FEB-04-2006 06:00 P.001/007 Bulletin-1 GGT High-Current Method of Testing Ground Grid Integrity Tue conventional methods of testing ground resistance, such as with the earth megger, are not adequate for successfully check- ing the adequacy of ground sys- tem connections. To understand the objectives of the high-current method of testing ground grid integrity, it is appropriate to briefly review the purpose of sub- station grounding systems. In principle, a safe grounding system has two objectives: (1) to provide means to carry electrical currents into the earth under nor- mal and fault conditions without exceeding any operating and equipment limits and (2) to assure that a person in the vicinity of grounded facilities is not exposed to the danger of electric shock. A practical approach to safe ground- ing, therefore, involves the inter- action of the intentional ground (ie, substation grounding sys- tem) and the accidental ground temporarily established by a per- son coming into contact with in- adequately grounded equipment or structure. The geometry, loca- tion of ground electrodes, local by A.S. Gill, PE. soil characteristics, and other fac- tors are taken into consideration when designing a substation gtound system, This is done to minimize the potential gradients along the earth’s surface which may endanger a person in the area during ground fault conditions. Several types of grounding sys- tems are employed, depending on the size of the substation. How- ever, the purpose of all grounding systems is to limit the effect of ground potential gradients to sucha level as to not endanger the safety of people or damage equip- ment under normal and fault con- ditions. Typical grounding sys- tems may consist of (1) a single- point ground electrode (2). a grounding grid or () a ground mat. A grounding grid or a ground mat arrangement system is usu- ally used for substations. These ground-grid and ground-mat sys- tems consist of horizontally inter- connected hare conductors to the vertically driven ground elec trodes or ground plates. This net- work of ground electrodes is bur- ied ina soil of good conductivity, providing an excellent grounding system. The equipment neutrals, frames, structures, and fault cur- rent sources (such as surge ar- restors, capacitor banks, etc.) are then connected to this ground- grid or ground-mat system. Reasons For Testing It is necessary to make ground resistance and ground continuity measurements in order to ensure the initial capability of a newly in- stalled ground system, and, there- after, periodically verify its adequacy. The purpose of these tests is to ensure that a proper ground system has been installed. and is maintained throughout its service life. The reason for having a properly designed, installed, and maintained grounding sys- tem is to eliminate the shock haz- ards and abnormal operating con- ditions that may arise due to fault currents. During fault conditions, the earth becomes saturated by currents emanating from the ground grid and ground elec- trodes buried below the earth's surface. The resulting potential gradients are proportional to the magnitude of the grid current and Reprinted by Mult-Amp Corporation with the permission frmNETA WORLD International Elect Testing Association ‘Winter 88-89 Issue, Vol. 10, No. 2FEB-04-2006 06:00 P.002/007 ELEETROOE Figure 1 — Connections for the two-terminal earth resistance test. Pages) Fee wwe od, the resistance across the path of | the ground current. The safe limits for such potential gradients are defined by means of the difference in surface potential, such as step- voltage and touch-voltage. To ensure that there is a low-resis- tance path for ground currents, all accessible ground leads should be inspected, and those that are bur- ied under the earth’s surface should be tested periodically. There are no specific code re- quirements for the testing of grounding systems. However, the standard for Electrical Safety Re- quirements for Employee Workplaces (NFPA 70E-1983, Part L. Chapter 2, Section F, Item 4) states that the path to ground from. circuits, equipment, and enclo- sures shall be permanent, conti ous, and effective. Also, Part lif of the above code (Chapter I, Section B, Item 1) requires that the equip- ment and enclosure bonding and grounding shall be maintained ‘The Occupational Safety and Health Act (OSHA) adopted NFPA 70E - Part I in 1981 as a specific OSHA safety requirement resistance test. for employees in the workplace Also, the Institute of Electrical and Electronics Engineers (IEEE) Stan- dard 81-1983, Section 8.3, states that the objective of testing the integrity of the ground grid is to determine whether the’ various parts of the grid are inter- connected with'a low-resistance connection. ‘To meet the intent of the above standards and OSHA. require- ments, it is necessary to periodi- cally perform ground resistance and ground-grid integrity meas- urement tests. The grounding sys- temis not needed for proper func- tioning of electrical power equip- ment during normal operating conditions. Therefore, the only way to assess the integrity and continuity ofa ground systemisto perform periodic tests to ensure its availability during fault condi- | tions. Measuring the Effectiveness of | a Grounding System ‘Themostcommontest for theef- fectiveness of a grounding system {s to measure its overall resistance to remote earth. The objective of this test is to determine whether } the actual resistance of a ground- Figure 2— Connections and principle of an earth ing system is less than or equal to the resistance value as designed and installed. Although this test determines the overall grounding system resistance, it does not as- sess the integrity of individual connections (i.e., whether the indi- vidual equipment and structure grounds are connected to the ground grid or mat with