Document Number: ECS 06-0030

Version: 1.0
Date: 12/11/2012


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ENGINEERING CONSTRUCTION STANDARD

ECS 06-0030

SUBSTATION EARTHING DESIGN AND CONSTRUCTION
GUIDANCE NOTES FOR DEVELOPERS (33KV LONDON ROUTES)


Network(s): EPN, LPN, SPN

Summary: This document provides guidance for developers on the design and construction of
earthing systems for the 33kV substations associated with London 33kV
distribution network.

Originator: Stephen Tucker Date: 12/11/2012

Approved By: Steve Mockford Approved Date: 07/12/2012

Review Date: 12/11/2017

This document forms part of the Companys Integrated Business System and its requirements are mandatory throughout UK
Power Networks. Departure from these requirements may only be taken with the written approval of the Director of Asset
Management. If you have any queries about this document please contact the originator of the current issue.

Document History
(The document history notes below are intended as a guide only and may not cover all of the changes. If you wish to make use
of this document it should be read in full.)

Version Date Details Originator
0.1 28/08/2012 Original by Earthing Solutions (not issued) Rob Weller
(Earthing Solutions)
1.0 12/11/2012 Document revised for publishing Stephen Tucker





Substation Earthing Design and Construction Guidance
Notes for Developers (33kV London Routes)
Document Number: ECS 06-0030
Version: 1.0
Date: 12/11/2012

UK Power Networks 2012 All rights reserved 2 of 27
Contents
1 Introduction ................................................................................................................ 4
2 Scope .......................................................................................................................... 4
3 References .................................................................................................................. 5
4 Abbreviations ............................................................................................................. 5
5 Earthing Standards .................................................................................................... 6
6 Earthing Overview and Definitions ........................................................................... 7
6.1 Overview ..................................................................................................................... 7
6.2 Basic Principles ........................................................................................................... 9
7 General Requirements for Customer Connections at 33kV ................................. 10
7.1 Shock Risk Outside the Building ............................................................................... 10
7.2 Shock Risk Inside the Building .................................................................................. 11
8 Specific Earthing/Bonding Requirements for Customer Connections at 33kV . 12
8.1 UK Power Networks Substation ............................................................................... 12
8.1.1 General Philosophy ................................................................................................... 12
8.1.2 Requirements for UK Power Networks Switchroom Earthing ................................... 12
8.2 Customer Installation ................................................................................................ 13
8.2.1 Earth Resistance ....................................................................................................... 13
8.2.2 Design Requirements ................................................................................................ 13
9 Design Guidelines .................................................................................................... 15
9.1 Design Parameters ................................................................................................... 15
9.2 Conductor Sizes ........................................................................................................ 16
9.2.1 UK Power Networks Substation ................................................................................ 16
9.2.2 Customer Switchrooms and Installations .................................................................. 16
9.3 Lightning Electrode Systems ..................................................................................... 17
9.4 Electrode Location and Caveats ............................................................................... 17
9.5 Segregated or Combined Earthing System ............................................................... 18
9.6 Use of Rebar/Piles .................................................................................................... 18
9.6.1 Sheet Steel Piles ....................................................................................................... 18
9.6.2 Horizontal Steel Reinforced Foundations .................................................................. 19
9.6.3 Vertical Steel Reinforced Ground Columns .............................................................. 19
9.7 Joints and Connections ............................................................................................. 19
9.7.1 General ..................................................................................................................... 19
9.7.2 Copper to Copper Connections ................................................................................. 20
9.7.3 Copper to Earth Pins ................................................................................................. 20
9.7.4 Electrode Test Points ................................................................................................ 20
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Notes for Developers (33kV London Routes)
Document Number: ECS 06-0030
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Date: 12/11/2012

UK Power Networks 2012 All rights reserved 3 of 27
9.7.5 Copper to Equipment Earths ..................................................................................... 21
9.7.6 Aluminium to Aluminium Joints ................................................................................. 22
9.7.7 Aluminium to Equipment Earths ................................................................................ 22
9.7.8 Aluminium to Copper Joints ...................................................................................... 22
10 Typical Designs ........................................................................................................ 23
Appendix A Design Checklist .......................................................................................... 25
Appendix B Drawings ....................................................................................................... 26

Figures
Figure 6-1 Illustration of Touch, Step and Transfer Potentials .............................................. 8
Figure 9-1 Typical Rebar Connections ............................................................................... 19
Figure 9-2 Test Point .......................................................................................................... 21
Figure 10-1 Overview Diagram Showing Common Mesh Arrangement (further detail is
given in Appendix B) ............................................................................................ 24

Tables
Table 6-1 Statistically Safe Step/Touch Potentials ............................................................... 8
Table 9-1 Design Parameters ............................................................................................. 15
Table 9-2 Low Fault Level Earth Conductor Sizes (12.5kA for 3 seconds) ........................ 16
Table 9-3 Maximum Current Rating of Earthing Rods ........................................................ 17
Table 9-4 Bolt sizes and Torques for Use on Aluminium .................................................... 22

