METHOD OF STATEMENT FOR INSTALLATION

OF EARTHING/GROUNDING SYSTEM & LIGHTNING PROTECTION

SYSTEM
1. INTRODUCTION & SCOPE OF WORKS :
This Method statement details the procedure of installation & testing of
Earthing/Grounding Systems and Lightning Protection Systems.

The Grounding System / Lightning Protection System are designed to ensure the complete
safety of both persons and equipment throughout the Plant

As BS EN/IEC 62305 Lightning protection standard, the required earth resistance for
lightning protection System is below 10 Ω

2. REFERENCES:
o Specification: IEC 62305
o Project drawings :
o Project Quality Plan (PQP)
o Inspection & Test Plan(ITP)

3. SEQUENCE OF WORKS:
3.1 Material and Equipment:
1) Copper earth rods
2) Bare copper cable
3) Cable clamp for earth rod and copper cable
4) Copper tape and clips
5) PVC pipe
6) Concrete grounding pit.
7) Cable lugs
8) Air terminal
9) Earth bar with disconnecting link
10) Exothermic Welding Set
11) Earth Tester
12) Field Tester

3.2 Type of connection:

o Connect Bare Copper Conductor to Bare Copper Conductor.
o Connect Earth Rod to Bare Copper Conductor Wire.
o Connect rebar to bare copper wire.
o Connect copper bar to bar copper wire.
o Connect cable trays/ladders and pipes to grounding system.
3.3 Procedure of installation of Grounding System:

3.3.1 General & Safety Precautions

A. Do not connect items except as detailed in instruction sheets. Failure to comply with these
instructions may result in improper and unsafe connections, damage to items being connected,
bodily injury and property damage.
B. Do not use worn or broken equipment which could cause leakage.
C. Do not alter equipment or material without authorization.
D. Do not use welding material package if damaged or not fully intact.
E. Do not tamper with or disassemble the welding material unit.
F. Make connections in conformance with manufacture instructions and all governing codes.

i. Personnel should be properly trained in the use of this product and must wear
safety glasses and gloves. Avoid contact with hot materials.
ii. Advise nearby personnel of welding operations in the area.
iii. Remove or protect fire hazards in the immediate area.
iv. Provide adequate ventilation to the work area.
v. Do not smoke when handling starting material.
vi. Avoid direct eye contact with “flash” of light from ignition of starting material.
G. Welding material is an exothermic mixture and reacts to produce hot molten material with
temperatures in excess of 1400°C (2500°F) and a localized release of smoke. These materials are
not explosive. Ignition temperatures are in excess of 900°C (1650°F) for welding material.
H. Adhering to the manufacture welding procedures will minimize risk of burns and fire caused by
hot molten material spillage. In case of fire, use of water or CO2 will aid in control of burning
containers. Large quantities of water will aid in controlling a fire should the exothermic materials
become involved. Water should be applied from a distance.
I.
i. Make sure there is proper mold fit and assembly of equipment.
ii. Avoid moisture and contaminants in mold and materials being welded. Contact
between hot molten metal and moisture or contaminants may result in spewing of
hot material.
iii. Base material thickness must be sufficient for the size and type of connection being
made to prevent melt-through and leakage of hot molten metal.
J. Applications or conditions may exist which require special considerations. The following are
examples, but are not intended to be a complete listing of applications/conditions.

3.3.2 Installation of Exothermic Welding System:

The mould crucible with suitable size shall be used for exothermic welding.
a) The following procedures shall be followed before conduct the exothermic welding.
i) Ensure that the mould is always clean and free of moisture.
ii) Ensure that the tap hole is always in well-defined condition.
iii) Ensure that the correctness of connection selector.
iv) Ensure that the correctness of welding powder
b) Procedure to conduct the exothermic connections.
i) Fix the connection selector to the handle clamp as per the require sizes of conductor to be
welded.
ii) Place the conductor in the mould; ensure that connection selector is used in accordance to
the conductor to be welded.
iii) Close the handle clamp and lock in the lock position, drop the metal retaining disc into the
bottom of the mould crucible. Ensure that the metal retaining disc is correctly, completely
seated and cover up the tap hole.
iv) Deposit the welding power into the crucible and spread a little amount on top of the mould
edge as a role of starting power.
v) Close the mould lips, and ignite with the flint gun.
vi) Open the mould after a few seconds where the reaction is completed or the metal has been
solidified.
vii) Do not touch the welding surface after the reaction.
viii) Clean up the mould for the next joint.

