DEPARTMENT OF THE AIR FORCE

HEADQUARTERS AIR FORCE CIVIL ENGINEER SUPPORT AGENCY

9 FEB 2007
FROM:

HQ AFCESA/CESM 139 Barnes Drive Suite 1 Tyndall AFB FL 32403-5319 Engineering Technical Letter (ETL) 07-1: Design Criteria for Underground Electrical Distribution Systems Using Directional Boring (DB) Installation Methods for Installing High Density Polyethylene Electrical (HDPE) Conduit

SUBJECT:

1. Purpose. This ETL provides technical guidance and criteria for directional boring (DB) trenchless technology methods to install high density polyethylene electrical (HDPE) conduit used for underground electrical distribution systems. Note: This ETL is applicable to high-voltage (HV) underground distribution systems between 1000 volts (V) and 34.5 kilovolts (kV) (nominal) and all lowvoltage (less than 1000 V) distribution systems only and is not applicable to airfield lighting circuits. Use of DB techniques to install electrical conduit for high-voltage distribution voltages greater than 34.5 kV (nominal) is prohibited. 2. Application. Requirements in this ETL are mandatory, except at overseas locations where host nation codes, norms, standards or status of forces agreements apply. Any deviations shall require written approval from HQ AFCESA/CESM. 2.1. Authority: Air Force instruction (AFI) 32-1063, Electric Power Systems Air Force joint manual (AFJMAN) 32-1080, Electrical Power Supply and Distribution ETL 04-4, Trenchless Technology (TT) for Crossing Air Force Pavements 2.2. Effective Date: Immediately. 2.3. Intended Users: Major command (MAJCOM) engineers Base civil engineers (BCE) Base maintenance organizations 2.4. Coordination: MAJCOM electrical engineers APPROVED FOR PUBLIC RELEASE: DISTRIBUTION UNLIMITED

Air Force Safety Center (AFSC)

3. Referenced Publications. 3.1. Air Force: AFI 32-1063, Electric Power Systems, available at http://www.e-publishing.af.mil AFJMAN 32-1080, Electrical Power Supply and Distribution, available at http://www.e-publishing.af.mil ETL 04-4, Trenchless Technology (TT) for Crossing Air Force Pavements, available at http://www.afcesa.af.mil/library/etl.asp?Category=Engineering%20Technical% 20Letters 3.2. Industry: 3.2.1. American Society for Testing and Materials (ASTM) (available at www.astm.org): ASTM D2447, Standard Specification for Polyethylene (PE) Plastic Pipe, Schedules 40 and 80, Based on Outside Diameter ASTM D2657, Standard Practice for Heat Fusion Joining of Polyolefin Pipe and Fittings ASTM D2683, Standard Specification for Socket-Type Polyethylene Fittings for Outside Diameter-Controlled Polyethylene Pipe and Tubing ASTM D3035, Standard Specification for Polyethylene (PE) Plastic Pipe (DR-PR) Based on Controlled Outside Diameter ASTM D3350, Standard Specification for Polyethylene Plastics Pipe and Fittings Materials ASTM F1056, Standard Specification for Socket Fusion Tools for Use in Socket Fusion Joining Polyethylene Pipe or Tubing and Fittings ASTM F1290, Standard Practice for Electrofusion Joining Polyolefin Pipe and Fittings ASTM F2160, Standard Specification for Solid Wall High Density Polyethylene (HDPE) Conduit Based on Controlled Outside Diameter (OD) ASTM F2176, Standard Specification for Mechanical Couplings Used on Polyethylene Conduit, Duct and Innerduct 3.2.2. Underwriters Laboratories (UL) (available at www.ul.com): UL 651, Schedule 40 and 80 PVC Conduit UL 651A ,Type EB and A Rigid PVC Conduit and HDPE Conduit UL 651B, Continuous Length HDPE Conduit

