311

The IEE Buildings Electrical Technology Professional Network

Earthing In Industrial and

Pharmaceutical Plants

Kieran Fallon, DPS Engineering &

Construction Ltd

0 The IEE
Printed and published by the IEE. Michael Faraday House, Six HiIls Way,
Stevenage. Herts SGI 2AY, UK

EARTHING IN INDUSTRIAL AND PHARMACEUTICAL PLANTS

Kieran Fallon, Chartered Engineer FIE1
Electrical & Instrumentation Manager, DPS Engineering & Construction
(www.dps.ie)
Abstract - Earthing (or grounding) is an essential part of any electrical installation. Within industrial
and pharmaceutical plants with potentially explosive atmospheres earthing plays an essential role in
maintaining the electrical and instrumentation systems in safe condition. The earthing system,
although a single physical system, it carries out many different functions including automatic
detection and clearance of electrical faults, prevention of dangerous potential differences which
could cause injury, prevention and dissipation of static charges, screening and reduction of
interference in instrumentation systems and provision of a reference point for intrinsically Safe
Zener barriers systems.

INTRODUCTION
The basic reasons for earthing and bonding in an electrical installation are
To provide a reliable low impedance return path for fault currents so that the fault can be
detected and the source of power removed as quickly as possible.
To prevent potential differences which would create a possible electrocution hazard.
To minimise damage due to lightning strikes and associated surges.
1
To prevent the build up of static charges to a level where their discharge would be a source
of ignition or potential safety risk.
To minimise electrical interference to instrument and communication signals.
To provide a reference point to allow Intrinsically Safe systems to limit energy available in
Potentially Explosive Atmospheres.

On industrial or pharmaceutical plants with Hazardous Areas the requirements for earthing and
bonding are higher than in normal industrial or commercial environments. This is in order to
minimise potential sources of ignition from static charges and lightning and to ensure rapid
clearance of faults.
The earthing system provides a low impedance return path so that any fault that results in metal
parts not intended to be live, becoming live will result in a high current forcing the circuit protection
to operate. This earth loop impedance and the time taken for protection to operate is defined by
the within the regulations. A low earth loop resistance is necessary for a system to operate safely.

Faults within an electrical system may result in an area or object rising in voltage in comparison with
other adjacent areas or objects. Such a fault would create a danger for any person who is near or
in contact with items at different voltage. To prevent a voltage gradient within a plant all metal items
are connected (bonded) together and to earth. This equipotential and supplemental bonding is a
requirement of a safe electrical installation.

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The earthing system also prevents the build up of static charges within plant areas. Any build up of
charge may result in sparks which may ignite the potentially explosive atmospheres which exist
within the plant. Anti-static earthing, an essential safety requirement, extends to a larger range or
items and equipment than equipotential bonding.
Lightning strikes and associated electrical surges in a building have the botential to cause
significant damage and be a source of ignition where potentially explosive atmospheres occur. To
reduce the effect of a strike a lattice of conductors is installed around the building. This Faraday
Cage conducts the surge currents safely to .earth. Following the lightning strike flash over may
occur to any other earthed metalwork creating-a parallel conductive path to earth. To prevent this a
definite bond is installed between the lightning protection system, equipotential bonding system and
electrical safety earth. This ensures that all earthed equipment is at the same potential in the case
of a lightning strike or surge.
One technology for elimination of ignition sources in Hazardous Areas (Potentially Explosive
Atmospheres), Intrinsically Safe Systems, reties on the concept of limiting energy available within
the hazardous areas. One of the methods to limit energy requires a reference voltage to be
available to which voltage and current is referred. This reference voltage is always earth potential,
zero volts. Without an effective and reliable earth system some intrinsically safe systems may
become unsafe.

REGULATIONS, STANDARDS AND RULES

The electrical installation regulations referred to in this paper are the Electro-Technical Council of
Ireland (ETCI) Rules for Electrical Installations 3d Edition ET101-2002. These rules, derived from a
CENELEC document, are similar but not the same as the IEE Regulations.
Other standards referred to are generally euro norm standards IS-EN-XXXX which are identical to
the UK versions BS-EN-XXXX or British Standards which are used and accepted in Ireland.

