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Earthing & Lightning Protection Calculation

10013-EGC-CHC501-001

Contractor: Aker Powergas Pvt Ltd

Client:
Location:
Job No.:
APG Project No:

APG
Rev Date PEM Document Status Prepared by Checked By Approved By
Status
Earthing & Lightning Protection Calculation

Record of Revisions

Rev. Date Revision Details

Table of Holds

The following holds have been identified. They will be cleared as soon as practicable.

Section Details of Hold Hold Cleared (rev)

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Earthing & Lightning Protection Calculation

TABLE OF CONTENTS

Section-1 : Earthing Study

1 Scope 4
2 Reference documents 4
3 Design inputs 4
4 Formulae 4
5 Calculations 6
A Main earth grid GI strip sizing 6
B Plant earth grid GI strip sizing 6
C Calculation of number of earth electrodes 7
D System resistance 8
E Grid resistance 8
6 Conclusion 8
7 Recommendations 8

Section-2 : Lightning Study

1 Scope 1
2 Reference documents 1
3 Design inputs 1
4 Formulae 1
5 Calculation for Requirement of LPS 2
A Substation Building 2
B Plant Interface Building (PIB) 3
C Maintenance Building 4
D Catalyst Storage Building 5
E LPS For Metallic Structures/Buildings 6
6 Summary 7

Annexure-1 -- Fault current calculation -

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Earthing & Lightning Protection Calculation

Section-1 : Earthing Study

1 Scope:
This section of document covers the calculation to determine the size of main earth strip & number of total earth electrodes required for
the earthing system .

2 Reference Documents:
This calculation is based on following documents :
1> IS 3043-1987 Code of Practice for Earthing (Including Amend. 1 & 2)
2> Doc No. 10080-1-DBD-EL-001: Electrical Design Basis
3> Doc No. 10080-1-SS-EL-046: Standard Specification for Cable Trays & Earthing Materials
4> Doc. no. 10080-E12-033 to 048: Standard Installation details for Earthing
5> Doc No. 10080‐1‐ENGG‐DBD‐CS‐006 : Report for Foundation Design Basis - Priority Area-1,2,3,4 & 5. (For Soil Resistivity data)

3 Design Inputs:
1> Soil Resistivity is taken as 45 ohm-m as per Clause no 11 (Page 25 of 42) of Ref Documents as mentioned under 5> above.
2> Depth of pipe electrode in contact with earth is considered as pipe length = 3 m
3> For earth grid design, duration of fault current considered is 0.5 sec as per Electrical Design Basis.
4> 11kV System : Resistance earthed by 250A NER.
6.6kV System : Resistance earthed by 250A NER.
0.415kV & 0.690kV System : Solidly earthed.
5> Material of earth electrode is considered as 100NB Class 'B' GI pipe Electrode ‐ 3m long as per Standard Specifiaction for Cable Trays &
earthing Material.

4 Formulae:
4.1. Resistance of pipe electrode (ref. 9.2.2. of IS: 3043 - Amend No. 2)
Re = [100р/2Лl] x [loge (2l/d)] ohm

where, l = length of pipe in cm.

d = diameter of pipe in cm
р = resistivity of soil in ohm-m

4.2. Permissible current density for given value of soil resistivity & for given duration (ref. 10.3 of IS: 3043)
J = 7.57 x 103
Ört
where t = duration of fault (sec)

4.3. The cross-sectional area of earthing conductor for disconnection time not exceeding 5 sec (ref. 12.2.2.1 of IS: 3043)

1/S = K * 1 / I Öt

where,
S = cross sectional area in sq.mm.
I = r.m.s. value of fault current of system in amperes
K = factor from IS: 3043 table 6.

Table 6A Table 6D
Bare Conductor with No Risk of Fire or Danger Protective Bare Conductors in Hazardous Areas Where There is Risk
to Any Other Touching or Surrounding Material of Fire from Petroleum Bound Oil or Other Surrounding Material

Copper 205 Copper 153

Aluminium 126 Aluminium 101
Steel 80 Steel 56

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Earthing & Lightning Protection Calculation

4.4 Inputs:

1 : Maximum Fault Current (for Main Earth grid sizing) (LV Switchboard / PCC design fault current) 65 kA
: Maximum Fault Current (for Plant Earth grid sizing) (Refer - Annexure-1) * 15.45 kA
2 : Duration of Fault (Fault Clearing Time) 0.5 Sec.
3 : Average soil resistivity 45 Ohm-m
4 : Pipe electrode length (l) 300 cm
5 : Pipe electrode length in contact with ground (l) 300 cm
6 : Pipe electrode diameter (D) 10 cm
7 : Corrosion allowance for GI strip (As per Design Basis CL No. 8.10) 30 %
* 11kV & 6.6kV Systems are resistively earthed with NGR rating 250A. Therefore plant earthing is designed considering Maximum earth
fault current on 415V & 690V system 15.45kA as calculated in Annexure-1.

