ECS 06-0030 Substation Earthing Design and Construction - Guidance Notes For Developers (33kV London Routes) PDF

Document Number: ECS 06-0030 Version: 1.
ENGINEERING CONSTRUCTION STANDARD
ECS 06-0030
SUBSTATION EARTHING DESIGN AND CONSTRUCTION GUIDANCE NOTES FOR DEVELOPERS (33KV LONDON ROUTES)
Network(s): EPN, LPN, SPN
Summary:
This document provides guidance for developers on the design and construction of earthing systems for the 33kV substations associated with London 33kV distribution network.
Originator:
Stephen Tucker
Date:
12/11/2012
Approved By:
Steve Mockford
Approved Date:
07/12/2012
Review Date:
12/11/2017
This document forms part of the Companys Integrated Business System and its requirements are mandatory throughout UK Power Networks. Departure from these requirements may only be taken with the written approval of the Director of Asset Management. If you have any queries about this document please contact the originator of the current issue.
Document History
(The document history notes below are intended as a guide only and may not cover all of the changes. If you wish to make use of this document it should be read in full.)
Version 0.1 1.0
Date 28/08/2012 12/11/2012
Details Original by Earthing Solutions (not issued) Document revised for publishing
Originator Rob Weller (Earthing Solutions) Stephen Tucker
THIS IS AN UNCONTROLLED DOCUMENT, THE READER MUST CONFIRM ITS VALIDITY BEFORE USE
Date: 12/11/2012
Substation Earthing Design and Construction Guidance Notes for Developers (33kV London Routes)
Document Number: ECS 06-0030 Version: 1.0 Date: 12/11/2012
Contents
1 2 3 4 5 6 6.1 6.2 7 7.1 7.2 8 8.1 8.1.1 8.1.2 8.2 8.2.1 8.2.2 9 9.1 9.2 9.2.1 9.2.2 9.3 9.4 9.5 9.6 9.6.1 9.6.2 9.6.3 9.7 9.7.1 9.7.2 9.7.3 9.7.4 Introduction ................................................................................................................4 Scope ..........................................................................................................................4 References ..................................................................................................................5 Abbreviations .............................................................................................................5 Earthing Standards ....................................................................................................6 Earthing Overview and Definitions ...........................................................................7 Overview ..................................................................................................................... 7 Basic Principles ........................................................................................................... 9 General Requirements for Customer Connections at 33kV .................................10 Shock Risk Outside the Building ............................................................................... 10 Shock Risk Inside the Building .................................................................................. 11 Specific Earthing/Bonding Requirements for Customer Connections at 33kV .12 UK Power Networks Substation ............................................................................... 12 General Philosophy ................................................................................................... 12 Requirements for UK Power Networks Switchroom Earthing ................................... 12 Customer Installation ................................................................................................ 13 Earth Resistance ....................................................................................................... 13 Design Requirements ................................................................................................ 13 Design Guidelines ....................................................................................................15 Design Parameters ................................................................................................... 15 Conductor Sizes ........................................................................................................ 16 UK Power Networks Substation ................................................................................ 16 Customer Switchrooms and Installations .................................................................. 16 Lightning Electrode Systems ..................................................................................... 17 Electrode Location and Caveats ............................................................................... 17 Segregated or Combined Earthing System ............................................................... 18 Use of Rebar/Piles .................................................................................................... 18 Sheet Steel Piles ....................................................................................................... 18 Horizontal Steel Reinforced Foundations .................................................................. 19 Vertical Steel Reinforced Ground Columns .............................................................. 19 Joints and Connections ............................................................................................. 19 General ..................................................................................................................... 19 Copper to Copper Connections ................................................................................. 20 Copper to Earth Pins ................................................................................................. 20 Electrode Test Points ................................................................................................ 20
UK Power Networks 2012 All rights reserved
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9.7.5 9.7.6 9.7.7 9.7.8 10
Copper to Equipment Earths ..................................................................................... 21 Aluminium to Aluminium Joints ................................................................................. 22 Aluminium to Equipment Earths ................................................................................ 22 Aluminium to Copper Joints ...................................................................................... 22 Typical Designs ........................................................................................................23
Appendix A Design Checklist ..........................................................................................25 Appendix B Drawings .......................................................................................................26
Figures
Figure 6-1 Illustration of Touch, Step and Transfer Potentials ..............................................8 Figure 9-1 Typical Rebar Connections ...............................................................................19 Figure 9-2 Test Point ..........................................................................................................21 Figure 10-1 Overview Diagram Showing Common Mesh Arrangement (further detail is given in Appendix B) ............................................................................................24
Tables
Table 6-1 Statistically Safe Step/Touch Potentials ...............................................................8 Table 9-1 Design Parameters .............................................................................................15 Table 9-2 Low Fault Level Earth Conductor Sizes (12.5kA for 3 seconds) ........................16 Table 9-3 Maximum Current Rating of Earthing Rods ........................................................17 Table 9-4 Bolt sizes and Torques for Use on Aluminium ....................................................22
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Introduction
This document provides guidance for developers on the design and construction of earthing systems for the 33kV substations associated with London 33kV distribution network. This document is intended to assist designers/planners/developers working on new build (brownfield) or developing existing buildings along the North London 33kV routes between Finsbury Market and Back Hill. It is assumed that the buildings will be supplied at 33kV derived from one or more of the Red, Green, Blue or Yellow routes . The earthing needs special consideration because the supply arrangements are unusual. In particular, buildings are generally supplied from a specific cable or cables and do not obtain any parallel earth benefits from adjacent buildings or substations. The cables are plastic/triplex type and the only electrode connection is locally and at the remote cable ends. This document describes the requirements for electrical earthing of a customers installation, but does not go into detail regarding supply arrangements, protection, cable sizing etc. These issues are beyond the scope of this document. The term Customer includes any end-user connected to UK Power Networks distribution system. The reason for this document is to assist designers/developers to design and construct an earthing system that is fit for a building supplied at 33kV. UK Power Networks has noted that some developers have proposed earthing systems for their buildings that are not appropriate or adequate for a building that contains 33kV equipment. In some situations, poor design can lead to shock risk (to public both inside and outside the building), and fire risk or structural damage (due to overheating earth conductors and/or rebar). The customers own installation will be designed and built by the developer with refere nce 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.
Scope
This document applies to the to UK Power Networks and Customer substations associated with the North London 33kV routes between Finsbury Market and Back Hill. The information this document contains is specific to the North London routes and should not be used for other purposes.
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References
EAS 06-0011 Earthing Materials EDS 06-0012 Earthing Design Criteria EDS 06-0013 Grid and Primary Substation Earthing Design EDS 06-0017 Customer Installation Earthing Design ECS 06-0022 Grid and Primary Substation Earthing Construction EDS 07-0105 Grid and Primary Substation Civil Design Standards EDS 07-0102 Secondary Substation Civil Design Standards ENA TS 41-24 Guidelines for the Design, Installation, Testing and Maintenance of Main Earthing Systems in Substations ENA ER G12 Requirements for the Application of Protective Multiple Earthing to Low Voltage Networks ENA ER S34 A Guide for Assessing the Rise of Earth Potential at Substation Sites ENA ER S36 Procedure to Identify and Record HOT Substations BS EN 50522:2010 Earthing of Power Installations Exceeding 1kV AC BS 7354:1990 Design of High Voltage Open Terminal Substations BS 7430:2012 Code of Practice for Protective Earthing of Electrical Installations BS 7671:2008 incorporating Amendment No 1: 2011 Requirements for Electrical Installations (IEE Wiring Regulations Seventeenth Edition) Electricity Supply Quality and Continuity Regulations 2002
4
Term DNO EHV ENA EPR HV LV ROEP
Abbreviations
Definition Distribution Network Operator Extra High Voltage (usually refers to voltages above 11kV) Energy Networks Association Earth Potential Rise High Voltage (greater than 1000V) Low Voltage (less than 1000V) Rise of Earth Potential
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Earthing Standards
ENA Technical Standard (ENA TS) 41-24 provides Guidelines for the Design, Installation, Testing and Maintenance of Main Earthing Systems in Substations. Its scope includes all equipment within HV and EHV substations. It is adopted by all Distribution Network Operators (DNOs) in the UK, is referred to in the UK Distribution Code and is written into DNOs own standards. ENA TS 41-24 provides guidelines that are necessary to ensure the safety of DNO staff as well as members of the public. Given that 33kV customers will effectively establish their own substations (typically in the form of 33/11kV or 33/0.4kV transformation), it is the view of UK Power Networks that the general requirements of ENA TS 41-24 shall apply to all customer installations, unless the developer can provide good reason for deviation from these standards. In most cases, the close proximity of customer substations to members of the public and/or staff in and around the buildings means that ENA TS 41-24 should be rigorously applied. Developers will be expected to demonstrate compliance with ENA TS 41-24 and UK Power Networks own standards, or to provide design calculations to demonstrate why an alternative approach has been considered. UK Power Networks earthing design standards derive from the industry standard documents including ENA TS 41-24 and ENA ER S34 and S36. UK Power Networks current standard for customer installations is EDS 06-0017, and for primary substation design/construction are EDS 06-0013 and ECS 06-0022 respectively. Relevant information from those standards is included in this document. It is assumed also that the developers will wish to consult ENA ER S34, ENA ER S36, BS EN 50522, BS 7430, BS 7671 and BS 7354.
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6
6.1
Earthing Overview and Definitions

