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Persian Gulf Bid Boland Gas Treating Project
Part B: Pipelines & Mahshahr Facilities
Document Title:
Document Number:
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TABLE OF CONTENTS
1.
PURPOSE ................................................................................................................................. 5
2.
3.
4.
CONSIDERATIONS .................................................................................................................. 5
5.
6.
CALCULATION BASIS.............................................................................................................. 7
6.1. THE CROSS - SECTIONAL AREA ................................................................................. 7
6.2. EARTHING RESISTANCE.............................................................................................. 8
7.
CALCULATION ......................................................................................................................... 8
7.1. THE CROSS - SECTIONAL AREA ................................................................................. 8
7.2. ELECTRICAL GRID EARTHING RESISTANCE CALCULATION................................. 10
7.3. INSTRUMENT AND TELECOM GRID EARTHING RESISTANCE CALCULATION .... 10
7.4. BUILDINGS ELECTRICAL GRID EARTHING RESISTANCE CALCULATION ............ 10
8.
9.
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1.
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PURPOSE
This calculation covers the design of earthing system for the Mahshahr Storage and loading area. The
specific purpose of this calculation is to establish a basis for design, the safe size of earthing conductor
& actual number of earthing rods.
The study has been performed by use of ETAP PowerStation Version 7.5.0 from Operation Technology
Inc., USA
2.
3.
4.
IEC 60009
BS-6651
REFERENCE DOCUMENTS
MHS-E000-EL-DC-001
MHS-E000-CV-RT-001
MHS-E000-EL-SP-013
MHS- E000-EL-RT-101
MHS-E000-EL-LY-113
MHS-E000-EL-DW-126
CONSIDERATIONS
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According to IEC 62305-3 Protection of Structures against lightning, section D.5.5.2 Storage tanks:
Certain types of structures used for the storage of liquids that can produce flammable vapors or used to
store flammable gases are essentially self-protecting (contained totally within continuous metallic
containers having a thickness of not less than 5 mm of steel or 7 mm of aluminum, with no spark gaps)
and require no additional protection. All equipments in process area are respecting this condition
therefore they do not require a dedicated lightning protection system. As a measure of protection, an
additional earthing rod will be provided as close as possible to the tank, as shown on area grounding
drawings.
According to MHS-E000-EL-DC-001, Electrical Design Criteria section 2.10, substation, control
buildings, structures and towers shall be protected against Lightning in accordance with BS 6651. A
separate calculation shall be done for the grid separated from the plant grid, and the maximum value of
earthing resistance shall be 5.
Every independent earthing system shall be measured during commissioning and if the values of earth
resistance are over the design values, then additional rods shall be installed.
5.
5.1.
5.2.
SOIL RESISTIVITY
Average value of the soil resistivity of 100m was assumed for first layer of soil (2.5m backfill). Average
value of the soil resistivity of 2.2m was considered for the second layer of soil (local soil) based on
geotechnical investigation report (MHS-E000-CV-RT-001). Surface layer resistivity was considered to be
2500m (for a depth of 100mm)
5.3.
DESIGN DATA
11KV
6kV
400V
25
25
50
17562
12173
47830
0.210
0.110
46301
0.5
0.5
0.02/0.4*
Voltage Level
Design Symmetrical Fault Current (kA)
Fault current values are from MHS-E000-EL-RT-101, Short Circuit Study Report.
For body resistance default typical values was used (1000).
For fibrillation data was used values for 70kg body according to IEEE 80.
5.4.
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The ground grid current to fault current ratio (Sf) was calculated utilizing the graph shown on Figure C.16
of IEEE Standard 80-2000, included in Appendix A - Graphical and approximate analysis of current
division and the following considerations:
Category A: 100% remote and 0% local fault current contribution, representing typical distribution
substations with delta-wye transformer (See Annex C IEEE Standard 80-2000)
The ratio of the ground current to the fault current was found to be 0.5 considering grid resistance
of 0.428 Ohm (calculated at paragraph 7.2)
The ground fault current was calculated utilizing the following formula:
6.
CALCULATION BASIS
6.1.