4.5 Symbols

I : Fault Current in kA 65

t : Fault duration in seconds 0.5

K : Constant (for GI Earth strip in safe area) (ref. Table 6A of IS 3043:1987) 80

(for GI Earth strip in Hazardous area) (ref. Table 6D of IS 3043:1987) 56

w : Depth of burial of the strip in cm (ref. Cl 20.6.3.2 of IS 3043:1987) 60

t : Width of strip in cm 7.5

4.6 Estimated Strip Laid Area (Substation): Estimated Strip Laid Area (Plant):

Strip laid 600mm below ground over (Approx) 250 mtr Strip laid 600mm below ground over (Approx) 2260 mtr

N
32

150
130
269

269

150
195
80

Substation
- Plot
296 NTS

NTS

Earth Grid around the Substation Earth Grid around the Plot & below Piperacks
(Approx length for calculation purpose only) (Approx length for calculation purpose only)

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Earthing & Lightning Protection Calculation

5 Calculation:

A Main Earth Grid GI Strip Sizing (Around Substation)

Cross sectional area of Main earth strip (GI) required to carry the rated fault current for 0.5 sec
Design fault level for LV Switchboard / PCC is 65 kA for 1sec.
Hence Main earth strip shall be designed for this fault current
1/S = K * 1 / I Öt

K= 80.00 (for Non hazardous area near Substation)

S = I/K * Öt = 65 * 1000 * Ö 0.5

80
= 574.52
Required Cross sect. area of GI strip = 575.00 sq.mm

Considering 30% Corrosion allowance : 747.50 sq.mm

Since Cross sect area of 75 x 10mm GI Stip = 750.00 sq.mm

75 x 10 mm GI strip to be selected

Therefore, Earth grid around Substation shall be by 75 x 10mm GI earth Strip

B Plant Earth Grid GI Strip Sizing

The max. earth fault current to be dessipated by plant earth grid is same as that of the earth fault current of the largest kW motor
(LV) located near the source. Refer Annexure-1 for earth fault current calculation of SEED BED BLOWER MOTOR
(Tag no. MA-CHC501-M5613, 5614) of rating 225 kW on 415V system & PELLET WATER PUMP MOTOR (Tag no. MP-CHC501-M7012 /
7017) of rating 250kW on 690V system.

Max Cross sectional area of Plant earth strip (GI) required to carry the fault current of 15.45 kA for 0.5 sec is calculated as follows,
1/S = K * 1/ I Öt

K= 56.00 (for hazardous area)

S = I/K * Öt = 15.45 * 1000 * Ö 0.5

56
= 195.02

Required Cross sect. area of GI strip = 196.00 sq.mm

Considering 30% Corrosion allowance: 254.80 sq.mm

Since Cross sect area of 50 x 6mm GI Stip = 300.00 sq.mm

50 x 6 mm GI earth strip may be selected.

However for Standardization purpose, Earth grid for Plant shall be by selected as 75 x 10mm GI earth Strip

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Earthing & Lightning Protection Calculation

C Calculation for Number of Earth Electrodes:

1. Resistance to pipe electrode

r = 45 ohm-m
l = 300 cm (length in contact with ground)
d = 10 cm

Re = [100р/2Лl] x [loge (2l/d)] ohm

= 9.77 ohm

In order to achieve an overall earth resistance below 1 ohm, 10 nos min. pipe electrodes are required.

2. Permissible current density for given value of soil resistivity & for given duration of 0.5 sec.

J = 7.57 x 103 A/sq.m

Ört
r = 45 ohm-mtr
t = 0.5 sec

J = 1595.9 A/sq.m

3. Total area of each pipe electrode in contact with ground

A = pDl
= 0.9425 sq. m

Considering 5% reduction in the gross area of pipe electrodes due to perforations & also tapering of pipe electrodes at bottom.
Hence net area of each pipe electrode 0.895 sq.m.

4. Total surface area of pipe electrode required for fault current dissipation =
Fault current component in amperes for dissipation through earthing elements
current density in A/sq.m
Substation Plant
Total Fault kA = 65.0 kA 15.45 kA
Current Density = 1595.9 A/sq.m 1595.9 A/sq.m
Total surface area of earth elements required = 40.7 sq.m 9.7 sq.m

5. Minimum Total number of pipe electrode required to be interconnected for Plot spread

Total Earth Electrode Area = 40.7 sqm (Max of the surface area calculated above in 4.)

Considering corrossion allowance : = 52.95 sqm

Area of each earth electrode = 0.895 sqm

Total no. of earth electrodes = 59.14 Nos.

In order to achieve an overall earth resistance below 1 ohm & dessipation of 65kA of earth fault current, min 60.0 Nos.
electrodes will be required.

