GP-16!04!01 Grounding and Overvoltage Protection

GP 16-04-01 Grounding and Overvoltage Protection January 2008
Grounding and Overvoltage

Protection
GP 16-04-01
Scope
1) [I] This Global Practice (GP) covers bonding, grounding, overvoltage protection, and lightning
protection facilities for electrical power systems and equipment, structures and buildings, and product
loading stations.
2) [I] This GP does not cover process instrumentation or cathodic protection systems. However, overall
grounding system design shall include requirements specified in other practices, e.g., instrumentation.
Contractor shall submit overall grounding design to the Owner's Engineer for approval.
Refining/Chemicals For Company Use Only Version 1.1.0
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Table of Contents
1. Required References ............................................................................................ 4

1.1. API–American Petroleum Institute ................................................................ 4
1.2. IEC–International Electrotechnical Commission ........................................... 4
1.3. IEEE–Institute of Electrical and Electronics Engineers ................................. 4
1.4. NFPA–National Fire Protection Association ................................................. 4
2. Definitions.............................................................................................................. 5
3. Bonding and Grounding Materials and Methods ............................................... 6

3.1. Bonding and Grounding Conductors ............................................................ 6
3.2. Bonding and Grounding Connections ........................................................... 7
3.3. Grounds........................................................................................................ 8
3.4. Substation and Generating Station Grounds ................................................ 8
3.5. Grounding Buses .......................................................................................... 9
4. System Neutral Grounds ...................................................................................... 9
4.1. Grounding Conductor Size ........................................................................... 9
4.2. Grounding Conductor Routing .................................................................... 10
4.3. Grounding Conductor Insulation and Protection ......................................... 10
5. Enclosure Grounding.......................................................................................... 11
5.1. Wiring Systems........................................................................................... 11
5.2. Equipment .................................................................................................. 11
5.3. Ground Resistance ..................................................................................... 12
6. Ground Returns ................................................................................................... 12
6.1. Ground Return through Flexible Conduit .................................................... 13
6.2. Conductor Ground Returns ........................................................................ 13
7. Overvoltage Protection for Power Systems...................................................... 14
8. Structure Lightning Protection .......................................................................... 15

8.1. Secondary Effects of Lightning ................................................................... 17
9. Bonding at Tank Truck, Tank Car, or Container Loading Stations ................. 17
10. Protection at Marine Terminal Loading Stations .............................................. 18
RFCH For Company Use Only Version 1.1.0

Record of Change ....................................................................................................... 20
Attachment: Purpose Code Definitions.................................................................... 21

1. Required References
This section lists the Practices, codes, standards, specifications, and publications that shall be used with
this document. Unless otherwise specified herein, use the latest edition.
1.1. API–American Petroleum Institute

API RP 540 Electrical Installations in Petroleum Processing Plants
API RP 2003 Protection Against Ignitions Arising out of Static, Lightning, and Stray
Currents
1.2. IEC–International Electrotechnical Commission

IEC 62305-3 Protection Against Lightning - Part 3: Physical Damage to Structures
and Life Hazard
1.3. IEEE–Institute of Electrical and Electronics Engineers

IEEE 80 Guide for Safety in AC Substation Grounding
IEEE 81 Guide for Measuring Earth Resistivity, Ground Impedance, and Earth
Surface Potentials of a Ground System
IEEE 142 Recommended Practice for Grounding of Industrial and Commercial
Power Systems - IEEE Green Book
IEEE 837 IEEE Standard for Qualifying Permanent Connections Used in
Substation Grounding
1.4. NFPA–National Fire Protection Association

NFPA 70 National Electrical Code
NFPA 780 Standard for the Installation of Lightning Protection Systems

2. Definitions
Term [I] Description
Acceptable and [A] Where this GP lists more than one type of equipment or method as
Preferred Practices acceptable, Contractor shall make the selection based on the installed
cost. Where one particular type of equipment or method is listed as
preferred, it shall be selected, provided: (1) it is lower or equivalent in
installed cost than other acceptable types or methods, and (2) it has
reduced maintenance and operating costs that provide sufficient cost
benefit to offset an initial added investment. Owner's Engineer shall
approve alternative choices.
Bonding Two or more objects are considered to be bonded if connected together
through a conducting path. Objects that are not inherently in contact
with each other through a conducting path may be bonded by connecting
them together with a bonding conductor. The conductor shall be sized to
safely conduct the current or dissipate the charge likely to be imposed.
Ground Return Path A metallic connection between the metal enclosure of electrical
equipment and the system neutral ground of the power supply to the
equipment. If the systems neutral is grounded through impedance, the
ground return path must connect on the ground side of the impedance.
The path is a low-impedance path from the equipment enclosure to the
neutral ground. It serves as the equipment grounding conductor in
grounded neutral systems.
Grounding An object is considered to be grounded when connected by a conducting
connection, either inherently, by a grounding conductor to the earth, or
to some conducting body that serves in place of the earth, such as where
rock or high resistivity soil is present.
Grounding Electrode Grounds are the Grounding Electrode System. The electrodes may be
System buried grounding conductors, underground metallic water piping, or
large underground metallic objects in intimate contact with earth, such
as metallic building frames, pile casings, driven rods, or concrete
encased electrodes consisting of reinforcing bars or copper conductors in
underground foundations or footings.
Lightning Arrester A protective device for limiting surge voltages on equipment by
(Surge Arrester) discharging or bypassing surge current. It prevents continued flow of
follow current to ground, and is capable of repeating these functions.
Use of arcing horns and or rod gaps is not an acceptable method of
suppressing electrical surges.

