Electrical Earthing and Bonding System

2/2/2011
1
A Warm Welcome to All Delegates
A Technical Presentation on
McML
1
Earthing & Bonding System
By
Mr T N Rao
McML Protection Technologies Pvt Ltd
Hyderabad
McML
Earthing&BondingSystem
McML
ATechnicalPresentationon
McML Protection Technologies Pvt Ltd McML Protection Technologies Pvt Ltd
Plot No 42 , Vijaypuri Colony
Sainikpuri, Hyderabad- 62
Mobile : +91-9704456808
Fax : +91-40-4012 0478
Email : tn.rao@mcmlptl.com
Web : www.mcmlptl.com
McML
Agenda
Introduction
Codes & Standards
Design Principles
Soil Resistivity , Measurement of soil resistivity
Treatment of soil , Earth Enhancing Compound
Earth Resistance Measurement of Earth Resistance
2Feb11 3
Earth Resistance , Measurement of Earth Resistance
Deep Earth or Multiple earth pits
Permanent Connections Exothermic welding
Common Bonding Network (CBN)
Case studies RDSO Specification
Practical
Measurement of soil resistivity
Measurement of earth resistance
McML
Modern electronic equipment is
sensitive.
More susceptible to surges and
electromagnetic interferences.
Components size is reduced.
More components per chip.
Why failures are more now ?
4
p p p
Poor Insulation resistance.
More number of appliances
An effective low impedance earthing is
mandatory for any protective device to
operate and protect the equipment
4 2Feb11
2/2/2011
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McML
Introduction
EarthingisanintegralpartofanymodernElectrical&Electronic
equipmentprotectionsystemdesign.
An effective, lowimpedance ground system is a key element of
power quality assurance.
Itiscrucialnotonlytoensurepersonnelsafetybut,toprovide
li bl t ti f it l i t
reliableprotectionforvitalequipment:
Reducingambientnoiselevels
Improvedsystemperformance
Toincreaseequipmentlife
Tominimizeinterruptionsofserviceandcostlydowntime.
5
2Feb11 2Feb11
McML
Codes & Standards:
IS 3043:1987 - Code of Practice for Earthing
IEEE Standard 80 - IEEE Guide for Safety in AC Substation Grounding
IEEE Standard 1100 - IEEE Recommended Practice for Powering and Grounding
Electronic Equipment ( IEEE Emerald book)
IEEE Standard 142 - IEEE Recommended Practice for Grounding of
Industrial and Commercial Applications( IEEE Green book)
IEEE Standard 81 - Recommended Guide for Measuring Ground
IEEE Standard 81 Recommended Guide for Measuring Ground
Resistance and Potential Gradients in the Earth
IEEE Standard 837 - IEEE Standard for Qualifying Permanent Connections
Used in Substation Grounding
IEC 60364-5-2002 - Electrical installations of buildings
ANSI UL 467 - Grounding and Bonding Equipment
BS 7430: 1998 - Code of Practice for Earthing
BS EN 50164-7:2008 - Requirements for Earthing Enhancing Compounds
6 2Feb11
McML
Design of Earthing System :
1. TypeofEarthing
2. ElectrodeMaterial
3. ElectrodesShape
4. ElectrodeTypes
7
5. SoilResistivity
6. SoilTreatment
7. MultiplePitsorDeepElectrode
8. Bonding PermanentConnections
2February2011 2Feb11
McML
Classification of Earthing / Grounding
Safety or Protective Earth - For safety of personnel
Main Earth, General Electrical Earth, Equipment Grounding, Body Earthing
Associated with Non current carrying body/ conductor
88
System or Technical Earth - For stable earth reference or noise
suppression
DC Earth, System Neutral, Telecom Earth, Instrumentation Earth
Functional, Clean Earth
Associated with current carrying current conductor
2Feb11
2/2/2011
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McML
Electrode Material
1. Protection against Corrosion
CorrosionResistance ofdifferentmetals
Copper(0.2%)
CastIron/MS(2.2%)
9
2. Protective Coating
Copperbondedelectrodes 0.2%peryear
(Recommendedmin250microns)
HotdipGalvanization(GI) 0.5%peryear
3. High tensile low carbon steel
MaterialgradeBS4360grade43A
Tensilestrengthofmin600N/mm2
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McML
1. Underground Corrosion National Bureau of Standards Circular 579
From 1910 to 1955, the National Bureau of Standards conducted an extensive underground
corrosion study in which 36,500 specimens, representing 333 varieties of ferrous, nonferrous,
and protective coating materials were exposed in 128 test locations throughout the United
States.
