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West Qurna Field 2nd

Phase Project
(Early Oil Phase)
TECHNICAL SPECIFICATION FOR Page 2 of 30
DOC. TITLE
EARTHING AND LIGHTNING SYSTEM Rev. 01

DOC. NO. 8015-0151-SECL-00-890-EL-SP-00001 Job No. SO2476

REVISION LIST
REV.
DATE MADE BY PAGE NO. DESCRIPTION
NO.

09.JUN.
B T.H.KIM ALL ISSUED FOR REVIEW
2012

29.JUN
C S.H.JOO ALL ISSUED FOR APPROVAL
2012

APPROVED FOR USE


21.SEP
00 T.H.KIM 18 - The size of Earthing wire for motors up to and including 3kW was
2012
changed from 6mm2 to 25mm2 for uniformaty.

26.APR
01 J.Y.YANG - For Final Documentation
2015

Note: 1. Revision part of document is easily identified by drawing a vertical line on the right margin
and
applied revision number. Also revision part of document will be written in bold.

2. Revision number shall be identified as following;

Class Revision Number

Revision code Issue status Revision description

A IDC Issued for Discipline Check

B,C, -W IFA, IFR, IFI, IFE, IFD Issued for Approval


Issued for Review
Issued for Information
Issued for Enquiry
Issued for Design
00, 01... AFC, AFP, AFU Approved for Construction
Approved for Procurement
Approved for Use
Z CAN Cancelled

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West Qurna Field 2nd
Phase Project
(Early Oil Phase)
TECHNICAL SPECIFICATION FOR Page 3 of 30
DOC. TITLE
EARTHING AND LIGHTNING SYSTEM Rev. 01

DOC. NO. 8015-0151-SECL-00-890-EL-SP-00001 Job No. SO2476

SUMMARY

1. SCOPE ......................................................................................................................... 5
2. REFERENCE STANDARDS, CODES AND DOCUMENTS ........................................ 5
2.1. General .................................................................................................................... 5
2.2. Compliance with EC (European Community) directives .................................... 6
2.2.1. Applicable directives .............................................................................................. 6
2.2.2. EC declaration of conformity and CE marking ....................................................... 6
3. AMBIENT CONDITIONS .............................................................................................. 7
4. GROUNDING AND EQUIPOTENTIAL BONDING ...................................................... 8
4.1. Design criteria ........................................................................................................ 8
4.1.1. General criteria ...................................................................................................... 8
4.1.2. Materials ................................................................................................................ 9
4.1.3. Resistance values .................................................................................................. 9
4.2. Grounding calculations ....................................................................................... 10
4.2.1. Introduction .......................................................................................................... 10
4.2.2. Computation of body current ............................................................................... 10
4.2.3. Resistance of the human body ............................................................................ 10
4.2.4. Fundamental formulas ......................................................................................... 10
4.2.5. Grid wire sizing (thermal withstand) ..................................................................... 12
4.3. Grounding of Equipment ..................................................................................... 12
4.3.1. General ................................................................................................................ 12
4.3.2. Buildings elements ............................................................................................... 13
4.3.3. Overhead lines ..................................................................................................... 13
4.3.4. Substation equipment .......................................................................................... 14
4.3.5. Surge arresters .................................................................................................... 15
4.3.6. Motors .................................................................................................................. 15
4.3.7. Power and control cables .................................................................................... 16
4.3.8. Cable trays ........................................................................................................... 16
4.3.9. Lighting fixtures and lighting poles ....................................................................... 16
4.3.10. Vessel, tanks, exchangers, towers and other process containment equipment .. 16
4.3.11. Fences and perimeter earthing ............................................................................ 17
4.3.12. Steel structures .................................................................................................... 17
4.3.13. Piping ................................................................................................................... 17
4.3.14. Loading areas ...................................................................................................... 17
4.4. Neutral grounding ................................................................................................ 18
4.5. Grounding wires sections ................................................................................... 18
5. STATIC ELECTRICITY PROTECTION ...................................................................... 18
6. LIGHTNING PROTECTION ....................................................................................... 20
6.1. Design criteria ...................................................................................................... 20
6.2. General .................................................................................................................. 20
6.2.1. Lightning Protection Level (LPL) .......................................................................... 20
6.2.2. Lightning Protection Zones (LPZ) ........................................................................ 21
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West Qurna Field 2nd
Phase Project
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TECHNICAL SPECIFICATION FOR Page 4 of 30
DOC. TITLE
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DOC. NO. 8015-0151-SECL-00-890-EL-SP-00001 Job No. SO2476

6.3. Lightning Risk Assessment (LRA) ..................................................................... 22


6.3.1. Evaluation ............................................................................................................ 22
6.3.2. Lightning Ground Flash Density (Ng) ................................................................... 23
6.3.3. Equivalent Collective Area of a Structure (Ae) ..................................................... 23
6.3.4. Environmental Coefficient (C1)............................................................................. 24
6.3.5. Direct Lightning Flash Frequency (Nd) ................................................................. 24
6.4. Lightning Protection System (LPS) .................................................................... 24
6.5. Specific requirements.......................................................................................... 26
6.5.1. General ................................................................................................................ 26
6.5.2. Air terminals ......................................................................................................... 26
6.5.3. Buildings .............................................................................................................. 27
6.5.4. Substations .......................................................................................................... 27
6.5.5. Substation equipment .......................................................................................... 27
6.5.6. Overhead lines ..................................................................................................... 28
6.5.7. Vessel, tanks, exchangers, towers and other process containment equipment .. 28
6.5.8. Cable ways .......................................................................................................... 28
7. ELECTROMAGNETIC COMPATIBILITY .................................................................. 28
7.1. Cable shielding..................................................................................................... 28
7.2. Communications and instrument cable protection .......................................... 29
8. SURGE, LIGHTNING AND OVERVOLTAGE PROTECTORS .................................. 29
8.1. Lightning arresters .............................................................................................. 29
8.2. Coupling................................................................................................................ 30

Samsung Engineering Co.,Ltd


West Qurna Field 2nd
Phase Project
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TECHNICAL SPECIFICATION FOR Page 5 of 30
DOC. TITLE
EARTHING AND LIGHTNING SYSTEM Rev. 01

DOC. NO. 8015-0151-SECL-00-890-EL-SP-00001 Job No. SO2476

1. SCOPE

This specification defines technical requirements for design of the grounding and
lightning protection system for the West Qurna 2 Early Production Facilities.

