FINAL Report of Lightning Protection Survey

REPORT NO.
:- GCI/V/CFCL/LPS/2012-13/MARCH/RMS-106/R00
LIGHTNING PROTECTION
SURVEY
PREPARED FOR
CHAMBAL FERTILIZERS & CHEMICALS LIMITED

KOTA, RAJASTHAN
CONDUCTED & PREPARED BY
GREEN CIRCLE INC.

Integrated HSEQR Consulting Engineers, Scientists & Trainers
(MoEF Recognised Environment Laboratory)
(An ISO: 9001, 14001 & OHSAS: 18001 Certified Organization)
REGD.OFFICE: Green Empire (Anupushpam), Beside Canara Bank, Nr. Yash Complex,
Above Axis Bank, Gotri Main Road, VADODARA 390 021, (Gujarat), India
Tel:- 0265- 2371028 / 2371269
www.greencircleinc.com E: info@greencircleinc.com
ALSO AT
NEW DELHI MUMBAI PUNE BANGALORE HYDERABAD
OVERSEAS: AUSTRALIA OMAN DUBAI NIGERIA
LIGHTNING PROTECTION SURVEY AS PER IS 2309:1989
REPORT NO.:-GCI/V/CFCL/LPS/2012-13/MARCH/RMS-106/R00
QUALITY CONTROL SHEET
Prepared Reviewed Approved

Rev. Date Reason History
By By By
Draft Report of Lightning

00 19/03/13 DC AS PJ
Protection Survey
DC : DEVANG CHAUHAN
AS : ANIL SHAH
PJ : PRADEEP JOSHI
Mr. Devang Chauhan, Executive- Electrical Risk

Prepared by
Signature
Reviewed by Mr. Anil Shah - Sr. Manager HSEQR Consulting
Signature
Approved by Mr. Pradeep Joshi - Group President & CEO
Signature
Released by Mr. Nachiket Joshi - Sr. Group Manager-Accounts & Finance
Signature
Green Circle Inc

ACKNOWLEDGEMENT
WE EXPRESS OUR SINCERE THANKS TO MANAGEMENT & EMPLOYEES
OF CHAMBAL FERTILIZERS & CHEMICALS LIMITED, KOTA,
RAJASTHAN FOR THEIR CO-OPERATION & UNSTINTED HELP
WITHOUT WHICH THE LIGHTNING PROTECTION SURVEY COULD
NOT HAVE BEEN POSSIBLE. THE COURTESY EXTENDED TO OUR TEAM
IS HIGHLY APPRECIATED.
For: GREEN CIRCLE INC.
AUTHORISED SIGNATORY
Green Circle Inc

INDEX
Page
Sr. No. Content No.
1 Organization Profile 2
2 Credits 3
Section-1
2 Introduction 4
3 Need of Protection 8
4 Lightning System Parameters 9
5 Calculation of Collection Area (Ao) 10
6 Weighing Factors 12
7 Working out Overall Risk Factors 15
8 Fixed Roof Tanks & Floating Roof Tanks 17
9 Deciding quantity of Down Conductors 19
10 Section-2 Township & Non-plant Buildings 42
11 Section-3 Specific Recommendations & Maintenance 64
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1. ORGANIZATION PROFILE
Chambal Fertilizers & Chemicals Limited (CFCL) is a fertilizers manufacturing company. It is one
of the largest and most respected companies in India's private sector. It is one of the companies
of Birla group. Expansion is already under progress.
Customer-focused approach and the continuous quest for world-class quality have enabled it
to attain and sustain leadership in its major lines of business.
CFCL believes that progress must be achieved in harmony with the environment. A commitment
to community welfare and environmental protection are an integral part of the corporate vision.
This can be seen by any visitor, from the lush green landscaping maintained in the plant and the
township. The company has high standard of safety not only for their employees, but also for
the contract personnel working in the plant.
The company's businesses are supported by a wide marketing and distribution network, and
have established a reputation for strong customer support.
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CREDITS
M/S. Chambal Fertilizers & chemicals limited appointed M/S. GREEN CIRCLE INC., VADODARA to
conduct LIGHTNING PROTECTION SURVEY. An audit team to plant site comprising Mr. N.N Parekh
Asso -VP - Electrical & Sanat Pandya, Asso -GM- Electrical from M/S GREEN CIRCLE INC.
The auditors from M/S. Green Circle Inc. conducted LIGHTNING PROTECTION SURVEY from 07th to
15th February 2013 with standard (Reference Std. IS 2309:1989 Protection of Building and Allied
Structure against Lightning Code of Practice)
Following were the key coordinating persons from the Plant:
Mr. N P Singh DGM EIP

Mr. Dhiraj Dhone DM Electrical
Mr. Dinesh Gupta Manager Electrical
Mr. Sandeep Gupta Asst. Manager Electrical
Mr. Askok Chhipa Dy Manager - Electrical
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SECTION-1 (Chapter-2 to 9)
2. ABOUT LIGHTNING
1.0 INTRODUCTION
Lightning is a natural hazard, generally experienced during monsoon season. Some lightning
strokes may result in damage to the buildings, structures, equipments, etc., and few strokes even
kill or injure people and animals, as we normally come across during monsoon season. The
damage caused to the property and equipments may run into substantial amount depending
on the intensity of lightning stroke.
There are various theories explaining the phenomena of lightning. The most logical and
understandable is Precipitation Theory. During monsoon, clouds in the sky have water particles
of two types heavy particles (mist) & light particles (water droplets). As the cloud travels, heavy
particles, which are negatively charged settles in the bottom part of the cloud and Light
particles remain in the top portion of the cloud.
When the negative charge becomes very heavy, it will try to find its way to earth. The air
between bottom part of the cloud and the earth breaks down which results in LIGHTNING. We
see streak of lightning for fraction of second.
Ironically, damage due to lightning can be reasonably prevented by providing suitable lightning
protection system. The protection methods to prevent damage due to lightning are simple,
reasonably reliable and rather inexpensive, particularly when compared to the cost of
equipment repair and replacement, as well as possible consequences of harm to the people.
Lightning is the visible discharge of static electricity within a cloud, between clouds, or between
the earth and a cloud". Thunderstorms occur when warm and cold air masses meet. Charges of
electrical energy build up within the air masses and periodically discharge as energy flows from
one area to another. Air moving upwards in the churning causes a separation and movement of
positively charged ions or particles to the top of clouds, where the cold and warm fronts meet,
leaving negative charges at the bottom of clouds. The lightning strokes may pass vertically or
horizontally between clouds or may move between the air and the ground where energy is
finally dissipated.
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2. CHARACTERISTICS OF LIGHTNING STROKE
(a) Current in lightning stroke

A lightning flash striking the ground, known as "Groundstroke lightning, produces a tremendous
electrical current of the range of about 2,000 amp to 2,00,000 amp or even more. The energy in
lightning stroke of such current magnitude in turn produces very high temperatures up to 27,760
deg C (or 50,000 deg F), which is almost five times hotter than the surface of the sun. Rapid
heating (expansion) and then cooling (contraction) of air around a lightning stroke produces
the shock wave due to air movement, which is heard as a thunderclap during lightning storms.
(b) Voltage in lightning stroke

It is difficult to estimate the potential of lightning charge just before lightning flash. Whatever
estimate is made is based on basic formula Q = CV, where Q is charge in coulomb, C is ion
capacitance, and V is voltage. The potential so considered is high enough to ensure that the
potential is sustained by whatever building/structure struck would be controlled by the product
of current and impedance, because this product would never be high enough in comparison
with the cloud potential to modify the magnitude of current.
(c) Vulnerability of high structures to lightning stroke

When the lightning stroke from cloud reaches near enough to earth, The upward streamer starts
from the earth depending on a critical field bring exceeded at the earth emission point and
hence it is a function of the charge deposited by the down-coming flash. The length of the
upward streamer will be greater for greater charges and hence high current flashes will start
preferentially from high structures due to high field enhancement.
The magnitude of the cloud-to-ground lightning hazard is understood better today than had
been in earlier days. In this part of India, the lightning strokes are generally experienced during
monsoon season of around 4 months. Since lightning strikes the ground not in a large numbers
and is not exceedingly widespread, the data collection for arriving at thunderstorm days is also
limited. For this reason, lightning can be considered the most dangerous weather hazard that
many industries and people encounter each year. Lightning-specific warnings systems have not
been in existence in our country so far.
3. EFFECTS OF LIGHTNING STROKE

There are three types of effects of lightning viz. electrical, mechanical and thermal as follows
(a) Electrical effect is of rise in voltage and current. Voltage is very high and time is very short. In
some cases, voltage reaches as high as 170 kV in 1.2 microseconds. Afterwards, on 50th
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microsecond voltage reduces to 85 kV. The lightning current rises steeply to its crest valve, at
the rate of 10,000 Amps per microsecond. It may produce around the earth electrodes, a
high potential gradient dangerous to persons and animals.
(b) Mechanical effect is exerted due to sudden high temperature. The space between the
thundercloud & the lighting conductor suddenly gests heated up to very high temperature.
This results in a strong pressure wave, which can damage structures & buildings. It is not
possible to provide protection against such an effect.
Considerable mechanical stresses are developed at sharp bends. Therefore, bends should
be minimized as far as possible. If this is unavoidable, secure (fix) the bends and strip or
conductor tightly.
(c) Thermal effects, during stroke, air temperature reaches as high as 30,000 K. This creates a
very big shock wave. Thermal effect is also there on the conductor, through which lighting
current passes. Because, time is very short, thermal effect on of lightning protective system is
negligible. In practice, the cross sectional area of a lightning conductor is decided primarily
by mechanical consideration.
4. TYPES OF LIGHTNING
There are total five types of Lightning. Based on clouds & ground discharge direction, these are
divided into three groups
GROUP 1: CLOUD TO GROUND LIGHTNING DOWNWARD DISCHARGES
(a) Negative Downward Discharge: Negative charge of cloud goes downward to the earth to
meet the Positive charge. 90% of lightning is of this type.
(b) Positive Downward Discharge: Positive charge of cloud goes downward to the earth to meet
the Negative charge.
GROUP 2: GROUND TO CLOUD LIGHTNING UPWARD DISCHARGES
(c) Negative Upward Discharge: Negative charge of the earth goes upward to meet the
Positive charge of cloud.
(d) Positive Upward Discharge: Positive charge of the earth goes upward to meet the Negative
charge of cloud.
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GROUP 3: CLOUD-TO-CLOUD DISCHARGES
(e) Positive charge of on cloud meets Negative charge of the other cloud. Such discharge does
not reach ground. It is in the sky only.
5. DAMAGE DUE TO LIGHTNING
The necessity for systems offering protection against the effects of lightning is becoming ever
greater. The increased use to domestic and industrial electronic components, tall buildings and
high-risk or dangerous sites within city limits have led legislators to include lightning risk
assessment in their safety regulations and to lay down guidelines for appropriate protection
systems.
Despite their best efforts, instances of material damage and human casualties still prevail.
Abbreviations used
IS Indian Standard
AT Air Terminals (spike)
DC Down Conductors
EP Earthing Pits
LA Lightning Arrestor
RMS Risk Management Services
ORF Overall Risk Factor
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3. NEED OF PROTECTION
Before proceeding to design a detailed lightning protection system, one should carefully
consider, do the structure needs protection. In many causes, it is observed that some form of
protection is required. High-risk structures i.e. explosives factories, oil refineries etc will require the
highest possible class of lightning protection to be provided. In many cases, the need for
protection is not so evident.
IS: 2309-1989 provides a simple mathematical overall risk factor (ORF) analysis. Calculation
assesses whether a structure needs protection or not. An acceptable lightning strike risk factor is
taken as 10-5 per year, i.e. 1 in 100,000 per year. If risk factor is less than 10-5 (1 in 100,000), for
example 0.8 in 100,000, then protection is deemed unnecessary. If risk factor is greater than 1 in
100,000, for example 5 in 10,000, then protection would be required.
For structures requiring protection, various data (like dimension, criticality, type of service, type of
terrain etc.) are required.
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4. LIGHTNING SYSTEM PARAMETERS
1.CURRENT
In view of difficulty in describing an Average lightning flash, ranges of various parameters in

