Fermilab Engineering Standards Manual
August,August 20012
Any Fermilab standard, or a part of a standard, which is directly related to safety, will be in the Fermilab ES&H Manual. Only the technical instructions or reproductions from the National Standards, other codes, or sources of technical information will reside in the Fermilab Engineering Standards Manual.
The Fermilab Engineering
Standards Manual is supplementary to the Fermilab ES&H Manual. Engineers
shall consult first with the ES&H manual for safety considerations, thenand then seek
the supplementary instructions and technical data in the Engineering Standards
manual.
A policy for administration of the Fermilab Engineering Standards Manual is established in Chapter 1. This policy includes formalized procedures for writing, updating and deleting chapters as well as for changing the status of a chapter, e.g. from guidance to advisory, or from guidance to mandatory. The Engineering Policy Committee is advisory.
The status of each chapter is to be interpreted as follows:
Mandatory: Mandatory engineering standards shall be used. The Fermilab Director or other specified external authority must approve any deviation from the recommendations spelled out in the chapter.
Guidance: Guidance engineering standards should be used. The authority, as specified in the chapter, must approve any deviation from the recommendations spelled out in the chapter.
Advisory: Advisory engineering standards are suggestions for good practices. Use is optional and better recommendations may be sought from other sources.
Although a chapter may have a mandatory status, it may contain mandatory, guidance, or advisory requirements. For example, the chapter "Installation of liquid nitrogen dewars" has mandatory provisions, standard practices and suggested practices.
The
Associate Director
forof
Operations Support will be the custodian of the Engineering Standards Manual. He is responsible for the maintenance of the manual and the
issuance of updates as applicable. All Fermilab Engineering Standards require
review and approval of the Fermilab Engineering Policy Committee. Approved standards shall be incorporated into the Fermilab
Engineering Standards Manual, made available by the FESS Directorate Section
with web site support from the Administrative Associate to the Director for Operations
Support. ES&H Section.
The
manual shall be reviewed annually as scheduled by the Associate Director for Operations
Support
FESS Section Head. The reviewing agency will be the Engineering
Policy Committee. All
standards in the manual shall be reviewed for applicability to Fermilab and
adopted or modified as necessary. The
Associate Director for Operations Support shall approve any changes and .
The FESS Section Head will be responsible for updating and
re-issuing the manual after each review if necessary.
Requests
for new or modified Fermilab Engineering Standards may also be internally
initiated by Fermilab staffFermilab staff may also internally initiate requests
for new or modified Fermilab Engineering Standards. In this case the Associate Director for Operations
SupportFESS Section Head will forward the
request to the Engineering Policy Committee whichCommittee, which
will evaluate the request, formulate a response, and return forward
it to the Associate Director for Operations Support FESS
Section Head for appropriate action as determined by the
Engineering Policy Committee. All
changes to the Fermilab Engineering Standards Manual shall be approved by the
Associate Director for Operations SupportThe Associate
Director for Operations Support shall approve all changes to the Fermilab
Engineering Standards Manual after appropriate additional review.
Self-assessments
performed, as part of the ongoing Fermilab Self-Assessment Program, shall
include assessment of the Fermilab Engineering Standard Manual to assure that
actual practices or operations are consistent with the intent of the Fermilab
Engineering Standards Manual and any implementing procedures.
All
proposed modifications that affect the exterior appearance of buildings or modify
landscaping, roads or parking areas are to be reviewed and accepted by the
Directorate.
2.2.1
CIVIL DESIGN CRITERIA |
U.S. CODE OF FEDERAL |
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EXECUTIVE ORDERS |
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STATE OF ILLINOIS STANDARDS |
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FERMI STANDARDS |
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REGULATIONS |
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DESIGN
ELEMENTS |
10
CFR 1021 (DOE NEPA rules) |
29
CFR 1910 (OSHA Gen Ind Stds) |
29
CFR 1926 (OSHA Constr Ind Stds) |
71
IAC (Illinois Accessibility Code) |
77
IAC 920 (Water well constr code) |
77
IAC 925 (Well pump installation) |
92
IAC 700 (Constr/water course permit appl) |
92
IAC 704 (Regulation of public waters) |
Nat'l.
