OTC Surge Protection WhitePaper

APRIL 2012
The use of surge protective devices in

mitigating the effects of lightning strikes in
offshore oil applications
A white paper presented by
James L. Schroeder | Schroeder Consulting Services
Fred Czubba | Phoenix Contact
Executive Summary TABLE OF CONTENTS

The frequency and magnitude of lightning strikes in Primary strike methods
the Gulf of Mexico and their effect on offshore oil and procedures . . . . . . . . . . . . . . 2
applications are well documented. Recognizing the
prevalence of lightning strikes in this region, several Induced secondary
system specifications and practices written for lightning transient effects . . . . . . . . . . . . . . 5
mitigation have been applied and implemented in
Surge protective devices . . . . . . . . . . . . . . 6
offshore applications over the last decade. These
system specifications and practices have focused on SPD applications . . . . . . . . . . . . . . 8
directing the primary lightning strike to ground via air
terminals, downers, etc. Inductive coupling . . . . . . . . . . . . . . 10
Lightning monitoring systems . . . . . . . . . . . . . . 10

Little has been written about the induced transient
secondary effects that occur as a result of inductive or Conclusion
. . . . . . . . . . . . . . 11
capacitive coupling during a lightning strike. This paper
References
. . . . . . . . . . . . . . 11
will examine the links between the primary lightning
strike and induced transient secondary effects. It will
also discuss the mitigation of conducted transient
effects in power and monitoring circuits through the
proper application of surge protective devices (SPDs).
© 2012 PHOENIX CONTACT PHOENIX CONTACT • P.O. BOX 4100 • HARRISBURG, PA 17111-0100 1
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APRIL 2012
Primary Strike Methods and Procedures
The frequency and magnitude of lightning strikes in the Gulf of Mexico and their effect on offshore oil applications
is well known. Flash density maps from the U.S. National Severe Storms Laboratory, a division of the National
Oceanic and Atmospheric Administration, such as the one shown in Graph 1, demonstrate the frequency of the
strikes sustained in this region.
International standard bodies and industry trade groups Figure 1 National Severe Storms Laboratory –
National Oceanic and Atmospheric
have written specifications that deal with the mitigation
Administration
of effects of primary lightning strikes. More than 100
lightning protection codes and standards are in use API RP 14C – Seventh 2001 Edition, American
by various countries and agencies around the world. Petroleum Institute – Recommended Practice for
Although none of these specifications deal directly with Analysis, Design, Installation, and Testing of Basic
offshore oil lightning strikes1, some that have been used Surface Safety Systems for Offshore Production
in the offshore oil applications are shown below: Platforms.
ANSI/NFPA – 780-2008. Among the best-known All of these specifications and procedures focus on
sources of information for the protection of external mitigating primary lightning strikes and address the
lightning protection systems, the U.S. National Electric problems of grounding, bonding and shielding of
Code covers grounding, bonding, and shielding primary conduction paths. Figure 2 (next page) shows
issues related to conducting primary strike currents a typical example as applied to an offshore oil platform.
to ground. Note the primary conduction paths and the focus
of the primary current strike to the earth ground.
IEC 62305 Series. The Technical Committee
This figure also illustrates the critical importance of
TC81, (Lightning Protection) of the International
maintaining low-impedance grounding and bonding of
Electrotechnical Commission (IEC) has released a
series of five documents under the general heading
“Protection against Lightning.” The five parts (Part 1,
Protections of Structures against Lightning: General
Principles; Part 2, Risk Management; Part 3, Physical
Damage and Life Hazard; Part 4, Electrical and
Electronic Systems within Structures; and Part 5,
Services) provide a comprehensive standard. PRIMARY STRIKE METHODS continued ��
APRIL 2012
PRIMARY STRIKE METHODS continued ��
Figure 2 Surge current path and charge distribution for lightning strike
APRIL 2012
Figures 3 and 4 show a more detailed illustration of the grounding, bonding and shielding methodologies used for
primary strike mitigation.
Figure 3 Radial connection from enclosure to

