D0246 Concept of Earthing Bonding PS-PRD-ALL-EnB-GEN-03001-D - Annex 1

Infrastructure & Cities
KOLKATA METRO RAIL CORPORATION LIMITED

EAST WEST METRO PROJECT
DESIGN, SUPPLY, INSTALLATION, TESTING AND

COMMISSIONING OF POWER SUPPLY AND
DISTRIBUTION SYSTEM, THIRD RAIL SYSTEM AND
SCADA SYSTEM
CONCEPT OF EARTHING AND BONDING

ANNEX 1: REQUIREMENTS FOR CIVIL WORKS AND
TRACKWORK
CONTRACT PS
signed 28.02.2012
Released Vogt, Thorsten IC RL CS&TS TS PM
Thorsten Vogt
signed 28.02.2012
Checked Altmann, Martin IC SG RE EN TP SE
Martin Altmann
signed 28.02.2012
Author Dietrich, Klaus IC RL CS&TS TS EN EP
Klaus Dietrich
Name Department Signature
Client : Kolkata Metro Rail Corporation Ltd. Date : 2012-02-24

Project : East West Metro Project ; Contract : PS SIEMENS Page 1 of 27
Document : Annex 1 to Concept of E&B Doc No.: PS-PRD-ALL-ENB-GEN-03001 Revision : D
Revision Log
Rev Author Date Input Reference Changes/Subject of revision

A Dietrich, Klaus 18.02.2011 All First issue
B Dietrich, Klaus 10.03.2011 All Update following discussions
during presentation 1./3.03.2011
C Dietrich, Klaus 19.10.2011 All Renewed submission of
preliminary design after SRS acc.
to meeting dated 20.09.2011
D Dietrich, Klaus 24.02.2012 All Correction of errors from PDF
conversion
E
F
G
The reproduction, transmission or use of this document or its contents is not permitted
without express written authority. Offenders will be liable for damages. All rights, including
rights created by patent grant or registration of a utility model or design, are reserved.

Table of Contents
1 SCOPE......................................................................................................... 5
2 BASIC RULES FOR CIVIL WORKS AND TRACKWORK .......................... 6

2.1 GENERAL NOTE .............................................................................................. 6
2.2 BASIC PRINCIPLE FOR CIVIL W ORKS................................................................. 6
2.3 STRUCTURE EARTH INCLUDING FOUNDATION EARTH ELECTRODE......................... 6
2.4 EARTH FARMS ................................................................................................ 7
2.5 EARTHING CONDUCTORS EMBEDDED TO CONCRETE ........................................... 7
2.6 EARTHING CONDUCTORS IN SOIL ...................................................................... 8
2.7 LIGHTNING PROTECTION DOWN CONDUCTORS ................................................... 8
2.8 WELDING ....................................................................................................... 9
2.9 TERMINALS .................................................................................................. 10
3 RULES FOR SPECIFIC EQUIPMENT AND LOCATIONS ........................ 12
3.1 RUNNING RAILS ............................................................................................ 12
3.2 BALLASTED TRACK ........................................................................................ 12
3.3 UNBALLASTED TRACK .................................................................................... 12
3.3.1 Track substructure of unballasted Track .................................................... 12
3.3.2 Measures for compatibility with track circuits ............................................. 13
3.4 FENCES, RAILINGS, NOISE WALLS .................................................................. 14
3.5 PLATFORMS ................................................................................................. 14
3.6 PLATFORM SCREEN DOORS .......................................................................... 14
3.7 SERVICES/ UTILITIES ..................................................................................... 14
4 TYPICAL MEASURES FOR DIFFERENT TYPES OF CIVIL
STRUCTURES AND THEIR PARTS ....................................................... 16
4.1 TUNNELS ..................................................................................................... 16
4.2 DEPRESSED STRUCTURES (CUTTINGS, RAMPS) .............................................. 16
4.3 VIADUCTS .................................................................................................... 17
4.4 CONTINUITY OF THE STRUCTURE EARTH FOR TUNNELS AND VIADUCTS ............... 18
4.5 PASSENGER STATIONS.................................................................................. 20
4.6 AC RAILWAY STATIONS SHARED WITH DC RAILWAYS ........................................ 23
4.7 BUILDINGS WITH WATERPROOF MEMBRANE ..................................................... 23
4.8 TECHNICAL ROOMS ....................................................................................... 23
4.9 ROOMS OF SERVICE POWER SUPPLY............................................................... 24
4.10 SUBSTATIONS ............................................................................................... 25
4.11 DEPOT AND MAINTENANCE AREA.................................................................... 25
5 VERIFICATION AND VALIDATION .......................................................... 27
5.1 SOIL RESISTIVITY .......................................................................................... 27
5.2 DECLARATION OF CONFORMITY FOR CONCRETE-EMBEDDED EARTHING
CONDUCTORS ............................................................................................... 27
5.3 RESISTANCE TO EARTH ................................................................................. 27
5.4 TEST OF CONTINUITY AND COMPLETENESS OF TERMINALS ................................ 27
5.5 CERTIFICATE OF BONDING FOR EXTERNAL LPS ............................................... 27

