Design Criteria for

Earthing / Grounding System

TITLE DESIGN CRITERIA FOR EARTHING

DOC NO SUR.100.U07 Rev No : A

Approved
V. Thulasiram Project
LAFARGE SURMA CEMENT PLANT
Checked
V.S. Bhadoria 17 km Long Belt Conveyor+ Crushing Shop

Larsen & Toubro Limited

Approved
R.R.Rao Resp. dept. INAT/ATPME OI No: ATPM-SC-3033
Checked
Ravishankar S
Prepd
Sudhir J. Documen 3BYN463033-SEA
Rev No : A
t Identity
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TEMPLATE: 3BSE012345 REV.B; FILENAME: 864258192.DOC; PRINTDATE: 2/3/2004 11:26:00 AM; SAVEDATE: 10/16/2023 06:16:00 AM SKELETON
3BYN200812E4006 REV ; OWNER: INAUT/AMME
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CONTENT

1. General 3

1.1 Definitions and Abbreviations 3

2. Design Criteria for developing the module 3

2.1 Function 3

2.2 Applicable standards and reference 3

2.3 Design requirement for hardware modules 3

2.3.1 Earthing concept 3

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1. General
The purpose of this document is to provide project specific basic design criteria for
the preparation of detailed engineering documents and drawings.
1.1 Definitions and Abbreviations

LBC Long Belt Conveyor

CP Crushing Plant
TT Transfer Tower
DG Diesel Generator
SS Substation

2. Design Criteria for developing the module

2.1 Function

Earthing system of the Crusher & LBC is a safety system supporting the main power
distribution system and providing a low resistance path to earth for the fault current
to keep the operating men and equipment safe and not allowing any current path
through their bodies in case of a faulty condition.
2.2 Applicable standards and reference

IEC Pub 60364 –5-54: Code for Earthing

IEEE 80-1986 : Guide for safety in AC substation grounding.
Lafarge Document : STD .002.U12, Rev-0
Lafarge Drawing No : SUR 1.82.0.N..01 (1/8, 7/8 & 8/8) ,SUR 107B01
L&T Drawing No. : M1-13960 & M1-A485 & SUR.100.D01 – RevA.
2.3 Earthing Concept

SCOPE

This covers the design of safety earthing system for the Electrical system for
Crushing plant and LBC substation ( SS03 ) at Meghalaya India to the head
end of the LBC at Bangladesh of Surma Cement Plant.

METHODOLOGY

a.The effective earth resistance required as per Lafarge technical

specifications / IEC 60364 / IEEE 80 - 1986 / IS 3043 for industrial plants is 1
(one) ohm.

b. Derive the size of earth conductor.

c. Derive the length and width of the grounding area of the control room.

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d. Derive the length of conductor buried in soil and number of electrodes.

e.Calculate the value of resistance of earth grid.

f. Calculate the value of resistance of earth electrodes.

g. Calculate the combined value of resistance of earth grid and electrodes.

Data Considered for the Calculations

Soil Resistivity : Soil resistivity is considered as 100-ohm meter for

design purposes at substation building area, upto 2km
before the border and 30 ohm meter for the LBC
section as the same can vary from 20 to 30 ohm
meter .(Considered river bed area from 2km inside the
border in India to the head end of LBS. in Bangladesh)

Size of Earth Electrode : 20mm dia. Cu pipe/ Cu rod

selected

Size of buried conductor : 20 mm dia. Bare Cu conductor

Fault level : Fault level considered is 50 kA for 1 sec.

Applicable Standard : IEEE 80 – 1986 and IEC-60364-5-54

CALCULATION FOR SIZING OF EARTH CONDUCTOR

Input Data

Ambient temperature : 36 oC
Design Ambient : 50 oC
Fault level : 50 kA for 1 sec as per Lafarge specifications
Corrosion allowance : 2.0 mm reduction in thickness / diameter
(Min 25 Sqmm area required without
corrosion protection against 16 Sqmm with
corrosion protection)
Material of Conductor: Cu conductor in all the places and GI strip
along LBS.

Size of earth conductor (Item 543.1.2 -IEC 60364-5-54 )

A = ( If  t ) / K

Where,
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A - Area of conductor in sq.mm.

If - Maximum earth fault current in amperes
t - Fault duration in secs.

