Voliro’s drone technology enhances the safety, efficiency, and precision of Lightning Protection System (LPS) testing by playing a crucial role in safeguarding industrial assets while streamlining inspections, reducing operational risks, and delivering comprehensive data through advanced solutions. Read more >>
Each year, lightning strikes the Earth over 2.1 billion times, releasing significant amounts of electrical energy. While most bolts discharge harmlessly into the ground, some impact critical industrial infrastructure.
For instance, certain U.S. wind farms endure more than 1,000 strikes annually, with each blade experiencing 8 to 14 direct hits. Such high-voltage exposure, particularly when recurrent, can cause extensive damage.
The Role of Lightning Protection Systems (LPS) in Industrial Safety
Lightning discharges produce up to 300 million volts and 30,000 amps, rapidly heating the surrounding air to 27,000°C. This extreme energy makes tall industrial structures prime targets. Without proper safeguards, facilities risk electrical failures, fires, and structural damage. In 2023 alone, lightning inflicted $76 billion in damages across North America and Europe, accounting for 60% of wind turbine blade losses.
LPS provides a critical defense by capturing lightning currents and channeling them safely to the ground. Installation is not just best practice—it’s often legally mandated by government bodies, regulatory agencies, and insurance firms.
Enhancing LPS Testing with Advanced Technology
Utilizing drones like the Voliro T enhances safety and efficiency. Equipped with specialized LPS probes, these drones can perform continuity, ground resistance, and inspections between LPS components swiftly and safely, even at heights of up to 250 meters.
Voliro T Advantages for LPS Wind Turbine Inspections:
- 10x faster than traditional methods (inspection time reduced by 90%).
- 50% reduction in inspection costs compared to traditional methods.
- Electrical resistance measurement of the LPS (4-wire method) – 20–30 minutes inspection time per turbine.
- Supports single and multi-rotor stop.
- Inspections comply with IEC/EN 61400-24.
- 250-meter inspection height capability.
- Single-person operation with no access to the hub or nacelle required, unless bridging of a spark gap in the hub is necessary.
Industrial Assets Requiring LPS
Assets that require Lightning Protection Systems (LPS) include power distribution centers, solar energy farms, radar installations, telecommunications and airport towers, storage tanks containing hazardous materials, and oil and gas infrastructure such as drilling rigs and pump stations. Additionally, construction sites and wind energy turbines also require LPS.
Failing to install or maintain an LPS can result in significant damage, operational downtime, and expensive repairs. Non-compliance may also lead to regulatory fines.
Case Study:
In 2016, an Australian wind farm operator, SWF2, neglected to equip turbines with LPS. A severe storm with 80,000 lightning strikes led to a widespread blackout, affecting over 850,000 people. Legal consequences followed, with SWF2 fined $1 million in 2020.
Key Lesson:
Ensure LPS installation and conduct regular inspections to mitigate risks associated with system malfunctions.
LPS Testing Frequency
Standards such as IEC 62305, NFPA 780, and UL 96A outline recommended inspection intervals, considering factors like system design, asset type, prior repairs, and environmental conditions.
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IEC 62305 Guidelines:
- Level 1 & 2 Systems (max current 200-150 kA): Visual checks annually; full inspections every 2 years.
- Level 3 & 4 Systems (max current 100 kA): Visual checks biennially; comprehensive inspections every 4 years.
- High-risk, flammable sites: Inspections every 6 months.
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NFPA 780 Recommendations:
- Post-installation and post-repair testing mandatory.
- Annual visual inspections; semi-annual in severe weather regions.
- Full inspections every 3–5 years; more frequent (1–3 years) for critical systems.
- Earth resistance tests during extreme seasonal changes.
- Explosive environments: Electrical tests every 17 months; surge protection devices every 7 months.
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UL 96A Requirements:
- Initial post-installation inspection.
- Re-inspection every 5 years to maintain certification.
Key LPS Testing Methods
Regular inspections ensure LPS reliability throughout the year. IEC 62305 and NFPA 780 highlight several effective methods:
Visual Inspection
Is used to identify visible wear, corrosion, and structural issues. This method requires direct access to all system components, which can be facilitated by using drones equipped with high-resolution cameras.
Continuity Testing
Confirms uninterrupted current flow through system components. This is commonly performed using digital multimeters, specialized testers, and low-resistance ohmmeters.
Surge Protection Device (SPD) Testing
Verifies SPD performance, ensuring it can divert excess voltage safely. The process involves checking bonding integrity, circuit continuity, and peak discharge capacity.
Ground Resistance Testing
Measures resistance between grounding electrodes and the earth to confirm effective current dissipation. Among the techniques used are soil resistivity, fall-of-potential, selective, and stakeless methods.
This guide underscores the importance of consistent LPS testing and the role of modern technologies in optimizing inspection procedures.