Poll Disch Elim System |
92
IAC 708 (Floodway constr permit appl) |
Illinois
Standard for Road and Bridge Construction |
Standards
and Specifications for Soil Erosion and Sediment Control 10/87, IEPA 87-102 |
Uniform
Federal Accessibility Standards, Ch 4, Accessible Elements and Spaces: Scope
and Technical Requirements |
IDOT
Design/Standards Manuals |
Illinois
Standards For Sewer and Water Construction |
Secondary
Containment for oil filled Transformers (Draft) |
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Civil
Construction Projects |
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Construction
Projects involving Waters of the State |
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Construction
Projects > 5 acres in size |
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Excavation |
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Erosion
Control Design |
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Water
Well Installation |
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Sewer
and Water Utilities |
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Roadway/Pavement
Design |
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Transformer
Containment Design |
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2.3.1 Design Criteria
Matrix for Architectural Work
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10
CFR 835 (Occup. Rad. Protection) |
28
CFR 36 (ADA) |
29
CFR 1920 (OSHA Construction Industry Standards) |
Occupational
Safety and Health Act |
71
IAC ( Illinois Accessibility Code) Illinois Administrative Code |
100
1AC (Fire prevention and Safety) ( Illinois Administrative Code) |
National
Fire Protection Association Fire Codes (NFPA) |
BOCA
Fire Prevention Code |
BOCA
National Building Code |
Uniform
Federal Accessibility Standards, CH 4, Accessible Elements and Spaces: Scope
and Technical Requirements |
FESHM 2010 Rev 11/95 (Planning
and review of accelerator facilities and their operations) Fermilab
Environmental Safety and Health Manual |
FESHM 5032.2
(Guidelines for the design, fabrication, testing, installation, and operation
of LH2 Targets) ( Fermilab Environmental, Safety and Health Manual |
Administration |
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General
Planning |
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Use
or Occupancy |
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Special
Use and Occupancy |
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General
Building Limitations |
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Types
of Construction |
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Fire
Resistant Materials and Construction |
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Means
of Egress |
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Accessibility |
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Roofs
and Roof Structures |
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Masonry |
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Wood |
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Glass
and Glazing |
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Gypsum
Board and Plaster |
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Elevators
and Conveying Systems |
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2.4.1
STRUCTURAL DESIGN CRITERIA |
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DESIGN
ELEMENTS |
ANSI
B30.20,B30.11,B30.17 |
National
Electric Code |
NFPA |
OSHA
2206&1910 |
Hoist
Manufacturers Institute |
BOCA
National Building Code |
1.
Structural loads |
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2.
Structural tests and inspections |
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3.
Foundations and retaining walls |
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4.
Structural concrete |
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5.
Structural masonry |
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6.
Structural steel |
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7.
Structural wood |
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8.
Overhead cranes |
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The following section addresses specific structural requirements
that either will further clarify the matrix-referenced codes or
site
specificsite-specific variations from them.
Structural Loadings
The
following section addresses specific structural requirements that either will
further clarify the matrix-referenced codes or site specificsite-specific
variations from them.
Structural
Tests, Inspections and Evaluations:
The
Facilities Engineering Services Section has the responsibility to load rate all
new and existing structures.
The
following section addresses specific structural requirements that either will
further clarify the matrix-referenced codes or site specificsite-specific
variations from them.
Structural Concrete:
The
following section addresses specific structural requirements that either will
further clarify the matrix referencedmatrix-referenced
codes or site specificsite-specific
variations from them.
Structural Steel:
1. The compression flange is mechanically fastened to a steel deck or bar grating with a lateral capacity equal or greater to 5% of the vertical load carried by the beam or girder. The deck or grating must provide a horizontal diaphragm to resist out of plane movement of the compression flange.
2. The compression flange is directly attached (bolted or welded) to a transverse member that has a lateral capacity at least 5% of the vertical load of the beam and the transverse member is attached to bracing or a horizontal diaphragm that resists out of plane movement of the compression flange.
· Connections shall generally be shop welded and field bolted with A325N bolts.