3.2.3. Other: National Electrical Manufacturers Association (NEMA) TC7, Smooth-Wall Coilable Polyethylene Electrical Plastic Conduit, available at www.nema.org National Fire Protection Agency (NFPA) 70 (latest version), National Electric Code (NEC), available at www.nfpa.org National Electrical Safety Code (NESC), available at http://standards.ieee.org/nesc PPI Handbook of Polyethylene Pipe, available at http://www.plasticpipe.org/general/ppi_handbook.php 4. Acronyms and Abbrevations: ASTM BCE DB HDPE HV kV MAJCOM Max Min P.E. psi PVC UL V - American Society for Testing and Materials - base civil engineer - directional boring - high density polyethylene electrical - high voltage - kilovolt - major command - maximum - minimum - Professional Engineer - pound per square inch - polyvinyl chloride - Underwriters Laboratories - volt

5. Background. DB is a drilling technique that uses a steerable drill system to create a pathway for conduit. The equipment operator can control the depth and direction of the boring with great accuracy. Currently, DB methods are not addressed in Air Force guidance for electrical distribution systems. However, there are advantages to DB that makes it an attractive conduit installation means at many Air Force installations. This technique: Preserves landscaping; and Can be cost-effective for crossing runways, taxiways, waterways, or other environmentally sensitive areas.

6. Requirements. All electrical equipment and materials shall conform to NEMA and/or UL standards. Workmanship and materials shall conform to the requirements of the NEC, NESC, and other references contained in this ETL as applicable.

Note: An AF Form 103, Base Civil Engineering Work Clearance Request (digging permit), shall be processed to ensure the bored area is clear of utilities or other obstructions. 6.1. Where Authorized. DB methods shall not be chosen as an installation means in lieu of concrete encasement or other approved jack-and-sleeve techniques outlined in AFJMAN 32-1080, based solely on cost. Concrete encasement and jackand-sleeve techniques always provide the best means to protect conduit and conductors; therefore, DB is authorized only for crossing under: Roads; Parking lots; Airfield aprons, taxiways, or runways (not airfield lighting circuits); Bodies of water; Environmentally sensitive areas with appropriate federal, state, and local government approval; Historical preservation areas with appropriate federal, state, and local government approval.

For applications not listed above, MAJCOM electrical engineers shall determine the applicability of this ETL. A copy of MAJCOM approvals shall be provided to HQ AFCESA/CESM. 6.2. Conduit Type. HDPE conduit shall be smoothwall, approved/listed for directional boring, approved/listed for electrical system installations, and minimum Schedule 80 meeting ASTM D2447/F2160/NEMA TC-7 (latest editions). Note: HDPE conduit shall always be installed below freeze lines and in no case shall the conduit be installed less than the minimum depths noted in paragraphs 6.2.1, 6.2.2, and 6.2.3. 6.2.1. Minimum size HDPE conduit shall be 5 inches for distribution voltages greater than 1,000 V and less than 34.5 kV (nominal). 6.2.1.1. Conduit fill shall not exceed 30 percent. 6.2.1.2. Installed HDPE conduit shall have a minimum ground cover of: 6.2.1.2.1. 120 inches in non-pavement-covered areas. 6.2.2.2.2. 48 inches in pavement-covered areas. 6.2.2. Minimum size HDPE conduit shall be 4 inches for distribution voltages less than 1,000 V. 6.2.2.1. Conduit fill shall not exceed 35 percent. 4

6.2.2.2. Installed HDPE conduit shall have a minimum ground cover of 48 inches in pavement- or non-pavement-covered areas. 6.2.3. Minimum size HDPE conduit for branch circuit wiring less than 600 V shall be determined by NEC calculation methods for, as a minimum, branch circuit conductor size, maximum allowable pulling tension, and maximum 5 percent voltage drop. 6.2.3.1. Conduit fill shall not exceed 40 percent. 6.2.3.2. Installed HDPE conduit shall have a minimum cover of 24 inches in pavement- or non-pavement-covered areas. 6.3. Installation Methods. This ETL does not mandate the use of specific conductor or insulation types for either high- or low-voltage installations. However, the combination of a chosen conductor and insulation type may not meet the requirements for the installation methods required in the following paragraphs where length, depth, and routing of the directional bore conduit may require an alternative conductor material and/or insulation type (i.e., maximum pulling tensions are different for aluminum and copper conductors). 6.3.1. If the directional bored portion of the cable run is more than 25 percent of the total run length, evaluate and document the conductor derated ampacity in accordance with NFPA 70 Article 310.60 (C) (2). 6.3.2. Water-jetting is not permitted. 6.3.3. Pre-installed cable-in-conduit is not permitted. 6.3.4. Drilling fluids used for DB methods shall be approved by federal, state, and local codes and authorized for use by the BCE. 6.3.5. The conduit(s) shall be installed immediately after the conduit hole is completed. 6.3.6. There is no restriction on DB distances provided the allowable pulling tension of the conduit and installed conductors are not exceeded, conductor splices are not within the conduit, and maximum ampacity of conductors due to depth derating is not exceeded. 6.3.6.1. A registered Professional Engineer (P.E.) shall calculate pulling tension requirements for each directional bore, taking into consideration the HDPE conduit(s) size and type, bend radius, elevation changes, vertical and horizontal path deviations, installed electrical conductor size and type, and any conductor ampacity derating due to depth of HDPE conduit. 5

