Grounding & Lightning

Protection
PROJECT NAME

: Khabat Thermal Power Plant Units 1&2 and

Bazyan 400kV Substation

TOTAL 34 PAGES
(Including Cover)

Purpose
For Information

DOCUMENT NO.

: KP-00B__-EE210-G6015

TITLE

: Grounding & Lightning Protection Technical

Specification

OWNER

: Ministry of Electricity (MOE) of

Kurdistan Regional Government

For Review
For Approval
For Construction
As-Built

09 April 2013

For Approval

H. Halvachi

S. Mikoleit

A. Zarali

H. zcan

17 February 2014

3rd Draft

H. Halvachi

S. Mikoleit

A. Zarali

H. zcan

20 January 2014

2nd Draft

H. Halvachi

A. Brutigam

A. Zarali

H. zcan

24 October 2013

1st Draft

H. Halvachi

A. Brutigam

---

---

Rev.
No.

DATE

DESCRIPTION

PREPARED
CHECKED
REVIEWED APPROVED
GAMA POWER SYSTEMS ENG &CONTRACTING,INC.

Owner

Ministry of Electricity (MOE)

of Kurdistan Regional Government
Contractor

POSCO ENGINEERING
& CONSTRUCTION CO., LTD.
Main Subcontractor

GAMA POWER SYSTEMS

ENGINEERING & CONTRACTING,INC.

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TABLE OF CONTENTS
1

INTRODUCTION AND LOCATION OF THE PROJECT:

INTRODUCTION OF GROUNDING AND LIGHTNING PROTECTION SYSTEMS:

2.1

General:

2.2

Implementing Specification:

2.3

Regulations and Standards:

2.4

General Abbreviations:

2.5

Existing Voltage Levels:

2.6

Basic Design:

2.7

Components and Systems:

GROUNDING SYSTEM:

3.1

Foundation Earth:

3.2

Ring Earth Electrode Around Building:

3.3

External Mesh Earth Electrode:

3.4

Grounding Outdoor Cable Routing:

10

3.5

Grounding Connections:

10

EXTERNAL LIGHTNING PROTECTION:

11

4.1

General:

11

4.2

Lightning Protection Zone (LPZ):

11

4.3

Lightning Protection Level (LPL):

12

4.4

External Lightning Protection Components:

13

4.4.1 Air-Termination System:

13

4.4.2 Down-Conductor System:

14

4.4.3 Grounding System:

14

INTERNAL LIGHTNING PROTECTION:

14

5.1

Equipotential Bonding:

15

5.2

Lightning Surge Suppressors:

15

SHIELDING OF BUILDINGS:

16

PERFORMANCE REQUIREMENT:

17

7.1

Interfaces:

17

7.2

Electrotechnical Installations in the Power Stations Outdoor Area:

17

7.2.1 High-Voltage Outdoor Switching Station:

17

7.2.2 Lighting Pole:

17

7.2.3 Cables Outside of Buildings (Above Ground):

17

Grounding of Electrical Equipment:

18

7.3.1 Generator / Generator Bus Ducts / GCB:

18

7.3.2 Medium-Voltage Transformer:

18

7.3.3 Low-Voltage Transformer:

18

7.3

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7.3.4 Cable Supporting Structures:

18

7.3.5 Grounding of Switch Cabinet Base Frames:

19

7.3.6 Grounding of Sub Distribution Boards and Measuring Racks:

19

7.3.7 Switchgear:

19

7.3.8 Electrical Machines:

20

7.3.9 Floor Surface in the Electric Rooms:

20

Grounding and Lightning Protection for Special Plant Areas:

20

7.4.1 Exhaust Chimney:

20

7.4.2 Tanks, Containers:

20

7.4.3 Pipeline Bridges, Conveyor Bridges:

21

7.4.4 Fences:

21

7.4.5 Track Installations:

21

7.4.6 Hazardous Areas:

21

Cable Ducts:

22

7.5.1 In-Situ Concrete Ducts:

22

7.5.2 Precast Ducts:

22

7.5.3 Cable Draw Pits of In-Situ Concrete:

22

7.5.4 Concealed Expansion Joint Bridging:

22

7.5.5 Visible Expansion Joint Bridging:

22

7.6

Materials:

23

REGULATIONS FOR SPECIFIC QUALITY ASSURANCE:

23

8.1

Requirements for Quality Management:

23

8.2

Performance and Functional Tests:

24

SCOPE OF SUPPLY:

25

9.1

Foundation Earth:

25

9.2

Ring Earth Electrode:

25

9.3

External Mesh Earth Electrode:

26

9.4

External Lightning Protection:

27

9.5

Internal Lightning Protection and Equipotential:

28

10

DOCUMENTATION REQUIREMENTS:

28

10.1

General Requirements:

28

10.2

Documentation Requirements:

28

10.3

Documents to be Provided:

30

10.4

Project Control:

30

10.5

Operating and Maintenance Manuals:

30

10.5.1 Section I. General:

30

10.5.2 Section II. Operation:

30

10.5.3 Section III. Maintenance:

31

7.4

7.5

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10.5.4 Section IV. Catalogue of Equipment:

31

11

QUALITY ASSURANCE REQUIREMENT:

31

11.1

General Requirements:

31

12

RATING:

32

12.1

Load Cases:

32

13

APPENDIX:

33

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List of Tables
Table 1: Lightning protection level

12

List of Figures
Figure 1: Location of the power plant
Figure 2: An example for the fixed grounding point
Figure 3: Lightning protection zone concept in accordance with IEC 62305-4
Figure 4: The expansion piece for the air termination
Figure 5: Internal lightning protection and equipotential bonding bar (EBB)
Figure 6: An example for equipotential bonding and an equipotential busbar
Figure 7: Arrangement of the foundation earth electrode
Figure 8: Earth termination system
Figure 9: An example for the external lightning protection
Figure 10: An example for the air termination system
Figure 11: Internal Grounding

6
10
12
13
14
15
25
26
27
27
28

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1INTRODUCTION AND LOCATION OF THE PROJECT:

The Kurdistan Regional Government (KRG), Republic of Iraq, Ministry of Electricity, intends to build
an oil-fired power plant in Khabat, Iraq.