5.6 RAIL INSULATION........................................................................................... 27

1 Scope
The construction of railway installations generally requires a concept for earthing and bonding
including provisions for lightning protection as a basic document for the involved parties in the
project. This is important particularly for modern systems with high traction currents and the
extensive use of electrical energy for many purposes.
The objectives for earthing and bonding are:
The safety of persons:
The safety of persons is characterised by the value of the touch voltage.
The protection of installations:
Damage of installations may arise from overheating of conductors, by arcing and by
electrical corrosion.
The intended operation of the system:
For the intended operation of the system the aspect of electromagnetic compatibility
(EMC) has to be considered too.
The safety of persons is considered to have the highest priority!

The present Concept deals with all aspects of earthing and bonding of KOLKATA METRO
RAIL.
The earthing system described in this concept is a combined system for all purposes:
Traction Power Supply and Traction Return Circuit
Service Power Supply of all voltage levels
Lightning Protection
EMC appropriate earthing design
Earthing and Bonding form the basis for EMC!
This volume gives on overview of the earthing and bonding measures to be implemented by
Civil Works for KOLKATA METRO RAIL as a precondition for a consistent earthing design. The
principles need to be considered by Civil Works for their design, delivery and installation of
structures.
For general information please refer to Overall Earthing Concept of the KOLKATA METRO
RAIL.

2 Basic Rules for Civil Works and Trackwork
2.1 General note

All the following descriptions and drawings show and explain typical solutions for earthing and
bonding measures of structures.
In the document “Concept for earthing and bonding“, where the present document forms an
attachment to, the requirements and principal solutions of the earthing system for the whole
railway are described. The measures described in the following are aimed to fulfil these
requirements for the civil structures. They form an essential part of the overall earthing system.
All earthing measures shall be subject of detailed design and may vary in details.
2.2 Basic Principle for Civil Works

Civil works shall bear in mind during design and construction of all civil structures the following
main principle:
The reinforced civil structures generally

form the basis for earthing and bonding of
an electrified railway system.
Therefore, the earthing conductors embedded in concrete are an essential part of the earthing
system of the railway and need careful design and installation.
Furthermore, selection of earthing components with different materials shall consider the
danger of electrochemical corrosion.
2.3 Structure earth including foundation earth electrode

All buildings made from reinforced concrete shall have a structure earth including foundation
earth electrode. For this purpose the foundation slab, the walls and the ceilings of the building
will get a mesh of earth wires welded at their nods. The standard mesh size is about 10x10 m.
This mesh shall be part of the reinforcement and wire-tied to the normal reinforcement at least
each 40 cm. Under exceptional conditions additional mild steel rods may be used instead, but
also these rods must be wire-tied to the existing reinforcement each 40 cm.
In technical rooms including the control centre and in power supply rooms the mesh size of the
structure earth shall be reduced to 5x5 m in the floor and surrounding walls. Power substations
additionally need a reduced mesh size of 5x5m for the foundation earth electrode.
While the structure earth in walls and floors shall be located about 5 to 10 cm from the
upper/inner surface the foundation earth electrode shall be located from 5 to10 cm from the
lower concrete surface (see chapter 2.4).
The earth electrode is the part of structure earth in underground parts of the structure which are
in touch to the soil. The earth electrode discharges fault and lightning currents to the soil.
For the welding of structure earth see chapter 2.8.

In case of insulating layers like waterproof membranes are applied to the structure an adequate
solution must be installed below this insulating layer to ensure electrical contact to the soil. This
additional earthing electrode must be connected to the structure earth. Refer to 4.7.
2.4 Earth farms