Term [I] Description
Liquids Classified as Liquids are Classified as Static Electrical Charge Accumulators if their
Static Electrical conductivity is 50 picomhos/meter (50 pS/m) or less. Distilled
Charge Accumulators petroleum products, including petroleum solvents, are generally
accumulators. Crude oil, residual fuel oil, asphalts (both penetration and
cutback), Bunker C, residual products with Conradson carbon above 1
percent, and water soluble products such as alcohol have high
conductivity and are classified as non-accumulators.
Switch Loading Loading a high flash product into a tank truck, tank car, or container
previously containing a low flash product, without cleaning or gas-
freeing the tank or container. The high flash product must be treated as
low flash during loading in such cases.
Zone of Lightning Space adjacent to a lightning protection system that is substantially
Protection immune to direct lightning flashes.
NFPA 780 Chapter 4, "Protection for Ordinary Structures," and
Chapter 7, "Protection for Structures Containing Flammable Vapors,
Flammable Gases or Liquids That Can Give Off Flammable Vapors,"
cover the cone and rolling sphere concepts for determining the zone
extent. Specific regional or national standards, while using the same
concepts, may have requirements that result in different extents of the
zone of protection.
3. Bonding and Grounding Materials and Methods

1) [S] Bonding shall be provided to insure the electrical continuity of grounding circuits, to provide
potential equalization, and where necessary, to provide a path for the dissipation of static charges.
2) [S] Bonds provided for the dissipation of static charges shall have a resistance of one megohm or less.
3.1. Bonding and Grounding Conductors

1) [*] [R] Hydrocarbon, steam, or other processed lines shall not be used for grounding purposes.
Unless otherwise specified, bonding and grounding conductors shall be bare stranded medium-hard-
drawn copper. Where the size is not specified elsewhere in this practice, minimum sizes shall be
2 AWG (35 mm2) for underground conductors and 6 AWG (16 mm2) for aboveground conductors.
Conductor sizes shall be increased above the minimum sizes if required to meet the following:
a) Insure adequate mechanical strength
b) Withstand the thermal stresses of ground fault currents
2) [*] [R] Ground return conductors located within cable assemblies, run with cable assemblies, or
enclosing individual circuit conductors are preferred. When specified, common ground return
conductors run with underground conduits or buried cables are acceptable.

3) [I] Ground return conductors located within cable assemblies may be uninsulated and shall be of the
same material and stranding as the cable line conductors. If insulated, color coding shall comply with
requirements of the applicable regulations.
4) [R] Grounding conductor burial depths shall be at least 18 in. (450 mm). Burial depths in switch or
transformer yards graded with stone shall be at least 12 in. (300 mm) below the stone.
5) [R] If the wiring method is buried cable, common grounding conductors run with the buried cable
shall be laid in the cable trenches as far as routing permits.
6) [R] If the wiring method is underground conduit, common grounding conductors run with the
conduits shall be laid along a formed side of the duct banks.
7) [I] Insulated copper conductors shall be provided in the following:
a) Corrosive environments (H 2 S, acids, caustics, etc.)
b) Highly corrosive soil conditions
c) Installations with close proximity to lead-covered power cables or extensive underground piping
systems
d) Installations with close proximity to buried metallic structures connected to cathodic protection
systems
8) [S] Grounding conductors leaving the ground at grade shall be protected as follows:
a) Conductors, except those used for lightning protection and lightning arrester grounding, shall be
protected by rigid metal, nonmetallic conduit, or pipe sleeves, where they extend above grade.
Lightning protection and arrester ground conductors shall be protected by nonmetallic conduit
sleeves.
b) Sleeves shall extend a minimum of 6 in. (150 mm) below grade and 10 in. (250 mm) above grade.
c) Metal sleeves shall be encased in concrete 3 in. (75 mm) thick all around.
d) Concrete encasement shall extend 6 in. (150 mm) above grade.
e) Nonmetallic sleeves shall be rigid, heavy-wall, polyvinyl chloride or high density, polyethylene
conduit.
f) Sleeves are not required within switch or transformer yards or under elevated substations.
3.2. Bonding and Grounding Connections

1) [S] All conductor connections to structures and equipment shall be made above ground as follows:
a) Conductors shall be installed in one length between aboveground connection points.
b) Single cable lengths shall also be installed between aboveground connection points and between
grounding electrodes or taps, on common ground return cables.
c) If splices or taps are required on underground runs, they shall be made with tool-installed
compression connectors, or by brazing or welding.
d) Bolted or screw type solderless connectors or similar mechanical connectors shall not be used
underground.
e) Splices or taps in underground runs shall be buried.
2) [M] On equipment, conductor connections that are regularly disconnected for maintenance of the
equipment shall be made with bolted or screw type solderless connectors. Other connections shall be