Overview
In short, earthing is necessary to ensure safety in the event of a fault. The terms earthing and bonding are often used interchangeably. In general terms, the installation shall be connected to the general mass of earth via an electrode system that provides a suitably low earth resistance value. In the event of an earth fault, the earth resistance shall be low enough to limit the earth potential rise (EPR) to safe values and to operate the earth-fault protection. It will also be capable of carrying, without damage, the fault current that will flow until the system protection can operate. ENA TS 41-24 describes the function of an earthing system: Every substation shall be provided with an earthing installation designed so that in both normal and abnormal conditions there is no danger to persons arising from earth potential in any place to which they have legitimate access. The installation shall be able to pass the maximum current from any fault point back to the system neutral without establishing dangerous potential gradients in the ground or dangerous potential drops between parts of the substation with which a person may be in simultaneous contact. Bonding refers to the connections between metallic parts of the system. Bonding serves to establish an equipotential zone by preventing significant (dangerous) voltage differences appearing between metallic items of equipment and/or structures. ENA TS 41-24 notes: During the passage of earth-fault current a substation earth electrode is subjected to a potential rise and potential gradients develop in the surrounding ground area. These gradients are highest adjacent to the substation earth electrode. The actual ground potential reduces to zero or true earth potential at some distance from the substation earth electrode. This distance forms a physical separation which, if it is not bridged by a metallic connection, renders any person in the high potential area immune from the possibility of simultaneous contact with zero potential. However, local potential gradients, if great enough, can present a hazard to persons and thus effective measures to limit them shall be incorporated in the design. It is usual in a substation environment to extend bonding to include below ground grading conductors and/or operator platforms. In this way, an operatives hands and feet will be at a similar potential in all circumstances. Below-ground (or in-concrete) conductors are usually necessary to limit step and touch potentials to safe values. ENA TS 41-24 defines touch, step and transfer potentials as follows: Transfer Potential A metallic object having length - a fence, a pipe, a cable sheath or a cable core, for example, may be located so as to bridge the physical separation referred to above. It can collect a remote voltage reference and introduce this into the substation area. By such means zero earth potential or some low value of earth potential can be 'transferred' into an area of high potential rise or vice-versa.
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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.
Voltage gradient across site Touch Potential (UST)
Touch Potential (UST) Earth Potential Rise, EPR (UE)
Step Potential (USS)
Transfer Potential (UTST)
Remote Touch Potential (UTSTE)