According to the contract an earth farm has to be installed for each substation; that means two
earth farms per passenger station.
An earth farm will not provide the same large surface in contact to the soil compared to the
large surface of the foundation of an underground station or the connected pier foundations of
an elevated station. Hence the earth farms only may be considered as an additional measure.
Examples:
Structure earth of underground station: 50 m wide and 150 m long = 7500 m² foundation slab,
walls not considered
Structure earth of elevated station: 10 piles, each 25 m effective length, 1.2 m diameter =
942 m²
Buried earth farm: 15 m * 20 m = 300 m²
With an estimated soil resistivity of 150 Ohms per m (in the delta of the river a lower value can
be assumed, measurement pending) the expected values of the resistance to earth would be:
Underground station: 0.5 Ohms; Elevated station: 0.6 Ohms; Earth farm: 3 Ohms
In any case the earth farms must be connected to the structure earth via the main earthing
terminal. Otherwise a dangerous voltage between the earth farm and the structure earth may
occur during earth fault. This situation is not considered in IEEE 80, one of the reasons that this
standard can not be applied to railway installations.
Even if the earth farms will be calculated and installed according to the rules of IEEE 80 safety
may only be ensured by the connection to the structure earth!
The connections shall be provided by means of copper cables of 50 mm² minimal cross section.
Connections must be well protected against removal.
2.5 Earthing conductors embedded to concrete

Usage of concrete embedded earthing conductors is the preferred solution for all types of
structures made from concrete.
Earthing conductors for all purposes, including lightning protection, have to be designed to
withstand mechanical and thermal stress. This also applies to earthing conductors embedded in
concrete, which shall be part of the reinforcement preferably.
If not otherwise stated, the following cross-sections shall be applied to embedded earthing
conductors according to international standards referred above and basing on experience from
typical electrified railway systems.
Material Minimum cross-section
Steel rod 200 mm²

Copper rod 50 mm²

For other shapes, stranded material etc. refer to table 6
of IEC/EN 62305-3. For dimensions of earth electrodes
refer to table 7 of the same standard.
Table 2-1: Minimum cross-sections for concrete-embedded earth conductors
If the cross section of 200 mm² can not be provided by a single rod (diameter less
than 16mm) multiple rods may be used in parallel.
The cross-section of earthing wires is subject of detailed design and will be identified
in the related design drawings
All embedded earthing conductors must be covered by at least 5 cm of concrete for
corrosion protection.
Conductors, which are part of an earth electrode, shall not be covered by more than
10 cm of concrete. That is necessary to ensure sufficient contact to the soil.
Earthing conductors from steel and copper shall not touch each other directly to avoid
galvanic corrosion. Connections inside of the concrete between copper and steel can
be made by thermal welding (Cadweld, Thermoweld), the welding point and the whole
copper cable shall be fully insulated from concrete by plastic tape wrapping or similar.
The down conductors inside of walls have to be connected to the reinforcement at
intervals of 400 mm by means of wire wrapping.
2.6 Earthing conductors in soil

Steel wires in soil, whether hot galvanized or not, will suffer heavy galvanic corrosion due to the
connection to the earthing system. Therefore in the soil only copper or stainless steel V4A (see
below) are allowed. If the earthing conductors in soil are for connection only and not to improve
the resistance to earth insulated cables shall be used.
Specification of V4A: Chromium 16%, Nickel 5%, Molybdenum 2%, Carbon 0,03%.
Earthing conductors in soil usually form a part of an earth electrode. Therefore table 7 of
IEC/EN 62305-3 applies.
2.7 Lightning protection down conductors

According to EN 62305-3 down conductors must be erected from the roof to the foundation
earth in the outer walls of buildings. Large buildings like Main Workshop buildings additionally
require down conductors inside the building. Steel columns and reinforced columns should be
utilised for this, otherwise additional conductors will be required. That will be subject of detailed
design. Earthing terminals shall enable the connection of down conductors to the air termination
system on the roof surface.
The minimal cross section of lightning protection down conductors shall meet the requirements
of EN 62305. The earthing conductors of chapter 2.4 meet the requirement.

The protection level defines the distance between down conductors. Corners of buildings are
the preferred locations of down conductors. Additional down conductors will be required in the
following typical intervals:
Average distance between

Protection level Recommended for
down conductors (m)
Control Centre and
I 10
Interlocking room
III 20 all other buildings
Table 2-2: Average distances of down conductors
All earthing conductors embedded to concrete including lightning down conductors have to be
connected to the reinforcement at intervals of 40 cm by means of wire wrapping.
The exact locations of down conductors will be subject of detailed design.
2.8 Welding
Figure 2-1 shows examples for welded connections. The minimum length of two opposite
welded seams is 50 mm. To ensure a fully electrical conductive length of 50 mm, a welding
length of at least 55 mm is recommended. In case of single side welding a minimum length of
the seam of 100 mm is required.

