(All observations/Statements are based on either BIS, IEEE or IEC Standards)

In the Foreword to IS: 3043/1987 in item 0.12, it has been stated that In the preparation of the
Code, assistance has been taken from the following: IEC, ANSI/IEEE Std. 142
Objectives of the Study
1. Comparison of Copper-Bonded rod and cast-iron plate in electrical earthing.
2. Can Copper-bonded rod replace plate earth electrode in HT (up to 33KV) Installations?

Copper-bonded steel rod is low carbon, high-tensile strength steel rod with a protective
coating of 99.9% pure electrolytic quality copper. Copper is molecularly bonded to nickel
sealed steel rod to eliminate steel to copper merging.
Current Carrying Capacity-Comparison
As per clause 10 of IS 3043/1987
Maximum permissible current density I = 7.57 x 10
3
A/m
2
at the surface of a plate earth electrode x t
Where = resistivity of soil in ohm meter
t = duration of earth fault in sec (3sec for HT-Installation)
As per Clause 4.1.6 of IEEE Std. 142/2007
Maximum permissible current loading I = 1140 x d x l Amp
Capacity of a rod electrode x t

Where d = diameter of the solid rod in mm
l = length of electrode in meters
= resistivity of soil in ohm centimeter
t = duration of earth fault in sec. (3 sec for HT- installation)
te (whether C I ,G I or copper) and 2 No 32mm dia 3.0m long C.B rod are equivalent to 1 No 12
A Study on the Merits of Copper-Bonded Rods in Electrical Earthing
Based on the above ,the current loading capacity of 1 No 19mm dia 2.5m long C.B rod is
equal to that of 1 No 600 x 600mm plate (whether C I ,G I or copper) and 2 No 32mm dia
3.0m long C.B rod are equivalent to 1 No 1200 x 1200mm cast iron plate.



Resistance to Earth of Electrodes

The resistance to earth of rod and plate electrode is almost the same
except for plate of size 600 x 600mm which is very high.
The chart shows the comparison and the No. of electrodes required to dissipate a fault
current 7.87kA (For 11 KV Installation) in a soil of resistivity 100 Ohm-meter. From the above
chart ,it can be seen that where 7 No C.I plates of Size 1200mm x 1200mm are required ,only
13 No 32mm dia 3.0m long or 16 No 25mm dia 3.0m long copper-bonded rods are sufficient.
Chart
Electrode
Type
Size Resistance
to earth
No of
electrodes
required
Combined
earth
resistance
G I Plate 600 x 600 x6.15mm 52 25 NO 4.5
C I plate 1200 x 1200 x 12.5mm 26 7 NO 6.2
Copper
bonded rod
19mm dia x 3.0m long 30 21 NO 2.9
Copper
bonded rod
25mm dia x 3.0m long 29 16 NO 3.5
Copper
bonded rod
32mm dia x 3.0m long 28 13 NO 3.8
G I pipe 38mm dia x 3.0m long 27 Not Comparable Not
Comparable

The formula for calculating the No.of earth electrodes required to dissipate a fault current of
I
SC
Amps is
No of plate earth electrodes required = I
SC
x




(As per IS: 3043/1987)
No of rod earth electrodes required = I
SC
x


(As per IEEE: 142/2007)
Where I
sc
= Max Fault Current in Amp, P = Resistivity of soil in Ohm-cm.
A = Area of both side of plate in m
2

t = Duration of fault (3 sec for HT Installation) in se

t = Duration of fault (3 sec for HT Installation) in sec
d = Dia of rod in mm
l = Length of rod in meter.












