Electrical Exterior Facilities

ARMY TM 5-684NAVY NAVFAC MO-200

AIR FORCE AFJMAN 32-1082

TECHNICAL MANUAL

FACILITIES ENGINEERINGELECTRICAL EXTERIOR FACILITIES

APPROVED FOR PUBLIC RELEASE: Distribution is unlimited

DEPARTMENTS OF THE ARMY, THE NAVY, AND THE AIR FORCE 29 November 1996

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

REPRODUCTION AUTHORIZATION/RESTRICTIONS

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

Copyrighted material included in the manual has been used with theknowledge and permission of the proprietors and is acknowledged assuch at point of use. Anyone wishing to make further use of anycopyrighted material, by itself and apart from this text, should seeknecessary permission directly from the proprietors.

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

If the reprint or republication includes copyrighted material, thecredit should also state: Anyone wishing to make further use ofcopyrighted material, by itself and apart from this text, should seeknecessary permission directly from the proprietor.

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

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


HEADQUARTERSTECHNICAL MANUAL No. 5-684

>

DEPARTMENTS OF THE ARMY,NAVY PUBLICATION NAVFAC MO-200 THE NAVY, AND THE AIR FORCEAIR FORCE JOINT MANUAL No. AFJMAN 32-1082 WASHINGTON , D.C. 29 November 1996

ELECTRICAL EXTERIOR FACILITIES

CHAPTER 1. INTRODUCTIONSECTION I-PRIMARY CONSIDERATIONS

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

SECTION II-SAFETYMinimizinghazards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Qualification of electric workers. ..........................................................Certification of electric workers ...........................................................Publicsafety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Personnel safetyy . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Live-linemaintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION III-AVOIDING PROBLEMSOperating conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Detecting potential trouble ...............................................................Electrical connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

CHAPTER 2. INSPECTION AND TESTSSECTION I-PERFORMANCE

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

SECTION II-REQUIREMENTSElectric workers, instruments, and reportsFrequencyofinspection.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

CHAPTER 3. TRANSMISSION AND DISTRIBUTION SUBSTATIONSSECTION I-GOVERNING CONSIDERATIONS

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

SECTION II-STRUCTURE MAINTENANCEImportance of maintenance.... .1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Galvanized steel structures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Painted steel structures.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Aluminumstructures.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Wood structures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Concrete for structure foundations ........................................................Structure connections and joints ..........................................................

SECTION III-SUBSTATION YARDSProvisionofyards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Fences for yards.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Warningsignsatyards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Substation yardss . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Paragraph Page

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

l - ll - ll - ll - ll - ll-2l-2

l-8l-9l-10l-111-121-13

l-3l-3l-3l-3l-3l-3

1-14 l-41-15 l-41-16 l-4

2-l 2-l2-2 2-l2-3 2-l

2-4 2-22-5 2-2

3-l 3-l3-2 3- l3-3 3-l3-4 3-l3-5 3-l3-6 3-l3-7 3-l

3-8 3-23-9 3-23-10 3-33-11 3-33-12 3-33-13 3-33-14 3-3

3-15 3-33-16 3-33-17 3-33-18 3-3

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


SECTION IV-INSULATORSFunction of insulators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Testsofinsulators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Inspection and repair of insulators ........................................................Cleaningofinsulators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION V-BUS STRUCTURESDefinitionofbus structures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Maintenance of bus structures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Cleaningofbus structures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Testingofbus structures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION VI-INSTRUMENT TRANSFORMERSDefinitions of instrument transformers ....................................................Short-circuiting dangers. .................................................................Maintenanceofinstrumenttransformers.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Tests of instrument transformerss . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION VII-BUSHINGSDefinition of bushings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Type of bushings covered . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Maintenanceofbushings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Bushingpowerfactortests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Bushing insulation resistance test. ........................................................

CHAPTER 4. OVERHEAD DISTRIBUTIONSECTION I-ASSOCIATED OVERHEAD DISTRIBUTION GUIDANCE

Relevant overhead distribution guidance. ..................................................General construction guidancee . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION II-DEFINING VOLTAGE NOMENCLATUREVoltage terminology . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Voltagelevelclassification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Voltagedeliveryusage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Voltage origination point ..................................................................Voltage terminology usage in this manual .................................................

SECTION III-TYPES OF MAINTENANCEComponentlinemaintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Other types of line maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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

SECTION V-CROSSARMS, BRACES, AND PLATFORMSPolecrossarms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Pole braces . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Pole platforms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION VI-MAINTENANCE WOOD PRESERVATIONInitialwoodtreatment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .In-place wood treatment above ground ....................................................Wood pole treatment at or below the ground line. ..........................................

