Fermilab Engineering Standards Manual

August,August 20012

PREAMBLE

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.

Chapter 1: Administration

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.

Chapter 2: Civil Engineering Standards

2.1 General Requirements

2.1.1 AestheticsArchitectural Approvals - - Mandatory

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.

2.1.2 Approval for Modifications to Buildings and Systems - - Mandatory

2.1.3 As-Built Documentation - - Reserved

2.1.4 Permits for Modifications to Critical Systems - - Reserved

2.2 Civil

2.2.1 Design Criteria Matrix to N&S Standards - - Mandatory

2.2.1 CIVIL DESIGN CRITERIA

U.S. CODE OF FEDERAL

EXECUTIVE ORDERS

STATE OF ILLINOIS STANDARDS

FERMI STANDARDS

REGULATIONS

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)

Civil Construction Projects

x

x

x

Construction Projects involving Waters of the State

x

x

x

x

Construction Projects > 5 acres in size

x

x

Excavation

x

x

Erosion Control Design

x

Water Well Installation

x

x

Sewer and Water Utilities

x

x

x

Roadway/Pavement Design

x

x

x

x

Transformer Containment Design

x

2.2.2 General Sitework - - Reserved

2.2.3 Demolition - - Reserved

2.2.4 Erosion Control - - Reserved

2.2.5 Soils - - Reserved

2.2.6 Underground Utilities - - Reserved

2.2.7 Beam Pipe Installation - - Reserved

2.2.8 Casing Jacking - - Reserved

2.2.9 Site Concrete - - Reserved

2.2.10 Roads and Parking - - Reserved

2.2.11 Landscaping - - Reserved

2.3 Architectural

2.3.1 Design Criteria Matrix to N&S Standards - - Mandatory

2.3.1 Design Criteria Matrix for Architectural Work

Design elements

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

X

X

X

General Planning

X

X

X

X

X

X

X

X

X

X

X

X

Use or Occupancy

X

Special Use and Occupancy

X

X

General Building Limitations

X

Types of Construction

X

Fire Resistant Materials and Construction

X

X

Means of Egress

X

X

Accessibility

X

X

X

X

X

X

Roofs and Roof Structures

X

Masonry

X

Wood

X

Glass and Glazing

X

Gypsum Board and Plaster

X

Elevators and Conveying Systems

X

X

X

X

X

2.3.2 Space Allocation - - Reserved

2.3.3 Common Materials and Finishes - - Reserved

2.3.4 Color Selections - - Reserved

2.3.5 Doors and Hardware - - Reserved

2.3.6 Accessories - - Reserved

2.4 Structural

2.4.1 Design Criteria Matrix to N&S Standards - - Mandatory

2.4.1 STRUCTURAL DESIGN CRITERIA
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
2. Structural tests and inspections						X
3. Foundations and retaining walls						X
4. Structural concrete						X
5. Structural masonry						X
6. Structural steel						X
7. Structural wood						X
8. Overhead cranes	X	X	X	X	X

2.4.2 Structural Loadings - - Mandatory

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

• Snow Loads: The flat roof snow load (Pf) shall not be less than 30.0 psf for any building on site.
• Wind Loads: The following shall be used for determining design wind loads
  Basic wind speed = 80 mph.
  Exposure Category = B
• Earthquake Loads: The following shall be used for determining design earthquake loads
  Av = 0.05
  Aa = 0.05
• Lateral Soil Loads: The following shall be used for determining design lateral soil loads, unless local soil tests have been performed.
  Active earth pressure coefficient, Ka = 0.5
  Unit weight of soil, [gamma] = 130 pcf
• Special Loads : The following shall be used for determining design special loads
  Down drag for vertical soil reaction on enclosures = 10%

2.4.3 Structural Tests, Inspections and Evaluations - - Reserved

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.

2.4.4 Structural Concrete - - Reserved

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:

• 4000 psi. minimum 28 day28-day concrete compressive strengths shall be used for design.
• 60,000 psi shall be used in the design for the yield stress in all reinforcing steel.

2.4.5 Structural Steel - - Reserved

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:

• Structural steel shall conform to ASTM A572, grade 50.
• The designer shall attempt to utilize conventional concentrically braced framing in all structural steel building designs.
• Bar joist shall may be used only in buildings where hoisting or lifting is not anticipated (e.g. office environments) or when they are enclosed by a ceiling structure (suspended or otherwise).
• Lateral bracing of steel members for use in calculation of their flexural capacity shall be considered adequate only if they meet at least one of the following criteria:

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

2.4.6 Underground Structures - - Reserved

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".

