Professional Documents
Culture Documents
Note: The source of the technical material in this volume is the Professional
Engineering Development Program (PEDP) of Engineering Services.
Warning: The material contained in this document was developed for Saudi
Aramco and is intended for the exclusive use of Saudi Aramcos
employees. Any material contained in this document which is not
already in the public domain may not be copied, reproduced, sold, given,
or disclosed to third parties, or otherwise used in whole, or in part,
without the written permission of the Vice President, Engineering
Services, Saudi Aramco.
Chapter : Electrical
File Reference: EEX20502
Engineering Encyclopedia
Electrical
Design and Application of Equipment Grounding
CONTENTS
PAGES
Engineering Encyclopedia
Electrical
Design and Application of Equipment Grounding
Engineering Encyclopedia
Electrical
Design and Application of Equipment Grounding
Chapter 6
Chapter 8
Chapter 9
Chapter 12
Chapter 13
Chapter 6
General Requirements
Generators and Motors
Switchboards
Transmission Substations
Transmission Lines
Overhead Distribution
Industrial Plant Areas
Distribution and Utilization - 600 V and Below
Cable Sheaths
Fences
Instruments, Meters, Relays, Instrument Transformers
Cable Trays
Conduits
Engineering Encyclopedia
Electrical
Design and Application of Equipment Grounding
Chapter 8
General Requirements
Grounding Electrode
Grounding Conductors
Installation
Chapter 9
General Requirements
Need for Protection
Materials
Component Parts of a Lightning Protection System
Chapter 12
General Requirements
Terminology
Design Criteria
Earth Resistance and Bonding Requirements
Review and Adoption of GTE Practices
Engineering Encyclopedia
Electrical
Design and Application of Equipment Grounding
Chapter 13 of SADP-P-111, titled "Safeguards Against Static Electricity, Lightning, and Stray
Currents," describes current Saudi Aramco practices and requirements to safeguard against
possible ignitions from static electricity, lightning, and stray currents when a hazard exists in
the handling of flammable materials.
Chapter 13 is intended to supplement but not to replace Article 250 (Grounding) of the
National Electrical Code (NFPA 70), which deals with the protection of electrical installations
by grounding or bonding.
Chapter 13 also discusses the Saudi Aramco requirements to safeguard against possible
degradation or possible failures, as a result of the presence of static electricity, of
microelectronic components currently in use in communications and in process control
computers. The following specific topics are discussed in Chapter 13:
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_
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Equipment Grounding
Fence Grounding
Tank Grounding
Lightning Protection
Engineering Encyclopedia
Electrical
Design and Application of Equipment Grounding
IEEE Standards
IEEE Standards give information on how to
This information is the consensus opinion of
standard that applies to the design and the
Standard 142. The following sections of
equipment grounding:
_
_
Section 2
Section 3
Section 2
Section 2 of IEEE Standard 142 is titled "Equipment Grounding." Section 2 discusses the
problems caused by connection of the frames and the enclosures of electrical apparatus (such
as motors, switchgear, transformers, buses, cables, conduits, building frames, and portable
equipment) to a ground system. Section 2 outlines the fundamentals of making the
interconnection system or the ground-conductor system between electrical equipment and the
ground rods. The following specific topics are discussed in Section 2:
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_
_
_
_
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Basic Objectives
Fundamental Concepts
Equipment Grounding as Influenced by Type of Use
Outdoor Open-Frame Substations
Outdoor Unit Substations
Outdoor Installations Serving Heavy Portable Electric Machinery
Interior Wiring Systems
Interior Unit Substations and Switching Centers
Section 3
Section 3 of IEEE Standard 142 is titled "Static and Lightning Protection Grounding."
Section 3 discusses the problems (such as how static electricity is generated) associated with
static electricity, what processes produce static electricity, what must be done to prevent static
electricity generation, or what must be done to drain static electric charges to earth to prevent
sparking. Section 3 also discusses the methods for protection of structures against the effects
of lightning. The following specific topics are discussed in Section 3:
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Static Grounding
Lightning Protection Grounding
Engineering Encyclopedia
Electrical
Design and Application of Equipment Grounding
Engineering Encyclopedia
Electrical
Design and Application of Equipment Grounding
Voltage Exposure
Minimum Equipment Damage
Isolation of Fault
Minimize Electric Noise in the System
Voltage Exposure
Voltage exposure is defined as the unintentional contact between an energized electrical
conductor and the metal frame or the structure that encloses (or is adjacent to) the conductor.
This unintentional contact causes the metal frame or the structure to become energized at the
same voltage level that exists in the energized conductor.
The method for reducing the possibility of voltage exposure is to install an effective
equipment grounding conductor on the metal frame or the structure that encloses the
energized conductor. An effective equipment grounding conductor must provide a low
impedance path from the metal frame (or structure) to the zero-potential ground reference
junction that is located at the equipment power supply. The impedance of the grounding
conductor must be low enough to carry full ground-fault current without creating an
impedance (IZ) voltage drop large enough to be dangerous to personnel.
Minimum Equipment Damage
Electrical equipment that does not have an equipment ground connection or that has an
improperly installed equipment ground connection can easily be damaged under ground fault
conditions. The damage can be caused by the heat that is produced from the increased current
flow, the magnetic forces that are produced from the increased current flow, or the energy that
is released from an arcing ground fault. The possibility of the occurrence of equipment
damage depends on the following variables:
_
The length of time that the ground fault current is allowed to flow
(amount of time before protective devices isolate the ground fault).
