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1LIGHTNING PROTECTIONREQUIREMENTS FOR DODAMMUNITION ANDEXPLOSIVES 129256621021301025648U.S. Army Engineering and Support Center, HuntsvillePrepared by Jeff Denton09 August 2018“The views, opinions and findings contained in this report arethose of the authors(s) and should not be construed as anofficial Department of the Army position, policy or decision,unless so designated by other official documentation.”Coulston ECM Assessment 2018 NDIASymposium 09 Aug 2018 .pptx130120111

2OVERVIEW OF PRESENTATION Case for Lightning Protection System (LPS) onAmmunition and Explosives (AE) Facilities DOD Criteria for LPS on AE Facilities Lightning Protection Principles Distinctive AE Requirementso Lightning protection systemso Inspection and testingo Records and training Common Deficiencies of LPS InstallationsFile Name

3CASE FOR LPSs ON DOD AE FACILITIES July 10, 1926, Lake Denmark Naval Ammunition Storage Depotoooo600,000 tons explosives21 people killedAbout 200 buildings destroyedDDESB established in 1928 Lightning Incidents to International Arsenals and Storage Depots “Properly Maintained LPSs are required for AE Facilities.” DOD6055.09-M, V2.E4.1. DOD Ammunition and Explosives SafetyManual.File Name

4DOD CRITERIA FOR LPS ON AE FACILITIES DOD 6055.09-M, Ammunition and Explosives Safety StandardsoooApplicable to DOD ComponentsVolume 2 contains electrical and LPS safety standardsSelects NFPA 780 as the LPS criteria for AE facilities (V2.E4.1.) NFPA 780, Standard for the Installation of Lightning ProtectionSystemsoooIndustry standard for lightning protectionChapter 4 – General requirements for ordinary facilitiesChapter 8 – Protection of structures housing explosive materials UFC 3-575-01, Lightning and Static Electricity Protection SystemsooooooFile NameNot specific to AE facilitiesApplicable to DOD facilities, including AEApplies NFPA 780 as the LPS criteriaDirects that a risk assessment per NFPA 780 be performedUL certificate requiredAir Force requires commercial third-party certificate

5DOD CRITERIA FOR LPS ON AE FACILITIES DA PAM 385-64, Ammunition and Explosives Safety StandardsoooApplicable to Army ComponentsSection IV of Chapter 17 has LPS requirementsImplements safety requirements of DOD 6055.09-M AFM 91-201, Explosives Safety StandardsooApplicable to Air Force ComponentsImplements in full DOD 6055.09-M AFI 32-1065, Grounding SystemsoooFile NameApplicable to Air Force ComponentsNot specific to AE facilities. Attachment 5 specific to explosive facilitiesImplements maintenance requirements of DOD 6055.09-M

6DOD CRITERIA FOR LPS ON AE FACILITIES NAVSEA OP 5, Ammunition and Explosives Safety AshoreooApplicable to Dept. of Navy ComponentsDistribution to U.S. Government agencies and contractors DDESB TP 22, Lightning Protection for Explosives FacilitiesooooGuidance for installation and maintenance of LPSProvides clarification to DOD 6055.09-M and NFPA 780Authored by DDESB (Dr. Josephine Covino)Distribution to U.S. Government agencies and contractors Non-DOD LPS Standards for Explosives FacilitiesooFile NameDOE Manual 440.1-1A, Explosive Safety ManualNASA Standard 8719.12, Safety Standard for Explosives, Propellants, andPyrotechnics

7LIGHTNING PROTECTION PRINCIPLES No lightning protection system is 100% effective. It is an matter ofstatistical probabilities and risk management. Per NFPA 780, two design methods for protection againstlightning.ooRoof types (cone of protection)Rolling Sphere Method (RSM) RSM is widely used and required by:oooooFile NameDOD 6055.09-M, V2.E4.2NFPA 780, 8.2.1.DA PAM 385.64, 17-19.b.AFMAN 91-201. 5.23NAVSEA OP 5, 6-3.a.