HAZARDOUS AREAS
In the many industrial processes and pharmaceutical plants where flammable materials are
handled, any leak or spillage may give rise to an explosive atmosphere. To protect both personnel
and plant, precautions must be taken to ensure that this atmosphere cannot be ignited. The areas
at risk are known as hazardous areas or potentially explosive atmospheres. The materiats that
are commonly involved include solvents, natural and man-made process gases, alcohols, metal
dusts, carbon dust, flour, starch, grain and fibres.
Protection of workers within Hazardous Areas or Potentially Explosive Atmospheres is now
governed by statute throughout Europe as a result of EU Directives. The directive requires sources
of ignition including static discharges, lightning and equipment under fault conditions to be gives
specific consideration.

EARTH ELECTRODES
The regulations require that all TN systems be earthed. The physical connection to the general
mass of earth is achieved by use of an earth electrode. The concept is that the mass of earth is at
zero potential and everything connected to it is thus also at zero potential.
The regulations require connections to earth electrodes to have the following properties;

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1
1

=
I

Adequate electrical conductivity

Mechanically robust
Protected against corrosion
Clamp does not damage earthing conductor
Be accessible for inspection
Labelled SAFETY ELECTRICAL CONNECTION - DO NOT REMOVE

Although there are a variety of earth electrodes available generally driven rods or buried tape are
used. The number of earth electrodes and dept to which they have to be driven is dependant of the
quality and type of soil in the area. Although theground surveys required by the civil engineers
may give an indication of the soil types details of the soil resitivity 1s not generally available at the
electrical design stage of a project. From a practical point of view a decision is required prior to
tender as to how many earth electrodes should be supplied, usually an earth nest is specified with
three to four driven 2m / 3m rods.
The earth electrodes will be installed usually as in straight line or in a square / triangular formation,
the latter been preferred for space reasons. Where a number of earth electrodes are provided they
should be spaced apart a minimum of the driven dept. Thus to install say a four electrode nest a
linear space of eight to ten meters. Thus spatial requirements for earth electrodes can be
significant and should be indicated on drawings (together with earth cable routes).
The number of electrodes required for power system earthing is usually low, however when
combined with lightning protection there may be in excess of a hundred electrodes on a site.
Maintenance, even inspection of the earthing system may thus be a considerable maintenance
task, Earth electrodes are an essential part of the electrical installation it is not unusual for sites to
give little or no maintenance to these items unless there is a specific problem with the site earthing.
Testing of the main earth electrodes may require disconnection of the electrodes from the system
and comparison with reference electrodes. This may require isolation of the supply and disruption
to the site. For some sites a second earth nest may be required.
Sizing of the earth conductor is a similar procedure to the sizing of a CPC conductor, however
considering it5 importance it should always be mechanically robust.
Typically industrial sites grow and change with time as production expands or changes. This often
results in the electrodes been lost or covered during building expansion, provision of hard-standing
or concreting over of yard areas.
In addition to the safety notice consideration should be given to providing a reference number for
each earth electrode such that traceable records may be kept of the testing and inspection of each
item.
Key Points to Note
Establish whether ground is made up or rock or whether there are other potential problems
Ensure sufficient space is available for earth nest
1
Co-ordination with architectural features
Ensure a suitable route is available from main switchgear to earth nest
Clearly label electrodes
Consider maintenance, inspection and testing

EARTH BARS
The regulations require that a main earth bar be provided in every installation for the

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interconnection of the following conductors:

General Earthing
Protective Conductors
Main Equipotential Bonding Point
Functionat Earthing
Bonding Conductors for Lightning

For large sites there should also be a sub-mai? earthing bar within each building. In addition it is
normal practice to provide earthing bars throughout a plant to which vessels and equipment may be
bonded. These earth bars are generally connected in loop back to the main building earth bar
using a robust earth cable, say 50 mm sq. copper / PVC. These earth bars as with the main earth
bar are generally mounted on walls or structural elements using insulated supports. The earth bars
must be both mechanically and electrically capable of carrying the high currents and stresses
possible in case of large fault currents. Care is required to ensure that the effective earth cable csa
is not reduced at the bar even where the largest lug bolt is fixed.

Often the earth bars and cables are not identified other than the green/yellow colour coding. It is
recommended that each bar and associated cables be identified. This will allow traceable records
to be kept of inspection and tests on the bars.
Key Points to Note
Access for maintenance and additional cables
Label
Mechanically and electrically robust

INDUSTRIAL ELECTRICAL POWER SYSTEM

Electrical power is generally delivered to large electrical consumers at medium voltage and is
stepped down to 400V / 230V via a transformer either owned by the utility or the customer. Key
elements of a power distribution system is the earthing consisting of;
Medium Voltage Earthing
Transformer star point earth (Neutral Earth link)
Earth distribution throughout the Site
Generator Earthing
Earthing of Final Circuits
Medium Voltaae
T h e Medium Voltage (1OkV or 2OkV) system in Ireland is operated as an earth free system.