made by brazing, welding, or with connectors that qualify as permanent grounding connections per
IEEE 837.
3.3. Grounds
1) [S] All Grounds shall have a resistance to earth not exceeding 5 ohms throughout the year,
considering seasonal variations in soil conditions. Grounds for low resistance grounded systems shall
not exceed 2 ohms.
2) [R] If permanently installed and located within a reasonable distance of the equipment or structure to
be grounded, the following may be used as grounding electrodes:
a) Buried grounding conductors at least 20 ft (6 m) long and buried to a depth of 30 in. (760 mm).
Minimum size shall be No. 2 AWG (35 mm2).
b) Underground metallic water piping, if buried portion is more than 10 ft (3 m) long.
c) Large underground metallic objects in intimate contact with earth, such as metallic building
frames, pile casings, or concrete encased electrodes consisting of reinforcing bars, or copper
conductors that are part of an underground foundation or footing. These electrodes shall provide
the conductive equivalent of at least 20 ft (6 m) of electrically conductive reinforcing bar, not less
than 1/ 2 in. (13 mm) diameter, or 20 ft (6 m) of No. 2 AWG (35 mm2) copper conductor. The
thickness of concrete encasement shall be not less than 2 in. (50 mm).
d) [A] Artificial made electrodes consisting of driven copper-clad steel rods or equivalent. Unless
specified otherwise, rods shall be copper-clad steel equivalent to Copperweld, with a minimum
diameter of 5/ 8 in. (16 mm) and a minimum length of 8 ft (2.5 m). The tops of rod and grounding
conductor connections shall be buried at least 18 in. (450 mm) below grade. A ground well shall
be provided for each rod and its connector, when specified. Where blocking obstructions are
encountered at depths less than 8 ft (2.5 m) that prevent vertical installation, trench burial may be
used as the placement method, with the approval by Owner's Engineer.
e) If more than one electrode is connected to a grounding system, the electrode spacing shall be at
least 10 ft (3 m) apart.
f) Electrodes of different systems shall be bonded together when in reasonable proximity.
3) [M] Electrode grounding conductors and connections shall comply with the following:
a) A grounding conductor shall connect the top of each electrode to an accessible aboveground
connection point. The minimum size shall be No. 2 AWG (35 mm2).
b) The connection point may be located on the structure or equipment to be grounded, or on a
nearby permanent structure, to serve as a tie-in point for other grounding conductors. At tie-in
points, conductors from electrodes shall be identified with corrosion resistant metal bands to
facilitate their removal for test purposes.
c) The grounding conductor shall be connected to the electrode by brazing or welding and to the
connection points by a bolted or screw-type solderless connector. In ground wells, the rod
connection may use bolted or screw type connectors.
3.4. Substation and Generating Station Grounds

1) [S] All grounding electrodes at substations and generating stations shall be interconnected by
grounding conductors.

2) [S] The design of grounding systems shall provide protection from step, touch, mesh, and transfer
potentials at the following areas:
a) Outdoor switchyards and main substations that are supplied by overhead lines at utility company
voltage
b) Substations adjacent to a utility-supplied switchyard or main substation
c) Generating stations
d) Gas-insulated substations (GIS)
e) [A] Grounding system design shall be evaluated using the guidelines presented in IEEE 80, or
equivalent regional or national standards. Grounding system design for these areas shall be
submitted for approval by Owner's Engineer.
3.5. Grounding Buses

1) [M] [R] Grounding buses shall be installed as required and connected to the grounding grid electrode.
These buses shall be used for connecting the grounding conductors from several pieces of equipment
that may be in the immediate area.
2) [M] [R] As a minimum, field-installed grounding buses shall consist of 3/ 4 in. x 1 1/ 2 in. (19 mm x 38
mm) copper bars. Tinned copper bars shall be installed in locations with H 2 S or highly corrosive
atmospheres.
3) [M] [R] Grounding buses shall be mounted on steel columns or structures.
4) [M] [R] Equipment grounding buses over 30 in. (762 mm) long shall have two connections to the
grounding grid.
4. System Neutral Grounds

4.1. Grounding Conductor Size
1) [O] [R] Grounding conductors used to ground power transformer or generator neutrals shall have a
cross sectional size not less than 2 AWG (35 mm2). In addition, the size shall limit temperature
reached by the conductor, when it is carrying maximum ground fault current for the time allowed by
the slowest responsive relay to the following:
a) For insulated conductors—to within the transient temperature for no damage to the insulation.
b) For bare conductors—to 250°C rise, if connections to cable are made with pressure connectors; to
450°C rise, if connections to cable are brazed or welded.
For copper conductors at 26°C ambient temperatures, the required size is:
FI t
Where:
I = Current (amps)
t = time (seconds)
F = 0.0106 for answer in kcmil and 250°C rise

= 0.0087 for answer in kcmil and 450°C rise

= 0.0054 for answer in mm2 and 250°C rise
= 0.0044 for answer in mm2 and 450°C rise
c) For impedance grounded systems, the grounding conductor ampacity for the time allowed by the
lowest responsive relay shall be not less than the maximum current rating of the impedance and
the minimum size specified by the applicable regulations.
4.2. Grounding Conductor Routing

1) [R] For solidly grounded systems, the grounding conductor shall be routed as follows:
a) If the neutral grounding connection is made at a transformer or generator, or at an adjacent
neutral current transformer, the conductor shall be routed via the shortest path to ground. For
transformers, the shortest path is usually via the transformer ground pad.
b) [*] If the neutral ground connection is made in the transformer or generator switchgear, the
conductor shall be routed to ground via the switchgear ground bus. All connections in the
grounding path between the neutral point and the outdoor ground shall be accessible for visual
inspection. When specified, the conductor shall be insulated between the neutral and the
grounding point in the switchgear.
c) For grounded lighting systems having individual lighting transformers and panels, the transformer
neutral shall be grounded only at the transformer.
2) [R] For impedance grounded systems, the neutral impedance element shall be located as close to the
neutral as practicable. From the impedance element, the neutral grounding conductor should be
routed to the ground by the shortest path.
4.3. Grounding Conductor Insulation and Protection

