Main Earth Conductor Current (Bridge structure TN-C-S)

I have recently been tasked with carrying out some Inspection & Testing on a critical infrastructure graded bridge as part of a short term contracting position. 

I was sent out with the companies "Lead" electrician who is in the practice of making up paperwork/test results and trying to "look" busy whilst finding as much time as possible to dedicate to internet browsing. It put me in a bit of a pickle because I couldn't be a part of that when I'm part of the team responsible despite my signature not being asked for.

So I took the apprentice and decided to do some test & inspection. The particular job was a 3 yearly Inspection of the lighting and power circuits on the towers part of the bridge. There are three phase power circuits, three phase lighting circuits (phases split in the bridge but haven't yet found where) and single phase 110 volt sockets. 

The bridge is extensively metal. Every location where internal circuits are installed one is surrounded by box sections of steel bolted together.

The supply arrangement confirmed only by measurement (0.12 ohms) is TN-C-S fed from an adjacent 11KV transformer inside the bridge bowels sat on a concrete plinth in the basement. 

The inspection and testing has proven challenging due to scale, access and lack of prior adequate records  and I am still gathering evidence between juggling our other basic maintenance and reactive maintenance tasks. We were allotted 2 weeks to complete the lighting and power testing and had no schematics or location drawings to aid us everything has been visually verified and proven by testing. The area these circuits covers is huge and original installation between 1983 and 1985 with additions over the years. 

Wiring is almost entirely SWA, potentially some MICC left in the circuits.

Anyway that's the background. My concerns are as follows:

1. A reading as high as 730 mili amps - Taken with a clamp meter on the main earth supply from the HV/LV Transformer to MET. 

2. Suitability of a TN-C-S supply when surrounded by steel work and stood on a potentially great conductor. 

3. I have not been able to verify visually, or by test, the presence of main bonding conductors for the structural steel - This is due to the cable tray behind the main switch gear being inaccessible for visual inspection however I can see an unsheathed copper conductor, either 35mm or 50mm sq leaving the void. I have not worked out where the void enters the structure and require a long wander lead to carry out further investigation.

4. Due to limitations I had to test the final lighting circuit I.R at 250v with line & neutral connected together to earth. We have old 3c +N  PILC sub mains cables where the armouring is the CPC excellent I.R results > 700 Mega ohms some better than 999 Mega ohms. However on the PVC swa final lighting circuits we have readings as low as 0.4 megaohms and lots of them. Some are fine at 37-50 Mega ohms. The circuits are protected by BS88 10 amp fuses and have a mixture of LED and Fluorescent lighting.

5. There are a myriad of "end of line" points because the circuits have not been wired from point A-Z. Instead we have a main trunk in the towers with innumerous spurs off the main branch. Initially I was carrying out ZS readings (Live using insulated gloves) for convenience and to get a rough idea of Zs condition. However at some point I started to suspect the potential for parallel paths was almost certain given that many of the old fluorescent lights are metal clad, have bonding straps to the case from the cpc and are fixed to the steel by Unistrut fixings and similar providing earth continuity to the structural steel. 

6. I do not know if there is any continuity between the bridge structure and "true" earth, either by an intentional electrical conductor or by the natural design of the structure.

7. Reduced voltage readings were observed at several lighting junction boxes between 83 and 153 volts. No labelling and no way to determine circuit and phase. 415 is present in some JB's

8. Multicore swa cables some with 8 conductors, have not been identified in anyway. I am most concerned that neutral and cpc's have been mixed and the bridge is forming a neutral.

This inspection has me wanting to pull the main fuses and hand it to the client in a sealed skull and cross bone bag. If I were to go off coding, individually there are no C1 faults. But as a whole, without other records, design data and further verification I have reasons to suspect it could be extremely unsafe and due to the age, vibration and hot cold fluctuations if a fault does occur, at this stage I cannot say how risky it is.

I have all my guidance notes here and am preparing a customised report with photographs, test results etc. 

I am seriously concerned with the possibility of the PEN conductor being lost, and where would that 700 or so miliamps flow to? I have no reference earth to use.

My main recommendation is that the bridge requires a robust bonding system, and a back up TT earth system which is tested regularly due to general public pathway on the bridge (Being metal) contractors and employee's traversing the internal bare metal structure daily.

I would really appreciate your thoughts 

Parents
  • 700mA for a substantial installation doesn't feel too bad to me - at first (and of course ill-informed guess) I'd start by looking at the light fittings - small amounts of damp ingress can easily reduce IR readings and Class I LED drivers can have have a.c. leakage due to filters.

    BS 7671 is happy with high leakage currents provided the c.p.c.s. are "high integrity" - which is generally satisfied by a single ≥10mm² conductor, or  ≥4mm² conductor with some mechanical protection, or duplicated conductors if smaller than that. Even using extraneous-conductive-parts as c.p.c.s is permitted - provided reasonable precautions are taken against their removal - and I think most would agree that it's not likely that structural parts of a bridge are likely to be removed (at least not while its electrical installation remains in operation).

    Broken PEN conductors are pretty rare and when they do happen are often caused by fallen overhead lines or damaged underground cables - neither of which sound particularly likely if you're running off your own HV transformer within the structure.