Figure 2-1: Welded earthing connections
2.9 Terminals
Terminals for the connection of embedded parts to other parts of the earthing systems will be
required. This can be:
copper cables exothermic welded to the reinforcing rods, the cables shall be insulated
for mechanical protection especially where leaving the concrete, the welding zone
including all bare copper parts shall be protected by plastic tape wrapping
flat or round conductors made from hot galvanised steel
specific designed terminals for bolted connections made from hot galvanised steel or
stainless steel These terminals are furnished with a thread inside for 1 bolt M16
fixation elements like C-shaped rails from hot galvanised steel (“Halfen-Rails”),
provided they are welded to the reinforcement before pouring the concrete.
In any case, the requirements of corrosion protection have to be considered to achieve reliable
earthing connections. Inside of buildings and other closed structures hot galvanised steel may
be used. For connections facing outdoor conditions stainless steel terminals shall be used only.

Earthing terminals shall be welded to the reinforcing rods dedicated for earthing according to
the welding requirements above. The earthing terminals shall be accessible in a height from 30
to 50 cm above concrete floor or final ground level.
Terminals are required at the following locations (at minimum, but not limited to):
connection of embedded earthing wires to other parts of the earthing system
connections between different parts of concrete (prefabricated parts, expansion joints)
connection from structure earth to steelwork
connection from structure earth to lightning air termination
connection from structure earth to large metallic parts (elevator guide rails, escalator
support frame, handrails, large E&M equipment like AFC ticket vending machine and
access gate etc.)
connection from structure earth in technical rooms (up to 30 m² 2 terminals, above 4
terminals)
connection from structure earth to neighbouring buildings or to the line, one terminal at
each of the four corners of the building
connection from structure earth to additional earthing electrodes for power substations
on each of the four corners of the building
mild steel rod Ø 16,

for welding to earthing
wires on site
stainless steel
cylinder Ø 38 mm x
45 mm long with
thread M16
stainless steel plate
50x50 mm, 4 mm thick,
for fixation at the
formwork and as
contact surface
Figure 2-2 Examples of earthing terminals

3 Rules for specific equipment and locations
3.1 Running Rails

The running rails are the return conductors of the DC railway system. In contrast to an AC
railway system the running rails are not earthed and are not allowed to be connected with the
structure earth, any earthing conductor or any part in contact to soil. The rail fixation must
provide sufficient insulation between rail and substructure.
As the insulation value required by the standard must be fulfilled during the whole lifetime of the
system the test values of the new installed clean and dry track must provide sufficient margin
for degradation by corrosion, dust and ageing.
According to the particular specification the trackwork supplier shall ensure a minimum rail
insulation value of 20 ·km.
Next to the stray current mitigation requirements the signalling subsystem may require certain
rail insulation for sufficient operation of the track release system. Usually the insulation values
provided for stray current mitigation fulfil the requirements of the signalling system.
3.2 Ballasted track

Sections of ballasted track with reinforced substructure are treated like unballasted track. In line
sections with ballasted track without conductive substructure no additional measures are
implemented to the track or the substructure for stray current protection other than the rail
insulation. The ballast itself may be sufficient for this purpose if kept clean by adequate
maintenance.
Attention is required to conductive utilities crossing or in parallel to the track. If no sufficient
distance may be ensured insulating separators may be inserted or an insulating layer may be
used between the track and the utility.
3.3 Unballasted track

3.3.1 Track substructure of unballasted Track
The unballasted track consists of the track slab and the track bed, depending on track
construction. It forms the track substructure of slab tracks, tunnels, ramps, viaducts, bridges,
stations and other civil structures.
The reinforcing rods of reinforced concrete structures must be protected against stray current
corrosion. For this purpose a conductive mesh must be established near to the surface of the
concrete as earthing system and for stray current control. The topmost layer of reinforcement
may be utilised for this purpose by longitudinal continuous welding and cross-connecting as
follows:
At least one longitudinal rebar below each rail made continuously by welding
At least one cross connection in each separated part of construction.
Two cross connections in parts longer than 10 m in parallel to the track (one on each
side).

In long parts further cross connections each 60m.
The total cross section of steel bars per track shall be 800 mm² for light rails and 1600 mm² for
metro systems. This corresponds to 4 or 8 steel rods Ø16 mm per track.
Earthing terminals have to be provided at locations, where gaps in the continuously welded
longitudinal bars are necessary (expansion joints) and in regular distances of 50 m to enable
earthing of equipment. The following figure shows an example.
Terminal for
connection of sections
50 m
track slab
earthing rebar
(stray current collector)
welded connection
cross-connection
(at beginning and end of track slab segment)
Figure 3-1: Example of earthing connections in unballasted track slab
The detailed arrangement of earthing connections in the track bed depends on its reinforcement
construction. In general, the topmost layer of reinforcement shall form the earthing and stray
current control system.
At least two redundant jumper connections shall be provided at each expansion joints. Lost
connections will cause electrochemical corrosion of the reinforcement.
If continuity of the reinforcement including all jumper connections may not be guaranteed by
Civil Works it may be necessary for them to install an earthing cable which can bridge lost
connections so that a broken link will not interrupt the chain. Refer to 4.4 for details.
3.3.2 Measures for compatibility with track circuits