Figure 1: Location of the power plant

Khabat is about 35 km away from Erbil and can be reached by car in about 35 minutes.
The present specification is applicable for the design and erection of grounding and lightning
protection systems for the 2 x 150 MW Khabat Power Plant Project.

2INTRODUCTION OF GROUNDING AND LIGHTNING PROTECTION SYSTEMS:

2.1

General:

The grounding and lightning protection system shall be required for personal protection and
minimization of material damage. Thus, the apparent short-circuit and lightning currents must be
safely dissipated, and the exposure of people to voltages and the risk of over voltages for
electrical, instrumentation and control equipment must be limited to acceptable values.
The grounding system shall ensure protective and system grounding for the electrical power and
instrumentation and control installations as well as sufficient grounding for the lightning protection
systems.
A grounding system shall assure:

The safety of personnel

Limitation of contact and step voltage
Static electricity protection
Lightning discharge protection
Service earthing
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Implementing Specification:

Grounding and lightning protection systems shall comply with the requirements specified in the
following sections. The effect of the lightning protection system must conform to lightning
protection class I according to standards for buildings with control rooms, instrumentation and
control computers, protective devices or central switchgear and to lightning protection class II for
other buildings such as turbine house, boiler house or administrative buildings.
The earthing of instrumentation and electronic circuits shall be done according to their
manufacturer requirements and IEEE 1050.
The Supplier shall point out any deviations from these specifications already at the tendering
stage.

2.3

Regulations and Standards:

IEC 62305-1

Protection against lightning, Part 1: General principles

IEC 62305-2

Protection against lightning, Part 2: Risk management

IEC 62305-3

Protection against lightning, Part 3: Physical damage to structures

and life hazard

IEC 62305-4

Protection against lightning, Part 4: Electrical and electronic systems

within structures

IEC 60228

Conductors of insulated cables

IEEE 80 - 2000

IEEE Guide for Safety in AC Substation Grounding

IEEE 998

Lightning protection system

IEEE 1050

Earthing of instrumentation and electronic circuits

BS 6739

Code of practice for instrumentation in process control systems:

installation design and practice

BS 7430

Code of practice for protective earthing of electrical installations

NFPA 780

Standards for the Installation of Lightning Protection Systems

2.4

General Abbreviations:

2.5

Lightning Protection Zone

Lightning Protection System
Lightning Protection Level
Surge Protective Device

Existing Voltage Levels:

2.6

LPZ
LPS
LPL
SPD

132 kV
15.75 kV
6 kV
230/400 VAC
220 VDC
24 VDC

Main
Generator voltage
MV switchgear (IT system)
Consumer voltage (TN-C system)
DC - UPS voltage for control system
DC - UPS voltage for control system

Basic Design:

All components of the grounding and lightning protection system shall be dimensioned and
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designed so that the following requirements are met:

The mechanical strength and corrosion resistance must be ensured.
The highest fault current must be carried for a time of one second (short time temperature
rise).
Damage to property and equipment must be avoided.
The safety of individuals in terms of voltages to grounding systems that occur during the
maximum ground fault current must be ensured.

2.7

Components and Systems:

The components and systems belonging to the grounding and lightning protection systems are
listed below.

Grounding system
External lightning protection
Internal lightning protection
Equipotential bonding
Lightning surge suppressors
Shielding of cables

3GROUNDING SYSTEM:
A safe grounding system has to carry electric currents into the earth under normal and fault
conditions without exceeding any operating and equipment limits or adversely affecting continuity
of service. It has also to assure that a person in the vicinity of grounded facilities is not exposed to
the danger of critical electric shock.
The method of grounding resistance calculations and safety limits for equipment and personnel
protection has to be based on the standard IEEE 80.
The parameters used for design and the detailed grounding calculations are shown and explained
in the specification KP-00B__-EE365-G6025, including ground fault potential rise, and step and
touch potential study.
A common grounding system shall be provided for the power plant. The following system
components are considered:
High-voltage protective grounding
Medium-voltage protective grounding
Low-voltage grounding
Functional grounding (error-free functioning of an electrical system and ensuring that there
is electromagnetic compatibility)
Lightning protective grounding
The grounding system shall consist of a foundation earth of each building, a ring earth electrode
around every building and an external mesh earth electrode.

3.1

Foundation Earth:

The foundation earth is a conductor that is installed with a connection to the reinforcing steel in the
concrete foundation and is used as an earth electrode. The foundation earth must be enclosed and
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sealed on all sides by at least 5 cm of concrete, so that it is adequately protected against

corrosion, and must be laid out as a closed ring.
The ground conductor shall be connected by clamped connection conductively to the
reinforcement of the foundations and the floor plates at a distance of 1-2 m. To connect the inner
and outer ground lines or grounding lugs, grounding points of V4A steel (StSt 1.4401 / X5CrNiMo
17-12-2) are provided. The grounding points shall be installed in the walls, ceiling or floor.
The foundation earth electrodes shall consist of round steel bars or strip steel encased in concrete
and shall be galvanized. The mesh earth electrode has to be installed under a minimum concrete
cover of 5 cm. The mesh sizes in the foundation plate must not exceed 10 m x 10 m.
Additionally, stranded copper conductors with maximum mesh sizes of 10 m x 10 m shall be
installed below water-tight foundations. The mesh network shall be adapted to the various depth
sections of foundation.
The stranded copper conductors shall be laid along the outer walls of the buildings up to the
detachable connecting points and be connected by means of cable lugs.

3.2

Ring Earth Electrode Around Building:

A 120 mm (see specification KP-00B__-EE365-G6025) stranded copper conductor shall be

installed around every building at a distance of about 1 m as earth electrode. The earth wire shall
be buried in the ground as a ring earth electrode at a depth of about 0.8 m. Conductors shall be
high-conductivity copper to IEC 60228.
The ring shall be connected at the detachable connecting points at the outer walls of the building at
intervals of about 10 m. Where the size of a side of a building is smaller than this interval, the
corners of the building must be connected.
All ring earth electrodes shall be connected to the external mesh earth electrode at intervals of
about 20 m. If the distance between the corners of the foundation is shorter than 20 m, the ring
earth electrode shall be connected at the corners with the external mesh earth electrode.
Every ring earth electrode must be connected at least four times to buildings, and at least two
times to shafts and column footings.