2. REFERENCE STANDARDS, CODES AND DOCUMENTS

2.1. General

System shall be designed, manufactured and tested according to the requirements


of the relevant applicable IEC (International Electrotechnical Commission) and ISO
(International Organization for Standardization) standards and in compliance with
local codes, with particular reference to the Iraq Ministry of Electricity regulations.

Should no IEC or ISO standard be available in any case, relevant British (BSI) or
National standards shall apply.

In case none of the above standards would be available, additional standards


might be considered among those listed herebelow:

ANSI American National Standards Institute


API American Petroleum Institute
IEEE Institute of Electrical and Electronic Engineers
NEMA National Electrical Manufacturers Association
NFPA National Fire Protection Association
ULUnderwriters Laboratories

The listed Standards and Codes, together with their all parts and subparts, shall be
applied considering their latest applicable issue available.

The measurement system is the SI metric unit system.

IEC (International Electrotechnical Commission)

 IEC 60050-195 International Electrotechnical Vocabulary - Part 195:


Earthing and protection against electric shock
 IEC 60364-5-54 Electrical installations of buildings - Part 5-54: Selection
and erection of electrical equipment - Earthing
arrangements, protective conductors and protective
bonding conductors
 IEC 60529 Degrees of protection provided by enclosures
 IEC 61000 Electromagnetic compatibility (EMC)
 IEC 61024-1 Protection of structures against lightning
 IEC 61024-1-1 Protection of structures against lightning – LPL

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West Qurna Field 2nd
Phase Project
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TECHNICAL SPECIFICATION FOR Page 6 of 30
DOC. TITLE
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DOC. NO. 8015-0151-SECL-00-890-EL-SP-00001 Job No. SO2476

 IEC 62305 -1 Protection against lightning

BS (British Standard)

 BS 5859 Code of Practice for Control of Undesirable Static Electricity

IEEE (Institute of Electronic and Electrical Engineers)

 IEEE 80 Guide for Safety in AC Substation Grounding


 IEEE 142 Recommended Practice for Grounding of Industrial and
Commercial Power Systems

NFPA (National Fire Protection Association)

 NFPA 780 Standard for the Installation of Lightning Protection


Systems

2.2. Compliance with EC (European Community) directives

2.2.1. Applicable directives

Even if the equipment and material supplied are to be installed in Iraq, that is not a
member country of the European Union, it shall be supplied in accordance with all
applicable European Community directives.

In particular, for the supply related to this specification falling within the scope and
applicability limits of each pertinent EC Directive, compliance shall be given with:

 94/9/EC Equipment for Explosive Atmospheres (ATEX)


 2004/108/EC Electromagnetic Compatibility Directive
 2006/95/EC Low Voltage Directive

2.2.2. EC declaration of conformity and CE marking

When required from the applicable EC Directives, Supplier shall provide an EC


Declaration of Conformity indicating the following:

 Contact and reference information such as corporate name, location, etc.


 A list of all the European Directives that Supplier declares compliance with.
 A list of standards the supply complies with.
 A legally binding signature on behalf of the Supplier Company.

Samsung Engineering Co.,Ltd


West Qurna Field 2nd
Phase Project
(Early Oil Phase)
TECHNICAL SPECIFICATION FOR Page 7 of 30
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DOC. NO. 8015-0151-SECL-00-890-EL-SP-00001 Job No. SO2476

EC Declaration of Conformity shall be referred to the supply as an overall


assembly. A collection of certificates referred to single components of the supply
cannot be considered as the EC Declaration of Conformity of the supply. CE
Marking shall be provided for the overall supply alike.

By affixing, when required, the CE Marking, the Supplier ensures that the overall
supply meets all the safety requirements as per the CE Marking Directives as well
as that the appropriate conformity assessment procedures have been successfully
completed.

In regard to the CE Marking extent stated on the applicable CE Marking Directives,


the following documentation, within the limits of the Directive requirements, shall
be included in the scope of supply:

 Technical documentation.
 Essential Safety Requirements (ESR) check list.
 Self declaration of conformity.
 Operating instructions.
 CE Marking nameplate.

3. AMBIENT CONDITIONS

The design of the equipment and of its components shall comply with the following
environmental conditions:

 Altitude : < 1000 m a.s.l.


 Pollution level : Heavy
 Dust storm : 21.5 days /
year
 Thunder storm : 15 days / year
 Design maximum wind velocity : 40.2 m/s
 Ice loading : None
 Earthquake (as per Uniform Building Code) : Zone 1

 Design maximum ambient temperature outdoor : 55 °C


indoor : 40 °C
 Highest maximum temperature for 6 hours a day : 55 °C
 Maximum daily / yearly average : 40 / 30 °C
 Design minimum ambient temperature outdoor : -5 °C
indoor : 0 °C
 Highest one day variation : 25 °C
 Sun temperature in direct sunlight : 83 °C
 Maximum ground temperature at 100 mm depth : 35 °C

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West Qurna Field 2nd
Phase Project
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TECHNICAL SPECIFICATION FOR Page 8 of 30
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DOC. NO. 8015-0151-SECL-00-890-EL-SP-00001 Job No. SO2476

 Maximum relative humidity at 40°C : 86 %


 Minimum relative humidity : 18 %
 Yearly average : 38/44 %

4. GROUNDING AND EQUIPOTENTIAL BONDING

4.1. Design criteria

4.1.1. General criteria

The earthing system design and installation will be in accordance to the IEC and
IEEE Standards, and in particular with IEC 60364-5-54 for general grounding and
IEEE 80 for substations grounding grid.

