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Static Electricity

Hazards & Controls

Static Electricity Generation


When ? When two dissimilar materials come in contact with each other or they remain in contact while they are in motion there is a transfer of electrons between them which results in Static electricity generation.
If any one of these materials is a non conductor then accumulation of electron occurs on them.

Static Electricity Generation


How ?
All materials are made of atoms. Atoms contains positively charged Protons neutrally charged Neutrons in Nucleus.

Electrons are moving in different orbits around nucleus. Various orbits can accommodate different no.s of Electrons e.g. 2,8,18,18,32
Atoms have tendency to become stable by accepting or donating electrons from the outer orbits.

Static Electricity Generation


How ?
Sometimes electrons from outer orbits are separated from stable atoms due to rubbing action between them. Materials with deficiency of electrons becomes positively charged & excess of electrons becomes negatively charged resulting into potential difference between them.

Static Electricity Precautions for plant safety


Remember, Static Electricity is one of the less acknowledged reasons for fire and explosion in Chemical Processing. Its generation is not realized and accumulation is not identified till it discharges in the form of Electrical spark.

Static Electricity Precautions for plant safety


Liquid flowing in pipelines.
If the liquid or the pipeline is non conducting, it leads to the charge build-up in liquid or pipeline or isolated conducting parts.

Static Electricity Precautions for plant safety


Discharge of liquid or powder from pipe.
Pneumatic conveying of powders. If the pipeline is non-conducting, then both pipe and also the powders get charged.

Static Electricity Precautions for plant safety


Pouring of liquid or powder into/ from a container.
While pouring liquids or powder from a container, if the container or the material is non-conducting will lead to accumulation of charges. Adding material into reactor through man-hole is dangerous.

Static Electricity Precautions for plant safety


Spraying of liquid through a nozzle.
Spray drying, spray painting etc. are some to the operations of this type. This is the reason for powder coating the job is kept charged to attract paint particles.

Static Electricity Precautions for plant safety


Stirring of material in a reactor.
If the material is non-conducting or the reactor is glass-lined, the charges will build up in liquids. The problem is more pronounced if the reactor is glass lined.

Static Electricity Precautions for plant safety


Use of normal plastic containers and liners.
Normal plastics have high resistance, this leads to charge generation and accumulation. Plastic containers can not be easily discharged by Earthing and Bonding. Antistatic/ Static dissipative plastics are available.

Static Electricity Precautions for plant safety


Belt moving on a pulley
If the belt used is normal and not antistatic, then it will lead to the build of charges on the belt.

Characteristics of Materials
Materials have tendency to release electrons Leather Glass Wool Human hair Aluminum Materials have tendency to accept electrons Hard Rubber Vinyl (PVC) Silver Polyester Acrylic

Examples of Static Electricity Generation


Static Electricity is usually generated when two dissimilar materials are rubbed against each other. e.g.
Wool on plastic Plastic comb on dry hair Shoes sole on carpet

Static Electricity Generation in Industry


Solid Solid
Between Belt & Pulley

While Grit / Sand Blasting


Charging dust or powder in Hopper

Static Electricity Generation in Industry


Solid Liquid
Liquids flowing through pipeline While Filling liquids in Storage tanks

Static Electricity Generation in Industry


Solid Gas
Steam coming out from pin hole Gas coming out from nozzle.

Static Electricity Generation in Industry


Liquid Liquid
Water settling in Hydrocarbon filled tan Liquid Gas Air bubble rising through tank filled with liquid

Static Electricity Generation in Industry during various operations


Loading - Unloading While loading or unloading materials from tankers, drums, carboys there are chances of Static charge generation. Generation of charge depends on type of container & materials which are to be unloaded.

Static Electricity Generation in Industry during various operations


Agitation, Mixing or Blending While Agitation operation there are chances of rubbing actions between material & Agitator or Reactor. During mixing rubbing action can also occur between two materials which are to be mixed.

Accumulation of Static charge


Generation of Static charge is not a hazard on its own. Accumulation of Static charge occurs when out of two material, one is non conductor. Accumulation of charge also occurs if generated charge is not discharged or rate of generation is higher than rate of dissipation or discharge. This process is also known as Electrostatic Induction

Accumulation of Static charge Examples

Plastic drums

Non Conductive Filter bags

Plastic Suction devices

Electrostatic Discharge
Accumulated Electrostatic charge can discharge in following ways:Sparks Brush Discharge Corona Discharge Lightning like Discharge.

Electrostatic Discharge
Sparks

Discharge occurs between two conductors.


Discharge occurs in a sudden burst.
Equivalent Energy=0.2 mJ

Radius of curvature is >=5cm

Electrostatic Discharge
Brush Discharge

Discharge occurs between conductors & charged conductive surface.