Engineering Encyclopedia
Electrical
Design and Application of Equipment Grounding
The type of conductors that are used as the ground return path (insulated
or non-insulated).
The possibility of equipment damage increases with the length of time that the ground fault
current is allowed to flow. This length of time can be minimized by ensuring that a sufficient
amount of ground fault current is available to quickly operate the protective equipment. The
major step involved in providing a sufficient amount of ground fault current is to ensure that
the equipment ground return path has the lowest possible impedance. A low impedance
ground return path can be achieved through use of the following techniques:
_
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Design and Application of Equipment Grounding
The bonding surfaces should not be made from raw (untreated) metal.
The possibility of equipment damage also increases with the use of non-insulated equipment
ground conductors. Large voltage differences can exist between components such as
raceways and a non-insulated equipment ground conductor under ground fault conditions.
This voltage difference can cause arcing between the non-insulated equipment ground
conductor and the raceway. This arcing can damage adjacent conductors. The possibility of
equipment damage from non-insulated equipment ground conductors can be eliminated
through use of insulated equipment ground conductors.
Engineering Encyclopedia
Electrical
Design and Application of Equipment Grounding
Isolation of Faults
An electrical fault is defined as a physical condition that causes a device, a component, or an
element to not perform in a required manner. Although this definition applies to all types of
electrical faults, this section is only concerned with ground faults. The specific definition of a
ground fault is an insulation failure between a conductor and a ground or a frame.
The following methods of system grounding are used in Saudi Aramco electrical systems:
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Solid grounding
Resistance grounding
Impedance grounding
Ungrounded
The method of system grounding that is applied in a given Saudi Aramco electrical system
has no bearing on the method of equipment grounding for use in a Saudi Aramco electrical
system. The only method of equipment grounding is to connect a suitable conductor size
between the noncurrent-carrying metal parts of all equipment, raceways, and other such
enclosures and the system ground conductor and/or the grounding electrode conductor. The
use of this method of equipment grounding will allow the protective devices to quickly isolate
the ground faults should a ground fault occur.
The following two types of protective devices are used to isolate ground faults:
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Fuses
Circuit Breakers
E2 starters for H.V. motors or NEMA starts for low voltage motors
Figure 1 shows the use of fuses to isolate a ground fault in a motor. The fuses that are shown
in Figure 1 contain internal conductors or links that melt when the current that is passing
through the fuse exceeds the rating of the fuse. The fuse isolates a ground fault through
reaction of an open circuit when the internal link melts. The following sequence of events
occurs during the isolation of a ground fault in a motor by fuses:
_
A ground fault develops between one of the motor windings and the
motor enclosure.
Ground fault current in excess of the rating of the fuses begins to flow
from the transformer secondary windings through the fuses.
Engineering Encyclopedia
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Design and Application of Equipment Grounding
The ground fault current flows through the motor windings to the motor
enclosure through the ground fault.
The ground fault current causes the internal links in the fuses to melt.
This melting creates an open circuit and isolates the ground fault.
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Design and Application of Equipment Grounding
A ground fault develops between one of the motor windings and the
motor enclosure.
The ground fault current flows through the motor windings to the motor
enclosure through the ground fault.
The ground fault current then flows through the motor enclosure to the
separate equipment ground conductor and back to the power source
through the system ground.
The ground fault current in excess of the setpoints of the 50GS ground
sensing relays begins to flow from the transformer secondary windings
through the current transformers to the 50GS ground sensing relays.
The ground fault current that flows through the current transformers of
the 50GS ground current sensing relays causes the 50GS ground sensing
relays to activate.
The 50GS ground sensing relays send a signal to the circuit breaker (52)
that causes the circuit breaker to open to interrupt the power and to
isolate the ground fault.
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Design and Application of Equipment Grounding
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Crosstalk
Hum
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The grounding connection will be made through use of thermite welding, brazing, or
approved compression grounding connections (Burndy Hyground System or equivalent).
Bolted or a ready means of disconnection for testing purposes, such as bolted connections,
shall be provided in the grounding connection to the following:
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Generator neutrals
Transformer neutrals
Grounding electrodes such as grounded well or groups of grounded
rods.
The sizing of the ground conductor is dependant on the voltage level and the short circuit of
the power system of the electrical system to which the equipment is connected. The
conductor size for the higher voltage system should be used for mixed voltage systems. The
voltages are broken down as follows:
_
_
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The size of the copper grounding conductors for power source transformer tanks, transformer
neutrals, main switchboards, or other equipment that is supplied directly from the LV (low
voltage) side of a transformer, without an intervening protection device in a system rated
600V and below, depends on the following:
_
The type of protection that is provided for the primary winding of the
lower source transformer (e.g., fuses or circuit breakers).
Section 1 of Work Aid 2 contains the formula, the table, and the procedure for use in
determining the size of the grounding conductors that were previously described.
The size of equipment grounding conductors for equipment that is beyond the main
switchboard or the transformer output protection device in systems rated 600V and below
must comply with Article 250-95 of the National Electrical Code (NEC). Article 250-95
states that the size of the equipment grounding conductor is based on the rating of the
automatic overcurrent device in the circuit that is ahead of the equipment. Section 2 of Work
Aid 2 contains a procedure and a table for use in determining the size of the equipment
conductors that were previously described.
