13_27_54.01_10_AM_11.pdf

AM#11 READY TO ADVERTISE CLR039a LRDR Construction Package #1 - Clear AFS, Alaska

SECTION 13 27 54.01 10

HIGH ALTITUDE ELECTROMAGNETIC PULSE (HEMP) PROTECTION SUBSYSTEMS

PART 1 GENERAL

1.1 REFERENCES

The publications listed below form a part of this specification to the extent referenced. The publications are referred to within the text by the basic designation only.

AMERICAN WELDING SOCIETY (AWS)

AWS BRH (2007; 5th Ed) Brazing Handbook

AWS D1.1/D1.1M (2015; Errata 2015) Structural Welding Code - Steel

AWS D1.3 (1998; Errata 1998) Structural Welding Code - Sheet Steel

AWS D9.1M/D9.1 (2012) Sheet Metal Welding Code

ASTM INTERNATIONAL (ASTM)

ASTM A1008/A1008M (2015) Standard Specification for Steel, Sheet, Cold-Rolled, Carbon, Structural, High-Strength Low-Alloy and High-Strength Low-Alloy with Improved Formability, Solution Hardened, and Bake Hardened

ASTM A 227/A 227M (2006) Standard Specification for Steel Wire, Cold-Drawn for Mechanical Springs

ASTM A 36/A 36M (2014) Standard Specification for Carbon Structural Steel

INSTITUTE OF ELECTRICAL AND ELECTRONICS ENGINEERS (IEEE)

IEEE 299 (2006; R 2012) Standard Method for Measuring the Effectiveness of Electromagnetic Shielding Enclosures

IEEE 519 (2014) IEEE Recommended Practice and Requirements for Harmonic Control in Electrical Power Systems

NATIONAL ELECTRICAL MANUFACTURERS ASSOCIATION (NEMA)

NEMA ICS 6 (1993; R 2011) Enclosures

NEMA RN 1 (2005; R 2013) Polyvinyl-Chloride (PVC) Externally Coated Galvanized Rigid Steel Conduit and Intermediate Metal Conduit

SECTION 13 27 54.01 10 Page 1

READY TO ADVERTISE

NATIONAL FIRE PROTECTION ASSOCIATION (NFPA)

NFPA 70 (2014; AMD 1 2013; Errata 1 2013; AMD 2 2013; Errata 2 2013; AMD 3 2014; Errata 3-4 2014; AMD 4-6 2014) National Electrical Code

U.S. DEPARTMENT OF DEFENSE (DOD)

MIL-HDBK-423 (15 May 1993) High-Altitude Electromagnetic Pulse (HEMP) Protection for Fixed and Transportable Ground-Based C4I Facilities, Volume I: Fixed Facilities (Metric)

MIL-PRF-15733J (2010) Filters and Capacitors, Radio Frequency Interference, General Specification For

MIL-STD-188-125-1 (1998; Basic; Notice 1 2005) High-Altitude Electromagnetic Pulse (HEMP) Protection for Ground-Based C41 Facilities Performing Critical, Time-Urgent Missions, Part I Fixed Facilities

MIL-STD-220C (2009) Method of Insertion Loss Measurement

UNDERWRITERS LABORATORIES (UL)

UL 1283 (2015) Electromagnetic Interference Filters

UL 1449 (2014;Reprint Mar 2015) Surge Protective Devices

UL 6 (2007; Reprint Nov 2014) Electrical Rigid Metal Conduit-Steel

1.2 SYSTEM DESCRIPTION

This section covers the components, fabrications, installation, and testing for high-altitude electromagnetic pulse (HEMP) protection subsystems for Mission Control Facility (MCF), at Clear AFS, Alaska. The HEMP protection subsystems to be provided by the Contractor on this project include, but are not be limited to, the following:

a. The welded steel HEMP shields.

b. HEMP protection treatments at all penetrations for structural members through HEMP shields.

c. Shielded vestibule entryways, including shielded doors and associated door control, interlock, and alarm circuits, for personnel access into the HEMP protected areas of the facilities. Refer to Section 08 34 49.01 20 HEMP SHIELDED DOOR for detailed requirements.

d. Welded access closure panels for moving large equipment through facility HEMP shields.

e. Electrical filter/electrical surge arrester (ESA) assemblies for

SECTION 13 27 54.01 10 Page 2

HEMP protection at all electrical, communication, instrumentation and control penetrations through the facility HEMP shields.

f. Waveguides below cutoff and waveguide-below-cutoff arrays for HEMP protection at all piping and HVAC penetrations through HEMP shields.

g. Waveguides below cutoff for HEMP protection at all fiber optic cable penetrations through HEMP shields.

h. Shielded duct bank, including rigid steel conduits for HEMP protection of HEMP-hardened portions of the 12.47 kV and 480 V electrical distribution systems.

The HEMP protection subsystems shall comply with the requirements of MIL-STD-188-125-1 and shall be in general accordance with the guidelines of MIL-HDBK-423 unless otherwise shown in the HEMP design drawings or explicitly stated in these specifications. In the event of conflict between this specification and MIL-STD-188-125-1 or other specifications sections, the contractor shall notify the Contracting Officer in writing.

Pending resolution by the Contracting Officer, this specification section shall govern.

1.3 SUPERVISION BY HEMP PROTECTION SUBSYSTEM (SHIELDING) SPECIALIST

The HEMP protection subsystems shall be provided by a HEMP protection subsystem (shielding) specialist, approved by the Contracting Officer. The shielding specialist shall be an experienced firm that has been regularly and successfully engaged in the manufacturing, installation, and supervision of equivalent HEMP shielded systems.