The factor K is determined from the formula ( Annex A –IEC –60364-5-54)

K=  [ {Q ( B+20) / P
c 20 } ln { 1+ [(Qf – Qi ) / (B+ Qi )] }]

Where,

Qc = Volumetric heat capacity of conductor material ( j / oC mm3 )

B = Reciprocal of temp. coefficient of resistivity at 0 oC for the
conductor (234.5 oC- Table A.54.1 –IEC 60364-5-54 )
P20 = Electrical resistivity of conductor material at 20oC ( Q - mm )
Qi = Initial temperature of conductor ( 40 oC- )
Qf = Final temperature of conductor (395 oC-)

The value of  {Q ( B+20) / P

c 20 } is “226” for Copper as per, Table A.54.1 of IEC
60364-5-54

Hence K = 226  ln { 1 +((395 – 40) / (234.5 + 40) ) } = 204.65

Therefore, the area of conductor is

A = (50000 *  1) / 204.65 = 244.3 sq.mm.

For calculation of Earth Grid with Cu Rod:

Hence, dia =  {(244.3 * 4) / 3.14} = 17.6 mm

Considering the corrosion allowance on dia. (2 mm), the dia. of the conductor will be
19.6 mm.

Hence, the conductor is selected as standard 20mm dia. Copper rod.

Alternatively if required

For calculation of Earth Grid with Cu Strip:

For achieving area of 244.3 sqmm we need a Cu Strip of standard size 35x8 Sqmm
(=280 sqmm)

RESISTANCE OF EARTH CONDUCTOR

Earth grid resistance is given by the formula as per IEEE 80 - 1986 , Eq.A84, Page 172

Rg = P { ( 1/ L ) + ( 1 / (  20*A) ) * ( 1 + ( 1 / (1 + h  (20*A) ) ) - eq-1

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Where,

Rg = Resistance of the earth conductor

P = Soil resistivity
L = Length of conductor buried
h = Depth of buried conductor
A = Area occupied by conductor buried
D = Diameter of electrode conductor.
N = No of electrodes

Please refer to the typical sketches for Design calculations

1. Substation SS03, Utility and DG building – Enclosed sketch no. 1.

2. Crusher house, TT and LBC - Enclosed sketch no. 2.

Substaion SS03, DG Building & Utility Bldg Grid:

Length of buried conductor (L) : 351 mtrs(L)

Area :23mtrs.*21mtrs.+30mtrs.*20mtrs+25*1.5+32*18+12*1.5): 1714.5 Sqmtr
Depth of burial of conductor (H) : 0.6 mtrs. (H)
Soil resistivity :100 Ohm meter
Diameter of conductor (d) : 2.0 cm(d)
Length of electrode conductor (l) :300 cm (l)
Length of strip(L) :300 cm(2 strips)
Width of strip(t) :4 cm( 35 x 8)

The resistance with above data works out to Rg = 1.32-( from eq-1) Ohms. In
addition to above 10 Nos of earth electrodes are provided.

The resistance of earth electrode is given by

Re = 1/n [ {(100*P) / (2 * * l )} * ln (4*l/d) –Eq 2 –For Round electrodes

Alternatively
Re = 1/n [ {(100*P) / (2 * * l )} * ln (2*L*L/l*t)- For Cu strip electrodes with
CI or GI Pipe electrode.(50 mm Dia Typical) recommended for high soil
resistivity. – Eq.3

Calculation for Round electrodes

Hence the resistance Re = 1/10[{(100* 100) / (2* 3.14*300)}* ln (4 *300/2)]

Re =3.39 Ohms(2)

Now the combined resistance (Parallel Paths) 1 and 2 works out 0.95 Ohms
which is very close to required 1 ohm. Hence for safer calculations we will add 2
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more pits and hence the no of pits will be 12, then the resistance comes out to be
Re=2.825 ohms.

Now Once again combined Value comes out 0.89 Ohms

With strip electrode by substituting the values in Eq-3 we get Re = 2.65 ohms.

The combined value workes out to be 0.88 ohms.

The internal earth grid formed by the earthing conductor along the cable trays and
trench shall be interconnected to external earthing grid resulting in still lower
resistance path for earth fault and also substantially brings down effective resistance
to much below 1 Ohm.

Please refer the detailed sketch enclosed for the substation,DG building and utility
Building for above calculations.

Generator and Distribution Transformer Neutral Earthing : As standard practice

generator and distribution transformer neutral shall be earthed through copper
conductors.