3.3

External Mesh Earth Electrode:

The external mesh earth electrode shall be established between the individual buildings at the
power plant site. The external mesh earth electrode offers a large surface to distribute the fault or
lightning currents.
All buildings and steel construction shall be connected to each other as well as to the grounding
system through the external mesh earth electrode.
The outlying electrical control cabinets and devices shall be connected to the grounding system by
means of external mesh earth electrode.

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The external mesh earth electrode shall be connected to the ring earth electrodes by means of the
detachable connecting points every 20 m. A 120mm stranded copper conductor shall be used for
the external mesh earth electrode, and the mesh size across the entire power station grounds will
be about 20 m.
The conductor earth electrodes (ring and external mesh earth electrode) must be laid in
consolidated, flush subsoil. The backfill must be free of stones, rough gravel, rubbish or slag.
The conductor earth electrodes shall be of stranded high-conductivity copper to IEC 60228.

3.4

Grounding Outdoor Cable Routing:

Any external cables shall be directly laid in the soil, PE tubing, duct blocks or precast ducts.
A grounding conductor shall be laid above buried cables for protection against direct lightning
strikes. Based on the distance between grounding conductor and cables, there shall be a resulting
protection angle of 90.
This grounding conductor has to be connected with the following components of the grounding
system:
External mesh grid (at intersection points)
Ring earth conductor (around building)
All grounding conductors, for example in cable ducts, have to be connected with each other.
The grounding conductor shall be of stranded high-conductivity copper to IEC 60228.

3.5

Grounding Connections:

The grounding connection points shall be provided to connect the grounding system to the process
and electrical components. The grounding connection shall be provided preferably as fixed
grounding points in the concrete and wall. Grounding lugs shall be used in the areas where no
fixed earthing terminals are mountable.

Figure 2: An example for the fixed grounding point

The grounding components shall be connected directly or via an equipotential bonding busbar to
the fixed grounding point or grounding lugs. The grounding components are the process and
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electrical components and steel constructions.

Connections to substation grounding systems shall be made by disconnecting links readily
accessible for test purposes. All disconnecting links and distribution bars shall be supported from
insulators. Grounding distribution bars shall be strategically positioned around the plant areas.
Dedicated earth bars and disconnecting links for electrical and electronic equipment shall be
clearly identified.
All metallic casings, frames and tanks of electrical equipment shall be bonded to the grounding
system, along with all structural steelwork, metallic fences and gates, and steel reinforcing.

4EXTERNAL LIGHTNING PROTECTION:

In addition to the grounding system, which consists of an external ground electrode and
foundations earth, external lightning protection also includes the air-termination system on the
roofs of buildings, containers and components, as well as the down-conductor system as
connection to the grounding system.

4.1

General:

The external lightning protection has the task of capturing the lightning, conducting the lightning
current from the point of impact to the earth, and of spreading it throughout the earth without
generating any damage to protected equipment or people through thermal or mechanical effects
when a dangerous overvoltage occurs.

4.2

Lightning Protection Zone (LPZ):

A lightning protection zone (LPZ) is a zone in which the electromagnetic environment is defined in
regard to lightning risk. The LPZ limit consists of the outer and inner zones.
The LPZ 0A and LPZ 0B are outer zones, which are located outside of the building. The inner
zones are located inside the building.
For this project, four LPZ are defined as follow:
LPZ 0A: Direct lightning strikes are possible; the entire lightning current or parts thereof may
occur, as well as the full electromagnetic field of lightning.
LPZ 0B: Protected against direct lightning strike; parts of the lightning current can occur, as
well as the full electromagnetic field of lightning.
LPZ 1: The lightning currents are limited by current sharing and possibly by surge protection
devices (SPD) at the zone boundaries. The electromagnetic field of the flash may be
attenuated by spatial shielding.
LPZ 2: The lightning currents are further limited by current sharing and possibly by surge
protection devices at the zone boundaries. The electromagnetic field of lightning is usually
further attenuated by shielding.

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Figure 3: Lightning protection zone concept in accordance with IEC 62305-4

4.3

Lightning Protection Level (LPL):

The lightning protection is divided into four levels. The levels appropriate different probabilities that
the peak value of lightning current is below a predetermined current strength.
The following table shows the definitions for the peak value of lightning current depending on the
lightning protection level:
Lightning protection level

II

III

IV

Probability of the upcoming lightning current

being less than the maximum lightning current
peak value

99%

98%

97%

97%

Maximum lightning current peak value

200kA

150kA

100kA

100kA

Probability of the upcoming lightning current

being higher than the minimum lightning current
peak value

99%

97%

91%

84%

Minimum lightning current peak value

3kA

5kA

10kA

16kA

Radius of the rolling sphere

20m

30m

45m

60m

Air termination mesh size

5x5 m

10x10 m

15x15 m

20x20 m

Table 1: Lightning protection level

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The lightning protection level affects only the dimensions and requirements of the external lightning
protection, particularly the air terminals and, to a limited extent, the requirements for surge
protection devices. The other parts of the lightning protection system are widely independent of the
lightning protection level.
It is also generally accepted that the buildings have different lightning protection levels even in a
cross-building LPZ.

4.4

External Lightning Protection Components:

The external lightning protection consists of the following components:

Air-termination system on the roofs of buildings and other elevated locations
Down-conductor system as connection to the grounding system
Grounding system for distribution of lightning current

4.4.1 Air-Termination System:

A complete air-termination network shall be installed on the surfaces of the roofs. No part of the
roofs shall be more than 10 m away from the nearest protective conductor.
The cross-points of the meshes must be conductively connected by means of clamps. The location
of the meshes must be adapted to the structural conditions of the roof, taking account of projecting
metal parts. All metal parts must be connected to the meshes.
Depending on the ambient temperature, the length of the air-termination electrodes could change.
To avoid damage to the middle of the air-termination electrode, an expansion piece shall be
mounted.

Figure 4: The expansion piece for the air termination

The design of the air terminals is determined by the rolling sphere method. The radius of the rolling
spare shall be considered for air terminal design.
Aluminum (AlMgSi) shall be used for the air terminal rods. The length and number of air terminals
are dependent on building and roof structures.

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4.4.2 Down-Conductor System:

The down conductors connect the air terminals to the grounding system. Metal facades shall be
used as additional down conductors.
The individual metal segments shall be conductively connected vertically and horizontally at
intervals of about 1 m. Local thermal expansion must be taken into account. Detachable ground
terminals in the area of metal facades shall be visible and accessible.
The steel structures, conductive facade and the ground conductors built into the concrete of
structures can be used as down conductors.