6.3.6.2. The electrical contractor shall provide certification of compliance with the P.E. directives. 6.3.6.3. The professional engineering design process must include consideration of tensile forces and bend radii created during the installation so that allowable limits are not exceeded. 6.3.6.4. Allowable tensile forces must be determined by a P.E. The P.E. certifying the installation shall account for the conduits allowable bend radius to prevent ovalization and kinking from installation. Ovalization of the conduit shall not exceed 5 percent. 6.3.7. HDPE Conduit Terminations. 6.3.7.1. HDPE conduits shall terminate into concrete-pad-mounted electrical equipment from either a pavement or non-pavement transitional area as indicated in Figures 1 through 5. 6.3.7.2. HDPE or rigid conduit shall be routed and terminated within the concrete pad such that no conductor exiting the conduit shall be bent past the vertical plane formed with the equipment pad when routed to conductor terminations and with approved insulated bushings (Figure 1).

Conductor Termination Point (Typical)

Pad-Mounted Electrical Equipment

Concrete Pad 1 Conductor bend past vertical plane not permitted

1
NOT TO SCALE

(Ilustrative Only)

Use approved reaming means to remove sharp edges and install approved adapter with insulated bushing prior to pulling conductors

Figure 1. HDPE or Rigid Conduit Electrical Equipment Transition 7

45 Degree Max

Pad-Mounted Electrical Equipment Extend conrete pad or concrete encase the HDPE until under concrete pad

Concrete Pad 1

Pavement Covered Area

48" Min - All voltages less than 34.5 kV nominal PVC Schedule 80 Long Sweep Conduit Transition (45 Degree or 90 Degree) Listed HDPE-PVC Electrofusion Type Coupling Use approved reaming means to remove sharp edges prior to joining conduits Bend radius not to exceed manufacturer's recommendation and 5% ovalization 5" Min diameter HDPE - 1,000 V to 34.5 kV (nominal) 4" Min diameter HDPE - less Than 1,000 V NOT TO SCALE (Ilustrative Only) 1 Use approved reaming means to remove sharp edges and install approved adapter with insulated bushing prior to pulling conductors

Figure 2. Pavement Covered Area to Electrical Equipment Transition Rigid Conduit (4590) 8

Pad-Mounted Electrical Equipment Extend concrete pad to pavement edge or concrete encase HDPE until under concrete pad Concrete Pad 45 Degree Max 1

Pavement Covered Area

48" Min - all voltages less than 34.5 kV nominal Bend radius not to exceed manufacturer's recommendation and 5% ovalization

5" Min diameter HDPE - 1,000 V to 34.5 kV (nominal) 4" Min diameter HDPE - less than 1,000 V NOT TO SCALE (Ilustrative Only)

Use approved reaming means to remove sharp edges and install approved adapter with insulated bushing prior to pulling conductors

Figure 3. Pavement Covered Area to Electrical Equipment Transition HDPE Conduit (2045)

45 Degree Max

Pad-Mounted Electrical Equipment Extend conrete pad or concrete encase HDPE until under concrete pad