    As for the multicore SWA, I'd hope the armour was the c.p.c. so it shouldn't be easy to "cross" N & PE by misidentifying cores. Perhaps if a core was used as an additional c.p.c. it could be crossed or bridged to the N core by mistake, but still the armour should remain as the primary c.p.c. and be able to keep exposed-conductive-parts at a reasonably low potential even if the N was broken/disconnected. Even if the worst did happen and the bridge was acting as N for some circuits, I suspect it would have more than adequate c.s.a. to cope.

    I'm no civil engineer, but I'd be very surprised if the bridge itself didn't act as a decent earth electrode. I know steel bridges have expansion joints and the like often filled with rubber compounds, but I've be very surprised if presumably several thousand tonnes of steel wasn't ultimately in pretty good contact with the equally massive concrete foundations, which were in pretty intimate contact with the ground below. A long lead test to an independent earth reference (say a screwdriver stuck into a grass verge) might provide some reassurance on that score. In any event simple continuity between the bridge structure and the MET/Tx Earth would provide adequate protection from local potential differences - and a large number of small connections can often provide just as good results, often with better resilience, than one large connection.

       - Andy.

Reply
  • 700mA for a substantial installation doesn't feel too bad to me - at first (and of course ill-informed guess) I'd start by looking at the light fittings - small amounts of damp ingress can easily reduce IR readings and Class I LED drivers can have have a.c. leakage due to filters.

    BS 7671 is happy with high leakage currents provided the c.p.c.s. are "high integrity" - which is generally satisfied by a single ≥10mm² conductor, or  ≥4mm² conductor with some mechanical protection, or duplicated conductors if smaller than that. Even using extraneous-conductive-parts as c.p.c.s is permitted - provided reasonable precautions are taken against their removal - and I think most would agree that it's not likely that structural parts of a bridge are likely to be removed (at least not while its electrical installation remains in operation).

    Broken PEN conductors are pretty rare and when they do happen are often caused by fallen overhead lines or damaged underground cables - neither of which sound particularly likely if you're running off your own HV transformer within the structure.

    As for the multicore SWA, I'd hope the armour was the c.p.c. so it shouldn't be easy to "cross" N & PE by misidentifying cores. Perhaps if a core was used as an additional c.p.c. it could be crossed or bridged to the N core by mistake, but still the armour should remain as the primary c.p.c. and be able to keep exposed-conductive-parts at a reasonably low potential even if the N was broken/disconnected. Even if the worst did happen and the bridge was acting as N for some circuits, I suspect it would have more than adequate c.s.a. to cope.

    I'm no civil engineer, but I'd be very surprised if the bridge itself didn't act as a decent earth electrode. I know steel bridges have expansion joints and the like often filled with rubber compounds, but I've be very surprised if presumably several thousand tonnes of steel wasn't ultimately in pretty good contact with the equally massive concrete foundations, which were in pretty intimate contact with the ground below. A long lead test to an independent earth reference (say a screwdriver stuck into a grass verge) might provide some reassurance on that score. In any event simple continuity between the bridge structure and the MET/Tx Earth would provide adequate protection from local potential differences - and a large number of small connections can often provide just as good results, often with better resilience, than one large connection.

       - Andy.

Children
  • 700mA for a substantial installation doesn't feel too bad to me

    What would people think was acceptable for an ordinary single-phase domestic installation please?

  • This is an interesting question, and under some non-fault conditions in a PME street could be several amps actually but usually isn't. It may well have almost  nothing to do with the installation itself, and everything to do with what is outside it.

    The problem is that the neutral and earthed services gas, water usually, maybe in some cases cast iron drains as well, are (usually) pretty solidly bonded at each property,  The street neutral will carry the out of balance current between the 3 phases, and that could well be many tens of amps and in a few cases a hundred or more - but that neutral is in effect in parallel with all that piping, which may be a comparable or even lower impedance than the street main itself so the current shares in the ratio of the conductivity of the 2 paths.

    Now, a large CPC current that changes with the house load, or goes off altogether if the CU is isolated, is not the same sort of thing at all and should direct attention at things like local EMC filters,  and if more than perhaps a few tens of mA, then also could be  neutral earth faults in the installation.

    It is worth comparing the CPC current, with a clamp measure of L & N tails measurement - they may well be quite different, and it allows currents originating inside and outside to be distinguished.

    Problems inside the installation should only be tens of milliamps at most.

    Mike.

  • This is an interesting question, and under some non-fault conditions in a PME street could be several amps actually but usually isn't. It may well have almost  nothing to do with the installation itself, and everything to do with what is outside it.

    Thanks, Mike. That'll be an FI then.

  • That'll be an FI then. 

    Yup.

    The test like an RCD - by which I mean that is L&N tails both go through the clamp meter is the more interesting - that is only a test of stuff inside the installation, and anything more than perhaps 0.1% of the main circuit breaker rating needs a very good explanation, The current in the bonding, or in pipes etc, may be  larger, and when it is, that is then due to things outside.  

    The regs may imply PENs never break, but they have been known to do so anyway ;-)

    Mike.

  • Mike and John, many thanks for your contributions. It all varies, but perhaps 80% of L going down N and 20% down the earthing conductor.

    House insurance renewed yesterday. :-)