GUIDELINES FOR EARTHING INSTALLATION

1. MATERIAL AND SIZE

Type, material and sizes of earthing conductors and earth electrodes and number of
equipment earthing leads shall be as given in the enclosed table in Clause 9.

2. EARTHING CONDUCTOR LAYOUT:

A. a) Earthing conductors in Switchyard/Transformer yard shall be buried 600 mm

below finished grade level unless stated otherwise. Refer Fig 7.

b) Earthing conductors around the station buildings shall be buried 800 mm below
finished grade level.

B. Minimum 6000 mm spacing between earth electrodes shall be provided unless

stipulated otherwise.

C. Earthing conductor around the building and switchyard/transformer yard fence shall
be buried in earth at a minimum distance of 1500 mm from the outer surface of wall
of building and switchyard fence/transformer yard fence.

D. Earthing conductors embedded in the concrete floor/walls of buildings shall have

approximately 100 mm concrete cover.

E. Earthing conductors along their run on columns, beams, walls, etc. shall be supported
by saddles at intervals of 750 mm. Refer Fig 1.

F. Tap connections from the main earthing grid and/or earthing pads provided near the
equipment to the equipment/structure to be earthed shall be terminated on theearthing
terminals of the equipment/structure.

G. In outdoor areas, (switchyard, transformer yard etc.) leads from buried conductors
shall be brought out 1000 mm above ground level for making tap connection to
equipment/structures.

H. Earthing conductors crossing the road shall be provided with suitable protection as
directed by the site engineer.

I. Wherever earthing conductor is required to cross underground service ducts, pipes,

trenches, tunnels, railway tracks, etc., it shall be laid 300 mm below them. The
earthing conductor shall be re-routed in case it fouls with the equipment foundations.

J. Whenever earthing conductor is required to pass through external walls, floors, etc.,
galvanised iron sleeves shall be provided for the passage of the conductor. Both ends
of the sleeve shall be sealed to prevent the passage of water through the sleeves.
K. Connection between the earthing grid inside and outside the building shall be through
copper water stops as shown in Fig 2. Location of these Copper water stops will be
shown in relevant earthing layout drawings.

3. EQUIPMENT AND STRUCTURE EARTHING:

A. Earthing terminals will be provided by the supplier of the apparatus/equipment at
accessible position. The connection between equipment earthing terminal and the
earthing pads shall be made by short and direct earthing leads free from kinks and
splices. Whenever it is to be laid on the floor a chase is to be made and after laying
the conductor it has to be grouted. Wherever finished floors are provided the leads
shall be laid below the finished floor while doing finishing of floor work.

B. Steel columns, metallic stairs, hand-rails etc. of building portions housing electrical
equipment shall be connected to the nearby earthing grid by one lead. Electrical
continuity shall be ensured by bonding different sections of hand-rails and metallic stairs.

C. Metallic pipes, conduits carrying electrical cables shall be bonded to ensure electrical
continuity. They shall be earthed at minimum two points.

D. Cable tray sections shall be properly bonded through coupling plates to ensure
electrical continuity. Earthing conductor shall run along the top trays and to be bolted
to trays before installation of cables. All the tiers of cable pans shall be connected at
every 2.5 m interval. The cable tray shall be earthed at minimum two points and in
addition at 25 meters interval for longer length. Apart from the intermediate
connections, beginning and end points shall also be connected toearthing system.

E. Metallic conduits, pipes and cable trays shall not be used as earth continuity
conductor.

F. A separate earthing conductor shall be provided for earthing lighting fixtures,

receptacles, enclosure of switches, junction boxes, lighting conduits, etc. They shall
be properly earthed by using copper wire of size not less than 14 SWG running along
the entire length of conduit between the fixture and corresponding lighting panel
where it will be connected to earth terminal of lighting panel. The earth wire shall
run outside the conduit and shall be bonded at every 1000 mm to the conduit with
copper earth clip of thickness not less than 26 gauge and screw and nuts.

G. Whenever earthing conductor is required to cross or run along metallic structures

which carry gas, water, steam and pipes, etc., it shall be bonded to the same.