· Bolted connections shall have a minimum of two ¾" dia bolts conforming to ASTM A325N.
· Double angle shear connections are preferred to single angle.
· Welded connections shall be performed with E70xx rod in accordance with AWS D1.1
The
following section addresses specific structural requirements that either will
further clarify the matrix referencedmatrix-referenced
codes or site specificsite-specific
variations from them.
Underground
Structures (cut and cover construction):
Unbalanced
load conditions shall be considered on all underground enclosures in accordance
with the engineering note attached to the February 11, 1998 memo to
distribution from Ed Crumpley entitled " Engineering/Safety Note Regarding
Underground Enclosures".
2.5.1
MECHANICAL DESIGN CRITERIA |
US
CODE OF FED REGS |
US
ACTS |
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STATE
OF ILLINOIS STANDARDS |
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LOCAL
ORDINANCES |
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STANDARDS |
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CODES |
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FERMI
STDS |
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DESIGN
ELEMENTS |
10
CFR Part 435 Subpart A / ASHRAE 90.1 - 1989 |
Clean
Water Act |
Safe
Drinking Water Act |
Toxic
Substances Control Act |
35
IAC (State of IL environmental regs) |
77
IAC 890 (Illinois Plumbing Code) |
77
IAC 920 (Drinking water syst req) |
77
IAC 920 (Water well constr code) |
77
IAC 925 (Well pump installation) |
120
IAC (Boiler & pressure vessels) |
Kane
County Health Department Ordinance 910191 Water Well Code |
City
Code of Warrenville, IL, Title 7, Chapter 4, sewer/sewerage ordinance |
Batavia
Code of Regulations, City Ordinance, Section 8-3-10-3 |
DuPage
County Health Department Private Water Supply Ordinance (OH-0002-90, Ch. 34,
DuPage County Code) |
American
Conference of Governmental Industrial Hygienist/Threshold Limit Values |
ANSI/ASHRAE
14 (Mechanical refrigeration) |
ANSI/ASME
B31.5 (Refrigeration piping) |
ANSI/ASME
B31.8 (Gas transmission and piping systems) |
ASME
Pressure Vessel Code-Section VIII |
National
Fire Protection Association National Fire Codes NFPA |
BOCA
National Building Code |
FESHM 5031 (Pressure
vessels) |
FESHM 5031.1
(Pressure piping systems) |
FESHM 5035
(Mechanical refrigeration systems) |
HVAC |
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Load
Calculations |
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Insulation |
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Ductwork |
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Piping |
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Design
Conditions |
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Ventilation |
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X |
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Special
Systems (Cleanrooms) |
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X |
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X |
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Central
Plant - Cooling |
X |
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X |
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Refrigeration |
X |
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X |
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Central
Plant - Heating |
X |
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Air
Handling Systems |
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Pumping
Systems |
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Testing,
Adjusting and Balancing |
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HVAC
Commissioning |
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Underground
Piping |
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Backflow
Prevention |
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Domestic
Water Systems |
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Drain,
Waste and Vent |
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Natural
Gas Systems |
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ICW
Systems |
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Water
Treatment |
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X |
X |
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X |
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Insulation |
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Strainers
and Filters |
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1) Inside Design Temperature/RH for conventional
buildings-Cooling
1.1) 78oDdb / 50%RH for office
1.2) No cooling for warehouses, shops, toilets
2) Inside Design Temperature/RH for conventional buildings-Heating
2.1) 72oFdb for offices
2.2) 55oFdb for Storage (occupied)
2.3) 50oFdb for Warehouses
2.4) 60oFdb for kitchens
2.5) 65oFdb for shops
2.6) 70oFdb for toilets
2.7) minimum 30% RH
3) Outside Design Temperature
3.1) Winter 99%/Summer 1% for process lab
3.2) Winter 97.5%/Summer 2.5% for personnel comfort
4) Typical Design criteria for Non-conventional facility
5) Thermal
Transmittance (U) value???