The safety ground network shall consist of a main underground grid, above ground
connection points, ground conductors from above ground connection points to
grounded metal parts, and rods driven vertically into the ground connected to main
grid. Within the grid, conductors shall be laid in parallel lines at reasonably uniform
spacing. They shall be located along rows of structures or equipment to facilitate
the making of earth connections, where practical.

The spacing between conductors forming the mesh system shall be such as to
limit the grid potential rise to a value that limits the touch voltage to a value not
greater than the maximum tolerable touch potential assuming a fault clearance
time equal to that of the main protection equipment being provided.

Areas of grid, where high concentrations of fault currents can appear as at neutral
earthing connections, shall have reinforced conductor sizes where necessary, to
handle adequately the highest fault current and its duration.

The functional ground network for instrumentation, control systems and DCS
system will have the same physical characteristics of the safety ground network,
and will be connected to the latter through one or more earthing system couplers
(surge arresters).

The conductors of ground grid shall be laid directly in the ground at a depth of 0.6
m at least.

Ground rods can be added to the main conductor grid, if necessary.

All connection points of grounding bars, steel structures, process containment


equipment and other equipment shall be located above ground, protected against
damage and corrosion, and accessible for inspection and testing purposes.

Samsung Engineering Co.,Ltd


West Qurna Field 2nd
Phase Project
(Early Oil Phase)
TECHNICAL SPECIFICATION FOR Page 9 of 30
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DOC. NO. 8015-0151-SECL-00-890-EL-SP-00001 Job No. SO2476

Metal parts of all equipment, other than those forming part of an electrical circuit,
shall be connected directly to the main earth system via a single conductor. The
arrangement of the mesh earth system shall be such as to minimise the length of
these single connections.

All exposed joints shall be at a minimum height of 150 mm above floor or ground
level.

Earth conductor joints that are required to be broken for testing or maintenance
shall have mating surfaces tinned.

4.1.2. Materials

Soil composition may be highly corrosive and special consideration shall be given
to this aspect; considering this, grounding conductors shall be made of copper,
insulated or bare tinned depending from soil corrosiveness.

Ground rods shall be copper clad type, having a ¾” diameter and a length of 3 m
that can vary between 1.5 and 6 m depending from soil requirements. Rods shall
be provided with inspection pits with cover. Top of rods shall be driven 30-50 cm
below the surface of the earth. Rods shall not be driven under slabs or buildings
and shall be separated by at least 60 cm from such structures.

All underground connections and joints in underground grounding conductors shall


be made by the exothermic welding process. Copper to copper joints on strip
conductor shall be brazed, using zinc-free brazing material with a melting point of
not less than 600°C, or by approved exothermic welding. All connections shall be
completely covered and sealed, leaving no copper exposed when used in
conjunction with insulated grounding conductors.

All aboveground earthing conductors shall be made of copper and PVC insulated.

All conductors coming out from the ground will be protected, against mechanical
damage with heavy duty PVC pipe.

4.1.3. Resistance values

The ground resistance of the safety ground network shall be built in order to
guarantee the safety under fault current at all voltage levels, anyway it shall not
exceed 1 Ω.

The ground resistance of the functional grounding network shall be specified


according to the characteristics of electronic connected equipment. If the
resistance value is not specified, it shall not exceed in any case 7 Ω.

After installation of the grounding system, earthing resistance shall be measured.


The method used shall be the "fall of potential" method.
Samsung Engineering Co.,Ltd
West Qurna Field 2nd
Phase Project
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TECHNICAL SPECIFICATION FOR Page 10 of 30
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DOC. NO. 8015-0151-SECL-00-890-EL-SP-00001 Job No. SO2476

4.2. Grounding calculations

4.2.1. Introduction

The primary objective in the design of a grounding system is to provide safe


conditions for personnel operating in and around the plant. Accidents to personnel
result from grid potential rise of the ground system during fault conditions on the
connected power system. Therefore, the grounding system must be designed to
limit the potential rise of the plant ground mat to an acceptable value for any
possible fault condition and to limit the resulting step, touch, and transfer potentials
to an acceptable value.

The surface potentials are approximately proportional to the grid potential rise, and
both are determined by the current flow from the grounding grid to earth.

4.2.2. Computation of body current

The non-fibrillation current IB is related by the shock energy SB absorbed by the


human body:

IB = k / sqrt (ts)

where k = sqrt (SB)

For persons of an approximate weight of 70 kg, k70 = 0.157.

A person of average weight could withstand current IB without ventricular fibrillation.

4.2.3. Resistance of the human body

The human body can be represented by a noninductive resistance RB for both DC


and AC at normal power frequency. A value of RB = 1000  is selected as a
resistance of a human body from hand to both feet, and also from hand to hand or
from one foot to the other.

4.2.4. Fundamental formulas

Some fundamental formulae are shown below.

1) Reflection Factor, K

  S
K
  S

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DOC. NO. 8015-0151-SECL-00-890-EL-SP-00001 Job No. SO2476

where ρ is the resistivity of the earth beneath the surface material in Ω-m; ρs is the
surface layer soil resistivity in Ω-m.

2) Surface Layer Derating Factor, Cs

0.009(1   /  S )
CS  1  (IEEE Std 80-2000)
2hs  0.009

1  
Kn 
CS  
0.96 
1  2  2 
n 1 1  ( 2nhs / 0.08 ) 
(IEEE Std 80-1986, IEEE Std 665-

1995)

hs = thickness of the surface layer in meters; Cs is 1 when K=0.