the lightning system designing are normally assumed. The lightning strike current considered for
design ranges from about 2000 A to 2,00,000 A.
2. VOLTAGE
The charge potential before stroke is based on 100oC and 1 km radius of an equivalent spherical
cell, which is considered about 10-7 F(farad) and the estimated potential is assumed 100 MV
from relation Q = CV.
3.AVERAGE THUNDERSTORM DAYS
Average thunderstorm days given in IS: 2309:1989 (Sr. no.30 on page 5) for Kota is 27
As the distance from the seacoast increases, the probability of thunderstorm has been found
increasing and the number of thunderstorm days has been observed generally increasing.
4. LIGHTNING FLASH DENSITY Ng
Data for number of thunderstorm days is translated in terms of estimated average annual density
Ng, i.e. Lightning flash per km2 per year, in referred IS as follow. Data for Thunderstorm days /
year and Lightning flashes / km2 / year is reproduced from IS 2309:1989 for information.
Average thunderstorm days given in IS: 2309:1989 (Page 5, Sr no.30) for Kota is 27.
Table-2 (at the end of this section) shows ESTIMATED AVERAGE ANNUAL LIGHTNING FLASH
DENSITY IN TERMS OF LIGHTNING FLASHES PER KM2 PER YEAR. (This table is from IS 2309:1989)
Lightning flash density considered in the assessment of lightning protection based on data
provided in IS 2309:1989, is worked out from the above table. It comes to 1.66 per KM2 per year
NG = Mean Lightning Flashes / km2 / year for Kota is 1.66
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5. CALCULATION OF COLLECTION AREA (A0)
The determination of collection area of buildings, structures, etc. required in the engineering
calculations for assessment of the lightning protection depends on length, width and height as
well as on the shape of individual building and structure.
The method of calculating collection area based on the shape of building and type of roof as
described in IS 2309. The formula for calculating Area for particular shape is also mentioned in IS
2309:1989
Further to above, the type of construction of building, i.e. steel structure, RCC or mix of both,
type of roof over building, i.e. RCC slab, metallic roof or asbestos sheet roof, etc are considered
in the engineering, wherever required. Table-1 (attached at the end of this section) shows the
details of buildings and structures considered for lightning protection system at CFCL, Kota.
Uncovered storage areas are considered for assessment based on various risk weighing factors
applied in accordance with the nature of goods stored, i.e. normal goods, inflammable and
explosive materials. The collection area is derived applying simple L x W formula.
(A) Sample Calculation of Collection Area (A0) For All Building Structures of Rectangular Shape
with Metallic Sloping Roof
Ao = Collection Area = 2(Length x Height) + (3.14 x Height2)
For Ammonia-1 plant compressor house shed,
Length = 50 Mt. and Height = 16.5 Mt
Ao = 2 (50 x 16.5) + (3.14 x 16.52)

= 2505 M2
For all structures of this type, calculations are tabulated in Table-3 of this section
(B) Sample Calculation of Collection Area (A0) For Tall Structure like Overhead Tank / Chimney /
Structural Tower / Lighting Mast
Ao = 3.14 X Height2
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For Urea Prilling Tower-1, area of collection, based on above formula is

Ao = 37994 M2
(C) Sample Calculation of Collection Area (A0) For Open Yard without Roof
Ao = Length X Width for flat area, or

= 0.785 x D2 for circular area
For cooling tower unit of Ammmonia-1 offsite, L= 135 Mt & W = 16 Mt.
Therefore, Ao = 135 x 16 = 2160 M2
For all this type of structures, calculations are tabulated in Table-5 of this section
(D) Sample Calculation of Collection Area (A0) For All Building Structures of Rectangular Shape
with RCC Flat Roof
Ao = (Length X Width) + 2(Length X Height) + 2(Width X Height) + 3.14 Height2

For Ammnia-1 SUB STATION WITH FLAT RCC ROOF (TERRACE)
Length = 48 Mt, Length = 9 Mt & Height = 8.5 Mt
Therefore, Ao = 1628 M2
Thus, for all buildings/ structures / Areas, Collection Area (A0) was worked out, which are shown
in Table-3 to Table-6. (Refer the Annexure)
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6. WEIGHING FACTORS
The weighing factors denote a relative degree of importance or risk in each case. These factors
are to be applied when assessing the overall assessment of risk due to the lighting stroke. Data
for Weighing Factors, which is as provided in, IS 2309:1989
TABLE.1
WEIGHING FACTOR A FOR ACTIVITY IN BUILDING OR USAGE OF STRUCTURE
VALUE OF
SR. NO USE TO WHICH STRUCTURE IS PUT WEIGHING
FACTOR A
1 Houses and other buildings of comparable size 0.3
2 Houses and other buildings of comparable size with outside aerials 0.7
3 Factories, workshops and laboratories 1.0

Office blocks, hotels, blocks of flats and other residential buildings 1.2
4
other than those included below.
Places of assembly, for example churches, halls, theatres, museums, 1.3

5 exhibition halls, department stores, stations, airports and stadium
structures
6 Schools, hospitals, children's and other such homes 1.7
TABLE.2
WEIGHING FACTOR B FOR TYPE OF CONSTRUCTION
VALUE OF
SR. NO TYPE OF CONSTRUCTION WEIGHING
FACTOR B
Steel framed encased, with roof made of any material other than
1 0.2
metal*
Reinforced concrete with roof made of any material other than
2 0.4
metal
3 Steel framed encased or reinforced concrete with metal roof 0.8
4 Brick, plain concrete or masonry with roof made of any materials 1.0
other than metal
5 Timber framed or clad with roof made of any materials other than 1.4
metal or thatch
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6 Brick, plain concrete or masonry, timber framed with metal roof 1.7
7 Any building with thatched roof 2.0

* A structure of exposed metal, which is continuous down to ground level, is excluded from the
tables, as it requires no lightning protection beyond adequate earthing arrangements.
TABLE.3
WEIGHING FACTOR C FOR CONTENTS OR CONSEQUENTIAL EFFECTS
VALUE OF
SR
CONTENTS OR TYPE OF BUILDING OR CONSEQUENTIAL EFFECTS WEIGHING
No.
FACTOR C
1 Ordinary domestic or office buildings, factories and workshops not 0.3
containing valuable or specially susceptible contents
2 Industrial and agricultural buildings with specially susceptible* contents 0.8
3 Power stations, gas works, telephone exchanges, radio stations 1.0

4 Industrial key plants, ancient monuments and historic buildings, museums, 1.3
and other buildings with specially valuable contents
5 Schools, hospitals, and other such places of assembly 1.7
* This means especially valuable plant or materials vulnerable to fire or the results of fire.
TABLE.4
WEIGHING FACTOR D FOR DEGREE OF ISOLATION
VALUE OF
SR.
DEGREE OF ISOLATION* WEIGHING
NO
FACTOR D
1 Structure located in a large area of structures or trees of the same or 0.4
greater height, for example, in a large town or forest
2 Structure located in an area with few other structures or trees of similar 1.0
heights
3 Structure completely isolated or exceeding at least twice the height of 2.0
surrounding structures or trees
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TABLE.5
WEIGHING FACTOR E FOR TYPE OF COUNTRY
Value of
Sr. No Type of Country Weighing
Factor E
1 Flat country at any level 0.3
2 Hilly country 1.0
3 Mountain country between 300 Meter to 900 Meter 1.3
4 Mountain country above 900 Meter 1.7
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7. WORKING OUT OVERALL RISK FACTOR
Acceptable risk due to lightning stroke mentioned in IS : 2309 is
PO = 1 x 10-5, i.e. 1 in 1,00,000 per year
After deriving the probable number of lightning strikes per year on a building / structure under
assessment, the Risk Weighing Factors are applied as shown in the sample method of
calculation provided and Overall Risk Factor (ORF) is found out and necessarily or otherwise of
the lightning protection is considered on following basis.
If Overall Risk Factor P < P0, i.e. less than 1 x 10-5, Lightning protection may not be necessary in
absence of other overriding considerations.
If Overall Risk Factor P > P0, i.e. greater than 1 x 10-5, Lightning protection will be necessary.
In case the ORF is found marginally greater or lower, it would be essential to provide sound
reasons for either providing or not providing the lightning protection.
The buildings / structures having chemical process of explosive or flammable nature and
covered / open storages containing explosive or flammable substances are to be provided with
the lightning protection irrespective of the estimated ORF more or less than acceptable risk of 1
x 10-5.
(A) Sample Calculation for Overall Risk Factor
FOR SAMPLE BUILDING

FOR SAMPLE BUILDING

= 2 (180 X 25.8) + 3.14 X 25.82
= 11378.1096 sq. Mt.
Over All Risk (P) = PA X Overall Weighing Factor
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Where
PA = Ao X Ng X 10-6
= 11378.1096 X 0.2 X 10-6
= 2275.62192 X 10-6
Overall Weighing Factor = A X B X C X D X E

A = 1, B = 0.8, C = 0.8, D = 1, E = 0.3 (FOR SAMPLE BUILDING)
Overall Weighing Factor = 1 X 0.8 X 0.8 X 1 X 0.3

= 0.192
Note: Weighting Factors are considered on the basis of IS 2309:1989 Tables
ORF = PA X Overall weighing Factor

= 2275.62192 X 10-6 X 0.192
= 436.91940864 X 10-6
= 43.691940864 X 10-5
Because ORF is more than 1x 10-5, protection is required.
From Table-7 it can be seen that protection against lightning is required for all structures /
buildings, because ORF in all cases are more than 1 in 1, 00,000.
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8. FIXED ROOF TANKS & FLOATING ROOF TANKS
For protection of tanks, in NFPA780, there are guidelines which are as under:
6.4 Protection of Specific Classes of Structures.

6.4.1 Aboveground Tanks at Atmospheric Pressure Containing Flammable Vapors or Liquids That
Can Give Off Flammable Vapors.
6.4.1.1 Fixed Roof Tanks.
Metallic tanks with steel roofs of riveted, bolted, or welded construction, with or without
supporting members, that are used for the storage of liquids that give off flammable vapors at
atmospheric pressure shall be considered to be protected against lightning (inherently self-
protecting) if the following requirements are met:
(1) All joints between metallic plates shall be riveted, bolted, or welded.
(2) All pipes entering the tank shall be metallically connected to the tank at the point of
entrance.
(3) All vapor or gas openings shall be closed or provided with flame protection in locations
where the stored stock might produce a flammable air-vapor mixture under storage
conditions.
(4) The roof shall have a minimum thickness of 3/16 in. (4.8 mm).
(5) The roof shall be welded, bolted, or riveted to the shell.
6.4.1.2 Floating Roof Tanks.

(a) General. Fires have occurred when lightning has struck the rims of open-top floating roof
tanks where the roofs were quite high and the contents volatile. Similar above-the-seal fires have
occurred when direct lightning strokes to the rims of floating roof tanks have ignited flammable
vapors within the open shells. These have occurred where roofs were low. The resulting seal fires
have been at small leakage points in the seal. An effective defense against ignition by a direct
stroke is a tight seal.
Fires have also occurred in the seal space of open-top floating roof tanks as a result of
discharges caused by lightning. These have occurred most frequently in tanks having floating
roofs and seals with vapor spaces below the flexible membranes. Similar vapor spaces will be
formed where tanks are fitted with secondary seals in compliance with environmental
regulations. Ignition can be from a direct stroke or from the sudden discharge of an induced
(bound) charge on the floating roof, released when the charge on a cloud discharges to
ground or to another cloud.
(b) Protection. Where floating roofs utilize hangers located within a vapor space, the roof shall
be electrically bonded to the shoes of the seal through the most direct electrical path at
intervals not greater than 10 ft (3 m) on the circumference of the tank. These shunts shall consist
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of flexible Type 302, 28-gauge [1/64 in. 2 in. (0.4 mm 51 mm)] wide stainless steel straps or
the equivalent in current-carrying capacity and corrosion resistance. The metallic shoe shall be
maintained in contact with the shell and without openings (such as corrosion holes) through the
shoe. Tanks without a vapor space at the seal shall not require shunts at the seal. Where metallic
weather shields cover the seal, they shall maintain contact with the shell.
Where a floating roof is equipped with both primary and secondary seals, the space
between the two seals could contain a vapor-air mixture within the flammable range; therefore,
if the design of such a seal system incorporates electrically conductive materials and a spark
gap exists within that space or could be created by roof movement, shunts shall be installed so
that they directly contact the tank shell above the secondary seal. The shunts shall be spaced at
intervals not greater than 10 ft (3 m) and shall be constructed so that metallic contact is
maintained between the floating roof and the tank shell in all operational positions of the
floating roof.
6.4.1.3 Metallic Tanks with Nonmetallic Roofs.