6) Ventilation
6.1) Personnel ventilation requirement- Ashrae 62
6.2) Industrial/Process ventilation requirement
6.3) Equipment room ventilation
7) Low Conductivity Water System
7.1) Materials
7.2) Use
of full or partial passivation
7.3) Water Quality
????Ohm-cm / ???ppm
8) Energy Conservation-
ECR is
required for Projects or retrofit where total energy consumption exceed 500
million BTU per year or if building is larger than 10,000 gross square feet
9) Hydronics
9.1) Chilled water system
9.2) Hot water system
9.3) Pumps
9.4) System pressurization
The design of buildings at Fermilab
shall comply with ASHRAE/IES Standard 90.1-1989 as well as 10 CFR Part 435
Subpart A, Performance Standards for New Commercial and Multi-Family High-Rise
Residential Buildings.
The purposes of the Standard include:
Guidance Engineering Standards
Advisory
Engineering Standards
Automatic sprinkler systems shall be
designed to a minimum of an Ordinary Hazard Group 1 classification, in
accordance with National Fire Protection Association (NFPA) latest edition. The
most commonly used NFPA standards relative to automatic sprinkler systems are:
13, 20, 25, 231, 231C, 318, and 750.
Fire alarm systems shall be designed
with a minimum standby power (battery) capacity. These batteries shall be
capable of maintaining the entire system in a non-alarm condition for 24 hours,
in addition to 15 minutes in full load alarm condition. The most commonly used
NFPA standards relative to fire alarm systems are: 70, 72, 90A, and 318.
The most commonly used NFPA standards
relative to special suppression systems are: 12, 12A, 17, 17A, 15, and 2001.
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71 IAC (Illinois Accessibility Code)
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77 IAC 890 (Illinois Plumbing Code |
National Fire Protection Association
(NFPA) |
BOCA Fire Prevention Code |
Uniform Federal Accessibility
Standards Ch4, Accessible Elements and Spaces; Scope and Technical |
Fire Alarm Systems (e.g.,
Conventional-hardwire, intelligent- analog/addressable, air sampling, and
agent releasing) |
X |
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Automatic Sprinkler Systems (e.g.,
Deluge, Dry, Preaction, Water-mist, and Wet Systems) |
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X |
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Special Extinguishing Systems (e.g.,
FM-200, Inergen, CO2, Halon, Dry Chemical, and Wet Chemical Systems) |
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2.8.1
ELECTRICAL DESIGN CRITERIA |
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DESIGN
ELEMENTS |
ANSI
(American National Standards Institute) |
ICEA
(Insulated Cable Engineers Association) |
IEEE
(Institute of Electrical and Electronic Engineers) |
NEMA
(National Electrical Manufacturer's Association |
NETA
(National Electrical Testing Association) |
National
Electrical Code (current edition) |
Life
Safety Code (current edition) |
OSHA
(Occupational Safety and Health Act) |
U.L.
(Underwriter's Laboratory) |
FESHM 5041 (Fermilab
Utilization Equipment Safety) |
FESHM 5042 (Fermilab
Electrical Power Distribution Equipment Safety) |
10
CFR Part 435 (Energy Conservation) |
Grounding |
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Raceways |
X |
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X |
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X |
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Cables
and Wires |
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X |
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X |
X |
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X |
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X |
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Transformers |
X |
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X |
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X |
X |
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X |
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Switchboards
and Panelboards |
X |
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X |
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X |
X |
X |
X |
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Safety
Switches |
X |
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X |
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X |
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X |
X |
X |
X |
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Motors |
X |
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X |
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X |
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X |
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X |
X |
Space
Heaters |
X |
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X |
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X |
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X |
Receptacles |
X |
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X |
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X |
X |
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X |
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Lighting |
X |
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X |
X |
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X |
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X |
Lightning
Protection |
X |
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X |
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X |
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X |
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Nominal
Voltage and Phase Rotation |
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Electrical
Nameplates |
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MANDATORY FERMILAB |
DATE |
PAGE |
|
CATEGORY |
SERIAL |
SUBJECT
POWER DISTRIBUTION VOLTAGES |
PREPARED
BY
R. Cassel |
APPROVED BY |
Electric power distribution throughout the laboratory shall be made only at the
following voltage levels.
All electrical equipment in the
Laboratory shall be constructed or converted to conform to these standard
distribution voltages.
