Facilities and Assets Covered

Production buildings and process areas

Included in the project-specific lightning, earthing and surge-protection review.

PLC, SCADA and DCS systems

Included in the project-specific lightning, earthing and surge-protection review.

MCC, VFD and automation panels

Included in the project-specific lightning, earthing and surge-protection review.

Warehouses and logistics buildings

Included in the project-specific lightning, earthing and surge-protection review.

Transformers, DG and substations

Included in the project-specific lightning, earthing and surge-protection review.

Fire alarm, CCTV and access control

Included in the project-specific lightning, earthing and surge-protection review.

Utilities and O&M facilities

Included in the project-specific lightning, earthing and surge-protection review.

Why Protection Is Critical

Production downtime

Requires dedicated engineering attention during risk assessment and detailed design.

Automation and control sensitivity

Requires dedicated engineering attention during risk assessment and detailed design.

Large metallic structures

Requires dedicated engineering attention during risk assessment and detailed design.

Multiple earthing networks

Requires dedicated engineering attention during risk assessment and detailed design.

Harsh industrial environments

Requires dedicated engineering attention during risk assessment and detailed design.

Sector Design Philosophy

The protection strategy should combine external lightning interception, down-conductor routing, earth termination, equipotential bonding and coordinated SPDs. The selected system must follow the current project specification, site conditions and authority requirements.

Engineering Design Workflow

1. Site Data

Collect drawings, dimensions, roof levels, coordinates, occupancy, critical equipment, hazardous classification and incoming services.

2. Risk Review

Evaluate strike exposure, local lightning activity, consequences of failure, fire risk, service continuity and project requirements.

3. System Selection

Select ESE or conventional IEC 62305 route only where accepted by the project specification.

4. External LPS

Define air termination, masts, down conductors, bonding and earth termination.

5. Internal Protection

Coordinate Type 1, Type 2 and signal-line SPDs with the electrical distribution and lightning protection zones.

6. Documentation

Prepare calculations, layouts, BOQ, technical specifications, method statement, test records and as-built drawings.

Typical BOQ

Item	Description	Quantity Basis
Air termination	ESE terminal or conventional rods/mesh as specified	Coverage and roof geometry
Mast/support	GI/SS mast, brackets, base or guying	Mechanical and wind-load design
Down conductor	Specified conductor, holders and test joints	Measured route and number of paths
Earthing	Electrodes, conductors, chambers and bonding	Soil study and earthing design
SPDs	Power and signal-line surge protection	Panel and circuit survey
Services	Installation, testing, commissioning and documentation	Complete project

Inspection, Maintenance and AMC

Visual Inspection

Check terminals, masts, conductors, joints, labels, supports, corrosion and mechanical damage.

Electrical Testing

Verify continuity, bonding, earth-system performance and SPD status using appropriate test methods.