Metallic tanks with wooden or other nonmetallic roofs shall not be considered to be self-
protecting, even if the roof is essentially gastight and sheathed with thin metal and with all gas
openings provided with flame protection. Such tanks shall be provided with strike termination
devices. Such strike termination devices shall be bonded to each other, to the metallic
sheathing, if any, and to the tank shell. Isolated metal parts shall be bonded as required by
Section 3.19. Any of the following strike termination devices shall be permitted to be used:
conducting masts, overhead ground wires, or a combination of masts and overhead ground
wires.
6.4.1.4 Grounding Tanks.

Tanks shall be grounded to conduct away the current of direct strokes and to avoid the buildup
and potential that can cause sparks to ground. A metal tank shall be grounded by one of the
following methods.
(a) A tank shall be connected without insulated joints to a grounded metallic piping system.
(b) A vertical cylindrical tank shall rest on earth or concrete and shall be at least 20 ft (6 m) in
diameter, or shall rest on bituminous pavement and shall be at least 50 ft (15 m) in diameter.
(c) A tank shall be bonded to ground through a minimum of two ground terminals, as described
in Section 3.13, at maximum 100-ft (30-m) intervals along the perimeter of the tank. This also shall
apply to tanks with an insulating membrane beneath the tank.
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9. DECIDING NUMBER OF DOWN CONDUCTORS FOR EXISTING STRUCTURE
About number of down comers, IS 2309:1989 recommends (in 12.2.3) as under
Structure with base area not exceeding 100 01 no. down conductor
m2
Structure with base area exceeding 100 m2 At least smaller of the following options:
1) 01 no. + additional no. for each 300 m2, or

part thereof, in excess of first 100 m2
OR
2) 01 no. for each 30-meter perimeter of the
structure protected.
Based on the perimeter and Base area of the structures, down comer, earth pits & spikes are
decided. Summary of the recommendation is given in the tabular form of next five pages. Last
three columns indicate additional hardware Air terminals (AT), down conductor (DC) and
earth pits (EP) required.
NAME OF EXISTING SYSTEM PROPOSED SYSTEM ADDITIONAL SYSTEM

BUILDING AT DC EP AT DC EP AT DC EP
Ammonia-1
Compr. House 0 1 1 In the protection zone of F301
Substation 0 0 0 2 2 2 2 2 2
G-1 control room 0 0 0 6 6 6 6 6 6
F301 HP Tower 1 1 1 1 1 1 0 0 0
F302 CO2 Abso. 0 0 0 1 0 1 1 0 1
Urea
U. Prilling Tower-1 3 3 3 3 3 3 0 0 0
Urea-11 substation 0 0 0 3 3 3 3 3 3
Urea-21 substation 0 0 0 3 3 3 3 3 3
Ammo. Sto.tank-1 2 2 2 2 2 2 0 0 0
Ammo. Sto. tank-2 2 2 2 2 2 2 0 0 0
Urea Product Handling
Main bldg. 1 & 2 2 2 2 6 6 6 4 4 4
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Main bldg. 3 2 2 2 3 3 3 1 1 1
Silo No change in the existing system - All existing earth pits shall be renovated
and continuity of DC with earth pit shall be ensured.
Screen house
2 2 2 2 2 2 0 0 0
(consider one blg)
Wagon loading
0 0 0 7 22 22 7 22 22
Area (left) 300 Mt
Wagon loading
0 0 0 9 28 28 9 28 28
Area (rt.)- 400 Mt.
Non Plant
Maint. Workshop 10 10 8 10 10 10 0 0 2
Store 0 0 0 10 10 10 10 10 10
Offsite -SPG
HRSG 1 (& stack) 1 1 1 1 1 1 0 0 0
HRSG 2 (& stack) 1 1 1 1 1 1 0 0 0
Aux Boiler 1 0 0 0 1 0 2 1 0 2
Aux Boiler 2 0 0 0 1 0 2 1 0 2
Aux Boiler 1 stack 1 1 1 1 1 1 0 0 0
Aux Boiler 2 stack 1 1 1 1 1 1 0 0 0
IAPA (Comp Hs.) 1 4 4 4 4 4 3 0 0
Emerg. DG-1 0 4 0 2 2 2 2 0 2
O&U CR building. 8 7 7 8 9 9 0 2 2
Offsite 1
DM-1 substation 0 0 0 1 1 1 1 1 1
DM-2 substation 1 2 0 2 2 2 1 0 2
Cooling towers
0 8 8 12 8 8 12 0 0
(12)
Naphtha Storage This tank is located on west side of SPG unit. It is inherently Self protected as
tanks per NFPA (check earth pits)
Naphtha Daily This tank is located on west side of SPG unit. It is inherently Self protected as
tank per NFPA (check earth pits)
Water pre treated
& Clarified filtered
Inherently protected (check earth pits)
water storage tanks
(T-912A)
Water pre treated
& Clarified filtered
water storage tanks Inherently protected (check earth pits)
(T-912B)
Green Circle Inc 20


Fire water storage
Inherently protected (check earth pits)
tank (T-5912)
Fire water pump
0 0 0 2 2 2 2 2 2
house
Raw/CW water
0 0 0 4 4 4 4 4 4
substation
ETP
Refer Section-2 of the report
NG station 0 0 0 0 0 1 0 0 1
Holding pond
0 0 0 1 1 1 1 1 1
MCC
On site-2
G-2 substn. bldg 0 0 0 3 3 3 3 3 3
Auxiliary Boiler 3 0 0 0 0 0 0 0 0 0
Aux boiler-3 stack 0 0 0 1 0 1 1 0 1
I.A. comp shed Covered under protection zone of Ammo.-2
0 0 0
compressor house
Ammonia-2
CR L shape-1 0 0 0 2 2 2 2 2 2
CR L shape-2 0 0 0 1 1 1 1 1 1
Compr. House. 0 0 0 4 3 3 4 3 3
Prilling tower 2 3 3 3 3 3 3 0 0 0
CO2 Stripper 402 0 0 0 1 0 1 1 0 1
CO2 absorber 0 0 0 1 0 1 1 0 1
Urea-2A
Compr. house 0 0 0 Covered under protection zone of Prilling Tower-2
carbonate
0 0 0 0 0 2 0 0 2
Solution tank-2401
urea solution tank
0 0 0 0 0 2 0 0 2
U-FA-2201
Urea-2B
Compr. house
0 0 0 Covered under protection zone of Prilling Tower-2
carbonate
0 0 0 0 0 2 0 0 2
Solution tank
urea solution tank 0 0 0 0 0 2 0 0 2
Guard pond bldg
0 0 0 1 1 1 1 1 1
(remote location)
Green Circle Inc 21


Naphtha storage Inherently protected if conditions of NFPA780 are
0 0 0
tank-A-FB -101A fulfilled. (Refer Chapter-8 of Section A in this report)
Naphtha storage Inherently protected if conditions of NFPA780 are
0 0 0
tank-A-FB -101B fulfilled. (Refer Chapter-8 of Section A in this report)
Emergency DG-2 0 0 0 2 2 2 2 2 2
EDG exhaust
1 1 1 0 0 0 0 0 0
Chimney.
Cooling Tower (11 1
1 per 1 per
per 11 8 8 0 0 0
nos.) cell cell
cell
G2-Flare Stack
0 0 0 1 0 1 1 0 1
Tower
Utility /CW substn. 0 0 0 1 1 1 1 1 1
Single Super Phosphate
SSP substation 0 0 0 Covered under protection zone of 3 nos. chimneys
SSP Control Room 0 0 0 Covered under protection zone of 3 nos. chimneys
SSP Chimney 201 1 1@ 0 1 1 1 0 1 1
Ball mill chimney

1 1 0 1 1 1 0 0 1
100SK01
Chimney inside
0 0 0 1 0 1 1 0 1
GSSP plant bldg.
H2SO4 tank no 1 0 0 0 0 0 1 0 0 1
H2SO4 tank no 2 0 0 0 0 0 1 0 0 1
Rock phosphate
0 0 0 4 4 4 4 4 4
shed
Rock phosphate
0 0 0 4 4 4 4 4 4
storage shed
GSSP Based
Storage &Plant 0 0 0 4 4 4 4 4 4
building
@ Down comer is left half the way. This will be brought up to the new earth pit, at the base
Green Circle Inc 22

Above table shows only three hardware Air terminal (spike), down conductor and earth pit. In
addition to these, on sloping roofs and flat roofs, earth mesh (of max 20 Mt x 10 Mt. size) is to be
laid. The details of this protection (wherever required) can be referred from Table-8 (Final
recommendations.
Following tables (attached with the report) show the various details:
Table-1 Details of buildings / structures considered for lightning protection at CFCL.

Table-2 Estimated Average Annual Lightning Flash Density
Table-3Collection Area for all buildings / structures of Rectangular shape with Metallic sloping
Roof
Table-4 Collection Area for tall structures like overhead tank / chimney /tower / lighting mast etc
Table-5 Collection Area for open yard without roof
Table-6 Collection Area for buildings / structures of Rectangular shape with RCC flat roof
Table-7 To find out Overall Risk Factor to decide - Protection required or not (for each structure/
building)
Table-8 Final Recommendations for AT, DC & EP. The above Table (on Page 19 to 22) shows
summary
Green Circle Inc 23

Table-1 Details of buildings / structures considered for lightning protection at CFCL.
Length Width Height Dia

Sr Description of building
Plant L W H D Type of building and roof
no structure.
METER METER METER METER
Onsite -1
Compressor House (Ammonia
1 Ammonia1 50 20 16.5 -- Metallic slopping roof
comp)
2 Ammonia 1 Ammonia -1 Substation 48 9 8.5 -- Rectangular shape with RCC flat roof
3 Ammonia1 G-1 Control room 72 20 6.8 -- Rectangular shape with RCC flat roof
4 Urea Urea Prilling Tower -1 -- -- 110 27.8 Tall structure
5 Ammonia Ammonia 1 Reformer 40 10 25 -- Metallic slopping roof
6 Urea Urea -11 Substation 40.5 14.55 8.5 -- Rectangular shape with RCC flat roof
7 Urea Urea -21 Substation 40.5 14.55 8.5 -- Rectangular shape with RCC flat roof
8 Ammonia Storage Tanks (2 no.) -- -- 21.6 25 Open area/Tall structure
9 Ammonia Storage Tanks (2 no.) -- -- 21.6 25 Open area/Tall structure
10 Ammonia F301 HP TOWER -- -- 70 2.5 Tall structure in Ammonia process area

11 Ammonia F302 CO2 Absorber -- -- 65 2.5 Tall structure in Ammonia process area
UPHS
12 UPHS Main building 1 and 2 60 15.3 35 -- Rectangular shape with RCC flat roof
13 UPHS Main building 3 55 15 35 -- Rectangular shape with RCC flat roof

RCC structure in half round semi
14 UPHS Silo 240 55 30 --
cylindrical shape
Green Circle Inc 24


no structure.
Screen house(consider one
15 UPHS 20 16.5 21 -- Rectangular shape with RCC flat roof
building)
16 UPHS Wagon Area left 300 25 9.5 -- Metallic slopping roof
17 UPHS Wagon Area right 400 25 9.5 -- Metallic slopping roof
Off site
18 SPG HRSG 1 STACK -- -- 13.2 1.5 Tall structure
19 SPG HRSG 2 STACK -- -- 13.2 1.5 Tall structure
20 SPG Aux Boiler 1 15 10 20 -- Metallic slopping roof
21 SPG Aux Boiler 2 15 10 20 -- Metallic slopping roof
22 SPG Aux Boiler 1 STACK -- -- 20 1.8 Tall structure
23 SPG Aux Boiler 2 Stack -- -- 20 1.8 Tall structure

Inst Air comp &Plant Air Comp
24 SPG 42 15 11 -- Metallic slopping roof
IAPA
25 SPG Emergency DG set -1 EDG-1 18 18 16 -- Rectangular shape with RCC flat roof
26 SPG O&U control room building. 72 12 14 -- Rectangular shape with RCC flat roof
27 DM-1 DM-1 substation 5 5 6 -- Rectangular shape with RCC flat roof
28 DM-2 DM-2 substation 24 12 10 -- Rectangular shape with RCC flat roof
29 CW Cooling tower 12 nos 135 16 24 -- Open area without roof