=
(
104
K 0 + Tm
) ln ( K 0 + Ta )
Where:
I
= RMS current in kA
tC
Tm
Ta
K0
=1 / o . or (1 / r) - Tr
TCAP
6.2.
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EARTHING RESISTANCE
The earthing resistance for one (1) rod is calculated based on following formula (ANSI / IEEE std. 80).
8
[ ( ) 1]
2
Where:
= Resistivity of soil in *m
The calculation of the total ground grid is done ignoring the mutual resistance of the grid.
According to table 4.1 of IEEE 142, the majority of the resistance to remote earth occurs within 7.6 m
from electrodes. Therefore for a distance between rods of 15.2 m, the mutual resistance between rods
can be ignored. The total resistance of the grid is calculated with the following formula:
1
1
1
+
+
1
This calculation does not take into consideration the grounding grid. The closer to reality value of
earthing resistance is the output from ETAP software according to Appendix B Safety Analysis Report.
7.
7.1.
CALCULATION
THE CROSS - SECTIONAL AREA
The cross - sectional area, shall be selected not less than the value is as follows:
Case 1 Medium Voltage 11kV
0.210
=
(
= 1.142
104
3.42
242 + 160
) ln (
)
0.5 0.003 1.72
242 + 52
0.110
104
3.42
242 + 160
(
) ln (
)
0.5 0.003 1.72
242 + 52
= 0.62
Minimum size for earthing high voltage equipment shall be copper wire 70mm2, according to job
specification MHS-E000-EL-SP-013
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23.150
3.42 104
242 + 160
(
0.4 0.0038 1.72) ln ( 242 + 52 )
= 112.932
Minimum size for earthing low voltage equipment at substation shall be copper wire, 120mm2
Main substation loop shall be copper wire 120mm2, while all electrical equipment in substation shall have
2 connections of 70mm2
Case 4 Low Voltage outside substation (rest of the plant)
23.150
3.42 104
242 + 160
(
)
ln
(
)
0.02 0.0038 1.72
242 + 52
= 25.32
Minimum size for earthing low voltage equipment shall be copper wire 35mm2.
The branch conductor shall be 35mm2 and main ground conductor shall be 95mm2.
Case 5 Control and small power systems, lighting systems
12.5
104
3.42
242 + 160
(
0.02 0.0038 1.72) ln ( 242 + 52 )
= 13.72
Minimum size for earthing control and small power equipment shall be copper wire 16mm2.
Case 6 Instrumentantion system
2.5
104
3.42
242 + 160
(
0.02 0.0038 1.72) ln ( 242 + 52 )
= 2.742
Minimum size for earthing instrument equipment shall be copper wire 6mm2.
7.2.
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100
8 2.5
[
1] = 39.03
2 2.5
16 103
=
For 6 rods:
1
1
1
++
1
91
7.3.
For Instrument and Telecom grid (both are identical) mounted in the proximity of the Operational Center
Building, it is considered that only half (2m) of the total 4m length of the rod is buried in the second layer
of soil. Since this portion has a much lower resistivity (2.2m compared to 100m of the first layer), the
resistance of the first layer of the rod was ignored. Earthing resistance of one rod is:
2.2
82
[
1] = 1.033
22
16 103
For 4 rods:
1
1
1
++
1
4
7.4.
100
8 2.5
[
1] = 39.03
2 2.5
16 103
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1
1
1
++
1
24
1
1
1
++
1
16
8.
1
1
1
++
1
14
8.1.
The tolerable Touch potential for the soil surface areas was calculated to be as follows:
where:
Cs = is the surface layer derating factor
s= is the surface material resistivity in m
tc = is the duration of shock current in seconds.
ET = is the touch voltage in V
= 805
ETAP software was used to perform the above calculations and is included in the attached computer
report in Appendix B.
Int. Rev.: 05a
8.2.
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(1000 + 6 ) 0.157
= 2559V
ETAP software was used to perform the above calculations and is included in the attached computer
report in Appendix B.
9.
1
1
1
+
1+
20
20
1 + )]
[
(
= 100
1
1
1
+
1+
= 0.0658
12550 20 600.7 103
20
1 + 0.5
[
(
600.7 103 )]
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=
= 23150 0.0658 = 1523.3
ETAP Software was used to perform the above calculations and is included in the attached report in
Appendix B.