Depending on the track release system provided by the signalling subsystem it may be
necessary at certain locations below the running rails to avoid closed loops formed by
reinforcing rods touching each other. Requirements, if any, need to be set by the signalling

system.
3.4 Fences, Railings, Noise walls

Metallic fences, railings, hand rails, noise walls, crash barriers may need to be earthed because
of lightning protection. They shall be connected to the structure earth.
3.5 Platforms
The voltage between the running rails and the local earthing system must be limited by a
voltage limiting device like e.g. a voltage fuse.
The protection of passengers against bridging between electrical equipment (e.g. escalator,
ticket vending machine) and train must be settled by clearances.
No earthed equipment shall be located in a distance of 2.5 m from the platform edge to avoid
bridging of train potential to earth by passengers.
Platforms shall be treated like workshops regarding accessible voltages for passenger comfort
according to chapter 7 of EN 50122-1. Therefore, the standing surface of passengers at the
platform edge shall be insulated in a width of 1.45 m at minimum. The insulation resistance
must be 20 kOhm/m2 at minimum in orientation to chapter 413.3 of IEC 60364-4-41.
3.6 Platform Screen Doors

The overall structure of platform screen doors shall be bonded at both ends of the frame by
connection to running rails to avoid inconvenient touch voltages between the train and the
platform door screen. This is an additional measure to the short circuiting device which is
limiting the voltage of the running rail to safe values.
To avoid stray current corrosion the whole frame of the platform door screen must be carefully
insulated to structure earth. The insulation level shall at least meet the requirement for the new
installed and clean running rails and shall be maintained at this level permanently. Refer to
chapter 3.1. An initial insulating test must be carried out after finalised fixation at civil structure.
The resistance shall be measured between the structure earth and the platform door screen
with the latter disconnected from the running rails.
3.7 Services/ Utilities

Conductive Services and Utilities entering or leaving the railway environment from/to the
outside are not allowed to transmit currents or dangerous voltages.
Therefore all such pipes need an insulating joint where they enter a building, which is
accessible for tests and maintenance.
According to the requirements of equipotential bonding all metallic utilities and devices must be
earthed. Potential equalisation is achieved by
Direct bonding of all extended metallic installations at their foot points like e.g.
escalators, elevators, banisters, air condition pipes

Direct bonding of all outgoing and incoming metallic installations at the inside of
building boundary like e.g. cable armour and pipes of water, gas etc.
For this purpose earthing terminals must be provided for these connections.
The locations of earthing terminals will be defined in the related drawings during detailed
design.
Service utilities in parallel to or crossing the tracks, which have applied active corrosion
protection, the requirements for separation or additional insulation have to be elaborated in
coordination with the owner of the utility.

4 Typical measures for different types of civil structures and their

parts
4.1 Tunnels
The reinforcement of the tunnel forms the earthing system of tunnel sections.
For tubing tunnels with prefabricated concrete sections, the embedded reinforcement can not
be used as structure earth. Here as shown in Figure 4-1 the trackbed reinforcement provides
the structure earth. The large surface of the track bed located on top of the prefabricated
concrete parts provides sufficient low resistance to earth as long as the surrounding soil has
sufficient conductivity.
Figure 4-1: Schematic earthing connections of tubing tunnels
4.2 Depressed Structures (Cuttings, Ramps)
The earthing rods of cuttings are the same as in the lower part of tunnels or in the viaduct
segments with plinth. The following figure shows the principle.

Figure 4-2: Schematic earthing connections of cuttings
4.3 Viaducts
The reinforcement of the viaduct forms the structure earth of viaduct sections. Therefore the
reinforcements of single segments have to be electrically interconnected and the dedicated
earthing rebars shall be welded together via cross connections. Figure 4-3 shows the schematic
earthing connections of viaducts. The foundations of the piers form the earth electrodes for
viaducts. The reinforcement of the foundation shall be electrically connected to the
reinforcement of the piers and the viaduct segments.

Figure 4-3: Schematic earthing connections for reinforced concrete viaduct
For continuity of the structure earth of viaducts refer to 4.4.