Although earthing of the MV system is not required a reliable earthing installation is required for the
cables and MV switchgear enclosures. All electric cables become charged in the same way as a
capacitor. On Medium Voltage systems the effect of charging is more significant and charge
retention lasts longer. Voltages are such on Medium Voltage systems that the stored charge on
cables may be dangerous. For this reason before work is permitted on Medium Voltage cables, the
cables are always earthed and facilities must be provided to allow such earthing.
In addition the 20,000 Volt system currently been rolled out may in future be earthed. Where low
voltage generators (400V) are used to feed a site MV system (1OkV / 2OkV) via step up
transformers, facilities must be provided such that the site system (if 20kV system is earthed)
retains an earth on disconnection from grid supply. This may entail the provision of W or DY step
up transformers.

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Transformer Star Point Earth (Neutral Earth.Link)

The regulations requires that "where an installation is supplied from a source such as a generator or
transformer forming part of the installation, the exposed conductive parts of the installation shall be
connected to the neutral conductor at one of the following points
earthed neutral point of the source, or
main distribution point of the installation, or
at each sub-distribution point"

._.

The regulations (542.5) also require that the neutralising conductor be insulated and of the same
cross sectional area as the cable to the earth electrodes. The neutral earth link must be of
sufficient cross sectional area to be capable of carrying the maximum fault current without damage
or significant volt drop.
This link is usually specified as part of the main switchboard, however unless specifically instructed
may be omitted. Sites may, due to increases in electrical loads, move from a utility owned
transformer (supply at low voltage) to customer owned transformers (supply at medium voltage). In
these cases, if the existing main distribution board is retained as the main board, provision of a
Neutral-Earth link may be required.
Key Points
With transformers or generators ensure N-E link is provided (TN)
Ensure size is adequate and robust
Disconnection link is provided
Generator Earthing
Standby generators are provided on a number of sites sized to handle the entire site load or
essential loads depending on the site. Generatly the standby generators are low voltage sets
(400V)feeding the distribution boards directly or occasionally stepped up to medium voltage and
distributed across the site. (Generators feeding the grid on an occasional or full time basis are
subject to specific requirements and outside and not considered here)
As with site based step down transformers the star point of any generator on a TN system must be
earthed. Care must be taken to ensure that in the event of disconnection of the grid supply the
system and generator remain earthed. Similarly where a standby generator only supplies a specific
sub-distribution board on site arrangements are required to ensure that at this point N-E link is
provided (while the generator is running)

Earth loop impedance should always be considered to ensure that protection will continue to
operate under all supply conditions. Where parallel sets are provided circu tation currents need to
be considered as requirements of BS7430 taken into account.
Mobile generators also require facilities for earthing and these should be considered where fixed
facilities are provided or generators are brought to site for a specific project.
Key Points
Ensure that when disconnected from grid standby generator I CHP remains earthed
Ensure star point is earthed

Earthinn of Final Circuits

The ETCl regulations (553.3) require that "circuits supplying socket outlets shall be protected by

317

one or more residual current devices having a rated operating current not exceeding 30 mA. The
ETCl regulations (553.4)also include a requirement that the earthing contact in socket outlets be
connected to earth. This should be checked during periodic testing and inspection of the sockets.
The maximum value of the earth loop impedance is defined in relation to the time taken to trip the
protective circuits rather than in absolute terms. With each electrical supply within a plant there will
be a earth or CPC cable sized to ensure that protection will operate within a specified time ( 0.4 sec
or 5 sec) disconnecting the mains supply. The CPC cable is designed to carry the full fault current,
however fault currents will not be restricted to this single CPC and may take parallel paths via other
CPCs, or other conductors to earth.
In addition within hazardous areas conductor temperatures under fault conditions must be
considered. The ETCl National Rules for Electrical Installations in Hazardous Areas specifically
required that the conductor temperature under fault conditions shall be lower that both the ignition
temperature of the explosive atmosphere and the manufacturers short time temperature rating
Key Points
RCDs required on all circuits feeding sockets (ETCI)
1
Check cable temperature under fault conditions (Hazardous Areas)