Po =
acceptable risk;
Pa =
overall risk;
Ng =
lightning flash density: the number of flashes to ground per km2 per year;
Ac =
Weighting factors:
A: use of structure;
B: type of construction;
C: contents or consequential effects;
D: degree of isolation;
E: type of country.
Wo = Overall weighting factor (A x B x C x D x E).
Wo = (1.0 x 0.4 x 1.0 x 1x 1.3)=0.52 (as per Tables 812, BS 6651)
INTERPRETATION OF ACCEPTABLE RISK (Po)
BS 6651 states:
"The risk factor method given in this code is intended to give guidance on what can, in some cases, be a
difficult problem. If the result obtained is considerably less than 10-5 (1 in 100,000) then, in absence of
other overriding considerations, protection does not appear to be necessary; if the result is greater than
10-5, say for example 10-4 (1 in 10,000), then sound reasons would be needed to support a decision not
to give protection."
Define the mean number of flashes to ground per km per year (Ng) for the geographic area concerned.
This figure is related to the number of thunderstorm days per year, see table below.
Document Title:
Proj. No.
Document Number:
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If no accurate site information is available, the number of thunderstorm days can be obtained from the
relevant map in BS 6651.
5
10
20
30
40
50
60
80
100
NOTES:
0.2
0.5
1.1
1.9
2.8
3.7
4.7
6.9
9.2
Limits
0.1 - 0.5
0.15 - 1
0.3 - 3
0.6 - 5
0.8 - 8
1.2 - 10
1.8 - 12
3 - 17
4 - 20
1.A thunderstorm day is a calendar day during which thunder is heard at a location.
2.The above data is taken from BS 6651.
For project locations, as per Figure 3, BS 6651, five thunderstorm days per year are considered.
Therefore, Ng=0.2.
Define the collection area of the structure (Ac).
Ac = (l x w) + (2 x l x h) + (2 x w x h) + ( x h2)
Calculate the risk using the formula: P = Ac x Ng x 10-6
Calculate the overall risk with the formula: Pa = Wo x P
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Pa = Wo x P = 1.99 x 10-4
Po = 10-4
Since Pa > Po, the building should be protected against lightning.
11. CONCLUSION
Average value of the backfill soil resistivity (100) shall be updated after receiving information
from the latest geological report.
Actual earth resistance according to ETAP report is 0.032 (vertical rods and horizontal grid).
Hand calculations shows earthing resistance to be 0.428 (for vertical rods), and 0.0658 for
grid. Installing vertical rods (2.5m) is essential because the superficial layer of soil may have high
resistivity during dry seasons, also to drain into the ground all faults currents and lightning strike
currents.
Main electrical ground grid conductor shall be 120 mm2 for substations area and 95 mm2 for the
rest of the plant. For electronic instrument system and telecom, main grounding grid conductor
shall be 95 mm2.
For high voltage equipments earthing, 70mm2 copper conductors has been considered adequate
in process area as branch ground conductor.
For low voltage equipments earthing, 35mm2 copper stranded conductors has been considered
in process area as branch ground conductor.
Tolerable touch potential was calculated to be 805V (see hand calculation in section 8.1). ETAP
report shows calculated touch potential to be 562.1V (see Appendix B)
Tolerable step potential was calculated to be 2559V (see hand calculation in section 8.2). ETAP
shows calculated step potential to be 146.8V (according to ETAP report in Appendix B)
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In order not to reach the tolerable touch potential and step voltage, it is necessary that the main
earthing conductor to be bare copper.
Grid potential rise was calculated to be 1523.3V (see hand calculation in section 9). In ETAP
report, taking into consideration the second layer of soil, it was calculated to be 764.7V (see
Appendix B).
Grid resistance for Instrument and Telecom was calculated to be 0.129, without considering the
horizontal grid. For the Operational Building, it was calculated to be 4.87, for substation 15
building 1.62, for substation 16 building 2.43. This values does not exceed the limits specified
in paragraph 4.