1) [S] For solidly grounded systems, the neutral grounding conductor shall be insulated for at least line-
to-neutral voltage where the conductor passes along or in the enclosure of electrical equipment.
Specifically this applies to the following:
a) Runs from transformer, generator terminal chamber, or CT enclosure to transformer ground pad
or generator grounding point
b) Runs from transformer or generator neutrals to switchgear neutral bus or ground bus
c) Runs from switchgear neutral bus to switchgear ground bus
2) [S] For impedance grounded systems, the connection between neutral and impedance must be
insulated for at least line-to-neutral voltage. Where required by regional or national standards, the
connection shall be insulated for phase-to-phase voltage.
3) [I] Insulation color coding shall comply with requirements of the applicable regulations.
4) [R] Protective conduits for neutral grounding conductors, if used, shall be rigid aluminum or
nonmetallic conduit. Nonmetallic conduit shall be heavy-wall, rigid, polyvinyl chloride, or high
density polyethylene.

5. Enclosure Grounding
5.1. Wiring Systems
1) [S] Metal enclosures for wire and cable, such as conduits, cable trays, and raceways, shall be
grounded at their supply ends by connection to the switchgear or control center ground bus, when
such equipment is used; or by connection to the grounded metallic equipment enclosures when
switchracks are used. The wire and cable metal enclosures shall have metal connections to the
utilization equipment enclosures at their load end.
2) [S] The electrical continuity of metal enclosures, or wire and cable, shall be ensured between
terminals. Nonmetallic conduit sections or fittings shall not be used in metal conduit systems, unless
bonding is provided across such sections and fittings.
3) [S] Metallic armor, sheaths, and metallic insulation shielding of all cables shall be bonded together
and grounded at the cable's supply end by connection to the switchgear or control center ground bus,
when such equipment is used; or by connection to the grounded metal equipment enclosures when
switchracks are used. Exception: insulation shields of high-voltage motor feeders may be grounded
at only the motor end as a means of controlling switching surge voltages, provided that cable armor
and or conduit is grounded at both ends.
4) [S] Metallic armor and sheaths of multi-conductor cables shall be bonded and grounded in accordance
with the following:
a) Bonded together and grounded at each cable termination
b) Bonded together at each splice and bonded across each splice
c) Bonded together and to equipment metal enclosures at the load end
5) [R] Metallic insulation shielding in shielded multi-conductor cables shall be grounded at each
termination and shall be bonded to the cable metal sheath and armor (if any). If practicable, the
insulation shielding of cables with multiple splices shall also be grounded at each splice and bonded
to the cable metal sheath and armor (if any).
6) [R] Bonding and grounding methods for single-conductor cables having metallic armor, sheaths, or
insulation shielding must be engineered for the specific installation to avoid dangerous sheath, shield
voltages, or excessive heating due to circulating currents. Generally, single-conductor cables smaller
than 500 kCM (240 mm2) with all three phases in the same duct may be bonded and grounded the
same as multi-conductor cables. Armor, sheaths, and shielding of larger cables may require single-
point grounding with insulating joints between grounded sections.
5.2. Equipment
1) [S] Metal enclosures of fixed equipment operating above 1000 volts between conductors shall be
grounded by a connection to a ground in their immediate vicinity, in addition to the ground return
conductor.
2) [S] Metal enclosures of fixed equipment operating at 1000 volts or less between conductors and
supplied from ungrounded or high resistance grounded systems shall be grounded by one of the
conductor types specified in Section 6, Item (5).

3) [C] If supplied from solidly grounded systems, metal enclosures of fixed equipment operating at 1000
volts or less between conductors are considered grounded through their ground return path and do not
require further grounding.
4) [S] Main distribution equipment such as metal-clad and metal-enclosed switchgear, control centers,
and turnaround power centers shall be grounded by two separate connections from their ground
busses to grounds in the immediate vicinity. The metal enclosures of the individual devices on
switchracks shall be bonded to the switchrack frame, and the frame shall be grounded by two separate
connections to grounds in the immediate vicinity. Equipment grounds in substations of grounded
neutral systems shall be interconnected with the substation neutral ground.
5) [S] Metal enclosures of portable equipment shall be connected to a grounding conductor located
within the same cable assembly as the line conductors supplying the equipment as follows:
a) Grounding conductor shall be the same size as the line conductor.
b) Grounding conductor shall be connected to the receptacle enclosure through separate contacts in
the supply plug and receptacle, and shall be bonded to the plug enclosure.
c) Plug and receptacle shall be polarized and arranged so that the ground connection makes first and
breaks last.
Note: For enclosed or confined conductive work spaces, applicable regulations may place
specific restrictions on grounding and power supply for portable equipment used in these spaces.
6) [S] Metal enclosures such as fences, partitions, and grill work around equipment operating above
1000 volts between conductors shall be grounded by connections to grounds in their immediate
vicinity.
7) [S] Metal fences and grills enclosing the space under elevated substation buildings shall be grounded
by connections to ground in their immediate vicinity.
5.3. Ground Resistance