EQUIPOTENTIAL BONDING
The object of equipotential bonding is to ensure that all adjacent metal work is at the same potential
(voltage) under normal or fault conditions. In case of fault which involves the outer metal enclosure
of an electrical apparatus becoming live there is a risk that, by contact with this live component and
another earthed piece of metal or conductor, a person could become the primary or a secondary
earth path for the fault current. To prevent any risk of a person becoming a current path (and thus
receiving an electrical shock) all exposed conductors and extraneous conductive parts within an
area are bonded together and to earth. This ensures that in case of fault,. when the outer metal
enclosure becomes live and rises in potential to mains voltage, everything in the area atso rises to
mains voltage, thus there is no potential difference between any metal parts,which a person may be
in contact. Without potential difference there is no current and no shock. The minimum size for
these bonding conductors is specified in the ETCl rules.
Equipotential bonding can be considered .as protection against indirect contact, that is, protection
against shock in the case of exposed conductive part or extraneous conductive part becoming live.
The ETCl regulations (544) require that main bonding conductors be insulated copper with cross
sectional area at least 50% of the largest protective conductor. However the main bonding
conductor need not exceed 25 mm sq. The ETCI regulations also require labelling of all main
bonding conductors with a label Safety Electrical Connection - Do Not Remove.
At various points throughout a plant there will be supplementary bonding where all local metalwork
is bonded together and possibly bonded again to earth. The Supplementary bonds are always in
addition to main bonding. Bonding in addition to creating an equipotential zone will also, in case of
fault which results in direct contact between live conductor and bonded metalwork, carry some fault
current. Both the main equipotential and supplementary bonding installation is required to be
robust and capable of surviving in an industrial environment.
Bonding conductors and supplemental bonding conductors tend to be of different sizes the latter
may be significantly smaller than main bonding conductors. In the case of bonding of say lined pipe

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running within a plant area, this would be generally considered to require supplemental bonding and
anti-static bonding. It would be usual to provide a minimum of a 4 mm sq copper conductor would
be adequate to meet ETCl requirements. However the pipe system also requires main bonding
conductor which would be as discussed above.
Within the ETCl National Rules for Electrical Installations in Potentially Explosive Atmospheres
there.is a specific requirement that in Zone 0 and Zone 1 areas the resistance, R, in ohms between
any two simultaneously accessible conductive parts not exceed;

Z = phase earth loop impedance of relevant circuits

U = phase earth voltage
Bonding throughout a plant area usually takes the form of a number of items of equipment,
pipework and ductwork connected directly to a local earth bar. This type of installation has the
advantage over a looped system in that removal or modification to plant items will not compromise
the overall bonding. Care must be taken to ensure that pipework, vessels etc are electrically
continuous throughout or that suitable bonding straps are provided.
Key Points to Note
Equipotential bonding required for safety
Supplemental bonding will also be required throughout the plant
Provide local earth bars
For each piping system ensure that at tease one equipotential bond is provided.
1
Ensure electrically continuous piping systems or bonding straps
Specific Hazardous Area requirements

LIGHTNlNG PROTECT10M
Provision of lightning protection for a building is normally based on a risk assessment of the building
and its contents. The risk assessments and requirement for lightning protection on specific
buildings iooks at the probability of a lightning strike in the area, relative size of the building,
structure and contents and is clearly described in the standards BS 6651 1991 Code of Practice for
Protection of Structures from Lightning. The standards recommend lightning protection for all
buildings with flammable or explosive contents. It states that structures with inherent explosion
risks usually need the highest possible class of lightning protection.
Lightning protection of buildings operates on the Faraday Cage principal where the lightning strike
is conducted to earth around the structure without entering it. The protection works on the theory
that for perfect conducting enclosure, electromagnetic radiation incident on the enclosure or current
flowing in the enclosure does not generate a fjeld within the space inside the enclosure. With
lightning protection what we try to achieve is something approximating this conducting enclosure by
placing a lattice of conductors over a building. For the protection to be effective the lattice must be
regularly spaced (10m or 20m spacing), uniform as far as possible and earthed. It is essential that
the down conductors are terminated in a low resistance earth system and the lightning transient
does not discharge to adjacent metal work or find alternative lower resistance paths to earth.
The object of the lightning protection system is to conduct the large surge of electrical energy to
earth without damage to the building or contents. The nature of the current and its very steep rate

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of rise and decay are such that a low impedance earth electrode system is required. The nature of
the waveform and frequency is such that what appears as a low impedance path at 50 Hz may
appear as medium or high impedance to a lightning surge. For example sharp bends in copper
tape may give rise to high impedance from a lightning perspective.

