SAE and Alectra gave an amazing presentation at EDIST 2018 about corrosion-proof, extended life ground plate called the ConduDisc. Alectra Utilities is one of the first utilities in Ontario to install the ConduDisc.

1. ConduDiscTM
the
Corrosion-Proof, Extended-Life
Ground Plate_________________________________________________________________________________________________________________
Presentation at
EDIST 2018, Operations Track B
Kris Cox, Utility Technical Advisor, SAE Inc.
Joe Crozier, Standards Engineer, Alectra Utilities
2018.01.18
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2. About SAE
• Privately held company, founded in 1990
• 26 years experience w/ grounding products &
services
• Production plant located in Canada
• Product development
• 13 years working in cathodic protection
• 7 years AC mitigation design and construction
• Offices in Canada and USA
• Technical and engineering support

3. Partial Client List
Commercial/Industrial
• Lowes
• Brosz Group of Co’s
• Piotrowski Consultants
• PBW High Voltage
• Powertel Utilities
• Peak Engineering
Government
• District Municipality of Muskoka
• DND
• Ministry of Natural Resources
• National Aeronautics and
• Space Administration ( NASA )
• Ontario Provincial Police
Telecommunications & Broadcast
• Bell Canada
• British Telecom
• Ericsson Communications Inc.
• Rogers Communications/Bell Mobility
• Telus
• T-Mobile, Verizon, Sprint PCS, NBC
• CBC, CTV
Power
• American Transmission
• Alectra Utilities
• CFE (Mexico)
• NB Power
• Hydro One / Ontario Hydro
• Santee Cooper
• Transalta Utilities
• TransCanada Energy

4. SAE Product Support &
Technical Services
• Soil resistivity testing (deep soil profiling)
• Grounding system audits
• System resistance (R-Value) testing
• Forensic analysis
• Lightning protection
• IEEE and ESA approved design, supply and install

5. SAE Advantages
• Local products and services
• Ability to offer full engineering support
• Experience with grounding challenges in Canada
Why Pay Attention to Grounding?
• Many owners have grounding concerns and require expertise
• Infrastructure aging is necessitating the review of existing grounding systems
• Proper grounding will minimize owners potential liability concerns

6. About Alectra Utilities
• Created in early 2017 through the amalgamation of Enersource
Hydro Mississauga, Horizon Utilities, Hydro One Brampton, and
PowerStream
• Distributes electric power and related services to approximately
one million residential and business customers in 15 communities
across a 1,500 sq. km.
• Service territory in Ontario’s Greater Golden Horseshoe area:
Alliston, Aurora, Barrie, Beeton, Bradford West Gwillimbury,
Brampton, Hamilton, Markham, Mississauga, Penetanguishene,
Richmond Hill, St. Catherines, Thornton, Tottenham and Vaughan
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8. Learning Objectives
1. Understand and mitigate the corrosion of copper and steel in
electrical distribution utilities’ grounding systems
2. Develop an understanding of semi-conductive materials for use in
grounding systems
3. Understand the potential benefits that Alectra Utilities has been
identifying during its ConduDisc pilot project
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9. Abstract
Alectra Utilities is one of the first utilities in Ontario to install the ConduDisc
The ConduDisc is a grounding solution developed by SAE Inc. that significantly
increases the life and reliability of grounding systems
Manufactured using a conductive carbonaceous polymeric molded material
ConduDisc significantly outlasts the competition by reducing corrosion by
99.9%
Alectra Utilities will continue their discussion outlining the importance of good
grounding practices that they started during their 2017 EDIST presentation
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10. Lightning W5 (from EDIST 2017)
• Median first stroke 30 kA but can exceed 100 kA
• Microsecond event times (BIL wave 1.2 x 50 μs)
• 2.34 million flashes/year in Canada, about once every three seconds
during the summer months
• Hot spots: southwest and southcentral ON
southwest MB & southeast SK
central AB east of Rockies
northeast BC (Peace region)
• Possible 50% increase in flash density by 2100 (Science, 14 Nov 2014)

11. Ontario Lightning Frequency
11
Source: Environment Canada

14. Seever’s Grounding Results
14 Source: O.C. Seevers, P.E., Power Systems Handbook
• Higher ground resistance correlated
directly with high rate of equipment
failure
• Target ground resistance at 10 Ohms
• Reduction of equipment failure by
80% with proper grounding
• Benefits of arresters with proper
grounding

15. 15
Pole Ground Resistance

16. •Failure rate almost exactly proportional to median ground ohms
16
Source: PowerStream
Pole Ground Resistance