[S] Grounds for enclosures shall have a resistance to earth not exceeding 15 ohms.
6. Ground Returns
1) [O] [R] A ground return path is required for each circuit in the following:
a) Solidly grounded systems
b) Impedance grounded systems
2) [O] [R] If switchgear or control centers are used, the supply ends of ground return paths shall
terminate at the switchgear or control center ground bus.
3) [O] [R] If switchracks are used, the supply ends of ground return paths shall terminate by connection
to the metal enclosure of the individual control devices.
4) [O] [R] The load ends of ground return paths shall terminate by connection to a ground bus, when
available, or to the metal enclosure of the equipment served by the ground path's circuit.
5) [I] Ground return paths shall be one of the following:
a) Rigid metal conduit

b) Wire or cable conductors run as a separate conductor or as part of a cable assembly

c) Type MI cable copper sheaths
d) Copper wire cable armor or other armor types acceptable under the applicable regulations
e) Electrical metallic tubing, armor, or sheaths of metal-clad cable used in circuits not more than
150 ft (45 m) long and protected by overcurrent devices having a nominal rating of 20 amperes or
less. Length restrictions apply to solidly grounded and low resistance grounded systems.
f) Metal covered cable sheaths of circuits protected by ground fault relaying in solidly grounded and
low resistance grounded systems, provided that the sheath is capable of carrying the maximum
ground fault current without damage (to the sheath or cable) for the time allowed by the slowest
responsive relay
g) Metal-enclosed bus duct enclosures where bus duct length does not exceed 25 ft (7.5 m). Length
restrictions apply to solidly grounded and low resistance grounded systems.
h) [A] Ground return paths using a combination of the paths listed are acceptable, subject to
approval by the Owner's Engineer.
6) [O] [R] For solidly grounded and low-resistance grounded systems, the combined impedance of the
ground return path and the supply circuit line conductors shall be low enough to insure operation of
the circuit overcurrent protective device in less than 2 seconds on a single line-to-ground fault at the
load end of the circuit. An arc voltage of 40 volts in phase with the line-to-neutral source voltage
shall be assumed at the fault point.
7) For receptacle circuits, the impedance of the plug connected portable cord shall be included in the
combined impedance used to check operation of the protective device. A maximum cord length of
100 ft (30 m) shall be assumed.
Notes:
(1) For circuits protected by ground relaying, circuit lengths established by voltage drop limits in
normal operation will generally result in ground return path impedance low enough to meet these
requirements.
(2) For circuits with phase protection only, (not protected by ground relaying), normal circuit lengths
may result in return path impedance too high to insure proper operation of the circuit overcurrent
protective devices on ground faults.
6.1. Ground Return through Flexible Conduit

[O] [R] Bonding jumpers shall be installed around flexible conduit connections used on solidly grounded
and low resistance grounded systems whenever a conductor ground return is not provided within the
flexible conduit.
6.2. Conductor Ground Returns

1) [O] [R] Wire or cable conductors used as ground return paths in metallic or nonmetallic conduit
systems shall be run within the same conduit as the circuit line conductors. The ground return
conductors shall be jacketed, if not located within the line conductor assembly. Such conductors are
required with nonmetallic conduit systems. Generally, such conductors are not required with rigid
metal conduit systems, but may be used to increase maximum circuit length in rigid steel conduit
systems.

2) [*] [C] When specified, one or more conductors may serve as the common (main) ground return path
for a group of circuits in direct buried cable systems, in nonmetallic conduit duct banks, or above
ground cable raceways. In such cases, the following shall apply:
a) Main ground return conductors shall be run within the same cable trench or above ground cable
raceway as their line conductors.
b) Main ground return conductors shall be run within separate conduits in the duct bank.
c) It is preferred that common ground return conductors be tapped or connected to local ground bars
and individual conductors run to the equipment enclosures along the route of the circuit
conductors. Alternatively, the main ground return conductor may be looped and connected to
each equipment enclosure.
d) Main ground return conductors and their branch conductors shall be arranged to maintain
minimum spacing to their associated line conductors as much as possible.
e) If more than one main ground return conductor is used, the conductors may be bonded together
and a single conductor used for connection to equipment enclosures.
f) Main and branch ground return conductors shall be bare stranded, medium-hard-drawn copper,
with a minimum size of 2 AWG (35 mm2).
7. Overvoltage Protection for Power Systems

1) [R] Power systems with supply circuits or distribution circuits subject to over-voltages from lightning
or switching surges shall be protected against over-voltage by the use of lightning arresters and, if
needed, capacitors.
2) [R] Arrester ground connections on dry type transformers having sheet metal enclosures shall be
made by grounding conductors run in as direct a path as possible to the transformer grounding pad.
3) [R] The ground terminals of lightning arresters that are installed at the junction of insulated cables
and overhead spacer cables or open wire lines shall be grounded according to the following:
a) Metallic sheaths of multi-conductor cables and multiple-grounded metallic sheaths of single
conductor cables shall be connected to the lightning arrester grounding conductor.
b) Single point, grounded, metallic sheaths of single conductor cables shall be connected to the
lightning arrester ground terminals and the arrester shall be grounded through an isolating gap.
c) Metallic conduits shall be connected to the lightning arrester grounding conductor.
d) For situations not covered by Items a), b), or c) above, a ground return conductor within
nonmetallic sheathed multi-conductor cables shall be connected to the lightning arrester
grounding conductor.
e) For situations not covered by Items a), b), c), or d) above, a ground return conductor within the
nonmetallic duct carrying, nonmetallic sheathed cables shall be connected to the lightning arrester
grounding conductor.
f) Grounding conductors shall run in as straight and short a path as possible from arrester grounding
terminals to the grounding electrode.
g) Conductors on wood poles shall be covered from arrester terminals to below ground by
weatherproof jackets, insulation, or wood ground moldings.