If the lightning protection system is hit by lightning then the current flowing through the system and
impedance offered by the conductors will determine the potentiat difference on the conductors with
respect to true earth potential. This potential difference may be in the order of megavolts
(1,000,000V) with respect to earth potential. Within the buildings and adjacent to the lightning
protection conductors there will be metalwork, pipes, cable armour etc that are connected to earth
via the equipotential bonding system. If the lightning surge current in the lightning conductors sees
a lower impedance path to earth via adjacent cables, metalwork, instrument cable screens etc. it will
attempt to flow down this path. To achieve the connection to this path it may arc across air gaps,
damp concrete, instrument circuit boards etc.
To minimise the risk of side flashing the impedance of down conductors must be minimised. The
impedance is minimised by taking the most direct route from air termination to earth and avoiding,
where practical, sharp bends in the conductors In addition equipotential bonding is linked to the
lightning protection so that as the potential on the lightning system rises the potential of all
conductors within the building will also rise. This is intended to reduce the possibility of the lighting
surge seeking alternative earth paths. Without a potential difference between the down conductors
and the parallel path current should not flow between them. Pipework and potential parallel earth
paths should be bonded to the lightning protection at both top and bottom of the structure. Offend
due to pipe supports from the structure of the building this is achieved without additional specific
bonding.
The concept of a Faraday Cage as a perfect box without openings or protrusions is not practical
when considering industrial and particularly pharmaceutical buildings which tend to have a number
of vents, pipework cables and process equipment entering and leaving the building. Any lightning
strike to say, the pipe bridges will result in a pulse of electrical energy travelling to earth via the
bridge supports. This surge will also travel to each building connected to the pipe bridge to find a
low impedance path to earth. This path wilt include equipotential bonding, lightning conductors,
instrument cable screens etc, within the building. It may also cause side flashes and resultant
damage to electronic and instrument systems. To prevent surges entering the building via the
pipework, pipe bridge supports or cable tray a low impedance path to earth should be provided at
the point of entry into the building. All pipework entering a building on external overhead pipebridges should be bonded (together and to earth) at the point of entry and at 20m intervals.
Steelwork forming part of lift structure or guides should also be bonded to the lightning protection /
earthing system.
In the same way as a surge originating on a pipe bridge can travel to buildings connected to the
structure, surges originating in any building on the site may be transferred around the site. In
addition to pipework and metalwork buildings are linked via the armour of power and signal cables.
The armour is normally bonded to earth at the steel frame of control and power distribution panels
which will allow surges to dissipate to earth without entering the panel.
The earth electrodes are considered as a network and specific individual earth resistance is not
specified as with power distribution earth electrodes. The entire network is required to have an
overall resistance to earth of less than 10 ohms. Individual earth electrodes should have a
resistance (ohms) not exceeding ten times (10 x) the number of electrodes provided on the building.
However when testing if a single earth eiectrode is found to be significantly higher resistance that ail

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others consideration should be given to replacement of that specific rod. The British Standards also
recommend buried ring electrodes.
The lightning protection system cannot be considered as a stand alone earthing installation since it
utilises a number of components (parallel earth paths) also used as main bonding and
supplementary bonding points (exposed conductors and extraneous conductive parts). The
regulations require that the lightning protection and power system earth be bonded together at the
main earth bar. This bonding cable should be clearly labelled as the lightning protection bond and
facilities provided for disconnection to allow testing.,
Surne Protection Devices
In addition to protection of the building structure, sensitive electronics within a building may also
require protection. This again is based on a risk assessment and business contingency
requirements. Surge diverters are fitted to the incoming power, telecoms and control signal lines.
The surge protection devices will also require a reliable and robust earth connection.

Key Points to Note

Lightning operates at a higher frequency than mains electricity and thus sees different
impedances for the same strip of copper.
Buildings do not form perfect faraday cages and protrusions need to be considered
1
Parallel earth paths need to be bonded
Hazardous Areas need higher levels of protection
Bonding to electrical power system earth is required
9

AN TI-STATIC EARTHING
Static discharges within Hazardous Areas have the potential to ignite the potentially explosive
atmosphere and need to be controlled and eliminated. Static electricity is generated when like or
unlike materials move against each other causing electrons the be stripped from one material and
attached to the other. This results is one of the materials having a positive electrical charge and the
other a negative. For significant charge to be developed one of the bodies must be a conductor and
insulated from earth. This creates a hazard if the body becomes sufficiently charged to create a
spark capable of discharging to an adjacent conducting body.
Potential Energy on Typical Plant Items (1OkV)
Road Tanker 250 mJ
Person
I O mJ
100 mm Flange 0.5 mJ
Minimum Ignition Energy (Vapours)
Propanol
0.65 mJ
Methane
0.28 mJ
Methanol
0.14 mJ
The most common source of danger from static electricity is the retention of charge on a conductor
because virtually all the stored energy can be released in a single spark to earth or another
conductor. The accepted method of avoiding the hazard is to connectall conductors to each other
and to earth with sufficiently low resistance to permit the relaxation of the charge.
In addition, as with any electric shock, a person discharging a static charge may as a result suffer
fall or other injury..