1.3.1 Responsibilities of the Shielding Specialist

It shall be the responsibility of the shielding specialist to supply and install all materials, products, and services necessary for complete, tested, and operational HEMP protection subsystems. All work performed under this section shall be supervised and inspected by the shielding specialist. Materials and equipment shall be approved and verified by the shielding specialist before being submitted to the Contracting Officer for approval. HEMP protection subsystem submittals shall be date stamped and signed by the shielding specialist. The shielding specialist shall be responsible for coordinating the HEMP protection subsystem work with the work of all other trades that will interface with or affect the performance of the HEMP shields and penetration protection devices. The shielding specialist shall provide sufficient and qualified supervisory and quality control personnel on site to supervise the installation crew and to conduct in-progress quality assurance inspections and tests. In addition, the shielding specialist shall provide the services of a qualified and independent shield testing specialist to perform the acceptance testing.

1.3.2 Qualifications of the Shielding Specialist

The name and background qualifications of the firm that will be the shielding specialist on this project shall be provided to the Contracting Officer for approval. The principal work of this firm shall be the satisfactory installation and construction of EM shielded protection systems. The firm shall be experienced in successful installation, supervision, and testing of equivalent HEMP shielding systems for at least 5 years. Experience of the shielding specialist shall include achieving specified requirements for shielded system attenuation and maintainability

SECTION 13 27 54.01 10 Page 3 of attenuation levels on work performed. A project experience list shall be furnished for projects that are similar in scope and have been completed during the previous 5 years. A brief description of the shielding system and the name and telephone number of the user and/or owner of each project shall be included. The Contracting Officer may reject any proposed shielding specialist who cannot show documented evidence of qualifying satisfactory experience.

1.3.3 System Commissioning

Refer to Section 01 91 00.01 15 TOTAL BUILDING COMMISSIONING and 01 91 19.01 00 EXTERIOR ENCLOSURE COMMISSIONING for general Cx process requirements, definition of Cx team members, and delineation of responsibilities.

System commissioning is a part of the construction process. Documentation and testing of systems, as well as training of the user's operation and maintenance personnel, is required in cooperation with the Government's Commissioning Authority. Substantial Completion is dependent on successful completion of all commissioning procedures, documentation, and issue closure. Refer to Section 01 91 00.01 15 COMMISSIONING for detailed commissioning requirements.

1.4 SUBMITTALS

Government approval is required for submittals with a "G" designation;

submittals not having a "G" designation are for information only.

Submittals with an "S" designation following the "G" are for inclusion in the Sustainability Notebook, in conformance to Section 01 33 29.01 00 SUSTAINABILITY REPORTING. Other designations following the "G" designation identify the office that will review the submittal for the Government. Submit the following in accordance with Section 01 33 00.01 00

SUBMITTAL PROCEDURES:

SD-02 Shop Drawings

HEMP Filter/Surge Arrester Assemblies; G JCM Mechanical WBC Shop Drawings; G JC Facility HEMP Shielded Enclosure Shop Drawings; G JBCM Facility Sequence of Assembly Shop Drawings; G JCM HEMP Protection Subsystem As-Built assembly drawings; G JCM WBC Array Assemblies; G JCM Shielded Equipment Access Panels; G JCM

SD-03 Product Data

Shielded Doors (identification and experience, catalog cuts, and other printed documentation for standard products); G JCM

Electrical Filters (electrical schematics including component sizes and connectivity, physical layout, identification, manufacturer experience, catalog cuts, and other printed documentation for standard products); G JCM

Electrical Surge Arresters (identification and experience, catalog cuts, and other printed documentation for standard products); G JCM

Shielded Conduit PVC Coating Repair Plan; G JCM

SECTION 13 27 54.01 10 Page 4

SD-06 Test Reports

HEMP Quality Control Plan; G JCM Detailed QC Test Plans and Procedures; G JCM Daily HEMP QC Reports; G JM Welding Procedures; G JM Welder Qualification and Monitoring Procedures; G JM Facility Shielding Effectiveness Acceptance Test Plan; G JCM Facility Shielding Effectiveness Acceptance Test Report; G JCM Facility Pulsed Current Injection (PCI) Acceptance Test Plan; G JCM Facility PCI Acceptance Test Report; G JCM Electrical Filter Factory Test Plan;G JCM Electrical Filter Factory Test Report; G JCM ESA Factory Test Plan; G JCM ESA Factory Test Report; G JCM Extended Frequency Test Plan; G JCM Extended Frequency Test Report; G JCM HVAC WBC Assembly Factory Test Plan; G JCM HVAC WBC Assembly Factory Test Report; G JCM

SD-07 Certificates

Welder Qualifications; G JM Qualifications of the Shielding Specialist; G JM Shield Testing Specialist Qualifications; G JM PCI Testing Specialist Qualifications; G JM Industrial Standards Compliance Certificates, When Required; G JM Welder qualification certificates; G JM Welder Disqualification Notices; G JM Welder Recertification Notices; G JM

SD-08 Manufacturer's Instructions

Shielded Door Posted Operating Instructions; G JCM

SD-10 Operation and Maintenance Data

HEMP Protection Subsystem Operation and Maintenance Manual; G JCM HEMP Hardness Maintenance/Hardness Surveillance Manuals; G JCM

1.5 QUALIFICATIONS

1.5.1 HEMP Protection Subsystem (Shielding) Specialist

Shielding Specialist qualifications shall be in accordance with Part 1 paragraph Qualifications of the Shielding Specialist

1.5.2 Shield Testing Specialists

1.5.2.1 Shield Testing Specialist

The Shield Testing Specialist shall have qualifications in accordance with Paragraph ACCEPTANCE TESTING, paragraph Shield Testing Specialist.

