Project name:

30106-B APODI
759 - APO - APODI, 3500 TPD COMPLETE PLANT

Owner:
COMPANHIA INDUSTRIAL DE CIMENTO APODI, BRAZIL

Main contractor:

L.V TECHNOLOGY PLC

Electrical engineering
& Utility system Design

DK ENGINEERING LTD.

Document Title:

DESIGN CALCULATION REPORT

GROUNDING CALCULATION FOR OVERALL PLANT

Document No.: 759-10-APO-700-E-701 Rev.: Page(s): 5+Cover

REV. DATE DESCRIPTION MADE BY CHECKED BY APPROVED BY

12-Mar-12 PRELIMINARY Nguyen Hung Binh Tran Duc Cuong Mikael Roejskjaer

File name.: 759-10-APO-700-E-701

 REVISIONS

Items Rev. Description Remark

EN-I01-F23/01/300611 File name.: 759-10-APO-700-E-701

 TABLE OF CONTENTS

1. OBJECTIVES ................................................................................................................. 1

2. DESIGN BASIS .............................................................................................................. 1

3. CALCULATION OF CONDUCTOR CROSS-SECTION ................................................. 1

3.1 EARTHING GRID LAYOUT ........................................................................................... 1

3.2 CALCULATION OF MINIMUM CONDUCTOR SIZE ...................................................... 2

4. CALCULATION OF EARTH RESISTANCE ................................................................... 2

4.1 SCOPE ........................................................................................................................... 2

4.2 DATA AND ASSUMPTION ............................................................................................ 3

4.3 FORMULAS: .................................................................................................................. 3

4.4 EARTH RESISTANCE CALCULATION ......................................................................... 3

5. CONCLUSION ............................................................................................................... 4

6. APPENDIX ..................................................................................................................... 5

EN-I01-F23/01/300611 File name: 759-10-APO-700-E-701

 EARTH GRID CALCULATION FOR OVERALL PLANT

1. OBJECTIVES
Calculation of earth conductor sizing and earth resistance are carried out in order to obtain the
following major objectives:
- Provide a low impedance earth fault current return path in order to activate the protection and
clear or alarm the earth fault as soon as possible
- Conductor size and connection will withstand the ground fault current.
- Limit the voltage on site structures and accessible equipment both during normal operation
and during electrical transients to safe level
- Minimize electrical noise interference in control and instrumentation system
- Minimize the effect of lightning strike on personnel, equipment and structures
2. DESIGN BASIS
IEEE 665-1995 & IEEE 80-2000 Standards are used for earth grid calculation.
The following design inputs are assumed or referred to other documents:
- Soil resistivity (ρ):
Refer to soil resistivity test report, average soil of 6.0725 Ωm for 8 (eight) measurements,
equivalent to a corresponding exploration of the soil resistivity depths of 0.5 and 1 meter.
- Earth fault current:
The earth fault current is taken from Short Circuit Calculation Report (Document No
759-10-APO-700-E-B00)
- Fault duration (tc) :
The fault duration of 0.5s is assumed by DKE in connection with design calculation of power
supply system
- Material of earthing conductor:
Underground earthing network shall be established by bare copper cable and deep- driven
copper-clad electrodes. Secondary earthing and bonding conductors shall be by PVC insulated
yellow/green copper cable
3. CALCULATION OF CONDUCTOR CROSS-SECTION
3.1 EARTHING GRID LAYOUT
The earthing system shall be consisted of two parts: primary earthing (underground) and
secondary earthing/bonding (above ground and/or inside building)
The primary earthing system shall be carried out as one big mesh network (grid). This helps to
avoid high current concentration and, hence, high gradients both in the grid area and near the
projecting cable ends
Primary earthing conductor shall be direct burial in the natural ground at the depth of
approximately 0.8-1.0 meter from surface level. Each department is encircled by a ring of
conductor at the distance of at least 1.0 meter from the foundation.
All departments are connected with minimum two interconnection conductors and bonding of the
primary earthing conductors to the reinforcement steel (Re-bar) of the building’s columns or
slabs.
The secondary earthing/bonding system shall be consisted of earthing/bonding conductors and

Page 1 of 5 File name: 759-10-APO-700-E-701

protective earth bars for buildings, fences and other structures. There shall be protective earth
bars distributed within each building or structure. A loop connection is carried out in order to link
these bars and to the primary earthing grid.
3.2 CALCULATION OF MINIMUM CONDUCTOR SIZE
Conductor size can be calculated by equation (37) IEEE 80-2000