low resis- tance). The only way to measure the integrity of the ground-grid connections is to test each ground connection one ata time. 1. Overall Ground Resistance Measurements Several methods are available for determining overall ground system resistance. The two meth- ods that are most commonly employed in making these meas- urements are the Two-Point and Fail-of-Potential methods. Two-Point Method With this method, the total resis- tance of the unknown and a refer- ence (known) ground is measured using AC voltage. The connection diagram for this test is shown inFEB-04-2006 06:00 eeu Figure 1. The resistance of the erence ground is presumed to be negligible in comparison with the resistance of the unknown ground. This method is subject to errors when used for measuring the ground resistance of large suby stations. However, this method is quite useful and best employed where a “go, no-go" type of test is all that is required. Fall-of-Potential Method ‘This method consists of inject- ing a known AC current into the ground system electrode to be measured and then measuring the voltage drop due to this current at various distances from the ground system electrode. The fall-of-po- tential method requires plotting the values of resistance as a func HH Figure 3 — High current Method of testing ground grid integrity. potential probe is moved away in steps from the ground electrode under test. A value of resistance is obtained at each step. The value of resistance at which the curve (te, resistance versus distance) levels tionof voltage probe spacing from | resStance versus distance) level the ground system electrode. The P.003/007 resistance of the grounding elec- trode. The connection diagram and the principle of an earth-resis- tance test is shown in Figure'2. 2. Ground-Grid Integrity Measurement The objective of this measure- ment is to determine whether the equipment, frame, structure, or enclosure grounds are connected with low resistance. The resis- tance value of such connections is expected to be below 100 micro- ohms. The overall ground resis- tance measurement as discussed before, does not provide adequate information for assessing the in- tegrity of such connections. The best method for making integrity- of-ground-grid tests is to use a large but practical current and some means of detecting the volt- age drop caused by this current. Measurements Before Test Hook-Up Test No. 1: Example of Test Data For Good Ground Connections 1, Current in transformer neutral (reference) = 82 amperes 2. Current in the post ground wire = 6 amperes 3, Distance between reference ground and post ground = 15 fot re 4. Voltage drop in test leads with 300 amperes = 7.5 volts ‘Measurements After Test Hook-Up and With 300 Amperes Flowing in The Test Circuit (Le,, test set meter reading) 1. Current flow in reference ground to grid = 270 amperes 2 Current flow in reference ground to TOO = 50amperes 3. Current flow from the grid to post ground = 280 amperes 44. Current flow from the structureto post ground = 1 ampere 5. Voltage reading a the tot sot meter = 7.9 volts Evaluation of the Test Data: Criterion 1: Current in reference ground to grid is nearly equal to current from grid to the [post ground. This exceeds the 150 am. eres criterion. Criterion 2: Voltage drop in the ground-grid circuit is, ‘equal to 0.4 volts (i.c.,7.9 volts -75 volts) for a 15 foot distance. This meets the 1.5, volt drop for a 50 foot distance. Figure 4 — Test No. 1 hook-up and connections.FEB-04-2006 06:00 P.004/007 The high-current method, test equipment, procedures, and guidelines for evaluation, includ- ing examples of test results, arede- scribed in the following. para- graphs, High-Current Method The high-current_ method of testing ground-grid continuity Ge, ground-grid connections) provides a reliable, accurate method of detecting faulty ground-grid connections. This Consists of passing approximately 300 amperes through the ground grid between a reference ground (usually a transformer neutral) and the ground to be tested. The voltage drop and the current mag- nitude and direction are moni- tored to verify the integrity of the ground connections. ‘Test Equipment Description ‘The test equipment consists of a variable current source capable of producing 300 amperes continu- ously with 105KVA capability. The test equipment output can be controlled manually or can be timed via an adjustable timer. The test equipment requires a 50-am- pere, 240 V AC power source. Test, leads ranging from 10 to 100 feet of 2/0 welding cables can be in- cluded as accessories. Procedure For Conducting The Test The following procedure is out- lined for performing ground-grid integrity tests with the high-cur- rent test set. 1. Establish a reference ground point, preferably a transformer neutral 2. From the high-current test equipment, connect the one test lead to the ground tobe tested and the second lead to the reference ground above grade but below any bonding connections or clamps (Figure 3). 3. Turn the test equipment on and adjust it to pass 300 amperes through the grid and between the reference ground and the ground being tested. The current should be passed for at least 3 minutes. 4. Using a clip-on ammeter, measure the test current flowing into the reference ground below the test lead (ie, into the grid) and the current flowing above (ie., into the equipment, structure, frame, etc.). Measure the test cur- rent flowing in the ground being tested below the test lead (ie, from the grid) and above the test Test No. 2: Examples of Test Data For Faulty Ground Connections ‘Measurement Before The Test Hook-Up 1. Current in transformer neutral (oference) ~ 82 amperes 2. Current in frame ground = None 3. Distance between reference ground and frame ground = 100 feet 4. Voltage drop of the test leads with 300 amperes = 75 volts Measurement After Test Hook-Up and With 300 Am- peres Flowing in the Test Circuit (ie, test set meter sce cee is] el ee So @ we oe" 8 reading) 1. Current low in the reference ground to grid = 270 amperes, 2. Current flow in the reference ground to TOO) = 50 amperes 3. Current in the frame ground from the grid = 25 amperes 4 Current flowin the frame ground from the structure = 280 5. Voltage reading at the test set meter = 15.6 volts Evaluation of TestResults 1. The current via the grid to the frame ground is only 25 amperes, .c,, much less than the 150 amperes criterion. 