1.5.2.2 PCI Testing Specialist

The PCI Testing Specialist shall have qualifications in accordance with Paragraph ACCEPTANCE TESTING, Paragraph PCI Testing Specialist.

SECTION 13 27 54.01 10 Page 5

1.5.3 Welders

Welder qualifications for welding on the facility HEMP shielded enclosure shall have qualifications in accordance with Subpart FACILITY HEMP SHIELDED ENCLOSURE, with Paragraph Welder Qualifications.

1.6 PREINSTALLATION CONFERENCE

A preinstallation conference for the HEMP protection subsystems shall be held with the Contractor and shielding specialist at the onset of the construction planning process. Coordination requirements shall be discussed and appropriate written instructions shall be developed as necessary to ensure the integrity of the shielding, penetration protection devices, and other HEMP protective measures.

1.7 MATERIALS, COMPONENTS, AND EQUIPMENT DELIVERY AND STORAGE

All HEMP protection subsystem materials, components, and equipment shall be delivered to the job site in a clean, corrosion-free, and undamaged condition. Materials, components, and equipment, along with the accompanying element identifications and certifications, shall be inspected by the shielding specialist upon receipt on site to ensure that they are the proper items and that their condition is satisfactory. Improper, defective, or damaged materials, components, and equipment shall be rejected and replaced at no additional cost. The Contractor and shielding specialist shall be responsible for adequately protecting HEMP protection subsystem elements during storage and after installation. Materials, components, and equipment shall be stored until ready for use under cover in a well-ventilated enclosure with proper drainage to prevent exposure to extreme temperature, humidity, moisture, dirt, and other contaminants that could cause damage.

1.8 FIELD MEASUREMENTS

The Contractor and shielding specialist shall become familiar with requirements and details of the HEMP protection subsystem work. They shall verify dimensions in the field and shall advise the Contracting Officer of any discrepancies before performing the work.

1.9 PROJECT/SITE REQUIREMENTS

Welding of HEMP shielding material and sheet steel shall be performed in accordance with the project welding procedures developed in Paragraph HEMP SHIELDED ENCLOSURE, paragraph Welding Procedures.

1.10 GENERAL HEMP QUALITY CONTROL REQUIREMENTS

1.10.1 HEMP Quality Control Plan

The Contractor and shielding subcontractor shall establish a quality control (QC) program to ensure that the HEMP protection subsystem is fabricated and assembled in accordance with the project drawings and these specifications. The QC program shall be documented in a HEMP Quality Control Plan, which shall be submitted to the Contracting Officer for approval within 30 days after notice to proceed. The plan shall include, but not be limited to, the following:

a. A description of the HEMP QC organization and its integration into job site management.

SECTION 13 27 54.01 10 Page 6

b. Names, qualifications, assignments, and responsibilities of leading QC personnel.

c. QC program methods for source quality control including specified in-factory testing, receiving inspections for purchased materials and components including review of accompanying data, on-site inspections and testing including in-progress weld inspections and testing, acceptance testing, and QC reporting.

Detailed QC test plans and procedures shall be provided as appendices to the QC plan or as separate documents.

1.10.2 Daily HEMP QC Reports

During the period when the HEMP protection subsystem is being assembled and during other periods when associated work is taking place, daily HEMP QC reports shall be submitted to the Contracting Officer within 24 hours of the date of the report. The daily report shall identify the type of work in progress, results of inspections and tests performed during the reporting day, and other relevant information.

1.10.3 Notification of Tests

The Government reserves the right to witness all specified in-factory and on-site tests of the HEMP protection components and subsystem. The Contracting Officer shall be notified at least 30 days before in-factory tests are scheduled to be performed and at least 14 days before on-site tests are scheduled to be performed.

1.11 OPERATION AND MAINTENANCE MANUAL

AM#11...HEMP Hardness Maintenance/Hardness Surveillance Manuals shall be provided in accordance with the requirements of MIL-STD-188-125-1 and MIL-HDBK-423, and paragraph OPERATION and MAINTENANCE (O & M) MANUALS in Section 01 78 23.01 00 OPERATION AND MAINTENANCE DATA, except as required in this section. The HM/HS manuals shall address all HEMP shielding systems and components within the scope of this project. The contents shall include, but not be limited to, the following:...AM#11

a. This construction specification section for the HEMP protection subsystems including all approved change orders.

b. A complete set of as-built assembly drawings including shield penetration locations and installation details.

c. As-built shield penetration schedules.

d. The as-built filter/electrical surge arrester assembly schedule.

e. The list of hardness critical items (HCIs) and hardness critical assemblies (HCAs) incorporated into the HEMP protection subsystem.