2.4.7 National Performance Criteria for Tornado Shelters (FEMA)

2.5 Mechanical

2.5.1 Design Criteria Matrix to N&S Standards - - Mandatory

2.5.1 MECHANICAL DESIGN CRITERIA

US CODE OF FED REGS

US ACTS

STATE OF ILLINOIS STANDARDS

LOCAL ORDINANCES

STANDARDS

CODES

FERMI STDS

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

X

X

Load Calculations

X

X

Insulation

X

X

X

Ductwork

X

Piping

X

X

X

X

X

Design Conditions

X

X

Ventilation

X

X

X

Special Systems (Cleanrooms)

X

X

Central Plant - Cooling

X

X

X

X

X

X

X

X

Refrigeration

X

X

X

X

X

X

X

X

Central Plant - Heating

X

X

X

X

X

X

Air Handling Systems

X

X

Pumping Systems

X

X

X

X

X

Testing, Adjusting and Balancing

X

X

HVAC Commissioning

X

Underground Piping

X

X

X

X

X

Backflow Prevention

X

X

X

X

X

X

X

Domestic Water Systems

X

X

X

X

X

X

X

X

X

Drain, Waste and Vent

X

X

X

Natural Gas Systems

X

X

X

X

ICW Systems

X

X

X

Water Treatment

X

X

X

X

X

X

X

X

Insulation

X

Strainers and Filters

X

X

X

2.5.2 Design Conditions - - Reserved

1) Inside Design Temperature/RH for conventional buildings-Cooling

1.1) 78^oDdb / 50%RH for office

1.2) No cooling for warehouses, shops, toilets

2) Inside Design Temperature/RH for conventional buildings-Heating

2.1) 72^oFdb for offices

2.2) 55^oFdb for Storage (occupied)

2.3) 50^oFdb for Warehouses

2.4) 60^oFdb for kitchens

2.5) 65^oFdb for shops

2.6) 70^oFdb 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

• 4.1) ????Fdb/???RH for beam tunnels
• 4.2) ????for cleanroomsclean rooms

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

2.5.3 Energy Efficiency Requirements - - Mandatory

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:

• To set minimum requirements for the energy-efficient design of new buildings and construction
• To provide criteria for energy-efficient design and methodologies for measuring projects against these criteria
• To provide guidance in designing energy-efficient buildings and building systems.

2.6 HVAC Control Systems

2.6.1 Guidance Engineering Standards - - Guidance

Guidance Engineering Standards

• All Direct Digital Control (DDC) systems shall be Johnson Controls (JCI) Metasys Facilities Management Systems or compatible with the Metasys system through a Johnson Controls Integrator.
• All DDC systems shall communicate over the DDC sitewidesite wide ARCNET network. Preferred mediums of communication are coaxial cable, twisted pair cable, or optical fiber.
• Any control functions that are related to life safety shall be "hard-wired" as opposed to being staged/controlled through a DDC computer.
• Any programming modifications to existing DDC systems shall be performed or coordinated by the FESS DDC group.
• Any addition of points to existing DDC systems shall be performed or coordinated by the FESS DDC group.
• When a system is designed for a dehumidification application, the heating device shall be placed after the cooling device. This design allows the heating device to temper the air after the cooling device has removed the moisture.
• When a system is designed using outside air, a low limit thermostat shall be used to protect water coils. Upon sensing temperatures below the low limit thermostat, the system shall be hardwired such that the fans are shutdown, the outside air dampers are closed, and all water coil valves are positioned for full flow through the coil.

2.6.2 Advisory Engineering Standards - - Advisory

Advisory Engineering Standards

• Control cable 24 volts or less should be 18 AWG, stranded, shielded cable, 2 or 3 conductors as required.
• 120-volt control cable should be 12 AWG, stranded cable.
• Systems designed using outside air should have a minimum outside air damper position for improved indoor air quality. It is also good practice to install carbon dioxide sensors. Upon sensing high carbon dioxide readings, the outside air dampers shall open to improve the indoor air quality. Wall-mounted carbon dioxide sensors are preferred over duct-mounted sensors.
• SCR vernier control is recommended when using staged electric heaters.
• Proportional analog control is preferred over modulated control.
• Whenever possible, systems with economizer controls are recommended to provide outside air for free cooling. Dry bulb switchover is usually adequate. Larger HVAC systems (25 tons or greater) should consider using enthalpy switchover.
• Pneumatic actuators should be used whenever clean, dry air is available.
• Johnson Controls UNT and AHU controllers are recommended for applications where packaged control programs are sufficient. For more flexibility, the Johnson Controls DX9100 Controller is recommended.

2.7 Fire Protection

2.7.1 Design Criteria Matrix to N&S Standards - - Mandatory

1. Automatic Sprinkler Systems

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.

2. Fire Alarm Systems

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.

3. Special Extinguishing Systems

The most commonly used NFPA standards relative to special suppression systems are: 12, 12A, 17, 17A, 15, and 2001.