2. Voltage drop in the ground circuitis 8.1 volts (.e., 156 volt -7.5 volts) for a 100 foot dis- tance. This does not meet the 15 volt criterion for a 50 foot distance. Conclusion: Based upon the above test data, it was determined that the ground connections are faulty. NOTE: This ground was dug up and found to be ly connected. 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The clip-on ammeter posi- tions for these locationsareshown in Figure 3. The purpose of the clip-on ammeter readings is to determine the magnitude and di- rection of current flowing in the ground-grid circuit and the cur- ent flowing in the foundations, enclosures, frames, etc. 5. Record the voltage drop read- ing. and the currents measured in Item 4. 6. Alter the test is completed, disconnect the test leads, short the two test leads, and pass 300 am- es for 3 minutes. Record the voltage drop of the leads. ‘Guidelines For Evaluation of Test Data 1. The desired voltage drop of the ground path being. tested should be approximately 1.5 valts for each 50 feet of straight line distance tested for indication of good connections. This voltage value is obtained by subtracting the leads voltage drop from the voltage value recorded during the test. 2. On substations with single grounds (ie, not ground-grid or mat), at least 200 amperes should flow back to the test source via the ground path to the ground under test to indicate good connections. In most cases, approximately 300 amperes will flow back via the grid. However, in certain cases, some current is expected to flow back to the ground under test via the equipment structure, founda- tion connections, etc. 3. On substations with multi- grounds (ie, ground grids or mats, at least half (ie, 150 am- peres) of the test current should return to the test source via the grid to the ground undertest. Ifthe Current istess than half (regardless of the 1.5 volt drop for the 50 foot criterion) it indicates a potential bad ground connection. 4. "The suspected bad ground should be dug up and the connec- tions reworked. After repair of the bad connections, the ground should be retested. 5. All grounded points in the substation should be tested one at a time to assess their integrity (ie, ood ground connections should iave low resistance). Examples of Test Data and Results, To help explain the evaluation of test data, results from two re- cently conducted tests are pre- sented. Test No. 1 comprises data which indicated a good ground connection, whereas Test No. 2 comprises data which indicated a faulty ground connection. Since the ground connections to the ground grid are buried below the earth, it is not easy to determine the integrity of these connections. The faulty connections (as found in Test No. 2) may have gone un- detected without indication from such tests (since the ground-grid resistance tests checked okay) and could have compromised ground integrity. The evaluation of test results of the high-current method is easy and straightforward, as il- lustrated by these two examples. The connection for the two test examples are shown in Figures 4 and 5. Safety Precautions 1. Personnel operating the high- current test leads should always wear safety gloves. 2, No grounds should be re- moved from theequipment unless a second ground is provided. Conclusion Measurement of ground resis- tance and the integrity of the ground grid are necessary to ver- ify the adequacy ofa new ground- ing system and to detect changes in an existing grounding system and to detect changes in an exist- ing grounding system. The tech- niques for measuring the overall resistance of new or existing ground systems are well estab- lished and understood. However, the need and the methods for as- sessing the integrity of ground- grid connections are not that well established or understood. The aim of this article is to bring atten- tion to this very important aspect, of grounding system verification and the need for conducting this verification test periodically. A new method and equipment are now available to conduct the ground-grid integrity tests dis- cussed. These tests should be con- ducted along with other sched- uled maintenance tests to deter- mine the safe limits for people and equipment during normal and fault conditions at substations and other electrical power facilities. Retrenens [este of leetcal and Becton Engin IEEE Guide for Seyi AC Substaon Grounding, THES, 0-186 NewYork 2 Insite of Beetical and Becton Engine REE Guide for Meauring lah Rent, Groard Ipedanc, an Us Surface Dlenat os Ground Sytem, TEEE St, 6-550. New York "3 Risloral Fie Potecdan Awaciaon. NEPA Stndard or ect Safety Regan FE Hloyes Workplee, NCPA THEBES. Quincy, Ma ‘ames Biddle Co, Bose 25Ts 195. 5. Gecrical Equipment Testing snd Maintenance, [AS. Gil Pode Hal 1962 “6 ELL, Instruments Ine. GTS 30 Safty Cenant Test Set Operational Marl Re 1 197 Spr Me AS. (Pol) Gil sa Sener Engineer with he US, (actear Regulatory Canes and has over 20 ears exprionce tthe electrical indusry. He is thor of Electrical Equipment Testing and ‘Maintenance and is recipient of the 1933 NETA Mar ofthe Your Avard ‘This reprint provided by jnuiltFEB-04-2006 06:00 P.007/007 Will Your Safety Ground Devices Work When You Need Them? Don’t wait to find out! 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