6. Earth Strip Areas =

Substation Plant
Area of Strip in contact with ground 250 * {(75 * 2) + (10 *2)} Area of Strip in contact with ground 2260 * {(75 * 2) + (10 *2)}
(Refer Section B) 1000 (Refer Section C) 1000
Strip run around Substation 42.5 sq.m Strip run over Plant 384.2 sq.m

Total Area covered by earth strip in Plant & Substation 426.7 sq.m
Therefore, the total surface area covered by earth grid is more than the required area of earth elements to dissipate 65kA fault current
for the 0.5sec duration as calculated above in 4.
C Calculation for Number of Earth Electrodes:
Page 7 of 9
Earthing & Lightning Protection Calculation

D. System Resistance:

Resistance of one electrode: 9.77 ohm

No. of electrodes forming Grid: 60

Effective Resistance achieved: Re = 0.163 ohm

E. Grid Resistance

Substation Plant
Resistance of strip electrode (ref. 9.2.3 of IS: 3043_Amend 2) Resistance of strip electrode (ref. 9.2.3 of IS: 3043_Amend 2)
Rs = [100p/2pi*l] x [loge(4l/t)] Rs = [100p/2pi*l] x [loge(4l/t)]

where, where,
r = 45 resistivity of soil in ohm-metre r = 45 resistivity of soil in ohm-metre
l = 25000 length of strip in cm l = 226000 length of strip in cm
w = 60 depth of burial of the electrode in cm w = 60 depth of burial of the electrode in cm
t = 7.50 width of strip in cm t = 7.50 width of strip in cm

Rs 0.27 ohm Rs 0.037 ohm

Hence, Effective resistance of Substation & Plant Earth Strip, Substation Strip Rs x Plant Strip Rs
=
Substation Strip Rs + Plant Strip Rs

= 0.033 Ohm

Effective Plant Earth Resistance Electrodes Re x Strip Rs

=
Electrodes Re x Strip Rs

= 0.027 Ohm

6 Conclusion:
The effective resistance of the grounding system is 0.03 ohm, which is within the maximum permissible value of 1 ohm.

7 Recommendations:

1. Provide min. 60.0 nos. 3.0 m. Long, 100.0 NB Class 'B' GI, pipe electrodes Distributed around substation & Plant
2. Each Transformer shall have 2 Nos. dedicated earth pits for Neutral grounding.
3. Provide GI Earth strip for main earth grid 75 x 10 mm bare strip … installed at 600mm depth around Substation
4. Provide GI Earth strip for plant earth grid 75 x 10 mm bare strip … installed at 600mm depth in plant area
5. Plant earth grid shall be connected to substation earth grid at Minimum two locations.
6. Further, this plant earth grid shall be connected to earth grids of the adjacent areas surrounding to plant at Minimum two locations.
7. Size of Earth conductors for various equipments shall be as given in the table below (referred from electrical standard installation dwg):

Type of Equipment Bare GI Strip / AL or Cu cable

1. Motors above 2.2kW up to and including 30 kW (Refer E12-048) 1C x 35 sqmm AL, PVC Cable 2 Nos.
2. Motors from 37 kW and above including MV motors (Refer E12-048) 1C x 70 sqmm AL, PVC Cable 2 Nos.
3. HV / MV / LV switchgear, Main earth grid around substation, Plant earth grid 75 x 10 mm GI strip
4. NGR Earth Terminal (Refer E12-041) 75 x 10 mm GI strip 2 Nos.
5. Distribution Transformer Neutral (Refer E12-040) 75 x 10 mm GI strip 2 Nos.
6. Power & Distribution Transformer Body (Refer E12-040 / 041) 75 x 10 mm GI strip 2 Nos.
7. Transformer HV Terminal Box (Refer E12-040 / 041) 75 x 10 mm GI strip 2 Nos.
8. Transformer LV Terminal Box (Refer E12-040) 1C x 70 sqmm AL, PVC Cable 2 Nos.
Contd on next sheet…
Page 8 of 9
Earthing & Lightning Protection Calculation

Type of Equipment Bare GI Strip / GI Wire

Contd from previous sheet…

8. Local Control stations (LCS) ** 1C x 6 sqmm Cu, PVC Cable 1 No.

9. Rectifier / battery charger, Local Panels 1C x 35 sqmm AL, PVC Cable 2 Nos.
10. Lighting Transformers 50 x 6 mm GI strip 2 Nos.
11. Lighting, Small Power and Instrument panels, UPS 1C x 70 sqmm AL, PVC Cable 2 Nos.
12. Street lighting poles (Refer E12-012) 1C x 35 sqmm AL, PVC Cable 2 Nos.
13. Pipe racks & cable Trays on Piperack (Refer E12-042) 50 x 6 mm GI strip at min 30 m interval 1 No.
14. Bonding of pipeworks (Refer E12-047) 1C x 35 sqmm AL, PVC Cable 1 No.
(For pipelines entering & leaving hazardous area)
15. Building columns / Steel Structure 50 x 6 mm GI strip at min 30 m interval
16. Storage tanks (vertical and horizontal) 50 x 6 mm GI strip 2 Nos.
17. Stairs & Ladders (Refer E12-046) 1C x 35 sqmm AL, PVC Cable 1 No.
18. Vessels and heat exchangers (Refer E12-042) 1C x 35 sqmm AL, PVC Cable 2 Nos.
19. Small equipment and instruments 1C x 16 sqmm AL, PVC Cable 1 No.
20. Instrument reference earth Bus (Insulated earth bus) (Refer E12-044) 1C x 70 sqmm AL, PVC Cable from Earth pit to
earth Bus & 1C x 6 sqmm Cu, PVC Cable from
Earth Bus to equipment
21. Horizontal Air Termination for lightning protection of buildings 50 x 6 mm GI Strip (mesh of 20 m x 10 m)
22. Down conductor for lightning protection of buildings ##
50 x 6 mm GI Strip (Qty As calculated)
23. Power JBs 1C x 35 sqmm AL, PVC Cable 2 Nos.
24. Motors up to and including 2.2 kW $$
1C x 6 sqmm Cu, PVC Cable 2 Nos.