3) Decrement Factor, Df

Ta
Df  1  (1   2tf / Ta )
tf

tf = fault time to determine decrement factor in seconds


Ta = equivalent system subtransient time constant in seconds.

4) Tolerable Step Potential, Estep and Etouch

For body weight of 70 kg

0.157
E step 70  (1000  6CS  S )
ts
0.157
E touch 70  (1000  1.5C S  S )
ts

5) Maximum Grid Current, IG

IG  Sf C p Df (3I 0 )

where:

IG = Maximum grid current in A


Sf = Current division factor - relating the magnitude of fault current to
that of its portion flowing between the grounding grid and
surrounding earth
Df = Decrement factor for entire duration of fault in seconds

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TECHNICAL SPECIFICATION FOR Page 12 of 30
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DOC. NO. 8015-0151-SECL-00-890-EL-SP-00001 Job No. SO2476

Cp = Projection factor for future system growth


3I0 = RMS symmetrical grid current in A

Approximately 50 - 60% of the fault current flows through the grid to remote earth.

4.2.5. Grid wire sizing (thermal withstand)

The wire size can be calculated with the following formula (ANSI / IEEE Std 80, p.
67), for a standard copper wire:

IG
s
 T  Tamb 
log10  m  1
1973.5   234  Tamb 
33  t c

where:

IG = Grid current in A
s = Grid conductor cross-section (mm²)
tc = Time in s
Tm = Maximum allowable temperature (°C)
Tamb = Ground temperature (°C)

The values 1973.5 and 33 are typical and depends from the material constants, as
shown on ANSI / IEEE Std 80, p.66, table I.

4.3. Grounding of Equipment

4.3.1. General

In general, the following items shall be grounded:

a) All the metallic frames of the electrical equipment such as switchgears, local
panels, motors, outlets, junction boxes, cable trays, conduits, etc.
b) All steel structures, vessels, columns, tanks, etc.
c) The metallic elements of the industrial buildings.
d) All piping, at the pipe rack entrance of each unit (as minimum) and where
necessary, if the metallic continuity is not assured.

Equipment shall be grounded by a connection to the ground network or, for


electrical users, by a ground conductor in multiconductor cables.

Equipment shall not be loop or series connected to earth in such a way that
removal of the earth connection from one item would disconnect others from earth.
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DOC. NO. 8015-0151-SECL-00-890-EL-SP-00001 Job No. SO2476

All equipment aboveground connections shall be accessible for inspection.

Plastic enclosures (e.g. motor control stations, junction boxes) shall incorporate an
internal metal plate to maintain continuity with the earthing system.

Where a cable enters through a flexible conduit in any metallic enclosure, the
enclosure itself shall be earthed.

Structural steelwork may be considered as a protective conductor provided it is a


part of the common static and lightning earthing system and there is a permanent
metallic path for fault current via such steelwork and other earthing conductors
back to the source of the power supply.

For outdoor substation equipment, when it is widely spaced, individual local grids
may be established at the various equipment locations and the local grids shall be
interconnected and connected to earthing grid. Interconnecting conductors shall
not be less than the size of the conductor for main grid.

4.3.2. Buildings elements

The steel framework of buildings shall be grounded at the base of every corner
column and intermediate columns.

Pipe stanchions shall be grounded at every other stanchion by individual ground


rods or to ground grid and connected to the steel columns with minimum 70 sqmm
ground conductors.

Metal doors in buildings shall be bonded to their associated support posts by


means of flat, extra flexible copper braid or flexible cable.

4.3.3. Overhead lines

4.3.3.1. General

The earth system shall be designed so as to include all overhead line terminal
towers, which shall be earthed by extending the system so as to envelope all
towers within the earth system. Each tower shall be bonded directly to the earth
system from at least two locations.

4.3.3.2. Steel lattice structures

The reinforcing steel cage of the concrete foundation shall be bonded to the
respective tower stub angle by using a suitable size of steel wire. The connection
of wire to the stub angle shall be preferably through a mechanical connector
(clamp) and buried inside the concrete.
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TECHNICAL SPECIFICATION FOR Page 14 of 30
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DOC. NO. 8015-0151-SECL-00-890-EL-SP-00001 Job No. SO2476

Two opposite legs of lattice steel structures shall be grounded by means of


counterpoise conductors and two exothermic coupled copper clad ground rods. In
case the resistance is more than the required value, deep grounding or additional
counterpoise conductors and ground rods may be required on the remaining legs
of lattice steel structures.

When rocks is encountered, radial counterpoise or continuous counterpoise


arrangements terminated by a ground rod at the end may be required.

Wherever possible ground rods shall be installed underneath the footing (spread
foundations) to a minimum depth of 3 meter. For other types of foundations the
ground rod shall be placed at a distance of 8 m from the center of footing.

4.3.3.3. Steel pole structures

The reinforcing steel cage of the concrete foundation shall be bonded to the
anchor bolts.

Two exothermic coupled ground rods shall be connected at the base of steel pole
structures. Where greater resistance is encountered, multiple ground rods may be
also required. The spacing between the two rods shall be in the range of one to
two times the length of the rod.

4.3.3.4. Overhead ground wire

The overhead ground wire shall be electrically bonded at each structure as well as
tied solidly to the grounding system of the relevant substation.

Overhead ground wires terminated at steel structures shall be electrically bonded


to the structure. The mechanical dead-end hardware shall not be used as the
electrical path for conducting lightning surges or fault currents to the dead-end
structure. Steel dead-end structures are considered adequate for solidly grounding
properly terminated overhead ground wire to the grounding mat.

4.3.3.5. Ground resistance

The ground resistance of overhead lines structures located within a distance of


maximum 1.5 km from the connected substation shall be 10 Ω or less.

For distances of more than 1.5 km from the substation, the ground resistance shall
be 20 Ω or less.

4.3.4. Substation equipment

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Substation earth loop shall be made of a tinned copper rectangular bar connected
to the plant safety ground. All substation equipment enclosures and earth bars
shall be connected to the loop through bolted connections.