Conductor Sizes - Systems Over 600V
The size of the grounding conductor for electrical systems over 600V is based on the
following type of system grounding that is used.
_
_
Solidly Grounded Systems - Grounding conductor sizes for solidly grounded systems
over 600V are based on the three-second, short-time current capabilities of the circuit
breaker that is ahead of the grounding conductors. The three second, short-time
current capability must be derived through use of a formula in cases where a circuit
breaker is not installed or where a three-second, short-time current capability is not
assigned.
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Design and Application of Equipment Grounding
systems over 600V are based on the ten second rating of the neutral grounding device,
or the ten second rating of the combined neutral grounding devices for systems that
have multiple grounding devices that are connected in parallel. This basis applies to
most impedance grounded installations. The two exceptions to the basis for the sizing
of grounding conductors in impedance grounded systems over 600V are as follows:
_
Section 4 of Work Aid 2 contains the table and the procedure to be used to determine
grounding conductor sizes in impedance grounded systems over 600V. This section of
Work Aid 2 applies to determining the size of all grounding conductors in impedance
grounded systems over 600V. These grounding conductors include the following:
_
_
_
_
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Design and Application of Equipment Grounding
Conduit Grounding
Conduit must be satisfactorily grounded to prevent creating electrical shock hazards due to
voltage exposure. A faulted conductor that contacts metal conduit will raise the conduit to the
voltage level of the failed conductor. A person that contacts this energized conduit and
ground will receive an electrical shock unless the conduit is satisfactorily grounded. All
conduits must be directly grounded regardless of the system voltage.
Conduit that does not comply with the termination methods listed above must have a separate
grounding connection bonded to both ends of the conduit. Metal conduit that contains
conductors of systems above 600V must also have a separate grounding connection bonded to
both ends of the conduit.
Connections to Earth
A very important aspect of grounding equipment is the final connection to the earth. This
section provides information on the methods for use in making ground connections to earth in
the following locations:
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Saudi Aramco uses the following approved methods for ground connections below ground
line:
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making electrical connections between two pieces of copper or between copper and
steel. The thermite welding process does not require an outside source of heat to
produce the weld. The weld is produced by mixing powdered aluminum and iron or
copper oxide in a container and by placing this mixture in a graphite crucible (mold).
The mixture is then ignited through use of a flint lighter, which starts the highly
exothermic reaction. The heat from the exothermic reaction turns the two metals into a
superheated liquid that flows through and around the conductors to be joined, thus
welding the conductors together.
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Ground connections between the equipment ground conductors and the earth
electrodes that are made through use of thermite welding must also be equipped with a
separate disconnecting means, such as bolted joints. The separate disconnecting
means must facilitate separation of the equipment ground from the system ground
during testing.
Brazed Connections - Brazed connections are for use in making electrical connections
A brazed connection is made by placing together the two surfaces to be joined and
then applying heat to the surface through use of a torch. The two surfaces are
preheated with the torch, and then a copper alloy filler material is applied to the
surfaces to be joined. The filler material will melt when heated by the torch and will
flow through and around the surfaces to be joined. The filler material solidifies and
fuses the two surfaces together after the heat is removed. The electrical connection
that results from brazing has characteristics that are similar to the characteristics of a
thermite welding connection. Thermite welding connections are preferred over brazed
connections because thermite welding connections require fewer skills, less
equipment, and less time to install than brazed connections.
Compression Connections - A compression connection is made by placing a compression
fitting (lug) over the end of the grounding conductor and by crimping the fitting to the
conductor through use of a special compression tool and die. The only approved
compression connectors for use in making ground connections in Saudi Aramco
electrical systems are Burndy Hyground Systems or an equivalent. An acceptable
compression grounding connection must have the following characteristics:
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Design and Application of Equipment Grounding
The tensile strength and the torque strength of the connection joint
should be greater than the tensile strength and the torque strength of the
conductor.
The sequential aging test (sequential heat cycle, freeze-thaw cycle, salt
spray test, heat cycle, and short circuit) should not damage the
grounding connector.
After compression, the DIE should leave a mark on the connector that
matches the original DIE index number on the connector.
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For ground connections that are made above the ground line in Saudi Aramco electrical
systems, the three methods that apply to ground connections made below the ground line must
be used, in addition to bolted connections.
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Bonding
Bonding is defined as the permanent joining of metallic parts to form an electrically
conductive path that will assure electrical continuity and the capacity to safely conduct any
current likely to be imposed.
There is a difference between equipment bonding and equipment grounding. Equipment
bonds are installed to ensure that continuity exists between all the noncurrent-carrying metal
portions of electrical equipment. Equipment grounds are installed to ensure that continuity
exists between the noncurrent-carrying metal portions of electrical equipment and an earth
ground. Equipment bonds should be installed when it is possible that continuity will not exist
between one noncurrent-carrying metal portion of electrical equipment and the noncurrentcarrying metal portion of the electrical equipment that is connected to the equipment ground
conductor. Figure 3 shows an example of when an equipment bond should be installed.
Equipment Bond
Figure 3
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Design and Application of Equipment Grounding
Figure 3 shows that the equipment ground conductor is terminated at the ground terminal on
the back of the noncurrent-carrying, metal outlet box. Figure 3 also shows an equipment
bonding jumper that connects the noncurrent-carrying metal portions of the receptacle to the
ground terminal. This bonding connection is necessary to ensure that there is continuity
between the noncurrent-carrying metal portions of the receptacle and the noncurrent-carrying
metal outlet box.