Substation Earthing Design and Construction Guidance
Notes for Developers (33kV London Routes)
Document Number: ECS 06-0030
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UK Power Networks 2012 All rights reserved 4 of 27
1 Introduction
This document provides guidance for developers on the design and construction of earthing
systems for the 33kV substations associated with London 33kV distribution network.
This document is intended to assist designers/planners/developers working on new build
(brownfield) or developing existing buildings along the North London 33kV routes between
Finsbury Market and Back Hill. It is assumed that the buildings will be supplied at 33kV
derived from one or more of the Red, Green, Blue or Yellow routes. The earthing needs
special consideration because the supply arrangements are unusual. In particular, buildings
are generally supplied from a specific cable or cables and do not obtain any parallel earth
benefits from adjacent buildings or substations. The cables are plastic/triplex type and the
only electrode connection is locally and at the remote cable ends.
This document describes the requirements for electrical earthing of a customers installation,
but does not go into detail regarding supply arrangements, protection, cable sizing etc.
These issues are beyond the scope of this document. The term Customer includes any
end-user connected to UK Power Networks distribution system.
The reason for this document is to assist designers/developers to design and construct an
earthing system that is fit for a building supplied at 33kV. UK Power Networks has noted that
some developers have proposed earthing systems for their buildings that are not appropriate
or adequate for a building that contains 33kV equipment. In some situations, poor design
can lead to shock risk (to public both inside and outside the building), and fire risk or
structural damage (due to overheating earth conductors and/or rebar).
The customers own installation will be designed and built by the developer with reference to
the appropriate standards. It is not UK Power Networks role to carry out design work for a
developer. However, UK Power Networks does have a duty of care to ensure that any
installation connected to the network is safe. An audit of the earthing design will be carried
out to ensure that the design meets relevant UK Power Networks and UK standards as
described in this document. Connection will be refused if UK Power Networks considers a
design to be unsafe, as outlined in Paragraph 26 of the Electricity Safety Quality and
Continuity Regulations (ESQC Regulations) 2002.
This guide is intended to assist designers to produce a system that will satisfy UK Power
Networks requirements in this regard. It is intended as a guide only; ultimately the choice of
earthing system is at the discretion of the designer.
2 Scope
This document applies to the to UK Power Networks and Customer substations associated
with the North London 33kV routes between Finsbury Market and Back Hill. The information
this document contains is specific to the North London routes and should not be used for
other purposes.
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Notes for Developers (33kV London Routes)
Document Number: ECS 06-0030
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3 References
EAS 06-0011 Earthing Materials
EDS 06-0012 Earthing Design Criteria
EDS 06-0013 Grid and Primary Substation Earthing Design
EDS 06-0017 Customer Installation Earthing Design
ECS 06-0022 Grid and Primary Substation Earthing Construction
EDS 07-0105 Grid and Primary Substation Civil Design Standards
EDS 07-0102 Secondary Substation Civil Design Standards
ENA TS 41-24 Guidelines for the Design, Installation, Testing and Maintenance of Main
Earthing Systems in Substations
ENA ER G12 Requirements for the Application of Protective Multiple Earthing to Low
Voltage Networks
ENA ER S34 A Guide for Assessing the Rise of Earth Potential at Substation Sites
ENA ER S36 Procedure to Identify and Record HOT Substations
BS EN 50522:2010 Earthing of Power Installations Exceeding 1kV AC
BS 7354:1990 Design of High Voltage Open Terminal Substations
BS 7430:2012 Code of Practice for Protective Earthing of Electrical Installations
BS 7671:2008 incorporating Amendment No 1: 2011 Requirements for Electrical
Installations (IEE Wiring Regulations Seventeenth Edition)
Electricity Supply Quality and Continuity Regulations 2002
4 Abbreviations
Term Definition
DNO Distribution Network Operator
EHV Extra High Voltage (usually refers to voltages above 11kV)
ENA Energy Networks Association
EPR Earth Potential Rise
HV High Voltage (greater than 1000V)
LV Low Voltage (less than 1000V)
ROEP Rise of Earth Potential