8LIGHTNING PROTECTION PRINCIPLESRSM Principle: The attractive effect of the lightning rod is afunction of a striking distance (ds) that is determined by theamplitude of the lightning current. Lightning Strike Magnitudes 99% exceed 3,000 A 90% exceed 8,000 A 50% exceed 28,000 A 10% exceed 80,000 A 1% exceed 200,000 A(Per DDESB TP22) Striking Distance (ds) r 10 Ip 0.65File NamerIp20m3kA30m5.4kA45m10kA61m16kA

9LIGHTNING PROTECTION PRINCIPLES Four Protection Levels (IEC 62305-3)LevelMin. Ip% Eff.RSMI3kA99%66 ft.II5.4kA97%100 ft.III10kA91%150 ft.IV16kA84%197 ft. Example: LPS designed to LPL II is expected tointercept all strikes with an amplitude current of5.4kA or greater. Lightning strikes below 5.4kA maybypass the protection system. So, a minimumcurrent level is selected to achieve the maximumprotection. Thus the more stringent requirements toprotect against smaller amplitude lightning strikesthan larger amplitude strikes.File Name

DISTINCTIVE AE REQUIREMENTSLPSLPS RequirementPrinciple Criteria Reference100 ft. radius zone of protectionDOD 6055.09-M, V2.E4.2.NFPA 780, 8.2.1DA PAM 385-64, 17-19.b.AFMAN 91-201, 5.23.NAVSEA OP 5, 6-3.a.Power / comm. installed in metallic conduit and rununderground 50 ft. before entering the facilityDOD 6055.09-M, V2.E3.6.2.DA PAM 385-64, 17-26.b.AFMAN 91-201, 5.23.5.AFI 32-1065, 15.1.NAVSEA OP 5, 6-7.2.(Surge protection normally referenced within thesame section is very critical and a requirement for alltypes of facilities with an LPS)Above ground metallic utility lines bonded to thestructural steel of LPS at entrance to the facilityDOD 6055.09-M, V2.E3.6.DA PAM 385-64, 17-26.d.AFMAN 91-201, 5.23.5.AFI 32-1065, 15.2.NAVSEA OP 5, 6-6.3.3.OH power line distances from AE facilitiesDOD 6055.09-M, V2.E3.5.DA PAM 385-64, 8.13File Name10

DISTINCTIVE AE REQUIREMENTSLPSFile NameLPS RequirementPrinciple Criteria ReferenceGround ring electrodeNFPA 780, 8.4.1DA PAM 385-64, 17-25.AFI 32-1065, A4.1.15.NAVSEA OP 5, 6-5.1.Ground ring electrode must be sized to Class IImaterial requirementsNFPA 780, 8.4.3DA PAM 382-64, 17-25.AFI 32-1065, A4.1.15.NAVSEA OP 5, 6-5.1.Railroad tracks must be bonded to the LPSNFPA 780, 8.5.7DA PAM 385-64, 17-22.f.NAVSEA OP 5, 6-6.3.1.Metallic access doors and doorframes shall bebonded to the ground ringNFPA 780, 8.5.5.1NAVSEA OP 5, 6-6.3.4.Metallic fences must be grounded or bonded tothe ground ring electrodeNFPA 780, 8.8.1DA PAM 385-64, 17-22.e.NAVSEA OP 5, 6-6.3.2.Bonding techniquesNFPA 780, 8.5.4NAVSEA OP 5, 6-6.1.LPS for earth covered magazinesNFPA 780, 8.7.1UFC 4-420-01, 3-8.6DA PAM 385-64, 17-19.g.NAVSEA OP 5, 6-8.2.11

DISTINCTIVE AE REQUIREMENTSLPSFile NameLPS RequirementPrinciple Criteria ReferenceLPS for wharves and piersNFPA 780, 8.7.2NAVSEA OP 5, 6-8.2.3.1.LPS inspection certificate by UL oranother third-partyUFC 3-575-01, 3-1Air Force facilities with perimeters largerthan 300 ft. and structural steel not usedfor air terminals must use a mast orcatenary type LPSAFI 32-1065, 14.5.Naval facilities implement a primary andsecondary ground system that must bebonded together at two locationsNAVSEA OP 5, 5-5; 6-5.12

DISTINCTIVE AE REQUIREMENTSInspection and TestingFile NameCriteriaLPS Inspection or TestIntervalsDOD 6055.09-M, V2.E4.3.1.Visual InspectionOne year or per the DODComponent and approved byDDESBD0D 6055.09-M, V2.E4.3.2.Electrical TestsMaximum every two years orper the DOD Component andapproved by DDESBNFPA 780, 8.10Visual InspectionSeven monthsNFPA 780, 8.10.6.3Visual inspection of theSPDSeven months or after anysuspected lightning strikeNFPA 780, 8.10.7Electrical tests14 monthsDA PAM 385-64, 17-28.Visual inspection12 monthsDA PAM 385-64, 17-28.Electrical testsTwo years13