8. Structure Lightning Protection

1) [I] Any structure within a zone of protection may be considered to be adequately shielded against
lightning so that further protection is not required.
2) [S] For structures that do not contain appreciable quantities of flammable and combustible material,
or are not part of process or offsite facilities, the zone of protection is as follows:
a) For 50 ft (15 m) heights and lower, the space under a cone with apex at the highest point of a
properly grounded metal structure, mast, wire, or air terminal with radius twice the height, if the
height does not exceed 25 ft (7.5 m), or radius equal to height, if the height does not exceed 50 ft
(15 m).
b) For heights above 50 ft (15 m), and alternatively for 50 ft (15 m) and lower, the space underneath
a rolling sphere. The space can be determined using the relationship in Item 3 below. Since
NFPA 780 Chapter 4 uses 150 ft (45 m) striking distance, 300, rather than 200, is used in the
relationship.
3) [S] For structures containing appreciable quantities of flammable and combustible materials, or which
are part of process or offsite facilities, the zone of protection is as follows:
The space underneath a rolling sphere as determined by the relationship:
d = h 1 (200 − h 1 ) − h 2 (200 − h 2 )
Where:
D = horizontal distance protected
h1 = height of the properly grounded structure, mast, wire, or air terminal
h2 = height of structure or equipment to be protected
Striking distance is 100 ft (30 m) as specified in NFPA 780 Chapter 7.

4) [C] Metallic structures for storage of liquids that can produce flammable vapors, or for storage of
flammable gases that are electrically continuous that are tightly sealed to prevent the escape of
liquids, vapors, or gases, and have thickness not less than 3/ 16 in. (4.8 mm) sheet steel, are inherently
self-protecting and need no additional lightning protection. For the purposes of this paragraph, fixed
and floating roof atmospheric storage tanks, and any vessels or pressure storage spheres equipped
with pressure relief valves discharging to atmosphere shall not be considered tightly sealed and shall
meet the requirements of Table 1.
5) [S] Important structures not within a zone of protection (i.e., not shielded) or not inherently self-
protecting shall be protected against damage from lightning. The following structures are considered
important:
a) Structures that are normally occupied by personnel
b) Structures that contain appreciable quantities of flammable and combustible materials
c) Structures which, if seriously damaged, could result in a major loss either in the structure itself or
from the effect on other facilities. Most substations are in this category.
d) For structures not covered above, risk assessment procedures are provided in regional and
national standards, and shall be used to determine if lightning protection is required.

6) [S] Important structures that are not within a zone of protection (i.e., shielded) or are not inherently
self-protective shall be protected as follows:
Structure Lightning Protection Method
a. Metallic Structures: Ground as required by Table 1

(includes storage tanks, vessels, and buildings with
metallic frames or metallic siding)
b. Nonmetallic Structures: Per NFPA 780 or an equivalent national
(includes buildings with nonmetallic frames and standard
siding)
7) [S] Lightning protection requirements for metallic structures shall be per Table 1.
Table 1: Lightning Protection
Structure Foundation Type Grounding Requirements
A. 1. Tank bottom resting on nonreinforced Ground at perimeter spacing intervals

Storage Tanks concrete pad not exceeding 100 ft (30 m) with a
minimum of two ground connections
located at opposite extremities
2. Tank bottom resting on any of the None (adequate grounding).
following types of pad construction:
Note: If an impermeable membrane is
reinforced concrete; ringwall
used under the tank bottom, the
construction; asphalt, oiled sand, or
requirements of Item A.1 shall be met.
crushed stone pads
B. 1. Column or skirt supports resting on a None
Vessels reinforced concrete foundation that
(adequate grounding)
or meets all of the following:
Pressure Storage Spheres
a) The below grade footing contains at
least 20 linear feet (6 m) of
reinforcing bar that is not less than
1
/ 2 in. (12 mm) diameter.
b) The piers or pedestal includes
vertical bars or lapped dowels that
continue into the footing.
c) The anchor bolts are embedded in
the concrete and have metallic
contact with the vessel.
2. Supports resting on foundations not Ground at perimeter spacing intervals
meeting all of the above (Item 1.) not exceeding 100 ft (30 m) with a
minimum of two ground connections
located at opposite extremities
C. Construction with metallic frames or Ground at perimeter spacing intervals
Structure metallic siding not exceeding 100 ft (30 m) with a
or minimum of two ground connections
Building located at opposite extremities

8) [S] Bonding of metallic structures is as follows:

a) Floating roof tanks—Bonding between roof and shell shall be provided by the tank vendor for
designs requiring it (e.g., pantograph type). Provisions shall include the requirements for both
primary and secondary seals.
b) Buildings—All metallic parts forming the roof and main framework shall be bonded to each
other.
c) Metallic bodies of considerable size located inside of metallic structures and within 6 ft (2 m) of
the structure roof or frame—The metallic body shall be bonded to the structure, if not inherently
bonded.
9) [S] Cables connecting metallic structures to grounding electrodes shall be routed in as straight and
direct a path as possible. Spacing of approximately 2 ft (600 mm) shall be maintained, where
possible, between artificial grounding electrodes and concrete or masonry foundations.
10) [S] Grounds shall be buried conductors, concrete encased electrodes, artificial grounding electrodes,
or combinations. Resistance to earth shall not exceed 15 ohms.
8.1. Secondary Effects of Lightning