Considering the same short circuit level as that of Main earh grid Bare Copper
conductor of 20mm Dia rod or 35 x 8 Flat strips shall be used.

Two Numbers of separate earth pits will be made for connection of Copper grid
with two runs of 35 x 8 mm strip separately brought out above the ground .

Summary of Calculations and proposed Method for Substation / DG room /

Utility Building

Area Buried Conductor along Transformer Electrodes

Description Conductor cable tray/trench and DG Neutral
(External Grid) (Internal Grid) Earthing
Substation SS03 20mm Dia Cu 35 x 8 Cu strip or 35 x 8 Cu strip or 20mm Dia
Bare conductor 20mm Dia Cu 20mm Dia Cu copper Pipe
Conductor Conductor 3mtr depth
BetweenSS03 2X20mm Dia Cu 20mm Dia
&DG Building Bare conductor copper Pipe
3mtr depth
DG Building 20mm Dia Cu 35 x 8 Cu strip or 35 x 8 Cu strip or 20mm Dia
Bare conductor 20mm Dia Cu 20mm Dia Cu copper Pipe
Conductor Conductor 3mtr depth
Utility Building 20mm Dia Cu 35 x 8 Cu strip or 20mm Dia
Bare conductor 20mm Dia Cu copper Pipe
Conductor 3mtr depth

We now shall estimate the Grid resistance for the other areas:(Ref: sketch-2)
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Now From the building dimensions for Primary crusher shop ,secondary crusher
shop, and Transfer tower TT3 and TT2 , the length of conductor shall be
[2*{(15.5 +20.5 +3)+(12+8+3)+(12+8+3)+(20+10+3)}]= 236 mtr = 250 mtr (approx)

(+3 mtr ) is addition in the perimeter as conductors are considered 3 mtr away from
the building)

The summation area of each building(15.5*20.5+12*8+12*6.5+20*10)= 691.75 Sqmtr

Soil resistivity P= 100Ohm meter

Now length for Grid will be 250 mtr(L)
Area of grid will be 691.75 Sqmtr(A)
Depth =0.6mtr(H)
Once again substituting these values in eq –1

We get
Rg= 2.0 Ohms

Now 2 runs of Earth conductors along cable trench and cable trays from
Substation building to TT2.

The total length of conductor will be (2 * (50+25+90.53+25) =381.06mtr(L)

Area Occupied by this grid 2X 381.06*.04=30.48 Sq.mtr(A) (35 x 8 mmstrip
considered for calculation)
The depth= 0(H)

Substituting Values in eq-1

Rg = 8.2 Ohms

We have considered a minimum of 3 pits/electrodes of standard size for every

building that is total of 12 Nos considered for the area in Sketch-2

The earth electrode resistance now works out as per Eq-2

Re= 2.825 Ohms

The effective resist. of grid (On Indian side before Conveyor 105BC01)is 1.0 Ohms

Now along the Conveyor extending from TT2 (Indian side) to TT1(Bangladesh side).
A run of 50 x 6 Sqmmm GI strip(Alternatively 2 Runs of 25 x 6 Sqmm) is considered
as per contract specifications.

The depth of conductor(H) =0

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Here now we will consider the 100 Ohm meter(P) as soil resistivity up to stretch of 5
km from TT2( 2Km before river river bed area on the Indian side) The remaining
11.95 Km which forms Part of soft soil and river bed area Up to TT1 on Bangladesh
side, the resistivity considered is 20 Ohm meter

The stretch of Conveyor on Indian side is 7.185 Km( From DWG SUR 105 E10 &
E15)
The stretch of conveyor on Bangladesh side is 9.623 Km(From DWG SUR 105
E50,E17 & E18)

Now We shall estimate the resistance in 2 separate portions:

1. For Soil resistivity 100 Ohm meter for 5 Km

Now length of conductor will be 5000mtrs (L)

Area of conductor will be 5000X 0.05= 250 Sqmtr(A)
Depth will be =0(H)

Substituting above in eq-1

Rg= 2.84 Ohms

2. For soil resistivity 20 Ohmmeter for 11.95 Km

The length of conductor will be 11950 mtr
The area occupied by conductor 11950*0.05=597.5 Sqmtr
Depth will be =0(H)

Substituting above in Equation 1

Rg= 0.36 Ohms

Along the conveyor line We shall consider Cu Rod( 20mm Dia) driven earth
Electrodes.
The depth of electrode shall be 1500mm and as per requirement at regular
interval of 150 mtr .