The list shall include the item/assembly nomenclature, manufacturer, manufacturer's part number, and federal stock number (if assigned).

f. The acceptance test plan and the acceptance test report.

g. Preventive maintenance instructions for periodic inspection, SECTION 13 27 54.01 10 Page 7 testing and servicing, lubrication, alignment, calibration, adjustment,and other routine maintenance actions. The maintenance instructions shall be extracted from vendor or manufacturer data or, in the case of complex instructions, may refer to the manufacturer's data. This information shall be derived from engineering data considering local environmental conditions, manufacturer's recommendations, estimated operating life for the specific application and use of the equipment, and types of job skills available at the operating site.

h. Repair and replacement procedures for all hardness critical items are as follows: The procedures shall include instructions and drawings necessary for the repair or replacement, requirements for tools and supplies, and other information needed to perform the corrective maintenance. The procedures shall also identify testing required to verify that the maintenance has been properly done and the required HEMP performance has been restored.

i. The shielding specialist's recommendations for spare and repair parts, maintenance supplies, and special tools and test equipment.

j. Manufacturers' data for all shielded doors, filter/electrical surge arrester assemblies, and other purchased HCIs and HCAs used in the HEMP protection subsystem.

AM#11...1.12 Deleted...AM#11

1.13 WORKMANSHIP

All work required under this section shall be performed in a professional manner and shall be in accordance with accepted industry standards. All materials, components, equipment, and assemblies shall be of good quality, uniform in appearance, and free of defects that affect life, performance, or serviceability.

1.14 SYSTEM COMMISSIONING

System commissioning is a part of the construction process. Documentation and testing of systems, as well as training of the Owner's operation and maintenance personnel, is required in cooperation with the Government's Commissioning Authority. Substantial Completion is dependent on successful completion of all commissioning procedures, documentation, and issue closure. Refer to Section 01 91 00.01 15 COMMISSIONING for detailed commissioning requirements.

PART 2 PRODUCTS

2.1 GENERAL REQUIREMENTS

2.1.1 New and Standard Products

All materials, components, and equipment shall be new and shall be standard products of a manufacturer regularly engaged in the manufacture of such products. The products shall essentially duplicate items that have been in satisfactory use for a period of at least 2 years prior to bid opening.

Equipment shall be supported by a service organization that is, in the opinion of the Contracting Officer, reasonably convenient to the site.

Vendor identification and experience data, catalog cuts, and other printed documentation shall be submitted to the Contracting Officer for approval.

SECTION 13 27 54.01 10 Page 8

2.1.2 Nameplates and HCI Marking

Each major item of equipment shall have the manufacturer's name, address, type or style, model or serial number, and catalog number on a plate secured to the item of equipment. In addition to the nameplate, each hardness critical item (HCI) or hardness critical assembly (HCA) shall be distinctively marked with a Hardness Critical Label, DD form 2639, or a Hardness Critical Tag, DD Form 2640.

2.1.3 Reliability, Maintainability, Testability, and Safety

Materials, component, and equipment shall be designed and built to be rugged and reliable and to facilitate maintenance and testing. They shall be engineered for safety of personnel during operation, routine maintenance and testing, and repairs.

2.1.4 Standards Compliance

When material, components, and equipment are specified to conform to requirements of standards published by industrial organizations, such as ASTM or ANSI, proof of such conformance shall be provided to the Contracting Officer. The label and listing of the specified organization will be acceptable evidence. In lieu of the label and listing, a written compliance certificate stating that the item has been tested and conforms to the specified standard from a testing organization equipped and competent to perform such testing shall be submitted.

2.1.5 Corrosion Control

Materials, components, and equipment shall be inherently corrosion resistant, or they shall be protected against corrosion by metallurgical processing, use of coatings, or other means.

2.1.6 Factory Test Plans

Detailed test plans/test procedures shall be prepared for all required factory tests by the Contractor and shielding specialist and shall be submitted to the Contracting Officer for approval. The test plan contents shall include an introduction that states the purpose of the testing, a list of tests to be conducted, and the testing location and schedule; a list of applicable references; a general description of each test method and the associated test equipment requirements; detailed procedures including test equipment calibration, test configurations, measurement locations, data requirements, and pass/fail criteria; examples of all test data sheets, and the format and outline of the test report to be provided.

With the approval of the Contracting Officer, previous documented tests of components that are identical to those to be provided will be allowed to substitute for in-factory type tests.

2.1.7 Factory Test Reports

Factory test reports shall be prepared for all required factory tests by the Contractor and shielding specialist and shall be submitted to the Contracting Officer. The format shall be in the format described in the approved factory test plan. The contents shall include copies of measured and processed test data, identification and rationale for any deviations from the test plan, and pass/fail conclusions.

SECTION 13 27 54.01 10 Page 9

2.2 SHIELDING EFFECTIVENESS

The HEMP shielded system, complete with all equipment access covers, waveguides below cutoff, and other penetration protection devices, shall provide at least the minimum shielding effectiveness described in this paragraph and shown in Figure 1, of MIL-STD-188-125-1, when measured in accordance with shielding effectiveness test procedures in Appendix A of MIL-STD-188-125-1. The minimum magnetic field attenuation shall be 0 dB at 1 kHz, increasing at 20 dB per decade to 80 dB at 10 MHz; the minimum magnetic field attenuation shall be 80 dB from 10 MHz to 20 MHz. The minimum resonant range/plane wave attenuation shall be 80 dB from 20 MHz to 1 GHz.

2.3 HEMP SHIELDED ENCLOSURE

The intent of this subsection of the specifications and the drawings is to form a continuous HEMP shielded enclosure consisting of metal walls, floor, and ceiling; embedded metal structural members; appropriate protection devices at all other shield penetrations; and welds to close the seams and joints between adjacent plates and between the plates and other elements.

2.3.1 Shop Drawings

Shop drawings for the HEMP shielded enclosure, including all shield penetrations and penetration protection devices and treatments, shall be prepared by the Contractor and shielding specialist and submitted to the Contracting Officer for approval before shield assembly and installation is commenced. The drawings shall provide a complete list of materials and parts, sizes, arrangements, and the methods and sequence of assembly.

