

Consider acquiring and using the following specialty tools and equipment:

• Remote racking mechanisms for switchgear circuit breakers – several manufacturers provide remote racking mechanisms that allow the electrical worker to stay well outside the arc flash boundary during circuit breaker racking operation;

• Remote switching actuators for circuit breakers – enables remote circuit breaker operation (open or close);

• Thermal imaging cameras;

• Power quality data loggers – for evaluation of normal system parameters, such as voltage, current, power factor and harmonic distortion, as well as for evaluation of abnormal events, such as voltage swells, sags, or outages;

• Wet/dry hot stick tester;

• Pad-mounted switchgear portable motor operator – for use on pad-mounted switchgear that is not operated with a hot stick; and

• Fault locating equipment.

3-2.4 Care and Storage of Tools and Equipment.

Tools and equipment will be kept in proper operating condition and used only for the purpose for which they were designed. If proper and safe tools are unavailable, report tool needs to a Supervisor.

Inspect all tools at regular intervals and any tool that develops defects when in use will be taken from service, tagged, and not used again until restored to proper working condition.

3-2.5 Electrical Inspecting and Testing Equipment.

The number and types of testing/inspection devices needed will depend on local needs.

When available, follow the manufacturer’s instructions for the care and maintenance of test equipment. The schedules for the calibration and tests of instruments and meters are dependent upon the particular installation. When precision is not essential, the period between tests is not critical and may be assigned as convenient. For units provided with built-in diagnostic capabilities, check diagnostics when their associated power apparatus is checked.

3-2.5.1 Maintenance of Instruments, Meters, and Test Equipment.

Only personnel trained and qualified to maintain instruments, meters, and test equipment, or personnel under the immediate supervision of such qualified personnel, are allowed to perform accuracy tests, repairs, calibrations, and adjustments of instruments and meters. When selecting meters, match meter accuracy to the requirements of which the reading and records are being used. Procuring equipment with higher accuracy than requirements dictate must be economically justified.

3-2.5.2 Frequency of Inspections.

Use the manufacturer’s maintenance recommendations intervals as the initial inspection frequencies for normal conditions. Shorten intervals where adverse conditions exist and may be lengthened only where experience under better-than-normal conditions show this can be done safely. The inspection frequency may vary for similar equipment operating under different conditions.

If calibration standards and equipment are not available, instruments and meters of nearly the same rating can be checked against each one another. When wide discrepancies are noted or the instrument or meter that is obviously incorrect, recalibrate and make any needed repairs.

3-2.5.3 Test instrument Calibrations.

Calibrate instruments every 12 months. Calibrate analog instruments every 6 months.

Calibration to provide the full-scale accuracy based on the manufacturer’s data, usually

1% for switchboard instruments and 0.25 % for portable instruments. Ensure dated calibration labels are visible, and maintain up-to-date calibration records, instructions, and procedures for each instrument which have had a calibration standard of higher accuracy than that of the test instrument.

3-3 HAZARDOUS MATERIAL PROCEDURES.

Implement a hazard communication program in accordance with 29 CFR 1910.1200 or 29 CFR 1926.59, and DoDI 6050.05, DoD Hazard Communication (HAZCOM) Program, as amended by Agency guidance. The major hazardous items to which electrical workers may be exposed are asbestos, polychlorinated biphenyls (PCB’s), sulfur hexafluoride (SF6) and some of the chemicals used to control undesirable brush or pests or to preserve wood. For PCBs, comply with 40 CFR 761 and Overseas Environmental Baseline Guidance Document (OEBGD) DOD 4715.05-G.

3-4 SYSTEM DATA, EQUIPMENT DATA, AND DOCUMENTATION.

Prior to performing any fieldwork, review historical Electrical Preventative Maintenance (EPM) data and applicable safety requirements.

• Assemble all documentation applying to the apparatus being checked:

− Documentation Maintenance. Installation engineering function must ensure all documentation is maintained for each specific item of electrical apparatus which makes up the facility electrical power systems.

− Available From Design/Construction Files. The available data may include all of the inspection and testing procedures for the facility, copies of previous reports, single-line diagrams, schematic diagrams, electrical equipment plans, records of complete nameplate data, submittals, and manufacturer’s service manuals and instructions.