4.4.3 Grounding System:

The external grounding system must be designed for a sufficiently low earth electrode and impulse
resistance, and must ensure a safe step and touch voltage within the power plant property by
means of potential gradient control in the event of ground fault or lightning strike.
A grounding system shall be established for the distribution of lightning current into the earth. The
grounding system is described in detail in Chapter 3.

5INTERNAL LIGHTNING PROTECTION:

Internal lightning protection comprises lightning surge suppressors and the integration of cable
trays, cabinets, shielding of cables, etc., into the equipotential bonding.

Figure 5: Internal lightning protection and equipotential bonding bar (EBB)

5.1

Equipotential Bonding:

In the event of ground fault or lightning strike, effective equipotential bonding shall be provided
inside of buildings. The sufficiently low impedance connections among the equipment shall be
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ensured, grounded and connected to the external grounding system.

Figure 6: An example for equipotential bonding and an equipotential busbar

Equipotential bonding can be executed by several connected equipotential bonding bars on a level.
A copper ground bus shall be installed on the bottom level of every building. The ground bus can
be a closed or non-closed ring. The ground bus shall be connected to the external grounding
system via fixed grounding terminals.
All conductive plant components (extraneous conductive parts), which must have the same
potential and be connected with electrical equipment, shall be connected to the equipotential
bonding by the shortest route. These are mainly containers, parts of the building structure,
pipelines, ventilation ducts, stairs, railings, grids, cable support structures, switchgear, etc.

5.2

Lightning Surge Suppressors:

Lightning surge suppressors need only be installed in particular cases for buildings or components
subject to increased lightning hazards. Mainly, these are:

Incoming-feeder cables of the communication system into the power station

Cameras, antennas, sensors on the roofs of buildings and on walls in lightning strike areas
Selected sensitive electronic equipment
Cables for the chimney

The lightning surge suppressors shall be installed directly at the entry into the building.
The cables leading to the lightning surge suppressors from outside must not be laid in parallel with
other indoor cables up to the lightning surge suppressor.
The lightning protection concept should be designed so as to avoid the need for lightning surge
suppressors wherever possible.
The cabinets and racks for the lightning surge suppressors shall be connected to the mesh earth
electrode or the building reinforcement by the shortest route via the ground stud.

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The following must be observed with regard to lightning surge suppressors:

The mounting rail for the arrestors shall be conductively connected directly to the housing of
the lightning protection box
The cable inputs and outputs must be separately wired in different locations
All cores of a cable must be protected by suppressors
The current-carrying cable screen and the foil screen must be connected to the lightning
protection box
The lightning protection box must be connected to the mesh earth electrode or the building
reinforcement

6SHIELDING OF BUILDINGS:
Buildings with control rooms, instrumentation and control computers, protective devices or central
switchgear shall be shielded with one of the following measures:
1. Electrically interconnected reinforcement of reinforced concrete
2. Metal facades
3. Air terminals and down conductors installed at the outer surfaces with a maximum mesh
size of 5m x 5m
For the first measure, the reinforcement can be used as shielding according to IEC 61024-1-2 if the
reinforcement steel is weldable. In this case, the reinforcement bars shall be welded to each other
every 1 m.
Note: The steel qualities usually used for concrete reinforcement at the moment are suitable for
welding.
With regard to the second measure, the metal facade covers the building as shielding. The metal
facade shall be mounted electrically conductive. The facade shall be connected to the grounding
system.
For the third measure, the mesh earth electrode shall consist of round steel bars and has to be
installed under a minimum concrete cover of 5 cm.
The mesh sizes in the roof ceilings shall not exceed 5m x 5m. The mesh sizes in the foundation
plate shall not exceed 10m x 10m.
In concrete outer walls, the mesh size shall not exceed 5m x 5m. In concrete columns or precast
concrete columns of outer walls, low impedance connection possibilities should be provided at the
top and bottom.
All concrete-encased mesh earth electrodes shall be electrically connected to the equipotential
bonding of the electrical installation by means of detachable connecting elements.
The number of detachable connecting elements results from the mesh size for:

The outsides of the outside walls of the buildings

The attic insides
The area of the generator and auxiliaries transformers
The rooms of the low-voltage transformers (however, with two connecting points at least)

All connecting elements must be labelled and visible; where the size of a side of a building is
smaller than the interval, the corners of the building must be connected, e.g., facade sheet steel.

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7PERFORMANCE REQUIREMENT:
7.1

Interfaces:

Connecting points of the external and internal lightning protection, and metal parts of the building
structure for equipotential bonding strips inside of buildings. All major equipment and tanks shall be
connected to the main ground grid in two places on opposite sides.
All metallic structures and equipment, such as motor frames, switchgear, unit substations, motor
control centers, panelboards, lighting cabinets, conduits, cable trays, crane rails, stairs, handrails
and tracks shall be permanently and effectively grounded.
It must be ensured that there is no electrically conducting connection directly or indirectly
between cathodically-protected equipment and other parts. These parts in particular include
structures made of reinforced concrete, grounding systems and all other buried metallic piping,
vessels, sheeting walls, etc.
Detailed information is included in the Cathodic Protection Specification KP-00B__-EE210-G6005.

7.2

Electrotechnical Installations in the Power Stations Outdoor Area:

7.2.1 High-Voltage Outdoor Switching Station:

The outdoor switching station shall be integrated into the grounding system of the power station.
A grounding and lightning protection system must be installed in the area of the high-voltage
switching station. The grounding system consists of an external mesh earth electrode and
connection to the steel structure. The cross section of grounding cable must be chosen according
to the sustained short-circuit current.
All metallic structures and supports shall be bonded to the grounding system.
The overhead lines must be connected to the grounding system via the surge arrester. The highvoltage switchgears shall be provided with the grounding switch. The connection to the grounding
system is made via grounding switches. A lightning protection wire shall be laid parallel to the
overhead lines where applicable. The wire shall be connected to the grounding system.
The grounding system of high-voltage switchgear is described in detail in the 132kV HV
Switchgear Substation - Technical Specification KP-00UBB-EE210-G6360.
7.2.2 Lighting Pole:
The lighting masts within the area of the power stations mesh earth electrode must be connected
to the grounding system. The touch voltage is therefore reduced.
The grounding conductor laid above the lighting cables must be connected at the lighting pole. The
grounding conductor will be connected at the mesh earth electrode.
7.2.3 Cables Outside of Buildings (Above Ground):
Cables laid outside of buildings (above ground) are cables which lead to drives, sensors, antennas,
telephones, cameras, etc., at or on buildings outside.
The cables shall be laid in such a way that they cannot be struck directly by lightning.