In cooperation with the National Association of Corrosion Engineers, the NCEL conducted a
7-year program of testing metal rods for electrical grounding. Copper bonded, stainless clad,
and galvanized steel rods were included among other materials
2. Field Testing of Electrical Grounding Rods Naval Civil Engineering Laboratory (NCEL)
Technical Reports : Review
10 10
and galvanized steel rods were included among other materials.
3.National Electrical Grounding Research Project (NEGRP) Pawnee Site Excavation
The NEGRP was started in 1992 to compare the long-term performance of different types
of grounding electrodes.
In 2003, one of the original sites (Pawnee) was excavated and the electrodes removed
5/8 copper bonded and galvanized rod samples were exhumed.
The results were definitive :
The 5/8 copper bonded rod was virtually free of corrosion while the galvanized
rod showed significant deterioration (see the pictures on next slide).
2Feb11
McML
National Electrical Grounding Research Project Pawnee Site Excavation
11
x10galvanizedrodremovedafter
10years(PawneeSite).
2February
2011
11
5/8 x 8 Copper Bonded ground rod
removed after 10 years (Pawnee Site).
McML
National Electrical Grounding Research Project Pawnee Site Excavation
12
3/4x10galvanizedrodremovedafter
10years
12
5/8 x 8 Copper Bonded ground rod
removed after 10 years
Recommendations :
10 mil copper coating: Service life - up to 40 years.
UL 467 recommends 10 mils (0.25mm) of copper coating
2February2011
2/2/2011
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McML
UL 467 Grounding & Bonding Equipment
R
E322481
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McML
Vertical Electrodes
Plate Electrodes
Horizontal Strip Electrodes
Electrode Shape
14
The low current density can be achieved by designing the electrode
in such a way that the dimensions in one direction is large compared
to the other two, thus a pipe/rod has a much lower resistance than a
plate of equal surface area.
PlateElectrodesarenotverycommonastheyarenotaseffectiveasvertical
electrodeandalsoexpensive.
2February2011
McML
Types of Earth Electrodes
Vertically Electrodes
Pipe or copper clad steel
Plate Electrodes
2ft x 2ft x 6 mm copper plate is used.
Horizontal Strip Electrodes
15
A strip is buried in a trench in rocky area
Ring Earth
Earthing conductor buried around building perimeter
Chemical Earth Rods
Integral chemical treatment
Ufer Earth
Metallic conductor embedded in structural concrete
2Feb11
McML
IEC603645:Electricalinstallationsofbuildings
Electrodes :
Copperbondedroddia =14mmcoating90micronsminimum.
Copperstrip50sqmm(25x2mm).
GIstrip=90sqmm(30x3mm)(6070microns)
Earthing Conductor Sizing
16
2
February
p q ( ) ( )
GIPipe=25sqmm(2mmthickness)
EarthingConductor:Mincrosssectionalarea(Cl 542.3)
Protectedagainstcorrosion 16sqmmcopper
Notprotectedagainstcorrosion 25sqmm.copper,50sqmm.Fe
Equipotential bondingaccordingto413.1.2.1ofIEC60364441
6mmcopper;or
16mmaluminium;or
50mmsteel
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McML
Earthing Conductor Sizing
IEEE837
17 2Feb11
McML
Soil Resistivity
2Feb11 18
McML
Earth Resistance Testers
Ground Resistance Tester
3 or 4-wire Tester
Types :
Analogue
Digital
Clamp on
Fluke
Megger
2Feb11 19
Clamp on
GEOHM
Clamp On
Digital
Analogue
McML
Soil Resistivity Measurement Wenner Method
SoilResistivity()=2aR
2Feb11 20
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McML
SoilResistivity()=2aR
2Feb11 21
McML
Microsoft Office
2Feb11 22
Microsoft Office
el 97-2003 Worksh
McML
Typical Soil Resistivity
2Feb11 23
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Soil Resistivity - Effect of Salt, Moisture and Temperature
2Feb11 24
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Soil Treatment to lower the resistivity
Conventional Methods
Use of sodium chloride, magnesium, and copper sulfates, or calcium
chloride, to increase the conductivity of the soil immediately
surrounding an electrode.