Layouts of the shield plates, details for welding the seams and joints, connections to structural members, and all other attachments to the shield shall be detailed. The number and locations of penetrations and the method of HEMP protection at each penetration shall be shown. Hardness critical items and hardness critical processes shall be identified on the drawings with HCI and HCP symbols, respectively, per MIL-STD-188-125-1 and

MIL-HDBK-423.

2.3.2 Shield Plates

The metal plates used to form the shield walls and floor shall be steel, 1/4 inch in thickness and conforming to ASTM A 36/A 36M. The metal plates used to form the ceiling shields shall be steel, 1/8 inch in thickness and conforming to ASTM A 36/A 36M. The floor shield plates shall be as shown in the HEMP design drawings, based upon reference HEMP details included in design documents. All steel sheets shall be free of oil, rust, dents, and other defects. All surface area on each side of the shield plates that will not require welding during installation shall be coated in shop with a rust inhibiting primer per Section 09 90 00.01 00 PAINTS AND COATINGS.

After installation and welding is complete, the primer shall be touched up/repaired. Exposed areas of shielded plates shall be finished per the room finish schedule.

2.3.3 Other Metal Shield Members

Structural steel shapes, plates, and miscellaneous metal shall conform to ASTM A 36/A 36M. Furring channels shall conform to ASTM A1008/A1008M. All surfaces of the members that will not require welding during installation shall be coated in shop with a rust inhibiting primer per Section 09 90 00.01 00 PAINTS AND COATINGS. After installation and welding is

SECTION 13 27 54.01 10 Page 10 complete, the primer shall be touched up/repaired. Exposed area of shield members shall be finished per the room finish schedule.

Metal shield members include, but are not limited to:

Strips, angles, and other items used to join individual wall shield plates and to join the wall shield to the floor and ceiling shields.

2.3.4 Penetration Plates

Penetration plates shall be used for treatment of penetrations of the HEMP shield. The plates shall be constructed of 1/4 inch thick ASTM A 36/A 36M steel plate welded to the shield or as shown on drawings. Waveguide, conduit, and piping penetrations shall be circumferentially welded at the point of penetration to the inner surface of the penetration plate.

Penetration plates shall extend at least 6 inches beyond all penetrations, unless otherwise detailed on HEMP design drawings, based upon reference HEMP details included in design documents. Plate penetration devices shall be shop fabricated, unless otherwise indicated.

2.3.5 Floor Shield Anchors

Self-tapping screws shall not be used for attachment of shielding.

Power-actuated or manually driven pins may be used. Pins shall be steel, Type I, pin size No. 4 to secure steel sheets to concrete surfaces and to light gauge furring channels. The drive pins shall conform to ASTM A 227/A 227M Class 1 for materials.

2.3.6 Mounting Rails

Unistrut (or approved equal) rails and other strips or attachments shall conform to ASTM A1008/A1008M and shall be tack welded to the shield for mounting equipment or as detailed on the drawings. Welds and attachments shall not penetrate the shield in any way to impair its shielding properties.

2.3.7 Welding Procedures and Welder Qualification and Monitoring Procedures

2.3.7.1 Welding Procedures

The Contractor and shielding specialist shall prepare detailed procedures for all types of welds required for assembling the facility HEMP shielded enclosure and installing the shield penetration protection devices. The procedures shall be derived from the appropriate AWS standard(s) and shall define the types of welds, the welding materials to be used, detailed procedures, and the ambient environmental conditions to be maintained. The welding procedures shall be submitted to the Contracting Officer. The welding procedures employed shall emphasize the requirement for continuous or circumferential, defect-free, low resistance welds at the above locations.

2.3.7.2 Welder Qualification and Monitoring Procedures

The Contractor and shielding specialist shall prepare detailed procedures for training and qualifying HEMP protection subsystem welders on the specific types of welds that they will be performing. They shall also develop procedures for monitoring the quality of the welds produced in the field by each qualified welder. The welder qualification and monitoring procedures shall be submitted to the Contracting Officer for approval.

SECTION 13 27 54.01 10 Page 11

2.3.7.3 Welder Qualifications

Welding on the HEMP protection subsystem shall be performed only by qualified and certified welders. The Contractor shall provide the names of the welders to be employed and certification that each welder has passed qualification tests within the last 2 years in the processes specified in AWS D1.1/D1.1M, AWS D9.1M/D9.1, and as required by the Shielding Specialist and the Contracting Officer. Welder qualification certificates shall be submitted to the Contracting Officer for each qualified welder before that individual is permitted to perform work on the project. Whenever the results of welder monitoring creates a reasonable doubt of a welder's proficiency, that individual shall be removed from the job and retrained/recertified or discharged. Welder disqualification notices and recertification notices shall be provided to the Contracting Officer within 24 hours of the event.

2.3.8 Miscellaneous Metal Parts

Miscellaneous bolts and anchors, supports, braces, and connections necessary to complete the miscellaneous metal work shall be provided. The necessary lugs, rebar, and brackets to assemble work shall be provided.

Miscellaneous metal parts that attach to the HEMP shield shall designed to be tack welded or continuous welded to the shield unless otherwise shown in the HEMP design drawings, based upon reference HEMP details included in design documents. Bolts and screws shall not penetrate the HEMP shield.

Thickness of metal and details of assembly and supports shall provide ample strength and stiffness. The materials shall be galvanically similar.