nearest equipotential ring (EQ-Ring)
Figure 4 Anomalous current path from

equipotential ring (EQ-Ring) into
marine soil and sea water
APRIL 2012
Induced secondary transient effects
A lightning strike on an
offshore oil platform causes
many secondary transient
effects. Inductive and capacitive
coupling mechanisms expose
secondary power and control
lines to radiated and conducted
electromagnetic interference
(EMI). Inductively coupled
conducted interference is
addressed by the use of surge
protective devices (SPDs) and
Figure 5 Component energy level damage chart
will be the main focus of this paper. Inductively and
capacitively coupled secondary radiated interference
is addressed by the use of shielding, where possible, of
power and control lines. The shield on all shielded lines
must be connected to the primary ground conduction
path. All secondary and control structure frames must
be bonded to the primary ground conduction path.
Inductively coupled conducted

interference is a primary
cause of failures for power
and control circuits during a
lightning strike. This conducted
interference is present at
all levels of circuitry on
the platform.
The sensitivity of the

components being used plays
a key role in the amount of
protection required at the
system and subsystem level.
The energy required to damage
typical components found in an Figure 6 Zone protection concept2
offshore oil platform is shown in Figure 5. As expected,
the sensitivity, and therefore, the amount of required
protection varies as a function of the power handling
capability of the component.
Figure 6 illustrates the bonding, shielding and

conductive measures required as a function of
location and component sensitivity relative to the
lightning strike. INDUCED SECONDARY TRANSIENT continued ��
APRIL 2012
INDUCED SECONDARY TRANSIENT continued �� Surge protective devices
The amount of protection required is defined, Surge protective devices (SPDs) are electronic devices
according to the zone protection concept, with zone used to shunt high-current magnitude pulses to
0 being exposed to unprotected electromagnetic field ground.3 SPD manufacturers have used three different
strength levels resulting from direct lightning strikes, design variations to provide performance choices with
and zone 2 being exposed to field magnitude levels regard to response time, current magnitude and cutoff
lowered by two layers of shielding. voltage variables to system users.
This is similar to the Lightning Protection Zone (LPZ) • T

