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Electrical Safety

Lightning Protection Risk Assessment and System Design

We run the IEC 62305 2 risk calculation to establish the protection level your site actually needs, then design the air termination, down conductor, earthing and surge protection to match it

Technical overview

Lightning Protection Risk Assessment
and System Design

Lightning protection is one of the few hazards where the required level of protection is a calculated output rather than an engineering preference. IEC 62305 2 works from the local flash density, the collection area of the structure, the construction and contents, the occupancy and the consequence of loss, and returns a risk that is then compared against a tolerable value. That calculation decides the protection level, and the protection level decides the rolling sphere radius, the mesh size, the down conductor spacing and the surge protective device coordination. Our work runs that assessment properly rather than defaulting to a level and fitting a finial to it, and for a process plant it also covers the parts that are frequently missed: the risk to services entering the structure, the bonding of external conductive parts, and the surge protection of the instrumentation and control systems that carry the real loss potential on a modern site. On a tank farm we work to the additional requirements that apply to flammable atmospheres, where an unbonded floating roof or a poorly earthed vent is the ignition path that matters.

Lightning Protection Risk Assessment and System Design Overview
Engineering process

Lightning Protection Risk Assessment and System Design workflow

Data Collection and Single Line

Verify the single line diagram against the installation, and collect utility fault levels, transformer and cable data, and protective device settings.

Network Model Build

Build the impedance model of the distribution system, including generation, motor contribution and every credible operating configuration.

Fault and Coordination Study

Run short circuit and protective device coordination, since incident energy is governed by clearing time as much as by fault current.

Hazard Calculation

Calculate the hazard at each working point across the operating configurations, and identify where the result is driven by a slow upstream device.

Mitigation Options

Test setting changes, maintenance mode, arc resistant equipment and remote operation, and rank them on the reduction each actually delivers.

Labelling and Work Practice

Issue the equipment labels, the boundary and PPE schedule, and the energised work procedure that the calculation supports.

Lightning Protection Risk Assessment and System Design Scope
Scope of work

Every deliverable from basis to handover

Complete Lightning Protection Risk Assessment and System Design scope covering every calculation, drawing, specification, and construction support activity.

We run the IEC 62305 2 risk calculation rather than assuming a protection level and designing backwards from it
We use the local ground flash density for the site, since a national average understates exposure in a high incidence region
We assess risk of loss of human life, of service to the public, of cultural heritage and of economic value separately, because they carry different tolerable values
We design air termination by the rolling sphere method at the radius the calculated protection level requires
We size and space down conductors and verify separation distance against the risk of dangerous sparking
We coordinate surge protective devices across the power and signal boundaries, which is where most of the real loss occurs
We cover storage tanks to API RP 545, including floating roof shunts, bonding and the vent arrangement
We bond services entering the structure, since an unbonded incoming line defeats an otherwise sound system
We define the inspection and test interval the standard requires, and what is measured at each one
Engineering outcomes

Outcomes of Lightning Protection Risk Assessment and System Design

Lightning Risk Reduction
  • We establish the protection level from a calculation rather than an assumption
  • We close the ignition paths that matter on a flammable inventory
  • We protect occupied structures against side flash and step potential
  • We bond the services that would otherwise carry a surge inside
IEC 62305 Compliance
  • We assess to IEC 62305 2 and design to IEC 62305 3 and 4
  • We apply IS 2309 and IS/IEC 62305 for Indian installations
  • We cover tank protection to API RP 545
  • We document the basis for the protection level selected
Surge and Continuity Protection
  • We protect instrumentation and control against surge damage
  • We reduce unplanned outages caused by transient events
  • We set a defensible inspection and test interval
  • We identify where an existing system has degraded
Protection Investment Targeting
  • We avoid over protecting a structure the calculation does not require it for
  • We target surge protection where the loss potential actually sits
  • We reduce repeat damage to electronic systems
  • We support insurance discussion with a calculated basis
Standards & references

Codes & standards we work to

IEC 62305 Parts 1 to 4 (protection against lightning)IS/IEC 62305 (India adoption)IS 2309 (Code of Practice for Protection of Structures against Lightning)NFPA 780 (Installation of Lightning Protection Systems)API RP 545 (lightning protection of above ground storage tanks)IEC 62561 (lightning protection system components)IEC 61643 (surge protective devices)IEC 60079 32 1 (electrostatic hazards)CEA Regulations 2010 (India Electrical Safety)IS 3043 (Earthing)
When to engage

Triggers that signal the need

No lightning risk assessment exists, only an installed system of unknown basisRepeated instrumentation or control damage during the storm seasonA new structure, tank farm or control buildingInsurer or authority query on lightning protection adequacyA site in a high ground flash density regionAn existing system that has never been inspected or tested
Industries served

Where Lightning Protection Risk Assessment and System Design applies

Oil & Gas, Upstream
UpstreamOffshoreFPSO
Refineries & Petrochemicals
RefiningPetrochemical
LNG & Gas Processing
LNGCryogenic
Specialty Chemicals
ReactiveBatch
Power Generation
PowerHydrogen
Pharma & Food
PharmaFood & Bev
What we deliver

Tangible deliverables

  • IEC 62305 2 risk assessment with the calculated protection level
  • Air termination layout with rolling sphere verification
  • Down conductor routing and separation distance calculation
  • Earth termination design and target resistance
  • Surge protective device coordination schedule across power and signal
  • Tank protection arrangement to API RP 545 where applicable
  • Bonding schedule for incoming services and external conductive parts
  • Inspection, test and maintenance schedule with measured parameters
Get Started

Send us the scope

We will scope Lightning Protection Risk Assessment and System Design against your site and come back with what it would take. Send us the process conditions, the equipment list and the stage the design has reached.