Naphtha
30 New Tanks -- -- 11.58 16.8 Open area without roof
Storage
Green Circle Inc 25


no structure.
Naphtha
31 New Tanks -- -- 11.58 16.8 Open area without roof
Storage
Naphtha Water pre treated & Clarified
32 Storage filtered water storage tanks -- -- 18 38 Open area without roof
no 1
No 2
No 3
35 Fire Pump Fire water pump house 39 10 9 -- Rectangular shape with RCC flat roof
36 Raw water Raw/CW water substation 45 25 10 -- Rectangular shape with RCC flat roof
Holding
37 MCC Room 5 5 5 -- Rectangular shape with RCC flat roof
Pond
Onsite-2
Ammonia-
38 G2 substation Building 61 12 11 -- Rectangular shape with RCC flat roof
II/Urea II
39 Ammonia-II Auxiliary Boiler no 3 20 15 25 -- Metallic slopping roof.
40 Ammonia-II Auxiliary Boiler 3 stack 35 2.5 Tall structure
41 Ammonia-II I.A.comp shed 15 7 6 -- Metallic slopping roof AC sheet

Ammonia 2 control room L
42 Ammonia-II 25 20 6 -- Rectangular/L shape with RCC flat roof
shape -1
Ammonia 2 control room L
43 Ammonia-II 10 10 6 -- Rectangular/L shape with RCC flat roof
shape -2
Green Circle Inc 26


no structure.
Ammonia 2 compressor
44 Ammonia-II 42 20 26 -- Metallic slopping roof
House.
CO 2 Stripper tag no 402in
45 Ammonia-II -- -- 70 2.5 Tall structure very important
Ammonia ii
46 Ammonia-II CO2 absorber in Ammonia 2 -- -- 60 2.5 Tall structure
47 Urea 2 Prilling tower 2 -- -- 117.85 26 Tall structure
48 Urea 2 Urea 2 A Process area -- -- -- --

49 Urea 2 A Compressor house 25 10 15 -- Metallic slopping roof
Urea 2A carbonate Solution
50 Urea 2 tank -- -- -- -- Open area without roof
No U-FA-2401
Urea 2A urea solution tank
51 Urea 2 -- -- -- -- Open area without roof
No U-FA-2201
52 Urea 2 Urea 2 B Process area -- -- -- --
53 Urea 2 Urea 2 B Compressor house 25 10 15 -- Metallic slopping roof

Urea 2 B carbonate Solution
54 Urea 2 -- -- -- -- Open area without roof
tank
55 Urea 2 Urea 2B urea solution tank -- -- -- -- Open area without roof
Guard pond building (remote
56 Guard Pond 5 4 5 -- Rectangular/L shape with RCC flat roof
location)
Naphtha Naphtha storage tank-A-FB -
57 -- -- 11.58 16.8 Open area without roof
Storage 101
Naphtha Naphtha storage tank-A-FB -
58 -- -- 11.58 16.8 Open area without roof
Storage 102
59 EDG Emergency Diesel Set Building 30 10 15 -- Rectangular/L shape with RCC flat roof
Green Circle Inc 27


no structure.
60 EDG EDG exhaust Chimney. -- -- 25 2.5 Tall structure
Cooling
61 Cooling Tower 11 nos 135 16 24 -- Open area without roof
Tower
62 G2 G2-Flare Stack Tower 10 10 70 -- Tall structure
63 G2 Utility /CW substation 22 10 11 -- Rectangular/L shape with RCC flat roof
SSP
64 SSP SSP substation 14 8.5 6 -- Rectangular/L shape with RCC flat roof
65 SSP SSP Control room 22 6 6 -- Rectangular/L shape with RCC flat roof
66 SSP SSP Chimney no 201 -- -- 40 22.5 Tall structure
67 SSP Ball mill chimney 100SK01 -- -- 40 22.5 Tall structure

Chimney inside GSSP plant
68 SSP -- -- 40 2.5 Tall structure
building
69 SSP H2SO4 tank no 1 -- -- 8 8.2 Open area without roof
70 SSP H2SO4 tank no 2 -- -- 8 8.2 Open area without roof
71 SSP Rock phosphate shed 25 35.5 15 -- Metallic slopping roof
72 SSP Rock phosphate storage shed 20 50 10 -- Metallic slopping roof

GSSP Based Storage &Plant
73 SSP 40 28.4 8 -- Metallic slopping roof
building
Green Circle Inc 28

Table-2: Estimated Average Annual Lightning Flash Density
Estimated Average Annual Lightning Flash Density in terms of Lightning Flashes per km2
per year
Lightning flashes per km2 per year

Sr No Thunderstorm days/year
Mean Limits
1 5 0.2 0.1 - 0.5
2 10 0.5 0.15 - 1.0
3 20 1.1 0.3 - 3.0
4 30 1.9 0.6 - 5.0
5 40 2.8 0.8 - 8.0
6 50 3.7 1.2 - 10
7 60 4.7 1.8 - 12
8 80 6.9 3.0 - 17
9 100 9.2 4.0 - 20
PLACE KOTA(RAJASTHAN)
In IS 2309 for specific place Kota thunder storm days mentioned are 27.
From above details lightning flash density calculated for Kota is

ng=1.66flashes/perkm2per year
Green Circle Inc 29

Table-3 Collection Area for all buildings / structures of Rectangular shape with Metallic sloping Roof
Dimension in meters collection area in

SQ Meters
Sr no Unit Plant Description of building structure.
L W H Formula
Ao=2(LxH)+(3.14xH2)
1. Onsite -1 Ammonia1 Compressor House (Ammonia comp) 50 20 16.5 2504.865
2. Onsite -1 Ammonia Ammonia 1 Reformer 40 10 25 3962.5
3. UPHS UPHS Wagon Area left 300 25 9.5 5983.385
4. UPHS UPHS Wagon Area right 400 25 9.5 7883.385
5. Off site SPG Aux Boiler 1 15 10 20 1856
6. Off site SPG Aux Boiler 2 15 10 20 1856
7. Off site SPG Inst Air comp &Plant Air Comp IAPA 42 15 11 1303.94
8. Onsite-2 Ammonia-II Auxiliary Boiler no 3 20 15 25 2962.5
9. Onsite-2 Ammonia-II I.A.comp shed 15 7 6 293.04
10. Onsite-2 Ammonia-II Ammonia 2 compressor House. 42 20 26 4306.64

11. Onsite-2 Urea 2 A Compressor house 25 10 15 1456.5
12. Onsite-2 Urea 2 Urea 2 B Compressor house 25 10 15 1456.5
13. SSP SSP Rock phosphate shed 25 35.5 15 1456.5
14. SSP SSP Rock phosphate storage shed 20 50 10 714
15. SSP SSP GSSP Based Storage &Plant building 40 28.4 8 840.96
Green Circle Inc 30

Table-4 Collection Area for tall structures like overhead tank / chimney /tower / lighting mast etc
collection area in SQ Meters

Sr no Plant Description of building structure. Dimension in meters
Formula Ao=3.14*(Sq of H)
L W H D Formula Ao=3.14H2
Onsite -1
1. Urea Urea Prilling Tower -1 -- -- 110 27.8 37994
2. Ammonia F301 HP TOWER -- -- 70 2.5 15386
3. Ammonia F302 CO2 Absorber -- -- 65 2.5 13266.5
Off site
4. SPG HRSG 1 STACK -- -- 13.2 1.5 547.1136
5. SPG HRSG 2 STACK -- -- 13.2 1.5 547.1136
6. SPG Aux Boiler 1 STACK -- -- 20 1.8 1256
7. SPG Aux Boiler 2 Stack -- -- 20 1.8 1256
On site 2
8. Ammonia-II Auxiliary Boiler 3 stack -- -- 35 2.5 3846.5
CO 2 Stripper tag no 402in
9. Ammonia-II -- -- 70 2.5 15386
Ammonia ii
10. Ammonia-II CO2 absorber in Ammonia 2 -- -- 60 2.5 11304
11. Urea 2 Prilling tower 2 -- -- 117.85 26 43610.27465
12. EDG EDG exhaust Chimney. -- -- 25 2.5 1962.5
13. G2 G2-Flare Stack Tower -- -- 70 15386
SSP
14. SSP SSP Chimney no 201 -- -- 40 22 5024
15. SSP Ball mill chimney 100SK01 -- -- 40 22.5 5024
Chimney inside GSSP plant
16. SSP -- -- 40 22 5024
building
Green Circle Inc 31

Table-5 Collection Area for open yard without roof
Sr no Plant Description of building Dimension in meters collection area in SQ Meters

structure. L W H D Formula Ao=LXW
OR 3.14/4*D2
Onsite -1
1. Urea Storage Tanks (2 no.) -- -- 21.6 25 490.625
2. Urea Storage Tanks (2 no.) -- -- 21.6 25 490.625
Off site
3. CW Cooling tower 12 nos 135 16 24 -- 2160
4. Naphtha New Tanks -- -- 11.58 16.8 221.5584
Storage
5. New Tanks Tank no-- -- -- 11.58 16.8 221.5584
6. Water pre treated & Clarified -- -- 18 38 1133.54
filtered water storage tanks no 1
filtered water storage tanks No 2
filtered water storage tanks No 3
Onsite-2
9. Naphtha Naphtha storage tank-A-FB -101 -- -- 11.58 16.8 221.5584
Storage
10. Naphtha Naphtha storage tank-A-FB -102 -- -- 11.58 16.8 221.5584
Storage
11. CW Cooling tower 11 nos 135 16 24 -- 2160
SSP
12. SSP H2SO4 tank no 1 -- -- 8 8.2 52.7834
13. SSP H2SO4 tank no 2 -- -- 8 8.2 52.7834
Green Circle Inc 32

Table-6 Collection Area for buildings / structures of Rectangular shape with RCC flat roof
Dimension in meters
Sr no Unit Plant Description of building structure. collection area in SQ Meters
Length width - Height AO=(LXW)+2(LXH)+2(WXH)+3.14H2
-L W -H
1. Onsite -1 Ammonia 1 Amm -1 Substation 48 9 8.5 1627.865
2. Onsite -1 Ammonia1 G-1 Control room 72 20 6.8 2836.3936
3. Onsite -1 Urea Urea -11 Substation 40.5 14.55 8.5 1751.99
4. Onsite -1 Urea Urea -21 Substation 40.5 14.55 8.5 1751.99
5. UPHS UPHS Main building 1 and 2 60 15.3 35 10035.5
6. UPHS UPHS Main building 3 55 15 35 9571.5
7. UPHS UPHS Screen house (consider one building) 20 16.5 21 3247.74
8. Off site SPG Emergency DG set -1 EDG-1 18 18 16 2279.84
9. Off site SPG O&U control room building. 72 12 14 3831.44
10. Off site DM-1 DM-1 substation 5 5 6 258.04
11. Off site DM-2 DM-2 substation 24 12 10 1322
12. Off site Fire Pump Fire water pump house 39 10 9 1526.34
13. Off site Raw water Raw/CW water substation 45 25 10 2839
Holding
14. Off site MCC Room 5 5 5 203.5
Pond
Ammonia-
15. Onsite-2 G2 substation Building 61 12 11 2717.94
II/Urea II
16. Onsite-2 Ammonia-II Ammonia 2 control room L shape -1 25 20 6 1153.04
17. Onsite-2 Ammonia-II Ammonia 2 control room L shape -2 10 10 6 453.04
18. Onsite-2 Guard Pond Guard pond building (remote location) 5 4 5 188.5
19. Onsite-2 EDG Emergency Diesel Set Building 30 10 15 2206.5
20. Onsite-2 G2 Utility /CW substation 22 10 11 1303.94
21. SSP SSP SSP substation 14 8.5 6 502.04
22. SSP SSP SSP Control room 22 6 6 581.04
Green Circle Inc 33