State or federal authorities may not permit using this method
because of possible leaching to surrounding areas.
The salt treatment must be renewed periodically.
Corrode and damage the earth electrode
2Feb11 25
McML
Soil Treatment to lower the resistivity
BS EN /IEC 50164-7 : the European (CENELEC ) standard specifies the
requirements for earthing enhancing compounds.
EEC effectively increase the diameter of the electrode by modifying the soil
surrounding the electrode
Earth Enhancing Compounds
surrounding the electrode.
EEC increases the contact surface area of the earth electrodes.
Cathodic Protection does not damage the earth electrode.
The EEC does not polluting the environment.
Note : Refill products are not in the scope of the standard
2Feb11 26
McML
Highly conductive cementious compound
Increases the contact surface area
Homogeneous and stable
Doesn't leach into the ground
Doesnt corrode the electrode
Enhances the life of earth electrode.
Earthing Enhancing Compound
27 27
Enhances the life of earth electrode.
Environmentally Friendly
Low Resistivity
Suitable for all terrain
Can be used in dry or slurry form
Permanent and Maintenance Free
Comply BS EN/IEC 50164-7 (
McML
Graphite based Earth Enhancing Materials
2Feb11 28
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McML
Earth Enhancing Compound- Application
Earth enhancement materials are typically placed
aroundtherodinanauguredholeor aroundgrounding
conductors in a trench, in either a dry form or
premixedinaslurry.
2Feb11 29
McML
Electrode Resistance Development
2Feb11 30
McML
Earth Resistance
1. Resistance of the electrode .
2. Contact Resistance between the electrode and the soil
3 Resistance of the soil from the electrode surface outward
Factors affecting Earth Resistance
3. Resistance of the soil from the electrode surface outward
The first two are negligible part of total resistance
The resistance of an earth is primarily determined by the
soil resistivity
2Feb11 31
McML
Earth Resistance
2Feb11 32
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Earth Resistance Calculation
33
2Feb11
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Earth Resistance Calculation
34
2Feb11
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Earth Resistance of Vertical Electrode
The most commonly used formula for single ground electrode systems
Developed by Prof. H B Dwight of the MIT.
2Feb11 35
McML
Microsoft Office
Earth Resistance of Vertical Electrode
2Feb11 36
Microsoft Office
el 97-2003 Worksh
2/2/2011
10
McML
How to reduce earth resistance ?
Increase the length of the electrode?
Increase the dia of the electrode ?
Use multiple earth pit ?
37
p p
Improve the soil resistivity ?
2February2011
McML
Deep Earth Electrode System
Electrode
Dia
38
2February2011
Electrodelengthinm
McML
Deep Earth Electrode System
Time :
50 (-m)
Rod Dia 12 mm 17 mm 19mm 25 mm
Length (m) 0.012 0.017 0.019 0.025
1 38.27 35.50 34.61 32.43
2 21.89 20.51 20.06 18.97
3 15.67 14.75 14.45 13.72
4 12.33 11.63 11.41 10.87
5 10.22 9.66 9.48 9.05
6 8.75 8.29 8.15 7.78
Design Engineer
Project : Deep Earth Electrode System
T NRao
Location :
Customer :
Soil Resistivity
McMLProtection Technologies
Length and Dia of Electrode
Rr={/2**lr}*{ln(4*lr/D)-1}, when
39
2February2011
Rev. No.: 0
Checked By Approved By
Mr.T.N.Rao Mr.Sumadeep
Form. No.: TEC-SFS-04
Mr.Sasirekha
Prepared By
35.50
20.51
14.75
11.63
9.48 8.15
32.43
18.97
13.72
10.87
9.05 7.78
0
5
10
15
20
25
30
35
40
45
50
1 2 3 4 5 6
E
a
r
th
R
e
s
is
ta
n
c
e
in
O
h
m
s
EarthResistance Homogeneoussoil
12mm
17mm
19mm
25mm
McML
ShallowEarthing
DeepEarthing
Limited Electrode Length- 6 to 8 feet
Doesnt touch natural soil
Offers Inconsistent resistance
Deep Driven Electrode > 12 feet
Greater contact with low resistant
natural soil
Maintains consistent resistance
Shallow / Deep Earth Grounding
LORESS
40 40
Offers Inconsistent resistance
Earth enriching agents - salt, charcoal,
are used
Has environmental concerns
Maintenance required
Short term solution
over time
No such chemical agents are used.
