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Substation, Earthing Design and Construction Guidance Notes For Developers (33kV London Routes) PDF
Substation, Earthing Design and Construction Guidance Notes For Developers (33kV London Routes) PDF
Version: 1.0
Date: 12/11/2012
THIS IS AN UNCONTROLLED DOCUMENT, THE READER MUST CONFIRM ITS VALIDITY BEFORE USE
ENGINEERING CONSTRUCTION STANDARD
ECS 06-0030
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.
This document forms part of the Company’s 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.)
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
Figures
Tables
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 describes the requirements for electrical earthing of a customer’s 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 Network’s 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 customer’s 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.
3 References
EAS 06-0011 – Earthing Materials
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
4 Abbreviations
Term Definition
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
DNO’s 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.
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.
’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.’
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.
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.
Touch Potential
Voltage (UST)
gradient Touch
across Potential
site (UST)
Earth Step Potential Transfer Potential Remote Touch Potential
Potential (USS) (UTST) (UTSTE)
Rise, EPR
(UE) (transferred (transferred source
Cable sheath voltage for touching if
source voltage for
earthed at sheath is earthed at
touching if sheath
substation remote end as well)
not earthed at
remote end)
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.
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 (RB) 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 Ohm’s Law which gives the EPR:
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 customer’s electrode system, the value Rb shall be low enough to limit EPR to
safe values. The value of Rb will reduce when the customer’s system is connected to the UK
Power Networks system, but this ‘parallel’ contribution cannot be used as the customer’s
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
In short, the customer’s 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 developer’s expense.
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.
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
burial1). 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 DNO’s LV
network (transfer potential risk).
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 Cage2. 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.
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 customer’s earthing system to achieve a satisfactory earth
resistance value, but will normally be connected to the customer’s 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).
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 customer’s installation will be COLD if an earth resistance value
of 0.5Ω can be achieved. However, a designer/developer might wish to aim for a lower value
of 0.3Ω. 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 0.3Ω 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 0.3Ω 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.
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 0.5Ω (measured
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 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 system’s earth connection. The integrity
of UK Power Networks’ earth could be affected by system faults or other damage. The
customer’s earth similarly could become disconnected or reduced in efficiency for
reasons beyond UK Power Networks’ control.
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.
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:
Parameter Value
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.
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)
Resistivity Copper Clad Steel (30%) 16mm Solid Copper 16mm Diameter
Diameter
Protection 1s 2s 3s 1s 2s 3s
Clearance Time
Lightning electrode systems, if any, will usually consist of downleads and ‘high frequency’
earth electrodes. These may be connected to the customer’s 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.
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 customer’s 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 customer’s system, a large proportion of earth fault current will flow in the services
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 customer’s 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).
The resistance value shall be confirmed by measurement before connection using the fall of
potential method or other technique.
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).
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.
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.
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.
9.7.1 General
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.
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).
Connections shall be brazed or exothermically welded. Bolting and U-bolts are not
acceptable.
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.
Inspection Chamber
Loop to allow clip-on meter to be fitted
around copper conductor
>80mm
Surface Backfill
>300mm
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.
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.
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.
The preferred method is either inert-gas tungsten-arc (TIG) or inert-gas metal arc (MIG)
welding. Bolted joints are acceptable above ground.
Bar Width Bar Bolt Hole Size Bolt Min Washer Washer
Overlap Diameter Torque Size Thickness
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.
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 customer’s 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).
Exothermic weld at
each connection
Building footprint
Earth Rods Bare copper earth
tapes
Figure 10-1 – Overview Diagram Showing Common ‘Mesh’ Arrangement (further detail is given in
Appendix B)
Appendix B – Drawings