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The British Standard 855985 Control of Undesirable Static Electricity Part 1 I991 & Part 2 1991
define the requirements for anti-static earthing installations. The standards generally require a
resistance of 10 Ohm from conductors (tanks, pipework etc.) to earth. However resistances up to
I O 6 Ohm will relax static charges.
The anti-static earthing system is part of the Overall earthing system. The system which provides
electrical safety earths and equipotential bonding will also provide anti-static earthing provided the
resistance to earth is sufficiently low.
Fixed Plant Items
In general the equipotential bonding and supplemental bonding within a plant area is sufficient for
static charge relaxation of fixed equipment. Attention is required for items which are not normally
considered within the scope of equipotential bonding systems such as vessel agitators (normally
sufficiently low resistance to allow relaxation but should be tested), vessel on weigh cells which may
be insulated from earth and removable components (chutes etc).
Glass Pipework
Some process applications require the use of all glass pipework and vessels. These pose specific
problems for anti-static earthing in particular earthing of flanges which are generally metal. All
flanges must be bonded to earth.

Mobile Items of Plant

Mobile items such as movable equipment, drums, mobile vessels and raw materials pose significant
risk for build up and generation of static charges within a plant. These items often have no
connection to the electrical network and must be specifically earthed at their point of use and
storage. This is generally achieved using earthing reels or earth bars within the plant areas. The
British Standard BS5989 and Cenelec technical report CLC/TR 50404 both give detailed guidance
on avoidance and control of static on mobile items. Typically wheels on mobile plant must be antistatic.

Tanker Bays
Loading and unloading of aviation, automotive and other petroleum fuels requires particular
precautions to ensure static discharges do not occur or, result in ignition. These installations are
governed by specific standards and legislation and are not addressed here. However tanker
loading and offloading is a common requirement on industrial and pharmaceutical sites and anti
static earthing facilities should be provided where ever flammable liquids are handled.
To eliminate this risk when earthing road tankers, a system has been developed which confirms a
secure connection by the earth clamp to the tanker body before zero earth potential is applied to the
clamp. The system operated by passing an Intrinsically Safe current through the prospective earth
circuit prior to application of the earth potential. These systems can also detect, by checking the
capacitance of the earthed object, whether the clamp has been applied to a tanker or just local
metalwork and can be used for interlocking of plant and equipment. These systems are commonly
referred to as earth rite systems (earth rite is a trade name of one of the system suppliers).

Control of the Generation of Static Electricity

It should be noted that earthing is not the only method for control of static electricity in internal plant
areas. Although humid air is not a conductor it may be used to control static. With high relative
humidity a moisture film forms on the surface of solids with a resultant reduction in surface
resistivity to a level where relaxation occurs. Standards recommend that RH s maintained above
65% and not be the only method of static control. There are also numerous methods applied on

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sites to reduce or eliminate the generation of static. These include anti static footwear and clothing,
reduced pumping rates, reduced splashing on charging vessels, use of metal containers for storage
and transfer of product and so.

INTRINSICALLY SAFE SYSTEMS

Industrial or pharmaceutical plants that use or store solvents, fine powders or flammable materials
are required to zone the plants into areas that contain potentially explosive atmospheres,
Hazardous Areas. Within these Hazardous Areas'all ignition sources are eliminated or controlled.
One of the methods of controlling ignition sources is by use of intrinsically safe installations. The
concept of intrinsically safe systems is that the energy available in the hazardous areas is limited
such that it is not capable of igniting the explosive atmosphere. The energy is limited by use of
safety barriers of which there are two types either with or without galvanic isolation. The safety
barriers without galvanic isolation require a high integrity earth to operate.
The shunt diode barrier limits the energy available by use of fuse and resister to limit current and a
diode (zener diode) to limit voltage. The principle of operation of the zener barrier is based upon
the reference voltage of the zener barrier not been exceeded in normal operation. If this voltage is
exceeded by for example a fault within the safe area then the diode will avalanche into conduction
and break the fuse which isolates the circuit. In order for the circuit to operate it must be connected
to a secure and effective zero reference point. This zero reference point is always the earthing
system with the plant.
In a shunt diode circuit fault, currents are returned to the neutral star point within the safe area.
However during that transient period the voltage difference between the star point and the barrier
earth bar is transferred to the hazardous area. In these circumstances it is necessary to maintain
the barrier earth connection as low as possible to prevent a source of ignition developing. The
usual limit on this potential difference is 1OV. The intrinsically safe earth bar must be secure,
reliable and paths to star point must be of low resistance.
The National Rules for Electrical Installations in Potentially Explosive Atmospheres ET105:2001
specifically requires that "the conductor used shall be insulated to prevent invasion of the earth by
fault currents, which might flow in metal parts with which the conductor could come into contact (for
example control panel frames)".