(transferred source voltage for touching if sheath is earthed at remote end as well)
(transferred Cable sheath source voltage for earthed at touching if sheath substation not earthed at remote end)
Earthing Electrode
S1
S2
S3
Earthing Electrode
Earthing Electrode
Cables having a continuous metal sheath insulated throughout but exposed at both ends
Potential grading earthing electrodes (eg ring earth electrodes), each connected to the earth electrode
Figure 6-1 Illustration of Touch, Step and Transfer Potentials
The statistically safe step and touch voltages are given in ENA TS 41-24, and relate to the time that a fault will be present on the system (protection clearance time). The acceptable values are reproduced in Table 6-1.
Table 6-1 Statistically Safe Step/Touch Potentials Protection Clearance Time 0.7 seconds 1 second Safe Touch Voltage (dry concrete) 250V 200V Safe Step Voltage (dry concrete) 830V 640V
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6.2
Basic Principles
During an earth fault, the potential of the earthing system rises until the protection can operate to clear the fault. The magnitude of the voltage rise (EPR) is determined by the resistance of the local electrode system (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 Ohms Law which gives the EPR: EPR = Earth Fault Level (A) x Igr% x Earth Resistance, Rb () The maximum value of Igr% has been calculated to be 30% and therefore this value shall be used in any design calculations (i.e. a maximum ground fault current of 810 amps refer to Section 9 for typical design parameters). In designing a customers electrode system, the value Rb shall be low enough to limit EPR to safe values. The value of Rb will reduce when the customers system is connected to the UK Power Networks system, but this parallel contribution cannot be used as the customers electrode and shall be viewed only as fortuitous. This is because: 1. The zones of influence of UK Power Networks earthing system and the customer earthing system will overlap, meaning that the contribution will be less than expected from a simple parallel resistances calculation, and 2. The UK Power Networks earthing system may be affected by maintenance or faults on the network. In short, the customers system shall be able to operate safely should UK Power Networks local earthing system become disconnected or otherwise compromised. In rare situations (e.g. a building with a very small footprint), if it is not possible to achieve a safe design without reliance on UK Power Networks earth written permission to rely on UK Power Networks system shall be sought from UK Power Networks. In many cases this will require significant lengths of duplicate earth conductor to be laid alongside the existing cable routes at the developers expense.
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General Requirements for Customer Connections at 33kV
It is generally necessary to apply substation design techniques to buildings housing 33kV/11kV or 33kV/0.4kV transformation. The substation boundary is normally considered to be the building perimeter, or beyond if there is metallic connection to adjacent buildings. Terms used in this document are defined in ENA TS 41-24 and the ESQC Regulations. The most general, and overriding requirement is that the installation shall be designed to prevent danger. This falls into two areas: Prevention of shock. Prevention of fire/thermal damage. Shock is described below. For fire/damage prevention, in the context of earthing systems, it is necessary for the designer to ensure that all conductors are adequately sized for the current that they will carry in all foreseeable fault conditions. Also, it is necessary to ensure that significant stray current will not flow in parts of the building stru cture, or other services, that could lead to damage. This is best prevented by the installation of dedicated low impedance bonds in strategic locations to safely convey the majority of fault current. Any electrode system that serves to reduce the overall resistance of the building earth shall be sized to cope with the maximum earth fault level (that it will see locally). It is not sufficient to rely on lightning protection systems, or beam lintel rebar etc. to carry such high fault currents since these can overheat (overheating rebar can split concrete piles etc.). Shock and thermal damage risks can be minimised by installing a dedicated and low resistance copper earth grid underneath the footprint of the building, and bonding all items of equipment to it. Typical designs are described in Section 10, although other methods are not precluded. 7.1 Shock Risk Outside the Building
The building that contains the 33kV equipment can theoretically rise in potential during a fault. It can cause a shock risk to public if the building is (or could become) metal clad or otherwise has accessible exposed metallic parts (e.g. handrails). For this reason it shall usually have a perimeter grading electrode installed in the soil around the building (i.e. a loop of conductor buried approx. 0.5m to 1m away from the building, and connected to the main earth terminal). The absence of such grading electrodes means that the full EPR could appear as a touch potential risk to those outside the building, whereas their presence will reduce the touch voltage to a smaller percentage of the EPR. The developer will be expected to demonstrate this, or other measures to prevent danger to the public. For example, UK Power Networks substations will often have an external (separately earthed) fence to prevent contact, or will be of insulated construction. A perimeter tape electrode is recommended, where practicable. A typical design using such a perimeter electrode is described in Section 10. Where perimeter tape electrodes are provided it is usually beneficial to site the main rod electrodes off this. In such cases there is little benefit in putting additional rod electrodes inside the footprint of building as they will contribute little other than to increase the resilience of the system. If it is not practicable to install a ring of copper tape around or under the building, the alternative solution is to install a surface laid ring inside the perimeter of the building, and to drive earth rods into the soil at regular intervals (at spacings less than half their depth of
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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 DNOs LV network (transfer potential risk). 7.2 Shock Risk Inside the Building
This is usually managed by equipotential bonding between structures and plant to ensure that all are at a similar potential. In theory, provided no remote references are introduced, a high EPR will introduce little or no risk to building occupants if the building structure acts as a Faraday 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.