No environmental concerns.
Maintenance free
Permanent & Economical solution
2February2011
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McML
Electrodes in Parallel
A useful rule is that grounding systems of 224 rods placed one rod length apart in a
line, hollow triangle, circle, or square will provide a grounding resistance divided by
the number of rods and multiplied by the factor F taken from Table
41
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2011
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Sphere of Influence
2Feb11 42
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Sphere of Influence Spacing between electrodes
2Feb11 43
McML
2Feb11 44
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Measurement of Earth Resistance
Fall of Potential Method
2Feb11 45
McML
Measurement of Earth Resistance
46
2February2011
McML
Measurement of Earth Resistance - Fall of Potential Method
2Feb11 47
McML
Measurement of Earth Resistance - Fall of Potential Method
2Feb11 48
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McML
Permanent Joint
Durable and Reliable
Corrosion Free
Exothermic Weld Connections
Permanent Connections
49
Offer no contact resistance
High Current Capacity
CPRI Testing
. The best choice where safety, reliability, current
carrying capacity and longevity are critical.
2February2011 2Feb11 49
McML
Exothermic Welding Process
LORESS
McML
Mandatory acc. to the following Standards:
ANSI IEEE Standard 80 IEEE Guide for
Safety in AC Substation Grounding
IEEE Standard 837 IEEE Standard for
LORESS
Exothermic Welding Process
51
Qualifying Permanent Connections Used in
Substation Grounding
ANSI UL 467 Grounding and Bonding
Equipment
ANSI-J-STD-607-A Commercial Building
Grounding (Earthing) and Bonding
Requirements for Telecommunications
McML
The earth system has to be considered as an integrated system,
telecommunications earth cannot be considered independently of power
earth or lightning earth.
Earthing as a system
52
2February2011
earth or lightning earth.
More than one earth systems will be connected to some equipment thereby
creating current paths that might not have been planned, might not be
adequate, or might not remain continuous.
Circulating currents and potential differences between the earth systems
can damage the equipment.
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McML
Equipotential Bonding - Use of Isolation Spark Gaps
53
Conducting Parts of Installation Non Conducting Parts of Installation
2February2011
McML
Bond all ground points to eliminate ground loops and create an
equipotential plane
Regulation requires that everything that is conductive is to be connected
to the network of protective conductors to create building CBN
All earth pits water pipe line gas pipeline and metal works ( metal stair
54
All earth pits, water pipe line, gas pipeline and metal works ( metal stair
case etc )to be bonded together in an installation.
Use Isolation Spark Gap devices for equipotential bonding of Conducting
and non conducting parts of the electrical installations.
54 2February2011
McML
Lowinresistanceandimpedance.
Adequatecurrentcarryingcapacity
Durableandreliable
Goodcorrosionresistance
Characteristics of an effective / good Earthing :
Consistencyinlowresistance
Areliablelifeof2530years
MaintenanceFree
Complywithnationalandinternationalcodes
McML
HoweffectiveisyourEarthingSystem?
9095%ofallfacilitiesinspectedlackaneffective
Earthingsystem.
2Feb11 56
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Conventional/TraditionalEarthing
57 2February2011 2Feb11 57
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ConventionalEarthing
Is bolt nut mechanism a
permanent solution ?
Is it non corrosive ?
Is it touching the natural soil ?
