Earthing and Bonding

Principles and Specification

Project: FSO UOTE 1

Customer: OMNI Offshore Terminal Pte. Ltd.

Contract number: Number of pages: 20

Z 19.06.13 Final Document / Final Issue MGC RB CW

0 06.08.12 Issued for Construction RB MM SB

B 17.07.12 Issued for Approval RB MM SB

A 25.06.12 Issued for IDC SB MM SB

Rev. Date Reason for issue Made by Checked Approved

16211 - KME - E - SA - 0002 Z

Project no. Origin Discipline Type Sequence no. Rev. no.

Client No._REV.: TP228-5050-SPEC-9001-Z

Sub-Vendor No._REV.:

© All rights reserved. This document is the property of Kongsberg Maritime, and is not to be reproduced or disclosed to any party
without the written consent of Kongsberg Maritime.
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Table of contents

1 ABOUT THIS DOCUMENT................................................................................. 3

1.1 DOCUMENT HISTORY ............................................................................................. 3
1.2 REFERENCES .......................................................................................................... 3
1.3 ABBREVIATIONS .................................................................................................... 3
1.4 DEFINITIONS .......................................................................................................... 3
2 INTRODUCTION .................................................................................................. 4
2.1 PURPOSE ................................................................................................................ 4
2.2 REFERENCE DOCUMENTS ....................................................................................... 4
2.3 CLASSIFICATION SOCIETY – RULES & REGULATIONS ............................................ 4
2.4 STANDARDS ........................................................................................................... 5
3 GENERAL REQUIREMENTS ............................................................................ 6
3.1 GENERAL ............................................................................................................... 6
3.2 DESIGN PRINCIPLES ............................................................................................... 6
4 EARTHING SYSTEM DESIGN........................................................................... 7
4.1 GENERAL ............................................................................................................... 7
4.2 EARTHING OF EXPOSED CONDUCTIVE PARTS ........................................................ 7
4.3 EARTHING IN HAZARDOUS AREA .......................................................................... 8
4.4 POWER AND CONTROL CABLES ............................................................................. 8
4.5 INSTRUMENT EARTHING / SCREENING ................................................................... 9
4.6 EQUIPOTENTIAL BONDING ..................................................................................... 9
4.6.1 Bonding Connections ................................................................................... 9
4.6.2 Connections to the Vessel Structure ........................................................... 10
4.6.3 Protection against Galvanic Corrosion ....................................................... 10
4.6.4 Earth Boss ................................................................................................... 11
4.7 BONDING OF CABLE TRAYS AND LADDERS ......................................................... 11
4.8 BONDING OF PIPING AND TANKS ......................................................................... 12
4.9 BONDING OF NON-ELECTRICAL EQUIPMENT ....................................................... 12
4.10 COLOUR CODING ................................................................................................. 12
4.11 LIGHTNING PROTECTION ..................................................................................... 13
5 EXAMPLES .......................................................................................................... 14
5.1 LV GENERATORS ................................................................................................ 14
5.2 LV SWITCHBOARDS ............................................................................................. 14
5.3 TRANSFORMER .................................................................................................... 15
5.4 PANELS ................................................................................................................ 16
5.5 CABLE LADDERS/TRAYS ..................................................................................... 17
5.6 TYPICAL EARTH BARS ......................................................................................... 18
5.7 TYPICAL EARTH BOSS ......................................................................................... 19
5.8 ICSS EARTHING .................................................................................................. 20

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1 ABOUT THIS DOCUMENT

1.1 Document history
Revision Description of Change
A Issued for IDC
B Issued for Approval
0 Issued for Construction
Z Final Document / Final Issue

1.2 References
No Doc No Description
1 TP228-5050-PH-0004 Earthing, Bonding and Screening Philosophy

1.3 Abbreviations
Abbr. Description
ACB Air Circuit Breaker
CCR Central Control Room
CER Central Equipment Room
CS Classification Society
DOL Direct On-Line
KME Kongsberg Maritime Engineering
MCCB Molded Case Circuit Breaker
TER Telecom Equipment Room

1.4 Definitions
Bonding; Connection of non-current-carrying parts to ensure continuity of electrical
connection, or to equalize the potential between parts.
Equipotential Bonding; Electrical connection putting various exposed conductive parts
and extraneous conductive parts at a substantially equal potential.
Exposed Conductive Part; Conductive part which can readily be touched and which is
not normally alive, but which may become alive under fault conditions.
Extraneous Conductive Part; Conductive part not forming a part of the electrical
installation and liable to propagate a potential, including earth potential.
Shall: Indicates requirements strictly to be followed and from which no deviation is
permitted.