Optimal spacing requires a consideration of EPR and detailed calculation / modelling. The rule of thumb quoted above will work in most situations. 2 An enclosure formed by conducting material or by a mesh of such material.
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Specific Earthing/Bonding Requirements for Customer Connections at 33kV
Earthing system requirements fall into two areas: Requirements for UK Power Networks substation. Requirements for the Customer installation. 8.1 8.1.1 UK Power Networks Substation General Philosophy
Buildings supplied at 33kV will typically have a UK Power Networks 33kV substation that houses the UK Power Networks circuit breakers and metering/telemetry/protection equipment. The earthing arrangement for the substation will be specified by UK Power Networks, and is designed to limit the earth potential rise (EPR) and step/touch potentials to acceptable and safe levels within that substation. UK Power Networks earthing system will not rely on a connection to the customers earthing system to achieve a satisfactory earth resistance value, but will normally be connected to the customers system after installation to improve security. In most cases UK Power Networks will install an external earth electrode, laid alongside the supply cables, to provide an earth connection for the substation equipment. The customer is not permitted to rely on a contribution from UK Power Networks earth in order to achieve a satisfactory resistance value see next section. Standard designs have been produced for UK Power Networks substations including new build developments as well as alteration of existing sites. An overview of the standard designs is provided in Section 8.1.2. The standard design drawings are included in EDS 07-0105 (grid and primary) and EDS 07-0102 (secondary). 8.1.2 Requirements for UK Power Networks Switchroom Earthing
The UK Power Networks switchroom earthing system shall: Be Specified by UK Power Networks according to a standard design, if applicable. Provide a local earth electrode system or remote earthwire connection sufficient to achieve an EPR less than 430V (COLD site) wherever practicable. Be Independent of the customers earth but generally combined after commissioning. Two earth terminals or connection points will be provided for connection to the customers system. Limit step and touch potentials to safe values inside the substation. Comply with UK Power Networks standards EDS 06-0013 and ECS 06-0022. Use conductors rated for fault current of 12.5kA/3 second as per ENA TS 41-24.
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8.2 8.2.1
Customer Installation Earth Resistance
It is assumed that developers will wish to design an earthing system that renders the site COLD (EPR<430V). Note that the terms COLD and HOT do not relate to safety, and it should not be implied that a COLD site is necessarily SAFE in terms of step/touch potentials. For a COLD site it is usual for the LV earths to be combined with the HV earths. In any case it is unlikely to be practicable to establish a segregated HV and LV earthing system in the same building. This document does not include HOT site design. A HOT site introduces complications (such as the need to provide isolation on all incoming telecoms circuits, pipework, etc) which shall be discussed with UK Power Networks. It also introduces transfer potential issues. It is assumed that all buildings supplied at 33kV do not receive duplicate or back-up supplies from the 11kV or LV networks. These additional services will introduce a remote earth reference which should only be connected to the 33kV earthing system or introduced into the building with the support of specialist advice. It has been calculated that a customers installation will be COLD if an earth resistance value of 0.5 can be achieved. However, a designer/developer might wish to aim for a lower value of 0.3. At this lower value the EPR is unlikely to exceed 250 volts, and thus touch voltages will be within the limit given in Table 6-1 if protection clearance time does not exceed 0.7 seconds. The requirements for grading electrodes etc. are less onerous as even 100% of the EPR appearing as a touch voltage will be acceptable. If it is considered that 0.3 is not achievable then an appropriate design will be required (as is usual) to ensure that step/touch voltages are an appropriate fraction of the EPR. In some cases the lower figure of 0.3 can only be achieved by combining the UK Power Networks/customer earths. If it is necessary for the customer installation to rely on UK Power Networks earth system for safety this shall be discussed with UK Power Networks or their agents (refer to the final paragraph of Section 8.2.2). This will not be accepted as a substitute for good design where other practicable alternatives exist. 8.2.2 Design Requirements
A customers earthing systems shall: Consist of main bonding conductors connecting together all 33kV plant, with bolted connections and duplicate connections to each item of plant. Employ measures to control touch/step potentials around those items of plant. Typically the rebar in plant rooms will be welded around the perimeter and bonded at two points to the main bonding conductors. (Appendix B shows typical connections) Employ measures to control step/touch voltages elsewhere in and around the building (in particular around the outer perimeter of the building if metallic parts of the structure are or could become exposed). Refer to previous section 8.2.1 for conditions that shall be satisfied if this requirement is to be relaxed. Provide sufficiently low earth resistance to make the site COLD for all local and remote (source substation) faults. In general terms, for buildings connected to the London Routes, this can be achieved with a local earth resistance value of 0.5 (measured