A secure earth is normally provided by connecting the barriers directly to the main distribution board
earth bar (transformer star point) via two separate earth cables with diverse routing. In addition to a
secure earth this arrangement allows testing of the earth installation (one cable at a time)'while the
plant is live.

Key Points to Note;

IS Safety barriers without galvanic isolation require a high reliability earth to operate
Earth connection must be less than 1 ohm
1
Insulated and isolated to prevent invasion by earth fault currents

INSTRUMENTATION EARTHS AND SHIELDING

Instrument cables in an industriaVprocess plants operate within an environment with electrical noise
emitted from power cables, motors, lightning and other electrical equipment.
The two types of induced noise affect signal cables are electrically coupled capacitively interface

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and magnetically coupled interface.

To minimise the capacitively coupled interference a screen is required around the signal cables with
a connection to earth. It is normal practice to earth this screen at one point only to prevent
circulating currents. To achieve a single earthing point instrument cables screens are normally
earthed on earth bars mounted on isolators. One bar, normally at the source of the cables i.e.
PLClDCS panel is connected to the earth system.
The reduction of magnetically couple interference can be achieved by creating an opposing
magnetic field. This can be achieved by providing on screen earthed at both ends to allow current
flow. The magnetic field will induce a current that will reduce magnetic flow within the shield area.
Correctly bonded cable tray and earthed cores within multicore cables will also contribute to the
shielding achieved by induced currents.
In addition to the requirements to reduce interference and noise the National Rules for Electrical
Installations in Potentially Explosive Atmospheres ET105:2001 restricts earthing of screens on
Intrinsically Safe cables to one point only, normally within the non-hazardous areas. It also
recommends that armour be bonded to earth at both ends.

REFERENCES
ETCl ET1012002 National Rules for Electrical Installations - Third Edition
ETCl T I 052002 National Rules for Electrical Installations in Potentially Explosive Atmospheres
BS 7430: 1998 Code of Practice for Earthing

BS 5958 Code of Practice for Control in Undesirable Static Electricity

BS 6651 1991 Code of Practice for protection of Structures from Lightning
IEE Guidance Notes on the Wiring Regulations.
Institute of Petroleum - Guidelines for the Control of Static Hazards arising from Static Electricity
Part 21 2ndEdition 2002
Cenelec CLCnR 50404 Electrostatics - Code of Practice for the avoidance of hazards due to static

electricity. June 2003

USEFUL WEB SITES

Electro-Technical Council of Ireland - www.etci.ie
National Standards Authority of Ireland - www.nsai.ie
Institution of Electrical Engineers - www.iee.org
Kieran Failon may be

contacted at kfallon@dm.ie or kifallon@iee.orq

3/14

EARTHING IN
AND PHARM
PLANTS
Kieran fallon, Chartered Engineer FIE1
Electrical 8 Instrumentation Manager,
DPS Engineering & Construction

WHY EARTH ELECTRICAL

SYSTEMS
Low Impedance Return Path for Fault
Currents.
* Prevent Potential Differences
(electrocution hazards).
Lightning Protection.
* Relax Static Charges.
. e Minimise electrical interference to
instrument signals.
Reference for Intrinsically Safe Syste

REGULATIONS, STAND
RULES
e

Electro Technical Council of Ireland

Euro-Norm Standards (IS-EN-0000 or BSEN-0000)
British Standards
Irish Standards (NSAI)

EARTH ELECTRODES

Adequate Electrical Conductivity

Mechanically Robust
Protected Against Corrosion
Clamp does not damage Earthing

Conductor
Accessible for Inspection
Label
%

3116

EARTH ELECTRODES
v

Quantity
Location
Co-ordination with Architect & Services
Cable Routes
Testing ti Maintenance

EARTH BARS
General Earthing
* Protective Conductors
e Main Equipotential Bonding PO,J
High Integrity Earths (IS Systems)
Bonding Conductors for Lightning
0