The required number and cross-section of the rebars used for earthing and the earthing wires
have to be designed with respect to the maximum earth fault currents, with respect to lightning
protection and with respect to the requirements for stray current protection and are subject of
detailed design. For the typical minimum cross sections refer to 3.3.1.
Earthing terminals for earthing measurements (monitoring of corrosion protection) and bonds
are recommended at approximately one metre above ground level of the piers of viaducts and
within the cable ducts at the top of the viaduct.
4.4 Continuity of the structure earth for tunnels and viaducts

In case that the longitudinal continuity can not be ensured by the reinforcement or dedicated
rebars connection, an earth wire per track has to be provided by civil works where the
reinforcement of the tunnel, viaduct or other conductive track substructure shall be cross-
bonded and bonded to this earth wire. The cross-section of the earth wires shall not be less
than 70 mm² copper section.

Figure 4-4: Schematic of electrical continuity of viaduct
Tunnel shell
rail to structure (tubing segments)
trackbed
insulation earthing rod in upper layer
Side View
Tunnel shell
(tubing segments)
Top View (single tunnel)
Figure 4-5: Schematic of electrical continuity of reinforced track substructures

It shall be ensured that there is no electrical connection between the return circuit and the
reinforcement of the reinforced track substructure or the earth wire. This shall be proven by
measurement, see 3.1 and 5.6.
4.5 Passenger Stations

Station buildings shall be provided with a structure earth.
Earthing terminals are necessary for LV power supply rooms, technical rooms and facilities like
elevator & escalator and for steelwork like the roof supports. The roof constructions of at grade
and elevated station and the above ground parts of underground stations (entrances, ventilation
shafts) need an external lightning protection system. The lightning protection system must be
connected to the structure earth to avoid dangerous voltage differences. Equipotential bonding
will avoid safety issues.
The trackside earthing and bonding measures, including stray current corrosion protection, are
the same as for the tunnels and viaducts.
The following drawings show examples of elevated and underground stations.

Figure 4-6:
Bonding for
lightning
protection
Document : Annex 1 to Concept of E&B

Client : Kolkata Metro Rail Corporation Ltd.
Project : East West Metro Project ; Contract : PS
Earthing terminal
(copper plate)
Reinforcement in the
substation floor must be Main Earthing Terminal
connected to the main Structure earth of the station must be connected
earthing terminal! to the structure earth of the viaduct to ensure
continuity of the track substructure!!
Arrangement of earth wires in elevated stations
SIEMENS
Earthing terminal
Doc No.: PS-PRD-ALL-ENB-GEN-03001

Welded connection
Earth farm
Earthing rebar welded
to cross connection
Revision : D
Page 21 of 27
Date : 2012-02-24
Figure 4-7
Arrangement of
earth wires in
underground
stations

4.6 AC railway stations shared with DC railways

The general approach for station buildings with AC and neighboured DC railways is to separate
the structural part of the DC railway from that of the AC railway to avoid the transmission of
stray currents to the AC system. This is applicable, if only the pedestrian bridges or tunnels
connect both parts.
For large station buildings with many structural connections between the AC and DC railway
installations (e.g. parallel run of tracks over the whole station length) this is impracticable. On
the other hand large buildings will provide a very low resistance to earth and this way reduce
the transmission of stray currents to other systems.
The DC railway shall apply the insulation measures as required by IEC 62128-2 mandatory and
in proven quality. Additionally, the feeding section of the DC railway in the station area shall be
short to further reduce the rail potentials.
4.7 Buildings with waterproof membrane

Buildings with a waterproof membrane like plastic foils or bituminous layers are electrically
insulated from soil. Therefore the foundation may not perform as an earthing electrode.
To provide appropriate earthing, an earthing electrode shall be placed below the membrane,
and connections must be brought up through the membrane or around its edge and connected
to the earthing grid in the foundation of the building.
The earthing grid in the foundation provides potential equalisation over the whole station area.
The earthing grid below the membrane may be constructed from bare copper rods in the soil or
from steel bars protected by concrete covering for about 10 cm all around them.
4.8 Technical Rooms

The technical rooms of each subsystem must include earthing terminals about 30 cm above
surface of floor level. In rooms up to 30 m² two terminal shall be provided, in larger rooms four
terminals. The locations of earthing terminals will be defined in the related drawings during
detailed design.
Figure 4-8 shows the implementation of structure earth including foundation earth electrode and
the earthing terminals in the corners of the room as an example for technical rooms (technical
room in upper floor level).