Reference: FESHM 5042TA, 1
Reference: FESHM 5042TA, 2
MANDATORY FERMILAB |
DATE |
PAGE |
|
CATEGORY |
SERIAL |
SUBJECT
POWER DISTRIBUTION AND |
PREPARED
BY |
APPROVED
BY |
Power shall be distributed for all standard voltages by a 30, 5 wire, grounded wye
distribution, except as noted below.
The
center of the wye transformer secondary shall be solidly grounded as close as
practical to the transformer. sufficient length shall be provided for the
installation of a current transformer or ground protection relay.
Reference: FESHM 5045
MANDATORY FERMILAB |
DATE |
PAGE |
|
CATEGORY |
SERIAL |
SUBJECT
LOW VOLTAGE PLUGS AND |
PREPARED
BY |
APPROVED
BY |
This standard describes electrical
distribution plugs and receptacles approved for use throughout the Laboratory. Such
receptacles and plugs may be installed as components of distribution systems or
equipment installed or fabricated in accordance with Laboratory standards and
applicable regulatory codes.
There are three classes of plugs and
receptacles as denoted by the voltage level and number of phases: 120 V, 1
phase; 120/208 V, 3 phase; and 480 V, 3 phase. The descriptive information of
paragraph 2.0 and 3.0 covers all three classes.
The use of plugs and receptacles shall
be restricted to the maximum values of current and voltage shown. The use of plugs and receptacles is not
recommended for currents in excess of 100 amperes.
2.1 Grounding
The power system equipment ground
shall be carried to the connected equipment through a contact on each plug and
receptacle. In each case, the ground connection of
the plug shall be the first connection made and the last connection to be
broken. The metal shell, when present, of any
receptacle, cord connector or plug, regardless of voltage class, shall be
grounded to the equipment groundingequipment-grounding
conductor. The use of the grounded circuit conductor (neutral conductor) for
equipment grounding is prohibited. The terminal intended for connection to the
grounded (neutral) conductor will be white or marked "white." The terminal for connection to the equipment
groundingequipment-grounding conductor shall be green
colored, a hex head, or marked "green."
2.2 Phasing
When viewed from the front of the
receptacle, the phasing on multiphase circuits shall be A-B-C (X-Y-Z),
clockwise from the neutral pin, key slot, or ground pin.
2.3 Circuit Protection
Each receptacle whose current rating
is in excess of 30 A shall be connected to the power distribution system
through a safety disconnect switch that is located in close proximity to the
receptacle. The safety switch shall have a current interrupting rating equal to
or greater than the available fault current, and when over-current protection
is included, such protection shall be compatible with the ampacity of the
receptacle protected.
- 2 - SD-3D
0121.210
2.4 Circuit Identification
Each receptacle shall be marked with
the identifying code of its distribution circuit breaker as indicated on the
electrical distribution drawing.
3.1 Construction
All plugs and receptacles shall be
constructed for load breaking applications. All
female receptacle contacts shall be supported in separate, insulated areas. All plugs and connectors shall be constructed
to avoid exposed current carrying parts except the prongs, blades, or pins. The cover for wire terminations shall
be mechanically secured to, or an integral part of the plug or connector. All units shall have solderless
connections. Flexible cords shall be so connected to
plugs, receptacles, and cord connectors that tension will not be transmitted to
joints or terminal screws. . Plugs or connectors supplying equipment
with 300 V or more shall be of the skirted type or otherwise constructed to
confine arcs.
3.2
Environment
All plugs, receptacles and connectors
shall be suitable for the environment in which they are used. . The
requirements for explosive and other hazardous areas are not included in this
standard.
3.3.
Keying
All plugs and receptacles shall be
keyed to prevent connection of improperly aligned contacts.
3.4
Interchangeability
It shall be impossible by design to
mate plugs and receptacles of differing types. Each type shall have a
distinctive plug and receptacle style unique to that type.
The information given in Table 4.1 is
a summary of the standard plugs and receptacles. Detailed information may be found in
the manufacturers' bulletins. Plugs and receptacles from other sources may be
substituted provided that the mechanical contacts and key arrangements are
identical and that the electrical specifications are equal to or better than
those specified. All
new construction or major modification after March 15, 1972, shall conform to the
above requirements, and comply with the national Electric Code, NFPA 70-1971 to
satisfy the Occupational Safety and Health Standards.