Concrete Pad 1

Non-Pavement Covered Area

PVC Schedule 80 Long Sweep Conduit Transition (45 Degree or 90 Degree) Listed HDPE-PVC Electrofusion Type Coupling Use approved reaming means to remove sharp edges prior to joining conduits Bend radius not to exceed manufacturer's recommendation and 5% ovalization 5" Min diameter HDPE - 1,000 V to 34.5 kV (nominal) 3" Min diameter HDPE - less than 1,000 V NOT TO SCALE (Ilustrative Only)

120" Min - 1,000 V to 34.5 kV nominal 48" Min - less than 1,000 V

Use approved reaming means to remove sharp edges and install approved adapter with insulated bushing prior to pulling conductors

Figure 4. Non-Pavement Covered Area to Electrical Equipment Transition Rigid Conduit (4590) 10

Pad-Mounted Electrical Equipment Extend conrete pad or concrete encase HDPE until under concrete pad Concrete Pad 45 Degree Max 1

Non-Pavement Covered Area

Bend radius not to exceed manufacturer's recommendation and 5% ovalization

120" Min - 1,000 V to 34.5 kV nominal 48" Min - less than 1,000 V

5" Min diameter HDPE - 1,000 V to 34.5 kV (nominal) 4" Min diameter HDPE - less than 1,000 V NOT TO SCALE (Ilustrative Only)

Use approved reaming means to remove sharp edges and install approved adapter with insulated bushing prior to pulling conductors

Figure 5. Non-Pavement Covered Area to Electrical Equipment Transition HDPE Conduit (2045)

11

6.3.8. Multiple Conduits and Wiring Methods. 6.3.8.1. Multiple HDPE conduits are permitted to be pulled through each bore. Designs requiring multiple conduits to accommodate parallel conductor installations must comply with NFPA 70 NEC grounding and wiring methods requirements. As an example, one set of paralleled conductor requirements is illustrated in the following excerpt from the 2005 NEC, Article 310.4, which states:
The paralled conductors in each phase, polarity, neutral, or grounded circuit conductor shall comply with all of the following: (1) Be the same length (2) Have the same conductor material (3) Be the same size in circular mil area (4) Have the same insulation type (5) Be terminated in the same manner

Thus, using DB methods to comply with (1) from the NEC excerpt, as well as other NEC requirements, may not be possible, especially for long boring distances. The NEC has other requirements for paralleled conductor installations that must also be considered when designing for these types of installations. Note: Any deviations from NEC requirements must be approved by HQ AFCESA/CESM, the authority having jurisdiction over the NEC. 6.3.8.2. If the directional bored portion of the cable run is more than 25 percent of the total run length, evaluate and document the conductor derated ampacity in accordance with NFPA 70 Article 310.60 (C) (2). 6.4. Joining Methods. Butt and electrofusion joining means are the only joining methods approved for HDPE conduit installations and shall be accomplished by persons certified in the process and in accordance with the manufacturers procedures. 6.5. Transition from HDPE to PVC. Transition from HDPE to PVC shall be made using only electrofusion coupling means with approved and listed materials. Coupling means shall be accomplished by persons certified on the equipment and process. 6.5.1. Coupling between HDPE and concrete-encased duct banks from pavement or non-pavement transitional areas shall be accomplished as indicated in Figures 6 and 7. 6.5.2. Transition from HDPE to concrete manholes from pavement or nonpavement transitional areas shall be accomplished as indicated in Figures 8 and 9. 12

5" Min diameter HDPE - 1,000 V to 34.5 kV (nominal) 4" Min diameter HDPE - less than 1,000 V

HDPE Conduit Transistion - layover to connect to PVC

Pavement Covered Area

Min depth per NEC 48" Min below surface of pavement all voltage classes less than 34.5 kV (nominal) Concrete encased PVC per NEC and AFJMAN 32-1080 guidance Listed HDPE-PVC Electrofusion Type Coupling Use approved reaming means to remove sharp edges prior to joining conduits New bend radius not to exceed manufacturer's recommendation and 5% ovalization Extend conrete encasement to pavement edge or until HDPE Min depth from ground level is achieved

NOT TO SCALE (Ilustrative Only)