Table-7 To find out Overall Risk Factor to decide - Protection required or not (for each structure/ building)
A. Calculation of weighing Factor as per IS 2309
Weighing Factors for Assessment of Lightning Protection for Buildings/Structures having normal Processes and Covered/Open Storage
as provided in IS:2309 1989
Value of Weighing Factor
Sr No Use to which structure is put
A
1 Houses and other buildings of comparable size 0.3
2 Houses and other buildings of comparable size with outside aerials 0.7
3 Small and medium size factories, workshops and laboratories 1
Big industrial plants, telephone exchanges, office blocks, hotels, blocks of flats and other
4 1.2
residential buildings other than those included in Item No. 5 and 6 below
Places of assembly, for example churches, halls, theatres, museums, exhibition halls,
5 1.3
department stores, stations, airports and stadium structures
6 Schools, hospitals, children's and other such homes 1.7
Table.2 Weighing Factor B for Type of Construction

Value of Weighing Factor
Sr No Type of construction
B
1 Steel framed encased, with roof made of any material other than metal* 0.2
2 Reinforced concrete with roof made of any material other than metal 0.4
3 Steel framed encased or reinforced concrete with metal roof 0.8
4 Brick, plain concrete or masonry with roof made of any materials other than metal 1
5 Timber framed or clad with roof made of any materials other than metal or thatch 1.4
6 Brick, plain concrete or masonry, timber framed with metal roof 1.7
7 Any building with thatched roof 2
* A structure of exposed metal which is continuous down to ground level is excluded from the tables as it requires no
lightning protection beyond adequate earthing arrangements.
Green Circle Inc 34

Table.3 Weighing Factor C for Contents OR Consequential effects

Sr No Contents OR Type of building OR Consequential effects Value of Weighing Factor C
Ordinary domestic or office buildings, factories and workshops not containing valuable
1 0.3
or specially susceptible contents
2 Industrial and agricultural buildings with specially susceptible* contents 0.8
3 Power stations, gas works, telephone exchanges, radio stations 1
Industrial key plants, ancient monuments and historic buildings, museums, and other
4 1.3
buildings with specially valuable contents
5 Schools, hospitals, and other such places of assembly 1.7
* This means special valuable plant or materials vulnerable to fire or the results of fire.
Table.4 Weighing Factor D for Degree of isolation

Sr No Degree of isolation* Value of Weighing Factor D
Structure located in a large area of structures or trees of the same or greater height, for
1 0.4
example, in a large town or forest
2 Structure located in an area with few other structures or trees of similar heights 1
Structure completely isolated or exceeding at least twice the height of surrounding
3 2
structures or trees
* If nearby structures are much higher than the protected structures or if their nature is such as would offer good protection, for
example, extremely high metallic structures as of switchyard, earth wires of transmission system, high vertical cliffs, etc. Due weightage
may be given to such factors in deciding the necessity of protection on the basis of risk Weighing.
Table.5 Weighing Factor E for Type of country

Sr No Type of Country Value of Weighing Factor E
1 Flat country at any level 0.3
2 Hilly country 1
3 Mountain country between 300 mtr to 900 mtr 1.3
4 Mountain country above 900 mtr 1.7
Calculated Weighing Factor for Plant Area = Multiplying Factor = A * B * C * D *E = 1 * 0.8 * 0.8 * 0.4 * 0. 3 = 0.0768
Green Circle Inc 35

B. Overall Risk Factor to decide - Protection required or not (for each structure/ building)
Overall Assessed
Collection Assessed Risk
Description of building Risk for structure/
Sr no Plant Area AO IN PA = A0 *Ng P*105 REQ/NOT REQ
structure. building P=Pa*MF
Sq Meter (1.66) * 10(-6)
(0.768)
AO PA P=Pa*MF
Onsite -1
Compressor House
1 Ammonia1 2504.865 0.004158076 0.00031934 31.934023 Protection required
(Ammonia comp)
2 Ammonia 1 Amm -1 Substation 1627.865 0.002702256 0.000207533 20.753325 Protection required
3 Ammonia1 G-1 Control room 2836.3936 0.004708413 0.000361606 36.160615 Protection required
4 Urea Urea Prilling Tower -1 37994 0.06307004 0.004843779 484.37791 Protection required
5 Ammonia Ammonia 1 Reformer 3962.5 0.00657775 0.000505171 50.51712 Protection required
6 Urea Urea -11 Substation 1751.99 0.002908303 0.000223358 22.33577 Protection required
7 Urea Urea -21 Substation 1751.99 0.002908303 0.000223358 22.33577 Protection required
8 Ammonia 1 Storage Tanks (2 no.) 490.625 0.000814438 6.25488E-05 6.25488 Protection required
9 Ammonia 1 Storage Tanks (2 no.) 490.625 0.000814438 6.25488E-05 6.25488 Protection required
UPHS
10 UPHS Main building 1 and 2 10035.5 0.01665893 0.001279406 127.94058 Protection required
11 UPHS Main building 3 9571.5 0.01588869 0.001220251 122.02514 Protection required
12 UPHS Silo 0 0 0
Screen house
13 UPHS (consider one 3247.74 0.005391248 0.000414048 41.404788 Protection required
building)
14 UPHS Wagon Area left 5983.385 0.009932419 0.00076281 76.280979 Protection required
Green Circle Inc 36

Overall Assessed
Sq Meter (1.66) * 10(-6)
(0.768)
AO PA P=Pa*MF
15 UPHS Wagon Area right 7883.385 0.013086419 0.001005037 100.5037 Protection required
16 Ammonia F301 HP TOWER 15386 0.02554076 0.00196153 196.15304 Protection required
17 Ammonia F302 CO2 Absorber 13266.5 0.02202239 0.00169132 169.13196 Protection required
Off Site
18 SPG HRSG 1 STACK 547.1136 0.000908209 6.97504E-05 6.9750419 Protection required
19 SPG HRSG 2 STACK 547.1136 0.000908209 6.97504E-05 6.9750419 Protection required
20 SPG Aux Boiler 1 1856 0.00308096 0.000236618 23.661773 Protection required
21 SPG Aux Boiler 2 1856 0.00308096 0.000236618 23.661773 Protection required
22 SPG Aux Boiler 1 STACK 1256 0.00208496 0.000160125 16.012493 Protection required
23 SPG Aux Boiler 2 Stack 1256 0.00208496 0.000160125 16.012493 Protection required
Inst Air comp &Plant
24 SPG 1303.94 0.00216454 0.000166237 16.62367 Protection required
Air Comp IAPA
Emergency DG set -1
EDG-1
O&U control room
building.
27 DM-1 DM-1 substation 258.04 0.000428346 3.2897E-05 3.2897004 Protection required
28 DM-2 DM-2 substation 1322 0.00219452 0.000168539 16.853914 Protection required
29 CW Cooling tower 12 nos 2160 0.0035856 0.000275374 27.537408 Protection required

Naphtha
30 New Tanks Tank no-- 221.5584 0.000367787 2.8246E-05 2.8246037 Protection required
Storage
Green Circle Inc 37

Overall Assessed
Sq Meter (1.66) * 10(-6)
(0.768)
AO PA P=Pa*MF
31 New Tanks Tank no-- 221.5584 0.000367787 2.8246E-05 2.8246037 Protection required
Water pre treated &
32 Clarified filtered water 1133.54 0.001881676 0.000144513 14.451275 Protection required
storage tanks no 1
Water pre treated &
storage tanks No 2
Water pre treated &
storage tanks No 3
Fire water pump
35 Fire Pump 1526.34 0.002533724 0.00019459 19.459003 Protection required
house
Raw/CW water
36 Raw water 2839 0.00471274 0.000361938 36.193843 Protection required
substation
37 ETP ETP 0 0 0
NG Receiving
38 NG 0 0 0
station
39 Holding Pond MCC Room 203.5 0.00033781 2.59438E-05 2.5943808 Protection required
Onsite - 2
Ammonia-
40 G2 substation Building 2717.94 0.00451178 0.000346505 34.650473 Protection required
II/Urea II
41 Ammonia-II Auxiliary Boiler no 3 2962.5 0.00491775 0.000377683 37.76832 Protection required
42 Ammonia-II Auxiliary Boiler 3 stack 3846.5 0.00638519 0.000490383 49.038259 Protection required
43 Ammonia-II I.A.comp shed 293.04 0.000486446 3.73591E-05 3.7359084 Protection required
Ammonia 2 control
44 Ammonia-II 1153.04 0.001914046 0.000146999 14.699876 Protection required
room L shape -1
Green Circle Inc 38

Overall Assessed
Sq Meter (1.66) * 10(-6)
(0.768)
AO PA P=Pa*MF
Ammonia 2 control
45 Ammonia-II 453.04 0.000752046 5.77572E-05 5.7757164 Protection required
room L shape -2
Ammonia 2
46 Ammonia-II 4306.64 0.007149022 0.000549045 54.904492 Protection required
compressor House.
CO 2 Stripper tag no
47 Ammonia-II 15386 0.02554076 0.00196153 196.15304 Protection required
402in Ammonia ii
CO2 absorber in
48 Ammonia-II 11304 0.01876464 0.001441124 144.11244 Protection required
Ammonia 2
49 Urea 2 Prilling tower 2 43610.27465 0.072393056 0.005559787 555.97867 Protection required
50 Urea 2 Urea 2 A Process area 0 0 0

Urea 2 A Compressor
51 1456.5 0.00241779 0.000185686 18.568627 Protection required
house
Urea 2A carbonate
52 Urea 2 Solution tank 0 0 0
No U-FA-2401
Urea 2A urea solution
53 Urea 2 tank 0 0 0
No U-FA-2201
54 Urea 2 Urea 2 B Process area 0 0 0
Urea 2 B Compressor
55 Urea 2 1456.5 0.00241779 0.000185686 18.568627 Protection required
house
Urea 2 B carbonate
56 Urea 2 0 0 0
Solution tank
Urea 2B urea solution
57 Urea 2 0 0 0
tank
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Overall Assessed
Sq Meter (1.66) * 10(-6)
(0.768)
AO PA P=Pa*MF
Guard pond building
58 Guard Pond 188.5 0.00031291 2.40315E-05 2.4031488 Protection required
(remote location)
Naphtha Naphtha storage
59 221.5584 0.000367787 2.8246E-05 2.8246037 Protection required
Storage tank-A-FB -101
Naphtha Naphtha storage
60 221.5584 0.000367787 2.8246E-05 2.8246037 Protection required
Storage tank-A-FB -102
Emergency Diesel Set
61 EDG 2206.5 0.00366279 0.000281302 28.130227 Protection required
Building
EDG exhaust
62 EDG 1962.5 0.00325775 0.000250195 25.01952 Protection required
Chimney.
Cooling
63 Cooling Tower 11 nos 2160 0.0035856 0.000275374 27.537408 Protection required
Tower
64 G2 G2-Flare Stack Tower 15386 0.02554076 0.00196153 196.15304 Protection required
65 G2 Utility /CW substation 1303.94 0.00216454 0.000166237 16.62367 Protection required

SSP
66 SSP SSP substation 502.04 0.000833386 6.40041E-05 6.4004076 Protection required
67 SSP SSP Control room 581.04 0.000964526 7.40756E-05 7.4075628 Protection required
68 SSP SSP Chimney no 201 5024 0.00833984 0.0006405 64.049971 Protection required
Ball mill chimney
69 SSP 5024 0.00833984 0.0006405 64.049971 Protection required
100SK01
Chimney inside GSSP
70 SSP 5024 0.00833984 0.0006405 64.049971 Protection required
plant building
71 SSP H2SO4 tank no 1 52.7834 8.76204E-05 6.72925E-06 0.672925 Not Required
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Overall Assessed
Sq Meter (1.66) * 10(-6)
(0.768)
AO PA P=Pa*MF
72 SSP H2SO4 tank no 2 52.7834 8.76204E-05 6.72925E-06 0.672925 Not Required
73 SSP Rock phosphate shed 1456.5 0.00241779 0.000185686 18.568627 Protection required
Rock phosphate
74 SSP 714 0.00118524 9.10264E-05 9.1026432 Protection required
storage shed
GSSP Based Storage
75 SSP 840.96 0.001395994 0.000107212 10.721231 Protection required
&Plant building
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Section-2 Township & Non-plant Buildings
1.0 In the Section 7 of the list furnished for lightning protection system, the buildings can
be divided into two groups Buildings outside the township and buildings located
inside the township. These are as under:
(A) Buildings outside the township
1 Canteen
2 Lab Tech Bldg.
3 IT Bldg
4 Health centre
5 Admin Block
6 Store
7 Maintenance workshop block
8 Fire station & Extension Building
9 Contractors shed
10 Security office
(B) Buildings inside the township

