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This document provides guidance for designing electrical manholes and underground distribution systems. It recommends minimizing the number of circuits in each manhole to allow for easier deenergization when working inside. Electrical manholes should be designed to restrict access when circuits are energized due to safety concerns. Underground distribution systems can be installed without manholes by using pad-mounted equipment, but manholes are generally required when numerous circuits are involved.
This document provides guidance for designing electrical manholes and underground distribution systems. It recommends minimizing the number of circuits in each manhole to allow for easier deenergization when working inside. Electrical manholes should be designed to restrict access when circuits are energized due to safety concerns. Underground distribution systems can be installed without manholes by using pad-mounted equipment, but manholes are generally required when numerous circuits are involved.
This document provides guidance for designing electrical manholes and underground distribution systems. It recommends minimizing the number of circuits in each manhole to allow for easier deenergization when working inside. Electrical manholes should be designed to restrict access when circuits are energized due to safety concerns. Underground distribution systems can be installed without manholes by using pad-mounted equipment, but manholes are generally required when numerous circuits are involved.
1. Purpose. This ETL provides technical guidance and criteria for the design of electrical manholes, with electrical safety and arc flash considerations as a design input. Associated underground distribution design criteria are also addressed. This ETL does not apply to manholes associated with airfield lighting circuits.
2. Application. Recommendations in this ETL are optional. The recommendations provided here apply to new designs.
2.1. Authority: Air Force instruction (AFI) 32-1063, Electric Power Systems
2.2. Effective Date: Immediately
2.3. Intended Users: Major command (MAJ COM) engineers Base civil engineers (BCE)
2.4. Coordination: MAJ COM electrical engineers
3. Referenced Publications.
3.1. Air Force (available at http://www.e-publishing.af.mil): AFI 32-1063, Electric Power Systems AFI 32-1064, Electrical Safe Practices Air Force Occupational Safety and Health (AFOSH) standard 91-25, Confined Spaces ETL 11-9, Electrical Manhole Entry and Work Procedures, http://www.wbdg.org/ccb/browse_cat.php?o=33&c=125
3.3. Industry: Institute of Electrical and Electronics Engineers (IEEE) 835, IEEE Standard Power Cable Ampacity Tables, http://www.ieee.org/index.html IEEE C2, National Electrical Safety Code (NESC), http://www.ieee.org/index.html National Fire Protection Association (NFPA) 70, National Electrical Code (NEC), http://www.nfpa.org/index.asp
4. Background.
4.1. AFI 32-1064, Electrical Safe Practices, states: Work on or near energized distribution lines is prohibited except in rare circumstances and then only when approved by the BCE. Work on or near energized electrical equipment in manholes is extremely dangerous and requires all circuits inside the manhole to be deenergized. UFC 3-560-01, Electrical Safety, O&M, states that all equipment inside a manhole, including insulated conductors, should be deenergized before allowing entry into a manhole. ETL 11-9, Electrical Manhole Entry and Work Procedures, expands on these requirements and provides guidance for work activities that can be performed inside electrical manholes containing energized circuits.
4.2. Because of the concerns regarding entry into electrical manholes containing energized circuits, underground distribution system designs should address access restrictions as a specific design consideration. UFC 3-550-01, Exterior Electrical Power Distribution, provides tri-Service design requirements for underground distribution systems, including electrical manholes. This ETL expands on the UFCs requirements and provides additional recommendations for work inside electrical manholes containing energized electrical equipment with arc flash as a concern. Underground distribution system design is also addressed.
5. Definitions.
5.1. Duct bank. Two or more conduits (or ducts) routed together in a common excavation with or without concrete encasement.
5.2. Handhole. An opening in an underground system containing cable, equipment, or both, into which personnel reach but do not enter, for the purpose of installing, operating, or maintaining cable, equipment, or both.
5.3. High voltage. For the purpose of this ETL, a class of nominal system voltages greater than 34,500 volts.
5.4. Low voltage. For the purpose of this ETL, a class of nominal system voltages less than or equal to 600 volts.
3 5.5. Manhole. A subsurface enclosure that personnel may enter, used for installing, operating, and maintaining cable.
5.6. Medium voltage. For the purpose of this ETL, a class of nominal system voltages above 600 volts and less than or equal to 34,500 volts.