H. The earthing of street lighting poles, junction boxes on the poles, and flood light
supporting structures etc. shall be done by 8 SWG copper wire unless specified
otherwise. The distribution boards shall also be earthed with earth lead as per table
under Clause 9. The conductor shall be run buried in ground at a depth of 600 mm along the
supply cable and looped in and out to each lighting pole. The earth conductor shall be
connected to the nearby main earthing grid at first and last poles of each feeder circuit and
 at some intermediate poles. Outdoor lighting boards are connected to the earth electrode.

I. Railway tracks within the plant area shall be bonded across by fish plates and
connected to earthing grid at one location as indicated in the relevant layout drawings.

J. Every alternate main post of the switchyard and transformer yard fence and gates
shall be connected to earthing grid by one lead. Gates shall be bonded by G.S. flexible
braid to the earthed post. Refer Fig 8.

K. Small electrical equipment like local push button stations, electrically operated
valves, power receptacles, small panels, small marshalling boxes, junction boxes,
exhaust fans shall be earthed by two earthing leads from the same earthing pad (with
two connections from the main embedded conductor to the pad).

L. Miscellaneous items such as junction boxes, metallic enclosures of field switches,

cable glands, etc. shall be earthed whether specifically shown or not.

M. The enclosures of generator, exciter, and turbine shall be earthed by two leads.
Generator circuit breaker enclosure shall not be earthed since isolated phase bus
duct (IPBD) shall be earthed at generator end only.

4. JOINTING:

A. Earthing connections with equipment earthing terminal shall be bolted type. Contact
surfaces shall be free from scales, paint, enamel, grease, rust or dirt. Two bolts shall
be provided for making each connection wherever possible.
B. For earthing connection, at equipment end as well as pad end, for conductor size equal
to and above 65.09 sq.mm connection will be through offset bar lugs using two bolts,
and for the conductor size less than 65.09 sq.mm connection shall be through
crimpable type lug with one bolt.
The lug shall be of copper alloys. The earthing lead shall be brazed to offset bar lugs
while earthing lead shall be crimpable type lugs. The lugs details are given in Fig 4.
Equipment earthing leads of 14 SWG copper and smaller size shall be directly bolted
to the earth pad which eliminates the provision of earthing lugs both at the equipment
and the pad end.

C. For the embedded earthing conductor copper to copper joints are done by cad weld
joint/brazing. The procedure and precautions to be followed is as follows:

I. BRAZING: (Refer Fig 5 & 6)

i. The brazing surface shall be cleaned and made free from oxide films, grease, oil and
any foreign material. Cleaning may be done either mechanically or chemically
without use of acids. The cleaned surface should be bright but not too smooth and
highly polished to prevent jointing metal from flowing away.
ii. Brazing operation shall be done using oxy-acetylene torch under reduced atmoshere
(i.e. contrary to oxidizing conditions). The brazing alloy shall conform to IS-2927-
classification Ba, Cu, Zn4. The brazing operation shall be controlled within melting
range recommended by IS-2927 for the brazing alloy.

iii. Borax or mixture of borax and boric acid shall be used as flux. The joint will be
washed with water after brazing to prevent corrosion due to residual flux.

II. CAD WELD JOINTING:

i. It is an exothermic welding process which can be used as a simple, self-contained
method of forming high quality electrical connections. The process requires no
external power or heat source, making it completely portable. Connections are made
inside a semi-permanent graphite mould using high temperature reaction of powdered
copper oxide and aluminium. Since the connection is a fusion of high conductivity,
high copper content alloy, it will withstand repeated fault currents and will not loosen
in the way that mechanical connectors can. Refer Fig 10.

ii. Once the joint is finished, the mould should be cleaned using a mold scrapper and
brush for the next joint.

iii. The conductors and as well as the mould used for jointing should be cleaned properly
and should be water or, moisture free for better results. Cleaning may be done either
mechanically or chemically without use of acids.