11 Club
12 Hostel
13 M.P. Hall
14 A type blocks
15 B type blocks
16 C type blocks
17 D type blocks
18 VIP Guest House
19 OH tank
20 Primary school
21 Shopping centre
22 A type s/s
23 B type s/s
24 D type s/s & Tel. Exchange
25 Security Barracks (data for each of six
sheds)
26 LPG Go-down
27 Post Office
28 Petrol pump (Strcture-1)
Petrol pump (Strcture-2)
29 ANS Office
30 Fire Barracks (total six sheds)
2.0 Based on the available data of dimensions and Area of conduction for all buildings,
probability was worked out for each of the above buildings. Findings are tabulated in
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Table-1. Except the Security office, for all other buildings in the above list need the
lightning protection. Details of working out probability (higher or lower than 1 in
100000) are shown in Table-1 attached.
3.0 For the buildings requiring the protection, various details of protection hardware were
worked out. Mainly number of down comers, (based on base area and perimeter of
each structure), were worked out. As per guidelines of IS 2309:1989, lower number is
taken for protection. These calculations results are tabulated in Table-2.
4.0 For some structure, protection is provided. However, in township, it was observed that
except (single lightning arrester) for water tank, none of the structures/buildings has
been provided lightning protection. Table-3 shows the summary of additional
hardware required.
5.0 Majority of the buildings are flat roof structures. Therefore, GI strip (25 mm x 3 mm) is
to be cleated on the parapet wall. Down comers are taken on the outer wall and
are terminated to respective earth pit.
In many cases mesh grid is required on the terrace /roof top. It will be ensured that all
cross points and T-points are properly connected to have p1989.roper/good contact.
Any member of mesh should not be larger than 20 Mt x 10 Mt. Other hardware details
are given in IS 2309:1989
6.0 Area of conduction for all the buildings, have not been calculated, but it has been
taken from the earlier records, which was calculated from CAD system. At present,
protection is required for all structures in township. In the following sections, wherever
details were available, sketch is made. For Lab Tech building, where full size drawings
were sent, down comers, mesh (on the terrace/parapet) are shown in the drawings.
This drawing is sent back to CFCL, along with other drawings in which radius of
protection zone were marked.
Nomenclatures are as below
For the club building, because the base shape is of irregular type, down comers
quantity is worked out based on perimeter only. As such also, out of two basis (base
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area or perimeter) lower number is to be selected, hence there is no harm is deciding

the down comers on any one basis.
While going through 7.0 and 7.0, Table-2 (Summary also will be referred). In few cases,
details are shown in full size drawings.
7.0 Non-plant buildings outside the township.

7.1 Canteen:
Fig.1 Canteen Plan

7.2 Lab Tech building:
For this building, drawing no. A1/1 dated 26-12-2005 shall be referred. In this drawing,
earth mesh on the terrace, earth pits & down comers are shown.
7.3 IT Building:
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Fig.3 IT Building
7.4 Health centre

Fig.4 Health Centre
7.5 Admin Block
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Fig 5 Admin Block
7.6 Maintenance Workshop Building

This building is already provided lightning protection, but some additions are
recommended, as below:
(a) On the south side of the workshop structure, two spikes are provided at the bottom
side of the ridge. These will be shifted on the top most part (notch) of the roof. This will be
similar to the other spikes. Down comer GI Strip shall be extended up to these points.
(b) On the flat terrace on north side mesh will be laid and connected as shown in Fig.7.
(c) Where ever earth pits are not traceable, new pits will be provided and connected to
the respective down comer.
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Fig.6. Maintenance Workshop Building
7.7 Fire station & Extension building
Fig.7 Fire station & Extension building
7.8Contractors shed
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Fig.8Contractors shed
8.0 Non plant buildings inside the township
8.1Club.
Shape of the base is very odd one.
Fig. 9 Club
8.2 Hostel
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Fig. 10 Hostel
8.3 Multi purpose Hall
Figure-11 Multi-Purpose Hall
This hall has a trapezoidal dome having metallic top. There is a space between dome
and parapet wall. The earth strip will be cleated on the parapet. Bottom (four) corners of
the hall shall be connected with the earth strip running on the parapet. Because the
dome itself is of metal sheet, the strip need not be laid on the dome.
8.4 A type Blocks and B type blocks
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Fig. 12 A type blocks & B type blocks
In each types of these blocks, there are two spikes and two earth pits, as shown in Fig.14
above.
8.5 C type blocks
Fig.13
8.6 D type blocks
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Fig.14 D type blocks
8.7 VIP Guest House
Fig.15
8.8 Overhead Tank
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Fig.16 Overhead tank

Down comer will be brought down from central hollow space (from top to bottom)
8.9 Primary School
Fig.17 Primary School
8.10 Shopping centre
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Fig.18
8.11 A type & B type substations
Fig. 19
8.12 D type substation and Telephone exchange
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Fig.20
8.13 Security Barracks
There are total six sheds. On each shed there will be two spikes as shown in the fig.
21 below
Fig. 21
8.14 LPG Godown
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Fig. 22
8.15 Post Office
Fig.23
8. 16 Petrol Pump
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Fig. 24
8.17 ANS Office
Fig. 25
8.18 Fire Barracks
There are total six sheds. Fig 27 is shown on the next page
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Fig. 26
Sheds 4 & 6 have two spikes each. Remaining sheds have one spike each.
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Table-1 working out probability for lightning strokes
Table 1A - Non-plant buildings outside the township

Sr. Structure Condtg. Weighing Factor Overall Ng P= ORF Protection
no Area AC A B C D E WF AC x Ng x = P x OWF Required /
(Sq.mm) 10-6 Not Reqd.
1 Canteen 1169 1.0 0.4 0.8 1.0 0.3 0.096 1.66 1.9 x 10-3 18.4 x 10-5 Required
2 Lab Tech Bldg. 3524 1.0 0.4 0.3 1.0 0.3 0.026 1.66 5.8 x 10-3 21 x 10-5 Required
3 IT Bldg 562 1.2 0.4 0.3 1.0 0.3 0.0432 1.66 9.3 x 10-4 4 x 10-5 Required
4 Health centre 688 1.2 0.4 0.3 1.0 0.3 0.0432 1.66 1.1 x 10-3 40 x 10-5 Required
5 Admin Block 4055 1.2 0.4 0.3 1.0 0.3 0.0432 1.66 6.7 x 10-3 29 x 10-5 Required
6 Store 6440 1.0 0.4 0.3 1.0 0.3 0.036 1.66 1.1 x 10-2 38 x 10-5 Required
7 Maint.. work- -shop block 5130 1.0 0.8 0.3 1.0 0.3 0.072 1.66 8.5 x 10-3 61 x 10-5 Required
8 Fire station & Extn. Bldg 757 1.2 0.4 0.3 1.0 0.3 0.0432 1.66 1.3 x 10-3 5.4 x 10-5 Required
9 Contractors shed 1272 1.2 0.4 0.3 1.0 0.3 0.0432 1.66 2.1 x 10-3 9.1 x 10-5 Required
10 Security office 468 0.3 0.4 0.3 1.0 0.3 0.0108 1.66 0.776x 10-3 0.84 x 10-5 Not Reqd.
Table-1B - Buildings inside the township

11 Club 2771 1.2 0.4 0.8 1.0 0.3 0.0432 1.66 1.9 x 10-3 8.4 x 10-5 Required
12 Hostel 2325 1.2 0.4 0.3 1.0 0.3 0.0432 1.66 3.9 x 10-3 17 x 10-5 Required
13 M.P. Hall 1858 1.3 0.8 1.3 1.0 0.3 0.4056 1.66 3.1 x 10-3 12.6 x 10-5 Required
14 A type blocks 541 1.2 0.4 0.3 1.0 0.3 0.0432 1.66 0.9 x 10-3 3.9 x 10-5 Required
15 B type blocks 445 1.2 0.4 0.3 1.0 0.3 0.0432 1.66 0.74x10-3 3.2 x 10-5 Required
16 C type blocks 1493 1.2 0.4 0.3 1.0 0.3 0.0432 1.66 2.5 x 10-3 11 x 10-5 Required
17 D type blocks 1035 1.2 0.4 0.3 1.0 0.3 0.0432 1.66 1.7 x 10-3 7.4 x 10-5 Required
18 VIP Guest House 1473 1.2 0.4 0.3 1.0 0.3 0.0432 1.66 2.4 x 10-3 1.1 x 10-5 Required
19 OH tank 2427 1.7 0.4 1.0 1.0 0.3 0.204 1.66 3.88x10-3 79.2 x 10-5 Required
20 Primary school 3168 1.7 0.4 1.7 1.0 0.3 0.3468 1.66 5.3 x10-3 180 x 10-5 Required
21 Shopping centre 507 1.3 0.4 1.7 1.0 0.3 0.2652 1.66 3.6 x 10-3 9.5 x 10-5 Required
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22 A type s/s 395 1.0 0.4 0.8 1.0 0.3 0.096 1.66 0.66x10-3 6.3 x 10-5 Required
23 B type s/s 395 1.0 0.4 0.8 1.0 0.3 0.096 1.66 0.66x10-3 6.3 x 10-5 Required
24 D type s/s & Tel. Excha. 306 1.2 0.4 1.0 1.0 0.3 0.144 1.66 0.51x10-3 2.2 x 10-5 Required
25 Security Barracks (data 400 1.2 0.4 0.3 1.0 0.3 0.0432 1.66 0.66x10-3 2.9x 10-5 Required
for each of six sheds)
26 LPG Godown 393 1.2 0.4 0.8 1.0 0.3 0.1152 1.66 0.65x10-3 7.5 x 10-5 Required
27 Post Office 513 1. 0.4 1.0 1.0 0.3 0.156 1.66 8.5x 10-3 13.3 x 10-5 Required
3
28 Petrol pump (Strcture-1) 183 1.2 0.4 0.8 1.0 0.3 0.1152 1.66 0.3 x 10-3 3.5 x 10-5 Required
Petrol pump (Strcture-2) 251 1.2 0.4 0.8 1.0 0.3 0.1152 1.66 0.4 x 10-3 4.8 x 10-5 Required
29 ANS Office 524 1.0 0.4 0.8 1.0 0.3 0.096 1.66 0.87x 10-3 3.8 x 10-5 Required
30 Fire Barracks
Shed-1 233 1.2 0.4 0.3 1.0 0.3 0.0432 1.66 0.39 x 10-3 1.7 x 10-5 Required
Shed -2 328 1.2 0.4 0.3 1.0 0.3 0.0432 1.66 0.54 x 10-3 2.4 x 10-5 Required
Shed -3 233 1.2 0.4 0.3 1.0 0.3 0.0432 1.66 0.39 x 10-3 1.7 x 10-5 Required
Shed -4 580 1.2 0.4 0.3 1.0 0.3 0.0432 1.66 0.98 x 10-3 4.2 x 10-5 Required
Shed -5 310 1.2 0.4 0.3 1.0 0.3 0.0432 1.66 0.51 x 10-3 2.2 x 10-5 Required
Shed -6 580 1.2 0.4 0.3 1.0 0.3 0.0432 1.66 0.98 x 10-3 4.2 x 10-5 Required
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Table 2 A - No. of Down Comers (D/C) for Non-plant buildings outside the township
Sr. Structure Dimensions (Meters) Base Perimeter No. of D/C based on Recommended
no L W H Area Base Perimeter No. of D/C
(Sq. Mt) Area
1 Canteen 26 25 5.0 650 113 3 4 3
2 Lab Tech Bldg. 112 33.0 4.7 1632 402 7 14 7
3 IT Bldg 14.26 13.9 5.0 188 67 2 3 2
4 Health centre 26.14 13.8 4.4 336 84 2 3 2
5 Admin Block 47.2 50.8 6.3 2500 212 9 7 7
6 Store 84.23 54.23 9.4 4568 277 16 10 10
7 Maint. workshop block 125 18.0 12.6 2250 271 9 9 9
8 Fire station & Extn. Bldg 21.4 14.4 6.0 376 85 2 3 2
9 Contractors shed 100 8.0 3.0 800 214 4 7 4
10 Security office Not Required
Table 2 B - No. of Down Comers (D/C) for buildings inside the township
11 Club Irregular -odd shape 1800 225 7 8 8
12 Hostel 50.0 18.7 8.0 1000 164 4 6 4
13 M.P. Hall 30.9 18.5 11 575 130 3 4 3
14 A type blocks 22 13.2 4.17 276 75 2 3 2
15 B type blocks 17 11 4.17 170 68 2 3 2
16 C type blocks 48 12 7.3 480 204 3 7 3
17 D type blocks 27.04 12.55 9.42 350 127 2 5 2
18 VIP Guest House 37.0 27.0 5.0 785 124 3 4 3
19 OH tank Dia of top-11.6 27.8 105 (top) 37 2 2 2
20 Primary school 55 50 5 2750 257 10 9 9
21 Shopping centre 17 20.6 4.4 350 97 3 4 3
22 A type s/s 12.75 11.3 4.5 144 48 2 2 2
23 B type s/s 12.75 11.3 4.5 144 48 2 2 2
24 D type s/s & Tel. Excha. 9.5 13 5 86 46 1 2 1
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Sr. Structure Dimensions (Meters) Base Perimeter No. of D/C based on Recommended
no L W H Area Base Perimeter No. of D/C
(Sq. Mt) Area
25 Security Barracks (6 17 6.8 5 115.6 47.6 2 2 2
nos.) each shed
26 LPG Godown 10 8 8 80 36 1 2 2
27 Post Office 18.1 13.6 5 149 63.5 2 3 2
28 Petrol pump
Structure-1 (LHS) 6.2 3.8 5 23.5 20 1 1 1
Structure-2 (RHS) 7.6 7.6 5 58 30.4 1 1 1
29 ANS Office 20 11 5 220 62 2 2 2
30 Fire Barracks
Shed-1 7 7 5 49 28 1 1 1
Shed -2 12.6 7 5 88.2 39.2 1 1 1
Shed -3 7 7 5 49 28 1 1 1
Shed -4 24 9 5 216 66 2 3 2
Shed -5 12.7 6 5 76.2 37.4 1 2 1
Shed -6 24 9 5 216 66 2 3 2
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Table-3 Summary of Hardware required for Lightning Protection for Non-Plant Buildings
Sr. Building Presently provided Recommended quantity Net additional required