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Should: Indicates that among several possibilities one is recommended as particularly

suitable, without mentioning or excluding others, or that a certain course of action is
preferred but not necessarily required.

2 INTRODUCTION
2.1 Purpose
The purpose of this document is to define the earthing, bonding and screening
requirement for use on the FSO.
This specification shall be used throughout the design, fabrication, installation,
commissioning and operational phases of the project to achieve a reliable and
satisfactory installation.
This specification shall be used in conjunction with datasheets and other specifications
attached. This document supplements the design, fabrication and inspection
requirements of IEC and the other specifications and standards referenced within.

2.2 Reference documents

Design and engineering shall conform as a minimum requirement to the current edition
of the following in order of preference:
 Applicable laws and regulations of the country in which the system will be
operated. Note Brazil NR-10 requirement;
 End-customer specifications and requirements;
 Classification Society – Rules & Regulations;
 Applicable International Electrotechnical Commission (IEC) publications.
Reference Title
NR-10 Security Systems and Services in Electricity

2.3 Classification Society – Rules & Regulations

ABS Class Notation:
+A1 FSO (Service at Campos Basin-Brazil)
The following ABS documents (latest revision) are applicable:
Reference Title
ABS – Rules Steel Vessels - Part 4 - Ch 8 - Section 3 – Electrical
ABS – Guide – Floating Production Installations
Publications 82
ABS – Guide – Facilities on Offshore Installations
Publications 63
ABS – Guide – Fac-E Facilities on Offshore Installations

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2.4 Standards
Reference Title
IEC 60079-14 Electrical installations in hazardous areas (other than
mines)
IEC 60092 Electrical installations in ships
IEC 60228 Conductor of insulated cables
IEC 60287 Electric Cables – Calculation of the current rating
IEC 60479 Effects of current on human beings and livestock
IEC 61000-5-2 Electromagnetic compatibility (EMC) - Part 5: Installation
and mitigation guidelines - Section 2: Earthing and
cabling
IEC 61557-4 Electrical safety in low voltage distribution systems up to
1000 V A.C. and 1500 V D.C. - Equipment for testing,
measuring or monitoring of protective measures - Part 4:
Resistance of earth connection and equipotential bonding
IEC 61557-5 Electrical safety in low voltage distribution systems up to
1000 V A.C. and 1500 V D.C. - Equipment for testing,
measuring or monitoring of protective measures -
Resistance to earth
IEC 61892 Mobile and fixed offshore units – Electrical installations
API RP 14F Recommended Practice for Design and ,Installation, and
Maintenance of Electrical Systems for Fixed and
Floating Offshore Petroleum Facilities for Unclassified
and Class I, Division 1 and Division 2 Locations

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3 GENERAL REQUIREMENTS
3.1 General
The performance of the earthing systems shall comply with the rules, regulations, codes
and standards. This design basis is meant to emphasize important rules and to clarify
possible obscurities. It is not intended to deviate from the rules and regulations in any
way. In section 5 typical earthing arrangements are shown.

3.2 Design Principles

The electrical system shall be economically designed for safe use, ease of maintenance
and operation, minimum power losses, mechanical protection of equipment,
interchangeability of equipment and possible addition of future load. The design shall
also meet the CS requirements, Client operational requirements and expectations.
All electrical equipment and materials shall be designed for a service life of at least 25
years in an offshore marine environment.