 TCAP *10  4   K  Tm 
I  Amm 2   * ln o 
 tc * r *  r   K o  Ta 
Where
Amm2 conductor cross-section in mm2
I rms current in kA (fault current)
tc fault duration in s
TCAP thermal capacity per unit volume in J/(cm3. 0C)
Tm maximum allowable temperature in 0C
Ta ambient temperature in 0C (Ta = 350C)
Tr reference temperature for material constants in 0C
αr thermal coefficient of resistivity at reference temperature Tr in 1/0C
ρr resistivity of the ground conductor at reference temperature Tr in μΩ -cm
Ko (1/αr) -Tr
From Table 1, IEEE 80-2000 base on conductor material to be copper, commercial hard-drawn
type, the following factors are selected:
TCAP = 3.42; Tm = 1084; Tr = 20; αr = 0.00381; ρr = 1.78; Ko= 242
Therefore:

 3.42 * 10  4   242  1084 

I  Amm 2   * ln   Amm 2 * 0.3974
 0.5 * 0.00381 * 1.78   242  35 
The fault current applied to above equation shall be extracted from Document No
759-10-APO-700-E-B00 (Short Circuit Calculation Report):
- Minimum conductor size for Pyroprocess Substation (E4a)
The maximum single-phase short-circuit current level at Main LV switch board PD1MCC01:
IN1 = 59.14kA -> A = 148.8mm2
The conductor size of 150mm2 is selected: S1 = 150 mm2
- Minimum conductor size for remaining Substations
The maximum single-phase short-circuit current level at Main LV switch board UT1MCC1:
IN1 = 47.99kA -> A = 120.7mm2
The conductor size of 120mm2 is selected: S2 = 120 mm2

4. CALCULATION OF EARTH RESISTANCE

4.1 SCOPE
To demonstrate that the overall earth resistance less than 1omh for the overall plant.

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4.2 DATA AND ASSUMPTION
- Soil resistivity data were taken from the soil resistivity test report.
- Horizontal grid conductor (bare copper) is buried at h = 0.8 m depth.
- Vertical grid conductor (copper cladded electrode) is 2.4 m length.
- Size of site areas: A = 115,750 m2.
4.3 FORMULAS:
The following formula (the Sverak's equation) is used to calculate the earth resistance for overall
plant

1  1 1 
Rg      (1  
 LT  20A 1  h 20 / A 
Where:
Rg: is the total ground resistance in Ω.
ρ: is the soil resistivity in Ω.m.
LT: is the total length of conductor and rods in m.
A: is the area occupied by the ground grid in m2.
h: is the depth of the grid in m (h = 0.8m).

4.4 EARTH RESISTANCE CALCULATION

Step 1: The average soil resistivity at depths of 0.5 and 1 meter

Depth Quantity of points

Total Average
(m) A B C D E F G H

0.5 8.33 8.41 10.18 3.97 8.87 7.33 11.65 14.57 73.31
6.0725
1 2.30 2.91 3.22 1.17 2.33 2.40 4.26 5.26 23.85

Step 2: Total length of Ring Conductor and rods

The total length of primary ring conductor and number of rod is determined from the primary
earthing system drawings
Total length of buried conductor: Lc = 6150 (m)
Total length of rods: n*Lr = 121*2.4 = 290.4 (m)
Total length of conductor and rods (LT): LT = Lc + n.Lr = 6440.4 (m)

Step 3: Calculation of earth resistance Rg

1  1 1 
Rg      (1  
 T
L  20 A 1  h 20 / A 
Rg = 0.0089 (Ω)
This value satisfies the limitation of 1 Ω.

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5. CONCLUSION
- The earthing grid conductors will be bare copper cables of 120mm2 cross-section for overall
plant ((Except Pyroprocess Substation is used bare copper cables of 150mm2 cross-section)
- The earthing resistance of overall plant: Rg = 0.0089 (Ω).

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6. APPENDIX
TABLE OF SOIL RESISTIVITY

No Depth Quantity of points

(m) A B C D E F G H

1 0.5 8.33 8.41 10.18 3.97 8.87 7.33 11.65 14.57

2 1 2.30 2.91 3.22 1.17 2.33 2.40 4.26 5.26

3 2 0.48 0.65 0.86 0.49 0.71 0.55 1.00 1.48

4 3 0.65 0.55 0.33 0.26 0.40 0.20 0.41 0.70

5 4 0.39 0.24 0.29 0.22 0.22 0.22 0.25 0.35

6 6 0.36 0.20 0.19 0.11 0.16 0.28 0.16 0.17

7 8 0.16 0.15 0.13 0.23 0.08 0.11 0.23 0.09

8 16 0.26 0.17 0.06 0.09 0.05 0.16 0.09 0.13

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