Anyway, as suggested by IEEE Std. 80, commissioning and periodic measurements shall be
performed in order to verify the design results, and to ensure that safe conditions for step and
touch voltage are guaranteed. Also, grid resistance shall be tested after commisioning and
periodically. If the measurements are as per design results, earthing system shall be extended in
order to meet the design criteria.
Following usual practice, in order to improve local safe conditions, in substations areas it is
recommended to foresee an horizontal grid of bare conductors at about 0.5m depth, eventually in
suitable filling material. Besides, additional vertical rods shall be foreseen along substations
perimeter and in correspondence of transformers neutral connection to ground. As per results
presented in table below, the decision is the usage of bare grounding conductor, as per Appendix
C (Instrument grounding system) and Appendix B (General grounding system). The results
presented in the table below represent the minimum requirement. Additional grounding rods or
grounding conductors may be added as needed. This calculation provides the minimum
requirement. The final configuration of ground grid is presented in doc. no. MHS-E000-EL-LY113. A separate single point grounding system for electronic instrument system and telecom at
Operational Building will be provided; specific study/calculation (if necessary) will be included in
relevant specific documentation managed by Instrumentation Department. For details see
Appendix C.
The Integrated Earthing System is the current state of art solution and an indispensable part of
electrical & instrument operations as per IEC-61000-5.2. As recommended by IEC 61000-5-2 &
unless otherwise specified in Instrumentation design basis a single integrated earthing system
shall be installed. The objective of this integrated earthing system is to provide a common ground
plant reference for lightning protection, electrical & electronic systems and a well-defined return
current path resulting in a low transfer impedance of equipment to be protected. As per IEC
62305-3 and BS 6651, a single integrated earth termination system is preferable and is suitable
for all purposes (i.e. lightning protection, power systems, telecommunication systems, instrument
systems). The earthing resistance shall be, in this case, the lowest value needed for any of the
individual services. Electronic systems shall be protected by using surge protection devices.
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Summary Table
Case study
Ground
resistance
(ohm)
GPR
(V)
Instrument grounding
system (see Appendix C)
0.322
0.032
Conductor length
/size
No
of
rods
Tolerable
Calculated
Tolerable
Calculated
867.8
4032.9
4012.5
12801.3
2023.1
40m/95mm2
764.7
901.8
562.1
2862.5
146.8
12550m/95mm2 *
91
12.
APPENDICES
1. Appendix A Graphical and approximate analysis of current division
2. Appendix B Safety Analysis Report General grounding grid
3. Appendix C Safety Analysis Report Instrumentation grounding grid
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APPENDIX B
Project:
Location:
MAHSHAHR
Contract:
38687901
Engineer:
TGA
ETAP
7.5.0
Study Case:
ELE-GND
16
91
12550.00 m
228.00 m
Frequency: 50.0
Unit System:
Metric
Page:
Date:
03-19-2016
SN:
12345678
Filename: GROUNDING
APPENDIX B
Project:
Location:
MAHSHAHR
Contract:
38687901
Engineer:
TGA
ETAP
7.5.0
Study Case:
ELE-GND
Page:
Date:
03-19-2016
SN:
12345678
Filename: GROUNDING
Freq.
Hz
50.0
70
Total
Fault
Current
kA
52.00
Cp
Tf
Tc
Ts
Division
Projection
Factor
%
Factor
%
for
Total Fault
Duration
for Sizing
Ground
Conductors
for
Available
Body Current
50.0
100.0
0.40
0.40
X/R
5.00
46.301
Sf
0.40
Soil Data:
Surface Material
Material Type
Resistivity
W.m
Depth
m
Material Type
Resistivity
W.m
Clean limestone
2500.0
0.100
Moist soil
100.0
Material Constants:
Depth
m
MaterialType
2.50
Moist soil
Resistivity of
Fusing
Ground Conductor
Temperature
@ 20C
Conductivity
r Factor
@ 20 C
K0 @
1/C
0 C
Conductor/Rod
Type
Conductor
97.0
0.00381
242.0
Rod
20.0
0.00378
245.0
Length
cm
No. of
Rods
1.600
2.50
91
1084.0
1.78
3.42
1084.0
8.62
3.85
100.00
Grid Configuration:
Conductor
Size
mm
95
Grid Length m
Number of Conductors
Depth
m
Lx
Ly
in X
Direction
0.50
700.00
850.00
in Y
Direction
Separation m
in X
Direction
87.5
Cost:
Conductor
Total
No.