58
Can it offer consistent
resistance ?
Can it carry the required
current safely to ground ?
Is it Maintenance Free ?
McML
LORESS
TM
Here is the solution from McML
LORESS
LORESS
59
ACompleteMaintenanceFreeEarthingSolution
R
E322481
Approved and Tested by International /
National certifying bodies
CPRI
McML
Copper bonded Rods
Compression Couplers
LORESS
Unique features of the solution
R
E322481
60
2
February
60
Earth Enhancing Compound
Connections using Exothermic Welding
2/2/2011
16
McML
High tensile low carbon steel
Complies BS 4360 grade 43A
6 10 long X - dia
Molecularly bonded with 99.9% copper
Coating thickness - 10 mil ( 254 microns)
Copper Bonded Rods
R
E322481
61 61
Coating thickness 10 mil ( 254 microns)
UL listed Rods
Tensile strength of min 600 N/mm
2
Bending strength of min 12.12 KN
CPRI
+
tested 23 kA for 1 second
Meets IS:3043 , UL 467, EN 50164-2 standards
Service Life - up tyo 40 years
2February2011
McML
Test Reports
R
E322481
UL Conformance Certificate
Tensile Strength test report
Stripping Test report
62 62 2February2011
Bending Strength Test report
Coating Thickness test report
Current Carrying capacity test report
McML
Used for joining two rods
Deep earth electrode system
Good rod to rod contact (tight fit)
Preferred to Threaded ones
N li ibl R i t
Compression Couplers
R
E322481
LORESS
63
Negligible Resistance
Higher Current carrying capacity
Durable and reliable
Percussion strength of min 200N .
CPRI
+
tested 23 kA for 1 second
McML
Resistivity Test Report
Compression Test Report
TestReports&Approval:CompliesBSEN/IEC501647
64
pH Measurement Test report
Solubility in acidic environment Test report
Leaching of Fe Cu Zn Ni Cd Co Pb Test Report
Sulphur Determination Test Report.
Environmental Safety (RoHS) Test Report.
Pollution Control Board Certificate
2/2/2011
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McML
LORESS
65 65
HighVoltage/CurrentTest
McML
ElectrodeSurroundedbyEarthEnhancingCompound LORESS
66
2Feb11 66
McML
LORESS
Horizontal Earthing or Ring Earthing
67 2February2011 2Feb11 67
McML
Permanent Joint
Durable and Reliable
Corrosion Free
Exothermic Weld Connections
LORESS
68
Offer no resistance
High Current Capacity
Tested at CPRI
. The best choice where safety, reliability, current carrying capacity and longevity are critical.
2/2/2011
18
McML
Earth Chamber
LORESS
69
2February2011
A300X300X300mmPrefabricated
concretebox
2Feb11 69
McML
50 200
1
0
0
2
0
0
Concrete Cover
250x250x25mm
Cement concrete
Chamber
300 300 300
Inspection
chamber
EBB
Stainless steel
Bolt and nut
Exothermic
Weld
Insulated twin 35 sq mm
copper cable
300x25x6 mm Cu Bus
Bar mounted on wall
with insulated studs Handle for lid
50
RDSO/SPN/197 : 2008
LORESS
70
Conducrete
EEC
10(3000 mm) x (17.2 mm)
Copper bonded MS Rod
300x300x300 mm
Augured Hole length 6
to 8 feet with 4 to 6
Dia
Natural Soil
McML
50 200
1
0
0
2
0
0
Conducrete
EEC
Concrete Cover
250x250x25mm
Cement concrete
Chamber
300x300x300 mm
Inspection
chamber
1
.8
M
m
in
im
u
m
EBB
Stainless steel
Bolt and nut
Exothermic
Weld
Insulated 10 sq mm
copper cable
300x25x6 mm Cu Bus
Bar mounted on wall
with insulated studs Handle for lid
50
71
2
February
71 2February201
EEC
6(1800 mm) x (17.2
mm)
Copper bonded MS Rod
Compression Coupler
1
.8
M
m
in
im
u
m
Augured Hole length 6
to 8 feet with 4 to 6
Dia
Natural Soil
McML
LORESS
Ring Earth or Earth Grid
2/2/2011
19
McML
Conventional
Earthing
LORESS
Maintenance Free Earthing
GI / CI Pipes Corrosion
Shallow Earth Electrode 8-10 feet
Copper Bonded Steel Rods
Adequate copper bonding 254 Microns Inadequate Galvanization ( 60-80 microns)
Deep Earth Electrode upto 40 feet
Doesn't touch the natural soil Greater contact with natural soil & moisture
73
Inconsistent resistance
Corrosive agents - salt, charcoal are used
Nut & Bolts loose or corroded
Installation requires more space
Short life 2 to 4 years
Consistent resistance
No corrosive agents are used.