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4 EARTHING SYSTEM DESIGN

4.1 General
The LV system shall be isolated (no neutral) and unearthed (IT System). The star points
of the essential and emergency generators will not be earthed. The system shall be
equipped with an earth fault monitoring (insulation monitoring) system. An earth fault
on the LV system shall initiate alarm through the ICSS, indicating which switchboard is
faulty.
The procedure for locating the fault will be to disconnect consumers one by one until
the faulty circuit is identified.
LV switchboards, MCCs and main distribution boards (normal, emergency and UPS)
shall be equipped with insulation monitoring.
The earthing system shall be installed in accordance with the approved drawings and
shall also comply with relevant standards, codes and regulations.
Separate earthing systems shall be provided for ICSS as follows:
 Protective Earth (PE) system;
 Instrument Earth (IE) system;
 Intrinsically Safe Earth (ISE) system.
IE and ISE shall be kept isolated from PE all the way to main earth. Earth bosses from
different earth systems shall be located of a minimum of 1.5 m apart.
PE, IE and ISE earth bars shall be installed within the CCR, CER, TER and Power
Module.
All main switchboards and MCCs shall be provided with a copper PE bar (inside
switchboards or MCCs). The PE bar shall be connected to the main PE bar located in
the Power Module.
Instrument cabinets and panel shall be provided with copper earth bars for IE and ISE
(where IS equipment is used). These earth bars shall be isolated from the chassis of their
cabinets or panels. The IE and ISE bars shall be connected to the main IE or ISE bar in
the CCR, CER, TER or Power Module.

4.2 Earthing of Exposed Conductive Parts

Unless specifically included in the following exemption, all exposed conductive parts
shall be earthed.
Exemption:
 Lamp caps;
 Shades, reflectors and guards, supported on lampholders or luminaires
constructed of, or shrouded in, non-conducting material;

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 Metal parts on, or screws in or through, non-conducting material, which are

separated by such material from current-carrying parts, and from earthed non-
current-carrying parts in such a way that in normal use they cannot become live
or come into contact with earthed parts;
 Portable appliances which have a double and/or reinforced insulation (see lEC
61892-1) provided that the appliances conform with recognized safety
requirements;
 Bearing housings which are insulated in order to prevent the circulation of
current in the bearings;
 Clips for fluorescent lighting tubes;
 Equipment supplied at extra-low voltage (safety voltage);
 Cable clips;
 Equipment of "all-insulated" construction in which the insulation enclosing the
equipment is durable and continuous;
 Fixed equipment or parts of equipment which, although not shrouded in
insulation material, are nevertheless protected in such a way that they cannot be
touched and cannot come into contact with exposed metal;

4.3 Earthing in Hazardous Area

In hazardous areas, all exposed conductive parts shall be connected to earth. Exposed
conductive parts of electrical equipment shall be earthed through supply cable armour
(preferred) or a separate PE conductor. In addition equipotential bonding to the structure
must be provided. Bonding by welding or bolting the equipment to the structure is
preferable if achievable. Bonding by separate earth conductor to be used when galvanic
connection is not achieved or achieved by serial connection and when equipment /
instruments are isolated from the structure.

4.4 Power and Control Cables

All electrical equipment should be earthed only through supply cable armour or in
special circumstances a dedicated earth cable. Where a separate earth cable is used for
earthing, this cable shall have a green / yellow sleeve. The cable armour shall be earthed
at both ends (except for single core cables, see below). Reducing of the cable armour
dimension will not be accepted.
For single core cables installed in non-hazardous areas, the armour is to be earthed at
the feeder end only. However, for single core cables installed in hazardous areas, the
armour is to be earthed at the hazardous end only. A separate PE conductor is required
for earthing.

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4.5 Instrument Earthing / Screening

Cable screens shall be earthed at one end only. Cable screens shall be earthed on a
dedicated IE or ISE copper bars located within the panel / rack at the non-field end.
Where cables pass through junction boxes or marshalling boxes, the screens shall be
continued, via terminals, the screens shall not be earthed within the junction boxes or
marshalling boxes. At the field end the screens shall be terminated in dedicated
terminals and isolated from each other and earth.
Armoured IS cables shall have the armour earthed at both ends, if the cable is screened.
However, if the cable is un-screened, it shall be earthed at the non-field end only.
Instrumentation that is susceptible to the influence of radio interference e.g. vibration
monitors, shall be earthed as per the manufacturers recommendations.

