Pharmaceutical Manufacturing | Mission-Critical Surge & Lightning Protection"
A High-Precision Facility, Exposed to Unpredictable Surges
In 2023, a pharmaceutical manufacturer based in Genome Valley—India’s leading life sciences cluster—faced a recurring threat few anticipate but many suffer from: uncontrolled power disturbances.
Despite using standard local surge devices, the facility witnessed:
Sudden shutdowns in R&D and HVAC systems
Batch record loss due to corrupted backups
Sensor drift in stability chambers compromising data
Repeated equipment failures risking GMP compliance
With an upcoming MHRA audit, the stakes were more than operational—regulatory reputation was on the line.
The Challenge: Precision Equipment vs. Unpredictable Power
The pharma plant housed:
Oral Solid Dosage (OSD) lines
R&D zones with sensitive instrumentation
API storage with solvent handling
Cleanrooms regulated under WHO GMP and US FDA 21 CFR Part 11
Surges and improper grounding threatened not just uptime—but data integrity, batch traceability, and audit-readiness.
Our Solution: Integrated Grounding + Lightning Protection, Built for Compliance
LPES conducted a full risk assessment under IEC 62305-2 and mapped each building’s vulnerability—from cleanrooms to chemical yards. Our engineering team proposed a modular system designed to:
🛠 Key Systems Deployed
🔌 Grounding & Bonding (IS 3043 + IEEE 80):
30+ deep-earth electrodes with GEM backfill
Equi-potential mesh grid inside labs and cleanrooms
Step/touch voltage simulations to ensure personnel safety
⚡ Lightning Protection (IEC 62305-3):
ESE air terminals positioned on exposed rooftops
Strategically routed down conductors
Unified earth termination system
🛡 Surge Protection (UL 1449 + IEC 62305-4):
Type 1 SPDs at incoming LT panels
Type 2 SPDs at DBs for SCADA, HVAC, and BMS
Type 3 SPDs at sensitive nodes: autoclaves, HMI, and monitoring systems
📏 Safety & Compliance (NFPA 780 + NBC 2016):
Flameproof motor bonding and HVAC unit protection
Hazardous zone isolation per NBC Part 8
Documentation and protocols aligned with WHO GMP
🧪 Execution: Precision Without Downtime
With zero disruption as a core mandate, LPES implemented the solution in phases:
Night installs for grounding in admin and warehouse
Surge device setup synced with HVAC validations
Bonding done under cold work permits in flammable zones
Final verification audited by third-party electrical inspector
✅ Results
Ground resistance consistently brought under 1 ohm
Zero downtime from surge-related events post-implementation
Successful MHRA and WHO GMP audits — no remarks
Client greenlit expansion for a new injectable line within 6 months
🌐 Why It Matters
Pharmaceutical manufacturing isn’t just about machines—it’s about data, precision, and people’s lives. With LPES’s engineered protection, this facility now runs safer, more reliably, and more confidently—no matter the weather.