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before connection to UK Power Networks earthing system). A HOT site design will not be acceptable unless all associated risks can be mitigated against. Be adequate to carry a fault current of 12.5kA for 3 seconds in substation areas, and 2,700A elsewhere (refer to Table 9-1). Make provision for connection to UK Power Networks earthing system by two 25 x 4mm copper tapes or equivalent. The customers earthing system shall be designed to operate independently of UK Power Networks earthing system. The two systems shall be interconnected before commissioning but it shall not be assumed that this will result in a significant reduction in earth resistance for the reasons given in Section 6.2 , namely: The areas of influence of the two systems will overlap to some degree, meaning that the resultant overall earth resistance will not be as low as a parallel resistances calculation might suggest. Neither system shall be dependent on the other systems earth connection. The integrity of UK Power Networks earth could be affected by system faults or other damage. The customers earth similarly could become disconnected or reduced in efficiency for reasons beyond UK Power Networks control. As stated above, in rare cases if it is necessary for a customers installation to rely on a contribution from UK Power Networks earth for safety, this shall be discussed with UK Power Networks at an early stage. However an earth resistance value of 0.5 or less should be achievable in most situations and requests to rely on UK Power Networks contribution will not normally be agreed without a good reason. A checklist is provided in Appendix A to assist with the assessment of an earthing design.
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Design Guidelines
This section provides information to assist the designer. The values provided are for guidance only, and their relevance to a given application should be confirmed prior to reliance on them. 9.1 Design Parameters
The following parameters apply to the North London 33kV routes and should be used for design purposes unless revised figures are provided by UK Power Networks:
Table 9-1 Design Parameters Parameter 33kV 3-phase fault current 33kV earth fault Igr% (percentage of earth fault current that will return via soil) worst case Target resistance to achieve <430V EPR Target resistance to achieve <250V EPR Typical soil resistivity value (to be confirmed by designer) Normal 33kV protection clearance time (max) at UK Power Networks outgoing feeders to customer installation Backup protection clearance time Protection settings (typical) Value 12.5kA 2,700A 30% 0.5 0.3 20 - 100m depending on geographical area and depth of burial. Lower resistivity clays exist typically >3m below surface soil 0.7 second (earth fault) 1 second (overcurrent)
3 seconds (stuck CB condition) clearance at source (overcurrent and earth fault) HSOC 3000A INST, OC 600A 0.3TM SI EF 300A 0.1TM SI
Maximum acceptable step voltage (1 second, concrete) Maximum acceptable touch voltage (1 second) Minimum conductor size for 12.5kA/3s rating Minimum conductor size for 2,700A/1 second or 3 second Source substation Ra and EPR (max)
650V 200V Duplicate 25mm x 4mm copper tape or single 40mm x 4mm copper tape 70mm2 stranded copper Finsbury Market Substation 0.15, 403V Back Hill Substation 0.2, 526V
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9.2 9.2.1
Conductor Sizes UK Power Networks Substation
The main bonding conductors shall be sized to cope with a fault current of 12.5kA for 3 seconds (refer to Table 9-2). The conductor sizes are given in Table 9-2 below (a minimum of two 25mm x 4mm copper tapes or equivalent as shown above). This requirement derives from ENA TS 41-24 paragraph 8.2. 9.2.2 Customer Switchrooms and Installations
According to ENA TS 41-24, the main bonding conductors should be sized to cope with the full phase-phase fault level of 12.5kA for 3 seconds. This figure is used in UK Power Networks substations and should be used in customer switchrooms and transformer rooms. Given that the 33kV system is impedance earthed, with a limited earth fault level of 2,700A it is economical and appropriate to use this lower figure for design purposes in other parts of the customer installation, unless higher 11kV or LV earth fault currents can flow, in which case the higher figures should be used. Section 8.2.1 of ENA TS 41-24 describes the use of earth electrode current in design calculations. Although the likelihood of phase-phase fault current flowing in earth bonds is small, UK Power Networks will not accept the use of smaller conductor rated at 2,700A for 3 second in switchrooms/transformer rooms except for bonding ancillary items such as enclosures, doors etc. The UK Power Networks standard conductor sizes for low fault level sites, defined as 12.5kA for 3 seconds, are shown in Table 9-2. These should be adopted for 33kV switchroom and transformer rooms. Care should be taken not to exceed the current rating of individual rod electrodes as given in Table 9-2.
Table 9-2 Low Fault Level Earth Conductor Sizes (12.5kA for 3 seconds) Use Earth Grid Primary equipment connections that may be required to carry the full fault current e.g. power transformers, switchgear, transformer neutrals, busbar supports etc Conductor* Copper Tape Copper Tape Specification BS 1432 C101/C103 BS 1432 C101/C103 Connection Duplicate Single Brazed/Welded Single Double Bolted Duplicate Brazed/Welded Duplicate Double Bolted Copper Stranded Hard drawn high conductivity copper to BS 125 Single Brazed/Welded Single Double Bolted Duplicate Brazed/Welded Duplicate Double Bolted Size 25mm x 4mm 25mm x 4mm 40mm x 3mm 25mm x 4mm 25mm x 4mm 100mm2 125mm 70mm2 75mm2
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Use Secondary equipment connections e.g. protection/relay panels metalwork, cubicles, kiosks, building steelwork etc)
Conductor* Copper Tape
Specification BS 1432 C101/C103 Hard drawn high conductivity copper to BS 125 Hard drawn to BS 2898 1350 or aluminium alloy to BS 3242
Connection Single
Size 25mm x 4mm
Copper Stranded
Single
70mm
Above ground equipment connections using tape or structure parts (such as support framework) Equipment connections via structure legs
Aluminium
Single Brazed/Welded Single Double Bolted Duplicate Brazed/Welded Duplicate Double Bolted Single structure leg Two structure legs
60mm x 3mm 60mm x 3mm 25mm x 4mm 40mm x 3mm Min 380mm2 Min 225mm2
Galvanised Steel
Table 9-3 Maximum Current Rating of Earthing Rods Resistivity Copper Clad Steel (30%) 16mm Diameter 1s 40.8kA 31.6kA 22.3kA 18.2kA 15.8kA 2s 28.8kA 22.3kA 15.7kA 12.8kA 11.1kA 3s 23.4kA 18.2kA 12.9kA 10.6kA 9.1kA Solid Copper 16mm Diameter
Protection Clearance Time 30 m 50 m 100 m 150 m 200 m
1s 69.7kA 54.0kA 38.2kA 31.2kA 27.0kA
2s 49.2kA 38.1kA 27.0kA 22.0kA 19.0kA
3s 40.2kA 31.2kA 22.0kA 18.0kA 15.6kA
9.3
Lightning Electrode Systems
Lightning electrode systems, if any, will usually consist of downleads and high frequency earth electrodes. These may be connected to the customers perimeter electrode system and will provide a contribution to reducing the earth resistance. However, this contribution should not be relied on as the sole means of earthing unless the conductors and electrodes are shown to be sufficiently rated to carry fault current. 9.4 Electrode Location and Caveats