SECTION VII-METAL POLESMetalpoleusage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Distribution line metal poles ..............................................................Transmission line metal towers ...........................................................Pole-linemetalhardware . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Paintingofmetalpoles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Paragraph Page

3-193-203-213-22

3-43-43-43-5

3-23 3-73-24 3-73-25 3-73-26 3-7

3-27 3-73-28 3-73-29 3-73-30 3 -8

3-31 3 -83-32 3-83-33 3-83-34 3-103-35 3-12

4-14-2

4 -34 -44-54 -64-7

4 -84 -9

4-44-4

4-10 4-44-11 4-44-12 4-44-13 4-64-14 4-64-15 4-74-16 4-94-17 4-104-18 4-10

4-19 4-114-20 4-124-2 1 4-12

4-22 4-134-23 4-134-24 4-13

4-25 4-144-26 4-154-27 4-154-28 4-154-29 4-15

,-

ii


Paragraph

SECTION VIII-CONCRETE POLESConcrete pole overvieww . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Concrete pole foundations ................................................................

SECTION IX-OVERHEAD OPEN WIRE CONDUCTORSOverhead conductor construction. .........................................................Overheadconductormaterial . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Overhead conductor covering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Overheadconductorsag . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Overheadconductordamage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Overheadconductorrepairs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION X-OVERHEAD CABLEOverhead cable construction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Overhead cable repair requirements. ......................................................

SECTION XI-CONDUCTOR CONNECTIONSOverhead line conductor requirements. ....................................................Overhead line conductor splices. ..........................................................Overhead line connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Overheadline armor rods _ . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION XII-POLE-LINE INSULATORSPole-line insulator related material. .......................................................Insulator operating performance.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Types of pole-line insulators... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Pole-line insulator class requirements .....................................................

SECTION XIII-GUYSGuy functional requirements. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Guy strand . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Anchor assemblies.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Guy attachments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Guystraininsulators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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

SECTION XV-LIVE-LINE MAINTENANCELive-line maintenance requirements. ......................................................Categories of energized-line maintenance ..................................................Energized-linemethods . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Live-line operations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION XVI-AERIAL LIFT REQUIREMENTSAerial lift construction ...................................................................Aerial lift specificss . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

CHAPTER 5. UNDERGROUND AND SUBMARIK E CABLESSECTION I-ASSOCIATED GUIDANCE

Relevant cable guidance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .General construction guidance ............................................................

SECTION II-SAFETY PRECAUTIONSCablesafety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Structure safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION III-INSPECTIONFrequency of underground system inspections. .............................................Structureinspections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Cableinspections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Underground equipment inspections ......................................................

4-304-31

4-154-15

4-32 4-164-33 4-164-34 4-164-35 4-164-36 4-174-37 4-18

4-38 4-184-39 4-18

4-40 4-184-41 4-194-42 4-204-43 4-22

4-44 4-224-45 4-224-46 4-224-47 4-24

4-48 4-254-49 4-254-50 4-254-51 4-264-52 4-27

4-53 4-294-54 4-304-55 4-314-56 4-314-57 4-324-58 4-324-59 4-324-60 4-334-61 4-33

4-62 4-334-63 4-334-64 4-344-65 4-34

4-66 4-354-67 4-35

5-l 5-l5-2 5-l

5-3 5-25-4 5-2

5-55-65-75-8

5-35-35-35-3

. . .111

Page

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

SECTION IV-MAINTENANCE AND REPAIR OF DUCT SYSTEMSStructure maintenance and repair ........................................................Duct line maintenance and repair. ........................................................

SECTION V-CABLE FAULTS AND FAULT LOCATIONSCable faults.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Visual methods of cable fault locating .....................................................Determining type of cable fault ...........................................................Cable fault locating test methods .........................................................Simplifying cable fault locating ...........................................................Cable fault locating equipment. ...........................................................Tracing the cable fault signal .............................................................Selecting cable fault locating methods. ....................................................

SECTION VI-CABLE REPAIRUndergroundcablerepairs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Submarinecablerepairs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Cablerepairsafety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Makingcablerepairs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Solid dielectric cable repairs ..............................................................Other cable insulation and covering repairs. ...............................................Othercablecomponentrepairs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION VII-CABLE TESTINGCabletests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Cable insulation resistance tests ..........................................................Cable overvoltage testss . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Cable power factor testss . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Cablemoisturetests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Cabletestrecords . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION IX-UNDERGROUND CORROSION CONTROLImportanceofcorrosioncontrol . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Types of corrosionn . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Prevention of corrosionl . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

CHAPTER 6. OUTDOOR LIGHTINGSECTION I-LIGHTING AND CIRCUIT TYPES

Outdoorlightinguse . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Types of lighting circuits ..................................................................

SECTION II-MULTIPLE TYPE LIGHTINGMultiple type lighting system components .................................................Luminaires . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Lamp types. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Luminaire components.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Luminairemaintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Multiple type lighting controls ............................................................