The metal structures of switchgear, lightning arresters, motor control centers,


disconnect switches, transformers, motors, etc., shall be individually connected to
the ground grid.

All grounding cable connections to electrical equipment shall be made only at the
points provided by the manufacturer.

Transformers tanks shall be grounded at two diagonally opposite points.

All control and relay panels shall have a continuous earth bus run along the bottom
of the panels. MV switchgears, LV switchgears and MCCs shall be connected to
the substation earth loop at two separate points.

Armor and metallic sheath (if provided) of all multicore cables shall be, unless
specified otherwise bonded to the switchboards earth bars.

Isolating and earth switch mechanism boxes shall be earthed by a connection


separate from that effecting the earthing of the associated switch.

Current and voltage transformers secondary circuits shall be earthed at one point
through links situated in an accessible position. Each separate circuit shall be
earthed through a separate link, suitably labelled. The links shall be of the bolted
type, having necessary provision for attaching test leads.

Instrument panels shall be grounded at each end of the panel lineup with separate
minimum grounding conductors run to the instrument ground grid.

4.3.5. Surge arresters

For surge arresters a local earthing connection shall be made by driving electrodes
into the earth near the arresters.

The connection from arrester to earth shall be as short and as straight as possible.

4.3.6. Motors

All motors shall have a ground conductor from the MCC or distribution panel
ground bus to the motor, connected in the motor terminal box. Such ground
conductor shall be part of the relevant multi-conductor power cable.

In addition, all motors shall have a visible, external ground connection from the
motor frame to the local ground grid.

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For all medium voltage (above 1 kV) motors, the number of external grounding
connections from the motor frame to the grounding grid shall be two.

4.3.7. Power and control cables

Cable armour shall be connected to earth at both sides (at the user side by means
of cable glands), with the exception of power single core cables.

High voltage cables (45 kV and above) armour earthing will be specifically
analysed and decided depending from the length, route and application.

4.3.8. Cable trays

Metallic cable trays shall be grounded to structures at regular intervals.

Bonding jumpers shall be installed in all those conditions where electrical


continuity between tray consecutive elements cannot be ensured. Namely:

 expansion splice plates (expansion joints);


 adjustable horizontal and vertical hinged connectors;
 situations where two adjacent cable trays are physically separated.

Non-metallic or coated with non-conductive coatings cable trays shall have


aground conductor installed in the tray.

4.3.9. Lighting fixtures and lighting poles

The conductive parts of the indoor installed lighting fixtures, junction boxes &
convenience sockets shall be connected to the earth by means of the protective
conductor of multicore cable connected to earth bus bar of lighting panel.

In case of outdoor equipment such as lighting pole, the protective conductor shall
be connected to its earth terminal.

4.3.10. Vessel, tanks, exchangers, towers and other process containment equipment

Exposed conductive parts of these elements shall be connected to earth loop of


each unit. Any relatively small equipment in a pipe line, such as a strainer, filter,
dropout drum, trap, etc., shall not be classified as an individual process
containment equipment but shall be treated as a part of the piping.

The electric continuity of this kind of equipment shall be assured at manufacturing


stage.

Process containment equipment that is located in a process structure and are not
insulated from the structure shall be considered grounded through their supports.
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4.3.11. Fences and perimeter earthing

Substation and electrical equipment enclosure fences shall be grounded. The


fence surrounding the substation shall be earthed to its own earth grid and the
fence earth grid shall be connected to the main station earthing grid.

A continuous conductor having a section 70 mm2 of shall be laid outside the


periphery of the substation site at a distance of 1.5 to 2.0 meters from the
boundary fence and at a depth of about 0.6 meters below the surface. This shall
be welded to earth rods installed at adequate intervals and at points adjacent to
each corner and immediately below any overhead line entering or leaving the site.
The system shall be incorporated as an integral part of the plant ground grid.

The location of the mesh conductors shall be such as to enable all items of
equipment to be connected to the earth system via the shortest possible route. All
corner fence posts and posts adjacent to earth rods shall be effectively connected
to the earth conductor.

Perimetral fences shall be grounded at intervals not to exceed 150 m and shall
also be grounded at all power line crossings by grounding at the crossing and
again within 45 m on each side. Posts shall be grounded with minimum 25 mm2
conductor.

All elements of swinging metallic fence gates shall be bonded to their associated
support posts by means of flat, extra flexible copper braid. Cross-sectional area of
braid shall equal or exceed minimum 25 mm2. Gate support posts shall be
grounded.

4.3.12. Steel structures

The main members of the steel structures shall be earthed by continuous copper
connections bonded to the steelwork and these connections shall be connected
separately at each column to the main or subsidiary earth.

Steel structures and the steel framework of buildings shall be grounded at the base
of every corner column and intermediate columns at distances not greater than 18
m.

4.3.13. Piping

Unless otherwise specified, steel piping is generally considered adequately


grounded through its associated process containment equipment and pipe
supports.

4.3.14. Loading areas

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Loading area and lorry’s tanks shall be connected to earth through an earthing reel
or a permissive earth detector, if required by process or safety.

4.4. Neutral grounding

The 132 kV system shall be effectively earthed.

33, 6.6 kV systems shall be earthed through a grounding resistor.