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Additionally, it shall be observed that flashovers into the cables shall not occur due to the vicinity to
the air terminals and down conductors. Such cables shall be laid in closed sheet-metal gutters,
cable tray, metal pipes or behind metal facades. The electrically connected sheet-metal gutters,
cable tray and metal pipes shall be connected to the mesh earth electrode at the ends.

7.3

Grounding of Electrical Equipment:

7.3.1 Generator / Generator Bus Ducts / GCB:

For the grounding of all components to be connected to the generator bus ducts, the casing of
phase L1 or L3 must be used as a ground bus and be fitted to the component housings with a
conducting connection via expansion bands designed to handle double earthing current (two-pole
short-circuit). The connection of the ground bus to the power station earth must be made via the
housing of the generator unit transformer and the unit auxiliary transformer.
The generator busbar conduits and also the GCB are insulated from the support structures. The
support structures of the GCB and IPB will be separately earthed.
See also the isolated phase bus duct IPB Technical Specification KP-00B_-EE210-G6014 and
Generator Circuit Breaker Technical Specification KP-00B__-EE210-G6012.

7.3.2

Medium-Voltage Transformer:

The transformer tank of the step up transformer must be connected to the grounding system at
least twice.
The star point of the transformer must be connected to the grounding system via the surge
arrester. The cross section of grounding cable to the grounding system must be chosen according
to the sustained short-circuit current.

7.3.3 Low-Voltage Transformer:

The low-voltage transformer shall be placed in a transformer box. On the walls of the transformer
box a busbar shall be mounted as grounding system at a height of one meter. All metal parts of the
transformer and its attached accessories must be connected to the grounding system. The cross
sections of grounding wire on the outside of the transformer must not be less than 70 mm.
The neutral point of the low-voltage transformer must be connected to the grounding busbar. The
cross section of grounding cable to the busbar must be chosen according to the sustained shortcircuit current.

7.3.4 Cable Supporting Structures:

Cable supporting structures shall be conductively connected over their entire course, e.g., by
means of threaded connections with serrated lock washers and by means of stranded copper
conductors at the isolating points.

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The individual cable trays of a cable route shall be conductively connected by means of the joint Hsupports.
At the ends and the building borders, cable routes/trays shall be connected to the foundation earth
electrode, the reinforcement, the steel structure, etc., by the shortest route.
Two stranded copper conductors for cable trays with power cables > 1 kV and one stranded
copper conductor for cable trays with power cables < 1 kV, each with 70 mm cross-section, shall
be installed in the corner of a tray rail. In the course of a cable route, only one ground wire
connection shall be carried.
For electrically conducting between the grounding conductor and the cable tray there shall be a
connection every 20 m between the two elements using an appropriate clamp.

7.3.5 Grounding of Switch Cabinet Base Frames:

The base frames of the cabinets for power as well as instrumentation and control installations must
be grounded via the switch cabinets.
If a false floor is used, the base frame shall be conductively connected to the false floor several
times. The entire construction of the false floor of a room shall be conductively connected. The
false floor shall be connected several times to the connecting points of the foundation earth
electrode by means of stranded copper conductors.
Base frames of control room panels and switchboards shall also be connected to the foundation
earth electrode.

7.3.6 Grounding of Sub Distribution Boards and Measuring Racks:

Sub distribution boards and measuring racks shall be connected to the ground bus by the shortest
route (e.g., ground wire on a cable tray).
The sub distribution boards and measuring transducers shall be conductively connected to the
mounting rack.

7.3.7 Switchgear:
In addition to the protective conductor of the incoming feeder cable, the ground busbars shall be
connected to the grounding system at each end of the equipment.
The ground bus carried on the cable route shall be connected to the PE or PEN bar in the
incoming-feeder panel of every low-voltage switchgear.
The ground bus carried on the cable route shall be connected to the protective conductor bar of the
medium-voltage switchgear.
The switchgear shall be conductively connected to the base frame.

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7.3.8 Electrical Machines:

The low-voltage motors and actuators shall be grounded via the protective conductor in the cable.
The enclosures of the medium voltage motors shall be connected to the two stranded copper
conductors of the cable trays.
The protective conductor carried in the cable shall be connected to the ground terminal within the
terminal box.

7.3.9 Floor Surface in the Electric Rooms:

The floor surface in the areas of power currents, instrumentation, as well as control switchgear
rooms and in computer rooms, shall be installed as conductive floors.
The conductive floors according to standards with a leakage resistance of < 10 7 shall be
conductively connected to the grounding system.

7.4

Grounding and Lightning Protection for Special Plant Areas:

7.4.1 Exhaust Chimney:

An air terminal shall be installed at the chimney mouth. The down conductors shall connect the air
terminal to the foundation earth and shall be encased in concrete. The exhaust chimney grounding
shall be connected about 0.4 m above the ground to exterior test joints.
From the test joints, connection shall be made to the ring earth electrode, which must at least be
equipped with four connections to the mesh earth electrode.

7.4.2 Tanks, Containers:

Containers must be connected to the mesh earth electrode. The number of connections depends
on the largest horizontal dimension (diameter or length) of the container:
Up to 20m: twice
More than 20m: four times.
Necessary connecting points for the connection of earthing conductors to containers shall be
provided.
A lightning protection measure for a tank is required when it is not in the lightning protection area of
another building.
Buried tanks and pipes in contact with the soil do not require special lightning protection.
Refer to the Cathodic Protection Specification KP-00B__-EE210-G6005 for exceptions.