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Bonding (Cont'd)
Equipment bonding is accomplished through use of approved bonding jumpers.
following are examples of approved bonding jumpers:
The
Bonding screws that are included as part of electrical equipment for the
sole purpose of equipment bonding.
A copper conductor with approved lugs that are attached to both ends of
the conductor.
Motor/Generator Grounding
Saudi Aramco requires the frames of generators to have at least two grounding connections
and the generator prime mover to have a separate grounding connection. Saudi Aramco also
requires motor frames to have at least one grounding connection.
Care should be taken to ensure that insulated components, such as insulated bearing pedestals,
remain ungrounded. A shorting strap should be installed across the insulation on the coupling
end to maintain the motor frame at ground potential. This shorting strap should contain a test
link that is to be removed when the bearing insulation is tested. The bearing on the noncoupling end of the motor should remain insulated at all times to prevent shaft currents.
High Voltage Switch Grounding
For high voltage disconnecting switches to be hand operated, an operator must be present
near a grounded structure, at a point where an opening of an energized circuit or a mechanical
failure and electrical breakdown of the switch insulator could result in an arc to the structure.
Because a large percentage of fatal accidents is associated with the operating handles of high
voltage switches, high voltage switches must be grounded.
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Conduit, cable tray, cable armor, or cable shield is not to be the sole
means of grounding equipment. A segment equipment grounding
conductor also must be installed in the conduit, cable tray, cable, or
cord. Metallic conduit and cable tray is to be grounded at both end
points.
The shields and the armor of power cables are to be grounded at both
ends. The continuity across splices is to be maintained through bonding
across the splices.
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Switchboards
SAES-P-111 and SADP-P-111 establish the following grounding requirements for
switchboards:
_
All switchboards are to be equipped with a grounding bus that runs the
length of the switchboard and that is mounted in or on the switchboard.
This grounding bus is usually supplied by the manufacturer. The
grounding bus is to be connected at each end to the installation ground
bus or ground grid.
Transmission Substations
SAES-P-111 and SADP-P-111 contain the grounding requirements for transmission
substations. These requirements are sub-divided as follows:
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The equipment grounding connections are to be separate from the system or neutral
grounding connection. Power transformer tanks due to have two grounding connections.
Cooler banks, control kiosks, and other such equipment associated with power transformers
are to have separate grounding connections.
Circuit Breakers
Circuit breakers with separate pole construction are to have a separate grounding connection
to each pole. Operating mechanisms are to have a separate connection unless the mechanism
is integral to the breaker.
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The grounding terminals of lightning arrestors shall be directly connected to the ground grid
or ground bus with a minimum of bends. The grounding conductor shall be of a size
appropriate to the other equipment on the same system, and the conductor shall not be run
through any conduit or metal enclosure. The grounding conductor is to have no 90 degree
bends and is to be as short as possible to the ground grid.
Substation Equipment on a Steel Structure
Provided that the structure is grounded, disconnects (but not the operating mechanisms) and
insulator anchorages on steel structures can use the steel structure itself for grounding. Each
leg of the steel structure shall be grounded at a point near the structure base with a conductor
appropriate to the equipment mounted on the structure. All other equipment on the steel
structures shall have separate grounding conductors. The conductors shall be supported at 0.9
m (3 ft) intervals through the use of clamps.
Substation Equipment on a Wood Structure
All electrical equipment (e.g., transformers, disconnects, insulated anchorages) and the steel
associated with the electrical equipment (e.g., steel platforms and cross-arms) are to be
grounded to the same standard as other equivalent electrical equipment in the substation.
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Transmission Lines
SAES-P-111 and SADP-P-111 establish the following grounding requirements for
transmission lines:
_
Overhead Distribution
SAES-P-111 and SADP-P-111 establish the following grounding requirements for overhead
distribution:
_
At other locations, and at all other voltages, the equipment and the metal
hardware must be grounded through use of a minimum 25 mm2 (No. 4
AWG) conductor or of an 8 mm (5/16 in) copperweld ground rod.
Downleads and pole butt wrappings must be 8 mm (5/16 in)
copperweld. Pole downleads within industrial plant areas having a
ground grid must be connected to the ground grid with a conductor
whose minimum size is 25 mm2 (No. 4 AWG).
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Disconnects that are rated above 600 V, that are operated from a
mechanism at ground level, and that are located in plant areas where a
ground grid exists are to be treated as disconnects in a transmission
substation.
The equipment grounding conductor that is run with or that encloses the circuit conductors
must be a copper conductor or other corrosion-resistant conductor. This conductor can be
solid or stranded; insulated, covered, or bare; and in the form of a wire or a busbar.
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The ground loop impedance of the circuit that is formed by the line conductor from the power
source to the equipment and by the grounding path from the equipment back to the power
source neutral must be low enough to allow sufficient fault current to pass to operate the
protection device. The following equation should be satisfied:
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Difficulties in attaining an adequately low value of Zgl are unlikely to arise but can occur at
low voltages/high ratings.
Residential occupancies must have ground-fault circuit protection for all 115V, 15A, and 20A
receptacle outlets or feeders supplying the outlets that are installed outside or in bathrooms.