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5 Earthing Standards
ENA Technical Standard (ENA TS) 41-24 provides Guidelines for the Design, Installation,
Testing and Maintenance of Main Earthing Systems in Substations. Its scope includes all
equipment within HV and EHV substations. It is adopted by all Distribution Network
Operators (DNOs) in the UK, is referred to in the UK Distribution Code and is written into
DNOs own standards.
ENA TS 41-24 provides guidelines that are necessary to ensure the safety of DNO staff as
well as members of the public. Given that 33kV customers will effectively establish their own
substations (typically in the form of 33/11kV or 33/0.4kV transformation), it is the view of UK
Power Networks that the general requirements of ENA TS 41-24 shall apply to all customer
installations, unless the developer can provide good reason for deviation from these
standards. In most cases, the close proximity of customer substations to members of the
public and/or staff in and around the buildings means that ENA TS 41-24 should be
rigorously applied. Developers will be expected to demonstrate compliance with
ENA TS 41-24 and UK Power Networks own standards, or to provide design calculations to
demonstrate why an alternative approach has been considered.
UK Power Networks earthing design standards derive from the industry standard documents
including ENA TS 41-24 and ENA ER S34 and S36. UK Power Networks current standard
for customer installations is EDS 06-0017, and for primary substation design/construction
are EDS 06-0013 and ECS 06-0022 respectively. Relevant information from those standards
is included in this document.
It is assumed also that the developers will wish to consult ENA ER S34, ENA ER S36,
BS EN 50522, BS 7430, BS 7671 and BS 7354.
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6 Earthing Overview and Definitions
6.1 Overview
In short, earthing is necessary to ensure safety in the event of a fault.
The terms earthing and bonding are often used interchangeably. In general terms, the
installation shall be connected to the general mass of earth via an electrode system that
provides a suitably low earth resistance value. In the event of an earth fault, the earth
resistance shall be low enough to limit the earth potential rise (EPR) to safe values and to
operate the earth-fault protection. It will also be capable of carrying, without damage, the
fault current that will flow until the system protection can operate.
ENA TS 41-24 describes the function of an earthing system:
Every substation shall be provided with an earthing installation designed so that in both
normal and abnormal conditions there is no danger to persons arising from earth potential in
any place to which they have legitimate access. The installation shall be able to pass the
maximum current from any fault point back to the system neutral without establishing
dangerous potential gradients in the ground or dangerous potential drops between parts of
the substation with which a person may be in simultaneous contact.
Bonding refers to the connections between metallic parts of the system. Bonding serves to
establish an equipotential zone by preventing significant (dangerous) voltage differences
appearing between metallic items of equipment and/or structures.
ENA TS 41-24 notes: During the passage of earth-fault current a substation earth electrode
is subjected to a potential rise and potential gradients develop in the surrounding ground
area. These gradients are highest adjacent to the substation earth electrode. The actual
ground potential reduces to zero or true earth potential at some distance from the substation
earth electrode. This distance forms a physical separation which, if it is not bridged by a
metallic connection, renders any person in the high potential area immune from the
possibility of simultaneous contact with zero potential. However, local potential gradients, if
great enough, can present a hazard to persons and thus effective measures to limit them
shall be incorporated in the design.
It is usual in a substation environment to extend bonding to include below ground grading
conductors and/or operator platforms. In this way, an operatives hands and feet will be at a
similar potential in all circumstances. Below-ground (or in-concrete) conductors are usually
necessary to limit step and touch potentials to safe values.
ENA TS 41-24 defines touch, step and transfer potentials as follows:
Transfer Potential
A metallic object having length - a fence, a pipe, a cable sheath or a cable core, for example,
may be located so as to bridge the physical separation referred to above. It can collect a
remote voltage reference and introduce this into the substation area. By such means zero
earth potential or some low value of earth potential can be 'transferred' into an area of high
potential rise or vice-versa.
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UK Power Networks 2012 All rights reserved 8 of 27
Step Potential
Any potential gradient in the ground is greatest immediately adjacent to the substation earth
electrode area. Accordingly the maximum 'step potential' at a time of substation potential rise
will be experienced by a person who has one foot on the ground of maximum potential rise
and the other foot one step towards true earth. For purposes of assessment the step
distance is taken as one metre.
Touch Potential
The 'step potential' referred to above relates to the ground surface potential which, relatively,
is somewhat lower in value than that present on the buried earth electrode (or building
structure) itself. It is thus evident that a metal structure bonded to the earth electrode will
assume the same potential. If the structure is accessible, a person standing on the ground
one metre away and touching the structure will be subject to the 'touch potential'. For a given
substation (or building housing substation equipment) the maximum value of 'touch potential'
can be up to two or three times greater than the maximum value of 'step potential'. As a
consequence, if a substation or building is safe against 'touch potentials', it will normally be
safe against 'step potentials. These are shown schematically in the figure below.




Cable sheath
earthed at
substation
Earthing
Electrode
Earthing
Electrode
Potential grading earthing
electrodes (eg ring earth
electrodes), each
connected to the earth
electrode
S1
S2
S3
Step Potential
(USS)
Touch Potential
(UST)
Touch
Potential
(UST)
Earth
Potential
Rise, EPR
(UE)
Voltage
gradient
across
site
Cables having a continuous metal sheath
insulated throughout but exposed at both ends
Earthing Electrode
(transferred
source voltage for
touching if sheath
not earthed at
remote end)
Transfer Potential
(UTST)
Remote Touch Potential
(UTSTE)
(transferred source
voltage for touching if
sheath is earthed at
remote end as well)

Figure 6-1 Illustration of Touch, Step and Transfer Potentials

The statistically safe step and touch voltages are given in ENA TS 41-24, and relate to the
time that a fault will be present on the system (protection clearance time). The acceptable
values are reproduced in Table 6-1.
Table 6-1 Statistically Safe Step/Touch Potentials
Protection
Clearance Time
Safe Touch Voltage
(dry concrete)
Safe Step Voltage
(dry concrete)
0.7 seconds 250V 830V
1 second 200V 640V