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7.4.3 Pipeline Bridges, Conveyor Bridges:

The foundations shall be equipped with a foundation earth. Depending on the size of the
foundation, there shall be a ring earth electrode. Detailed specifications are included in the
particular KP-00B__-EE165-G6024 grounding and lightning protection plan. The concreteencased mesh earth electrode shall be provided with detachable connecting points. The steel
columns shall be connected to the grounding system. Insulated bearings, such as in the case of
the flue gas duct, shall be electrically bridged.
Pipelines entering the site shall be fitted with an insulated flange at the boundary. The minimum
resistance across the flange shall be one thousand ohms (1 k).

7.4.4 Fences:
When using bare metal fence, it must be earthed. This is to cater for the situation where a live
conductor (overhead line) has come into contact with the fence or to prevent the fence voltage
rising due to coupling with nearby live conductors.
The fence shall therefore be connected to the grounding system at intervals of about 15 m. The
individual fence fields within the power station grounds shall be connected among each other.
This shall be done by installing a 70 mm stranded copper conductor at a depth of 0.5 m along the
fence and connecting it to the fence posts. The earthing system shall be extended such that the
grounding conductor is 1 meter outside the fence. This ensures that touch voltage on the fence will
remain at a low level.
A conductive connection shall be installed from the fence posts to every framed fence element and
the doors. The parts of the power station border fence must also be connected to each other and in
intervals of about 50 m to the potential gradient control ring that follows the fence.

7.4.5 Track Installations:

The tracks on the power station grounds shall be connected to the grounding system and the rail
joints must be conductively connected.
Tracks exiting the power station grounds shall be decoupled from the outside tracks by means of
isolating pieces at the exit points.

7.4.6 Hazardous Areas:

The specifications described above apply to the foundation earth and the lightning protection
system of hazardous areas.

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Cable Ducts:

7.5.1 In-Situ Concrete Ducts:

At intervals of about 1 m round steel bars shall be inserted lengthwise and twisted with the
reinforcement.
The round steel bars shall be connected about every 10 m around the duct via round steel bars.
The foundation earthing shall be connected to the main grounding system.

7.5.2 Precast Ducts:

Ducts made of precast elements shall consist of U-shaped reinforced segments. The cover plates
shall also be reinforced.
In precast ducts round steel shall be installed as foundation earth and the connection points inside
and outside of ducts. The outside connection points are for connection to the external mesh earth
electrode.
The cable laying is regarded as direct burial installation.

7.5.3 Cable Draw Pits of In-Situ Concrete:

A mesh of round steel bars shall be inserted as foundation earth. The round steel bar mesh size
shall be about 1 m. The round steel bars shall have a conductive connection with the reinforcement
at intervals of 1 m.
The mesh earth electrode of the cable draw pits shall be connected to the stranded copper
conductors of the outdoor cable routing, of the cable trays in the cable draw pit and, in the case of
building entries, to the buildings reinforcement.
7.5.4 Concealed Expansion Joint Bridging:
An expansion strap (several sections) shall be mounted to lead the foundation earth electrode
through the expansion joints of extended foundations. Therefore, it is not necessary to lead the
earth electrode out of the base plate.
The expansion joint bridging in buildings shall be carried out according to the mesh size as
specified.

7.5.5 Visible Expansion Joint Bridging:

The bridging of expansion joints of the buildings and the individual duct segments shall be flexible
and low inductive. For connections to buildings, flexible connections to the fixed earthing terminals
(concrete-encased grounding) of the building walls shall also be provided.
For the connections at the locations of the joints of the duct segments and the locations of the
joints between the ducts and the buildings, fixed earthing terminals shall be embedded in concrete
at both sides and connected to the grounding system. The fixed earthing terminals shall be
connected to each other by means of 70 mm stranded copper conductor.

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Materials:

Stranded copper conductors with a cross section of 120 mm shall be used for grounding
electrodes and earthing conductors.
Stranded copper conductors with a cross section of 70 mm shall be used for protective conductors
and main equipotential bonding conductors. In particular cases (e.g., grounding of door frames),
fewer cross sections or less galvanized flat iron is admissible. The ground buses inside the
buildings shall consist of stranded copper conductors with a minimum cross section of 70 mm.
Stranded copper conductors shall be connected by means of clamps.
The equipotential bonding strips shall be made of flat copper, minimum 40 x 5 mm. The conductors
shall be connected by means of clamps. If a screw connection is necessary, then a wider bus must
be used.
The concrete-encased mesh earth electrode shall be made of smooth round steel bars, 10 mm
diameter.
As conductor material for the air terminals round aluminum (AlMgSi) with 10 mm diameter shall be
used; for down conductors 8 mm diameter shall be used.

8REGULATIONS FOR SPECIFIC QUALITY ASSURANCE:

The Supplier shall implement a quality management system in accordance with the requirements
of the buyer.

8.1

Requirements for Quality Management:

Refer to Appendix Quality Management.

KP-00___-EV210-G1101

Requirements for Quality Management

KB-00+++-PS732-P0001

Contractors Shop Quality Control Requirement.

KB-00+++-PS732-P0003

Contract Time Line for Quality and Delivery Processes

KP-00+++-MQ732-G0008

Packing Guideline

KP-90HDE-EM241-G-1012 Progress Reporting

In general, the Supplier shall submit its quality system certifications and quality manual to GAMA to
be designated on GAMAs Approved Supplier List or Approved Subcontractor List.
The Subcontractors shall, prior to the commencement of the works, prepare and submit a quality
plan (Quality Assurance Plan) to GAMA for acceptance.
GAMA and/or the Employer and/or their Representatives reserve the right to carry out appraisals
and quality audits at any time during the period of the contract to determine if the Supplier is in
compliance with the documented requirements.
The Supplier/Subcontractor shall submit a list of all sub-tier suppliers and sub-tier subcontractors
during the proposal stage to GAMA for approval.
The Supplier shall provide an Inspection and Test Plan to GAMA for review and acceptance prior
to initiation of the work. Inspections and tests shall be carried out by the Supplier in accordance
with the approved Inspection and Test Plan that explicitly and correlatively develops each and
every one of the phases of the procurement, manufacture and testing, and preparation for
shipment.
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For each point the Supplier shall indicate the internal procedure that is applicable. He shall also
indicate whether a report or protocol will be generated for each point, or whether other associated
documentation will be provided (quality certificates, reception reports, etc.).
The Buyer may select the points on this program which they or their representatives can witness.
During the inspection visits, the Buyer reserves the right to review applicable documentation that
has not been presented for his approval (reception procedures, manufacturing procedures, etc.).
In addition to the points mentioned in the appendices, the Inspection and Test Plan shall comprise
a minimum of the following sections, in which the following information shall be given:
a) Materials inspection
Main materials and components: Inspection upon receipt of materials to be used in manufacture,
with indication of those that will require quality certificates.
Auxiliary elements: Inspection of receipt of components with indication of those that will be required
with reception test protocols.
b) Inspection of manufacturing
List of the main as a minimum, the construction phases of the grounding and lightning protection
systems.
c) Examinations and tests
A list of all the tests indicated in this specification, with reference to each associated procedure that
specifies the acceptance criteria for the test in question.
d) Protection, cleaning, painting, labeling and delivery; final documentation
A statement of the monitoring or inspection of these activities setting out the procedures to be
applied and including a revision point for the final documentation dossier and an issue point for the
Delivery Note.
Inspection call will be used for inspection notifications with sequential numbering.
All of the required inspections and tests shall be made at the Suppliers / Subcontractors expense,
including the cost of all samples used.