he use of spark gaps in combination with
concept used by the IEC and defined in the IEC 62305- metal oxide varistors (MOVs) (see Figure 7).
4 specification. The IEC specification definitions are This combination of components is associated
as follows: with the highest lightning test current peak values,
typically 100 kA. It has a high voltage protection
• L
PZ OA – The zone where the threat is due level, approximately 1000 V. Open-air spark gaps
to the direct lightning flash and the full lightning have a wide variation of triggering voltage, due to the
electromagnetic field. Internal systems may be effects of differences in humidity, temperature and
subjected to full lightning surge current. altitude. In an effort to mitigate the triggering voltage
variations, many manufacturers now use a triggered
• L
PZ OB – The zone where a direct hit is not
spark-gap design, which provides a tighter band of
possible, but the unattenuated electromagnetic field
triggering voltage values.
is present.
• L
PZ 1 – A zone where a direct hit is not possible
and the surge current is limited by current sharing
Figure 7 – Spark gap in
and by SPD at the boundary. parallel with MOV
• L
PZ 2 – A zone where a direct hit is not possible
and the currents in all conductive components
are lower than in LPZ 1. In this zone, the
electromagnetic field is attenuated through multiple
screening measures.
• T
he use of gas discharge tubes in combination
It is worth noting that the sensitivity of equipment with MOVs (see Figure 8). This combination of
being protected varies greatly and ranges from motors, components is associated with lightning test current
generators, etc., to control circuitry containing ICs peak values in the range of 50 kA and voltage
and PROMs. protection values of approximately 800 V. Compared
to the open-air spark gap, the gas discharge tube
is environmentally sealed, has a tightly controlled
trigger voltage level, faster response time and a lower
discharge surge current rating.
Figure 8 – Gas
discharge tube in
parallel with MOV
SURGE PROTECTIVE DEVICES continued ��
APRIL 2012
• T
he use of parallel MOVs (see Figure 9). This Table 1 shows typical SPD test parameters for SPDs
combination of components is associated with used to protect signal line electronic components in an
lightning current peak values in the range of 25-40 kA offshore environment.
and the lowest voltage protection values, typically in
the range of 400 V. When compared to the other Table 1 Typical SPD specifications for SPDs used in
signal line applications
two configurations, this combination has the fastest
surge current reaction time and the lowest lightning Specifications Symbol Type 1/Class 1 Type 2/Class 2
current peak values. Nominal voltage UN 60 V DC 60 V DC
Rated voltage UC 75 V DC 75 V DC
Voltage protection UP 700 V 500 V
level, line-PG
Figure 9 – Two
Nominal discharge IN 12.5 kA 10.0 kA
MOVs in parallel current (8/20 µS
waveform)
Max discharge surge
current
(8/20 µS waveform) IMAX 50 kA 40 kA
Lightning test Iimp 12.5 kA 4.0 kA
current, peak
value (10/350 µS
SPDs are rated according to their ability to withstand waveform)
surge currents. Their current surge ratings are related
to performance criteria given in the IEC 62305
specification series referenced earlier. The IEC 62305
specification also relates current surge values to the Table 2 is a comparison of typical SPD test parameters
Lightning Protection Zone concept, also discussed for SPDs used to protect power line electronic
earlier. The IEC 62305 specification establishes values components in offshore environments. As can be seen
for the IMAX parameter, which is 99% of the maximum in Table 2, the performance characteristics of the SPDs
expected IMAX value in LPZ 1 during a lightning strike. used vary as a function of whether they are used at T1
The value of IMAX for LPZ 2 is derated to 75% of the or T2 interfaces.
maximum expected value.4
Table 2 Typical SPD specifications for SPDs used in
SPDs are classified as T1 or T2 devices correlated to power line applications
LPZ 1 or LPZ 2 ratings as shown in IEC 62305. They
Specifications Symbol Type 1/Class 1 Type 2/Class 2
are positioned at the interface boundary of two LPZs. Nominal voltage UN 240 V AC 230 V AC
A T1-rated SPD would be inserted on lines entering an Rated voltage UC 350 V AC 275 V AC
LPZ 1 zone from an LPZ 0 zone. Similarly, a T2 device Voltage protection UP <1.5 KV <1.0 KV
level, line-PG
would be inserted on lines entering an LPZ 2 zone from
Nominal discharge IN 25.0 kA 20.0 kA
an LPZ 1 zone. current (8/20 µs
waveform)
Max discharge surge IMAX 50 kA 40 kA
current (8/20 µs
waveform)
Lightning test Iimp 50.0 kA 25.0 kA
current, peak value
(10/350 µs waveform)
APRIL 2012
SPD Applications
The effectiveness of SPDs in a lightning strike #2 AWG solid round wire to connect the SPD to the
environment depends on both the proper rating of equipment and to ground the SPD, we can calculate
the SPD and the proper application of the SPD in the voltage seen at the input side of the protected
the circuit. There are two potential misapplications equipment (VT) using the method shown in Figure 12.
that system integrators need to be aware of when
using SPDs for lightning protection: 1) excess wire
length in connecting the SPD to the equipment and/or
ground, and 2) inductive coupling from unprotected to
protected leads due to poor routing practices.
Lead length control

A typical installation for an SPD in a lightning-prone
environment is shown in Figure 10.
The SPD cabinet is typically mounted on the outside

of the motor control center and is used to protect
equipment inside the motor control center from
conducted interference due to lightning strikes and
current surges. Figure 11 shows this configuration. Figure 10 Typical SPD installation
During a current surge, the length of