SECTION III-LIGHT DISTRIBUTIONLight distribution standards. .............................................................Roadway lighting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Floodlighting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Airfield lighting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION IV-SERIES TYPE AIRFIELD LIGHTINGSeries type lighting system components ...................................................Series type lighting control and protection .................................................Series type lighting power supply equipment. ..............................................Maintenance and troubleshooting series type lighting. ......................................

CHAPTER 7. TRANSFORMERS AND REGULATORSSECTION I-CONSIDERATIONS

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

Paragraph Page

5-95-10

5-115-125-135-145-155-165-175-18

5-19 5-105-20 5-105-2 1 5-115-22 5-115-23 5-125-24 5-125-25 5-13

5-26 5-145-27 5-145-28 5-155-29 5-165-30 5-175-31 5-17

5-32 5-185-33 5-185-34 5-18

6-16-2

6 - l6 - l

6-3 6 - l6-4 6 - l6-5 6 - l6-6 6-26-7 6-26-8 6-3

6-96-106-116-12

6-136-146-156-16

6-66-66-7

7-17-27-3

7-l7-l

7-l

iv

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

SECTION II-MAINTENANCETransformer inspection and maintenance frequencies. ......................................Transformer inspectionss . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Transformer testing guidance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Solid (winding) insulation tests ...........................................................Transformer insulation liquids. ...........................................................

CHAPTER 8. OVERCURRENT PROTECTIVE AND SWITCHING DEVICESSECTION I-CONSIDERATIONS

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

SECTION II-FUSESFuseusage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Fuse operating safety considerations ......................................................Fuse replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Fuse maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION III-SWITCHESSwitchusage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Operationofswitches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Switch maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION IV-CIRCUIT BREAKERSCircuitbreakerusage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Frequency of circuit breaker maintenance .................................................Maintenance of nonmetalclad switchgear circuit breakers. ..................................Maintenance of metalclad circuit breakers .................................................Maintenance of low-voltage power circuit breakers .........................................Repairofcircuitbreakers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION V-MISCELLANEOUS DEVICES.. Circuit switchers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Automaticcircuitreclosers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

CHAPTER 9. OVERVOLTAGE PROTECTIONSECTION I-CONSIDERATIONS

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

SECTION II-SURGE (LIGHTNING) ARRESTERSDefinition of a surge arrester .............................................................Typesofsurgearresters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Classification of surge arresters. ..........................................................Maintenance of surge arresters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION III-OTHER DEVICESSurgeshieldingdevices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Surge capacitors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Surgeprotectivegaps.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Surgebypassresistors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

CHAPTER 10. GROUNDINGSECTION I-CONSIDERATIONS

Basic principles of grounding .............................................................Groundingprovisions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION II-MAINTENANCEGroundingmaintenancesafety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Visual inspection of grounds ..............................................................Galvanic corrosion of grounds. ............................................................

SECTION III-TESTINGGround resistance tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Groundvaluemeasurements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Paragraph Page

7-4 7-27-5 7-37-6 7-67-7 7-67-8 7-7

8 - l8-28-38-4

8-18-18-18-1

8-5

8-78-8

8-18-28-28-3

8-98-108-11

8-3

8-128-138-l48-l58-168-l7

8-68-68-78-108-128-12

8-18 8-148-l9 8-14

9 - l9-29-39-4

9-5

9-79-8

9-99-109-119-12

10-l10-2

10-310-410-5

10-610-7

9-l9-19- l9 - l

9 - l9 - l9-29-2

9-29-39-39-3

10-l10-l

10-l10-l10-2

10-210-2

V


Methods of measuring ground resistances. .................................................Methods of reducing ground resistances ...................................................

CHAPTER 11. RELAYS AND CONTROLSSECTION I--RELAYS, ELECTRIC POWER APPARATUS

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

SECTION II-CONTROLSControl functions.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Preventive maintenance and inspections of controls ........................................Troubleshootingcontrols . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

CHAPTER 12. INSTRUMENTS AND METERSSECTION I-CONSIDERATIONS

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

SECTION II-PREVENTIVE MAINTENANCEMounting of instruments and meters ......................................................Installation of instruments and meters ....................................................Maintenance of instruments and meters. ..................................................

SECTION III-CALIBRATION AND ADJUSTMENTAccuracy check of instruments and meters .................................................Adjustment of instruments and meters ...................................................

SECTION IV-REPAIRS

Paragraph Page10-8 10-210-9 10-4

11-l 11-l11-2 11-l11-3 11-l11-4. 11-211-5 11-211-6 11-311-7 11-311-8 11-411-9 11-5

11-10 11-611-11 11-711-12 11-8

12-l 12-112-2 12-112-3 12-112-4 12-112-5 12-112-6 12-112-7 12-1

12-812-912-10

12-212-212-2

12-1112-12

12-212-2

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

SECTION V-TROUBLESHOOTINGTemperature influence on instruments and meters .........................................Stray-field influence on instruments and meters ...........................................Calibration of instruments and meters ....................................................Other instrument and meter considerations ................................................