-
3 - SD-3D
0121.210
TABLE 4.1 STANDARD PLUGS AND
RECEPTACLES
Voltage Class (V) |
Operating Voltage (V) |
Phases |
Wires |
Description |
Diagram |
Current Rating (A) |
NEMA Config. |
Source |
125 |
120 |
1 |
2 plus ground |
duplex receptacle (grounded) |
|
20 |
5-20R |
Hubbell 5362 |
125 |
120 |
1 |
2 plus ground |
connector, female body, with
insulated cord grip |
|
15 |
5-15R |
Hubbell 5269-C |
125 |
120 |
1 |
2 plus ground |
connector, female body with
insulated cord grip |
|
20 |
5-20R |
Hubbell 5369-C |
125 |
120 |
1 |
2 plus ground |
plug, male cap, with insulated cord
grip |
|
15 |
5-15P |
Hubbell 5266-C |
125 |
120 |
1 |
2 plus ground |
plug, male cap, with insulated cord
grip |
|
20 |
5-20P |
Hubbell 5366-C |
-
- 4
- SD-3D
0121.210
-
TABLE 4.1 STANDARD PLUGS AND
RECEPTABLES (Cont.)
Voltage Class (V) |
Operating Voltage (V) |
Phases |
Wires |
Description |
Diagram |
Current Rating (A) |
NEMA Config. |
Source |
120/208 |
120/208 |
3 |
4 plus ground |
receptacle, female outlet, single
unit |
|
20 |
|
Hubbell 3520 |
120/208 |
120/208 |
3 |
4 plus ground |
plug, male cap, with cord grip |
|
20 |
|
Hubbell 3521 |
120/208 |
120/208 |
3 |
4 plus ground |
connector, female body, with cord
grip |
|
20 |
|
Hubbell 3523 |
120/208 |
120/208 |
3 |
4 plus ground |
receptacle, female outlet, single
unit |
|
30 |
|
Hubbell 45805 |
120/208 |
120/208 |
3 |
4 plus ground |
plug, male cap, with cord grip |
|
30 |
|
Hubbell 45815 |
120/208 |
120/208 |
3 |
4 plus ground |
connector, female body, with cord
grip |
|
30 |
|
Hubbell 45835 |
-
5 - SD-3D
0121.210
TABLE 4.1 STANDARD PLUGS AND
RECEPTACLES (Cont.)
Voltage
Class (V) |
Operating
Voltage (V) |
Phases |
Wires |
Description |
Diagram |
Current
Rating (A) |
NEMA
Config. |
Source |
480 |
480 |
3 |
3 plus ground |
receptacle housing, with spring door |
|
30 60 100 |
|
Crouse-Hinds Crouse-Hinds Crouse-Hinds |
480 |
480 |
3 |
3 plus ground |
plug with cord grip, plain |
|
30 60 100 |
|
Crouse-Hinds Crouse-Hinds Crouse-Hinds |
480 |
480 |
3 |
3 plus ground |
connector female body, with cord grip |
|
30 60 100 |
|
Crouse-Hinds Crouse-Hinds Crouse-Hinds |
MANDATORY FERMILAB |
DATE |
PAGE |
|
CATEGORY |
SERIAL |
SUBJECT
DRAFTING SYMBOLS, |
PREPARED
BY |
APPROVED
BY |
The
symbols contained in the following documents shall be used on electrical and
electronic drawings prepared by or for the Fermi National Accelerator
Laboratory.
Reference: FESHM 5043
3.8 Computers
Reference: FESHM 5031.3
Reference: American Society of Mechanical Engineers - BPVC
Reference: American Society of Mechanical Enginners – B31.3
Reference: Compressed Gas Association – CGA 1.2
Reference: CGA S-1.3; 341; V-6
There is a set of up-to-date CGA Standards residing in the PPD Mechanical
Support library (WH-11NE).
|
Last Update – August 8, 2002
metelman@fnal.gov - P. Metelmann