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200093-01 Lighting Surge Protection DD 6.11.15
200093-01 Lighting Surge Protection DD 6.11.15
Contents
1 DEFINITIONS, ABBREVIATIONS AND REFERENCES .............................................................. 5
1.1 DEFINITIONS ............................................................................................................................. 5
1.2 ABBREVIATION .......................................................................................................................... 7
1.3 REFERENCE DOCUMENTS ............................................................................................................ 8
2 INTRODUCTION .................................................................................................................. 9
2.1 PURPOSE.................................................................................................................................. 9
2.2 SEVERITY OF LIGHTNING IN MALAYSIA ........................................................................................... 9
3 SYSTEM DESCRIPTION....................................................................................................... 10
4 LIGHTNING PROTECTION SYSTEM..................................................................................... 10
4.1 ZONE OF PROTECTION.............................................................................................................. 10
4.2 DIRECT STRIKE PROTECTION ...................................................................................................... 11
4.3 METHOD OF PROTECTION. ........................................................................................................ 12
5 SURGE PROTECTION SYSTEM ............................................................................................ 15
5.1 PROTECTION REQUIREMENT ...................................................................................................... 16
5.2 SELECTION OF SPD. ................................................................................................................. 16
5.3 POSITIONING OF SPD ............................................................................................................... 17
5.4 SURGE PROTECTOR EARTHING. .................................................................................................. 18
6 SURGE PROTECTION FOR HIGH VOLTAGE ......................................................................... 19
6.1 BULK SUPPLY STATION - HIGH VOLTAGE 132KV. .......................................................................... 19
6.2 STATION SUB-STATION HIGH VOLTAGE 33KV. ............................................................................. 19
6.3 TRACTION POWER SUB-STATION 33KV / 750V DC. ..................................................................... 19
7 SURGE PROTECTION OF POWER, DATA AND COMMUNICATION LINES ............................ 20
8 MINIMUM CONSIDERATIONS FOR SELECTION OF SPDS.................................................... 21
Table of Figures
List of Table
1.1 Definitions
The terminology used in this document is compatible with that currently appearing in
documentation related to or contained in the relevant national and international
standards.
Terms Definition
Accessible voltage The part of the rail potential under operating conditions that
can be bridged by persons, the conductive path being
(Touch & Step
conventionally from either hand to both feet through the
potential)
body, or from hand to hand.
Load current The current that flows as a result of the operation of electrical
systems/equipment.
Stray current Electrical current that follows paths other than intended
paths. Stray currents occur in DC traction systems.
Terms Definition
of the supplying power source of the electrical
installation:
T direct earthing of one point of the powersource (generally
the neutral point of thetransformer), Insulation of all active
components from theearth or connection of one point of the
powersource to earth via an impedance.
The SECOND LETTER describes the earthing conditions of the
bodies of the equipment of the electrical installation:
T Body of the equipment is earthed directly,
regardless of any possible existing earthing of
one point of the power supply, N Body of the electrical
equipment is directly connected to the power system
earthing (earthing of the power source of the electrical
installation).
subsequent letters describe the arrangement
of the neutral conductor and the protective conductor:
S Neutral conductor and protective conductor
are separate from each other,
C Neutral conductor and protective conductor are combined
(in one conductor).
Table 1-1 : Definition
1.2 Abbreviation
Abbreviation Explanation
AC Alternating Current
CCTV Closed-Circuit Television
DB Disconnection Box
DC Direct Current
ELR Earth Leakage Relay
EMC Electromagnetic Compatibility
EMI Electromagnetic Interference
EN European Norm (Standard)
HV High Voltage
IEC International Electro Technical Commission
kA kilo Amps
kV kilo Volts
LV Low Voltage
L-N Live to Neutral
L-G Live to Ground
L-L Live to Live
N-G Neutral to Ground
M&E Mechanical and Electrical
MCB Main Circuit Breaker
PA Public Address
PIDS Public Information Display System
RCCB Residual Current Circuit Breaker
SPS Surge Protection System
SPD Surge Protection Device
TEC Technical Earth Conductor
TNB Tenaga National Berhad
UPS Uninterruptible Power Supply
µs microsecond
Standard Description
2 INTRODUCTION
This lightning and surge document describes the general configuration in which the
traction system, facilities buildings, signalling, communication and monitoring
equipment get their power supply complete with earth system that will be arranged in
order to meet the requirements of the various lightning and surge regulations and
standards. The purpose is to ensure proper functioning of the electrical system and the
safety of persons and equipment during normal and fault conditions. The non-traction
power element includes HV/LV power supplies to M&E equipment, signalling and
telecomm systems and any other system/subsystem which draws power from the
HV/LV supply.