** Based on mail dated 10th Feb 2014

##
Based on mail dated 20th May 2014
$$
based on confirmation to TQ-0077 dated 07th July 2014

Summary of Earth Electrodes

1. Earth Pits for 4 Nos Power Transformers Neutral Earthing : 8 Nos

2. Earth Pits for 8 Nos Distribution Transformers Neutral Earthing : 16 Nos
3. Earth pits along the piperack (Approx. every 30m) : 30 Nos
4. Earth pits inside plant : 27 Nos
5. Earth Pits for Instrument Clean Earthing - Near Substation Treated Earthpits (Refer E12-38) : 3 Nos
6. Earth Pits for Instrument Clean Earthing - Near PIB Treated Earthpits (Refer E12-38) : 3 Nos
7. Earth Pits for Instrument Clean Earthing - in Reaction Area Treated Earthpits (Refer E12-38) : 3 Nos
8. Earth Pits for Instrument Clean Earthing - in Elutriator Area Treated Earthpits (Refer E12-38) : 3 Nos
9. Earth Pits for Lightning Protection System (Various structures as calculated in Section-2) : 26 Nos

Note : For actual location of earth electrodes refer Overall Plot Plan (ISBL) Earthing layout Dwg No. 10013-E61-CHC501-000001.

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Earthing & Lightning Protection Calculation

Section-2 : Lightning Study

1 Scope:
This document covers the calculation to determine and establish the adequecy of Llightning Protection System (LPS) requirements
(for the Tall structures, Substation, PIB building & Maintenance building) .

2 Reference Documents:
1. IS 2309 : Protection of Buildings and Allied Structures Against Lightning - Code of Practice
2. Doc No. 10013-P50-CHC501-001-REV-3 : Unit Plot plan

3 Design Inputs:
1. No. of thunderstorm days per year = 6 (Ref Fig. 1 of IS 2309)
2. Number of flashes to ground per sq.km per year = 0.5 (Ref section 8.1.2 of IS 2309)
3. Earth resistance: 10 Ω for lightning
4. Down comer size 32x6 mm GI strip

Lightning Protection System (LPS)- General

The principal components of Lightning Protection System are:

a. Air terminations (e.g. rods, horizontal roof conductors, metallic roofs, hand rails etc)
b. Down conductors (e.g. metal strips, part of building metal frame work, interconnected steel frame work of structure etc)
c. Earth termination network/electrode (e.g. main earthing grid & earth electrodes)

Lightning Protection System - Plant

From lightning protection point of view, buildings / process units of the Plant can be broadly classified in two categories viz.

a. RCC Buildings (e.g. Substations, PIB building & Maintenance building).

b. Metallic structures/buildings (e.g. Resin Degassing & Pelletising Building, Reaction Area (including Compressor shed), Seed Bed Silos,

Pellet Blending Silos, Vent Gas Recovery & Compression and Purification )

4 Formulae: Ac x N g x10  6

1. Total Collection Area (in m2) (Ref.equation 1 of 8.1.2 of IS-2309-1989)

Ac =
where, Ac = Collection Area in m2
L=
L xW  Length of2the
2 LxH   WxHstructure in 2meter
 3 . 14 xH
W = Width of the structure in meter
H = Height of the structure in meter

2. The probable no. of strikes (Risk) to the structure per year (Ref.equation 2 of 8.1.2 of IS-2309-1989)

P =
where, P = The probable no. of strikes (Risk) to the structure per year
Ac = Collection Area in m2
Ng = Lightning flashes per sq. Kilometer per year

3. Recommended No. of Down Conductors (Ref.12.2.3 of IS-2309)

For a structure having a base area exceeding 100 sq.meter , the number of Down conductors should be at least
the smaller of the following:

a) One plus an additional one for each 300 sq.meter, or a part thereof , in excess of the first 100 sq.meter.

b) One for each 30 meter of perimeter of the structure protected.

Section-2 : Lightning Study
1 Scope:
Page 1 of 7
Earthing & Lightning Protection Calculation

5 Calculations:

A. Determination of requirement of lightning protection for substation building

Determination of “Ng” ( Lightning flash density ) :

The lightning flash density “Ng” is the number of flashes to ground per sq.km per year.

Ng = 0.5

Determination of “Ac” ( Effective collection area of structure ):

The effective collection area of structure is the area of the plan of the structure extended in all direction to take account of its height.