wire from the SPD to the input of the
equipment (L1) and the length of wire
from the SPD to ground (L2) represent
inductances. The magnitudes of these
inductances at surge frequencies are
proportional to the length of wire
used to connect to the equipment and
ground respectively.
Figure 11 Schematic representation of SPD
installation
During a lightning strike, a surge voltage of some
magnitude will flow into the SPD from the unprotected
wire. The SPD will clamp the surge to a predefined
level (typically 500 V) and shunt the
surge current to ground. The length of
the wire from the SPD to the equipment
and to ground, the size of the wire used
to connect the SPD to the equipment
and to ground, and the geometry of the
wire are variables that determine the
magnitude of the voltage seen on the
input side of the protected equipment.
Figure 12 Schematic for calculation of VT
If we assume that the SPD shown in Figure 12 clamps

the voltage surge at 500 V, and we use two feet of SPD APPLICATIONS continued ��
APRIL 2012
SPD APPLICATIONS continued ��
If a current surge of 20 kA with a rise time of 8 µs is In summary, wire length is the predominant factor in
impinged on the unprotected line of Figure 10, the SPD determining induced voltage values, with wire size and
will limit the voltage developed across the line to 500 wire shape contributing secondary values. The message
V (V2). The voltage seen by the protected equipment, is clear: keep wire lengths as short as possible to
however, will be the summation of voltages V1, V2, minimize induced voltages.
and V3 or VT, where V1 and V3 are the induced
voltages developed across the lead length inductances
connecting the SPD to the source and ground
Table 3 Self-inductance (µH) of leads of various
potentials. These voltages are defined as: diameters and lengths5
Wire size 2-foot length 3-foot length 4-foot length

V1 = V3 = L(Δi/Δt)
#0 Round 0.60 0.97 1.37
#2 Round 0.63 1.02 1.43
Using Table 3, the inductance of a #2 AWG wire two #6 Round 0.68 1.10 1.54
feet long is shown to be 0.631 µH. Δi is 20 kA as given #O Rectangular 0.59 0.96 1.36
above, and ΔT is 8 µs. Substituting these values into the #2 Rectangular 0.61 0.99 1.39
above equation yields: #6 Rectangular 0.63 1.02 1.43
V1 = V3 = 0.63 x 10-6 x (20x103 / 8x10-6)

= 1,578 volts
Therefore, the total voltage seen by the equipment to

be protected is VT = V1 + V2 + V3 or VT = 1,578 +
500 + 1,578 = 3,656 volts. This value is more than
seven times the limiting voltage of the SPD.
Note that the values of induced voltages V1 and V3

change significantly as a function of wire length and
wire diameter. If the wire length of the example above
is changed from two feet to three feet, the self-
inductance values change from 0.63 µH to 1.10 µH, and
the values of V1 and V3 increase from 1,578 volts to
2,550 volts. The value of VT increases from 3,656 volts
to 5,600 volts. A one-foot change in length of the two
connecting wires results in the protected equipment
seeing an approximately 2,000-volt change in voltage. A
change in wire size from #2 to #6 results in an increase
of self-inductance values from 0.63 µH to 0.68 µH and
an increase in value of V1 and V3 from 1,578 volts to
1,700 volts. The value of VT increases from 3,656 volts
to 3,900 volts.
Finally, a change in the geometry of the wire will also

change the self-inductance of the wire. A rectangular-
shaped wire will reduce the self-inductance values, as
Table 3 shows.
APRIL 2012
Inductive coupling
The concept of inductive coupling is generally well understood.
Differential mode Common mode

Figure 13 Inductive coupling concept
Figure 13 illustrates the classic concept of both the Lightning monitoring systems
differential and common mode inductive coupling
effect. Current flow in the disturbing cable (sometimes In addition to applying the SPD information given
called the aggressor) generates a magnetic field in above, it is recommended that consideration be given
a clockwise direction based on the direction of the to the implementation of a lightning detection system
current flow. The resulting magnetic field generates at the platform level. A lightning monitoring system
a current flow in the victim cable in the opposite would facilitate the coordination of information about
direction. The magnitude of the current in the victim strikes (and potential equipment outages) for a specific
line is a function of: production system, including platform configurations
that include remote unmanned platforms. This lightning
• Distance between the two cables monitoring system, if equipped with remote monitoring
• Length of coupling between the two cables capability via an RJ45 Ethernet interface, would
significantly aid in analyzing data to promote remedial
• Diameter of wire of the two cables
action that would prevent future equipment outages.
• In general, increasing the distance between the
cables, minimizing the length of coupling (distance)
the cables run in parallel, and increasing the diameter
of the cables will reduce the inductive coupling effect.
The message is clear – keep aggressor and victim