Construction sites are to have ground-fault circuit protection for all 115V, 15A, and 20A
receptacle outlets or feeders supplying the outlets that are not part of the permanent wiring.
Conduit is not to be the sole means of grounding equipment, except for overhead lighting
within buildings that are installed with rigid conduit.
A bonding jumper is to be installed at flush-mounted, grounding-type receptacles to connect
the receptacle grounding terminal and the box. Reliance is not to be placed upon contact
devices or yokes to provide the connection (exception 2 of NEC, Article 250-74 is excluded).
Lighting fixture outlet boxes are to be grounded and a bonding jumper is to be installed to
connect the fixture to the box.
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Cable Sheaths
SAES-P-111 and SADP-P-111 establish the following grounding requirements for cable
sheaths:
_
The lead sheaths, the shields, and the armor of multi-conductor power
cable must be bonded and grounded at both ends. The continuity at
splices is to be assured by bonding across the splice. Steel wire armor is
to be bonded and grounded at both ends but must not constitute a
grounding conductor.
The metallic sheath and the armor, if any, of single core power cables
below 240 mm2 (500 MCM) is to be bonded and grounded at both
ends. At 240 mm2 (500 MCM) and above, short lengths (such as road
crossings and line terminations into substations) are to be treated
similarly.
Fences
SAES-P-111 and SADP-P-111 establish the following grounding requirements for fences:
_
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Fences (Cont'd)
_
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NEC Section 550-4(a) covers mobile homes that are not intended as
dwelling units. A particular application of this Article would be
electrical installations at construction sites where trailers are required.
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Portable Equipment
The following grounding requirements for Portable Equipment are found in SAES-P-111 and
SADP-P-111:
_
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250-154
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The system complies with all other provisions of NEC Article 250.
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Grounding
SADP-P-111
Grounding
AA-036572
Switch
AB-036562
SAES-O-101
SAES-P-100
Basic Criteria
SAES-P-119
Substations
SAES-T Series
Communications Standards
IEEE 80
IEEE 81
IEEE 142
IEEE 367
NFPA 76A
NFPA 76B
NFPA 78
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DETERMINING
THE
BUILDING
AND
STRUCTURE
GROUNDING
REQUIREMENTS FOR SAUDI ARAMCO INSTALLATIONS (CONT'D)
This section will familiarize the Participants with the application of the basic safety codes to
different facilities. This section includes the more important aspects of safety grounding for
the following types of buildings and structures:
_
_
_
_
Residential Building
Industrial Building
Manned Structures
Unmanned Structures
Residential Building
Grounding for residential buildings starts with the system grounding at the service
disconnect(s). Ground wires are then run from the main service panel, with the power
conductors, to the equipment or the electrical outlets. System grounding is normally
accomplished through connection of the grounded conductor and the grounding conductor to
the grounding electrode conductor. In the case of small residential buildings, the grounding
electrode conductor often consists of underground metal piping and building steel. Ground
loops for grids are seldom required for residential buildings.
Industrial Building
An industrial building is a facility in which products are manufactured or stored.
Industrial buildings are usually part of a complex with large power requirements. Substation
grid grounding, building ground loops, and an extensive system of ground conductors that tie
all necessary items back to their respective power source are used.
Manned Structures
Manned structures are facilities that are occupied during normal business hours or on a 24hour basis.
Manned structures are grounded in the same manner as industrial buildings.
Unmanned Structures
An unmanned structure is a building that is not occupied during normal business hours.
Examples of unmanned structures are pumping stations and water treatment plants. The same
grounding rules apply to unmanned structures and to manned structures.
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Nature of Lightning
Equipment and Structures to be Considered
Requirements for Good Protection
Practices for Lightning Protection
Nature of Lightning
Lightning is the discharge of high-potential cells (usually negative) between clouds or from a
cloud to the earth. These charged cells normally attract the charges of opposite polarity on
the surface of the earth or on high objects. When the charge reaches a critical level (when the
air insulation between the cloud and the earth breaks down), the charge develops a stepped
ionized path, resulting in a high current discharge (stroke) that neutralizes the cloud charge
and earth charge. The discharge current increases from zero to a maximum in 1 to 10 _s, then
declines to half the peak value in 20 to 1000 _s. This discharge can be repeated one or more
times over the same path, in rapid succession, because of the recharging in the cloud. The
average peak stroke current is about 20,000 A, although some peak stroke currents are as
great as 27,000 A.
SAES-P-111 assists the Electrical Engineer in deciding when to protect or when not to protect
a building or structure from lightning. Specifically, SAES-P-111 provides information on
how to determine the "Risk Index."
The Risk Index Tables are in Work Aid 6. Each table has a list of conditions. The Electrical
Engineer selects the condition that is correct for the building or structure that is being
considered for lightning protection and then records the risk figure for that condition. Once
the risk figure for all seven tables has been determined, the Electrical Engineer sums the
seven risk figures. The total is known as the Risk Index. If the Risk Index is 40 or greater,
lightning protection must be provided.
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Design and Application of Equipment Grounding
Schools
Hospitals
Equipment and structures can be separated into five classifications according to the need for
lightning protection. These classifications are listed in IEEE Standard 142 and are as follows:
_
_
_
_
_
First Class
Second Class
Third Class
Fourth Class
Fifth Class
First Class
First class equipment and structures need very little or no additional protection. This class
includes the following:
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Water tanks, silos, and similar structures that are largely constructed of
metal.