4.6 Equipotential Bonding

Extraneous conductive parts shall be connected to the equipotential bonding system as
described in 4.5.
Metal frames or enclosures of equipment mounted in direct metallic contact with the
unit structure need no supplementary bonding, provided that the surfaces in contact are
clean and free from rust, scale or paint when installed and are firmly bolted together.
Alternatively, they may be connected to the unit structure by a connection complying
with 4.5.
Removable gland plates shall be separately bonded to the parent equipment, unless the
connection between the gland plate and the parent equipment complies with the
requirement in this section.
Enclosures of high-voltage equipment located in hazardous areas shall be connected to
PE and bonded to the main structure.

4.6.1 Bonding Connections

Every bonding connection to earth shall be of copper or other corrosion-resistant
material and shall be securely installed and protected where necessary against damage
and also against galvanic corrosion. Connections shall be secured against becoming
loose due to vibration.
The nominal cross-sectional area of every copper bonding connection shall be not less
than required in the table below. Every other bonding connection shall have a
conductance not less than that specified for a copper bonding connection.

Type of Earthing Cross-sectional area of Minimum cross-sectional area of

Connection associated current- copper earthing connection
carrying conductor
PE conductor in Any Same as current-carrying
flexible cable or conductor up to and including 16

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flexible cord mm2, or 50% above 16 mm² but at

least 16 mm2
PE conductor Up to and including 16 Same as current-carrying
incorporated in fixed mm2 conductor up to and including 16
cable mm2 but at least 1,5 mm2
a) insulated PE Over 16 mm2 50 % of the current-carrying
conductor conductor but at least 16 mm2
b) bare PE conductor 1 mm2 to 2,5 mm2 1 mm2
in contact with 4 mm2 to 6 mm2 1,5 mm2
metallic covering
Separate fixed Not exceeding 2,5 mm2 Same as current-carrying
earthing conductor conductor subject to minimum of
1,5 mm2 for stranded earth
conductor, or 2,5 mm2 for solid
earth conductor
Exceeding 2,5 mm2 but 50% of the cross-sectional area of
not exceeding 120 mm2 the current-carrying conductor,
subject to a minimum of 2,5 mm2
Exceeding 120 mm2 70 mm2
Equipotential bonding connections for extraneous conductive parts shall have a cross-
sectional area of at least 6 mm2.

4.6.2 Connections to the Vessel Structure

The bonding shall be achieved by means of a separate bonding conductor unless the
parts under consideration are installed in accordance with 4.6
Every connection of an earth conductor or a bonding conductor to the unit structure or
hull shall be made in an accessible position, and shall be secured by a screw of brass or
other corrosion resistant material, which shall be used for this purpose only. In all cases,
care shall be taken to ensure clean metallic surfaces free from rust at the contact areas
immediately before the screw is tightened.
Any electrical or instrumentation equipment attached, but not welded, to the structure
steelwork, for example to hand rails, ladders and stairways, shall be bonded to the
nearest structural steelwork.
To minimize shock from high-frequency voltage induced by the radio transmitter,
handles, handrails, etc., made of metal shall be in good electrical connection with the
hull or superstructure.

4.6.3 Protection against Galvanic Corrosion

Methods of securing dissimilar materials, often include insulation to prevent galvanic
corrosion between the materials. In such cases, a separate bonding connection shall be
provided between, for example, which shall be made in such a manner that galvanic
corrosion is avoided and the points of connection may be readily inspected.

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4.6.4 Earth Boss

PE conductors for local earthing of cabinets to structure, as well as bonding of exposed
conductive parts shall be as short as possible and connected to main earth (earth boss)
with possibility for separation and inspection.
Earth bosses shall have an M10 threaded hole and be welded to the structure of the
vessel, as close as possible to equipment being protected. Earth bosses shall not be
exposed to corrosive environments.
Connection to the earth boss shall be by corrosion resistant stainless steel M10 stud
bolts, nuts and washers. Spring washers shall be used to ensure that the earth connection
does not come loose.
No more than two earth cables shall be connected to a single earth boss. Where there is
a requirement to earth more than two cables, an earth bar shall be used.
Skids, frameworks, modules, etc. do not need any bonding / earth boss if welded or
bolted directly to structure. If bolting connections do not lead to permanently sufficient
galvanic connection (due to few numbers of bolts, painted surface against washers, etc.)
effort must be made for improving the galvanic connection by using corrugated
washers. If galvanic connection is not achieved, or achieved by serial connections,
bonding must to be provided by separate earth conductors connected to welded earth
bosses.
Additional bonding by separate isolated PE conductor, directly connected to a local
earth boss, is required for larger units such as:
 Generators;
 Motors;
 Transformers;
 Switchboards;
 MCCs;
 Distribution boards;
 Instrument cabinets;
 Telecommunication cabinets;
Bonding cross sectional area shall be in accordance to CS requirements and colored
green / yellow.
Aluminum or aluminum alloy enclosures shall not be bonded directly to earth, a bi-
metallic (CuAl) washer must be used.