The lightning and surge scheme will need to undergo continuous development as the
various engineering disciplines submit their final designs. Close co-ordination with
specific project reports (i.e. EMC Management, Stray Current Control, Lightning
Protection System, etc.), is required to ensure the lightning and surge protection
arrangements are suitable and provide adequate electrical protection for all specialist
disciplines connected to the M&E lightning and surge system.
The principal applicable standard covering lightning and surge on the SSP Line Project is
BS EN 50122-1 ‘Railway Applications - Fixed Installations - Electrical safety, earthing and
the return circuit’ for the traction power supply installations. For systems not
endangered by the traction power supply, the applicable standards are IEC62305 and
BS 7430.
2.1 Purpose
This document outlines a system-wide earthing and bonding strategy for all systems
and sub-systems that will be available on the SSP Line Project.
The statements and parameters contained herein relate only to lightning and surge
protection for systems and sub-systems.
Malaysia climatic condition which is wet and humid makes the sky cloudy and easily
developed into the thunder cloud. The humidity factor makes it easy for high charged
thunder cloud to discharge and is called lightning. This condition has made Malaysian
to experience one of the highest lightning rate in the world.
The following shall be noted about lightning activity in Malaysia
The isokeraunic level in Malaysia is about 250 thunderstorm -days/year
Based on IEC-62305, this translates to about 25 flashes/sq.km/year.
The average lightning strike is about 37kApeak electrical current with a mean deviation
of 18.4kA. The highest recorded lightning strike was 352kA, peak electrical current with
about 13.5% of strikes around 100kA, and 0.3% at 200kA.
3 SYSTEM DESCRIPTION
The system protection under this scope is divided into two parts that is the lightning
protection system and the surge protection system.
Based on the Malaysian average lightning discharge current peak is 37kA, is therefore.
The Lightning Protection Level II shall be used for the design of lightning protection
system.
Lightning protection system shall be designed to MS IEC 62305. Zoning principles shall
be adopted as in the illustration below which shows an example of the four general
zones.
The Lightning Protection System shall have air termination system, down conductors
and earthing. Bonding shall also be included to minimize the touch and step potential
difference at any two points during lightning strike.
Lightning Protection Designed shall comply with MS IEC 62305 Standard.
4.3.1 Air Terminations
The external Lightning Protection System is intended to intercept direct lightning
flashes to structures and conduct the lightning current from the point of strike to the
ground safely.
There are three methods in deciding the layout of an air termination network. As shown
in Table 2 of MS IEC 62305 Standard, analysis has to be made in selecting the air terminal
layout. Metallic roofing can be regarded as a natural component and can be used as an
Air Termination if its thickness is not less than the value stated in MS IEC 62305-3.
copper cable be installed from the horizontal conductors’ down to earth electrodes at
ground level at every pier or at regular distances as calculated in the design. Down
conductors shall have their own path and not share a common path with any other
conductor.
Other protection on the viaduct shall include SPDs and earth metallic shielding for
services. SPDs of suitable protection levels shall be used where deemed required. All
SPDs shall be installed at proper locations so as to achieve their purpose.
When masts are erected along the viaduct, a lightning protection conductor shall be
installed the full height of the mast and connected to an air rod / terminal which shall
be fixed at the top of the mast. The conductor shall be connected to the viaduct tinned
copper tape lightning protection bare conductor at nearest point along the viaduct. The
services leading to the masts shall be bonded to the lightning protection system via
SPDs. A rolling sphere or angle method shall be used to ascertain the protection zone
coverage. Where other systems metallic structures are the highest point they shall be
connected to the lightning protection.
Figure 4.2 is an indicative sketch showing the position of the copper conductor running
along the parapet wall, in this instance connected to a handrail. Note that the horizontal
conductor is 25mmx3mm bare tinned copper tape.
4.3.4 Protection for Tunnels
Lightning is not a direct problem within the tunnels, thus, no separate lightning
protection system is required however, it is possible for surges to be induced by
lightning or from other causes. Surge protection shall be applied to all cables which
enter into the tunnels as per the viaduct. For cables and equipment within tunnels,
surge protection shall be applied and designed according to MS IEC 61643-12 and MS
IEC 61643-22. Proper bonding of all metallic casing of the equipment and metallic object
shall be done to ensure equal potential due to lightning discharge current induction
Care shall be taken during design to restrict lightning strike surges from entering the
tunnels along metallic structures.