16
Total Length
m
12550.00
Rod
Cost
$
125500.00
Total
No.
91
Total Length
m
227.50
Cost
$
9100.00
Total Cost
$
134600.00
in Y
Direction
141.7
Thermal
Capacity
Per Unit Volume
J/(cm.C)
Cost
$/Rod
Arrangement
2.2
.cm
Rod Data:
Diameter
Resistivity
W.m
Cost
$/m
10.00
Shape: Rectangular
APPENDIX B
Project:
Location:
MAHSHAHR
Contract:
38687901
Engineer:
TGA
ETAP
7.5.0
Study Case:
ELE-GND
Page:
Date:
03-19-2016
SN:
12345678
Filename: GROUNDING
GPR
Ground
Potential Rise
Volts
0.032
764.7
Touch Potential
Tolerable
Volts
901.8
Calculated
Volts
562.1
Step Potential
Calculated
%
62.3
Tolerable
Volts
2862.5
Calculated
Volts
146.8
Calculated
%
5.1
46.301 kA
-0.923
23.607 kA
0.702
1.020
APPENDIX C
Project:
Location:
MAHSHAHR
Contract:
38687901
Engineer:
TGA
ETAP
7.5.0
Study Case:
INS-GND
40.00 m
16.00 m
Frequency: 50.0
Unit System:
Metric
Page:
Date:
03-13-2016
SN:
12345678
APPENDIX C
Project:
Location:
MAHSHAHR
Contract:
38687901
Engineer:
TGA
ETAP
7.5.0
Study Case:
INS-GND
Page:
Date:
03-13-2016
SN:
12345678
Freq.
Hz
50.0
70
Total
Fault
Current
kA
52.00
Cp
Tf
Tc
Ts
Division
Projection
Factor
%
Factor
%
for
Total Fault
Duration
for Sizing
Ground
Conductors
for
Available
Body Current
50.0
100.0
0.02
0.02
X/R
1.00
5.000
Sf
0.02
Soil Data:
Surface Material
Material Type
Resistivity
W.m
Depth
m
Material Type
Resistivity
W.m
Clean limestone
2500.0
0.100
Moist soil
100.0
Material Constants:
Depth
m
MaterialType
2.50
Moist soil
Resistivity of
Fusing
Ground Conductor
Temperature
@ 20C
Conductivity
r Factor
@ 20 C
K0 @
1/C
0 C
Conductor/Rod
Type
Conductor
97.0
0.00381
242.0
Rod
20.0
0.00378
245.0
Length
cm
1.600
4.00
No. of
Rods
4
1084.0
1.78
3.42
1084.0
8.62
3.85
100.00
Grid Configuration:
Conductor
Size
mm
Depth
m
95
0.50
Grid Length m
Number of Conductors
Lx
Ly
in X
Direction
10.00
10.00
in Y
Direction
Separation m
in X
Direction
in Y
Direction
10.0
10.0
Cost:
Conductor
Total
No.
4
Total Length
m
40.00
Rod
Cost
$
400.00
Total
No.
4
Total Length
m
16.00
Cost
$
400.00
Total Cost
$
800.00
Thermal
Capacity
Per Unit Volume
J/(cm.C)
Cost
$/Rod
Arrangement
2.2
.cm
Rod Data:
Diameter
Resistivity
W.m
Cost
$/m
10.00
Shape: Rectangular
APPENDIX C
Project:
Location:
MAHSHAHR
Contract:
38687901
Engineer:
TGA
ETAP
7.5.0
Study Case:
INS-GND
Page:
Date:
03-13-2016
SN:
12345678
GPR
Ground
Potential Rise
Volts
0.322
867.8
Touch Potential
Tolerable
Volts
4032.9
Calculated
Volts
4012.5
Step Potential
Calculated
%
99.5
Tolerable
Volts
12801.3
Calculated
Volts
2023.1
Calculated
%
15.8
5.000 kA
-0.923
2.692 kA
0.702
1.077