Shielding a Distillery Giant — LPES International’s Turnkey Lightning & Surge Protection Solution
When it comes to alcohol manufacturing plants, lightning isn’t just a weather event — it’s a threat to life, compliance, and the bottom line.
In early 2024, LPES International was approached by a large distillery operating in one of India’s most lightning-prone zones. The site stored massive volumes of flammable ethanol, housed explosive godowns, and relied on continuous automated operations involving LT panels, DG sets, boilers, and packaging lines.
The facility had no dedicated lightning protection system in place. Their surge protection relied on consumer-grade devices — creating critical vulnerabilities across production and storage.
With the monsoon approaching, the risks were too severe to ignore.
⚠️ The Threat: Fire, Downtime, and Non-Compliance
Alcohol manufacturing units like this one are complex ecosystems, with:
Fermentation, blending, and bottling halls
Spirit storage warehouses and packaging godowns
Boiler houses, turbine generators, and power control centers
Admin buildings, canteens, and medical units
Each of these zones has unique electrical needs — and unique vulnerabilities.
A single lightning event could result in:
Fire or explosion in flammable vapor zones
Control system failure in VFD motors or PLC stations
Shutdowns in bottling or filling lines, wasting raw material
Loss of compliance with OISD, IEC, and factory inspectorate norms
Personnel risk in congregation areas like offices and welfare blocks
🧠 The LPES Approach: Application-Centric, Zone-Wise Protection
Instead of offering a “standard” lightning solution, LPES engineers conducted a comprehensive risk assessment as per IEC 62305-2. The site was categorized under Lightning Protection Level I (LPL-I) — the highest protection level — due to its explosive risk and spatial layout.
We implemented a turnkey, standards-based protection system across the facility:
🛡️ What We Delivered
✅ External Lightning Protection (IEC 62305-3)
ESE Air Terminals installed over chimneys, rooftops, and godowns
Down Conductors with symmetrical routing to eliminate potential difference
Maintenance-Free Earth Electrodes at all key zones for dissipation
Spark Gaps used in Ex zones to prevent ignition during strike discharge
✅ Surge Protection System (IEC 62305-4, UL 1449)
Type 1 SPDs at main LT panels and DG incomers
Type 2 SPDs at fermentation DBs, packaging, and HVAC
Type 3 SPDs at HMI panels, scanners, and lab workstations
Surge Filters for VFD-driven conveyors and automated filling lines
Surge Counters installed to monitor real-time protection activity
✅ Grounding & Bonding (IS 3043, IEEE 80)
<1 ohm resistance across all zones using GEM-enhanced earth pits
Equipotential bonding in control rooms, packaging, and process lines
Chemical grounding for corrosion-prone outdoor areas
✅ Hazardous Zone Compliance (NFPA 780, OISD)
Flameproof-rated SPDs in spirit storage and chemical godowns
All protective elements cleared for Ex environments
Routing compliant with NBC 2016 and safety audit norms
⚙️ Seamless Execution, Zero Interruption
To prevent production disruption, LPES designed a phased execution plan in sync with shift schedules. Key installations like SPDs and earth pits were executed during plant breaks or non-critical hours. All work in hazardous zones was conducted under cold work permits with fire safety supervision.
Post-installation, the system underwent:
Continuity checks of all conductors
SPD functionality tests
Ground resistance testing by third-party inspectors
A detailed compliance report was submitted, and the client’s maintenance staff was trained on upkeep protocols.
✅ The Outcome: Zero Downtime, Full Compliance
Since commissioning, the distillery has experienced multiple lightning events — without a single incident of downtime or damage. Regular audits and annual maintenance confirm the system’s reliability.
Ground resistance: <1 ohm across all locations
Standards met: IEC 62305, IS 3043, NFPA 780, UL 1449
Zero SPD failures or surge-triggered equipment loss
Client cleared for insurance and statutory audits
The plant has since approved LPES to expand protection for its upcoming capacity addition.
📘 What This Means for the Industry
In alcohol manufacturing, lightning protection is not optional — it’s an operational and compliance imperative. From godown fires to automated system faults, surge and lightning threats require engineered, application-specific solutions.
With LPES’s approach — rooted in engineering precision, compliance, and risk-based protection — distilleries can ensure safety without sacrificing productivity.