8.2

Performance and Functional Tests:

The site tests of lightning protection systems/components shall be generally by visual inspection.
Visual inspection of the lightning systems shall take place in order to ensure that all components
are mechanically assembled and fixed properly and that there are no imperfections.
Electrical tests related to lightning systems, such resistance measurements and insulation /
shielding, shall also be carried. The test results shall be submitted immediately following the
completion of tests as computer printout or, alternatively, hand written.
Site test reports shall illustrate all test details as well as details of all applied testing equipment and
their calibration validity.
The field measurement of the constructed grounding system shall be done according to IEEE80.
The lightning protection system shall be inspected according to NFPA 780 Annex D.

9SCOPE OF SUPPLY:
The equipment for grounding and lightning protection shall include but not be limited to the
following:
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All other materials which may be necessary, but which are not mentioned herein specifically, to
complete the grounding and lightning protection in all respects to the best engineering practices
shall be in the Sellers scope.
All materials, consumables, special tools and tackle, testing instruments and machines required for
execution of the work are also included in Sellers scope.

9.1

Foundation Earth:
Round steel bars, 10 mm diameter
Clamp connections
Fixed earthing terminal

Figure 7: Arrangement of the foundation earth electrode

9.2

Ring Earth Electrode:

Stranded copper conductors (annealed soft-drawn) (120 mm)

Clamp connections
Connection to foundation earth
Connection to external mesh earth electrode

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External Mesh Earth Electrode:

Stranded copper conductors (annealed soft-drawn) (120 mm)

Stranded copper conductors (annealed soft-drawn) (70 mm)
Clamp connections
Connection to ring earth electrode

Figure 8: Earth termination system

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External Lightning Protection:

Rods; AlMgSi 10 mm diameter

Roof and down conductor; AlMgSi 8mm diameter
Roof conductor holders
Expansion pieces
Clamp connections
Earth rods
Connections to steel girder and facade

Figure 9: An example for the external lightning protection

Figure 10: An example for the air termination system

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Internal Lightning Protection and Equipotential:

Busbar flat copper, minimum 40 mm x 5 mm
Connections to fixed earthing terminal
Pipe clamps

Figure 11: Internal Grounding

10DOCUMENTATION REQUIREMENTS:
10.1

General Requirements:

A technical documentation must be prepared for the systems, plants, components, operating
materials and spare parts, which guarantees the erection, commissioning, operation and
maintenance of the power unit.
This specification details the definitions regarding types of documents, document forms,
information mediums, identification, number, terms and conditions of handing over, registration and
administration of documents and data.
The scope of supply will be considered as unfulfilled if the listed documents were not submitted to
the Purchaser.

10.2

Documentation Requirements:

All documentation, manuals, drawings, etc., must be in English. The final version of the operation
and maintenance manual and training course documentation must be in English.
Drawings shall be made available in CAD format. In general, all documents will be provided in both
native and portable (PDF) format.
The document and drawing numbering systems of the Purchaser shall be used throughout the
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project
The Supplier shall issue a document list containing all the documents that he will issue under the
contract. This list will be reviewed/commented by the Purchaser. The status of this document list
will continuously be updated by the Supplier and included in the monthly progress reports.
The size of the documents shall be in accordance with ISO A-series of Technical product
documentation. Sizes and layout of drawing sheets EN-ISO 5457. Drawings shall not exceed the
A0 size. All drawings shall remain legible when printed at A3 size for site use. Documents in
electronic format shall be provided in accordance with the following software:

Text documents, spread sheets, data bases: MS Office.

Drawings: AutoCad 2004.
Time schedule: Primavera.
Portable document format: Adobe Acrobat.

Other electronic formats shall only be used following written approval of the Purchaser.
All documents issued by the Supplier (drawings, texts, etc.) must be developed according to the
project-specific formats and must include the project-specific cover or title box (to be provided
later).
The revision and/or approval by the Purchaser of the drawings or other documents issued by the
Supplier will not release the Supplier from his responsibility of complying with all the contract
requirements.
The documentation coding procedure of the Purchaser will be used for the revision process of the
documentation. After reviewing a drawing or another document, the Supplier will issue an upper
revision indicating the reason of the modification in the title box. Modifications with respect to the
previous revision shall be identified in the drawing or document with a revision cloud or mark.
Any changes to the documents must be controlled during the development of the project. Changes
may be originated from design modifications, non-conformities, as-built deviations, etc. All changes
approved by the Purchaser shall be incorporated in order to maintain all project documents
updated. The final edition of all documents in the as-built edition must be incorporated into a final
dossier.
The Supplier must not carry out any changes in drawings or other documents already approved
without the Purchasers written acceptance.
Revision to the documents will be made by the Purchaser / Architect Engineer in the first round,
and after the updated documents have no more comments, further revisions will be made by the
Owner / Owners Engineer.
The Supplier will answer and clarify any comment to the documentation until it is closed before
issuing an upper revision of each document.
The Purchaser will usually have a two-week period to return the document with comments to the
Supplier.

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Documents to be Provided:

The applicable technical must be submitted by the Supplier for Contractor information or approval
in accordance with the contract. These documents must include all information needed for project
interfaces, input data, contract follow-up and maintenance and operation.
The specific project document list will be provided by the Supplier during the contract.
The documentation marked as critical will be considered in payment milestones and/or may be
penalized according to purchasing conditions.
The Supplier shall also provide all the necessary documentation and project files that may be
required for the official legalization of equipment.