CHAPTER 13. POWER CAPACITORSSECTION I-CONSIDERATIONS

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

SECTION II-MAINTENANCE AND INSPECTIONEnsuring safe capacitor deenergizing ......................................................Power capacitor inspection schedule .......................................................Ventilation of power capacitors. ...........................................................Temperature influence on power capacitors ................................................Exposure influence on power capacitors ...................................................Voltage influence on power capacitors .....................................................Fusesforpowercapacitors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION III-TESTS

12-13 12-412-14 12-4

12-15 12-512-16 12-512-17 12-612-18 12-6

13-l 13-113-2 13-113-3 13-113-4 13-1

13-5 13-113-6 13-113-7 13-113-8 13-213-9 13-213-10 13-213-11 13-2

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

_-

Vi


CHAPTER 14. STORAGE BATTERIESSECTION I-CONSIDERATIONS

Battery usage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Battery types . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Battery safetyy . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .General battery maintenance procedures ..................................................

SECTION II-FLOODED LEAD-ACID BATTERY MAINTENANCEVisual inspections of batteries ............................................................Measurements of battery condition. .......................................................Battery maintenance specifics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Testingofbatteries . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION III-FLOODED LEAD-ACID BATTERY CHARGINGBattery charging precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Battery charging considerationss . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Normal floating battery charge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Equalizing battery charge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION IV-VALVE-REGULATED LEAD-ACID CELL BATTERIESValve-regulated cell differences ...........................................................Charging or valve-regulated cells .........................................................Temperature compensation for valve regulated cells ........................................

SECTION V-Nickel-cadmium cell batteriesDescription of nickel-cadmium batteries ...................................................Requirements for nickel-cadmium batteries ................................................

SECTION VI-CHECKS AND TROUBLESHOOTINGInspectionsofbatteries . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Troubleshooting batteries. ................................................................

SECTION VII-BATTERY CHARGING EQUIPMENTBatterychargingrequirement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Rectifier type battery chargers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Accessories for battery chargers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Maintenanceofbatterychargers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION VIII-PLACING A NEW BATTERY IN SERVICEPlacing lead-acid batteries in service ......................................................Placing nickel-cadmium batteries in service. ...............................................Connections for batteries .................................................................

SECTION IX-PUTTING A BATTERY IN STORAGEBatterystorageprocedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Periodic check of a stored battery .........................................................

SECTION X-REPLACEMENT AND DISPOSALReplacementofa battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Disposal of batteries.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

CHAPTER 15. TOOLS AND EQUIPMENTSECTION I-USE

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

SECTION II-HAZARDOUS MATERIAL PROCEDURESHazardous substances . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Asbestos containing materials . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Polycholorinated biphenyl (PCB) insulated equipment ......................................Sulfur hexifluoride (SF,) insulated equipment. .............................................Chemicals used for outside maintenance. ..................................................

SECTION III-PROTECTIVE EQUIPMENTProtective electrical rubber goods .........................................................Helmets for electrical work ...............................................................Barrier protection for electrical work ......................................................Visual warnings for electrical work. .......................................................Protective grounding of deenergized lines. .................................................

Paragraph Page

14-114-214-314-4

14-114-114-314-4

14-5 14-414-6 14-614-7 14-714-8 14-8

14-914-1014-1114-12

14-914-914- 1014-10

14-1314-1414-15

14-1114-1114-11

14-16 14- 1214-17 14-12

14-18 14-1414-19 14- 14

14-20 14-1414-21 14-1514-22 14-1514-23 14-15

14-24 14-1614-25 14-1614-26 14-16

14-27 14-1714-28 14-17

14-2914-30

14-1714-17

15-1 15-115-2 15-115-3 15-1

15-4 15-115-5 15-115-6 15-215-7 15-215-8 15-2

15-9 15-215-10 15-315-11 15-315-12 15-315-13 15-3

vii


SECTION IV-CLIMBING EQUIPMENTBody belts, climber straps, and safety straps ...............................................Climber gaffs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Ladders for electrical work ...............................................................

SECTION V-LIVE-LINE TOOLSCertification of live-line tools .............................................................Careoflive-line tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Repairs of live-line tools. .................................................................

SECTION VI-HAND TOOLSHandtoolsafety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .General requirements for hand tools ......................................................Power tool electric shock hazard avoidance ................................................

SECTION VII-ROPEC a r e o f r o p e . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15-23 15-8Splicingrope . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15-24 15-8

SECTION VIII-LARGE PORTABLE AND MOBILE EQUIPMENTLarge portable and mobile equipment covered. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Large portable and mobile equipment maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION IX-ELECTRICAL INSPECTING AND TESTING EQUIPMENTMinimum facility field test equipment requirements. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Maintenanceoftestequipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

CHAPTER 16. ELECTRICAL SERVICE INTERFERENCESECTION I-DISTURBANCE PRODUCERS

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

SECTION II-ELECTROMAGNETIC INTERFERENCEElectrical distribution system interference .................................................Electrical noise origin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Electrical interference during bad weather conditions. ......................................Methods of electrical interference location .................................................Instrument requirements for checking electrical interference. ...............................Communication interference from electrical lines. ..........................................