400 V system shall be solidly earthed.

4.5. Grounding wires sections

The followings minimum grounding wires cross sections shall be applied:

 Main underground grid 70 mm2


 Main U/G loop around substations 70 mm2
 Generators 70 mm2
 Power Transformers 70 mm2
 MV and LV Switchgears and MCCs 70 mm2
 UPS and DC systems 70 mm2
 MV motors 70 mm2
 LV motors up to and including 30 kW 25 mm2
 LV motors above 30 kW 70 mm2
 Local motor control stations 6 mm2
 LV Junction boxes 6 mm2
 MV Junction boxes 70 mm2
 Lighting Dist. Boards 25mm2
 Power Dist. Boards 70 mm2
 Steel structures 70 mm2
 Tanks, Exchangers, Vessels and Towers 70 mm2
 Fencing 25 mm2

5. STATIC ELECTRICITY PROTECTION

Static electricity protection shall be provided in all those cases where:

a) operating personnel may be subject to discharge of static electricity;


b) quality of material is affected by static electricity;
c) operating efficiency of machines is impaired by static electricity;
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d) explosions or fires from flammable liquids, gases, dust and fibers may be
caused by a spark.

Whenever flammable vapor, liquid or combustible dust is present, grounding and


bonding facilities for static electricity control shall be provided for connecting
discharge nozzles, trucks and tank cars, drums, piping systems etc.

Electrically conductive piping and process equipment carrying flammable materials


shall be grounded and continuity bonded. Standard flanged joints are considered
to achieve sufficient continuity bonding through normal joint components (nut-to-
flange contact).

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6. LIGHTNING PROTECTION

6.1. Design criteria

6.2. General

The lightning protection system design shall be based on IEC and NFPA standards.

The protected zones shall be evaluated using the rolling sphere method (RSM). As
the step leader of a lightning bolt jumps toward the ground, it steps toward the
grounded objects nearest its path.

The maximum distance that each step may travel is called the “critical distance”
(striking distance) and is proportional to the electrical current. Objects are likely to
be struck if they are nearer to the leader than this critical distance.

Electricity travels along the path of least resistance, so an object outside the critical
distance is unlikely to be struck by the leader if there is a grounded object within
the critical distance. Noting this, locations that are safe from lighting can be
determined by imagining a leader’s potential paths as a sphere that travels from
the cloud to the ground.

Given an assumed striking distance, one can define an imaginary surface above
the ground and above objects on the ground such that, when the downward
propagating leader passes through that surface at a specific location, the leader is
“captured” by a specific point on the ground or on a grounded object.

For lightning protection it suffices to consider all possible spheres as they touch
potential strike points. To determine these points, RSM simulates a potential
leader position and considers a sphere around it with an associated radius equal to
the striking distance.

At any point where the sphere touches the ground the lightning is most likely to
strike, and the points which the sphere cannot roll across and touch are the safest
from lightning.

6.2.1. Lightning Protection Level (LPL)

For each LPL a set of maximum and minimum lightning current parameters is fixed.
Maximum values are used to design lightning protection components (e.g. cross-
section of conductors, thickness of metal sheets, current capability of surge
protection devices and separation distance against dangerous sparking) and to
define test parameters simulating the effects of lightning on such components.

On the other hand, minimum values of lightning current amplitude for different LPL
are used to derive the rolling sphere radius in order to define the lightning
protection zone which cannot be reached by direct strike.
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The minimum values of lightning current parameters together with the rolling
sphere radius are used for positioning the air termination system and to define the
Lighting Protection Zones LPZ (IEC 62305-1 § 8.1).

6.2.2. Lightning Protection Zones (LPZ)

As per NFPA 780, § 4.7.3, the zone of protection shall include the space not
intruded by a rolling sphere having a radius of 150 ft (45.7 m).

Figure 1 Protection Zones delimited using the RSM

Where the sphere is tangent to earth and resting against a strike termination
device, all space in the vertical plane between the two points of contact and under
the sphere shall be considered to be in the zone of protection.

A protected zone shall also be formed where such a sphere is resting on two or
more strike termination devices and shall include the space between those devices
(see Figure 1).

All possible placements of the sphere shall be considered when determining the
zone of protection using the rolling sphere model.

For structure heights exceeding 150 ft (45.7 m) above earth or above a lower strike
termination device, the zone of protection shall be considered to be the space in
the vertical plane between the points of contact and under the sphere where the
sphere is resting against a vertical surface of the structure and the lower strike
termination device or earth.

The zone of protection shall be limited to the space above the horizontal plane of
the lowest terminal unless it can be extended by further analysis, such as in rolling
the sphere to be tangent to earth.

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6.3. Lightning Risk Assessment (LRA)

6.3.1. Evaluation

NFPA 780 § Annex L and IEC 61024-1-1 provide a methodology to determine the
risk of damage due to lightning. This methodology considers only the damage
caused by direct strike to the building or structure to be protected and the currents
flowing through the lighting protection system.

The complete risk assessment method is a guide that takes into account not only
the lightning but rather also factors such as building environment, type of
construction, structure occupancy, structure contents and lightning stroke
consequences.

Particularly, lightning risk for a structure can be assessed as the product of


accepted average annual frequency of lightning and the consequences of the
strike to the structure (NFPA 780 § L.1.5).

For a given structure, the procedure for the LPS selection (IEC 61024-1-1) is as
follows:

- Estimation of the ground flash density (Ng).

- Calculation of the equivalent collection area (Ae) from the structure’s dimensions
and position.

- Selection of the class of the structure.

- Assessment of the direct lightning flash frequency to a structure (Nd) from the
above parameters.

Finally, with the accepted lightning flash frequency (Nc) provided according to the
type of structure, the values of Nd and Nc are compared between them in order to
determined whether the structure is already protected or not.

If Nd < Nc non additional protection for the structure is required. But if Nd > Nc the
critical efficiency must be computed and a LPS with an efficiency equal or bigger
than that must be secured.

Efficiency of an LPS (E) is defined as the ratio of the average annual number of
direct lightning flashes which cannot cause damage to the structure to the direct
lightning flash number to the structure (Nd) (IEC 61024-1-1 §1.2.13). Efficiency
values are used to rank the Lightning Protection Levels; a LPL I has a higher
efficiency that a LPL IV.