The only real requirement for this class is to connect the equipment or structure to a suitable
grounding electrode.
A typical Saudi Aramco example of first class equipment or structure would be a water tank.
Second Class
Second class equipment and structures consist of buildings with conducting surfaces and nonconducting framework, such as metal-roofed and metal-clad buildings. This class requires the
addition of down conductors to connect the exterior roof and cladding to suitable grounding
electrodes.
A typical Saudi Aramco example of a second class structure would be a chemical storage
building.
Third Class
Third class equipment and structures consist of metal-framed buildings with nonconducting
facings. These buildings need the addition of conducting air terminals that are suitably
located and connected to the frame. The conducting air terminals must project beyond and
above the facing in order to act as the lightning terminal points and to thus eliminate the
potential of a puncture of the facing.
Chemical processes are often housed in this type of structure and are an example of the third
class structures at Saudi Aramco.
Fourth Class
Fourth class equipment and structures consist of non-metallic structures, either framing or
facing. These structures require extensive protection treatment. The following are examples
of fourth class structures:
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An example of this class at Saudi Aramco includes the stacks for boilers.
Fifth Class
Fifth class equipment and structures consist of items of high risk or loss consequences that
normally receive full lightning protection treatment, including air terminals or diverters, down
conductors, and grounding electrodes. This class includes the following:
_
Transmission lines.
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Air Terminals
Down Conductors
Joints and Bonds
Ground Terminations
Air Terminals - NFPA 78 contains detailed information on air terminal design and
support. No part of a flat or gently sloping roof on structures is to be more than 7.5 m
(25 ft) from the nearest horizontal conductor.
Down Conductors - Two or more down conductors must be provided on most kinds of
structures. One down conductor is permitted for flag poles, masts, spires or similar
structures. The total number of down conductors on structures having a flat or gently
sloping roof, and on irregular shaped structures are to be such that the average distance
between the down conductors does not exceed 30 m (100 ft).
The bend in a conductor that embraces a portion of a building, such as an eave, must
have a radius that is greater than 200 mm (8 in). The angle of any turn must not
exceed 90o, and the conductors must preserve a downward or horizontal course.
Enforcing rods that are butt-welded together are acceptable as down conductors, but
reinforcing rods that are overlapped and bound with tye-wire are not acceptable as
down conductors.
Down conductors should be installed within the building or the structure to avoid the
potential "removal for gain" that can occur with external copper conductors. In order
to prevent lightning from "jumping" off the down conductor and to the conduit, down
conductors must not be installed inside a metallic conduit.
Joints and Bonds - Joints and bonds must be made to the same standard as required for
electrical installations.
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terminations must be tested through use of an earth tester that is to be clamped to any
convenient part of the lightning protective system. The combined resistance to earth
of the whole of the lightning protection system must be as low as economically
possible but must not exceed 25 ohms. Other grounds, such as substation grids or
consumer grounding, must be bonded to the lightning protection grounds. The intent
of the grounding is to minimize the risk that is due to differential voltages that could
cause hazards to personnel or "sideflash" possibilities. Reinforcing rods in reinforced
concrete foundations are not required to be bonded to the ground termination.
Practices for Lightning Protection
IEEE Standard 142, Section 3.3.4 provides the practices for lightning protection.
information is divided into the following seven (7) sections:
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_
_
_
_
_
_
This
General
Tanks and Tank Farms
Non-Conducting Heavy-Duty Stacks
Steeples
High Masts
Power Stations and Substations
Communication Towers
General
Buildings and structures involving hazardous liquids, gases, or explosives require additional
protection. In these buildings and structures, the object of the additional protection is to keep
the current away from the structure without use of the building's metal skin or the framework
as a down conductor. A separate diverter protection system is employed for these buildings
and structures (e.g., tanks, tank farms, and explosive manufacture and storage).
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Provided that the base of the tank is adequately grounded, a tank that contains flammable
liquids or gases does not always need to be protected against lightning. Direct lightning
strikes to the tank top or walls are permitted as long as the steel is thicker than 3/16 inches
(0.476cm). These strikes are allowed because there is little danger of the lightning strikes
puncturing the tank. Steel tanks with steel roofs and floating metal roofs are generally
considered to be self-protecting. Tanks with nonmetallic roofs are not self-protecting and
should be protected with air terminals, conducting masts, or elevated ground wires. In all
cases, joints and piping connections should be electrically continuous. All vapor or gas
openings should be closed or flame-proof. The possibility of a direct strike to the vicinity of a
vent or leak is eliminated by an air terminal of suitable length.
Refer to the Addendum, Saudi Aramco Drawing AB-036387, for grounding of floating tanks.
Non-Conduction Heavy-Duty Stacks
Heavy-duty stacks (including stacks in petroleum and in chemical plants) require air terminals
that are connected to a loop conductor around the top of the stack and at least two down
conductors that are connected to grounding electrodes at the base of the stack. Air terminals
should be made of solid copper or stainless steel and should be uniformly distributed around
the top of cylindrical stacks, at intervals not exceeding 8 feet (2.44m). On square or
rectangular stacks, air terminals should be located not more than 2 feet (0.61m) from the
corners and should be spaced not more than 8 feet (2.44m) apart around the perimeter.