17. 17
Source: PowerStream
Ground Resistance Standard

18. ConduDiscTM Benefits Investigated
1. How much are job costs reduced, compared with ground rods?
• Piggy-backed the ConduDiscTM pilot project on our program for replacing
deteriorated single-phase pad-mounted transformers (minipads)
• Compared time and material costs (N = 13 at Alectra Utilities)
2. How much is ground resistance reduced, compared with rods?
• Measured ground resistance with clamp-on ground resistance meter
• Several utilities, including Alectra, are investigating this (N = 1 at Alectra)
3. How much is grounding system corrosion reduced – and life
increased – compared with metal ground rods?
• SAE has extensively documented this benefit
18
$
Ω
Years

19. First Day of Pilot Project
October 31, 2017

21. Remove padmount
transformer from
replacement program

22. Vacuum area for
ConduDisc and copper
ground grid

23. Put ConduDisk in
trench and amp
together tails and
make connections in
transformer

24. Add Conducrete®

25. What is Conducrete®?
• Conducrete is a Conductive, Cementitious and Carbonaceous Material
that enhances the performance, reliability and longevity of grounding
systems
• Conducrete is: Ground enhancement material
• Conducrete is: Conductive material that sets
• Conducrete is: Conductive backfill

26. Once installed and cured, the Conducrete® conductive cement electrode
surround:
• Creates excellent contact with surrounding soil
• Reduces impedance (larger electrode surface area), reduce R value
• Reduce GPR, step and touch potentials
• Enables dissipation of lightning
• Prevents theft and corrosion
• Conducrete® is environmentally neutral
Conducrete® Advantages

27. Add ConduFlow

28. Mix ConduFlow

29. What is ConduFlow?
• ConduFlow is a long-term solution for utility pole, padmount transformer,
and tower grounding virtually eliminating electrodes corrosion
• ConduFlow is: Liquid ground enhancement material
• ConduFlow is: Conductive pourable material that sets
• ConduFlow is: Conductive Backfill

30. Once installed and cured, the ConduFlow conductive cement electrode
surround:
• Significant dust reduction
• Pourable – no need to transfer to mixing container
• Offers 96% reduction in copper corrosion
• Environmentally neutral
• Liquid installation adheres well to native material
• Extends the life of the grounding system
• Is black when dry
ConduFlow Advantages

31. ConduFlow
covering
ground grid
and
condudisk

32. Make sure all of
conductor is covered
in Conducrete or
ConduFlow

33. Backfill vacuum trench

34. New padmount & grid
installed
3.6Ω

35. Scenario 1:
• Cost estimate based on 13 ConduDisc installs done in Markham,
and include labour, materials, vac truck, and work order burdens
• Estimate includes only those cost components attributable to the
replacement of the grounding system
• Work done by contractor
• TXPD and grounding system replaced the same day
• Savings, ConduDiscTM compared with 4 ground rods = $2,285
35
ConduDisc Job Cost Savings

36. Scenario 2:
• Cost estimate based on 13 ConduDiscTM installs done in Markham,
and include labour, materials, vac truck, and work order burdens
• Estimate includes only those cost components attributable to the
replacement of the grounding system
• Work done by Alectra Utilities
• TXPD and grounding system replaced the same day
• Savings, ConduDiscTM compared with 4 ground rods = $1,246
36
ConduDiscTM Job Cost Savings

37. Scenario 3:
• Cost estimate based on 13 ConduDiscTM installs done in Markham,
and include labour, materials, vac truck, and work order burdens
• Estimate includes only those cost components attributable to the
replacement of the grounding system
• Work done by contractor
• TXPD and grounding system replaced different days
• Savings, ConduDiscTM compared with 4 ground rods = $17
37
ConduDiscTM Job Cost Savings

38. Scenario 4:
• Cost estimate based on 13 ConduDiscTM installs done in Markham,
and include labour, materials, vac truck, and work order burdens
• Estimate includes only those cost components attributable to the
replacement of the grounding system
• Work done by Alectra Utilities
• TXPD and grounding system replaced different days
• Savings, ConduDiscTM compared with 4 ground rods = $774
38
ConduDiscTM Job Cost Savings

39. 39
ConduDiscTM Job Cost Savings

40. Conclusions:
• Job cost savings of at least $2,000 are possible by installing two
ConduDiscsTM instead of four ground rods for grounding electrodes
• Since two ConduDiscsTM c/w 12 metres 2/0 Cu cost $921, most of
the job cost reductions are due to labour cost reductions
• Savings vary greatly depending who does the work
• Savings increase significantly if all work done the same day, TXPD as
well as grounding system replacement –
mobilization/demobilization costs (travel time, etc.) cut in half
40
ConduDiscTM Job Cost Savings