5m
12 No 32 mm dia x 3.0 m long rod
(125m
2
)
5m
mm
5m 5m
5m
5m 5m 5m 5m
Fig: 1
5m
5m
5m
5m
5m
5m
5m
5m
5m
5m
5m
5m
Fig: 2 Total area 86m
2
8m 8m
8m
8m 8m
8m
8m
8m
8m
8m
8m 8m
Fig: 3
6 No C I plates
( 1200 x 1200 x 12.5mm)
128m
2
6 no
Plate 110m
2
6 No
Rod 43m
2
6 No
Rod 43m
2
5m
Fig: 4
5m
5m
For 12 nos C.B rods - 6 No cast iron plates are required. These rods can be installed in a hollow triangle,
square or rectangle. 12 nos of rods (32mm dia 3.0m long) can be placed in a rectangle or hollow triangle
as shown in fig.1 and fig.2. The area required for rectangular placing is 125m
2
and for triangular placing is
86m
2
.For installing equivalent no .of plates with same current loading capacity, we require 128m
2
or
110m
2
for rectangular and triangular placing respectively.(Fig.3 and Fig.4)
From the above it can be seen that the land required to install cast iron plate electrode is more than the
area required to install equivalent current loading capacity C.B rod electrodes. For installing cast iron
plate of size 1.2 x 1.2 meter, we require a min. of 2m x 2m area and a min depth of 3.2m.for excavation.
In most premises, this much of space may not be available
In the present scenario, even 50m
2
free land in city limits will be a luxury .Electrical engineers will be
forced to install these plates at shorter span, ultimately sacrificing the effectiveness of fault current
dissipation.




Cost Effectiveness Comparison
The cost of C B rod is very less compared to C I or G.I plates.
C.B rod can be used in soil by driving while for plate large and deep pits to be excavated.
The rod can be directly installed; no welding or drilling is required.
C.B rods can be used even on rocky terrain by drilling a hole and inserting the rod.
C I/G I plate cannot be installed in rocky area such as granite quarries.
The installation charges of C.B rods are very less.
Labour charge for installation of C I/G I plate will be high and additional strips are required for
effecting the connection. In fact, the total installation cost alone will be more than the cost of
one no plate. But C.B rod can be driven to ground easily.
Life Span
Corrosion is the major factor affecting the life of an electrode. Protecting the steel electrode by
molecular bonding of copper is a globally accepted and efficient method to avoid corrosion. The
percentage of corrosion of different materials in the same soil in 10 years life is shown in chart
given (as per IS: 3043/ 87).
Earthing Materials Corrosion in 10 years by weight
Copper 2%
Copper Bonded 2%
Hot Dipped Galvanized 5%
Cast Iron 22%

Efficiency
Copper-bonded rods are also available with flat strips so that an efficient
connection between the electrode and earth leads is ensured. In cast iron
Plate earth, most of the joints between the plates and external strip connection
are under-ground which will be affected by corrosion. In copper bonded rods
no such underground connections. More over the external joints can be
protected by tinning. The copper bonded rods allows copper to copper
connection. Even G I strips can be connected to these rods after tinning both ends.

Conclusion:

Copper bonded rods can very well replace cast iron plates forLT/HT installation earthing.
Such rods are widely used all over the world just because of the easiness of installation,
cost effectiveness, more life, efficiency and low resistance to ground.



No.of copper- bonded earth rods for earthing of an LV/MV installation based on
maximum incomer Fuse/MCCB rating (Assuming Soil Resistivity as 100 .m)
Rating of the maximum
incomer fuse or MCCB in the
installation
Size of Copper-Bonded
Earth rod
No.of rods required
Dia in mm Length in M
16 A


14.2


1.2/1.5


1
25 A
32 A
40 A
50 A
16.0 1.5 1

63 A
16.0 2.0 1
17.2 1.5 1

80 A
16.0 1.5 2
16.0 2.5 1

100 A
16.0 2.0 2
17.2 1.5 2
20.0 2.5 1

125 A
17.2 2.5 2
20.0 2.0 2

160 A
25.0 2.5 2
20.0 2.5 2

200 A
25.0 3.0 2
32.0 2.5 2
20.0 3.0 3

250 A
32.0 3.0 2
32.0 2.5 3






For 125 A fuse, Max. let through energy I
2
t (Max) = 140 x 10
3
A
2
Sec - (eq 1)
Assuming the soil resistivity as 100 Ohm-meter ,for earthing an installation with maximum
incomer fuse rating of 125 A we use 17.2mm dia 2.5m long rods,
Current loading capacity of 1 no rod = 1140 x 17.2 x2.5 A
100 x 100 x 3
Squaring, we get (1140 x 17. 2 x 2.5)
2
A
2
- (eq 2)