10.4

Project Control:

The Supplier shall submit monthly progress reports on the activities performed during the period.
The monthly progress report must be brief and concise. Any deviation from the project schedule
must be identified. An activities plan for the next period and a corrective and preventive actions
plan to avoid deviations and to eliminate pending items must be included in the report.
Meetings at the Suppliers facilities can be held to ascertain the project quality and progress.
Development of the design, material take-off, manufacture, procedures, tests, etc., will be analyzed
during these meetings.

10.5

Operating and Maintenance Manuals:

The manuals shall be organized by sections, in accordance with the following contents:
10.5.1 Section I. General:

Title page.
Index of sections and reference to the content of the remaining sections.
Table of contents.
Description of how to use the manual and introduction.
General description and performance.
General philosophy of operation.
Operating conditions.
General description of the system equipment and controls.
Start-up, shutdown and emergency procedures.
Risk prevention measures.
Arrangement drawings.

10.5.2 Section II. Operation:

General description.
Operating specifications.
Start-up instructions.
Operating instructions.
Shutdown instructions.
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Conservation instructions.
Installation and commissioning instructions.
Design data and curves.
Control operating sequences.

The start-up, operating and shutdown instructions shall include, step by step, the procedures,
precautions and critical points to be observed, and they will differentiate between those considered
as preliminary, normal and post-maintenance.

10.5.3 Section III. Maintenance:

Maintenance plan.
Search, diagnosis and repair of failures.
Disassembly instructions.
Maintenance instructions.
Arrangement, clearances and adjustment data.
Assembly instructions.

10.5.4 Section IV. Catalogue of Equipment:

Equipment outlines and data sheets.

Spare parts and tools.
Drawings and other documents.
Instructions for purchasing replacement parts and list of suppliers.
Packing, storing and shipping instructions for spare parts and tools.

11QUALITY ASSURANCE REQUIREMENT:

11.1

General Requirements:

The Supplier must maintain a quality assurance system according to ISO 9001/9002/9004 or an
equivalent quality management system which must be approved by MoE.
The Supplier shall prove that a quality management system according to ISO 9001/9002/9004 has
been introduced and is being applied by furnishing a certificate of an accredited certifier.
The Supplier must impose appropriate obligations on his subcontractors.
For the implementation of quality assurance primarily quality planning and inspection the
Supplier must draw up plans for quality assurance for the entire plant.
The Supplier must document the quality assurance measures taken. In particular, the following
must be observed:
CE labelling or presentation of declarations of conformity or manufacturers declarations
must be carried out according to legal requirements. The declarations of conformity or
manufacturers declarations must be handed over with the final documentation.
If no CE labelling is required by law, the Supplier must still hand over declarations of
conformity or manufacturers declarations for the respective equipment/systems with the
final documentation. Additionally, the documentation must include notes for the client
informing him of how to proceed when replacing spare parts or carrying out repair work in
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order to maintain conformity.

The routine test is a manufacturing inspection and is to document the new condition. The
Supplier must carry it out for every component.
The type test is to prove compliance with the rating. The type test will be performed on the
prototype and remains valid for subsequent deliveries unless design and rating are
changed. The testing of a selected component from a line must not be regarded as a type
test of components with other dimensioning of the same line of products.

12RATING:
12.1

Load Cases:

The ground buses shall be dimensioned according to the maximal thermal load in case of fault.
The tripping time of the superordinate protection system shall be taken into account with regard to
the thermal rating of the current discharging grounding components

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13APPENDIX:
1) Typicals for grounding and lightning protection
KP-00B__-EE165-G6024
No.

Description

Typical 1

Clamp Connection Flat/Flat

Typical 2

Clamp Connection Round/Flat

Typical 3

Clamp Connection Round/Round

Typical 4

Connecting to Fixed Earthing Terminal

Typical 5

Connection to Steel Girder and Facade

Typical 6

Connection Subconcrete and Foundation Earth

Typical 7

Connection Foundation Earth with Connector Lug

Typical 8

Connection Foundation Earth to Anchor Plate

Typical 9

Connection Foundation Earth to Fixed Earthing Terminal

Typical 10

Connection Fixed Earth Terminal to Facade

Typical 11

Connection Foundation Earth to Steel Column

Typical 12

Connection Foundation Earth to the Mesh Network

Typical 13

Connection Foundation Earth to Downspout and Air Terminal Rod

Typical 14

Connection Steel Building to Facade and Flashing

Typical 15

Lightning Protection of the Cat Ladder

Typical 16

Connection Foundation Earth to Steel Stairs

Typical 17

Grounding the Handrail of Staircases

Typical 18

Grounding Connection to the Turbine Foundation

Typical 19

Lightning Protection

Typical 20

Connection expansion strap for foundation earth electrode

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KHABAT TPP UNITS 1&2 AND BAZYAN 400kV SUBSTATION

Doc. No

KP-00B__-EE210-G6015

Grounding & Lightning Protection

Technical Specification

Rev. No.

Page

34 of 34

2) Grounding Dimensioning Calculation

KP-00B__-EE356-G6025
3) Lightning Protection Dimensioning & Risk Report
KP-00B__-EE350-G6015
4) Grounding Mesh Net
KP-00B__-EE159-G6027
5) Quality Management
KP-00+++-PS732-P0001 - Contractors Shop Quality Control Requirement
KB-00+++-PS732-P0003 - Contract Time Line For Quality And Delivery Processes
KP-00___-EV210-G1101 - Requirements For Quality Management
KP-00+++-MQ732-G0008 - Packing Guideline
KP-90HDE-EM241-G-1012 - Progress Reporting
6) Document Management
KB-00+++-EV712-E0002 - Project Numbering Procedure
KB-00+++-MV712-E0002 - Procedure For Documentation Of Engineering Deliverables
KP-00___-EV210-G1003 - Manual Documule
KP-00___-EV210-G1004 - Transmittal Form
KP-00___-EV210-G1005 - Title Block
KP-00___-EV210-G1007 PDMS Manual
7) Communication Procedure
KP-00+++-MQ732-G0013 Communication Procedure for Suppliers

End of Document

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