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6.2 Basic Principles
During an earth fault, the potential of the earthing system rises until the protection can
operate to clear the fault. The magnitude of the voltage rise (EPR) is determined by the
resistance of the local electrode system (R
B
) and the current that flows into it. Typically a
large proportion of fault current will return to the source via the cable sheath, and the
remainder (Igr%) will flow into the ground via the local electrode system. It is simply the
application of Ohms Law which gives the EPR:
EPR = Earth Fault Level (A) x Igr% x Earth Resistance, Rb ()
The maximum value of Igr% has been calculated to be 30% and therefore this value shall be
used in any design calculations (i.e. a maximum ground fault current of 810 amps refer to
Section 9 for typical design parameters).
In designing a customers electrode system, the value R
b
shall be low enough to limit EPR to
safe values. The value of R
b
will reduce when the customers system is connected to the UK
Power Networks system, but this parallel contribution cannot be used as the customers
electrode and shall be viewed only as fortuitous. This is because:
1. The zones of influence of UK Power Networks earthing system and the customer
earthing system will overlap, meaning that the contribution will be less than expected
from a simple parallel resistances calculation, and
2. The UK Power Networks earthing system may be affected by maintenance or faults on
the network.
In short, the customers system shall be able to operate safely should UK Power Networks
local earthing system become disconnected or otherwise compromised.
In rare situations (e.g. a building with a very small footprint), if it is not possible to achieve a
safe design without reliance on UK Power Networks earth written permission to rely on UK
Power Networks system shall be sought from UK Power Networks. In many cases this will
require significant lengths of duplicate earth conductor to be laid alongside the existing cable
routes at the developers expense.
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Notes for Developers (33kV London Routes)
Document Number: ECS 06-0030
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7 General Requirements for Customer Connections at 33kV
It is generally necessary to apply substation design techniques to buildings housing
33kV/11kV or 33kV/0.4kV transformation. The substation boundary is normally considered to
be the building perimeter, or beyond if there is metallic connection to adjacent buildings.
Terms used in this document are defined in ENA TS 41-24 and the ESQC Regulations.
The most general, and overriding requirement is that the installation shall be designed to
prevent danger. This falls into two areas:
Prevention of shock.
Prevention of fire/thermal damage.
Shock is described below. For fire/damage prevention, in the context of earthing systems, it
is necessary for the designer to ensure that all conductors are adequately sized for the
current that they will carry in all foreseeable fault conditions. Also, it is necessary to ensure
that significant stray current will not flow in parts of the building structure, or other services,
that could lead to damage. This is best prevented by the installation of dedicated low
impedance bonds in strategic locations to safely convey the majority of fault current.
Any electrode system that serves to reduce the overall resistance of the building earth shall
be sized to cope with the maximum earth fault level (that it will see locally). It is not sufficient
to rely on lightning protection systems, or beam lintel rebar etc. to carry such high fault
currents since these can overheat (overheating rebar can split concrete piles etc.).
Shock and thermal damage risks can be minimised by installing a dedicated and low
resistance copper earth grid underneath the footprint of the building, and bonding all items of
equipment to it. Typical designs are described in Section 10, although other methods are not
precluded.
7.1 Shock Risk Outside the Building
The building that contains the 33kV equipment can theoretically rise in potential during a
fault. It can cause a shock risk to public if the building is (or could become) metal clad or
otherwise has accessible exposed metallic parts (e.g. handrails). For this reason it shall
usually have a perimeter grading electrode installed in the soil around the building (i.e. a
loop of conductor buried approx. 0.5m to 1m away from the building, and connected to the
main earth terminal). The absence of such grading electrodes means that the full EPR could
appear as a touch potential risk to those outside the building, whereas their presence will
reduce the touch voltage to a smaller percentage of the EPR. The developer will be
expected to demonstrate this, or other measures to prevent danger to the public. For
example, UK Power Networks substations will often have an external (separately earthed)
fence to prevent contact, or will be of insulated construction. A perimeter tape electrode is
recommended, where practicable. A typical design using such a perimeter electrode is
described in Section 10. Where perimeter tape electrodes are provided it is usually beneficial
to site the main rod electrodes off this. In such cases there is little benefit in putting
additional rod electrodes inside the footprint of building as they will contribute little other
than to increase the resilience of the system.
If it is not practicable to install a ring of copper tape around or under the building, the
alternative solution is to install a surface laid ring inside the perimeter of the building, and to
drive earth rods into the soil at regular intervals (at spacings less than half their depth of
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UK Power Networks 2012 All rights reserved 11 of 27
burial
1
). Their zone of influence will then extend outside the building footprint and will
contribute to a reduction in touch potential. The effectiveness of such an approach will
usually require computer modelling or detailed calculations to find the worst case step and
touch potentials.
LV or HV services, or metalwork connected to them, should not be taken from the building
where they could come into proximity of LV or HV services from other sources. The earths
from these different sources could be at different potential and thus should be separated by
at least two metres. One example is metallic streetlight columns supplied from the DNOs LV
network (transfer potential risk).
7.2 Shock Risk Inside the Building
This is usually managed by equipotential bonding between structures and plant to ensure
that all are at a similar potential. In theory, provided no remote references are introduced, a
high EPR will introduce little or no risk to building occupants if the building structure acts as a
Faraday Cage
2
. In practice, localised voltage gradients can occur around certain items of
plant. For this reason, bonding of rebar beneath switchgear/plant is required to provide
additional safety to operatives.
Bonding should be designed to ensure that it will not be possible for a person to bridge two
items of equipment that might be at different voltages.
Current flows for 33kV, 11kV and 0.4kV earth faults should be considered. In many cases
the lower voltage levels can produce more onerous current flows (and resultant voltage
gradients).
Earth bonds should be a minimum size in operational areas, as described in Table 9-2
(Section 9). Smaller sized conductors might be justified in other areas of the building (e.g. to
bond items of secondary equipment) provided that the developer can demonstrate that they
will be appropriate to withstand foreseeable levels of fault current for faults on that
equipment and elsewhere.