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Steeples are similar to stacks except that they are sharp peaked and thus require only one air
terminal. This one air terminal should project far enough above the top ornamentation to
meet the requirements of lightning protection. Otherwise, multiple air terminals or a
multipointed terminal should be used to provide equivalent protection. Steeples are
frequently framed with wood, not metal, so adequate down conductors are a basic
requirement.
High Masts
Equipment on the sides of very high masts, such as television or FM antennas, can be
protected from direct stroke damage through the addition of lateral spikes or thorns projecting
outward from the sides of the mast. At heights above the critical radius of 100 or 200 feet (30
or 60m), spikes in a horizontal or near horizontal position with suitable spacing will cause
strokes coming from the side to terminate on the spikes rather than on the mast itself. This
practice will greatly reduce the possibility of damage to electrically fragile components by the
termination of the lightning stroke arc. The number of spikes around the mast (three, four,
five, or six), the length of the spikes, the vertical spacing along the mast need to be
determined for optimum economics, and in accordance with the principles of lightning
protection. When masts are installed on top of a building, the bottom of the mast structure
must be bonded to the building grounding network at a minimum of two points.
Power Stations and Substations
While transmission-line protection against lightning is an inherent part of the design and is
well documented, the protection of stations and substations has received little attention.
Lower stations and substations require protection from direct strokes. Masts or overhead
wires (or both) can be used to ground lower stations and substations to the grounding network
of the power station or substation.
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=
=
=
potential, in Volts
charge
capacitance in farads
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Material Characteristics
Speed of Separation
Area in Contact
Effect of Motion Between Substances
Atmospheric Conditions
Material Characteristics
One of the materials or substances must have a higher insulating property than the other
material or substance to generate static electricity. The amount of static electricity that exists
between two materials will be proportional to the difference between the dielectric constants
of the materials.
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Design and Application of Equipment Grounding
As the speed of separation of two substances is increased, the potential of the static electricity
is increased.
Area in Contact
The area of the contact between the substances has a direct bearing on the amount of static
electricity. A larger contact area allows a greater charge to be transferred from one substance
to the other. As the area in contact increases, the potential of the static electricity increases.
Effect of Motion Between Substances
It is well known that humidity conditions are related to the production of static electricity. As
humidity increases, the potential for static electricity decreases; therefore, the hazard of static
electricity increases in an operation that requires controlled low-humidity conditions.
Hazards of Static Electricity and Control in Various Areas
The accumulation of static electricity on equipment, on materials being handled or processed,
and on operating personnel introduces a potentially serious hazard in any area where
flammable liquids, gases, dusts, or fibers are present. The discharge of the static electricity
from an object to ground or to another object can be the cause of a fire or an explosion if the
discharge takes place in the presence of readily flammable materials or combustible vapor and
air mixtures.
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The requirements for preventing a static electrical charge from accumulating on agitators,
stills and similar equipment and the subsequent discharge are found in SAES-P-111 and
SADP-P-111, as follows:
_
Belts-Pulleys
Belts that are made of rubber, leather, or other insulating materials, that are running at
moderate or high speeds, generate considerable quantities of static electricity. Generation
occurs when the belt separates from the pulley. The charges will exist on the pulley
(regardless of whether the pulley is conducting or nonconducting) as well as on the belt.
The requirements for preventing a static electrical charge from accumulating on belts and
pulleys and the subsequent discharge are found in SAES-P-111 and SADP-P-111:
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The use of flat belts in hazardous areas must be avoided. The risk of
static ignition from V-belts is negligible.
Static combs are ineffective in draining off the static electrical charge
and should not be used.
Pipelines-Manifolds
The requirements for preventing a static electrical charge from accumulating on pipelinesmanifolds and the subsequent discharge are found in SAES-P-111 and SADP-P-111, as
follows:
_
The requirements for preventing a static electrical charge from accumulating on steel
equipment and process units and the subsequent discharge are found in SAES-P-111 and
SADP-P-111, as follows:
_
The requirements for preventing a static electrical charge from accumulating on tank cars,
loading racks and spur tracks and the subsequent discharge are found in SAES-P-111 and
SADP-P-111, as follows:
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To prevent arcing where stray currents are likely to occur, the rails must
be bonded to each other. This bond must be a conductor not smaller
than 25 mm2 (No. 4 AWG), and it must be an adequate ground.
Tanks-Atmospheric
Tanks-Floating Roof
The requirements for prevention of the accumulation of a static electrical charge on tanks with
a floating roof and for prevention of the subsequent discharge are found in SAES-P-111 and
SADP-P-111, as follows:
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The roof seal must be maintained to provide a tight closure that reduces
the chance of a vapor ignition at the seal. The possibility of vapor
ignition at the seal must be further reduced by the installation of metallic
shunt strips at each pantagraph hangar in the sealing mechanism from
the roof to the tank shell. These metallic shunt strips must be spaced a
maximum of 3m (10 ft.) apart and must be bolted to the sealing ring and
to the roof per Standard Drawing AB-036387, which is located in the
Addendum. The metallic shunt strips and the roof also must be bonded
to the tank shell.
The requirements for prevention of accumulation of a static electrical charge on tanks and
barges and for prevention of the subsequent discharge are found in SAES-P-111 and SADPP-111, as follows:
_
Leakage from power systems where return circuits through the earth can
cause currents to flow through nearby piping in contact with the earth.