SECTION III-HARMONIC INTERFERENCEHarmonic causing devices and their effects ................................................Electric power quality responsibilities .....................................................Electric power quality data ...............................................................Electrical distribution system interference .................................................

CHAPTER 17. MAINTENANCE SCHEDULESSECTION I-CONSIDERATIONS

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

SECTION II-SCHEDULESMaintenance frequency guides . . . . . . . . . . , . . . . . . . . . . . . . . . . .Revisions to maintenance frequencies . . . . . . . . . . . . . . . . . . . . .

APPENDIX A-REFERENCESAPPENDIX B-BIBLIOGRAPI-IYAPPENDIX C-ADDITIONAL WOOD POLE DATAINDEX

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Paragraph Page

15- 14 15-415-15 15-515-16 15-5

15-17 15-615- 18 15-615-19 15-7

15-20 15-715-21 15-715-22 15-7

15-25 15-1015-26 15-10

15-27 15-1115-28 15-11

16-4 16-116-5 16-116-6 16-316-7 16-316-8 16-316-9 16-4

16-1016-1116-1216-13

16-416-416-416-5

17-317-4

17-l17-l

Figure 3- l .3-2.4- l .4-2.4-3.

. . .v i i i

LIST OF FIGURES

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

3-123-124-24-34-5

4-4.4-5.4-6.4-7.4-8.4-9.

4-10.4-11.4-12.4-13.4-14.4-15.4-16.4-17.4-18.4-19.4-20.4-21.4-22.4-23.4-24.4-25.4-26.

5-1.5-2.5-3.6-1.

10-l.10-2.10-3.10-4.10-5.11-1.11-2.11-3.11-4.11-5.12-l.12-2.13-1.13-2.14-1.15-1.15-2.15-3.15-4.c-1.c-2.c-3.

Table 3-l.3-2.3-3.3-4.4- l .4-2.4-3.4-4.4-5.5-l.6-1.7-1.


Typical pole branch and key . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .The increment borer . . .Sealing a test hole with a

. . . . . . . . . . . . . . *treated wooden

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

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

LIST OF TABLES

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

Page4-64-84-84-114-124-144-174-174-194-194-204-204-214-234-254-264-274-284-294-304-304-3 14-325-85-95-166-5

10-310-310-410-510-611-311-411-411-511-612-312-313-313-414-215-815-815-915-9c-3c-3c-4

Page3-23-63-113-134-84-104-244-244-305-176-57-3

ix


7-2.7-3.8- l .8-2.

11-l.11-2.12-l.12-2.13-1.13-2.14-1.14-2.14-3.14-4.15-1.16-1.17-l.

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

Page7-67-88-128-13

11-611-812-612-613-213-314-214-914-1114-1315-1116-517-l

_.--.-I


CHAPTER 1

INTRODUCTION

Section I - PRIMARY CONSIDERATIONS

1-1. Purpose and scope.This manual provides guidance for the maintenanceand repair of exterior electrical distribution sys-tems. New construction of exterior electrical facil-ities, even when funded from maintenance appro-priations, should comply with the appropriatedesign criteria. These systems include substations,overhead and underground electrical distributionsystems, exterior lighting systems, and electricalapparatus and components. Guidance for genera-tors and interior electrical systems (600 volts andless) are covered in the following publications:

a. TM 5-683/NAVFAC MO-ll6/AFJMAN32-1083.

b. TM 5-685/NAVFAC MO-912.c. MIL-HDBK-1003A/ll.

1-2. References.Appendix A contains a list of references used in thismanual.

1-3. Application of codes and publications.The information in this manual should not super-sede equipment manufacturers instructions and re-quirements. When conflicts exist the most rigorousrequirement should be followed. A11 maintenanceand repair of electrical systems should be performedin such a manner that the completed work willconform to the publications listed below to the de-gree indicated.

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

(1) The National Electrical Code (NEC), NFPA70.

(2) The National Electrical Safety Code(NESC), ANSI C2.

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

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

reference in preparing contract requirements formaintenance to be done by outside service agencies.

1-4. Standards of maintenance.Electrical systems will be regularly maintained toensure continued compliance with the codes andpublications referred to in appendix A. Such main-tenance will prevent system and equipment failuresand ensure maximum safety and efficiency in theutilization of the facilities. At each installation, aprogram for proper maintenance should be estab-lished and effectively followed. This program shouldinclude the scope of work, intervals of performance,and methods of application including safety require-ments, practices and procedures. When a number ofitems require servicing or renewal over a period ofyears, a proportionate number should be main-tained each year. For instance, if there are 100transformers on the system, requiring maintenanceat 5-year intervals, the work should be performedon 20 transformers each year.

a. Predictive maintenance. A predictive mainte-nance program is more desirable than routine re-curring maintenance. Predictive testing should oc-cur periodically but actual maintenance orreplacement should take place only when necessary.An automated testing and record management sys-tem should be utilized where available. Where sucha system is not available, its acquisition is recom-mended.