1
Optimal spacing requires a consideration of EPR and detailed calculation / modelling. The rule of thumb quoted
above will work in most situations.
2
An enclosure formed by conducting material or by a mesh of such material.
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8 Specific Earthing/Bonding Requirements for Customer Connections at
33kV
Earthing system requirements fall into two areas:
Requirements for UK Power Networks substation.
Requirements for the Customer installation.
8.1 UK Power Networks Substation
8.1.1 General Philosophy
Buildings supplied at 33kV will typically have a UK Power Networks 33kV substation that
houses the UK Power Networks circuit breakers and metering/telemetry/protection
equipment. The earthing arrangement for the substation will be specified by UK Power
Networks, and is designed to limit the earth potential rise (EPR) and step/touch potentials to
acceptable and safe levels within that substation. UK Power Networks earthing system will
not rely on a connection to the customers earthing system to achieve a satisfactory earth
resistance value, but will normally be connected to the customers system after installation to
improve security. In most cases UK Power Networks will install an external earth electrode,
laid alongside the supply cables, to provide an earth connection for the substation
equipment. The customer is not permitted to rely on a contribution from UK Power Networks
earth in order to achieve a satisfactory resistance value see next section.
Standard designs have been produced for UK Power Networks substations including new
build developments as well as alteration of existing sites. An overview of the standard
designs is provided in Section 8.1.2. The standard design drawings are included in
EDS 07-0105 (grid and primary) and EDS 07-0102 (secondary).
8.1.2 Requirements for UK Power Networks Switchroom Earthing
The UK Power Networks switchroom earthing system shall:
Be Specified by UK Power Networks according to a standard design, if applicable.
Provide a local earth electrode system or remote earthwire connection sufficient to
achieve an EPR less than 430V (COLD site) wherever practicable.
Be Independent of the customers earth but generally combined after commissioning.
Two earth terminals or connection points will be provided for connection to the
customers system.
Limit step and touch potentials to safe values inside the substation.
Comply with UK Power Networks standards EDS 06-0013 and ECS 06-0022.
Use conductors rated for fault current of 12.5kA/3 second as per ENA TS 41-24.
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UK Power Networks 2012 All rights reserved 13 of 27
8.2 Customer Installation
8.2.1 Earth Resistance
It is assumed that developers will wish to design an earthing system that renders the site
COLD (EPR<430V). Note that the terms COLD and HOT do not relate to safety, and it
should not be implied that a COLD site is necessarily SAFE in terms of step/touch potentials.
For a COLD site it is usual for the LV earths to be combined with the HV earths. In any case
it is unlikely to be practicable to establish a segregated HV and LV earthing system in the
same building.
This document does not include HOT site design. A HOT site introduces complications (such
as the need to provide isolation on all incoming telecoms circuits, pipework, etc) which shall
be discussed with UK Power Networks. It also introduces transfer potential issues.
It is assumed that all buildings supplied at 33kV do not receive duplicate or back-up
supplies from the 11kV or LV networks. These additional services will introduce a remote
earth reference which should only be connected to the 33kV earthing system or introduced
into the building with the support of specialist advice.
It has been calculated that a customers installation will be COLD if an earth resistance value
of 0.5 can be achieved. However, a designer/developer might wish to aim for a lower value
of 0.3. At this lower value the EPR is unlikely to exceed 250 volts, and thus touch voltages
will be within the limit given in Table 6-1 if protection clearance time does not exceed 0.7
seconds. The requirements for grading electrodes etc. are less onerous as even 100% of the
EPR appearing as a touch voltage will be acceptable. If it is considered that 0.3 is not
achievable then an appropriate design will be required (as is usual) to ensure that step/touch
voltages are an appropriate fraction of the EPR.
In some cases the lower figure of 0.3 can only be achieved by combining the UK Power
Networks/customer earths. If it is necessary for the customer installation to rely on UK Power
Networks earth system for safety this shall be discussed with UK Power Networks or their
agents (refer to the final paragraph of Section 8.2.2). This will not be accepted as a
substitute for good design where other practicable alternatives exist.
8.2.2 Design Requirements
A customers earthing systems shall:
Consist of main bonding conductors connecting together all 33kV plant, with bolted
connections and duplicate connections to each item of plant.
Employ measures to control touch/step potentials around those items of plant. Typically
the rebar in plant rooms will be welded around the perimeter and bonded at two points to
the main bonding conductors. (Appendix B shows typical connections)
Employ measures to control step/touch voltages elsewhere in and around the building (in
particular around the outer perimeter of the building if metallic parts of the structure are
or could become exposed). Refer to previous section 8.2.1 for conditions that shall be
satisfied if this requirement is to be relaxed.
Provide sufficiently low earth resistance to make the site COLD for all local and remote
(source substation) faults. In general terms, for buildings connected to the London
Routes, this can be achieved with a local earth resistance value of 0.5 (measured
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before connection to UK Power Networks earthing system). A HOT site design will not
be acceptable unless all associated risks can be mitigated against.
Be adequate to carry a fault current of 12.5kA for 3 seconds in substation areas, and
2,700A elsewhere (refer to Table 9-1).
Make provision for connection to UK Power Networks earthing system by two 25 x 4mm
copper tapes or equivalent.
The customers earthing system shall be designed to operate independently of UK Power
Networks earthing system. The two systems shall be interconnected before commissioning
but it shall not be assumed that this will result in a significant reduction in earth resistance
for the reasons given in Section 6.2 , namely:
The areas of influence of the two systems will overlap to some degree, meaning that the
resultant overall earth resistance will not be as low as a parallel resistances calculation
might suggest.
Neither system shall be dependent on the other systems earth connection. The integrity
of UK Power Networks earth could be affected by system faults or other damage. The
customers earth similarly could become disconnected or reduced in efficiency for
reasons beyond UK Power Networks control.
As stated above, in rare cases if it is necessary for a customers installation to rely on a
contribution from UK Power Networks earth for safety, this shall be discussed with UK
Power Networks at an early stage. However an earth resistance value of 0.5 or less should
be achievable in most situations and requests to rely on UK Power Networks contribution
will not normally be agreed without a good reason.
A checklist is provided in Appendix A to assist with the assessment of an earthing design.
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9 Design Guidelines
This section provides information to assist the designer. The values provided are for
guidance only, and their relevance to a given application should be confirmed prior to
reliance on them.
9.1 Design Parameters
The following parameters apply to the North London 33kV routes and should be used for
design purposes unless revised figures are provided by UK Power Networks:
Table 9-1 Design Parameters
Parameter Value
33kV 3-phase fault current 12.5kA
33kV earth fault 2,700A
Igr% (percentage of earth fault current that will
return via soil) worst case
30%
Target resistance to achieve <430V EPR 0.5
Target resistance to achieve <250V EPR 0.3
Typical soil resistivity value (to be confirmed by
designer)
20 - 100m depending on geographical area and
depth of burial. Lower resistivity clays exist
typically >3m below surface soil
Normal 33kV protection clearance time (max) at
UK Power Networks outgoing feeders to
customer installation
0.7 second (earth fault) 1 second (overcurrent)
Backup protection clearance time 3 seconds (stuck CB condition) clearance at
source (overcurrent and earth fault)
Protection settings (typical) HSOC 3000A INST, OC 600A 0.3TM SI
EF 300A 0.1TM SI
Maximum acceptable step voltage (1 second,
concrete)
650V
Maximum acceptable touch voltage (1 second) 200V
Minimum conductor size for 12.5kA/3s rating Duplicate 25mm x 4mm copper tape or single
40mm x 4mm copper tape
Minimum conductor size for 2,700A/1 second or
3 second
70mm
2
stranded copper
Source substation R
a
and EPR (max) Finsbury Market Substation 0.15, 403V
Back Hill Substation 0.2, 526V