When routing electrodes, extra care is required if the electrode will pass close to an area frequented by people with bare feet, e.g. swimming pools or showers. If in doubt consult an earthing specialist. Further information can be found in BS7671 and ENA ER G12. The customers electrode system shall not rely on buried pipework or metallic cable sheaths to reduce the earth resistance. If the resistance offered by such services is significantly lower than the customers system, a large proportion of earth fault current will flow in the services
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during a fault. An example is the braided sheath of a co-axial cable, which may be connected to a remote earth or global earthing system. This is another reason to design the system to be independent of other earths, and to limit the EPR to as low a value as is practicable. These fortuitous paths shall be bonded to the customers main earth terminal to prevent them introducing a touch potential risk (imported potential) except if the site is HOT, in which case it is important not to export potential to a remote system in this way (specialist advice is required in such circumstances). 9.5 Segregated or Combined Earthing System
It is not appropriate to design a segregated earthing system in a building, nor is it usually necessary particularly if the site is COLD. Therefore the customers installation shall be designed to achieve an earthing resistance of 0.5 as specified in Table 9-1 before connection of any cables or to UK Power Networks earthing system. The resistance value shall be confirmed by measurement before connection using the fall of potential method or other technique. 9.6 Use of Rebar/Piles
Rebar/Piles can be used to a) provide a connection to the general mass of earth, and b) in the case of rebar mesh, to provide grading to manage step and touch potentials. In providing a connection to the mass of earth, it should be viewed as fortuitous in that it will provide a parallel path for fault current. Vertical steel rebar piling can provide a useful reduction in earth resistance; however, it is supplementary to and does not replace the need for a dedicated electrode system. If it is necessary to rely on vertical piles, should the fault current magnitude require it, copper strip can be installed within the piles to supplement the current carrying capacity. For the purposes of step/touch potentials, the floor grid should be wel ded around the perimeter, and connected to the main earth terminal by two independent connections as shown in Appendix B. It is not usually necessary to install additional grading mats. The following sections are based on ECS 06-0022 (grid and primary substation earthing construction). 9.6.1 Sheet Steel Piles
Sheets that are more than 3m long and 2m wide are to be bonded to the earthing system, as specified by the design engineer. Stainless steel studs are to be exothermically welded to each second sheet at a suitable height (normally 600mm below finished ground level) and a strip of 40mm x 4mm copper tape will be bolted to these. The strip will in turn be connected to the main substation earthing system. If the piles form a separate electrode connected to the earthing system at one point, then the connection should be via a test chamber such that the contribution of the piles may be monitored. Note: The use of buried bolted connections in this case is reasonable as there are many parallel connections.
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9.6.2
Horizontal Steel Reinforced Foundations
For plant rooms, the rebar will be installed normally (i.e. with the rebar strips bound with soft steel wire), and welded connections around the perimeter. Connection is achieved by two rebar connections left protruding from the concrete for about 150mm, or a welded connection may be provided as shown in Figure 9-1.
Figure 9-1 Typical Rebar Connections
9.6.3
Vertical Steel Reinforced Ground Columns
Where these columns have steel reinforcing that extends more than 4m into the ground, then often the design will require these to be bonded to the earthing system. The easiest method is to leave a section of bonded rebar 150mm out of the concrete for a connection to be made later by the earth installers. This steel reinforcing bar shall have its electrical continuity maintained at joint positions by welding the connection. 9.7 9.7.1 Joints and Connections General
The methods described below are the only means permitted. Exothermic welded, brazed and compression type joints are acceptable. Bolted joints are only permissible above ground. For connections made to equipment welded joints may be possible, but in the majority of cases, bolted joints will be necessary. Nuts, bolts and washers for these are to be of high tensile stainless steel or galvanised steel. Bolted connections shall, wherever possible, be at least the double bolt fixing type, except where purpose designed connections are provided by the equipment manufacturers. Lugs for connecting cable screens shall be positioned to facilitate removal for testing/commissioning purposes. The screen wires shall be bunched to permit testing with a clamp-meter. Connections to/from equipment should be clearly labelled. Lugs should wherever possible have a two bolt connection and the holes drilled in earth bars should not significantly derate the bar (tee connection pieces can be brazed on to facilitate a bolted lug connection).
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9.7.2
Copper to Copper Connections
Tape to tape connections shall be brazed or exothermically welded. Stranded to stranded connections shall be exothermically welded or connected using compression joints. Stranded to tape connections shall be exothermically welded or a lug shall be compressed onto the stranded conductor, which for underground use is bolted and then brazed or welded onto the copper tape. For above ground purposes, the lug may be bolted to the tape but shall have a double bolt fitting. 9.7.3 Copper to Earth Pins
Connections shall be brazed or exothermically welded. Bolting and U-bolts are not acceptable. 9.7.4 Electrode Test Points
The design drawing will show the test points. Electrode test points are required either at the rod top for long single rods (Figure 9-2) or inline between a rod group and the main earthing system. To allow individual rod resistance values to be tested with a clip-on meter and facilitate electrode tracing all test points shall be stranded circular conductor. If strip has to be used it shall be folded over to allow the test clamp to fit. The traditional bolted connection offers no value.
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Inspection Chamber Loop to allow clip-on meter to be fitted around copper conductor
>80mm