Refer to HEMP design drawings, based upon reference HEMP details included in design documents for further information.

2.4 HEMP FILTER/SURGE ARRESTER ASSEMBLIES

2.4.1 General HEMP Performance Requirements

Filters and surge arresters shall be provided for all electrical conductors that penetrate the facility HEMP shielded enclosure. These conductors shall include, but not be limited to, power circuits, data lines, communications lines, alarm circuits, lighting circuits, and signal lines such as telephone lines, antenna lines, HVAC control lines, and fire alarms. However, all lines but power circuits shall be converted to fiber to penetrate the shield rather than installing filters unless otherwise approved as a variance with exception to the HEMP door controls. The combination of filters and ESAs shall pass the circuit operating signals, but shall limit the norms of the residual internal transient stresses to the maximums prescribed in MIL-STD-188-125-1, when prescribed pulses are injected at the external terminals. Filters and ESAs shall be installed in shielded enclosures that will meet the system shielding effectiveness requirement (see Paragraph SHIELDING EFFECTIVENESS) and protect the devices from moisture and mechanical damage.

2.4.2 General Electrical Requirements

Filters shall comply with NFPA 70 and UL 1283. The label and listing of the Underwriters Laboratories or other nationally recognized testing laboratory will be acceptable evidence that the material or equipment conforms to the applicable standards of that agency. In lieu of the label or listing, a certificate may be furnished from an acceptable testing organization adequately equipped and competent to perform such services.

SECTION 13 27 54.01 10 Page 12

The certificate shall state that the items have been tested and that they conform to the specified standard. Live parts shall be spaced in accordance with NFPA 70. Filters shall be labeled and built to have standard short circuit withstand ratings in accordance with UL 1283. The minimum ratings shall be greater or equal to the available short circuit current at the location of the filter.

2.4.3 Spare Filters and ESAs

At least 10 percent spares of each type of filter elements and ESA installed at the site shall be provided as spare and replacement parts.

2.4.4 Filter/ESA Enclosure

2.4.4.1 Enclosure Construction

Filter/ESA assembly enclosures shall be two-compartment electrical enclosures, constructed of steel and conforming to NEMA ICS 6 and meeting the requirements of UL 1283. The "dirty" (topologically outside the HEMP shield) compartment shall be of sufficient size to install the number of filters, surge arresters, and the associated wiring, with sufficient room to satisfy the requirements of NFPA 70 for spacing between live parts and wire bending space. The "clean" (topologically inside of the HEMP shield) compartment shall be of sufficient size to allow routing of the number and size of conductors required and to provide NFPA 70 wire bending space.

Both the input compartment and the output compartment shall be a shielded enclosure with welded seams and shall be separated from the other compartment by a steel barrier plate that extends across the entire width of the enclosure and is circumferentially welded to the enclosure walls.

Removable covers with handles shall be provided for access into both compartments; When installed as shown in the HEMP design drawings, the complete filter/ESA assembly enclosure, including the compartment covers and conduit connections, shall provide shielding effectiveness consistent with that of the HEMP shielded system described in Paragraph SHIELDING

EFFECTIVENESS.

2.4.4.2 Filter and ESA Mounting

Filter cabinet inserts shall be mounted on the barrier plate between the two compartments to provide an RF tight seal between the barrier plate and the filter case. The filter insert terminals shall project into the "clean" compartment through holes drilled in the barrier. The filter insert case shall also be mounted to and supported by the structure of the "dirty" input compartment as needed to prevent physical stress being applied to the RF seal. The filter cabinet inserts shall be individually removable and replaceable.

ESAs shall be mounted in the "dirty" compartment and shall be mounted to and supported by the structure. The mounting location shall be chosen to minimize the length of the conductor from the high-voltage terminal of the ESA to the filter terminal. The ground terminal of the ESA shall be electrically connected to the input compartment structure as recommended by the ESA manufacturer.

2.4.4.3 Conduit Connections to the HEMP Filters

Conduits shall be circumferentially welded to the shielded compartments of the HEMP filter/ESA enclosure as required and shown on the HEMP design drawings, based upon reference HEMP details included in design documents.

SECTION 13 27 54.01 10 Page 13

2.4.4.4 Test Penetrations

There shall be two capped N-type bulkhead feedthrough connectors and two 0.346-inch diameter X 2-inch long fiber optic waveguide below cutoff penetration protective devices through the barrier between the two compartments for use in performing pulsed current injection testing.

2.4.5 Electrical Filters

Filters shall be new and shall be standard products of a manufacturer regularly engaged in the manufacture of such products for at least the previous 5 years. The filters shall essentially duplicate items that have been in satisfactory use for a period of at least 2 years prior to bid opening. Filter vendor identification and experience data, drawings and catalog cuts for the filters to be supplied, manufacturer recommended installation and maintenance procedures, and other printed documentation shall be submitted to the Contracting Officer for approval at least 60 days before shield assembly and installation is scheduled to commence. All filters with the same operational ratings and functional requirements for the project shall be provided by the same manufacturer and shall be of the same model number.

2.4.5.1 Orientation

Filters shall be designed for operation, transport, and storage in any orientation.

2.4.5.2 Interchangeability

Filters with the same current and voltage ratings and functional requirements and furnished under the same part number shall be interchangeable, except filters not operated in parallel do not require current sharing tests. Filters not tested for parallel operation shall be labeled "NOT APPROVED FOR PARALLEL OPERATION".

2.4.5.3 Safety

Filters shall conform to the safety standards of UL 1283 and shall be listed and labelled by a Nationally Recognized Testing Laboratory.