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9.2 Conductor Sizes
9.2.1 UK Power Networks Substation
The main bonding conductors shall be sized to cope with a fault current of 12.5kA for 3
seconds (refer to Table 9-2). The conductor sizes are given in Table 9-2 below (a minimum
of two 25mm x 4mm copper tapes or equivalent as shown above). This requirement derives
from ENA TS 41-24 paragraph 8.2.
9.2.2 Customer Switchrooms and Installations
According to ENA TS 41-24, the main bonding conductors should be sized to cope with the
full phase-phase fault level of 12.5kA for 3 seconds. This figure is used in UK Power
Networks substations and should be used in customer switchrooms and transformer rooms.
Given that the 33kV system is impedance earthed, with a limited earth fault level of 2,700A it
is economical and appropriate to use this lower figure for design purposes in other parts of
the customer installation, unless higher 11kV or LV earth fault currents can flow, in which
case the higher figures should be used. Section 8.2.1 of ENA TS 41-24 describes the use of
earth electrode current in design calculations. Although the likelihood of phase-phase fault
current flowing in earth bonds is small, UK Power Networks will not accept the use of smaller
conductor rated at 2,700A for 3 second in switchrooms/transformer rooms except for
bonding ancillary items such as enclosures, doors etc.
The UK Power Networks standard conductor sizes for low fault level sites, defined as
12.5kA for 3 seconds, are shown in Table 9-2. These should be adopted for 33kV
switchroom and transformer rooms.
Care should be taken not to exceed the current rating of individual rod electrodes as given in
Table 9-2.
Table 9-2 Low Fault Level Earth Conductor Sizes (12.5kA for 3 seconds)
Use Conductor* Specification Connection Size
Earth Grid Copper Tape BS 1432 -
C101/C103
Duplicate 25mm x 4mm
Primary equipment
connections that may
be required to carry
the full fault current
e.g. power
transformers,
switchgear,
transformer neutrals,
busbar supports etc
Copper Tape BS 1432 -
C101/C103
Single Brazed/Welded 25mm x 4mm
Single Double Bolted 40mm x 3mm
Duplicate Brazed/Welded 25mm x 4mm
Duplicate Double Bolted 25mm x 4mm
Copper
Stranded
Hard drawn
high
conductivity
copper to BS
125
Single Brazed/Welded 100mm
2

Single Double Bolted 125mm
Duplicate Brazed/Welded 70mm
2

Duplicate Double Bolted 75mm
2

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Use Conductor* Specification Connection Size
Secondary equipment
connections e.g.
protection/relay panels
metalwork, cubicles,
kiosks, building
steelwork etc)
Copper Tape BS 1432 -
C101/C103
Single 25mm x 4mm
Copper
Stranded
Hard drawn
high
conductivity
copper to BS
125
Single 70mm
Above ground
equipment
connections using
tape or structure parts
(such as support
framework)
Aluminium Hard drawn to
BS 2898 -
1350 or
aluminium
alloy to BS
3242
Single Brazed/Welded 60mm x 3mm
Single Double Bolted 60mm x 3mm
Duplicate Brazed/Welded 25mm x 4mm
Duplicate Double Bolted 40mm x 3mm
Equipment
connections via
structure legs
Galvanised
Steel
Single structure leg Min 380mm
2

Two structure legs Min 225mm
2


Table 9-3 Maximum Current Rating of Earthing Rods
Resistivity Copper Clad Steel (30%) 16mm
Diameter
Solid Copper 16mm Diameter
Protection
Clearance Time
1s 2s 3s 1s 2s 3s
30 m 40.8kA 28.8kA 23.4kA 69.7kA 49.2kA 40.2kA
50 m 31.6kA 22.3kA 18.2kA 54.0kA 38.1kA 31.2kA
100 m 22.3kA 15.7kA 12.9kA 38.2kA 27.0kA 22.0kA
150 m 18.2kA 12.8kA 10.6kA 31.2kA 22.0kA 18.0kA
200 m 15.8kA 11.1kA 9.1kA 27.0kA 19.0kA 15.6kA