3.3.3 Earthing Cable Installation:

a) The earthing conductor, bare copper cable shall be installed as per approved shop drawing.
b) Ensure that the copper cable is straight (not wavy) so that it fits nicely into the exothermic
mould prior to the exothermic welding.
c) Ensure that the copper cable is free of dirt / oil and dry keeping.

3.3.4 Earth Rod Installation:

o The copper rod is to be driven into the ground by means hammer drill / sledge hammer.
o Make sure the rods are coupled with coupling and driving studs before hammering as it will
protect the thread or the head of the rods from damaged.
o After the desired depth has achieved, the earthing conductor will be joint to the earth bar
/ rod clamp of the earth pit and fastened it securely.
o Resistivity check should be taken and if the resistivity is not achieved to required value then
it is advisable to drive it deeper.
o The rod shall be driven as deep as possible and does not force to drive it as it may break
the coupler and loose the rod.
o The number of rods driven into the ground will be dependable to the soil resistivity on that
particular area and as per approved shop drawing.

3.3.5 Earth Pit:

a) Install the inspection pit and ensure that it is flush with the external ground / road level.
b) Ensure that the earth pit is free from dirt and rubbish.

3.4 Safety control method:

a) General:
The safety procedure generally has to be applied for all Engineers, Supervisors, and
Workers as following bellow:
o Make sure that all personal protection equipment (PPE) be provided on site before starting
work such as helmet, safety boot, safety glasses, glove, mask etc.
o Make sure that PPE must be wear in the correctly way when working.
o Tools and equipment shall be inspected by authorized person before carried out the work.
o Barricades and sign posts for warning shall be provided on site.
o Fire extinguishers shall be provided on site wherever exothermic welding works and always
ready to use.

b) Working exothermic welding:

o Ensure worker wear safety glasses, gloves, helmet etc.
o Fire extinguisher shall be always ready at work place

c) Working at height:
o Ensure every worker wear safety harness when working at more than 2 m height.
o Safety protected handrail on top layer of scaffolding shall be provided.
o Ensure A ladders are in good condition/quality.

3.5 Material storage:

a) Storage of exothermic welding materials should be in a clean, dry, “NO SMOKING” area and
should be restricted to access by authorized personnel only.
b) Storage condition shall be such that exothermic welding materials are not subject to rough
handling or physical damage. Storage shall be in cool place and in condition no humidity
and moisture.
c) All boxes or container of material should be stored in accordance with container (carton)
or label marking “This Side Up”
d) These materials must be stored under shelter to protect the boxes from the elements and
raised to protect them from dampness or wet surface.

3.6 Execution work for Earthing of Lightning Protection:

o Drive the earth rods into the earth by hammer.
o Excavate a trench (D x W: 800:500) to link earth rods together by soft drawn bare copper
wire.
o Link earth rods to Grounding network.
o Backfilling the trench.
o Testing and record earthing resistant value.
o Joints shall be protected against rust by cold galvanized paint.
o Contact surfaces shall be flush prior to jointing.
o Bolt connections of copper wire with hot dip galvanized steel bar and copper wire with
copper bar should reach mechanical effect and electrical effect.
o During the driving of the rods into the earth, it is better to measure value of the resistance
to earth in order to quantity of necessary grounding rod.

3.7 Handling of chemicals to reduce soil resistivity:

o Prepare wiring trench
o Ensure no garbage on the trench
o Put the chemicals along the track covers a thick layer of copper 3mm
o Backfilling the trench.
3.8 Procedure of installation of Lightning Protection system:
o The installation of the lightning arresters will be closely coordinated with Floodlight and
roofing works.
o The Grounding system for Lightning protection system must be established prior to install
Lightning protection system
o The down-conductor shall not be isolated nor enclosed in PVC pipe and placed internal in
the apron lighting towers.
o The down conductor should be fixed with a test joint in a position that is convenient for the
tests but shall not be reached by irresponsible persons.
o The down conductor bare copper wires shall be connected directly to the mounting base
of the lightning arrester by terminal lug.
o The lightning arrester should be fitted into the mounting base before lifting them and
connecting to the Apron Floodlight Mast.
o After completing the installation of Lightning arrester into the Apron Floodlight Mast, it
shall ensure that the down conductor connecting immediately to the mounting base and
the grounding system.