D. Steel to Copper connections shall be brazed type. Steel to steel connections shall be
welded type.

E. Resistance of the joint shall not be more than the resistance of the equivalent length
of the conductor.

5. CABLE EARTHING:

A. Metallic sheaths and armour of all multi-core power cables shall be earthed at both
equipment and switchgear ends. Metallic sheath and armour of single core power
cables shall be earthed at switchgear end only. The metallic sheaths and armour of
the cables shall be earthed through cable glands as shown in the drawing SH-25

6. INSTRUMENTATION EARTHING:

A. SAFETY EARTHING
All the metallic portion of instrument chasis, cabinets, panels and junction boxes
will be connected to the nearest earthing pad. The earthing pads are to the station
earthing system. The sizes of the copper earthing conductor will be as follows:
(a) Instrument chasis to Earthing bus - 14 SWG(4 sq.mm)
(b) Earthing bus to Earthing pad - 16 sq.mm
(c) Junction Box to Earthing pad -14 SWG(4 sq.mm)
B. SHIELD EARTHING
The shields of individual pair of signal cables will be connected to the zero signal
reference potential at only one point i.e. where the signal source is earthed. The other
end of the shield will be isolated from the zero signal reference point so that loops
are not formed.
The overall shields of control cables, instrument cables and compensating cables
are terminated on shield terminals in field junction boxes, CDF and panels/nodes.
The shield terminals inside the field junction boxes, CDF, and panels/nodes are
shorted respectively. The shield terminals are connected to safety earth bus bar of
CDF/panels/nodes in control centre by 2.5 sq. mm PVC insulated stranded copper
wire. The safety earth bus bar of CDF/panels/nodes is connected to nearest earthing
pad by 16 sq. mm bare copper conductor so as to ensure grounding at one end only.

C. SIGNAL EARTHING
The signal earth (zero reference signal point) for both digital and analog system will
be connected to signal ground bus bar inside the panel/node which is isolated from
safety ground. These signal ground bus bars inside nodes/panels are connected to
junction box by 10 sq.mm PVC insulated stranded copper wire. The bus bar inside
the junction box is connected to nearest earthing pad by 16 sq.mm PVC insulated
stranded copper wire.

D. GENERAL

The shield is connected to safety earthing at only one end and signal earthing is
connected to the safety earthing at only one point.
For signal grounding of TG and secondary cycle systems, the instrumentation
earthing will be brought out from the control centre with a two numbers of insulated
copper cables (50 sq. mm) and will be connected to the instrumentation earthing
through treated earth pit.

To control the earthing resistance of the Instrumentation earth grid to one Ohm, 216
meters length of earthing conductor will be provided in the earth.

The Instrumentation earthing mesh will be of 5 m x 5 m with parallel conductor spacing

of 250 mm. This mesh will have 4 nos. of treated earth pit with 3 meters long electrode
at four corners. The stranded copper earthing conductor size will be 126.7 sq. mm.

7. SPECIFIC REQUIREMENTS FOR EARTHING SYSTEM:

A. Two earthing leads from the neutral of indoor transformers shall be connected to the
earthing pad which is in turn connected to main earthing grid. In the case of outdoor
transformers HT side of GT and SUT, the two earthing leads from the neutral shall
be connected to the two electrodes which are further connected to station earthing.
Neutral of LT side of SUT and UT are connected to the earth mat through a resistor.
 Generator neutral through the grounding transformer is connected to theearthmat
provided partly below and above the raft of TB, by two leads. The earthmat will be
further connected to station earthing layout.

B. Earthing terminal of each lightning arrester shall be connected to electrode which in

turn, shall be connected to main earthing grid.

C. Earthing mat comprising closely spaced (150 mm approximately) Copper conductors

shall be provided below the operating handles of the 400 kV/220 kV isolator and for
circuit breaker control Kiosk. Operating handles of the isolators shall be properly
bonded with flexible braids.

