Petrochemical Case Study

🔥 Volatility Isn't Just in the Market  

Petrochemical plants operate with some of the most hazardous combinations in modern industry—combustible gases, high-pressure systems, volatile liquids, and explosive storage units. These facilities often span hundreds of acres with towering distillation columns, flare stacks, pipelines, and interconnected control systems.

A single lightning event or surge—direct or induced—can lead to:

• Arc flashes in flammable zones

• Fires in control rooms or substations

• Shutdowns in PLC-driven compressors and utility systems

• Signal faults in remote instrumentation or SCADA panels

In one such high-profile petrochemical plant in western India, LPES International was brought in to assess and redesign a mission-critical protection system across its refining and processing zones.

⚠️ The Challenge: Grounding and Surge Risks in Ex Zones  

The client’s pain points included:

• Multiple grounding systems with no equipotential bonding

• Frequent relay burns and surge-related tripping in remote panels

• Inadequate protection for data lines and instrumentation in Class I Div 1 zones

• Non-compliance with updated standards like OISD, IEC 62305, and NFPA 780

The stakes weren’t just operational—ES&H risks, insurance mandates, and compliance exposure made it imperative to act.

🛠 LPES Turnkey Solution: Engineered for Hazardous Environments  

We deployed a layered protection framework that fused grounding, bonding, surge arresters, and LPS into one unified ecosystem—customized for hazardous zones (Zone 0, Zone 1).

🌩 Lightning Protection System (IEC 62305-3):  

• ESE Lightning Air Terminals at flare stacks, admin blocks, sub-stations

• Down conductors routed through safe corridors

• Maintenance-free grounding electrodes near vertical tanks

⚡ Surge Protection Devices (UL 1449, IEC 62305-4):  

• Type 1 SPDs at incomers from transformers and substations

• Type 2 SPDs at DBs feeding critical systems like analyzers, pumps, and PLCs

• Type 3 SPDs for local panelboards near SCADA and telemetry systems

• Data Line SPDs for Ethernet, Modbus, RS485 instrument loops

🌍 Grounding & Bonding System (IS 3043 + IEEE 80):  

• Installed over 100 deep-driven earth rods with GEM backfill compound

• Bonded pipelines, tanks, and metal enclosures to eliminate floating potential

• Equipotential bonding in hazardous zones using copper bars and earth mats

• Spark gaps and isolators for grounding in Class I Div 1 areas

🏗 Execution Plan: Precision with Hazard Control  

• Hot Work Zones: All bonding in hazardous areas done under work permits with fire watch and calibrated gas sensors.

• Downtime Avoidance: Installation sequenced zone-wise to avoid shutdowns.

• Third-Party Validation: Testing and inspection verified by NABL-accredited labs.

• Digital Records: Delivered grounding grid layout, SPD specs, test logs, and resistance reports for insurance compliance.

✅ Impact & Outcomes  

• Reduced ground resistance to <1 ohm site-wide

• Zero surge-related faults post-implementation

• Full compliance with OISD, IEC, NFPA, and State Electricity Board audits

• Improved safety rating in client’s global EHSS audit

• Client expanded contract to cover new ethylene cracking unit under construction

📜 Compliance Standards  

• IEC 62305 – Risk Assessment + LPS + SPD Coordination

• IS 3043 / IEEE 80 – Grounding Grid Design + Touch/Step Simulation

• UL 1449 – SPD Performance Standards

• NFPA 780 / OISD Guidelines – Hazard Zone Safety & Bonding Compliance

• State Electricity Board Requirements – Regulatory Certification

🔎 Why LPES?  

For petrochemical facilities, safety is engineering—not insurance. LPES delivers compliance-backed protection that prevents failure before it happens. Because in this industry, a surge isn’t just a spike—it's a spark away from catastrophe.