− Locally Prepared. Prepare local EPM forms as necessary for installed equipment. Show each item of apparatus on an equipment location plan. Provide unique apparatus designations along with a locally prepared safety electrical one-line diagram and equipment location plan.

• Specific Assembling of Data. Assemble the following data, if available, for each specific item of apparatus:

− Locally prepared forms and as-built drawings for electric equipment layouts and elevations.

− Trend analysis data to include:

−− Installation acceptance data test results; and

−− Previous EPM reports including any previous systematic evaluations.

− Manufacturer’s service manuals including practices and procedures for:

−− Installation;

−− Disassembly/assembly (interconnection);

−− Wiring diagrams, schematics, bills of materials;

−− Operation (set-up and adjustment);

−− Maintenance (including parts list and recommended spares);

−− Software programs; and

−− Troubleshooting guidance.

Systematic Evaluation of Apparatus Condition. Perform a systematic evaluation the electric apparatus condition after an EPM which indicates repairs were necessary beyond normal expected maintenance. The systematic evaluation to include:

• Reasons for the required repairs;

• Work required to complete the repairs;

• Assessment of the remaining service life; and

• Determination of the need for a more frequent EPM.

3-5 TESTING INTERVALS.

Appendix I provides recommended testing intervals.

Comply with DISA Circular 350-195-2 for testing intervals for DoD Information Network facilities’ electric power systems.

3-6 RISK MANAGEMENT ANALYSIS.

Risk management is covered under IEEE 399 Chapter 12 and IEEE 493 (Gold Book) which address system reliability. IEEE 493 covers the IEEE recommended practice for the design of reliable industrial and commercial power systems. Risk management is based upon the probability of certain types of devices failing at a given period of time, and addressing maintenance according to schedules to avoid unknown or indeterminate outages. By following the recommendations in these guides, many risks can be mitigated without substantial extraneous failures.

3-7 RELIABILITY AND AVAILABILITY.

Power operational availability is the probability a system is not failed or is undergoing a repair action when it needs to be used. Availability is typically expressed as “nines.” A ‘three nine’ availably equates to 0.999 availability or a 0.001 unavailability. A 0.001 unavailability means the system has the probability of being down 8.76 hours a year (Table 3-1). Power reliability refers to the failure probability and is typically expressed as a percentage. A very reliable system is one that can be repaired or the power brought back rapidly. Resiliency is the capacity of the system to bounce back from a failure or a fault. TM 5-698-3 provides additional reliability background information.

System redundancies, either through loop feeds and/or generators/distributed generation, combined with ability to replace quickly failed components, contribute to high overall system availability. Evaluate mission availability needs when establishing O&M program requirements, specifically address personnel training, critical tools and supplies, and contracted functions response requirements.

Table 3-1 Availability and Downtime

Availability Unavailability (1-availability)

Hours Per Year Downtime (8760 hours/year x unavailability)

Minutes Per Year

Downtime

0.99 (2-9s) 0.01 87.6 -

0.999 (3-9s) 0.001 8.76 -

0.9999 (4-9s) 0.0001 - 52.56

0.99999 (5-9s) 0.00001 - 5.256

3-8 LIFE CYCLE COST ANALYSIS.

Life cycle cost analysis (LCCA) is a good tool for establishing an O&M program or contract scope. LCCA uses the effect of equipment age on the likelihood of failure and maintenance costs to determine when replacement with new equipment becomes the most cost effective O&M solution. Use LCCA to help direct available resources to requirements with highest life cycle and mission payback.

• IEEE 493 provides guidance on recommended design practices for reliable power systems; and

• See Appendices F, G, and H for sample maintenance program checklists, LCCA maintenance work sheet, and a Man-hour Ceiling/Priority Analysis Method (MAPCO) recurring maintenance document.

3-9 RECORD DOCUMENTS - MANUALS, DIAGRAMS AND DRAWINGS.

A comprehensive file of equipment and service records provide the necessary information for aiding inspections, maintenance, or tests. In addition to indicating basic information required for proper inspection of the equipment, these records would indicate where trouble has been experienced and where special procedures may be warranted.

3-9.1 Operation and Maintenance (O&M) Manuals.

Ensure that O&M manuals are provided for any new equipment or…