Main site earth bar

Individual building earth bars
Plant area earth bars
Robust
Clearly Labelled

ELECTRICAL POWER SYST

Medium Voltage Earthing
Neutral Earth link
Earth distribution throughout the Site
Generator Earthing
Final Circuit Earthing

3/18

ELECTRICAL POWE SYSTEM

Medium Voltaae
Discharge of Cables
Future Earthing of 20kV

ELECTRICAL POWER SYSTEM

Neutral Earth Link

Required for site generators and

transformers
Size
Usually in'Main Distribution Board

3/19

k PO

SYSUEM

Earthing if Grid I Utility supply

disconnected
Loop Impedance
BS7430

ELECTRICAL POWE
Y
Final Circuit Earthinq
0.

RCD protection on all sockets (ETCI)

Loop Impedance
Fault Currents, Conductor & Temperature
(Hazardous Areas)

3/20

EQUIPOTENTIAL 5ONDING
c,

Safety requirement
Protection against Indirect Contact
Insulated copper
Safety label
Size - 50% largest CPC
Need not exceed 25 mm Sq
Robust

EQUIPOTENTIAL BONDING

Supplementary bonding throughout plant

areas
Small cable size requirement than main
bonding cables
Specific Hazardous Area requirements
Electrical Continuity of Piping Systems

3/21

BS6651 Code of Practice for the

Protection of Structures against Lightning

* Risk Assessment
- Always required on buildings with Hazardous
Areas
- Always required where extending buildings
with existing protection
- Cost of loss of production

LIGHTNING
Faraday Cage
- Conducting box
- No openings

- Current flows over the outside

- No effect on interior

3/22

LIGHTNING B OUECTION
Structures in Pharmaceutical Plants
- Steel framed or RC Concrete
- Often insulated steel cladding

- Usually no requirement to hide down

conductors

LIGHTNING PROT
* Structures in Pharmaceutical Plants
- Usually contain Hazardous Areas
- Protrusions through building including vents,
ductwork, pipe systems, cable tray

3123

Down Conductors
-Steel Frame
- Cladding
- Copper Tape
- Bond all parallel paths
- No sharp bends
- IOm Grid

LIGHTNING PRQTECTI
Air Termination
- Cladding or lattice of copper conductors
- Cross bonding at roof level of all equipment
- 1Om spacing for hazardous areas

3/24

LIGHTNING PR TECTlON
* Earth Termination Network
- Overall network I O Ohm
- Individual electrode resistance = lox number
of electrodes
- As close as possible to building
- Ring electrodes should be considered

ANTI-STATIC EARTHING
e

Contact electrification

- Materials brought together and separated

- Flow of fluids

through pipes
- Mixing, agitation
- Movement on conveyer belts
-Walking, Moving equipment or drums
- Crystallization
- Dust collection & Pneumatic Conveying

3125

Potential Energy on Typical Plant Items (I

OkV)
- Road Tanker
250 mJ
- Person
- 100 mm Flange

10 mJ
0.5mJ

Minimum Ignition Energy (Vapours)

- Propanol
0.65 mJ
- Methane
0.28 mJ

- Methanol

0.14 mJ
Source- IChemE

ANTI-STATIC EARP
Relaxation of Charge
-Achieve I O Ohm bonding to all items (IOs
Ohm Minimum)
- Same earthing system as used for
Equipotential Bonding
- Control measures to reduce generation of
static outside scope of this discussion

3/26

ANTI-STATICEARTHING
Mobile Plant Items
Removable parts on Equipment
Road Tankers
Personnel
Drums
Raw Materials & IBCs
-

ANTI-STATIC EARTHING
Earth%Reels
and Clamps
Monitored and Interlocked bonding for

Tankers
Sampling procedures and equipment
Anti-static footwear and test stations

3/27

Safety Barrier without Galvanic Isolation

- Zener Diode & Fuse Circuit

- Requires Zero Volt reference

- Usually two earth cables from main earth bar

-Less than IOhm
- Isolated such that earth fault currents cannot

invade circuit.
- Clearly labelled & identified
*

INSTRUMENTATION E
AND SHIELBI
Shielding from capacitive and inductive
noise
- Bonding of shields at source only

- Bonding of armour, tray and parallel earth

paths at both source and destination
- IS Requirements reinforce this concept

3 128

EARTHING IN INDUSTRIAL
AND PHARMACEUTlCAL
PLANTS
Kieran Fallon, Chartered Engineer FIE1
Electrical & Instrumentation Manager,
I

DPS Engineering & Construction