D. Flexible earthing leads shall be provided for earthing the equipment on moving
platforms.
8. LEGEND

Main earthing conductor embedded in soil

195.1 mm2-37x2.62 mm stranded copper
conductor

Main earthing conductor embedded in

soil/concrete(floor slab/wall) 126.7 mm2 -
37x2.11 mm stranded copper conductor

Main earthing conductor embedded in

soil/concrete (floor slab/wall) 2x126.7 mm2-
2x37x2.11 mm stranded copper conductor

Earthing conductor for equipment earthing

65.09 mm2-19x2.11 mm stranded copper
conductor

50 mm2 -7x3.0 mm stranded copper conductor

35 mm2 -7x2.5 mm stranded copper conductor

10 mm2-7x1.4 mm stranded copper conductor

25x 6 mm – flat GS conductor

Main earthing conductor passing through sleeve

Braze/ Cad welded joint in earthing conductor

L Lightning protection conductor at roof level

EFP
Earthing pad flush with finished floor

Earthing pad flush with ceiling level

ECP

EWP
Earthing pad flush with wall/column surface

Suffix for earthing pad

M - Motor

F - Fan

CT - Cable Tray

S - Spare

RL - Rail For Crane & Monorails

P - Pump

V - Ventilation System

RE - 3 Phase – Receptacle

TN - Transformer neutral

PB - Push Button

MV- Motorized Valve

PL - Panel

TK - Tank

B - Busduct
 Earthing pad for connecting two earthing leads to same pad
from small equipment such as PB station etc.

Earth electrode (25 dia, 3000 mm long copper rod) directly

buried (Type I)

Earth electrode (25 dia, 3000 mm long copper rod) with

treated earth pit (Type II)
TP
Earthing conductor going up

Earthing conductor dropping down

Lightning protection system down conductor

Earthing mat (made from 35 mm2 stranded copper conductor)

Earthing conductor changing elevation

Lower level side as specified

Location of change in elevation as specified

Higher level side as specified

 Earthing conductor loop at expansion joint

TABLE
9.
EARTHING CONDUCTORS AND LEADS

Sr. Item Material Size No. of Leads

No.

1.0 MAIN EARTHING CONDUCTOR

1.1 Main Earthing Conductor for Plant Copper 126.7 mm2 NA
(buried in earth and floor slabs in (37x2.11 mm)
building)
1.2 400kV switchyard Copper 195.1 mm2 NA
(37x2.62 mm)
Transformer yard Copper 195.1 mm2 NA
(Near TG Building) (37x2.62 mm)

2.0 LEADS TO EQUIPMENT/STRUCTURES

2.1 Switchyard/structures and equipments:

2.1.1 400 kV Circuit breaker Copper 195.1 mm2 2
(37x2.62 mm)
2.1.2 400 kV Isolators Copper 195.1 mm2 2
(37x2.62 mm)
2.1.3 400 kV Lightning Arrestors Copper 195.1 mm2 2
(37x2.62 mm)
2.1.4 CT&PT/CVT body 400 kV Copper 195.1 mm2 2 each
(37x2.62 mm)
2.1.5 CT&PT secondary terminal boxes Copper 10 mm2 1 each
(7x1.40 mm)
2.1.6 Marshalling boxes Copper 10 mm2 2
(7x1.40 mm)
195.1 mm2
Towers & a) 400 kV Copper 2 each
(37x2.62 mm)
2.1.7 Equipment
Structure 195.1 mm2
b) 220 kV " (37x2.62 mm) 2 each

65.09 mm2 1 Alternate

2.1.8 a) Fence posts, Copper
(19x2.11 mm) main post
b) Gates GS 35x6 flexible GS braid
Earthing mat for Operators 35 mm2
2.1.9 Copper 2
safety. (7x2.5 mm)
2.2 Transformer Yard
GT Neutral to Earth grid Copper ≥ 350 mm2
2.2.1 1
Tubular Condr.
GT Tank and Radiator Copper 195.1 mm2
2 each
banks to earth grid (37x2.62 mm)
2.2.2 UTs
UT Tank & Radiator banks Copper 195.1 mm2
to earth grid 2 each
(37x2.62 mm)
NGR to earth grid Copper ≥ 350 mm2
Flat Condr. 2
NGR enclosure to earth Copper 2 x 126.7 mm2
2
grid (37x2.11 mm)
2.2.3 SUTs
HV neutral to earth grid Copper ≥ 350 mm2
Flat Condr. 2
SUT Tank & Radiator Copper 195.1 mm2
banks to earth grid (37x2.62 mm) 2 each
NGR to earth grid Copper ≥ 350 mm2
Flat Condr. 2
NGR enclosure to earth Copper 2 x 126.7 mm2
grid (37x2.11 mm) 2
2.2.4 Marshalling boxes Copper 10 mm2
(7x1.4 mm) 2
2.2.5 Equipment structures Copper 195.1 mm2
(37x2.62 mm) 2
2.2.6 a) Fence posts Copper 65.09 mm2 Alternate
1
(19x2.11 mm) main post
b) Gates GS 35x6 flexible GS braid
2.2.7 Lightning Arrestors 400kV Copper 195.1 mm2 2
(37x2.62 mm)