Exothermic Welding - Permanent
Installation requires less space
Maintenance required Maintenance free
Long life 25 30 years
Doesn t touch the natural soil Greater contact with natural soil & moisture
2February2011
McML
BS/EN
50164-7
EEazy azyEEar t h ar t h Salient Features :
highlyconductive
offerlargerconductivesurfacearea
lowertheearthresistanceby3040%
offerlessseasonalvariationsinOhmic value
offerlowersurgeimpedance
corrosion Proof
LORES LORESSS EEazy azyEEar t h ar t h
AnInnovativeMaintenanceFreeEarthingSystemfromMcML
corrosionProof
TheftProof
homogeneousandStable
hygroscopic
maintenanceFree
environmentallySafe
suitableforallterrain
lastlong 25years
easytoinstall
2Feb11 74
McML
BS/EN
50164-7
EEazy azyEEar t h ar t h Applications :
RailwayCommunication&SignallingEquipment
Computer&DataProcessingCenters,
BankATMs
LORES LORESS S EEazy azyEEar t h ar t h
AnInnovativeMaintenanceFreeEarthingSystemfromMcML
concrete Chamber
300x300x300 mm
EazyEarth
LightningProtectionSystems
TelecomTowers&Microwaveantennas
Transmission&DistributionSystems,
OilRefineries&PumpingStations.
AllFactories
EquipmentBodyEarthings.
Residential&CommercialBuildings
LORESS
RFC 25
y
Electrode
2Feb11 75
McML
Approved by
GROUNDINGANDBONDINGEQUIPMENT
(KDER)
LORESS
TM
A complete Maintenance Free Earthing System
McML
Protection Technologies
Approved by
FILE NO. E322481
Underwriters Laboratories Inc
R
E322481
2Feb11 76
2/2/2011
20
McML
Tested by
McML
TM
LORESS
A complete Maintenance Free Earthing System
Protection Technologies
CentralPowerResearchInstitute,Bangalore
ShortTimeCurrentCapacity
23.25 kA RMS 1.05 sec & 44.90kA peak
Report No. SC 07424A
2Feb11 77
McML
McMLStrengths
DesignExpertise
WellTrainedProfessionals
SuperiorinQuality.asperUL/IEEE/BS/IS
78 78
StronginSourcing
TimelyDelivery
Execution:SkilledManPower
McML
Professional & Skilled Staff
79
2Feb11 79
McML
MAJORCUSTOMERS
80 80
2Feb11 80
2/2/2011
21
McML
Beware!
Spuriousandsubstandardproductsinthe
market
eg. Pipe in Pipe or Flat in Pipe or any other Chemical earthing
systems being promoted in the name of Safe Earth Electrode or
systems being promoted in the name of Safe Earth Electrode or
Maintenance Free Earthing have no relevance to any national or
international standards.
2Feb11 81
McML
Substandardproductsinthemarket
PipeinPipeElectrodeafterTwoYears
CopperBondedRodafter10years
2Feb11 82
McML
Any?
LORESS
83
y
2Feb11 83
McML
Thank You
For further information please contact:
Mr T N Rao
Vice President Technical
Mob : +91-9704456808
42, Vijaypuri Colony, Sainikpuri, Hyderabad
Tel : +91-40 -4002 1604
Fax : +91-40-4012 0478
tn.rao@mcmlptl.com

Electrical Earthing and Bonding System

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Electrical Earthing and Bonding System

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2/2/2011

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