DISTINCTIVE AE REQUIREMENTSInspection and TestingFile NameCriteriaLPS Inspection or TestsIntervalsAFMAN 91-201(per AFI 32-1065, Table 1)Visual inspection1-2 years as determined byMAJCOM EEAFMAN 91-201(per AFI 32-1065, Table 1)Visual inspection of SPDSix months and after alightning strikeAFMAN 91-201(per AFI 32-1065, Table 1)Electrical tests24 monthsNAVSEA OP 5, 6-9.Visual inspection6 months(100% of air terminal ifintegral system)NAVSEA OP 5, 6-9.Electrical tests24 months(20% of air terminals ifintegral system)14

DISTINCTIVE AE REQUIREMENTSRecords and TrainingFile NameCriteriaRecords and TrainingDurationDOD 6055.09-M, V2.E4.3.3.Records and testmeasurementsKept on file for at least sixinspection cyclesDOD 6055.09-M, V2.E4.3.4.Establish training requirementsfor LPS personnelN/ANFPA 780, 8.9Develop maintenance andinspection planN/ANFPA 780, 8.10.7.7Document records & test dataand available for inspectionTime period acceptable tothe AHJDA PAM 385-64, 17-29.Maintain inspection and testreportsFor the last six inspectioncyclesAFMAN 91-201, 5.24.3.Maintain records and test dataFor the last six inspectioncyclesNAVSEA OP 5, 6-9.Develop inspection and testplan; training for personnel inDOD LPSN/A15

16COMMON DEFICIENCIESFile NameCommon DeficienciesPrinciple Criteria ReferenceSPDs not installed at the facility entrance and exitof power, data and comm. conductorsDOD 6055.09-M, V2.E3.6.1; E4.2.3.UFC 3-575-01, 3-4NFPA 780, 8.6DA PAM 385-64, 17-26.a, b.AFMAN 91-201, 5.23.5.AFI 32-1065, 15.NAVSEA OP 5, 6-7.Aboveground metallic utility lines and pipes notbonded to the structural steel before entering thefacility, or run underground the last 50 ft.DOD 6055.09-M, V2.E3.6.1.DA PAM 385-64, 17-26.d.AFMAN 91-201, 5.23.5.AFI 32-1065, 15.2.NAVSEA OP 5, 6-6.3.3.Power, data and comm. lines not run undergroundthe last 50 ft. before entering the facilityDOD 6055.09-M, V2.E3.5.1; 6.2.DA PAM 385.64, 17-26.b.AFMAN 91-201, 5.23.5AFI 32-1065, 15.NAVSEA OP 5, 6-7.2.Down conductors not secured every 3 ft.NFPA 780, 4.10DA PAM 385-64, 17-19.e.Down conductors not protected from physicaldamage up to 6 ft. above gradeNFPA 780, 4.9.11AFI 32-1065, A4.1.8.Main conductors bends less than 90 degrees, orhave radius less than 8 in.NFPA 780, 4.9.5DA PAM 385-64, Table 17-4AFI 32-1065, A4.1.5.

17COMMON DEFICIENCIESFile NameCommon DeficienciesPrinciple Criteria ReferenceMetallic doors and doorframes not bonded tothe ground ringNFPA 780, 8.5.5DA PAM 385-64, 17-22.b.(2)NAVSEA OP 5, 6-6.3.4.Metallic masses within sideflash distance of anLPS component not bonded to the LPSNFPA 780, 8.5.2DA PAM 385-64, 17-22.b.(1)NAVSEA OP 5, 6-6.Fences shall be grounded and bonded wherewithin 6 ft. of the AE facility, or within contactdistanceNFPA 780, 8.8.1DA PAM 385-64, 17-22.e.NAVSEA OP 5, 6-6.3.2.Air terminals exceeding 24 in. in height notsupplied with additional supportNFPA 780, 4.6.2.2.2Electrical testing and visual inspection notperformed or reports not availableDOD 6055.0-M, V2.E4.3.NFPA 780, 8.10DA PAM 385-64, 17-28.NAVSEA OP 5, 6-9.UL or third-party certificate does not existUFC 3-575-01, 3-1OH electrical power lines too close to the AEfacilityDOD 6055.09-M, V2.E3.5.2.DA PAM 385-64, 8-13 (Table 8-5)

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NFPA 780, 8.5.5.1 NAVSEA OP 5, 6-6.3.4. Metallic fences must be grounded or bonded to the ground ring electrode NFPA 780, 8.8.1 DA PAM 385-64, 17-22.e. NAVSEA OP 5, 6-6.3.2. Bonding techniques NFPA 780, 8.5.4 NAVSEA OP 5, 6-6.1. LPS for earth covered magazines NFPA 780, 8.7.1 UFC 4-420-01, 3-8.6 DA PAM 385-64, 17-19.g. NAVSEA OP 5, 6-8.2.