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6.3.2. Lightning Ground Flash Density (Ng)

The lightning ground flash density is expressed in terms of ground strokes per
square kilometer per year and should be determined by measurement. Being the
lightning ground stroke density Ng not available, it may be estimated using the
following relationship (IEC 61024-1-1, § 3.2):

N g  0.04  Td per km2 per year,


1.25

where Td is the number of thunderstorm days per year obtained from isoceraunic
maps.

Particularly for Iraq, Td = 15 (see paragraph 3) and

N g  0.04  131.25  1.1807  1.2 stroke per km2 per year

Figure 2 Isoceraunic Map of the World

6.3.3. Equivalent Collective Area of a Structure (Ae)

Ae refers to the ground area having the same yearly direct lightning flash
probability as the structure. In fact, it is an increased area for the structure that
includes the effect of the height and location of the structure (NFPA 780 § L.4).

The equivalent collective area, Ae, of a structure is the area obtained by extending
a line with a slope of 1 to 3 from the top of the structure to ground completely
around the structure.

Where the equivalent collective area of a structure totally covers another structure,
that structure is disregarded. And when the collective areas of several structures
are overlapped, the corresponding common collection area is considered as a
single collection area.

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For design purposes, in the assessment of Ae only those objects which have
permanent durability and adequate resistance against lightning stresses must be
taken into account (IEC 61024-1-1 § 4.2).

6.3.4. Environmental Coefficient (C1)

The environmental coefficient C1 accounts for the topography of the site of the
structure and any objects located within the distance 3H from the structure that can
affect the collective area (NFPA 780 § L.4.3).

Table 1 Determination of the Environmental Coefficient C1


(NFPA 780 Table L.4.3)

Relative Structure Location C1


Structure surrounded by equal or taller structures. 0.25
Structure surrounded by smaller structures. 0.50
Isolated structure. 1.00
Isolated structure on a hilltop. 2.00

6.3.5. Direct Lightning Flash Frequency (Nd)

The yearly lightning strike frequency Nd to a structure is determined by the


following equation (NFPA 780 § L.3):

N d  N g  Ae  C1  10 6

Where

Ng = Lightning ground flash density (km2 year)-1.


Ae = Equivalent collective area of the structure (m2)
C1 = Environmental Coefficient.

6.4. Lightning Protection System (LPS)

In absence of a LRA, LPS design basis assumptions will consider that the height of
the rods located around and within the periphery of the buildings shall be not less
than the sag of a 45 meters radius sphere between points, corresponding to a LPL
III level as the maximum Lightning Protection Level required according to the
regular rolling sphere radius associated to the LPLs (IEC 62305-1 Table 6).

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Table 2 Minimum Values of Lightning Parameters


(IEC 62305-1 Table 6)

Interception Criteria LPL


Symbol Unit III
Minimum Peak Current I kA 10
Rolling Sphere Radius R m 45

For a LPL III, assuming a polarity ratio of 10% positive and 90% negative flashes,
a logarithmic normal distribution for the parameter’ statistical behavior and the
cumulative frequency distribution as per IEC 62305-1 § Figure A.5; the values of
Table 3 must be used in the simulation of the LPS, the selection of the lighting
protection components and/or any further protective measures.

Table 3 Maximum values of lightning parameters


(IEC 62305-1 Table 5)

First short stroke LPL


Current Parameters Symbol Unit III
Peak Current I kA 100
Short Stroke Charge Qshort C 50
Specific Energy W/R MJ/Ω 2,5
Time Parameters T1/T2 µs/µs 10/350
Subsequent short stroke LPL
Current Parameters Symbol Unit III
Peak Current I kA 25
Average Steepness di/dt kA/µs 100
Time Parameters T1/T2 µs/µs 0.25/100
Long stroke LPL
Current Parameters Symbol Unit III
Long Stroke Charger Qlong C 100
Time Parameters Tlong s 0,5
Flash LPL
Current Parameters Symbol Unit III
Flash Charge Qflash C 150

Interception efficiency of a LPS depends on the minimum lightning current


parameters and on the related rolling sphere radius. For a given rolling sphere
radius it can be assumed that all flashes with peak values higher than the
corresponding minimum peak value will be intercepted by natural or dedicated air
terminations. Therefore the probability of the lightning parameters is assumed to
be the interception probability (IEC 62305-1 § A.4).

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Taking into account a polarity ratio of 10% positive and 90% negative flashes, the
interception probability can be calculated (see Table 4).

Table 4 Probabilities for the limits of the lightning current parameters.


(IEC 62305-1 Table 7)

Probability that lighting current parameters LPL III


Are greater than the minimum values defined in Table 0.91
Are smaller than the maximum values defined in Table 0.97

Since the protective measures specified in the standards are effective against
lightning whose current parameters are in the range specified by the LPL, the
efficiency of a protection measure is assumed to be equal to the probability with
which lightning currents parameters are inside the probability ranges of Table 4
(IEC 62305-1 § 8.1).

6.5. Specific requirements

6.5.1. General

Lightning protection of structures, where required, shall be achieved by means of


an air terminal system and/or an overhead ground wire connected with a metallic
conducting path to driven ground rods or ground grid, and/or by installing a wide
area coverage Early Streamer Emission (E.S.E) air terminal within the facility.

Lightning protection of buildings, where required, shall be achieved by means of a


Faraday cage connected with a metallic conducting path to driven ground rods or
ground grid.

Protective conduits for lightning protection wires shall be of plastic or non-ferrous


materials.

6.5.2. Air terminals

Air terminals may be of any form of solid or tubular cross-section. Air Terminals
may also be of a wide coverage ionization or Early Streamer Emission Type.

Air terminals shall be at least the equivalent in weight and stiffness of a copper
tube having an outside diameter of ⅝” and a wall thickness of 1 mm. ⅝” and ¾”
ground rounds, installed with the point upwards, can be used as air terminals.