6. Acronyms.
AFI - Air Force instruction AFOSH - Air Force Occupational Safety and Health BCE - base civil engineer (or equivalent) ft - foot IEEE - Institute of Electrical and Electronics Engineers m - meter MAJ COM - major command NFPA - National Fire Protection Association UFC - Unified Facilities Criteria UFGS - Unified Facilities Guide Specification
7. Requirements. UFC 3-501-01, Electrical Engineering, provides minimum requirements for design analyses and calculations. UFC 3-550-01 provides minimum requirements for underground distribution system design. The following subparagraphs clarify these requirements and provide additional recommendations.
7.1. Formal Design.
7.1.1. Provide a formal design and design analysis in accordance with UFC 3-501-01 for underground distribution systems.
7.1.2. Specify key features of the underground distribution system design and installation. UFGS 33 71 02.00 20, Underground Electrical Distribution, is recommended for use; edit the specification as necessary for base-specific design features. UFGS 33 71 02.00 20 also addresses personnel qualifications for performing conductor installation and splicingimportant for ensuring a reliable installation.
7.2. Electrical Distribution Systems Without Manholes.
7.2.1. The installation of electrical manholes is not a standard design requirement; underground distribution systems can be installed without the use of electrical manholes. An underground distribution system without electrical manholes is viable for installations involving a few circuits; however, electrical manholes will usually be required when many circuits are involved.
7.2.2. UFC 3-550-01 allows the use of pad-mounted sectionalizing termination cabinets only when switching, isolation, or electrical protection for the 4 downstream circuit is not required or anticipated. Sectionalizing termination cabinets can be used instead of in-line splices in manholes or for minor loads that do not warrant the expense of pad-mounted switchgear.
7.2.3. For a design that uses pad-mounted sectionalizing termination cabinets instead of electrical manholes, specify the maximum allowed distance between cabinets. UFC 3-550-01 requires the following for electrical manholes: Separation on straight runs must not exceed 400 ft (120 m). In situations where greater separation is desired and this greater separation is not prohibited by either excessive pulling tension or site requirements, separation of up to 600 ft (180 m) is permitted. Unlike a straight cable pull between two electrical manholes, a cable pull between two pad-mounted sectionalizing termination cabinets involves a minimum of two 90-degree bends. Confirm that the specified pull distance 1) satisfies the required maximum pulling tension; and 2) is within the ability of electrical shop personnel to replace, if necessary.
7.2.4. Install pad-mounted switchgear rather than pad-mounted sectionalizing termination cabinets at all locations where load break switching and isolation might be necessary.
7.3. Electrical Distribution System Configuration Preferences.
7.3.1. Minimize the number of circuits inside an electrical manhole. Installing many circuits inside an electrical manhole will make it more difficult to deenergize all affected circuits when working inside the manhole. It is preferable to have more manholes with fewer circuits per manhole rather than fewer manholes with more circuits per manhole.
7.3.2. Typically, the circuits installed inside an electrical manhole will share a common duct bank. As more sets of conductors are installed in a common duct bank, derate the ampacity of each set of conductors to account for the additional heat-loading of multiple sets of conductors. NFPA 70, National Electrical Code (NEC), provides a basis for conductor ampacity, and NFPA 70, Figure 310.60, provides basic underground duct configurations to consider. IEEE 835, IEEE Standard Power Cable Ampacity Tables, provides similar information and can also be used as a guide.
7.3.3. Evaluate the cross-connect capability between circuits. Avoid installing redundant circuits or circuits that provide alternate supply capability inside the same electrical manhole or duct bank.
7.3.4. Consider 500-kcmil (thousand circular mils) conductors for the main run for new or upgraded circuits. The intent is to improve cross-connect capability during periods that circuits inside an electrical manhole must be deenergized.
5 7.3.5. Directional boring for underground distribution system installation is authorized only to the extent allowed by UFC 3-550-01. Directional boring is not authorized as a standard installation practice for an entire circuit.
7.4. Electrical Manhole Design.
7.4.1. Handholes are prohibited by UFC 3-550-01 for medium-voltage primary distribution circuits.
7.4.2. Per UFC 3-550-01, the following equipment is prohibited inside electrical manholes: Load junctionsthis includes load junctions with either load-break or dead-break elbows; Separable splices used to supply lateral circuits (bolt-T connections); T-splices, Y-splices, and similar types of splices used to supply lateral circuits; Power distribution equipment, including transformers and switches.