2.4.5.4 Filter Construction

a. Filter Case: Filter components shall be securely mounted in an RF tight case for protection from moisture and mechanical damage. Power filters shall be heavy-duty type, and hermetically sealed in a steel case. The power filters shall be filled with a nonflammable impregnating or encapsulating compound that is chemically inactive with respect to the filter components and the case. If the compound is liquid, the seams of the case shall be welded. When a solid compound is used, the seams of the case may be sealed with solder.

b. Terminal Strength: Filter terminals shall withstand a 20-pound pull without damage or degradation when tested as detailed in the filter testing portions of this specification. Power filters shall be equipped with ceramic-insulated standoff terminals with threaded studs.

SECTION 13 27 54.01 10 Page 14

2.4.5.5 Filter Performance Requirements

a. Operational Ratings: The operating voltage ratings, the full-load current ratings, and the operating frequency or frequency band of electrical filters shall be as required for the equipment being installed and indicated in the design documents.

b. Insertion Loss: Filters shall provide insertion loss that meets or exceeds 100 dB from 14 kHz to 1 GHz for HEMP protection as detailed in the filter testing portions of this specification.

c. Voltage Drop: Voltage drop through the filters at their operating frequency and their rated full-load current into a resistive load shall not exceed two percent of the rated operating voltage. Voltage drop measurements shall be as detailed in the filter testing portions of this specification.

d. Current Overload Capability: Filters shall be capable of operating at 140 percent of their rated full-load current for 15 minutes without damage or degradation when tested in accordance with the filter testing portions of this specification.

e. Reactive Shunt Current: The reactive shunt current drawn by filters operating at rated voltage and frequency shall not exceed 40 percent of the rated full-load current when measured in accordance with the filter testing portions of this specification.

f. Current Sharing Among Parallel Filters: When two or more individual filters are connected in parallel to essentially form a larger filter, they shall equally share the load current. Equal sharing is defined to be within five percent of the average current.

g. Dielectric Withstanding Voltage: When tested in accordance with the filter testing portions of this specification, there shall be no breakdown, flashover, or impairment of any characteristic qualities sufficient to cause failure of the filter. The test voltage shall be dc and at a minimum shall be 2.5x rated voltage for dc-only rated filters, 2.5x rated dc voltage for filters with ac and dc ratings, and 2.8x rated rms voltage for ac-only rated filters. Each filter and its associated ESA, when operating at rated voltage and frequency, shall also be capable of withstanding a 20 kV (peak) or 4 kA (peak) transient pulse, with a full width at half-maximum amplitude of 20 nanoseconds, without damage or degradation.

h. Insulation Resistance: The insulation resistance between filter terminals and ground shall be greater than one megaohm when measured in accordance with the filter testing portions of this specification.

i. Harmonic Distortion: Harmonic content generated by the insertion of filters into circuits operating at rated voltage, frequency, and specified percentages of rated full-load current shall not increase line voltage distortion more than 2.5 percent with a unity power factor when tested in accordance with the filter testing portions of this specification.

j. Operating Temperature Range: Filters shall be designed for continuous operation at rated voltage, frequency, and full-load current in ambient temperatures from minus 55 degrees C to plus 85 degrees C.

Filters shall withstand temperature cycling without damage and

SECTION 13 27 54.01 10 Page 15 degradation.

k. Inductive Input Element: Filters shall be provided with inductive inputs. The input inductor shall ensure firing potential for the preceding ESA and shall limit the current through the filter capacitors. The input inductor shall be designed to withstand a 20-kV transient for 20 nanoseconds without damage or degradation.

l. Drainage of Stored Charge: Filters shall be provided with bleeder resistors to drain the stored charge from the capacitors when the filters are deenergized. Drainage of stored charge shall be in accordance with UL 1283.

m. Filter Life: Filters shall be designed for a minimum service life of 15 years.

2.4.5.6 Filter Factory Inspections and Tests

Visual inspections shall be conducted on 100 percent of the filters to be provided on this project to ensure that the units are of high quality and workmanship, to verify that the filter cases are properly sealed, and to ensure that they are properly marked with required standards compliance labels, nameplates, and HCI labels.

At least one electrical filter of each type to be provided to the project shall be factory tested to demonstrate satisfactory compliance with requirements for terminal strength, insertion loss, voltage drop, current overload capability, reactive shunt current, dielectric withstanding voltage, insulation resistance, harmonic distortion, and life at elevated temeperature. An Electrical Filter Factory Test Plan for the electrical filters shall be prepared by the Contractor and shielding specialist and shall be submitted to the Contracting Officer for approval. The Contractor shall notify the Contracting Officer at least 30 days before the scheduled performance of the factory tests, and the Government reserves the right to witness all required testing. Factory test results shall be documented in an Electrical Filter Factory Test Report and submitted to the Contracting Officer. The test filters shall not be furnished on the project.

A variance to performing the factory testing may be requested if the same filter type and model number by the same manufacturer was tested and provided as part of previous GMD projects at either Ft. Greely or Eareckson AS. The request for variance must include a letter from the manufacturer indicating that the type previously provided is the same, with no modifications, as that being provided now.

a. Terminal Strength Test: The filter shall be mounted and grounded in the filter/ESA assembly enclosure or mounted and grounded on a metal plate by the same methods that will be used for mounting and grounding in the enclosure. The maximum force to be applied to the terminals shall be 20 pounds. The force shall be applied gradually to the terminal under test in the direction of the axis of the terminal and shall be maintained at the maximum value for a period of 10 seconds.