1) [R] The basic lightning protection system provides the required low impedance metal path required to
intercept, conduct, and dissipate the main lightning discharge of strikes on the protected structure. It
does not assure safety for all equipment and circuits, particularly electronic systems using solid state
components, from the possible secondary effects of lightning strikes on the structure, the adjacent
area, or on interconnected structures.
[*] Additional provisions may be required to protect against inductive and resistive overvoltage that
may be produced on circuits and at equipment by the main discharge current or by currents entering
on utility services, and on control, communication, and data transmission circuits. Regional and
national standards contain information covering assessment and recommendations for coping with the
secondary effects.
9. Bonding at Tank Truck, Tank Car, or Container Loading

Stations
1) [S] Bonding is required only when all of the following loading conditions exist:
a) Loading is through open domes or into open drums, caps, cylinders, or similar metallic
containers.
b) The product loaded: (1) has a closed cup flash point below 100°F (37.8°C); (2) is handled within
15°F (8°C) of or above its flash point, or (3) is switch loaded into a tank truck or tank car
previously carrying material with a closed cup flash point below 100°F (37.8°C).
c) The product is classified as a static electrical charge accumulator.
2) [C] Bonding is not required around flexible metallic joints or swivel joints, or when loading
conditions are as follows:
a) If tank car or tank truck loading is through a closed system

b) If container filling is through a closed system, or if the filling nozzle is in electrical contact with
the container and will remain so throughout the filling operation
3) [S] Tank truck bonding conductors, when required, shall be provided at each loading or unloading
position as follows:
a) One end of the conductor shall be permanently connected directly to the fill stem or to other
points on the piping or steel loading rack that are electrically connected to the fill stem, (either
inherently or through bonding connections).
b) A battery type clip (or equivalent) shall be connected to the other end of the bonding conductor.
The conductor shall be long enough to permit attachment of the clip to the truck at a point that is
in metallic contact with the cargo tank being loaded or unloaded.
c) Bonding conductor shall be a 6 AWG (16 mm2) single conductor, rope-stranded, copper cable.
The cable shall have a thermosetting jacket for mechanical protection of the conductor.
4) [S] Tank car bonding, when required, shall be as follows:
a) Insulating rail joints shall be provided to isolate from the main track, the track section upon which
cars will stand while being loaded or unloaded. The purpose of these joints is to isolate stray
currents resulting from signal or power systems on the main track.
b) Joints shall be located to avoid being bridged by standing cars not loading or unloading.
c) Bond around all rail joints in the track section upon which cars will stand while being loaded or
unloaded.
d) Bond both rails of the track section upon which cars will stand while being loaded or unloaded to
the loading rack steel structure. If not inherently bonded together, the loading and unloading
piping shall be bonded to the loading rack steel structure.
5) [S] Container bonding, when required, shall keep the filling nozzle and container at the same
electrical potential to prevent a possible static spark in the area of a flammable mixture. Bonding
shall be as follows:
a) When the filling nozzle may not be or remain in electrical contact with the container, the
container shall rest on a metal base plate while being filled. This base plate shall be bonded to the
supply piping.
b) If the filling nozzle is inherently bonded to the supply piping, such as by the use of metallic hose
or pipe, no additional bonding to that specified in 5a) above is required.
c) If the filling nozzle is not inherently bonded to the supply piping, such as when a nonmetallic
hose or pipe is used, an additional bond shall be provided between the nozzle and supply piping.
d) All metallic parts of the fill assembly shall form a continuous electrically conductive path
downstream from the point of bonding on the supply piping.
10. Protection at Marine Terminal Loading Stations

1) [C] Bonding is not required between tankers or barges and the marine pier.
2) [S] Electrically insulated flanges are required to electrically isolate on-board (tanker or barge) piping
from the pier piping for the following:
a) At cathodically protected marine terminals

b) Where marine loading arms or electrically bonded oil cargo hoses are used
c) For loading and unloading products having closed cup flash points below 100°F (37.8°C), or
which are at a temperature above or within 15°F (8°C) of their flash point

Record of Change
Version 1.0.0 Date: 01/02
Location Action Description
Initial Publish.

Global Practice version number and format updated to comply with new
process; however, original publish date remains, and no content was
modified.

References Added IEC Reference to IEC for non-USA locations.
Section 3.1 Rearranged Former Item (c) moved to main body of text. It should not have been
part of the numbered list.
Section 5.1, Text Added Exception for motor surge protection technique described in ANSI/IEEE
Item (3) C62.21.
Section 8, Reworded Wording changes in "grounding requirements" column for improved
Table 1 comprehension.
Various Paragraph To comply with 2008 version of NFPA 780.
Reference
Number
Changed
All Global Modifications To standardize the format of the Global Practices and to meet other
Practices requirements, the following changes have been implemented:
"For ExxonMobil Use Only" has been replaced with "For Company Use
Only."
A copyright waiver has been added in the first page Footer.
The definition of asterisks in the Scope has been deleted. The asterisk is
now defined in the Purpose Code attachment and is used within brackets
as other Purpose Codes.
Multiple paragraphs within a Section have been numbered.
The standard text for Required References has been modified.
The standard text for Additional Requirements has been modified.
The [S] Purpose Code has been modified.
The following Purpose Codes have been added:
[*] for additional information or decision required of Owner's
Engineer.
[A] for approval requirements before beginning work or finalizing
design.