10
4
x 3
In equation 1, I
2
t (Max) = 140 x 10
3
A
2
Sec, take time as 1 sec
Equating 1 & 2 we get 140 x 10
3
A
2
x 1 = (1140 x 17. 2 x 2.5)
2
A
2


10
4
x 3
= 240.296 x 10
3
A
2
= 80 x 10
3
A
2

14080=1.75 say 2 nos 3
So for earthing the feeder 2 nos 17.2mm x 2.5m rods are required
2 nos 17.2mm dia x 2.5m long copper bonded rods are sufficient for earthing LV/MV installation
with loads where incomer fuse rating is 125 A (Suppliers LV supply is availed and earthing
system followed is T-T system)
Similarly for 16 A to 40 A fuse 1 no 14.2 x 1.2m long rod is sufficient
And for 80 A 1 no 16mm x 2.5m or 2 nos 16mm x 1.5m rods are sufficient.
Note:
1. The length of rod shown is the minimum length. Longer rods may be used to reach soil
with more moisture content.
2. The chart shows the no. of Copper-bonded rods required in an LV/MV installation where
Suppliers LV supply is availed (in a T-T system earthing)
3. The fuse ratings are the maximum income rating, not the rating of phase protection
device of individual equipment.
4. The calculations are based on the maximum let-through energy of the protective device.
(Ref: IEC : 60269-1 Low voltage fuse-general requirements)
5. No.of earth electrodes shown are the maximum no. of C.B rods. However in an MV
installation, minimum 2nos earth electrodes are to be provided as per standards.
6. The soil resistivity at the site is assumed as 100 Ohm-meter
(For decreasing the soil resistivity earthing compound should be used according to the
soil resistivity. For more details visit our website www.excelearthings.com



No.of copper bonded rod earth electrodes required for earthing of
3 phase,415V Alternators.
Generator
Capacity KVA
Full load
current A
Size of Copper-bonded rod No.of rods
Upto 10 KVA 14 A 14.0mm dia x 1.5 m long 3
15 KVA 21 A 14.0mm x 1.5m long
or
14.0mm x 2.0m long

3
15 KVA to 63 KVA 88 A 17.2 mm x 2.0m 3
63 to 82.5 KVA 115 A 20.0mm x 2.5m 3
100 KVA 140 A 20.0mm x 3.0m
or
25.0mm x 2.5m
3

3
125 KVA 175 A 25.0mm x 3.0m 3
160 KVA 224 A 25.0mm x 3.0m 4
200 KVA 280 A 25.0 mm x 3.0m
or
32.0mm x 3.0m
5

4
250 KVA 350 A 25.0mm x 3.0m
Or
32mm x 3.0m
6

5

For 250 kva, 415V Alternator, rated current = 250 x 10
3
= 350 A
3 x 415
Sub-Transient reactance = 0.12 p.u therefore max .fault current = 350 = 350 x 8.3 = 2900 A
.12
From the above the maximum fault current of an Alternator will be 8.3 times its rated current.
This is the Sub-Transient current that may develop during a bolted short circuit on the
alternator assuming the limiting Sub-Transient reactance as .12 or 12%
Based on this, a chart is prepared showing the No.of earth electrodes required for earthing of
an Alternator assuming the soil resistivity as 100 Ohm- meter and fault clearing time as 3 sec
For 250kva Alternator, Isc = 2900A, p =100 x 100-cm, t = 3sec, Using 25mm dia 3m long
copper bonded rod
No of rods required = Isc x


= 2900 x 100 x 100 x 3 = 5.8 say 6 nos

1140 x 25 x 3