no. quantity to present quantity
DC EP AT DC EP AT DC EP AT
1 Canteen nil nil nil 3 3 3 3 3 3
2 Lab Tech Bldg. nil nil nil 7 7 7 7 7 7
3 IT Bldg nil nil nil 2 2 2 2 2 2
4 Health centre nil nil nil 2 2 2 2 2 2
5 Admin Block nil nil nil 7 7 7 7 7 7
6 Store nil nil nil 10 10 10 10 10 10
7 Maintenance workshop block 10 10 10 10 10 10 nil nil nil
8 Fire station & Extension. Bldg nil nil nil 2 2 2 2 2 2
9 Contractors shed nil nil nil 4 4 4 4 4 4
10 Security office PROTECTION NOT REQUIRED BECAUSE OF LOW PROBABILITY
11 Club nil nil nil 8 8 8 8 8 8
12 Hostel nil nil nil 4 4 4 4 4 4
13 M.P. Hall nil nil nil 3 3 3 3 3 3
14 A type blocks nil nil nil 2 2 2 2 2 2
15 B type blocks nil nil nil 2 2 2 2 2 2
16 C type blocks nil nil nil 3 3 3 3 3 3
17 D type blocks nil nil nil 2 2 2 2 2 2
18 VIP Guest House nil nil nil 3 3 3 3 3 3
19 OH tank nil nil nil 2 2 2 2 2 2
20 Primary school nil nil nil 9 9 9 9 9 9
21 Shopping centre nil nil nil 3 3 3 3 3 3
22 A type s/s nil nil nil 2 2 2 2 2 2
23 B type s/s nil nil nil 2 2 2 2 2 2
24 D type s/s & Tel. Excha. nil nil nil 1 1 1 1 1 1
25 Security Barracks (Each shed) nil nil nil 2 2 2 2 2 2
26 LPG Godown nil nil nil 2 2 2 2 2 2
27 Post Office nil nil nil 2 2 2 2 2 2
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Sr. Building Presently provided Recommended quantity Net additional required

no. quantity to present quantity
DC EP AT DC EP AT DC EP AT
28 Petrol pump Structure-1 (LHS) nil nil nil 1 1 1 1 1 1
Petrol pump Structure-1 (RHS) nil nil nil 1 1 1 1 1 1
29 ANS Office nil nil nil 2 2 2 2 2 2
30 Fire Barracks
Shed-1 nil nil nil 1 1 1 1 1 1
Shed -2 nil nil nil 1 1 1 1 1 1
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Section-3 Specific Recommendations & Maintenance
1.0 Down comers of tall structures

About tall structures presenting inspection difficulties, section 12.2.3 gives guideline
that in such cases minimum two down conductors will be installed. In each Prilling
tower, three down comers are provided.
2.0 As described in 12.2.2 (Pattern of Down Conductors), for a steel framed buildings, no
added down comers are required.
For metallic stack/ chimney, continuity should be there from top to bottom. If there
are ant flanges with / without gaskets, minimum four bonding shall be provided
across the flanges. These will be spaced equally. Gor metal columns also same
guidelines are applicable. However, it was observed that many of the columns
/stacks have been provided separate down comers.
In all such cases, one should not forget to provide earth pits (preferably 2 nos.) near
the bottom part on the ground.
3.0 Down comers of tall structures

About tall structures presenting inspection difficulties, section 12.2.3 gives guideline
that in such cases minimum two down conductors will be installed. In each Prilling
tower, three down comers are provided.
4.0 Laying wire Mesh on the slant roof or terrace

IS 2309:1989 also gives guidelines for the size of the mesh that, any section should not
be larger than 20 Mt x 10 Mt. Following fig.1 shows the laid on the slant roof.
Fig. 1 Recommended mesh on roof or flat terrace of RCC
As shown in fig.1, recommended mesh size shall not exceed 20 x 10 Mt. If the roof is of
50 Mt x 20 Mt, mesh dimensions can be as Fig.1 or each mesh of 16.66 Mt x 10 Mt. or
as shown in Fig.2.
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Wherever earth mesh is to be laid on the roof or terrace, this point will be observed.
5.0 Aux. Boilers 1 & 2

As shown in Fig. 3, north side portion of these boilers are open type structure of MS
sections. South side portion has AC sheets over the shed. Therefore, GI strip shall be laid
on the AC sheet roofing. Down comer shall be connected to new earth pits.
Spike will be provided as shown I the fig. 3. It will be connected to earth mesh.
Because stack does not protect the metal structure totally, one spike will be provided
and connected to structure, as shown. No DC is required. The structure will be earthed
with new earth pit to be provided (Refer Fig.2) near the base.
The hardware of Aux Boiler 1 & 2 are included in the Table shown at the end of Section-1
of the report.
Fig.2 Auxiliary Boiler
6.0 O & U Control Room Building

This building has seven earth pits on south side of the building. These pits are of the
construction other than that shown in IS 3043:1987 (for earthing). To have some balance,
on north side of the building, two new pits shall be constructed as per IS 3043:1987
(locations as per Fig.4.
Other important point shown in the Fig.3 is the modification/ relocation required in earth
grid and spikes on the terrace.
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Fig.3 O & U Control Room Building
7.0 Outdoor conveyers in Urea Product Handling Area

There are five sets of conveyer systems in front area of Building 1, 2 &3. These conveyers
are at heights and do not come under protection zone of any building or structure. It is
therefore recommended to provide protection as shown in the sample section of the
conveyer duct and supporting structure.
Fig.4 Lightning protection system on the conveyers in UPHS

Supporting structure is metallic; hence separate down comer is not required. Mesh
conductor shall be connected with the structure by shortest route.
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As shown in Fig. 4, GI strip will be running on both side of conveyer duct. At every 20 Mt.
both sides mesh will be interconnected to make mesh on the top. At every 40 Mt, spike
will be installed on the ducting. (It is shown in the above drawing at 20 Mt. distances. But,
spikes will be installed at every alternate cross member. )
Because the drawings of these conveyers were not available, sample for small length is
shown. For spikes and earth pits, average spacing is shown for each. Down comer will be
on the top end location of earth pit.
These hardware are not included in Table-8 (XL sheets) and Table in Section-1
8.0 Radio Transmission Tower & connected Equipments
Fig.5 Surge Protection & Earthing in RF communication system
(a) Surge Protective Devices in communication panels

The term surge protective device (SPD) can refer to a device (SPD) designed to provide
a degree of protection against lightning &electrical surges regardless of its placement
with respect to the service entrance main over current protection device. NEC 2008
identifies four types of SPDs.
Type 1 - An SPD permanently mounted between the service transformers secondary
and the services main over current protection device. This type of SPD is
also referred to as a surge arrester.
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Type 2 - An SPD permanently mounted on the load side of the services main over
current protection device. This type of SPD is also referred to as a transient
voltage surge suppressor or TVSS.
Type 3 - A point-of-use SPD. This type of SPD is also referred to as a transient voltage
surge suppressor or TVSS. Point-of-use SPDs are discussed later in this course.
Type 4 - An SPD component or assembly. This includes MOVs (Metal Oxide Varistors)
and assemblies containing MOVs and related components.
It may be checked with the supplier of Radio signal transmission panels, whether they
have provided Surge Protecting Devices (SPDs) or not. (Refer Fig.5). Based on the
reply, further line of action shall be decided.
(b) Earthing:
Proper earthing and bonding at various points is very important. Locations are shown
in Fig.5
9.0 ETP
(a) On the NW side of the ETP, cable trays are located which come to the plant. On the
turning point location of the trays, spike shall be installed and DC/Earth pit shall be
provided.
(b) On the street light poles top part, spikes shall be fixed and earthing pits shall be
provided near the base of respective pole.
(c) On MCC Room RCC Terrace, GI strip mesh will be laid; One spike shall be provided
on south west corner. It will be connected with down comer. At the base, new earth
pit will be provided and down comer will be terminated to the E-pit.
The hardware referred in (a), (b) & (c) are not included in Table-8 (XL sheets) and Table in
Section-1
10.0 Water Pre Treatment plan

On pole nos WPT /P24 and WPT /P33, (on each pole) spike shall be fixed and earthing pit
shall be provided near the base of respective pole. Pole shall be earthed by
connection with respective Earth pit.
The hardware referred above not included in Table-8 (XL sheets) and Table in Section-1
11.0 Earthing system

Observations/Action points regarding earthing system are:
(a) Earthing pits of some down comers are not traceable. In such cases, new pits
shall be constructed and DCs will be connected with respective pits.
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(b) There is no uniform practice adopted about earth pits of Electrical system and
those of Lightning protection system. In section 12.3.3 (of IS 2309:1989), it is very
clearly mentioned that common earth termination network is recommended for
lightning system and all other devices.
In CFCL, somewhere pits are numbered as L EP (which means this is for lightning
protection) and some pits are EP (which indicates it is the pit for Electrical system).
However, may of the pits connected with DCs are numbered with prefix EP. This
means that there is no uniform practice. Also, in absence of composite Earthing
layout, this point could not be concluded.
(c) All earth pits shall be with chamber of 500 mm x 500 mm. This size is convenient for
opening the earth strip before testing.
(d) SS hardware shall be used for ease of opening.
(e) Earthing network layout plan shall be prepared area-wise.
(f) Nearby earth pits shall be interconnected.
(g) It will be ensured that all tanks are properly provided earthing at minimum two
points circumferentially.
(h) Earth pits shall be regularly tested and results shall be recorded.
(i) The resistance to earth for each earth electrode integrated with the lightning
protection should be measured after isolating the electrode from the lightning
protection system from the test joint. The earth electrode showing resistance of
more than 10 ohm should be revamped to reduce the resistance to the extent
feasible.
(j) It may be noted that the pits of earthing electrodes integrated with lightning
protection should not be provided alternate layers of charcoal and salt (as done
in equipment earthing and grounding system) to avoid effect of corrosion on the
buried earth electrodes. Moreover, the earth resistance value to be maintained is
also maximum 10 ohms against 01 ohm for normal earthing system.
(k) The resistance of earth of lightning protection system including integrated
earthing system installed for each building / structure should be measured at 2 3
points at an interval no exceeding 12 months. If the resistance is found more than
10 ohms, necessary revamping of the system should be carried out and the
resistance should be brought back to less than 10 ohms.
12.0 Maintenance of Lightning Protection system