Substation Dimensions : Length (L) = 78 m, Width (W) = 18 m, Height (H) = 11 m

Ac = (L x W) + 2(L x H) + 2(W x H) + (Π x H 2 ) (Refer IS 2309, Figure 2)
Ac = (78 x 18) + 2(78 x 11) + 2(18 x 11) + (3.14 x 112 )
Ac = 3896.1 m2

Calculation of “Probable number of strikers”:

P = Ac x Ng x 10-6 (Ref section 8.1.2 of IS 2309)
P = 3896.1 x 0.5 x 10-6
P= 0.00195 = 1.95 x 10 -3

Calculation of “Overall weighting Factors” :

Overall weigthing factors = A x B x C x D x E

= 0.7 x 0.4 x 0.8 x 1 x 0.3 ( Ref. IS 2309, Table 1 )
= 0.0672

· Determination of “Overall Risk Factor”

Overall Risk Factor = P x Overall weigthing Factor

= 0.00195 x 0.0672
= 0.000131 = 13.1 x 10 -5
13.1 x 10-5 > 10-5
As per IS 2309 Clause 8.1.3 If Overall Risk Factor is greater than 10 -5, protection is required.

Air termination (mesh of 20 m x 10 m) GI strip of size 50 x 6 mm may be employed as shown in typical arrangement fig 5 of IS 2309

Calculation for number of Down conductors required :

As per Clause 12.2.3 and 12.2.4 & Tabel - 4 of IS 2309, Down conductors required shall be as follows:

Base Area of Substation building = (Area of Switchgear room ) + (Area of VFD & maint room) + (Area of Staircases)
Base Area of Substation building = (78 x 12) + (6 x 24) + 3 x (6 x 6) 1188 m2 > 100 m2
Number of down conductors shall be at least the smaller of the following,

i) One + Additional one for each 300 m2 of base area in excess of first 100 m2

Number of down conductors = 1 + (1188 - 100) = 5 ~ 5

300
ii) one for each 30 m of perimeter of structure,
Perimeter of Substation building = 2 x (78 + 12) + (8 x 6) = 228 m

Number of down conductors = 228 = 7.6 ~ 8

30
Hence 5 numbers down conductors of GI earth strip size 50 x 6 mm are required. Down conductors shall be further
connected to dedicated earth pits (5 nos).

Page 2 of 7
Earthing & Lightning Protection Calculation

B. Determination of lightning protection for Plant Interface Building (PIB)

Determination of “Ng” ( Lightning flash density ) :

The lightning flash density “Ng” is the number of flashes to ground per sq.km per year.

Ng = 0.5 (Ref section 8.1.2 of IS 2309)

Determination of “Ac” ( Effective collection area of structure ):

The effective collection area of structure is the area of the plan of the structure extended in all direction to take account of its height.

PIB Building Dimensions : Length (L) = 37 m, Width (W) = 10 m, Height (H) = 5.65 m

Ac = (L x W) + 2(L x H) + 2(W x H) + (Π x H 2 ) (Refer IS 2309, Figure 2)

Ac = (37 x 10) + 2(37 x 5.65) + 2(10 x 5.65) + (3.14 x 5.65 2 )
Ac = 1001.34 m2

Calculation of “Probable number of strikers”:

P = Ac x Ng x 10-6 (Ref section 8.1.2 of IS 2309)
P = 1001.34 x 0.5 x 10-6
P= 0.00050 = 0.5 x 10 -3

Calculation of “Overall weighting Factors” :

Overall weigthing factors = A x B x C x D x E

= 0.7 x 0.4 x 0.8 x 1 x 0.3 ( Ref. IS 2309, Table 1 )
= 0.0672

· Determination of “Overall Risk Factor”

Overall Risk Factor = P x Overall weigthing Factor
= 0.00050 x 0.0672
= 0.000034 = 3.4 x 10 -5
= 3.4 x 10-5 > 10-5

As per IS 2309 Clause 8.1.3 If Overall Risk Factor is greater than 10 -5, protection is required.

Air termination (mesh of 20 m x 10 m) GI strip of size 50 x 6 mm may be employed as shown in typical arrangement fig 5 of IS 2309

Calculation for number of Down conductors required :

As per Clause 12.2.3 and 12.2.4 & Tabel - 4 of IS 2309, Down conductors required shall be as follows:

Base Area of PIB building = 37 x 10 = 370 m2 > 100 m2

Number of down conductors shall be at least the smaller of the following,

i) One + Additional one for each 300 m2 of base area in excess of first 100 m2

Number of down conductors = 1 + (370 - 100) = 1.9 ~ 2

300

ii) one for each 30 m of perimeter of structure,

Perimeter of PIB building = (2 x 30) + (2 x 10) = 80

Number of down conductors = 80 = 2.6667 ~ 3

30
Hence 2 numbers down conductors of GI earth strip size 50 x 6 mm are required. Down conductors shall be further
connected to dedicated earth pits (2 nos).
B. Determination of lightning protection for Plant Interface Building (PIB)

Determination of “Ng” ( Lightning flash density ) :

The lightning flash density “Ng” is the number of flashes to ground per sq.km per year.

Ng = 0.5 (Ref section 8.1.2 of IS 2309)

Determination of “Ac” ( Effective collection area of structure ):

The effective collection area of structure is the area of the plan of the structure extended in all direction to take account of its height.