7.4.3. Design electrical manholes with personnel access and adequate interior working space. Attachment 1 provides an example of an electrical manhole design that provides a large access door for improved personnel access and retrieval. The interior space also allows adequate working space. An electrical manhole does not require an oversized design if a single circuit passes through it.
Note: An oversized electrical manhole with a large entrance from above is intended to improve personnel safety from an arc flash event. However, active work inside an electrical manhole containing energized circuits will still be dangerous. AFI 32-1064, AFOSH Standard 91-25, Confined Spaces, and ETL 11-9 still apply.
7.4.4. Individually fireproof medium-voltage cables in all underground structures.
7.4.5. Label each conductor with the associated equipment identification, the electrical phase, and the conductor size.
7.4.6. Install all conductors on cable racks. UFGS 33 71 02.00 20 provides requirements.
7.4.7. UFC 3-550-01 states: Route cable installations inside manholes along those walls providing the longest route and the maximum spare cable lengths. One complete loop of conductors is recommended.
6 8. Point of Contact. The authority having jurisdiction on all matters discussed within this ETL is the Chief Electrical Engineer, HQ AFCESA/CEOA. To reach the Chief Electrical Engineer, e-mail AFCESAReachBackCenter@tyndall.af.mil, call DSN 523- 6995 or commercial (850) 283-6995, or mail to 139 Barnes Drive, Suite 1, Tyndall AFB, FL 32408-5319.
CLIFFORD C. FETTER, P.E., GS-15, DAF 2 Atchs Acting Chief, Operations and Programs Support 1. Electrical Manhole Design Examples 2. Distribution List
Atch 1 (1 of 6) ELECTRICAL MANHOLE DESIGN EXAMPLES
A1.1. Electrical Manhole Size. If multiple circuits are routed through a single electrical manhole, the manhole should be large enough to have all conductors secured on cable racks with adequate working room near the conductors. Figures A1.1 and A1.2 show an example of a manhole with large, hinged access doors for easier entry to and from the manhole. Galvanized-steel, spring-assisted access doors are available in standard sizes as large as 48 inches by 72 inches (1.21 meters by 1.82 meters). Figures A1.3 and A1.4 provide photographs of an installation.
Figure A1.1. Electrical Manhole Configuration
Atch 1 (2 of 6)
Figure A1.2. Electrical Manhole Access Doors
Figure A1.3. Electrical Manhole Installed with Large Entrance
Atch 1 (3 of 6)
Figure A1.4. Electrical Manhole Interior View
A1.2. Cable Racks. Cable racks are an important design and installation requirement. Safe entry into an electrical manhole containing energized circuits is not possible if the conductors are not neatly racked and out of the way. Figure A1.5 shows an electrical manhole where safe entry is not possible. Furthermore, the conductors shown in Figure A1.5 are not labeled in any way; there is no indication regarding which circuit is which. Figure A1.6 shows a typical cable rack. The routing of conductors inside a manhole also should be specified. Otherwise, there might not be any slack provided, as shown in Figure A1.7; repair activities will be more difficult in this location.
Figure A1.5. Unsecured Conductors Inside an Electrical Manhole
Atch 1 (5 of 6) A1.3. Conduit Entrance. The conduit entrance design and installation should be specified. Keeping the manhole clean and dry can be achieved if close attention is paid to sealing all entrances.
Figure A1.8. Typical Conduit Entrance Detail
A1.4. Conductor Routing Details. The design should specify, and the as-built documentation should confirm, the conductors installed inside each conduit. Labeling is necessary to facilitate conductor identification. Figure A1.9 shows an example drawing that details the location of each circuit.
Atch 1 (6 of 6)
Figure A1.9. Duct Configuration Detail
Atch 2 (1 of 1)
DISTRIBUTION LIST
DEPARTMENT OF DEFENSE
Defense Commissary Agency (1) AAFES (1) Design and Construction Division ATTN: RE-C 2250 Foulois St., Suite 2 PO Box 660202 Lackland AFB, TX 78236 Dallas, TX 75266-0202
SPECIAL INTEREST ORGANIZATIONS
Information Handling Services (1) Construction Criteria Base (1) 15 Inverness Way East National Institute of Bldg Sciences Englewood, CO 80150 1201 L Street NW, Suite 400 Washington, DC 20005