4.3.5 Protection for Elevated Stations and Above Ground Structures
Lightning protection shall be provided for all above ground structures of underground
stations and elevated stations. Where any part of the lightning protection system is
simultaneously accessible with exposed conductive parts or extraneous conductors on
the structure, they shall be bonded together to avoid the danger of touch potential, but
if any equipment is connected back to the electrical safety earth system it shall not be
connected to the lightning protection system. The first priority shall be to ensure all
System equipment is not installed close to any part of the lightning protection system
or physical shielding provided to prevent simultaneous touch.
Insulated conductors shall be used, where required, to assist in avoiding “flash over” of
lightning current from the down conductors to the surrounding objects or simultaneous
accessible touch.
Surge protection devices (SPD) shall be provided to circuits entering the equipment. On
detection of a lightning current surge the SPD shorts the circuit conductors to earth and
diverts the surge current to earth to avoid the lightning surge from damaging the
equipment. The distance of the earthing wire between SPD and earth shall kept is short
as possible.
Further protection against electromagnetic interference (EMI) due to lightning can be
provided by using shielded cables or installing the services cables in metallic conduits.
The metallic conduits shall be connected to the electrical safety earth. Where possible,
fibre optic cables can be considered as an option to avoid EMI from lightning by
induction.
High current lightning transient surges induced into the metallic cable conductor will
result to high voltage surges at the electrical or electronic equipment. The surges are
conducted or induced in the power, signal or communication cable as follows:
• By Conduction
• By Inductive coupling
• By Capacitive effect
• Due to Earth Potential Rise.
The above effect occurred not only within the building but it can also happen hundreds
of meters away from the building which the power, signal and communication cables
are laid and connected to electronic equipment in the building.
This high voltage surges can easily damage the electronic component or at least degrade
the component performance.
Due to the Malaysian climatic condition of high lightning activities, external surge
protection shall be provided and properly designed for all systems consisting of
electrical or electronic equipment. The Electronic equipment used in the systems and
facilities buildings, depots, mounted on poles and in equipment boxes on the track side
shall be protected against lightning transient surges. Cables for Power, signal, control
and communication are all connected from outdoor equipment to electronic equipment
in their respective control rooms. The design of the SPS shall ensure surge protective
devices (SPD) are correctly selected, positioned and installed. Malaysian lightning
conditions are required to be considered during the system designed, which should be
to MS IEC 61643-12 Standard for power and MS IEC 61643-22 for extra low voltage and
enhanced to meet local climatic conditions.
The high frequency of lightning surges requires that the SPD selection be able to
withstand this condition. Hence power SPD shall have live-neutral, live-earth and
neutral-earth protection or a full mode protection. A modular type of SPD will generate
high impedance at the contact due to frequent surges and will increase the let-through
voltage of the SPD. Permanently connected components shall be used in the SPD to
avoid this effect.
The Power line SPD is to be connected to the incoming power circuit. The failure of the
SPD will have no effect on the electrical power system if it remains open circuit.
The following are some of the parameters that will affect the selection of SPDs:
a) kA rating which affects the life of the SPD. This shall take into consideration of the
high lightning flash density in Malaysia, and also that of re-strikes which will stress
SPDs even more.
b) Let-through voltage of the SPD is the voltage that was set to limit the transient
over voltages or surges. It is critical to select the SPD which has the let-through
voltage match or lower than the equipment withstanding voltage.
c) It is important that SPDs installed in succession or in sequence, be coordinated
in order that the intended operation is achieved. For this coordination to occur
there should be sufficient impedance between successive SPDs
d) It is critical that the selected external SPD be coordinated with any surge
protective device or surge protective component that is built into the equipment.