9.3 Lightning Electrode Systems
Lightning electrode systems, if any, will usually consist of downleads and high frequency
earth electrodes. These may be connected to the customers perimeter electrode system
and will provide a contribution to reducing the earth resistance. However, this contribution
should not be relied on as the sole means of earthing unless the conductors and electrodes
are shown to be sufficiently rated to carry fault current.
9.4 Electrode Location and Caveats
When routing electrodes, extra care is required if the electrode will pass close to an area
frequented by people with bare feet, e.g. swimming pools or showers. If in doubt consult an
earthing specialist. Further information can be found in BS7671 and ENA ER G12.
The customers electrode system shall not rely on buried pipework or metallic cable sheaths
to reduce the earth resistance. If the resistance offered by such services is significantly lower
than the customers system, a large proportion of earth fault current will flow in the services
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during a fault. An example is the braided sheath of a co-axial cable, which may be
connected to a remote earth or global earthing system. This is another reason to design the
system to be independent of other earths, and to limit the EPR to as low a value as is
practicable. These fortuitous paths shall be bonded to the customers main earth terminal to
prevent them introducing a touch potential risk (imported potential) except if the site is
HOT, in which case it is important not to export potential to a remote system in this way
(specialist advice is required in such circumstances).
9.5 Segregated or Combined Earthing System
It is not appropriate to design a segregated earthing system in a building, nor is it usually
necessary particularly if the site is COLD.
Therefore the customers installation shall be designed to achieve an earthing resistance of
0.5 as specified in Table 9-1 before connection of any cables or to UK Power Networks
earthing system.
The resistance value shall be confirmed by measurement before connection using the fall of
potential method or other technique.
9.6 Use of Rebar/Piles
Rebar/Piles can be used to a) provide a connection to the general mass of earth, and b) in
the case of rebar mesh, to provide grading to manage step and touch potentials.
In providing a connection to the mass of earth, it should be viewed as fortuitous in that it will
provide a parallel path for fault current. Vertical steel rebar piling can provide a useful
reduction in earth resistance; however, it is supplementary to and does not replace the need
for a dedicated electrode system. If it is necessary to rely on vertical piles, should the fault
current magnitude require it, copper strip can be installed within the piles to supplement the
current carrying capacity.
For the purposes of step/touch potentials, the floor grid should be welded around the
perimeter, and connected to the main earth terminal by two independent connections as
shown in Appendix B. It is not usually necessary to install additional grading mats.
The following sections are based on ECS 06-0022 (grid and primary substation earthing
construction).
9.6.1 Sheet Steel Piles
Sheets that are more than 3m long and 2m wide are to be bonded to the earthing system, as
specified by the design engineer. Stainless steel studs are to be exothermically welded to
each second sheet at a suitable height (normally 600mm below finished ground level) and a
strip of 40mm x 4mm copper tape will be bolted to these. The strip will in turn be connected
to the main substation earthing system. If the piles form a separate electrode connected to
the earthing system at one point, then the connection should be via a test chamber such that
the contribution of the piles may be monitored. Note: The use of buried bolted connections
in this case is reasonable as there are many parallel connections.
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9.6.2 Horizontal Steel Reinforced Foundations
For plant rooms, the rebar will be installed normally (i.e. with the rebar strips bound with soft
steel wire), and welded connections around the perimeter. Connection is achieved by two
rebar connections left protruding from the concrete for about 150mm, or a welded
connection may be provided as shown in Figure 9-1.


Figure 9-1 Typical Rebar Connections

9.6.3 Vertical Steel Reinforced Ground Columns
Where these columns have steel reinforcing that extends more than 4m into the ground,
then often the design will require these to be bonded to the earthing system. The easiest
method is to leave a section of bonded rebar 150mm out of the concrete for a connection to
be made later by the earth installers. This steel reinforcing bar shall have its electrical
continuity maintained at joint positions by welding the connection.
9.7 Joints and Connections
9.7.1 General
The methods described below are the only means permitted.
Exothermic welded, brazed and compression type joints are acceptable. Bolted joints are
only permissible above ground.
For connections made to equipment welded joints may be possible, but in the majority of
cases, bolted joints will be necessary. Nuts, bolts and washers for these are to be of high
tensile stainless steel or galvanised steel. Bolted connections shall, wherever possible, be at
least the double bolt fixing type, except where purpose designed connections are provided
by the equipment manufacturers.
Lugs for connecting cable screens shall be positioned to facilitate removal for
testing/commissioning purposes. The screen wires shall be bunched to permit testing with a
clamp-meter.
Connections to/from equipment should be clearly labelled.
Lugs should wherever possible have a two bolt connection and the holes drilled in earth bars
should not significantly derate the bar (tee connection pieces can be brazed on to facilitate a
bolted lug connection).
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9.7.2 Copper to Copper Connections
Tape to tape connections shall be brazed or exothermically welded.
Stranded to stranded connections shall be exothermically welded or connected using
compression joints.
Stranded to tape connections shall be exothermically welded or a lug shall be compressed
onto the stranded conductor, which for underground use is bolted and then brazed or welded
onto the copper tape. For above ground purposes, the lug may be bolted to the tape but
shall have a double bolt fitting.
9.7.3 Copper to Earth Pins
Connections shall be brazed or exothermically welded. Bolting and U-bolts are not
acceptable.
9.7.4 Electrode Test Points
The design drawing will show the test points. Electrode test points are required either at the
rod top for long single rods (Figure 9-2) or inline between a rod group and the main earthing
system. To allow individual rod resistance values to be tested with a clip-on meter and
facilitate electrode tracing all test points shall be stranded circular conductor. If strip has to
be used it shall be folded over to allow the test clamp to fit. The traditional bolted connection
offers no value.
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>80mm
>50mm
>300mm
Surface Backfill
Diameter suitable for
civil purposes
Cadweld or braze
to earth rod
Backfill will depend on civil
requirements
Generally Bentonite for clay/
soft soil and Marconite mixed
with concrete for concrete/rock
Inspection Chamber
Loop to allow clip-on meter to be fitted
around copper conductor
Cadweld or braze of
bolt/crimp to earth tape
PVC covered 95mm
2
copper conductor
Earth rod
Surface
Backfill
OPTION 2
Copper earth tape