PIB Building Dimensions : Length (L) = 37 m, Width (W) = 10 m, Height (H) = 5.65 m

Ac = (L x W) + 2(L x H) + 2(W x H) + (Π x H 2 ) (Refer IS 2309, Figure 2)

Ac = (37 x 10) + 2(37 x 5.65) + 2(10 x 5.65) + (3.14 x 5.65 2 )
Ac = 1001.34 m2

Calculation of “Probable number of strikers”:

P = Ac x Ng x 10-6 (Ref section 8.1.2 of IS 2309)
P = 1001.34 x 0.5 x 10-6
P= 0.00050 = 0.5 x 10 -3

Calculation of “Overall weighting Factors” :

Overall weigthing factors = A x B x C x D x E

= 0.7 x 0.4 x 0.8 x 1 x 0.3 ( Ref. IS 2309, Table 1 )
= 0.0672

· Determination of “Overall Risk Factor”

Overall Risk Factor = P x Overall weigthing Factor
= 0.00050 x 0.0672
= 0.000034 = 3.4 x 10 -5
= 3.4 x 10-5 > 10-5

As per IS 2309 Clause 8.1.3 If Overall Risk Factor is greater than 10 -5, protection is required.

Air termination (mesh of 20 m x 10 m) GI strip of size 50 x 6 mm may be employed as shown in typical arrangement fig 5 of IS 2309

Calculation for number of Down conductors required :

As per Clause 12.2.3 and 12.2.4 & Tabel - 4 of IS 2309, Down conductors required shall be as follows:

Base Area of PIB building = 37 x 10 = 370 m2 > 100 m2

Number of down conductors shall be at least the smaller of the following,

i) One + Additional one for each 300 m2 of base area in excess of first 100 m2

Number of down conductors = 1 + (370 - 100) = 1.9 ~ 2

300

ii) one for each 30 m of perimeter of structure,

Perimeter of PIB building = (2 x 30) + (2 x 10) = 80

Number of down conductors = 80 = 2.6667 ~ 3

30
Hence 2 numbers down conductors of GI earth strip size 50 x 6 mm are required. Down conductors shall be further
connected to dedicated earth pits (2 nos).

Page 3 of 7
Earthing & Lightning Protection Calculation

C. Determination of lightning protection for Maintenance Building

Determination of “Ng” ( Lightning flash density ) :

The lightning flash density “Ng” is the number of flashes to ground per sq.km per year.

Ng = 0.5 (Ref section 8.1.2 of IS 2309)

Determination of “Ac” ( Effective collection area of structure ):

The effective collection area of structure is the area of the plan of the structure extended in all direction to take account of its height.

Maintenance Building Dimensions : Length (L) = 34.5 m, Width (W) = 23.50 m, Height (H) = 7.7 m

Ac = (L x W) + 2(L x H) + 2(W x H) + (Π x H 2 ) (Refer IS 2309, Figure 2)

Ac = (34.5 x 23.5) + 2(34.5 x 7.7) + 2(23.5 x 7.7) + (3.14 x 7.72 )
Ac = 1890.12 m2

Calculation of “Probable number of strikers”:

P = Ac x Ng x 10-6 (Ref section 8.1.2 of IS 2309)
P = 1890.12 x 0.5 x 10-6
P= 0.00095 = 0.95 x 10 -3

Calculation of “Overall weighting Factors” :

Overall weigthing factors = A x B x C x D x E

= 0.7 x 0.4 x 0.8 x 1 x 0.3 ( Ref. IS 2309, Table 1 )
= 0.0672
· Determination of “Overall Risk Factor”

Overall Risk Factor = P x Overall weigthing Factor

= 0.00095 x 0.0672
= 0.000064 = 6.4 x 10 -5
= 6.4 x 10-5 > 10-5

As per IS 2309 Clause 8.1.3 If Overall Risk Factor is greater than 10 -5, protection is required.

Air termination (mesh of 20 m x 10 m) GI strip of size 50 x 6 mm may be employed as shown in typical arrangement fig 6 of IS 2309

Calculation for number of Down conductors required :

As per Clause 12.2.3 and 12.2.4 & Tabel - 4 of IS 2309, Down conductors required shall be as follows:

Base Area of the building = 34.5 x 23.5 = 810.75 m 2 > 100 m2

Number of down conductors shall be at least the smaller of the following,

i) One + Additional one for each 300 m2 of base area in excess of first 100 m2

Number of down conductors = 1 + (810.7 - 100) = 3.4 ~ 4

300

ii) one for each 30 m of perimeter of structure,

Perimeter of the building = (2 x 34.5) + (2 x 23.5) = 116

Number of down conductors = 116 = 3.9 ~ 4

30
Hence 4 numbers down conductors of GI earth strip size 50 x 6 mm are required. Down conductors shall be further
connected to dedicated earth pits (4 nos).
Page 4 of 7
Earthing & Lightning Protection Calculation

D. Determination of lightning protection for Catalyst Storage Building

Determination of “Ng” ( Lightning flash density ) :

The lightning flash density “Ng” is the number of flashes to ground per sq.km per year.

Ng = 0.5 (Ref section 8.1.2 of IS 2309)

Determination of “Ac” ( Effective collection area of structure ):

The effective collection area of structure is the area of the plan of the structure extended in all direction to take account of its height.