Failure to coordinate this will very likely result in the in-built SPD preventing the
external SPD from firing, until the in-built SPD fails. This then normally results in
failure of the equipment such as printed circuit board tracks vaporize as the tracks
cannot handle the high kA, or the internal SPD components just short-out the
card.
e) It is also critical to ensure that if any device has a built-in SPD, then it may cause
upstream earth leakage devices to trip, in which adequate measures shall be
taken to avoid this situation
f) The rated current of the load - in the case the SPD carries the load current through
or using series SPD.
g) Cables connecting from line to the SPD and to earth shall be kept to minimum to
minimise the impedance as not to affect the let-through voltage.
h) The risk of Earth Potential Rise - as this will stress the SPD components between
line and earth.
i) Voltage limiting device type of power SPDs are preferred over switching device
type SPDs, as the latter may cause follow through current that can causes short
circuit in the SPD and tripping the system.
j) The Power type of SPDs shall be connected to the power line using switch fuse or
MCB MCCB of four pole type.
k) MS IEC 61643-12 shall be used for low voltage power distribution system with
regards to selection and application.TT vs. TN-S configuration of the power supply
system - the model selected shall take into cognizance of the power supply system
at the point of installation.
l) In the case of extra low voltage MS IEC 61643-22 shall be used in the design of
the SPD system connected to Telecommunication, data and Signalling Network.
m) Selection of SPD for the extra low voltage electronic equipment shall be in
accordance to its operational voltage level, frequency and also considering the dB
losses. The signal level shall not be unduly attenuated and noise shall not be
introduced when the SPD is connected to the system.
Lightning surges can be induced into cables in various forms and ways. The design of
the surge protection must ensure that the risk level of damage or injury is reduced to a
level as low as reasonably practicable. To achieve this result the SPD device shall be
installed in zones and must be coordinated with a suitable strength and let-through
voltage as indicated in Table 5.1
The SPD shall be provided at the end of conductors, before entering and after leaving
the equipment. If two equipment’s are linked by a conductor exceeding 10m then an
SPD is required for the second equipment.
The Recommended Rating of the Systems Power SPD and its Zone of protection is as
shown in the Table 5.1.
The earthing of surge protector shall be as near as possible to the earthing point.
Appropriate earthing cable size shall be used to minimize the net impedance to the
surge protector that can affect the rated let-through voltage. The earth resistance shall
be less than 5 ohm
Surge Arrestors will be installed on the 132kV system both at the incoming termination
from TNB and before the transformer bushing. The Surge Arrestors shall be bonded to
the Bulk Supply Station grid earthing system.
Medium Voltage Surge Arrestors shall be provided on the Secondary side of the
33kV/415Vtransformer, as well as on the outgoing feed to each of the UPS units and
non-essential DB’s. The Surge Arrestors shall be grounded to the Main Earth Bar.
As for the 33kV cables along the viaduct the surge arrestors shall be fitted at both end
point of the termination at the transformer or switchgears that shall be routed to the
nearest main earth pit .
Medium Voltage Surge Arrestors shall be provided on the Secondary side of the
33kV/750V transformer/rectifier, as well as on the outgoing feed to each of the traction
circuits. The Surge Arrestors shall be grounded to the Main Earth Bar.
To maximise the performance and reliability and to obtain the lowest possible let-
through voltages, the ac surge protection shall be integrated into electrical distribution
equipment including distribution and branch panel locations. The SPD shall protect all
modes of the electrical system being utilized such as L-N, L-G, L-L and N-G. A minimum
category C shall be applied for the Surge Current Capacity.
All SPD’s installed on the line side of the service entrance disconnect shall be Type 1 for
the load side of the service entrance disconnect shall be Type1 or type 2.
The application of SPDs for LV Power shall be in line with:
• IEC 61643-12 Low Voltage Surge Protective Devices - Surge Protective Devices
Connected to LV Power Distribution Systems - Selection & Application Principles
• IEC 61643-22 Extra Low Voltage Surge Protective Devices - Surge Protective
Devices Connected to Telecommunication & Signalling Networks - Selection &
Application Principles.
Table 7-1 : Minimum Surge Current Capacity based on ANSI/IEEE C62.41 location category
Adequate care shall be taken in the selection and discrimination of protective circuit
breakers (such as MCBs, RCCBs and ELRs) and fuses to reduce the risks of nuisance
tripping, including that due to static leakage currents, cumulative static leakage
currents, inrush currents, capacitive leakage trips during lightning activity, and
cascading trips during Neutral-Earth faults. Designers shall take note of the following:
a) MCBs - there are 'D' -curve MCBs in the market, which are more immune from
nuisance tripping as when inrush currents occur – example. feeds to UPS, feeds
to racks with many equipment
b) RCCBs - the standard G-type RCCBs offer some level of immunity to tripping
during lightning or switching surges. However this is minimal.
c) RCCBs are also available to minimize the risk of trips during lightning. S-type
RCCBs are also on option, but this incorporates a time delay, and the risks
associated with this delay should be assessed.
d) Auto-reclose systems (with limited retries) is another possibility for RCCBs in
distant locations.