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

1-5. Maintenance responsibilities.An adequate supply of dependable electrical energyis essential for the accomplishment of the installa-tion mission. Adherence to a well planned and wellorganized maintenance program, including the es-tablishment of specific goals and follow-up proce-dures will ensure the proper functioning of theequipment in the electrical distribution system.

a. Electrical supervisor. As used in this manual,the title electrical supervisor indicates the indi-vidual assigned the responsibility for maintenanceof electrical distribution systems and equipment.The maintenance of electrical distribution systemsis the responsibility of the installations commanderand a specific duty of an Army director of public

1-1


works, a Navy public works officer, or an Air Forcebase engineer. Operation and maintenance are asingle staff responsibility, and frequently the samepersonnel will perform both functions.

b. Electrical supervisortrical supervisor will:

responsibilities. The elec-

(1) Initiate positive action to remove, or reduceto a minimum, the cause of recurrent maintenanceproblems.

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

(3) Provide for the accomplishment of as muchwork as possible during each maintenance visit, andensure that spot checks, inspections, and repairsare made on all components of the electrical facil-ities.

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

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

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

1-6. Maintenance records.One of the most important sources of informationfor aiding inspections, maintenance, or tests is acomprehensive file of equipment and servicerecords. In addition to indicating basic informationrequired for proper inspection of the equipment,these records will indicate where trouble has beenexperienced and where special procedures may bewarranted.

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

(1) Instruction leaflets and manuals. Eachpiece of major electrical equipment purchasedshould be accompanied by an instruction leaflet ormanual outlining the desired methods of installa-tion, operation, and maintenance. These instruc-tions contain valuable information on maintenance

practices, part designations, and ordering proce-dures. Spare parts lists are a vital part of theserecords.

(2) Installation drawings. Maintenance is oftenaffected by the manner in which the equipment isinstalled. For convenience, and as a means of expe-diting maintenance, as-built installation drawingsshould be readily accessible to maintenance andinspection personnel.

(3) Wiring diagrams. Adequate and up-to-datewiring diagrams are important for proper mainte-nance. Diagrams facilitate locating troubles, whichotherwise may require extensive probing and test-ing procedures. Such diagrams should be readilyavailable to maintenance personnel.

(4) Distribution maps. Maps showing locationsof distribution lines, wire sizes, transformer sizes,pole numbers, voltage classes, and sectionalizingdevices are vital. Up-to-date distribution mapsmounted on the maintenance or electrical shop wallare very useful.

b. Service records. Service records constitute ahistory of all work performed on each item of equip-ment and are helpful in determining the overallcondition and reliability of the electrical facilities.Service records should show type of work (visualinspection, routine maintenance, tests, repair), testresults (load, voltage, amperes, temperature), andany other remarks deemed suitable. It is highlyrecommended that service records should include alog of incidents and emergency operating proce-dures.

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

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

1-7. Priority and scheduling.a. Priority. In regard to the support of the instal-

lation physical plant, it is the policy of the military

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departments that, in order of priority, maintenance manders to meet local requirements. Service in-should be second only to operations. It must be tervals may be lengthened only when justified bysystematic, and it must be timely. extenuating circumstances. Whenever service inter-

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

Section II - SAFETY

1-8. Minimizing hazards.Material specifications, construction criteria, instal-lation standards, and safe working procedures havebeen developed to minimize hazards. All work andmaterials should conform to the latest accepted pro-cedures and standards, as defined in publicationslisted or referred to in this manual.

1-9. Qualification of electrical workers.Due to the inherent hazards encountered in themaintenance of electrical distribution systems andequipment, it is essential that all electrical workersbe thoroughly trained and be familiar with theequipment and procedures to be followed.

1-10. Certification of electric workers.Properly trained electric workers will be certified inaccordance with applicable publications.

1-11. Public safety.All necessary precautions will be taken to warn thepublic of electrical hazards or other conditionswhich may constitute a danger. This is especiallytrue of temporary hazards due to work in progress.

1-12. Personnel safety.Any work on or close to electrical equipment of anykind should be considered dangerous and propersafety precautions will be taken. All personnel whoperform work of any kind on or near electricalequipment must be familiar with and observe allsafety precautions.

a. Safety first. Two safety rules are mandatory asfollows:

(1) Consider all electrical equipment to be en-ergized until it is known positively (as by the pres-ence of grounding clamps) that it is not energized.Comply with regulations and safety instructionscontained in NEC and NESC, the applicable depart-mental publications, and special publications issuedby the local command.