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Two or more of the steel platform legs must be used as the grounding
electrode. Where two or more platforms are connected by walkways,
two insulated grounding conductors must be installed to interconnect
the grounding electrodes between each pair of connected platforms.
A ground bus with a minimum size of 120 sq. mm (4/O AWG) must be
established in the main electrical room or area. Equipment and system
neutral grounds must be connected to this bus by grounding conductors.
This bus must extend to the grounding electrode by two separate
conductors that are each sized to carry the rated bus current.
Saudi Aramco Design Standard SADP-P-111 provides the following additional guidelines for
offshore platform grounding:
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Interference - An Introduction
Energy Storage in Electric Fields
Energy Storage in Magnetic Fields
Signal and Power Transfer
Electrical Power and signal Transport
Poynting's Vector
Reflection of Energy at a Surface
A New Look at Voltage
Fields and Ground Planes
Using Ground Planes
The Measurement of Interference
Passive Filters
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Design and Application of Equipment Grounding
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ESD Tests
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SAES-P-111 : Grounding
SADP-P-1111 : Grounding
IEEE Standards
_
IEEE STD 80-1986 : IEEE Guide for Safety in AC Substation
Grounding
_
Article 250
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WORK AID 2:
Section 1
Procedure, Table and Formula for Determining the Size of Copper Grounding Conductors for
Equipment Connected Directly to the LV Side of a Transformer Without an Intervening
Protection Device, for Systems Rated 600V and Below.
1.
Obtain the kVA rating of the power source transformer whose secondary is directly
connected to the equipment without an intervening protection device, through us of the
transformer nameplate or the following formula:
where:
V
I
=
=
System Voltage
Current
2.
Determine the type of protection (fuses or circuit breaker) provided for the primary
side of the power source transformer. This determination can be made through the use
of personal knowledge of the system, electrical drawings, or a visual inspection.
3.
Determine the size of the copper grounding conductor needed from the table of
Ground Conductor Sizes shown in Figure 14, through the use of the kVA rating
obtained in step 1, and the type of protection determined in step 2.
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Determine the rating of the automatic overcurrent protection device in the circuit that
is ahead of the equipment. This determination can be made through the use of
personal knowledge, electrical drawings, or a visual inspection.
2.
Determine the size of the equipment grounding conductor needed from Table 250-95
of the NEC (shown in Figure 15) through use of the automatic overcurrent protection
device rating determined in step 1.
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Table 250-95
Figure 15
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Determine the three second short-time current capability of the circuit breaker ahead of
the grounding conductors. This determination can be made through use of personal
knowledge, the circuit breaker nameplate, electrical drawing, or the following formula:
Note: The formula must be used in cases where circuit breakers are not installed or where
three second short-time capabilities are not assigned.
2.
Determine the size of the grounding conductor needed from the table of grounding
conductor sizes for solidly grounded systems over 600V (shown in Figure 16) through
use of the three second short-time current capability determined in step 1.
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Answer the following question to determine the basis for the size of the grounding
conductor in question.
2.
Determine the 10 second current rating of the neutral grounding device or the 10
second current rating of the combined neutral grounding devices for systems with
multiple neutral grounding devices connected in parallel. This determination can be
made through use of personal knowledge, the circuit breaker nameplate, or electrical
drawings.
3.
Determine the size of the grounding conductor needed from the table of grounding
conductor sizes for impedance grounded systems over 600V shown in Figure 17,
through use of the current rating determined in step 2.
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tc
3 seconds
ar
pr
ko
TCAP
3.422 j/cm3/oC
Tm
Ta
RMS current in kA
For stationary equipment grounding requirements the Engineer should refer to Saudi Aramco
Engineering Standard SAES-P-111-6 and Design Practice SADP-P-111 Chapter 3 & 6.
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where:
tc
3 seconds
ar
pr
ko
TCAP
3.422 j/cm3/oC
Tm
Ta
RMS current in kA
For mobile equipment grounding requirements, the Engineer should refer to Saudi Aramco
design practice SADP-P-111 Chapters 3 and 6 as well as Article 250 NEC.
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Risk Figure
2
4
6
7
8
10
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Risk Figure
1
2
4
5
7
8
2
5
6
8
10
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Risk Figure
2
5
10
2
6
8
10
Not Exceeding
15 m (50 ft)
18 m (60 ft)
24 m (80 ft)
30 m (100 ft)
2
4
5
8
11
10
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SAES-P-111
SADP-P-111 Chapter 14
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SAES-P-111
SADP-P-111 Chapter 8
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GLOSSARY
dielectric constants
effectively grounded
equipment ground
ground
ground bus
ground clamp
ground conduit
ground current
ground detector
ground grid
ground lug
ground-return circuit A circuit in which the earth is utilized to complete the circuit.
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grounded
grounded circuit
grounded concentric
wiring system
grounded conductor
grounded electrode
grounded system
grounding conductor
grounding connection A connection that is used in establishing a ground and that consists
of
a grounding conductor, a grounding electrode and the earth (soil)
that surrounds the electrode.
grounding outlet
grounding
transformer
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guard wire
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impedance grounded
neutral ground
reactance grounded
resistance grounded
solidly grounded
system grounding
conductor
ungrounded
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ADDENDUM A
Saudi Aramco Drawing AB-036387 IEEE Paper PCIC-91-11
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