Now for 33 pits( 5 Km stretch we will consider 100 Ohm meter as soil
Resistivity is considered )

Depth=150cm
Diametre=2 cm

Re = 1/n [ {(100*P) / (2 * * l )} * ln (4*l/d) ]-(2)

Substituting values in eq-2

Re=1.83 Ohms

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Now remaining stretch of 11.95 Km ie ( 79 Pits) resistivity of 20 Ohm meter is

considered.
Re= 0.15 Ohms

Now combined resistance of Conveyor belt line shall be parallel effective resistance
of 2.84 Ohms,0.36 Ohms,1.83 Ohms and 0.15 Ohms.
R= 0.09 Ohms

This indicates that the resistance of the earth grid designed above has already achieved
a resistance of less than 1(one) ohm, as required by the project specification with 100
ohm metre soil resistivity.and 20 Ohm meter.

Summary of Calculations and proposed Method for Crusher plant and Long
Belt Conveyor(105 BC01)

Area Description Buried Conductor along Electrodes

Conductor cable tray/trench
(External (Internal Grid)
Grid)
Primary 20mm Dia Cu 35 x 8 Cu strip or 20mm Dia
crusher,Secondary Bare 20mm Dia Cu copper Pipe
crusher.Tranfer tower conductor Conductor 3mtr depth
TT2 and TT3
Area in between 2X20mm Dia Cu 20mm Dia
Above mentioned Bare conductor copper Pipe
Buildings 3mtr depth
Long belt Conveyor 50 x 6 GI srip 20mm Dia
105 BC01 (2 runs of 25 X 6 copper rod 1.5
GI strip) mtr depth

NOTES ON BUILDING, EQUIPMENT AND MOTOR EARTHING

1. With existing buried earth grid a separate grid along cable routes in each building
for equipment earthing will be provided by using a copper conductor of atleast
95sqmm cross section or equally sized copper flat.
2. The grid above earth shall be interconnected with Main(Underground) in at least
two points.
3. At least two earth junction boxes with link shall be provided for each earth grid for
earth resistance measurement.
4. Motors shall be suitably earthed with required cross section of conductor at at
least two distinct points preferably with 95 Sqmm of 150 Kw and above and with
50 Sqmm and 16 Sqmm Cu conductor up to 150 Kw
5. Separate cables shall be used for earthing of sensitive equipment as and when
necessary. A common earth grid for electronic earth for information systems or
sensitive equipment mentioned above will be formed.
6. Adequate jumpers and links shall be provided between different earth grids for
interconnection.
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7. Vegetal (Soft soil) soil layer of 20cm above and under the buried conductor shall
be provided.
8. For interconnection of two conductors under the ground to form a continuous
conductor, lap welding shall be done in case of MS or GI conductors and lap
jointing with bolts / nuts shall be done for copper conductors. Brazing shall be
carried out for joining copper to copper series conection. For all the conductors the
connection with equipment shall be done to suit the site condition.
9. The Main cable tray in all sections shall carry 95 Sqm Cu conductor all along its
run and secondary trays shall be taped through the 50 Sqmm or 16 Sqmm based
on short circuit resistance.
10. As far as structures and conveyors are concerned they shall be earthed through
tapings from respective main grids passing through the areas via cable trench
/Tray.
11. The Main earth generally shown in sketch 1 and sketch 2 shall be for short circuit
level for 50 KA for 1 sec. All other sections shall be as per shortckt levels at
respective load centers. Gain generally adhering to minimum cross sections as per
Lafarge specifications of 95 Sqmm,50 Sqmm and 16 Sqmm as required.

CONCLUSION

From the above, it can be concluded that the earth grid designed for the Substation
room, DG room, Utility rooms, conveyor galleries, etc.are in order. The value of
earth grid resistance is less than 1 ohm..

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ENCLOSED WITH THIS DOCUMENT: SKETCH –1 (sheet-1)

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Sketch-1 (sheet2)

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Sketch2

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REVISION:

Rev. Page (P) Description Date

ind. Chapt.(C) Dept./Init.
- - New Document 2004.01.06
ATPME/SRS
A Revised based on L&T Comments dated: 23/01/2004 2004.02.05
ATPME/SRS
B
C
D
E

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