Protection of Organized Industrial Zones Against Lightning and Overvoltage

Today, there is a very popular term used within surge overvoltage and lightning protection systems: “EQUIPOTENTIAL BONDING“. Yes, the equipotential bonding system is one of the most critical components of the four-system integration that we always emphasize in protection against sudden overvoltage and lightning strikes. Hundreds of facilities located in organized industrial zones continuously cause damage to each other due to potential differences. A lightning strike directed at one factory can affect many surrounding facilities, or a sudden overvoltage occurring in one factory can damage neighboring facilities within nanoseconds. From an electrical perspective, the saying “neighbors do not need each other’s ashes” does not apply here. Especially lightning strikes and switching surges pose a major risk in facilities located side by side, such as organized industrial zones. These extremely fast transients pose a serious threat to all electrical systems, particularly automation systems, disrupting production and forcing maintenance engineers into constant overtime.

For factories that are directly exposed to these surges in addition to potential differences, problems become inevitable. Moreover, grid-originated sudden overvoltage surges also pose a major risk for organized industrial zones.

For factories that are directly exposed to these surges beyond potential differences, problems are unavoidable. In addition, grid-induced sudden overvoltage surges represent a significant risk for Organized Industrial Zones. Sudden voltage rises in the grid cause serious voltage fluctuations and financial losses. No matter how robust the infrastructure is, transformers feeding hundreds of factories within organized industrial zones generate peaks during sudden load changes. Similar issues also occur during power outages and subsequent restorations. Another frequent problem is lightning striking the grid and distributing the surge to factories. In addition to all these, harmonics—often underestimated but extremely dangerous—are among the worst enemies of electronic machine boards.

With so many risks present for a facility located in an organized industrial zone, are the correct protection measures against lightning and sudden overvoltage actually being taken? Our observation shows that the number of facilities properly protected is around only 10%. As a result, we frequently encounter burned systems, damaged machines, and recurring failures. The saying “everyone bears their own responsibility” is very relevant here. If you do not protect your facility, regardless of whether the issue originates from the industrial zone or neighboring factories, you will be the one dealing with the consequences. Therefore, proper protection measures must be implemented.

Lightning rod systems installed on the roofs of rapidly emerging facilities do not protect against sudden overvoltage surges. To be protected against lightning and other electrical transients, it is mandatory to install a LOW VOLTAGE SURGE PROTECTION SYSTEM consisting of four coordinated stages. Protection that starts from the main distribution panel and extends to sensitive equipment will reduce operating costs, minimize maintenance expenses, and ensure sustainable production. Site survey, correct product selection for the right point, and proper installation will provide the most effective results.

We recommend that facilities located in organized industrial zones use internal lightning protection systems to eliminate lightning effects and all other electrical surges.

In addition, the management of organized industrial zones can take an important step toward overall protection by installing B+C class VG technology surge protection devices in transformer low-voltage panels. However, due to distance and protection zone limitations, each facility must have its own local solution. In this solution, devices installed in industrial zone panels must operate in coordination with local systems.

When a lightning strike hits your lightning rod system, electrical systems are exposed to serious risk. Therefore, this risk can be eliminated with an optimum surge protection solution.