The lightning protection system requires routine periodic maintenance practices to
ensure its reliability and effectiveness. The maintenance aspects are divided into two
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principle areas, i.e. lightning protection system equipments and equipments of earthing
system integrated with the lightning protection.
(a) Visual inspection of system for looseness of fixing arrangements of vertical air
terminations, clamping of horizontal air terminations and down conductors should
be carried out at least once a year in areas with prevalent dry weather conditions.
Such checks should be carried out every six months in case the area is situated
nearer to the seacoast and plant surroundings with prevalent with corrosive fumes
and vapors.
(b) Wherever lightning air termination or down conductor is bonded with the metallic
structure, the inspection of bonding connection should be carried out for proper
bonding at least once a year or once every six months depending on the situation
of area.
(c) In addition, the mechanical conditions of all air terminations, conductors, bonding,
test joints, etc. should be carried out for effect of corrosion and observations should
be noted for future reference.
(d) The testing for electrical continuity of all the conductors, bonding and joints should
be carried out at least once a year and the observations should be recorded.
13.0 Preamble for Recommendations
The assessment for the lightning protection is carried out for entire plant and requirement
of provision of lightning protection is worked out in accordance with the procedure laid
down in the applicable Indian Standard. Based on assessment of type of lightning system
required to be installed and possible utilization of the existing system, the
recommendation for individual plant area is provided in the succeeding section.
The suggestions for the improvements of the existing lightning protection system are also
made so as to make the system having adequacy coupled with better reliability. The
suggestions are placed in the report based on the observations for the existing system
made during the plant visit.
Taking into consideration the existing system, the proposal for provision of lightning
protection system for individual building, structure and tall structure is worked out and the
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details are presented in recommended lightning system part in the report. The proposal
can be broadly divided into following manner.
(a) NEW LIGHTNING PROTECTION SYSTEM

The plant areas not covered by the lightning protection system are proposed to
be provided with the system and components in accordance with the
assessment carried out.
(b) INTEGRATION OF EXISTING SYSTEM

The plant areas found partially covered with the existing lightning protection
system are proposed to be strengthened by providing additional air terminations,
down conductors and earthing electrodes along with the use of all components
either of existing system or part of the existing system as found feasible during the
course of exercise of assessment. In most of the areas, the existing system
components are fully utilized.
(c) STRENGTHENING OF EXISTING SYSTEM

In few of the areas, the existing system is found adequate to provide the
protection with strengthening of down conductors, revamping of earthing
stations etc.
(d) Protective angle depends upon the severity of lighting stroke and the presence
within the protective zone of conducting objects offering the stroke independent
paths to earth. The protective zone area covered by a lightning arrestor increases
as the assumed protective angle decreases.
Based on above technical aspect, the acceptable protective angle for
practical purposes is considered as follows:
Protective angle for any ordinary single structure with a vertical or horizontal
conductor is 45o
14.0 Type of Lightning Protection System & components considered

The type of air terminals for the lightning protection system recommended for different
plant areas based on the assessment of requirement, shape of building, type of
construction, etc. are as follows :
(a) Vertical Air Terminations

Buildings having concrete / brick masonry walls and RCC slab construction, already
provided with Vertical Air Termination, to be strengthened with additional similar air
terminations, if required, and to be connected with number of down conductors.
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Tall structures such as Chimneys and other structures provided with Vertical Air
Termination to be strengthened by revamping down conductors system.
15. General Properties of Materials & Requirements of System
(a) The air terminations shall be made of electrolytic, high-density, solid, and copper.
The horizontal air terminations shall be hard drawn copper strips having material
properties as above. The vertical air terminations shall be of solid copper, round,
pointed, 3/8 or larger in diameter, project at least 250 mm above the object or
building section to be protected.
DATA OF MATERIALS AND MINIMUM SIZE OF VARIOUS COMPONENTS
AREA
SIZE
COMPONENT MATERIAL OF CONSTRUCTION (MM2)
(MM)
Fixed Air
Copper, Aluminum, GI 20 x 3 mm 60
Terminations
Down
Copper, Aluminum, GI 20 x 3 mm 60
Conductors
600 x 600 x 6
Copper, Aluminum, GI plate
mm
Hard-drawn copper rods for direct
12 Diameter 115
Earth driving into soft soil
Terminations Hard-drawn annealed copper rods
10 Diameter 78.54
for direct driving into soft soil
Copper clad or GI steel rods for
10 Diameter 78.54
direct driving into hard ground
Fixed Bonding Copper, Aluminum, GI Strip 20 x 3 mm 60
Connections Copper, Aluminum, GI rods 10 Diameter 78.54
(b) The air terminations shall be made of electrolytic, high-density, solid, and copper.
The horizontal air terminations shall be hard drawn copper strips having material
properties as above. The vertical air terminations shall be of solid copper, round,
pointed, 3/8 or larger in diameter, project at least 250 mm above the object or
building section to be protected.
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(c) Vertical air terminal bases shall be made of cast bronze and shall be securely
mounted using pressure bolt or crimp connectors and stainless steel screws, nails,
or bolts.
(d) Other hardware such as miscellaneous bolts, nuts, nails, screws, shall be of stainless
steel.
(e) Each down conductor must have a separate earth termination as far as possible.
(f) Moreover, provision should be made in each down conductor for disconnection
from the earthing electrode for the testing purposes. This is achieved with a test joint
made at convenient height from ground level.
(g) It is stipulated in the standard that the resistance to earth of the lightning protection
system, measured at any point, should not exceed 10 ohms.
(h) With the test joint disconnected, the resistance of each individual earth electrode
should not be more than ten times the number of down conductors in the
complete system, e.g. for a system with 15 down conductors, the individual earth
readings should not be more than 10 x 15 = 150 ohms.
16.0 Isolation for lightning conductors or bonding with metallic structures
When the lightning strike takes place on lightning protection system, its electrical
potential with respect to earth is raised, and unless suitable precautions are considered,
the discharge may divert to alternate available path to the earth by side flashing to the
metal in the structure.
To prevent the side flashing, two alternatives are implemented, i.e. either bonding of
lightning protection system with metallic structure or isolation of the lightning protection
system from the metallic structure.
Isolation requires generally large clearance between lightning protection system and
other metallic structures in the vicinity. Major drawback of isolation is difficulty in
maintaining necessary safe clearance and ensuring that the isolated metallic structure
has no connection with the earth such as through water or other service metallic
pipelines.
In view of difficulty discussed in foregoing point, the bonding is commonly used method
to prevent the side flashing.
Method is provided in the Indian Standard for deriving the clearance required to be
maintained form practicing isolation, which requires consideration of technical data as
follows. This method is used in the engineering for the assessment.
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17.0 Zone of Protections marked in the drawings
Table showing the values of Radius of Zone of Protection on drawings:-
Sr. Drawing title Drawing No:- Radius No. Radius in mtr

No.
1 Urea Unit Plot Plan (Gadepan-I) 11-GB-A-62830 R 110
2 Plot Plan for Urea Plant (Gadepan-II) 12T4311/E-U010 R 110
3 Plot Plan (DG Area) 80.790.11.0.03 R 25

4 Overall layout of Plant (SSP) SIL-J146-00-01-01 R1 40
R2 40
R3 40
5 Ammonia Unit Plot Plan (Gadepan-I) 02-GB-3B-62430 R1 70
R2 65
6 Plot Plan for Ammonia-2 Plant 11Y4311/E-A010-8 R1 60
(Gadepan-II)
R2 70
7 Plot Plan (Ammonia Storage Unit) E6072-2101 R1 21.8
R2 21.8
8 Plot Plan (CFCL-SPG plant, Kota) 0-38103-00135 R1 & R2 20
R3 & R4 13.2
R5 & R6 13.2
9 Wagon Loading Platform D-6059H-3201, Details of Hardware is given
in table 8 of Section 3
10 G.A of Wagon Loading Conveyor A-9001-G-30 Details of Hardware is given
in table 8 of Section 3
11 Plot plan of Cooling Tower Unit- E6059C-2012 Details of Hardware is given
Urea-1 in table 8 of Section 3
12 Lab tech building Layout plan DRG No. A1/1 Lightning hardware details is
given in table 8 of section 3
& Details are shown in
Drawing No. DRG A1/1.
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LEGAL DISCLAIMER & LIABILITY
The consulting services conducted by Green Circle Inc. (the Company) were
performed using generally accepted guidelines, standards, and/or practices, which the
Company considers reliable. Although the Company performed its consulting services
pursuant to reliable and generally accepted practices in the industry, the Company
does not guarantee or provide any representations or warranties with respect to Clients
use, interpretation or application of the findings, conclusions, and/or suggestions of the
consulting services provided by the Company. Moreover, the findings, conclusions, and
the suggestions resulting from the consulting service are based upon certain assumptions,
information, documents, and procedures provided by the Customer. AS SUCH, IN NO
EVENT AND UNDER NO CIRCUMSTANCE SHALL THE COMPANY BE LIABLE FOR SPECIAL,
INDIRECT, PUNITIVE OR CONSEQUENTIAL DAMGES OF ANY NATURE WHATSOEVER,
INCLUDING WITHOUT LIMITATION, ANY LOST REVENUE OR PROFITS OF THE CUSTOMER OR
ITS CUSTOMERS, AGENTS AND DISTRIBUTORS, RESULTING FROM, ARISING OUT OF OR IN
CONNECTION WITH, THE SERVICES PROVIDED BY THE COMPANY. The Customer agrees
that the Company shall have no liability for damages, which may result from Clients use,
interpretation or application of the consulting services provided by the Company.
Green Circle Inc

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REPORT NO.

CHAMBAL FERTILIZERS & CHEMICALS LIMITED

CONDUCTED & PREPARED BY

GREEN CIRCLE INC.

QUALITY CONTROL SHEET

Prepared Reviewed Approved

Draft Report of Lightning

Mr. Devang Chauhan, Executive- Electrical Risk

Reviewed by Mr. Anil Shah - Sr. Manager HSEQR Consulting

Approved by Mr. Pradeep Joshi - Group President & CEO

Released by Mr. Nachiket Joshi - Sr. Group Manager-Accounts & Finance

Green Circle Inc

WE EXPRESS OUR SINCERE THANKS TO MANAGEMENT & EMPLOYEES

OF CHAMBAL FERTILIZERS & CHEMICALS LIMITED, KOTA,

RAJASTHAN FOR THEIR CO-OPERATION & UNSTINTED HELP

WITHOUT WHICH THE LIGHTNING PROTECTION SURVEY COULD

NOT HAVE BEEN POSSIBLE. THE COURTESY EXTENDED TO OUR TEAM

For: GREEN CIRCLE INC.

Green Circle Inc

4 Lightning System Parameters 9

5 Calculation of Collection Area (Ao) 10

7 Working out Overall Risk Factors 15

8 Fixed Roof Tanks & Floating Roof Tanks 17

9 Deciding quantity of Down Conductors 19

10 Section-2 Township & Non-plant Buildings 42

11 Section-3 Specific Recommendations & Maintenance 64

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Following were the key coordinating persons from the Plant:

Mr. N P Singh DGM EIP

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2. CHARACTERISTICS OF LIGHTNING STROKE

(a) Current in lightning stroke

(b) Voltage in lightning stroke

(c) Vulnerability of high structures to lightning stroke

3. EFFECTS OF LIGHTNING STROKE

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GROUP 1: CLOUD TO GROUND LIGHTNING DOWNWARD DISCHARGES

GROUP 2: GROUND TO CLOUD LIGHTNING UPWARD DISCHARGES

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GROUP 3: CLOUD-TO-CLOUD DISCHARGES

5. DAMAGE DUE TO LIGHTNING

AT Air Terminals (spike)

RMS Risk Management Services

ORF Overall Risk Factor

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4. LIGHTNING SYSTEM PARAMETERS

In view of difficulty in describing an Average lightning flash, ranges of various parameters in

3.AVERAGE THUNDERSTORM DAYS

4. LIGHTNING FLASH DENSITY Ng

NG = Mean Lightning Flashes / km2 / year for Kota is 1.66

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5. CALCULATION OF COLLECTION AREA (A0)

Ao = Collection Area = 2(Length x Height) + (3.14 x Height2)

For Ammonia-1 plant compressor house shed,

Length = 50 Mt. and Height = 16.5 Mt

Ao = 2 (50 x 16.5) + (3.14 x 16.52)