Attachment: Purpose Code Definitions

Code Description
* Assigned to paragraphs that require the Owner's Engineer to provide additional information or
make a decision.
A Assigned to paragraphs that require approval from the Owner's Engineer before the work may
proceed or the design is finalized.
C Assigned to paragraphs whose primary purpose is reduced costs. Reduced cost in this context
refers to initial investment cost and does not include life cycle cost considerations. Life cycle
cost considerations are captured under reliability, maintainability, or operability purpose codes.
E Assigned to paragraphs whose primary purpose is driven by environmental considerations.
Environmental considerations typically include specifications intended to protect against
emissions/leakage to the air, water, and/or soil. Deviations from the specifications contained
in such paragraphs require formal review and approval according to local environmental
policy.
I Assigned to paragraphs that provide only clarifying information, such as Scope statements,
definitions of terms, etc.
M Assigned to paragraphs whose primary purpose is to provide for maintainability of equipment
or systems. Maintainability provisions are those that facilitate the performance of maintenance
on equipment/systems either during downtimes or during onstream operations.
O Assigned to paragraphs whose primary purpose is to assure operability of equipment or
systems. Operability is the ability of the equipment/system to perform satisfactorily even
though conditions are off-design, such as during start-ups, process swings, subcomponent
malfunction, etc.
R Assigned to paragraphs whose primary purpose is to improve or assure the reliability of
equipment or systems. Reliability is a measure of the ability of equipment/systems to operate
without malfunction or failure between planned maintenance interventions.
S Assigned to paragraphs containing specifications/guidance where the primary purpose is the
avoidance of incidents impacting personnel safety, operational safety, and the public in general
and/or involving responses to emergency situations. Any deviation from the specifications
contained in such designated paragraphs requires formal review and approval according to
local safety policy.
Personnel Safety: Refers to incident-related personnel injuries or illness, e.g., burns, cuts,
abrasions, inhalation of or exposure to dangerous substances, etc., that
could result in medical treatment, restricted work, lost-time incidents, or
fatalities.
Operational Refers to the prevention and control of process releases, fires, and/or
Safety: explosions that could result in damage to equipment, process disruption,
or personnel injury or illness.

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GP 16-04-01 Grounding and Overvoltage Protection January 2008

Grounding and Overvoltage

Refining/Chemicals For Company Use Only Version 1.1.0

Page 1 of 21 ExxonMobil Development Company

1. Required References ............................................................................................ 4

3. Bonding and Grounding Materials and Methods ............................................... 6

8. Structure Lightning Protection .......................................................................... 15

10. Protection at Marine Terminal Loading Stations .............................................. 18

RFCH For Company Use Only Version 1.1.0

Page 2 of 21 ExxonMobil Development Company

Record of Change ....................................................................................................... 20

Attachment: Purpose Code Definitions.................................................................... 21

RFCH For Company Use Only Version 1.1.0

Page 3 of 21 ExxonMobil Development Company

1.1. API–American Petroleum Institute

1.2. IEC–International Electrotechnical Commission

1.3. IEEE–Institute of Electrical and Electronics Engineers

1.4. NFPA–National Fire Protection Association

RFCH For Company Use Only Version 1.1.0

Page 4 of 21 ExxonMobil Development Company

RFCH For Company Use Only Version 1.1.0

Page 5 of 21 ExxonMobil Development Company

Term [I] Description

3. Bonding and Grounding Materials and Methods

3.1. Bonding and Grounding Conductors

RFCH For Company Use Only Version 1.1.0

Page 6 of 21 ExxonMobil Development Company

3.2. Bonding and Grounding Connections

RFCH For Company Use Only Version 1.1.0

Page 7 of 21 ExxonMobil Development Company

3.4. Substation and Generating Station Grounds

RFCH For Company Use Only Version 1.1.0

Page 8 of 21 ExxonMobil Development Company

3.5. Grounding Buses

4. System Neutral Grounds

RFCH For Company Use Only Version 1.1.0

Page 9 of 21 ExxonMobil Development Company

= 0.0087 for answer in kcmil and 450°C rise

4.2. Grounding Conductor Routing

4.3. Grounding Conductor Insulation and Protection

RFCH For Company Use Only Version 1.1.0

Page 10 of 21 ExxonMobil Development Company

RFCH For Company Use Only Version 1.1.0

Page 11 of 21 ExxonMobil Development Company

5.3. Ground Resistance

RFCH For Company Use Only Version 1.1.0

Page 12 of 21 ExxonMobil Development Company

b) Wire or cable conductors run as a separate conductor or as part of a cable assembly

6.1. Ground Return through Flexible Conduit

6.2. Conductor Ground Returns

RFCH For Company Use Only Version 1.1.0

Page 13 of 21 ExxonMobil Development Company

7. Overvoltage Protection for Power Systems

RFCH For Company Use Only Version 1.1.0

Page 14 of 21 ExxonMobil Development Company

8. Structure Lightning Protection

Striking distance is 100 ft (30 m) as specified in NFPA 780 Chapter 7.

RFCH For Company Use Only Version 1.1.0

Page 15 of 21 ExxonMobil Development Company

Structure Lightning Protection Method

a. Metallic Structures: Ground as required by Table 1

Table 1: Lightning Protection

Structure Foundation Type Grounding Requirements

A. 1. Tank bottom resting on nonreinforced Ground at perimeter spacing intervals