	71 IAC (Illinois Accessibility Code)	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		X	X	X
Automatic Sprinkler Systems (e.g., Deluge, Dry, Preaction, Water-mist, and Wet Systems)		X	X	X
Special Extinguishing Systems (e.g., FM-200, Inergen, CO2, Halon, Dry Chemical, and Wet Chemical Systems)			X

2.7.1.1 National Electrical Code

2.7.2 Automatic Sprinkler Systems - - Guidance

• Standard spray sprinklers should be manufactured by Viking.
• Return bends (arm-overs) shall be provided on all pendent sprinklers.
• Welding of sprinkler piping is permitted on site by a certified welder.
• Pipe should be steel, schedule 40, when sprinkler systems are supplied from the ICW system or are designed as a dry pipe system.
• 1/2" or 3/4" Pipe should be steel, schedule 80 when retrofitting existing upright sprinkler outlets supplying new pendent type sprinklers.
• Backflow preventers should be manufactured by FEBCO, model 880V.
• Fire Department connection should be a 4-inch "Storz" quick connect with a 22¼-degree straight-galvanized elbow on the exterior inlet pipe to the Storz connection. Also, the gasket should be removed from the Storz cap.
• Waterflow alarm detectors (switches) should be provided with double pole, double throw contacts, rated at 120 VAC at 3 amps.
• Preaction sprinkler systems should be configured as double interlocked as manufactured by Viking. In addition, the air supervisory switch should be cross-zoned with the releasing detection.
• A control valve should be provided after the preaction valve assembly, to facilitate testing without introducing water throughout the piping network.
• Waterflow supply test information can be obtained from the FESS-Engineering Group.
• For water-mist systems and preaction systems, refer to special suppression systems.
• All control valves should be provided with electronic valve supervisory (tamper) switches.
• As-built documents should be provided to FESS.

2.7.3 Fire Alarm System - - Guidance

• Acceptable equipment manufacturers for fire alarm control panels are Siemens-Cerberus (Pyrotronics) and Fire Control Instruments (FCI).
• All fire alarm control panels (FACP) should be provided with a T-45 key and lock assembly.
• FACPs should be provided with a silence switch or function key for all notification appliances.
• FACPs should be provided with a fire department testing switch or function key to disable notification devices and sub-functions during testing.
• FACPs should be provided with a by-pass switch for in-duct smoke detector fan shutdown operations.
• Addressable/analog circuits should be a minimum of 18 AWG solid twisted jacketed cable. Conventional (Hardwire) initiating circuits should be a minimum of 16 AWG solid cable. Indicating appliance circuits should be a minimum of 14 AWG solid cable.
• All cabling should be installed in conduit, EMT minimum. The minimum conduit size should be 3/4".
• When designing conventional systems, a supervisory zone should monitor the in-duct smoke detectors. In-duct smoke detectors should be manufactured by System Sensor.
• When designing an addressable/analog system, in duct smoke detectors should provide a supervisory or status alarm at the fire alarm control panel and signal output should be a supervisory alarm.
• Whether at the FACP, the in-duct smoke detector housing, or addressable module, relay contacts should be provided to monitor a single normal open or closed dry set of contacts for HVAC controls, i.e., fan shutdown.
• All manual pull stations should be dual action types and able to be reset with a T-45 key or a 9/16" allenAllen wrenches.
• Line type heat detection, manufactured by Protectowire, should be installed in beam enclosures.
• Air sampling smoke detection, manufactured by Fenwal, should be installed in experimental hall areas.
• All fire alarm systems should be connected to Fermilab's FIRUS systems, capable of indicating FIRE ALARM, SUPERVISORY ALARM, and TROUBLE ALARM.
• FACP should be provided with a walk-test feature.
• All FACP shall be provided with smoke verification.
• Addressable/analog device descriptions should be reviewed by the Fire Department and Fire Systems Maintenance Group prior to download program in FACP. In addition, a hard copy of software and as-built documents should be provided to FESS.

2.7.4 Special Suppression Systems - - Guidance

• If air sampling is the method of detection, then the air sampling display should be programmed so that 100% at 40 seconds sends a signal via FIRUS indicating that FIRST LEVEL OF AIR SAMPLING IN ALARM. Release of agent should be at 100% for 60 seconds.
• If cross-zone detection is provided, then additional signal outputs from the releasing control panel to FIRUS should indicate FIRST DETECTOR ZONE IN ALARM and SECOND DETECTOR ZONE IN ALARM.
• The manifold pressure switch should connect directly into FIRUS and indicate AGENT RELEASED.
• Provide a time delay after second alarm prior to releasing agent to facilitate HVAC shut-downshutdown.
• Equipment shut-downshutdown, such as dampers and electronics should be from a manifold pressure switch.
• Manifold pressure switches should be provided with a minimum of double pole and double throw contacts.
• HVAC shut-downshutdown should occur at second alarm of cross-zone.

2.8 Electrical

2.8.1 Design Criteria Matrix to N&S Standards - - Mandatory

2.8.1 ELECTRICAL DESIGN CRITERIA

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