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⚑ Lightning Strikes & Hydrocarbon Tank Fires – A Hidden but Deadly Risk

Did you know that lightning is one of the leading natural causes of fires at hydrocarbon storage facilities?
Over the last 10 years, industry and safety reports estimate over 150 lightning-related fires globally in tank farms and refineries. The U.S. Chemical Safety Board (CSB) and API studies confirm that over 30% of tank farm fires are initiated by direct or indirect lightning strikes. One major example includes the Intercontinental Terminals Company (ITC) fire in Texas, 2019, where multiple tanks burned for days, costing millions in damages and environmental losses. Closer to Asia, India and the Middle East have reported multiple lightning-triggered incidents due to monsoon activity and inadequate bonding/grounding systems.

Why Are Hydrocarbon Tanks Vulnerable?

Lightning can cause fires due to:

  • Direct strike on tank shells or floating roofs
  • Static discharge due to poor bonding
  • Arcing across gaps in conductive paths
  • Induced voltages in pipelines and metallic structures
When hydrocarbons like petrol, naphtha, or crude oil are stored in large quantities, even a small ignition source can escalate into massive fires or explosions.

πŸ›‘οΈ Precautions Required to Protect Your Tank Farm

Here are industry-recommended best practices (based on NFPA 780, API 545, and IS codes):

βœ… 1. Lightning Protection System (LPS)

  • Install air terminals (lightning rods) on fixed roof tanks.
  • Ensure adequate coverage and zone of protection.
  • Use UL-listed components with corrosion resistance.

βœ… 2. Floating Roof Tanks – Shunts and Seals

  • Install primary and secondary seals with approved materials.
  • Use conductive shunts or bypass conductors (API 545 compliant) to maintain equipotential bonding.

βœ… 3. Equipotential Bonding & Grounding

  • All tanks, pipelines, and metallic structures must be electrically bonded.
  • Maintain earth resistance below 10 ohms, preferably 1 ohm.

βœ… 4. Surge Protection Devices (SPD)

  • Protect control panels, gauging systems, and sensors.
  • SPDs must be maintained and tested regularly.

βœ… 5. Fire Detection & Suppression

  • Use heat/smoke/flame detectors for early warning.
  • Fixed foam systems, rim seal fire suppression, and manual firefighting lines should be well maintained and tested.

βœ… 6. Regular Testing & Audits

  • Inspect LPS annually or after every lightning storm.
  • Conduct risk assessments and compliance checks with current standards.

πŸ› οΈ Don’t Wait for a Spark to Start a Fire

The risk is real, but completely preventable with the right design, equipment, and maintenance.

πŸ‘‰ Contact us at agnirakshaniti@gmail.com

To validate your existing tank farm design, check grounding integrity, or design lightning protection systems for future expansion projects.

Let’s work together to safeguard your critical assets.

#FireSafety #LightningProtection #TankFarm #OilAndGas #NFPA780 #API545 #AgnirakshaNiti #ProcessSafety #EmergencyPreparedness #IndustrialSafety #RiskManagement #RefinerySafety

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