4.7 Bonding of Cable Trays and Ladders

All cable trays and ladders shall be bonded to the vessel every 25 m and at both ends
using a 25 mm² earth cable in the case the rack support does not give adequate earth
connection.
Electrical continuity shall be maintained at splices between sections of cable ladder,
rack or tray by the use of splice plates. Additional bonding is not required, unless cable

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ladder, rack or tray is insulated from the steel structure or hull to prevent galvanic
corrosion. In these cases bonding shall be carried out as required in 4.6.1

4.8 Bonding of Piping and Tanks

In order to prevent dangerous build-up of static charges resulting from the flow of fluid
in piping, the following items are to be earthed to the hull such that the resistance
between any point on the piping and the vessel (across joints, pipe to vessel) does not
exceed 1 mΩ.
 Piping and tanks containing fluids having flash point of 60°C or less;
 Piping that is routed through hazardous areas.
This can be achieved if the items are welded or bolted to the vessel, either directly or via
their supports. Bonding straps are required for items not permanently connected to the
vessel, e.g.:
 Piping which is electrically insulated from the vessel;
 Piping which has spool pieces arranged for removal.
Bonding straps are to be:
 Installed in visible locations and accessible for inspection;
 Made of corrosion-resistant material;
 Protected from mechanical damage.
Bonded straps shall be minimum 25 mm² earth cable.
The resistance between the pipe and the vessel (or across joints) shall be measured using
a 1 kV Megger, results shall be recorded on the ITR. The Megger shall have a valid
calibration certificate.

4.9 Bonding of Non-Electrical Equipment

All non-electrical metallic equipment e.g. heat exchangers, coolers etc. shall be bonded
directly to the steel structure of the FPSO. The bonding shall be achieved either by
separate earthing conductions or by welding the equipment to the steel structure of the
FPSO. The equipment shall be provided with two independent earth bosses, located at
diagonally opposite corners.

4.10 Colour Coding

PE conductors, armours, PE bars and bonding shall be marked Green / Yellow.
IE screens, bars (non-IS) shall be marked Green / Yellow with a Red mark.
ISE screens, bars (IS) shall be marked Green / Yellow with a Blue mark.

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4.11 Lightning Protection

Topsides modules consisting of steel structures, welded to the main deck of the FPSO
are considered to be adequately self-protected against lightning strikes. No additional
installations are required.
Lightning protection with air terminals shall be provided for masts above vessels, which
are made of non-conductive material. The air terminals shall reach a minimum high of
150 mm over the mast and down conductors terminated to the nearest steel structure,
welded to the main deck of the FPSO.
Vent outlets for flammable gases located at or near the top masts are to be protected by
air terminals which extend at least 2 m above the vent outlet. All such vents shall be
provided with flame arrestor to prevent back flash in the event of ignition by direct
lightning strike.

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5 EXAMPLES
5.1 LV Generators

Note: MV Generators shall have two earth connections.

5.2 LV Switchboards

Note: The grounding of 690V Switchboard shall be via a common ground bar isolated
from the general 440V grounding system.

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5.3 Transformer

Note: LV transformer of high MVA shall be grounded at 2 ends.

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5.4 Panels

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5.5 Cable Ladders/Trays

Note: This method to be used only in the case the cable ladders do not have splice plates
and the rack support does not give sufficient connection.

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5.6 Typical Earth Bars

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5.7 Typical Earth Boss

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5.8 ICSS Earthing

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