The Challenge – Tank Farm Lightning Protection for Calcasieu Refining

Calcasieu Refining Company sought a reliable solution to protect its refining operations in Lake Charles, Louisiana from direct lightning strikes and indirect lightning-related threats to maintain operational continuity and protect workers.

Located along the United States Gulf Coast, the most lightning-active region in North America, the Calcasieu Refinery faces frequent and severe thunderstorm activity. Lake Charles experiences very high lightning activity and the National Weather Service reports that between 2009-2018 (the most recent data), Louisiana had the second highest cloud-to-ground lightning flash densities in the U.S. at 18.9 per square mile, trailing only Florida at 20.8 flashes per square mile.

This significant lightning risk profile underscored the critical importance of robust lighting protection to safeguard personnel, prevent unplanned shutdowns, and ensure safe, continuous refining operations.

Historical Precedence

The refinery had experienced several lightning and electrical discharge events in its history, resulting in damage to storage tanks and downtime.

The photo sequence below is sourced from video published in Oil & Gas Journal as part of a story covering a lightning strike that caused a tank fire at Calcasieu Refining’s tank farm in Lake Charles (June 3, 2023).

This incident was not an isolated one, making protection of the refinery’s tank farm a key priority, including its internal floating roof tanks (IFRTs), external floating roof tanks (EFRTs), and fixed roof tanks.

These tanks store large volumes of crude oil, refined products, and naphtha – materials that pose significant hazards if ignited. A direct lightning strike or even a lightning-induced event presents serious risks to infrastructure, worker safety, operational continuity, and overall economic performance.

READ MORE: VIDEO: Analysis of Lake Charles lightning-related tank fire – June 2023

The Solution – Comprehensive Lightning Protection System from LEC

Calcasieu Refining chose Lighting Eliminators and Consultants (LEC) to evaluate its risk profile and then design, develop, and install a comprehensive lightning protection system. LEC consultants collaborated closely with Calcasieu Refining engineers and operators to define the protected area and develop an effective solution. The design focused on establishing the tank farm as the primary protected area for safeguarding the facility’s IFR, EFR, and fixed roof tanks.

The final design consisted of the following:

• Dissipation Array® Systems (DAS®) to prevent the formation of upward positively charged streamers from the ground connecting with negatively charged streamers from cloud bases, forming lightning. Suppressing upward streamers effectively prevents lightning in the protected area. Multiple DAS units were installed at strategic locations to protect tanks and equipment.
• Retractable Grounding Assembly® (RGA®), Gen 2, units were used to substantially reduce the risk of tank fires by subduing sustained arcs during lightning events and other electrical phenomena (e.g., static discharge).

LEC provided installation supervision services in coordination with trusted, vetted contractors to ensure the equipment was installed efficiently and commissioned correctly. Proper installation and commissioning performed or supervised by LEC are critical to system performance and are required to validate the DAS “No-Strike” Warranty.

Lightning Protection System Results

Since installing the LEC lightning protection system, the Calcasieu Refinery has not experienced a significant unplanned interruption in operations due to lightning and maintained operational continuity over years of inclement weather, including severe thunderstorms and hurricanes.

Key Benefits:

• Prevents lightning strikes in protected areas, significantly reducing the risk of tank fires, equipment damage, and operational disruptions.
• Maximizes operational uptime and refinery productivity by preventing lightning-related shutdowns and protecting critical refining and storage assets.
• Enhances personnel safety by reducing exposure to lightning and electrical discharge hazards in operational areas.
• Protects high-value infrastructure, including storage tanks, process equipment, electrical systems, instrumentation, and automated controls.
• Reduces financial risk and maintenance costs by preventing damage, avoiding lost production, and extending equipment lifespan.
• Provides proven performance in high-lightning regions, including Gulf Coast facilities exposed to frequent severe thunderstorms.
• Backed by professional design, installation, and the DAS “No-Strike” Warranty, ensuring long-term protection and operational confidence.

Protect Your Refinery from Lightning Before It Strikes

We Keep You Running Through the Storm

Lightning is not a matter of if – it’s a matter of when, especially in high-risk regions like the Gulf Coast. LEC’s proven solution deployed at Calcasieu Refining demonstrates that lightning protection can prevent strikes, protect critical assets, and ensure uninterrupted operations.

Don’t wait for a lightning event to expose vulnerabilities in your facility. LEC solutions are protecting critical operations in more than 80 countries.

Contact us today to schedule a no-cost lightning risk assessment and learn how our solutions, including the Retractable Grounding Assembly® and the Dissipation Array® System can protect your tanks, infrastructure, and personnel from lightning related risks.

Take the first step toward eliminating lightning risk and safeguarding your operations.

Contact

Lightning Eliminators & Consultants
6687 Arapahoe Rd. Boulder, CO 80303, USA
E: info@lecglobal.com
T: +1 303-447-2828