Surface Backfill Cadweld or braze to earth rod
>50mm
Cadweld or braze of bolt/crimp to earth tape
>300mm
Backfill will depend on civil requirements Generally Bentonite for clay/ soft soil and Marconite mixed with concrete for concrete/rock
Surface Backfill
Diameter suitable for civil purposes
OPTION 2
PVC covered 95mm2 copper conductor Earth rod Copper earth tape
Figure 9-2 Test Point
A test point associated with pile cap connections is useful but only if the design of the rebar is electrically separated from the rest of the site. At most sites the rebar will be connected together and while this provides an excellent earth, testing the individual pile cap earths is impossible. In these cases separate earth pins should have been provided in the design perhaps for high frequency and/or lightning protection which will allow testing between individual earth rods and the main earth grid. 9.7.5 Copper to Equipment Earths
Connections should, wherever possible, be in the vertical plane. Remove paint from the metal at joint position on the equipment earth, sand metal smooth and apply neutral jointing compound (e.g. Castrol Rustillo 431 or Shell Ensis CD). Drill the copper tape to accommodate the bolts (normal diameter is 10mm) and then tin the complete contact area. The bolt holes shall be less than one-third the width of the tape. Failing this a copper flag shall be jointed to the copper tape and the holes drilled into this. A two bolt fixing is preferred, unless a suitably rated fixing is provided by the manufacturer.
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Copper joint surfaces, once drilled are to be cleaned using aluminium oxide cloth (grade 80). Copper is tinned at all bolted connections the tinning needs to be thin and should not exceed an average of 0.5mm, otherwise it will flow from bolted sections under pressure . Neutral jointing compound (e.g. Castrol Rustillo 431 or Shell Ensis CD) is then to be applied to the joint faces. 9.7.6 Aluminium to Aluminium Joints
The preferred method is either inert-gas tungsten-arc (TIG) or inert-gas metal arc (MIG) welding. Bolted joints are acceptable above ground. For bolted joints: All joints require a two bolt fixing. Bolts shall be high tensile galvanised steel, fitted with large diameter galvanised steel washers. The surface aluminium shall be cleaned using grade 80 aluminium oxide cloth and coated with neutral compound grease (e.g. Castrol Rustillo 431 or Shell Ensis CD). Bolts shall be tightened using a torque wrench, to avoid over stressing, using the settings given in Table 9-4. All excess grease shall be wiped off the finished joint. The joint shall be sealed with two coats of bitumastic paint.
Table 9-4 Bolt sizes and Torques for Use on Aluminium Bar Width 40mm Bar Overlap 80mm Bolt Diameter 10mm Hole Size 12mm Bolt Min Torque 35 Nm Washer Size OD 25mm ID 11mm 60mm 100mm 12mm 14mm 50 Nm OD 28mm ID 12.5mm 3.0mm Washer Thickness 2.5mm
9.7.7
Aluminium to Equipment Earths
Aluminium conductor connections to equipment should, where possible, be in the vertical plane. In all cases joints shall be made in accordance with Section 9.7.6 above. 9.7.8 Aluminium to Copper Joints
Connections are to be in the vertical plane, at least 150mm above the ground or concrete plinth. They shall be located in positions where water cannot gather and the aluminium will be above the copper. Bimetallic joints shall not be made on buried sections of electrode. All connections involving dissimilar metals shall be cleaned with aluminium oxide cloth (grade 80) and have neutral compound grease applied before making a bolted connection. Copper shall be tinned prior to any such connection. Excess grease should be wiped off. The finished joint shall be sealed with two coats of bitumastic paint.
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10
Typical Designs
A standard design will typically consist of an outer (perimeter) loop of copper electrode, buried at a depth of 600mm (installed in a plastic duct where non plastic served cables or services cross the tape). The loop should ideally encircle the entire footprint of the building. If other metalwork (e.g. a metallic fence) encroaches on this area, the designer shall consider touch voltages that may arise should somebody be standing over the electrode whilst simultaneously touching the fence. The outer loop should be converted to a mesh by providing standard conductor (laid at 90 degrees to each other) to form a grid, ideally with a mesh size no greater than 10m x 10m. Earth rods should be installed at (or close to) the perimeter loop electrode, and at its corners. Some of the rods should have facilities to permit testing using a clamp meter, and should be driven to a depth of at least 3.6 metres or as necessary to achieve the desired earth resistance. Two connections from the main electrode system or perimeter electrode shall be taken to each of the main items of plant (switchgear, transformers, etc). The customer may choose to establish a main earth terminal from which duplicate connections to all main items of plant, and to grading electrodes, can be provided. Alternatively, a surface laid ring of conductor may be provided which will serve a similar purpose. All connections to this should be accessible for testing (typically using a micro-ohm meter or Ductor). The customers main earth terminal shall be connected to UK Power Networks earth terminal after testing, using two copper tapes of 25mm x 4 mm. The arrangement of a perimeter electrode system provides the most effective connection to earth, and the mesh provides a reduction in impedance as well as controlling the voltage gradient that will appear on the ground in fault conditions. It is not then normally necessary to install electrodes for each switch or transformer room within that perimeter provided that those rooms are connected to the perimeter electrode system by two duplicate connections. Were they to be installed, the contribution of such electrodes would increase the robustness of the system but the reduction in earth resistance will be minimal as they will be within the zone of influence of the outer (perimeter) electrode unless they are driven to a considerable depth. A typical layout is shown in Figure 10-1 a copper mesh is established underneath the building, and extends beyond the perimeter of the building in a way which will reduce touch potentials. The rods are established around the perimeter of the site, and connections from main items of plant to the mesh are made close to the plant (and duplicated where necessary).
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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)
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Appendix A Design Checklist