41. Further possible job cost reduction measures to be investigated:
• Use ConduCreteTM instead of ConduFlowTM
• Use 1/0 Cu (or smaller) ground wires instead of 2/0
• Treat TXPD+ConduDiscTM replacement as a single unit of work for
program planning purposes, instead of piggy-backing the grounding
system work on top of the transformer replacements as we did
during the ConduDiscTM pilot project
• Work with contractor to identify other improvements on a
continuous efficiency improvement (learning curve) basis
41
ConduDiscTM Job Cost Savings

42. • Focus of Nov-Dec 2017 work: identify potential job cost savings
• Only one set of before/after ground resistance readings taken:
• BEFORE: 5 Ω, measured on NW tail to TX ground bus with SE tail
disconnected
• BEFORE: 10 Ω, measured on SE tail to TX ground bus, NW tail
disconnected
• AFTER: 3.6 Ω on first reading, 3.2 Ω on second
• As ConduFlowor Conducrete cures in the week after installation,
ground Ω will fall another 20 per cent, to approximately 2.6 Ω
• Ground resistance measured after several installs from 1.6 to 11 Ω
• Focus of spring 2018 work: identify range of reductions in ground Ω
42
Ground Ω Reduction

44. Challenging Soil
Conditions

45. Roots permeating
soil

46. Limited space for
step & touch
potential zone

47. Initial ground
resistance reading
10.0Ω

48. ConduFlow liquid

49. Sand back-fill

50. Post install
ground reading
1.6Ω

51. Galvanized Steel Rods
● Underground Corrosion” –National Bureau of Standards Circular 579 From 1910 to 1955, the
National Bureau of Standards conducted an extensive underground corrosion study in which
36,500 specimens, representing 333 varieties of ferrous, nonferrous, and protective coating
materials were exposed in 128 test locations throughout the United States.
● It is widely regarded as one of the most comprehensive corrosion studies ever conducted.
ERICO will use this study to show that rods coated with 10 mils of copper can reasonably be
expected to perform well in excess of 40 years in most soil types. It will also be shown that
galvanized rods coated with 3.9 mils of zinc should be expected to perform for only 10-15
years in most soil types. The intent is to highlight the importance of choosing the proper
electrode for a given application by showing the difference in life expectancy
● https://www.erico.com/catalog/literature/LT0540.pdf
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52. Corrosion
• The most commonly used earthing/grounding materials worldwide are copper clad steel, copper and
galvanized steel. The effect of earthing/grounding material corrosion on the reliability of electrical
installations and electronic equipment is of paramount importance.
• Copper has an outstanding history of corrosion resistance in most underground environments. Copper
does not naturally corrode in most clays, chalks, loams, sands, and gravels. Certain aggressive soil
conditions, however, can cause it to corrode.
• The basic prerequisite for corrosion is the presence of appreciable amounts of moisture. Other factors
that can facilitate the corrosion process include soils having: elevated concentrations of sulfate, chloride,
ammonia compounds, or sulfide; poor aeration, which supports anaerobic bacteria activity; large
amounts of organic or inorganic acid; and large oxygen or neutral salt (especially chloride) differentials.
Copper is also subject to corrosion by stray DC electricity.
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55. SAE Grounding Products:
Prevent Corrosion

56. Ground Rod Resistance -
Simplified

57. Design Application Standards
Overhead Poles

58. Installed rods

59. Installed rods

60. Urban Installations
Initial Reading ∞Ω
Ground rods should never be installed in crushed stone.

61. Urban install with
ConduDisc & ConduFlow
9.0 Ω

62. Ground Resistance Measurements taken
Dec 7, 2017 Barriefield (Kingston, ON)
Pole ID
Prova
Model
5601
AEMC
Model
6416 Grounding
20702 136 140 ConduDisc with ConduFlow on pole butt with culvert
20700 154 160 ConduDisc with ConduFlow on pole butt with culvert
20706 937 950 Ground rod located inside culvert with limestone dust
20711 284 295 Ground rod located outside culvert

63. ConduDiscTM Benefits Investigated
1. How much are job costs reduced, compared with ground rods?
• Potential savings identified to date: up to $2,000 per install
• Savings depend on: labour/material costs, crew experience, job planning
• Continuous efficiency improvement may yield further cost savings
2. How much is ground resistance reduced, compared with rods?
• 28 per cent improvement (from 5 to 3.6 Ω) measured at start of pilot project
• Focus of 2018 work will shift more toward quantifying ground Ω
improvement
3. How much is grounding system corrosion reduced – and life
increased – compared with metal ground rods?
• SAE has extensively documented this benefit
63
$
Ω
Years

64. ConduDiscTM pilot – status & plan
Thank you for your consideration!
Questions?
Comments?
Suggestions?
on
ConduDiscTM – the Corrosion-Proof, Extended-Life Ground Plate
for Kris, Jeff, Joe, Todd, Mackenzie, Sean
64