Figure 6. HDPE-to-PVC Pavement Covered Area Concrete Ductbank Transition 13

5" Min diameter HDPE - 1,000 V to 34.5 kV (Nominal) 4" Min diameter HDPE - less than 1,000 V

HDPE Conduit Transistion - layover to connect to PVC Start of non-pavement covered area

Non-Pavement Covered Area

Min Depth Per NEC 120" Min - 1,000 V to 34.5 kV nominal 48" Min - less than 1,000 V Concrete encased PVC per NEC and AFJMAN 32-1080 guidance New bend radius not to exceed manufacturer's recommendation and 5% ovalization Extend conrete encasement until HDPE Min depth from ground level is achieved for specified voltage class

Listed HDPE-PVC Electrofusion Type Coupling Use approved reaming means to remove sharp edges prior to joining conduits

NOT TO SCALE (Ilustrative Only)

Figure 7. HDPE-to-PVC Non-Pavement Covered Area Concrete Ductbank Transition

14

5" Min diameter HDPE - 1,000 V to 34.5 kV (nominal) 4" Min diamter HDPE - less than 1,000 V

HDPE Conduit Transistion - layover to connect to Schedule 80 PVC

Pavement Covered Area

1

2 48" Min below surface of pavement all voltage classes less than 34.5 kV (nominal)

Concrete Manhole

PVC Schedule 80

Listed HDPE-PVC Electrofusion Type Coupling Use approved reaming means to remove sharp edges prior to joining conduits 1 Use approved reaming means to remove sharp edges and install approved adapter with insulated bushing prior to pulling conductors NOT TO SCALE (Ilustrative Only)

New bend radius not to exceed manufacturer's recommendation and 5% ovalization 2

Extend conrete encasement to pavement edge or until HDPE Min depth from ground level is achieved

Use approved end bell fittings on all conduits entering or leaving manhole

Figure 8. HDPE-to-Manhole Pavement Covered Area Transition 15

5" Min diameter HDPE - 1,000 V to 34.5 kV (nominal) 4" Min diameter HDPE - less than 1,000 V

HDPE Conduit Transistion - layover to connect to PVC Schedule 80 Start of non-pavement covered area

Non-Pavement Covered Area

1 120" Min - 1,000V to 34.5 kV nominal 48" Min - Less Than 1,000 V Concrete Manhole PVC Schedule 80

Listed HDPE-PVC Electrofusion Type Coupling

New bend radius not to exceed manufacturer's recommendation and 5% ovalization 1

Extend conrete encasement until HDPE Min depth from ground level is achieved for specified voltage class

Use approved reaming means to remove sharp edges and install approved adapter with insulated bushing prior to pulling conductors

NOT TO SCALE (Ilustrative Only)

Figure 9. HDPE-to-Manhole Pavement Covered Area Transition

16

6.6. Documentation. The location and depth of DB-installed HDPE electrical conduit shall be recorded and noted on applicable as-built drawings. Global Positioning System (GPS) recording means with resource grade accuracy shall be used to record HDPE conduit bore path. GPS coordinates shall be recorded at intervals not to exceed 50 feet along the bore path. This information, along with the size of conduit, number of conductors, conductor size, and insulation type, shall be provided to the appropriate base civil engineering office for incorporation into the GeoBase database. 7. Point of Contact. Recommendations for improvements to this ETL are encouraged and should be furnished to the Electrical Engineer, HQ AFCESA/CESM, 139 Barnes Drive, Suite 1, Tyndall AFB, FL 32408-5319, DSN 523-6352, commercial (850) 2836352, e-mail AFCESAReachbackCenter@tyndall.af.mil

BRENT E. HILL, Col, USAF Director of Engineering Support

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DEPARTMENT OF DEFENSE Defense Commissary Agency (1) Design and Construction Division 2250 Foulois St., Suite 2 Lackland AFB, TX 78236 SPECIAL INTEREST ORGANIZATIONS Information Handling Services 15 Inverness Way East Englewood, CO 80150 (1) Construction Criteria Base National Institute of Bldg Sciences Washington, DC 20005 (1) AAFES ATTN: RE-C PO Box 660202 Dallas, TX 75266-0202 (1)

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