(2) Work may be done on energized lines andequipment only by personnel qualified by their jobdescriptions for that voltage level. Job descriptionsshould require actual hands-on work service periodswhich meet local utility and the InternationalBrotherhood of Electrical Workers approval. All

tools and equipment must be maintained in properoperating order, be suitable for the maximum volt-age level involved, and should be periodically testedfor compliance with all safety requirements. De-partmental publications should be consulted forspecific requirements in each voltage level.

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

c. Personal protective temporary grounding. Thisis temporary grounding installed to protect workersengaged in de-energized line maintenance. Thegrounds are provided to limit the voltage differencebetween any two accessible points at the work siteto a safe value. An expanded discussion of protectivegrounding principles and practices is contained inIEEE 1048, NFPA 70B and The Linemans andCablemans Handbook.

1-13. Live-line maintenance.Aerial live lines are energized lines that are beingtested, repaired, and maintained more and more byelectrical utilities to reduce the number of outagesor service interruptions. The use of such procedureson DOD installations requires that good practice befollowed and that there is no conflict with localfacility rules.

a. Good practice. Personnel doing live-line workshould have satisfactorily completed a formal train-ing course of instruction and be examined periodi-cally. Live-line maintenance usually means anymaintenance activity performed on energized elec-trical conductors or equipment with a phase-to-phase voltage exceeding 600 volts. It usually doesnot include such activities as switching, hardwaretightening, climbing, hole digging, pole setting, con-ductor stringing, etc. The performance of this workrequires equipment and tools that meet applicableindustry standards for energized-line maintenance.

b. Local facility rules. Two considerations affectfacility rules on the type and extent of live-linemaintenance permitted: availability of qualified fa-cility personnel and equipment versus the facilitysrequirement for uninterrupted operation. If localmissions prevent electrical power shutdowns andlocal facilities are not qualified to perform live-line

l-3


work, then a live-line contractor may need to be and are not intended to substitute for training orhired on a scheduled and/or a nonscheduled basis. operating procedures; for meeting specific industryGeneral energized-line maintenance practices cov- guidelines; or for meeting federal, state, local, orered in chapter 4, section VI, serve only as a guide facility regulations and rules.

Section III - AVOIDING PROBLEMS

-

1-14. Operating conditions.Always observe the four cardinal rules of electricalmaintenance.

a. Keep the equipment clean.b. Keep the equipment dry or lubricated as ap-

propriate to the part.c. Keep screwed parts tight.d. Prevent friction on moving parts.

1-15. Detecting potential trouble.Diagnostic devices, where available, allow checkingthe system for potential trouble before it occurs.Potential problems may also be detected by the useof four of our five senses: see, hear, touch, and smell.

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

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

c. Touch. Among the damaging characteristicswhich may be identified by touch are vibration, wet-ness, and heat. Caution should be exercised intouching components which are normally hotenough to burn personnel on contact or live partswith hazardous potentials.

d. S m e l l . Burning insulation and battery fumesprovide distinctive odors which signal componentdeterioration.

1-16. Electrical connections.Connections are an essential part of any electriccircuit. Good electrical contact is essential. Dirt isthe enemy of good contact. Whenever an electricalconnection is to be made, extreme care must betaken to ensure all dirt, rust, corrosion, insulation,oil, and other contaminants are removed. The con-tact surfaces should be bright, clean metal. Thisrequirement applies to connections made by solder-ing, clamps, twisted sleeves, compression fittings, orany other method.

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

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

c. Dissimilar metals. Only connectors designedfor the purpose should be used to connect aluminumand copper items.

-

d. Testing. Accessible connections may be testedusing an infrared detector only if the connection isunder load as covered in chapter 3, section I.

l-4

TM 5-684/NAVFAC MO-200/AFJMAN

CHAPTER 2

INSPECTION AND TESTS

32-1082

Section I - PERFORMANCE

2-1. Determining equipment condition.The ability of equipment to perform its function, orto continue its function for its normal life cycle,must be determined if the distribution system is tooperate dependably and economically. The conditionof equipment can be determined by two methods:inspection and tests. Such things as broken insula-tors or oil leaks can easily be determined by inspec-tions, but other details such as the condition oftransformer oil or a trip setting for a circuit breakercan be determined only by tests. The scope of in-spection and tests is dependent on the type andcomplexity of the equipment, and the results de-sired. Inspections are normally visual, but hearing,touching, and smelling can also indicate problemareas. Tests can be electrical, physical, or chemical,or combinations of these. The selection of the test tobe made may be at least partially determined by theavailability of test equipment and of personnel ca-pable of using it.

-- 2-2. Reasons for inspections and tests.Inspections and tests are performed for several rea-sons.

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

b. Maintenance proof testing. This is testing toensure that maintenance/repair was done properly.This should be done when maintenance and/or re-pair are complete, and to show whether the equip-ment is operable and properly connected.