Catalyst storage Building Dimensions : Length (L) = 40 m, Width (W) = 40 m, Height (H) = 8.7 m

Ac = (L x W) + 2(L x H) + 2(W x H) + (Π x H 2 ) (Refer IS 2309, Figure 2)

Ac = (40 x 40) + 2(40 x 8.7) + 2(40 x 8.7) + (3.14 x 8.72 )
Ac = 3229.67 m2

Calculation of “Probable number of strikers”:

P = Ac x Ng x 10-6 (Ref section 8.1.2 of IS 2309)
P = 3229.67 x 0.5 x 10-6
P= 0.00161 = 1.61 x 10 -3

Calculation of “Overall weighting Factors” :

Overall weigthing factors = A x B x C x D x E

= 0.7 x 0.4 x 0.8 x 1 x 0.3 ( Ref. IS 2309, Table 1 )
= 0.0672
· Determination of “Overall Risk Factor”

Overall Risk Factor = P x Overall weigthing Factor

= 0.00161 x 0.0672
= 0.000109 = 10.9 x 10 -5
= 10.9 x 10-5 > 10-5

As per IS 2309 Clause 8.1.3 If Overall Risk Factor is greater than 10 -5, protection is required.

Air termination (mesh of 20 m x 10 m) GI strip of size 50 x 6 mm may be employed as shown in typical arrangement fig 6 of IS 2309

Calculation for number of Down conductors required :

As per Clause 12.2.3 and 12.2.4 & Tabel - 4 of IS 2309, Down conductors required shall be as follows:

Base Area of the building = 40 x 40 = 1600 m 2 > 100 m2

Number of down conductors shall be at least the smaller of the following,

i) One + Additional one for each 300 m2 of base area in excess of first 100 m2

Number of down conductors = 1 + (1600 - 100) = 6.0

300

ii) one for each 30 m of perimeter of structure,

Perimeter of the building = (2 x 40) + (2 x 40) = 160

Number of down conductors = 160 = 5.3 ~ 6

30
Hence 6 numbers down conductors of GI earth strip size 50 x 6 mm are required. Down conductors shall be further
connected to dedicated earth pits (6 nos).
Page 5 of 7
Earthing & Lightning Protection Calculation

E. LPS FOR METALLIC STRUCTURES / BUILDINGS

a. Resin Degassing & Pelletising Building:

Area of the Structure : 50.3 Mtr. x 45.5 Mtr. (Base Area)
Height of the Structure : 133.7 Mtr.

Resin Degassing & Pelletising is having Concrete Structure upto EL 69.8 m and metallic structures above (made of structural steel columns,
beams, interconnecting framework, platforms at different elevations, handrails etc.). Since the total structure is metallic and firmly bonded from
top to bottom they can be considered as “Natural components” of LPS. Hence no separate “Air Termination Network” and “Down Conductors” are
envisaged for Structure above EL 69.8 m Peripheral steel columns of these structures shall be connected (at every 30 Mtrs interval) to main
Earthing Network via 50 x 6 mm GI strips,

However Lightning Protection for the Concrete structure (terrace) at EL 63.300 & EL 69.800 shall be provided.

Air termination (mesh of 20 m x 10 m) GI strip of size 50 x 6 mm may be employed as shown in typical arrangement fig 5 of IS 2309

Since the Structure is above 20 m Height, calculation for Probable no. of strikes & Risk factor is omitted.
And it is considered that Lightning protection is required.

Calculation for number of Down conductors required :

As per Clause 12.2.3 and 12.2.4 & Tabel - 4 of IS 2309, Down conductors required shall be as follows:

Base Area of Structure = 50.3 x 45.5 = 2288.65 m 2 > 100 m2

Number of down conductors shall be at least the smaller of the following,

i) One + Additional one for each 300 m2 of base area in excess of first 100 m2

Number of down conductors = 1 + (2288.65 - 100) = 8.2955 ~ 9

300

ii) one for each 30 m of perimeter of structure,

Perimeter of Structure = (2 x 50.3) + (2 x 45.5) = 191.6

Number of down conductors = 191.6 = 6.4 ~ 7

30
Hence 7 Nos numbers down conductors of GI earth strip size 50 x 6 mm are required for the Lightning protection Grid.
Additionally 2 Nos Down conductors are required for Direct connection of Steel structure (above EL 69.8 m) to the Earth grid.
Therefore Total 9 Nos Down conductors shall be required to be connected to dedicated earth pits (9 nos).

b. Other Structures in the Plant (having Height above 20 m)

Most of the process units in the plant are metallic structures (made of structural steel columns, beams, interconnecting framework, platforms at
different elevations, handrails etc.) Since these structures are metallic and firmly bonded from top to bottom they can be considered as “Natural
components” of LPS and hence no separate “Air Termination Network” and “Down Conductors” are necessary.
(Refer sections 12.1, 12.2 & 12.5.3 of IS 2309:1989)

Peripheral steel columns of these structures shall be connected (at every 30 Mtrs interval) to main Earthing Network via 50 x 6 mm GI strips.
Resistance to earth for LPS shall be less than 10 Ω. (Refer IS 2309: 1989 section 12.3.1).

Since earth termination network of LPS and plant main earth network is common (as recommended in IS 2309:1989 section 12.3.3) the resistance
to earth shall be less than 1 Ω thus ensuring very efficient LPS.