Additional down conductors

according to requirements of LPS
Telecommunication
& Signalling Room
Down conductor for LPS
Earthing terminal
at each corner Bonding ring conductor
other floor level
ground level
Structure earth
Welded connection Foundation earth

electrode
Figure 4-8: Earthing & bonding of technical rooms
4.9 Rooms of service power supply

In rooms containing power transformers or switchgear the floor reinforcement shall be used for
internal potential grading by a structure earth grid of 5x5 m located near to the floor surface (5-
10 cm from the top of the floor).
The potential grading grid shall be connected to the foundation earth electrode by welding.
Earthing terminals as described in section 2.9 shall be provided near to each corner of the
rooms. Additional earthing terminals shall be provided at the outside of the building near to each
corner of the building and according to the specification of the power supply contractor.
Figure 4-9 shows the implementation of structure earth including foundation earth electrode, the
voltage grading in the floor and the earthing terminals in the corners of the room as an example
for power supply rooms.

Reinforcing rods dedicated for

lightning protection
Transformer room, high and medium voltage

Down conductor of LPS
switchgear room
Option for metallic gates/door Crossed

of transformer rooms earting rods
Earthing terminal
at each corner
welded
connection
Voltage grading grid
(Top layer of reinforcement)
Structure earth
Welded connection Foundation earth electrode
Figure 4-9: Earthing & bonding of low voltage power supply rooms
4.10 Substations
Power supply stations shall as a minimum consider the earthing requirements for power supply
rooms of chapter 4.9. Additionally the substation building shall have a foundation earth
electrode with reduced grid size of 5x5 m.
In case of open air HV switchgear or similar parts separated from the substation building an
earthing grid must be installed in the soil to ensure equipotential bonding of all separated parts.
Further requirements for Power Substations will be derived from the studies prepared by the
power supply subsystem during the basic design phase.
4.11 Depot and Maintenance area

Depot buildings shall be equipped with a structure earth according chapter 2.3.
Additionally for all major workshop equipment terminals for direct earthing at the structure earth
shall be provided like under floor wheel lathe, wheel press, maintenance platform, crane rails
etc.
All individual earthing installations and conductive parts of the depot and workshop area shall
be equipotential bonded. The totality of all earthing installations connected to the equipotential
bonding conductor forms the structure earth of the depot and workshop area.

In the depot and workshop area the return circuit shall be insulated against structure earth and
earth similar to the main line. The permanent accessible voltage generated by the railway
system must not exceed 60 V DC.
Potential differences between the structure earth of the workshop area and the return circuit
cause restrictions to operation and service activities. To avoid such restrictions, improve safety
and minimise stray currents at the same time the insulated return circuit shall be connected to
the structure earth exclusively in one centrally located point, accessible for inspection and
removable for measurement.
In order to avoid non-permissible touch voltages caused by the train operation on the main line
and to reduce stray currents the running rails of the depot and workshop area have to be
separated from the main line track system by insulating rail joint (IRJ).
For the purpose of redundancy two rail joints shall be installed in series within each running rail
at the entrance from the main line to the depot area. The distance of the 2 IRJ in each rails shall
be appropriate with respect to strength of running rail (to be determined by trackwork) and shall
not be greater than the distance between two bogies of one single car. No stop signal shall be
located within one train length at both sides of the insulated rail joints to avoid a prolonged
bridging period of the rail joints.
As the return circuit in the depot area is floating while in the workshop area it is earthed another
IRJ shall be installed in each rail in front of the workshop building. Again the position shall avoid
locations of operational train stops to not bridge the rail joints longer than necessary.
To further reduce stray current transfer between depot area and mainline the structure earth
shall also be separated between the two. The IRJ between mainline and depot shall located
near to or in line with the structure earth separation.
To avoid by-passing of IRJ by the return cables mainline, depot and workshop areas shall be
supplied from separate traction rectifiers. For backup purposes temporary feeding of one part
from another rectifier shall be allowed for a limited period of time.

5 Verification and Validation

The verification and validation starts during the construction phase. In that phase the later on
invisible and therefore incorruptible parts embedded to concrete have to be tested and certified
by the Civil Works contractor. During commissioning phase the E&M contractor will test and
certify its installations. Finally, during the operation period of the system, the operator will have
to conduct periodical monitoring of the situation of the installations.
Civil Works shall carry out measurements as described in the following chapters 5.1 to 5.5
during the construction phase.
5.1 Soil resistivity

At some selected locations, to be defined during basic design, the soil resistivity has to be
measured with the Wenner-method (4 electrodes) as basis for earthing calculations.
5.2 Declaration of conformity for concrete-embedded earthing conductors

The validation of earthing installations embedded in the concrete of civil structures has to be
carried out by the civil works contractor and has to be documented in the declaration of
conformity to be handed over to the power supply contractor. It has to include evidence for each
civil structure, which consists of at least
Photographic documentation showing all earthing conductors, earthing plates
(terminals) and earthing welds for each structure segment before pouring the
concrete.
Proof of completeness and accessibility of all earthing plates per segment.
Electrical continuity test of all earthing plates per segment against one of them used
as reference terminal. This test has to be carried out after pouring the concrete.
Measurement of resistance to earth at reference terminal.
5.3 Resistance to earth