Figure 9-2 Test Point

A test point associated with pile cap connections is useful but only if the design of the rebar
is electrically separated from the rest of the site. At most sites the rebar will be connected
together and while this provides an excellent earth, testing the individual pile cap earths is
impossible. In these cases separate earth pins should have been provided in the design
perhaps for high frequency and/or lightning protection which will allow testing between
individual earth rods and the main earth grid.
9.7.5 Copper to Equipment Earths
Connections should, wherever possible, be in the vertical plane.
Remove paint from the metal at joint position on the equipment earth, sand metal smooth
and apply neutral jointing compound (e.g. Castrol Rustillo 431 or Shell Ensis CD). Drill the
copper tape to accommodate the bolts (normal diameter is 10mm) and then tin the complete
contact area. The bolt holes shall be less than one-third the width of the tape. Failing this a
copper flag shall be jointed to the copper tape and the holes drilled into this. A two bolt fixing
is preferred, unless a suitably rated fixing is provided by the manufacturer.
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Copper joint surfaces, once drilled are to be cleaned using aluminium oxide cloth (grade 80).
Copper is tinned at all bolted connections the tinning needs to be thin and should not exceed
an average of 0.5mm, otherwise it will flow from bolted sections under pressure. Neutral
jointing compound (e.g. Castrol Rustillo 431 or Shell Ensis CD) is then to be applied to the
joint faces.
9.7.6 Aluminium to Aluminium Joints
The preferred method is either inert-gas tungsten-arc (TIG) or inert-gas metal arc (MIG)
welding. Bolted joints are acceptable above ground.
For bolted joints:
All joints require a two bolt fixing.
Bolts shall be high tensile galvanised steel, fitted with large diameter galvanised steel
washers.
The surface aluminium shall be cleaned using grade 80 aluminium oxide cloth and
coated with neutral compound grease (e.g. Castrol Rustillo 431 or Shell Ensis CD).
Bolts shall be tightened using a torque wrench, to avoid over stressing, using the settings
given in Table 9-4.
All excess grease shall be wiped off the finished joint.
The joint shall be sealed with two coats of bitumastic paint.
Table 9-4 Bolt sizes and Torques for Use on Aluminium
Bar Width Bar
Overlap
Bolt
Diameter
Hole Size Bolt Min
Torque
Washer
Size
Washer
Thickness
40mm 80mm 10mm 12mm 35 Nm

OD 25mm
ID 11mm
2.5mm
60mm 100mm 12mm 14mm 50 Nm OD 28mm
ID 12.5mm
3.0mm

9.7.7 Aluminium to Equipment Earths
Aluminium conductor connections to equipment should, where possible, be in the vertical
plane. In all cases joints shall be made in accordance with Section 9.7.6 above.
9.7.8 Aluminium to Copper Joints
Connections are to be in the vertical plane, at least 150mm above the ground or concrete
plinth. They shall be located in positions where water cannot gather and the aluminium will
be above the copper. Bimetallic joints shall not be made on buried sections of electrode.
All connections involving dissimilar metals shall be cleaned with aluminium oxide cloth
(grade 80) and have neutral compound grease applied before making a bolted connection.
Copper shall be tinned prior to any such connection. Excess grease should be wiped off.
The finished joint shall be sealed with two coats of bitumastic paint.
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10 Typical Designs
A standard design will typically consist of an outer (perimeter) loop of copper electrode,
buried at a depth of 600mm (installed in a plastic duct where non plastic served cables or
services cross the tape). The loop should ideally encircle the entire footprint of the building.
If other metalwork (e.g. a metallic fence) encroaches on this area, the designer shall
consider touch voltages that may arise should somebody be standing over the electrode
whilst simultaneously touching the fence.
The outer loop should be converted to a mesh by providing standard conductor (laid at 90
degrees to each other) to form a grid, ideally with a mesh size no greater than 10m x 10m.
Earth rods should be installed at (or close to) the perimeter loop electrode, and at its
corners. Some of the rods should have facilities to permit testing using a clamp meter, and
should be driven to a depth of at least 3.6 metres or as necessary to achieve the desired
earth resistance.
Two connections from the main electrode system or perimeter electrode shall be taken to
each of the main items of plant (switchgear, transformers, etc). The customer may choose to
establish a main earth terminal from which duplicate connections to all main items of plant,
and to grading electrodes, can be provided. Alternatively, a surface laid ring of conductor
may be provided which will serve a similar purpose. All connections to this should be
accessible for testing (typically using a micro-ohm meter or Ductor).
The customers main earth terminal shall be connected to UK Power Networks earth
terminal after testing, using two copper tapes of 25mm x 4 mm.
The arrangement of a perimeter electrode system provides the most effective connection to
earth, and the mesh provides a reduction in impedance as well as controlling the voltage
gradient that will appear on the ground in fault conditions. It is not then normally necessary
to install electrodes for each switch or transformer room within that perimeter provided that
those rooms are connected to the perimeter electrode system by two duplicate connections.
Were they to be installed, the contribution of such electrodes would increase the robustness
of the system but the reduction in earth resistance will be minimal as they will be within the
zone of influence of the outer (perimeter) electrode unless they are driven to a considerable
depth.
A typical layout is shown in Figure 10-1 a copper mesh is established underneath the
building, and extends beyond the perimeter of the building in a way which will reduce touch
potentials. The rods are established around the perimeter of the site, and connections from
main items of plant to the mesh are made close to the plant (and duplicated where
necessary).
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Figure 10-1 Overview Diagram Showing Common Mesh Arrangement (further detail is given in
Appendix B)

Exothermic weld at
each connection
Earth Rods Bare copper earth
tapes
Building footprint
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Appendix A Design Checklist
UK Power Networks will audit all proposed designs prior to connection. Sub-standard
designs will not be accepted. The developer will be required to provide the information below
prior to connection.
Item Value/Confirmation Pass/Fail
Earth grid resistance and overall earth return
impedance values

Maximum earth fault current
EPR (for a maximum value of earth fault current)
Substation Classification (HOT or COLD)
Limits of the HOT zone and appropriate zones of
influence (if applicable)

Internal maximum touch and step potentials at all
points are below the safe acceptable value.

Maximum touch potentials around the perimeter of the
building are below safe values

Maximum external step potentials are below the safe
acceptable value

All conductors are adequately sized and that the will
not be preferential parallel paths which could give rise
to danger

Design drawings/as built drawings

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Appendix B Drawings

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