There s money to be saved.
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- Rodney Adams
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1 TIPS OF THE TRADE There s money to be saved. C opperclad ground rods cost too much. Changing to galvanized steel can take up to 58 percent out of ground rod cost. Based on 1995 average prices, a 5 / 8 -inch 8- foot-long copperclad ground rod cost $6.25. Galvanized cost for the same size was $3.94 for a savings of $2.31 per rod. Calculate the savings over a utility s annual ground rod usage and the savings are substantial. There is little difference in electrical resistance between galvanized and copperclad rods; and, in any event, the resistance of the ground rod is negligible when compared to the resistance of the earth itself. Also, use of copperclad rods requires special care to prevent galvanic action and rapid corrosion of anchor rods, anchors, piles, and associated hardware. These are the major conclusions which may be drawn from a recent comparison study of galvanized-steel ground rods and copperclad-steel ground rods. Resistance Study Observation of a ground rod system shows that its resistance to the earth may be considered to have three components. 1. The resistance of the ground rod itself Ground rods are adequate in cross-section so their resistance is a negligible part of the total resistance of the ground rod system. The resistance of a 5 / 8 -inch mild-steel ground rod 8-foot-long is ohms, as calculated from the resistivity of mild steel. 1 1
2 2. The interface resistance between ground rod and earth Study by the National Bureau of Standards has shown that for a ground rod free of grease or paint, the contact resistance between the ground rod and earth is negligible Resistance of earth around ground rod The resistance of the earth around a single ground rod is commonly calculated from the following equation developed by H. B. Dwight. 3 ρ R = 2 π L [ ln ( 4 L a ) -1 ] Where ρ = Average soil resistivity - (ohms-cm) L = Ground Rod Length - (cm) a = Ground Rod Radius - (cm) R = Resistance of Ground Rod to Earth - (ohms) Figure 1 shows the earth resistance for a 5 / 8 - inch-diameter ground rod (8-foot and 16-foot lengths) in soils of various resistivities as calculated by the earth resistance formula. Note that the resistances are high as compared to the resistance of the ground rod itself. In fact, the earth resistance is 600 to more than 10,000 times the resistance of the ground rod itself. Corrosion of Ground Rods The earth s resistance is by far the major component of resistance in a grounding system. So, from an electrical standpoint, galvanized and copperclad rods are nearly identical. However, an installed ground rod should resist corrosion well enough to provide a sufficient metallic cross section throughout its anticipated life. The National Association of Corrosion Engineers conducted a seven-year study of grounding materials at 20 test sites across the nation. (4) The ground rods were examined at 1, 3, and 7 year intervals. The study was conducted both on individual ground rods and on various materials coupled to each other. The data on single copperclad rods, single galvanized rods, single CONTINUED, NEXT PAGE 2
3 bare-steel rods, and galvanized rods bonded to copperclad rods are shown in Figure 2, which compares ground rod weight loss per year for the various materials. Figure 2 shows, as expected, that the copperclad ground rod (A) has better corrosion resistance than the galvanized (B) or bare-steel ground rods (C). The graph also shows that when a galvanized rod is coupled to a copperclad rod (D), as would be the case with a copperclad ground rod and a galvanized anchor rod in a bonded system, a galvanized rod (D) corrodes at a rate of 10 times faster than would be the case if a galvanized ground rod (B) were used. This is one reason Rural Utility Services (RUS formerly REA) suggests the use of galvanized steel for grounding. To quote RUS: A B C D Corrosion Weight Loss (Grams Per Year) Copperclad Ground Rod Galvanized Steel Ground Rod Bare Steel Ground Rod Galvanized Ground Rod Coupled to Copperclad Ground Rod Average corrosion weight loss for 7-year period at 20 sites across the nation. Data from N.A.C.E. driven ground rod year test program Figure 2 Galvanized steel materials are suggested for grounding of all distribution lines, above ground and underground. This is a continuation of practices that have been recommended by RUS since the early 1960s for pole lines and, more recently, for underground construction. (5) The average corrosion rate of 5.6 grams per year of the galvanized ground rod shown in Figure 2 can be shown to represent approximately 15 years of service before the galvanizing is gone. This assumes average coating of 2.26 oz/ft 2 of galvanizing. Chance production SPC records on 5 / 8 - inch ground rods show an average coating of 2.26 oz/ft 2. When the galvanizing is gone, a bare steel rod corrodes at an average rate of 15 grams per year as shown in Figure 2. Assuming this rate for the balance of nominal 30-year service life, or 15 years (30-15=15), the diameter of the ground rod will be reduced by approximately inch. CONTINUED, NEXT PAGE 3
4 Of course, this diameter decrease will cause the ground rod resistance to increase; but as seen below, the increase is negligible. Resistance of 5 / 8 -inch ground rod reduced.019" in dia. = ohms. Original resistance 5 / 8 " ground rod = ohms. Resistance increase = ohms. This corresponds to a resistance increase of 6.4 percent. The resistance increase is obviously quite small when compared to the resistance of the earth as shown in Figure 1 (previous page) (0.01 percent to percent of the resistance of the earth). How to Install Ground Rods Ground rods should be installed near the ground wire and the base of the pole. The rod must be driven to its full length into the ground and, after driven in place must have a resistance less than 25 ohms (National Electric Safety Code Rule 96.8). If the resistance is greater than 25 ohms, an additional ground rod must be used in parallel. The ground wire must be wrapped around the mounting hardware bolt and the mounting hardware tightened firmly to assure a continuing bond. By using Chance galvanized ground rods, you can save money at no sacrifice of performance. Chance has a complete family of rods and the necessary clamps. Talk to your representative and cut your costs. References: (1) Resistivity of mild steel from page 15-6 of Marks Handbook 8th Edition. (2) Grounding Connections for Electrical Systems, O.S. Peters, U.S. Dept. of Commerce, National Bureau of Standards, Technological Paper 108, June (3) Calculation of Resistance to Ground, H.B. Dwight, Electrical Engineering, Vol. 55, December (4) Driven Ground Rod Year Test Program, Final Report, Draft No. 2 September 1971, National Association of Corrosion Engineers. (5) Manual on Underground Corrosion Control in Rural Electric Systems, REA Bulletin , October 1977, Part IV, page 18. 4
5 UNITED STATES HUBBELL POWER SYSTEMS, INC. 210 N. Allen Centralia, Mo Phone: Fax: CANADA HUBBELL CANADA, INC. 870 Brock Road South Pickering, Ontario L1W 1Z8 Phone: Fax: MEXICO HUBBELL DE MEXICO, S.A. DE. CV Av. Coyoacan No Col. Del Valle Mexico, D.F. Phone: Fax: ASIA HUBBELL S.E. ASIA PTE. LTD. 159 Sin Ming Road #05-08 Amtech Building Singapore Phone: Fax: EUROPE HUBBELL POWER SYSTEMS Ronald Close Woburn Road Industrial Estate Kempston, Bedford MK42 7SH, England Phone: Fax: TAIWAN HUBBELL TAIAN CO., LTD. 12th Floor 66 Sec. 2 Chien Kwo North Road Taipei, Taiwan Phone Fax: Fax: skao@hubbell-taian.com.tw Hubbell Power Systems, Inc. ANDERSON POWER SYSTEMS, INC Fax NOTE: Because Hubbell has a policy of continuous product improvement, we reserve the right to change design and specifications without notice. Copyright 2000 Hubbell 210 North Allen Street Centralia, MO & TiPS NEWS View from Vol 3 No 2 April WB 5
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