4. STANDARD PROCEDURES:
o Down conductor for air terminal (ESE type) shall be connected to earthing rods to ensure
direct connection to earth of any stroke current before interconnection with the general
Grounding System.
o All equipment connected to power supply must be grounded.
o All metal parts, structural steel, cable trays, piping, reinforced concrete must be grounded.
o All joints shall be according to shop drawing.
o Safety control:
- To secure an exit entrance whenever it has contingencies.
- Keep water out where is necessary.
- To keep workplace and amenities is always clean.
- Barricade and sign post are available around the site work.
- To pay attention to equipment/ tools as below:
+ Drill machine: insulation and earthing terminal
+ Cylinders: Pressure Gauge Set shall be inspected by authorities
+ Cutting machine: insulation and earthing terminal

5. INSPECTION AND TESTING PROCEDURES:

5.1 Inspection:
o The Grounding and Lightning Protection System shall be given a visual inspection by the
Engineer during the installation.
o The Contractor should not allow any backfilling of trenches or pits where these systems are
installed before inspection by the Engineer and the appropriate documents are signed.
o Material delivered shall be inspected under the Engineer’s supervisor about size, quality
and quantity.
o After performing, works shall be inspected. Inspection of lightning should be included two
steps: check underground system and general. For equipment fitted inside structural work
or fix underground shall be checked and inspect before backfilling.
o Check Grounding and Lightning Protection.
o Shop-drawing approved.
o Material approved.
o Test method of visual:
 Check quality of grounding conductor and grounding electrode delivered on site.
 Check installation (connection, routing, and quantity) according to approved shop
drawings.
 Check dimension, level and finishing of foundation of air terminal.
 Check installation according to approved shop drawings and manufacturer’s
recommendation.
 Functional Test: As per design and manufacturer’s recommendation.
 Grounding Resistance Value shall be measured.

5.2 Field test:

5.2.1 General:
o Grounding rods shall be tested for ground resistance value before any wire is connected.
The test shall be performed in normal dry weather, not less than 48 hours after rainfall.
o Ground resistance shall also be measured for each piece of equipment to the ground
electrode. Testing shall be with a portable ground testing megger for each ground or group
of grounds. The instrument shall be equipped with ammeter reading directly in Ohms or
fractions thereof to indicate the ground value of the electrode under test.
o All test equipment including test meter shall be provided and one copy of the ground
megger manufacturer’s directions, including the method shall be provided.
o The earth resistance shall be measured either soil resistivity testing or earth resistance
testing method.

5.2.2 Soil resistivity testing (based on Wenner method:

o Equipment and procedure for soil resistivity :
The test instrument is used Digital Earth Tester. The instrument is connected to the
electrodes as detail below:
Four electrodes are driven into the ground, in a straight line with equal spacing between
them. Let the spacing be called 'a'.
 The soil resistivity can then be calculated using the equation:
ƒ = 2 x 3.14 x a x R

Where ƒ = soil resistivity (ohm meters)

a = electrode spacing (meters)
R = measured resistance (ohms)

Test Procedure:
- Confirm the proposed test locations.
- Insert four electrodes into the ground in a straight line a= 2 meters spacing. Connect
instrument to the electrodes as shown above.
- Perform test and record measured resistance in Soil Resistivity Test Form.
- Shift electrodes to next spacing a= 4 meters and repeat test.
- Repeat tests a= 6 meters, 8 meters and 10 meters electrode spacing.
- Recorded measurements will be analyzed and presented in Soil Resistivity Test Report.

6. STATUTE OF COMPLETION:
After finishing the installation works of Grounding and Lightning Protection System,
inspection shall be carried out and approved by relative parties such as: Consultant, Main
contractor. We can ask the Experiment Center for inspection the whole system and then
issue the Certificate Completion.