UK Power Networks will audit all proposed designs prior to connection. Sub-standard designs will not be accepted. The developer will be required to provide the information below prior to connection.
Item Earth grid resistance and overall earth return impedance values Maximum earth fault current EPR (for a maximum value of earth fault current) Substation Classification (HOT or COLD) Limits of the HOT zone and appropriate zones of influence (if applicable) Internal maximum touch and step potentials at all points are below the safe acceptable value. Maximum touch potentials around the perimeter of the building are below safe values Maximum external step potentials are below the safe acceptable value All conductors are adequately sized and that the will not be preferential parallel paths which could give rise to danger Design drawings/as built drawings Value/Confirmation Pass/Fail
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Appendix B Drawings
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ECS 06-0030 Substation Earthing Design and Construction - Guidance Notes For Developers (33kV London Routes) PDF

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Document Number: ECS 06-0030 Version: 1.

ENGINEERING CONSTRUCTION STANDARD

Version 0.1 1.0

Date 28/08/2012 12/11/2012

Originator Rob Weller (Earthing Solutions) Stephen Tucker

Document Number: ECS 06-0030 Version: 1.0 Date: 12/11/2012

UK Power Networks 2012 All rights reserved

Document Number: ECS 06-0030 Version: 1.0 Date: 12/11/2012

9.7.5 9.7.6 9.7.7 9.7.8 10

Appendix A Design Checklist ..........................................................................................25 Appendix B Drawings .......................................................................................................26

UK Power Networks 2012 All rights reserved

Document Number: ECS 06-0030 Version: 1.0 Date: 12/11/2012

UK Power Networks 2012 All rights reserved

Document Number: ECS 06-0030 Version: 1.0 Date: 12/11/2012

UK Power Networks 2012 All rights reserved

Document Number: ECS 06-0030 Version: 1.0 Date: 12/11/2012

UK Power Networks 2012 All rights reserved

Document Number: ECS 06-0030 Version: 1.0 Date: 12/11/2012

Earthing Overview and Definitions

UK Power Networks 2012 All rights reserved

Document Number: ECS 06-0030 Version: 1.0 Date: 12/11/2012

Touch Potential (UST) Earth Potential Rise, EPR (UE)

Step Potential (USS)

Transfer Potential (UTST)

Remote Touch Potential (UTSTE)

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

UK Power Networks 2012 All rights reserved

Document Number: ECS 06-0030 Version: 1.0 Date: 12/11/2012

UK Power Networks 2012 All rights reserved

Document Number: ECS 06-0030 Version: 1.0 Date: 12/11/2012

General Requirements for Customer Connections at 33kV

UK Power Networks 2012 All rights reserved

Document Number: ECS 06-0030 Version: 1.0 Date: 12/11/2012

UK Power Networks 2012 All rights reserved

Document Number: ECS 06-0030 Version: 1.0 Date: 12/11/2012

Specific Earthing/Bonding Requirements for Customer Connections at 33kV

UK Power Networks 2012 All rights reserved

Document Number: ECS 06-0030 Version: 1.0 Date: 12/11/2012

Customer Installation Earth Resistance

UK Power Networks 2012 All rights reserved

Document Number: ECS 06-0030 Version: 1.0 Date: 12/11/2012

UK Power Networks 2012 All rights reserved

Document Number: ECS 06-0030 Version: 1.0 Date: 12/11/2012

UK Power Networks 2012 All rights reserved

Document Number: ECS 06-0030 Version: 1.0 Date: 12/11/2012

Conductor Sizes UK Power Networks Substation

UK Power Networks 2012 All rights reserved

Document Number: ECS 06-0030 Version: 1.0 Date: 12/11/2012

Conductor* Copper Tape

Size 25mm x 4mm

Protection Clearance Time 30 m 50 m 100 m 150 m 200 m

1s 69.7kA 54.0kA 38.2kA 31.2kA 27.0kA

2s 49.2kA 38.1kA 27.0kA 22.0kA 19.0kA

3s 40.2kA 31.2kA 22.0kA 18.0kA 15.6kA

Lightning Electrode Systems

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Document Number: ECS 06-0030 Version: 1.0 Date: 12/11/2012

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Document Number: ECS 06-0030 Version: 1.0 Date: 12/11/2012

Horizontal Steel Reinforced Foundations

Figure 9-1 Typical Rebar Connections

Vertical Steel Reinforced Ground Columns

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