The terminal shall be visually inspected after the test for broken seals, cracking of the materials surrounding the terminal, and other signs of damage or degradation. The filter terminal strength test shall be conducted before the electrical tests described in Paragraph Filter Performance Requirements, Items b through j.

b. Insertion Loss Measurements: The filter insertion loss

SECTION 13 27 54.01 10 Page 16 measurements shall be performed using the methodology specified in MIL-STD-220C with modifications as described below. The filter shall be mounted and grounded in the filter/ESA assembly enclosure or mounted and grounded on a metal plate by the same methods that will be used for mounting and grounding in the enclosure. For power filters, the load current power supply shall be capable of providing the equivalent of any current from no-load through full-load current. Insertion loss measurements shall be performed at 20 percent, 50 percent, and 100 percent load for frequencies between 14 kHz to 20 MHz and no load between 14 kHz to 10 GHz, inclusive.

c. Voltage Drop Measurements: The voltage drop measurements shall be performed with filter mounted and grounded in the filter/ESA assembly enclosure or mounted and grounded on a metal plate by the same methods that will be used for mounting and grounding in the enclosure.

d. Current Overload Test: The filter current overload test shall be performed in accordance with MIL-PRF-15733J, subsection 4.6.10, except that the filter shall be mounted and grounded in the filter/ESA assembly enclosure or mounted and grounded on a metal plate by the same methods that will be used for mounting and grounding in the enclosure.

The filters shall be loaded at 200 percent overload for one minute and 140 percent overload for 15 minutes.

e. Reactive Shunt Current Measurements: The reactive shunt current measurement shall be performed with the filter mounted and grounded in the filter/ESA assembly enclosure or mounted and grounded on a metal plate by the same methods that will be used for mounting and grounding in the enclosure. The filter output compartment terminal shall be open circuited. Rated operating voltage shall be applied between the filter input terminal and the enclosure or metal plate, and the ac current into the filter input terminal shall be monitored. This measured current is equal to the filter reactive shunt current.

f. Dielectric Withstand Voltage Test: The filter dielectric withstanding voltage test shall be performed in accordance with MIL-PRF-15733J, subsection 4.6.5, or UL 1283, with modifications as described below. The filter shall be mounted and grounded in the filter/ESA assembly enclosure or mounted and grounded on a metal plate by the same methods that will be used for mounting and grounding in the enclosure. The test voltage shall be dc and at a minimum shall be 2.5x rated voltage for dc-only rated filters, 2.5x rated dc voltage for filters with ac and dc ratings, and 2.8x rated rms voltage for ac-only rated filters. In addition to the post-test physical examination, insulation resistance measurements shall be made (or repeated) after the dielectric withstanding voltage test.

g. Insulation Resistance Measurements: The filter insulation resistance (terminal-to-ground) measurement shall be performed in accordance with MIL-PRF-15733J, subsection 4.6.7, or UL 1283, with modifications as described below. The filter shall be mounted and grounded in the filter/ESA assembly enclosure or mounted and grounded on a metal plate by the same methods that will be used for mounting and grounding in the enclosure. The test shall be conducted at the largest test condition voltage that does not exceed the rated peak ac operating voltage or the rated dc voltage. The insulation resistance reading shall be recorded after the reading has stabilized, rather than at a specified time.

SECTION 13 27 54.01 10 Page 17

h. Harmonic distortion measurements shall be made using test equipment suited for the purpose. In accordance with the requirements provided in IEEE 519, measurements shall be made up to the 35th harmonic order.

Total harmonic distortion shall be measured at the input and output terminals of the filter when operating at 25, 50, and 100 percent of rated full-load current.

i. Filter Life Test: The un-energized filter shall be heated to 85 plus/minus 5 degrees C for 24 hours, then immediately energized and operated at full load current and rated voltage for 8 hours. Following this test, the insertion loss shall be measured. In lieu of performing this test, a list of prior installations where the same filter type has been in service for at least 5 years may be provided.

2.4.6 Electrical Surge Arresters

ESAs shall be new and shall be standard products of a manufacturer regularly engaged in the manufacture of such products for at least the previous 5 years. The ESAs shall essentially duplicate items that have been in satisfactory use for a period of at least 2 years. ESA vendor identification and experience data, drawings and catalog cuts for the ESAs to be supplied, manufacturer recommended installation and maintenance procedures, and other printed documentation shall be submitted to the Contracting Officer for approval at least 60 days before shield assembly and installation is scheduled to commence. All ESAs with the same operational ratings and functional requirements at the site shall be provided by the same manufacturer and shall be of the same model number.

ESA single 8 x 20 us pulse peak kA rating shall be 50 kA for power filters and 10 kA for control filters.

2.4.6.1 Orientation

ESAs shall be designed for operation, transport, and storage in any orientation.

2.4.6.2 Interchangeability

ESAs with the same operational ratings and functional requirements and furnished under the same part number shall be interchangeable.

2.4.6.3 Safety

ESAs used in conjunction with HEMP filters shall be recognized per UL 1449, 3rd Edition.

2.4.6.4 Terminal Strength

ESA terminals shall withstand a 20 pound pull without damage and degradation when tested in accordance with the ESA testing portions of this specification.

2.4.6.5 ESA Performance Requirements

a. Operational Ratings: The operating voltage ratings, the full-load current ratings, and the operating frequency or frequency band of the circuits on which the ESAs will be installed shall be rated for the installed equipment and as described in the design documents.