The resistance to earth of completed earth electrodes shall be measured at one reference
terminal to ensure required values for safety of persons. Procedure will be according to the
3 electrodes method.
5.4 Test of continuity and completeness of terminals

Tests shall be conducted to ensure all required terminals are provided and have low impedance
connection to the reference terminal.
5.5 Certificate of bonding for external LPS

Checks shall be conducted to ensure appropriate measures for external lightning protection.
5.6 Rail insulation

The rail insulation of single-track segments shall be tested by the trackwork contractor before
welding of tracks to ensure stray current protection, test method as outlined in EN50122-2.


D0246 Concept of Earthing Bonding PS-PRD-ALL-EnB-GEN-03001-D - Annex 1

Uploaded by

Document Information

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

D0246 Concept of Earthing Bonding PS-PRD-ALL-EnB-GEN-03001-D - Annex 1

Uploaded by

Copyright:

Available Formats

Infrastructure & Cities

KOLKATA METRO RAIL CORPORATION LIMITED

DESIGN, SUPPLY, INSTALLATION, TESTING AND

CONCEPT OF EARTHING AND BONDING

Name Department Signature

Client : Kolkata Metro Rail Corporation Ltd. Date : 2012-02-24

Rev Author Date Input Reference Changes/Subject of revision

Client : Kolkata Metro Rail Corporation Ltd. Date : 2012-02-24

2 BASIC RULES FOR CIVIL WORKS AND TRACKWORK .......................... 6

Client : Kolkata Metro Rail Corporation Ltd. Date : 2012-02-24

5.6 RAIL INSULATION........................................................................................... 27

Client : Kolkata Metro Rail Corporation Ltd. Date : 2012-02-24

The safety of persons is considered to have the highest priority!

Earthing and Bonding form the basis for EMC!

Client : Kolkata Metro Rail Corporation Ltd. Date : 2012-02-24

2 Basic Rules for Civil Works and Trackwork

2.1 General note

2.2 Basic Principle for Civil Works

The reinforced civil structures generally

2.3 Structure earth including foundation earth electrode

Client : Kolkata Metro Rail Corporation Ltd. Date : 2012-02-24

2.4 Earth farms

2.5 Earthing conductors embedded to concrete

Material Minimum cross-section

Steel rod 200 mm²

Client : Kolkata Metro Rail Corporation Ltd. Date : 2012-02-24

Copper rod 50 mm²

2.6 Earthing conductors in soil

2.7 Lightning protection down conductors

Client : Kolkata Metro Rail Corporation Ltd. Date : 2012-02-24

Average distance between

Table 2-2: Average distances of down conductors

Client : Kolkata Metro Rail Corporation Ltd. Date : 2012-02-24

Figure 2-1: Welded earthing connections

Client : Kolkata Metro Rail Corporation Ltd. Date : 2012-02-24

mild steel rod Ø 16,

Figure 2-2 Examples of earthing terminals

Client : Kolkata Metro Rail Corporation Ltd. Date : 2012-02-24

3 Rules for specific equipment and locations

3.1 Running Rails

3.2 Ballasted track

3.3 Unballasted track

Client : Kolkata Metro Rail Corporation Ltd. Date : 2012-02-24

In long parts further cross connections each 60m.

Figure 3-1: Example of earthing connections in unballasted track slab

3.3.2 Measures for compatibility with track circuits

Client : Kolkata Metro Rail Corporation Ltd. Date : 2012-02-24

3.4 Fences, Railings, Noise walls

3.6 Platform Screen Doors

3.7 Services/ Utilities

Client : Kolkata Metro Rail Corporation Ltd. Date : 2012-02-24

Client : Kolkata Metro Rail Corporation Ltd. Date : 2012-02-24

4 Typical measures for different types of civil structures and their

Figure 4-1: Schematic earthing connections of tubing tunnels

4.2 Depressed Structures (Cuttings, Ramps)

Client : Kolkata Metro Rail Corporation Ltd. Date : 2012-02-24

Figure 4-2: Schematic earthing connections of cuttings

Client : Kolkata Metro Rail Corporation Ltd. Date : 2012-02-24

Figure 4-3: Schematic earthing connections for reinforced concrete viaduct

For continuity of the structure earth of viaducts refer to 4.4.

4.4 Continuity of the structure earth for tunnels and viaducts

Client : Kolkata Metro Rail Corporation Ltd. Date : 2012-02-24

Figure 4-4: Schematic of electrical continuity of viaduct

Top View (single tunnel)