lines separated. Never run aggressor and victim
lines side by side when going through a transition
portal.
APRIL 2012
Conclusion References
This paper reviewed steps used to mitigate primary 1. Arturo Galvan, “A Technical Basis for Guidance of
lightning strike damage. It discussed the linkage Lightning Protection for Offshore Oil Installations.”
mechanism between the primary strike current and Journal of Lightning Research, Vol. 3, 2007.
coupled secondary inductive and capacitive effects. 2. National Lightning Safety Institute, Section 5.1.5.
3. Uman, The Art and Science of Lightning Protection,
The paper focused on the role of the SPD in
Cambridge University Press, 2008.
mitigating the effects of conducted secondary coupled
interference. SPD construction detail variations and 4. F. Heidler, et al., “Parameters of Lightning Current
typical performance characteristics have been presented given in IEC 62305-Background, Experience and
to provide a frame of reference for the application of Outlook.” Twenty-ninth International Conference
SPDs in power and signal line circuits. on Lightning Protection, June 2008.
5. Grover, Frederick W., Inductance Calculations,
The information for SPD usage has focused on two Working Formulas and Tables, Dover Publishing,
areas of potential misapplication: the use of excess Inc., 1945.
wire length in connecting the SPD and the potential for
inductive coupling of interference as a result of poor
routing practices.
It is hoped the concepts presented in this paper will

add to industry knowledge relative to the application
of SPDs in mitigating infrastructure damage due to
lightning strike coupled secondary conducted effects.
ABOUT PHOENIX CONTACT
Phoenix Contact develops and manufactures industrial electrical

and electronic technology products that power, protect,
connect and automate systems and equipment for a wide range
of industries. Phoenix Contact GmbH & Co. KG, Blomberg,
Germany, operates 47 international subsidiaries, including
Phoenix Contact USA in Middletown, Pa.

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APRIL 2012

The use of surge protective devices in

Executive Summary TABLE OF CONTENTS

Lightning monitoring systems . . . . . . . . . . . . . . 10

Primary Strike Methods and Procedures

PRIMARY STRIKE METHODS continued ��

PRIMARY STRIKE METHODS continued ��

PRIMARY STRIKE METHODS continued ��

Figure 3 Radial connection from enclosure to

Figure 4 Anomalous current path from

Induced secondary transient effects

Inductively coupled conducted

The sensitivity of the

Figure 6 illustrates the bonding, shielding and

INDUCED SECONDARY TRANSIENT continued �� Surge protective devices

This is similar to the Lightning Protection Zone (LPZ) • T

SURGE PROTECTIVE DEVICES continued ��

SURGE PROTECTIVE DEVICES continued ��

SURGE PROTECTIVE DEVICES continued ��

Lead length control

The SPD cabinet is typically mounted on the outside

During a current surge, the length of

If we assume that the SPD shown in Figure 12 clamps

SPD APPLICATIONS continued ��

Wire size 2-foot length 3-foot length 4-foot length

above equation yields: #6 Rectangular 0.63 1.02 1.43

V1 = V3 = 0.63 x 10-6 x (20x103 / 8x10-6)

Therefore, the total voltage seen by the equipment to

Note that the values of induced voltages V1 and V3

Finally, a change in the geometry of the wire will also

The concept of inductive coupling is generally well understood.

Differential mode Common mode

The message is clear – keep aggressor and victim

It is hoped the concepts presented in this paper will

ABOUT PHOENIX CONTACT

Phoenix Contact develops and manufactures industrial electrical

You might also like

Figure 3 Radial connection from enclosure to

Figure 4 Anomalous current path from