Air terminals shall have a minimum height of 25 cm projecting above the protected
surface. Maximum height shall be 100 cm; any air terminal exceeding 60 cm in
height shall be braced. Air terminals shall be placed within 60 cm of the ends of
ridges, corners or edges of main roofs.

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6.5.3. Buildings

The required conditions of protection for buildings in general are met by placing
metal air terminals on the uppermost parts of the building or its projections, with
conductors connecting the air terminals with each other and to ground.

6.5.4. Substations

Power stations and substations require protection from direct strokes obtainable by
applying the circular-sided protection zone and in addition need protection from
induced stroke lightning (transient over voltage due to lightning or switching surges)
by properly applied arresters and surge protective equipment above 66 kV.

Additional protection of attached overhead lines by means of an overhead


grounded conductor or static wire for 600 meters away from the substation is
recommended to preclude direct strokes on this section of the line and to reduce
the duty on the station surge arresters.

6.5.5. Substation equipment

When required, the power transformer insulation must be protected from the
voltage surge of the traveling wave coming in on the lines. This protection shall be
accomplished by means of lightning arresters located as near as possible to the
equipment to be protected. A lightning arrester at the transformer terminals limits
the voltage to the discharge voltage of the arrester. An arrester whose discharge
voltage is lower than the BIL rating of the transformer insulation must be chosen. A
minimum of 20% margin shall be maintained.

Electrical systems which have the system neutral ungrounded require arresters
rated at 100 percent of system line-to-line voltage. Electrical systems which have
the system neutral grounded shall have arresters rated at 80 to 85 percent of the
system line-to-line voltage. This is usually accomplished by selecting an arrester
one nominal voltage increment below the line-to-line voltage. Several sets of
appropriately sized and located arresters may be necessary to properly protect the
substation.

All lightning arresters, air terminals and overhead static lines shall be connected to
the bonding and grounding system.

Whenever it is possible for direct strokes of lightning to strike a line at or near the
station, the margin of safety provided by the transformer protective equipment may
not be adequate to protect the insulators and switches in the switch yard. In this
case it may be necessary to install additional arresters at the entrance to the
station. These arresters will limit the magnitude of the voltage surges entering the
station, thereby protecting the switches and insulators.

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Substation grounding resistance shall assure proper arrester operation.


Additionally, the surge arrester ground conductor must be as short and straight as
possible.

6.5.6. Overhead lines

Ground or static wires with sufficient mechanical strength must be located to shield
the line conductors adequately from direct strokes. The size of the static line shall
be based on mechanical rather than electrical characteristics.

Adequate clearance from ground wires to conductors must be maintained. Mid-


span clearance must also be considered.

6.5.7. Vessel, tanks, exchangers, towers and other process containment equipment

Metallic process containment equipment, stacks and steel process containment


equipment of riveted, bolted, or welded construction with or without supporting
members, are considered to be reasonably well protected against lightning if:

- all metallic pipes entering the equipment are in contact with the equipment;
- equipment has adequate thickness.

For fixed roof tanks, roof shall be continuously welded to the shell to provide a
continuous electrical connection.

For floating roof tanks, flexible bonding conductors shall be provided between the
expandable roof and the rigid supporting structure. Conductors shall be made as
short as possible but shall be sufficiently long to prevent breakage due to the
movement of the roof.

6.5.8. Cable ways

Aboveground cable ways in cable tray could be subject to direct strokes. When the
tray is protected by overhead structures that provide the zone of protection, it shall
be considered as protected when bonded and grounded; in other situations (ex.
trays mounted on top of structures subject to direct strokes) they shall be protected
by overhead static lines.

Underground duct banks protection for lightning flashes striking the ground shall
be done by burying a bare copper wire in the earth above the duct bank.

7. ELECTROMAGNETIC COMPATIBILITY

7.1. Cable shielding

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Shielded cables shall be grounded to prevent or minimize the harmful effects of 50


Hertz power system induced currents and circulating currents from a lightning
stroke or switching surges.

7.2. Communications and instrument cable protection

Lightning protection usually consists of air terminals or static lines grounded at the
base of the poles, thereby establishing many ground points. This, in turn, results
in earth currents and induced currents circulating through the lightning protection
system. This current flow in these conductors causes a magnetic field which can
be undesirable in the vicinity of instrumentation and communication.

The correct practice is to ground the overall shield at both ends and the individual
pair shield at the controlling end only.

In lightning prone areas the use of armoured communications or instrumentation


cables offer additional surge protection. This armour shall be grounded at both
ends.

Transient surge suppressor networks (TSSN's) shall be used for lightning and
surge voltage protection of solid state equipment and regulators, computers,
critical instrumentation and critical buses. These units can be applied at 400 volts
and lower.

8. SURGE, LIGHTNING AND OVERVOLTAGE PROTECTORS

8.1. Lightning arresters

Lightning arresters shall be installed as required.

On systems having a solidly grounded neutral, reduced rating arresters can be


used.

Full rated arresters shall be required on ungrounded neutral systems or resistance


grounded systems. Arrester rating and equipment basic insulation level (BIL) shall
be coordinated.

When required, station-class zinc-oxide type arresters (MOV's) shall be used for
lightning and surge voltage protection of power transformers (defined as above
500 kVA) and other station apparatus. Intermediate class MOV's shall be utilized to
protect small and medium sized substations where the value of the protected
apparatus does not justify the use of station-class arresters.

Distribution type MOV's shall be used for lightning and surge protection of
distribution transformers (defined as up to 500 kVA), regulators, capacitors, cables,
and other apparatus on distribution circuits. Secondary zinc-oxide type arresters
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shall be used on electrical systems below 400 volts. It is recommended that a


wavefront capacitor be used in parallel with the arrester for protecting critical
transformers, motors, and electronic equipment.

8.2. Coupling

Safety grounding grid and functional grounding grid shall be connected through an
earthing system coupler. Coupler shall be located indoors, between a safety and a
functional grounding bar.

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