2-3. Associated test guidance and records.Tests are ordinarily used in the field to determinethe condition of various elements of an electricalpower-distribution system. The data obtained inthese tests provide information that is used to de-termine whether any corrective maintenance or re-placement is necessary or desirable. The ability ofthe element to continue to perform its design func-tion adequately can be ascertained. Also the gradualdeterioration of the equipment over its service lifecan be charted. Records must include factory testdata provided with shop drawing submittals, accep-tance testing data, and each routine maintenancetest, so that the history of the equipment may be

available for future reference. Records should bemaintained to indicate what test data are requiredand what means are to be used to provide this data.Nondestructive maintenance tests can cause insula-tion breakdown with no warning. A plan for copingwith this possibility should be included in the testprocedures.

a. Qualifications of test operators. If a testing pro-gram is to provide meaningful information relativeto the condition of the equipment under test, thenthe person evaluating the test data must be assuredthat the test was conducted in a proper manner andthat all of the conditions that could affect the evalu-ation of the tests were considered and any pertinentfactors reported. The test operator, therefore, mustbe thoroughly familiar with the test equipmentused in the type of test to be performed, and alsosufficiently experienced to be able to detect anyequipment abnormalities or questionable data dur-ing the performance of the tests.

b. Test equipment. It is important to have theproper equipment for performing the required testsin any test program. In general, any test equipmentused for the calibration of other equipment shouldhave an accuracy at least twice the accuracy of theequipment under test. The test equipment shouldbe maintained in good condition and should be usedonly by qualified test operators. All test equipmentshould be calibrated at regular intervals to ensurethe validity of the data obtained. In order to getvalid test results, it may be necessary to regulatethe power input to the test equipment for properwaveform and frequency and to eliminate voltagesurges.

c. Use of forms. To provide optimum benefits,record all testing data and maintenance actions ontest circuit diagrams and forms that are completeand comprehensive. Recording both test data andmaintenance information on the same form is rec-ommended. A storage and filing system should beset up for these forms that will provide efficient andrapid retrieval of information regarding previoustesting and maintenance on a piece of equipment. Awell-designed form will also serve as a guide or achecklist of inspection requirements. Samples oftypical forms that can be used are included in NFPA70B, appendix G.

2 - l


Section II - REQUIREMENTS

2-4. Electric workers, instruments, and re-ports.Tests of electrical equipment should be performedunder the supervision of qualified electric workers.If in-house personnel are not available for thesetests, the services of a qualified electrical testingagency may be used.

a. Testing agency qualifications. The testingagency should submit proof that it is a corporatelyindependent testing organization which can func-tion as an unbiased testing authority, professionallyindependent of the manufacturers, suppliers, andinstallers of equipment or systems evaluated by thetesting firm. The testing agency should meet OSHAcriteria for accreditation of testing laboratories,Title 29, Part 1910-7; or be a full member companyof the InterNational Electrical Testing Association(NETA) and be regularly engaged in the testing ofelectrical equipment devices, installations, and sys-tems. The lead technical agency member on-siteshould be currently certified by NETA or the Na-tional Institute for Certification in EngineeringTechnologies (NICET) in electrical power distribu-tion system testing.

b. Test instrument calibrations. Instrumentsshould have been calibrated within the last 12months except that analog instruments should havebeen calibrated within the last 6 months. Calibra-tion should provide the full-scale accuracy based on

the manufacturers data, usually 1 percent forswitchboard instruments and 0.25 percent for por-table instruments. Dated calibration labels shouldbe visible and up-to-date calibration records, in-structions, and procedures should be maintained foreach instrument which should have had a calibrat-ing standard of higher accuracy than that of the testinstrument.

._

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

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

(2) Description of equipment tested.(3) Description of test.(4) Test results.

2-5. Frequency of inspection.The intervals given in this manual and/or by manu-facturers maintenance recommendations should beconsidered an initial interval for normal conditions.Intervals should be shortened where adverse condi-tions exist and may be lengthened only where expe-rience under better-than-normal conditions showthis can be done safely. The frequency of inspectionmay vary for similar equipment operating underdifferent conditions. Critical equipment, heavilyloaded apparatus, operator handled, and intermit-tently operated units are examples of different op-erating conditions.

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2-2


CHAPTER 3

- TRANSMISSION AND DISTRIBUTION SUBSTATIONS

Section I - GOVERNING CONSIDERATIONS

3-1. Type of substations covered.This chapter includes a transmission and distribu-tion substation which is an assemblage of equip-ment for purposes other than generation or utiliza-tion, through which electrical energy in bulk ispassed for the purpose of switching or modifying itscharacteristics.

3-2. Electrical system relationship.A substation is an integral and vital part of anelectrical system. It does not exist independently ofthe rest of the system, though it is usually designedso that a failure of a single component will notinterrupt loads, except for switching times. Suchinterruption may force greater than normal loads tobe carried by other components of the station whilerepairs are being made. Most substations are de-signed so they do not re

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