Below is the list of such structures

i. Reaction Area (including Compressor shed)
Area of the Structure : 66 Mtr. x 31.5 Mtr.
Height of the Structure : 83.85 Mtr.

Page 6 of 7
Earthing & Lightning Protection Calculation

ii. Seed Bed Silos

Area of the Structure : 30.25 Mtr. x 8.5 Mtr.
Height of the Structure : 81.5 Mtr.

iii. Pellet Blending Silos

Area of the Structure : 94.65 Mtr. x 11 Mtr.
Height of the Structure : 79.5 Mtr.

iv. Vent Gas Recovery & Compression

VGR Structure
Area of the Structure : 34 Mtr. x 25 Mtr.
Height of the Structure : 59.15 Mtr.
Compressor shed
Area of the Structure : 42 Mtr. x 21 Mtr.
Height of the Structure : 50.7 Mtr.

v. Purification
Hexene & Butene Area
Area of the Structure : 36 Mtr. x 8 Mtr. + 12 Mtr. x 12 Mtr.
Height of the Structure : 63.2 Mtr.

Hydrogen Compressor Area

Area of the Structure : 33.5 Mtr. x 7 Mtr.
Height of the Structure : 52.5 Mtr.

Nitrogen Compressor Area

Area of the Structure : 30 Mtr. x 7 Mtr.
Height of the Structure : 47.65 Mtr.

ICA & Butane Area

Area of the Structure : 24 Mtr. x 8 Mtr. + 12 Mtr. x 12 Mtr.
Height of the Structure : 53 Mtr.

Ethylene Area
Area of the Structure : 59 Mtr. x 8 Mtr.
Height of the Structure : 57.8 Mtr.

Hydrogen compressor Shed

Area of the Structure : 11 Mtr. x 14 Mtr.
Height of the Structure : 9 Mtr.
Note: Although the structure height is less than 20m, due to potential hazard of Hydrogen gas
the structure is provided with 2 nos Lightning protection earth pits.

v. Piperack PR-12
Grid PR/18 to PR/96 of this piperack is having height Approx 23 m. Further this piperack is located between C&P Building & Reaction structure
Which are covered in lightning protection calculation above. Therefore separate lightning protection is not required for piperack PR-12,
However for additional safety 2 nos of Lightning Earth pits are considered for Lightning protection

6 SUMMARY

(a) For this Plant, LPS for RCC buildings has been determined as per IS-2309:1989 guidelines.

(b) For all process units which are metallic structures, no separate “Air Termination Network” and “Down Conductors” are proposed/provided. This is in line
with IS recommendations. At ground level, these structures are connected to “Main Earth Network” to ensure earth connectivity below 1 Ω.
Earthing & Lightning Protection Calculation
Page 7 of 7
Earthing & Lightning Protection Calculation
Annexure-1
1. Fault current calculations for 415V Motor
Largest LV Motor on 415V Switchboard in the plant is SEED BED BLOWER MOTOR (Tag no. MA-CHC501-M5613, 5614) of rating 225 kW.
The fault current calculated at this motor terminal is as below :

Fault current available at PMCC Bus 65.00 kA

Source Voltage 0.415 kV

Source Reactance (Xs) 0.0037 Ohm

Cable size used 3C X 300 sqmm Aluminium cable (Selected based on LV cable sizing table
10080-1-ENGG-GUI-EL-003)
No of runs 3
(Estimated from plot plan)
Cable Length 275 m

Cable Resistance (ohm/km) 0.128 ohm/km

Cable Reactance (ohm/km) 0.071 ohm/km

Actual Cable Resistance Rc 0.012 ohm

Actual Cable Reactance Xc 0.0065 ohm

Z total = Ö Rc 2
+ (Xs + Xc)2 Z total 0.0155 ohm

Fault current at end of Cable 15.45 kA

2. Fault current calculations for 690V Motor

From substation nearest 690V Motor in the plant is PELLET WATER PUMP MOTOR (Tag no. MP-CHC501-M7012 / 7017) of rating 250kW.
The fault current calculated at this motor terminal is as below :

Fault current available at PMCC Bus 65.00 kA

Source Voltage 0.690 kV

Source Reactance (Xs) 0.0061 Ohm

Cable size used 3C X 150 sqmm Aluminium cable (Selected as per LV cable sizing calculation
10013-EWLC-CHC501-002)
No of runs 2

Cable Length 190 m

Cable Resistance (ohm/km) 0.264 ohm/km

Cable Reactance (ohm/km) 0.072 ohm/km

Actual Cable Resistance Rc 0.025 ohm

Actual Cable Reactance Xc 0.0068 ohm

Z total = Ö Rc 2
+ (Xs + Xc)2 Z total 0.0282 ohm

Fault current at end of Cable 14.12 kA

Since calculated fault current for 415V system 15.45 kA is more than 14.12 kA calculated for 690V system. Maximum fault
current for Plant earth strip sizing shall be considered as 15.45 kA

Page 1 of 1
J3 Program
Specification for …….

Doc. No. 10013-EGC-CHC501-001 Page

Rev: 0
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