2.3 a) Isolated phase bus duct Copper 126.7 mm2 2 At

(37x2.11 mm) generator
end only
b) Isolated phase bus duct Copper 126.7 mm2 1
supports (37x2.11 mm)

a)Main Generator Neutral Copper 126.7 mm2 2

2.4
Earthing Transformer (37x2.11 mm)

b)Main Generator Neutral Copper 126.7 mm2 2

Earthing Transformer (37x2.11 mm)
enclosure
Enclosures of generator 2x126.7 mm2
2.5 Copper 2 each
exciter and Turbine (37x2.11 mm)
126.7 mm2
2.6 VT & SP cubicles Copper 2
(37x2.11 mm)
2.7 Main Plant Equipment
2.7.1 6.6 kV Diesel Generator Copper 126.7 mm2 2
NGR to grid (37x2.11 mm)
NGR enclosure to grid Copper 126.7 mm2 2
(37x2.11 mm)
6.6 kV switchgear & Copper 2x126.7 mm2 2 Each at
2.7.2
busduct (37x2.11 mm) both ends
126.7 mm2
2.7.3 6.6 kV motors Copper 2
(37x2.11 mm)
2.7.4 415V UPS Set neutral & 126.7 mm2
Copper 2 Each
Enclosure (37x2.11 mm)
2.7.5 415V switchgears, busducts
2x126.7 mm2
Auxiliary Transformers Copper 2
(37x2.11 mm)
(body & Neutral)
 2x126.7 mm2 2
2.7.6 415V MCCs Copper
(37x2.11 mm)
415V Lighting Load 2x126.7 mm2
2.7.7 Centres and panels Copper (37x2.11 mm) 2 Each

Lighting DBs/control
65.09 mm2
2.7.8 boards space heater board/ " 2 Each
(19x2.11 mm)
VDBs

Push button stations, Copper 14 SWG 2 Each

2.7.9
Marshalling Boxes and JBs
2.7.10 415V Motors
126.7 mm2
a) 75 kW and above Copper 2
(37x2.11 mm)
65.09 mm2
b) 20 to 74 kW Copper 2
(19x2.11 mm)
35 mm2 (7x2.5
c) 7.5 to 19 kW Copper 2
mm)
10 mm2 (7x1.4
d) Upto 7.4 kW Copper 2
mm)
Three Phase Receptacles & 10 mm2 (7x1.4
2.7.11 Copper 2 Each
welding outlets mm)
Lighting fixtures, single
2.7.12 phase receptacles, lighting Copper 14 SWG 1 Each
conduits and JBs
2.7.13 Cable Trays

- Connection to main grid Minimum 2

2
65.09 mm and further
Copper 2
(19x2.11 mm) at every int
of 25m)
- Along the cable tray and (At interval
GS 25x6 mm 1
interconnection of trays of 2.5 m)
2.7.14 Hand rails, EOT Cranes, 16 mm2 (7x1.70
Copper 1 Each
Monorails mm)
2.7.15 Metallic non current
 carrying structures, tanks & Copper 1 Each
16 mm2 (7x1.70
ventilation ducts
mm)
2.7.16 Along street lighting and
(loop in
Outdoor area lighting Copper 8 SWG 1
and out)
cables

25 dia 3000 mm
3.0 EARTH ELECTRODES Copper N.A.
long rod
FIG 1
FIG 2
FIG 3 TRANSFORMER NEUTRAL/LIGHTNING ARRESTOR EARTHING
FIG 4
FIG 5
FIG 6
FIG 7
FIG 8: FENCE AND FENCE GATE EARTHING
FIG 9: EARTHING DETAILS AT FLOOR & WALL/BEAM EXPANSION JOINTS
FIG 10: CAD WELDING