Rapid Discharge gives overall impression of brush.
Equivalent Energy=3 mJ

Luminous phenomenon emitted from conductor ends in a gap. Radius of curvature is 0.5cm

Electrostatic Discharge
Corona Discharge
Discharge occurs between conductive point & charged conductors.
Luminous phenomenon emitted from conductive point gives shape of Corona. Radius of curvature is <1mm.

Equivalent Energy<0.1 mJ

Electrostatic Discharge
Lightning Discharge

Discharge occurs similar to phenomenon of lightning. In industry, chances of such discharge are rare
Equivalent Energy=Very High

Discharge can occur in case highly charged dust clouds or betn. two dust clouds

Hazards of Static Charge


In industry, main hazard of Static charge is Fire or Ignition. Static charge can be hazardous if following condition are fulfilled : Generation of Static charge Accumulation of Static charge Electrostatic discharge. Presence of flammable source Required minimum Ignition energy

Conditions for Fire Explosion


For propagation of Fire or Explosion three elements are required. Air Combustible material Ignition Source with required Ignition Static Electricity provides source of ignition with required ignition energy

Minimum Ignition Energy


Minimum Ignition Energy (MIE) is lowest Energy required to ignite combustible mixture in air. Static charge provides this energy when discharged after accumulation. MIE is different for different material
MIE of various materials in Air { in mJ} Hydrogen-0.01, Methanol-0.14, Acetone-1.15,

Normal dust>10

Human Sensitivity Against Electrostatic Discharge


If human body comes in contact of Electrostatic discharge the effect on the body depends on amount of energy discharged. Severity of shock is not as great as power electricity For Example Discharge Energy of 0.002 J Perceptible 0.25 J - Severe Shock 10 J - Fatal

Control Measures to Prevent Hazards of Static Charge

Earthing & Bonding


Generated Static charge doesnt pose any hazards if it is grounded through earthing. Earthing is to be provided on pipelines, storage tanks, drums or carboys, vessels to ground generated static charge. Size & type of Earthing should decided considering total static charge to be grounded

Control Measures to Prevent Hazards of Static Charge


Earthing
Earthing wires, strips are to connected with Earth pits. Design of Earth pits is to be done as per IS-3043:1966 Continuity of Earthing & Resistance of Earth pits are to be measured regularly . In case of Large storage tanks two separate earthing are provided on opposite sides.

Control Measures to Prevent Hazards of Static Charge Bonding


Bonding is provided to carry over generated static charge if non conductive materials are placed between two conductors.

Bonding is done on pipe line flanges where there are chances of static charge due to flow of material inside Continuity of bonding strips & clits are to be checked regularly.

Control Measures to Prevent Hazards of Static Charge Use of conductive material


Static charge generation can be prevented / reduced by use of conductive material. Use of conductive liquids

Avoid use of plastic bags or containers


Use conductive pipes Use conductive filter bags in dust filter if dust is flammable.

Control Measures to Prevent Hazards of Static Charge


Non-Conductive liquids
Conductive liquids H/C with Polar group Alcohols, Aldehydes, ketones

Aliphatic & Aromatic H/C


Ethers & Esters Carbon disulphide Carbon tetrachloride Petrol, Benzene, Xylene Cyclohexane, Chloroform
Methanol, Ethanol Acetone Isopropanol Glycol Formic Acid

Control Measures to Prevent Hazards of Static Charge Avoid Explosive Mixture Formation
Remove Explosive dust, vapors, gases by use of vacuum suction devices Maintain inert atmosphere by nitrogen or other inert gas.
Use nitrogen pressure for charging flammable materials.

Control Measures to Prevent Hazards of Static Charge Consider Relaxation time


It is time required for discharge of static charge. Relaxation time is different for various liquids Liquid Toluene Hexane Heptane Methanol Ethanol Relaxation Time 21 s 46 h 42 min 0.18 s 9*10-6 s 1.6*10-4 s

Control Measures to Prevent Hazards of Static Charge Keep the velocity low
High velocity causes rubbing action & separation of electrons. Normally 1-1.5 m/sec can be maintained. Turbulence is to be avoided

Avoid Splash filling


Splash filling of liquids is to be avoided. Dip pipe is to be used for filling

Control Measures to Prevent Hazards of Static Charge Maintain Humid Atmosphere


Static charge generally discharges through air Conductivity of humid air is slightly more than dry air which helps in early discharge

Avoid charging on human body


Human body is considered as conductor Conductive floors and footwear's are to be used.

Control Measures to Prevent Hazards of Static Charge Use Antistatic Additives


Antistatic additives increases conductivity of materials or decreases the resistance which helps in discharge of static charge.
Additives should be chemically inert & should not react with parent material.

Control Measures to Prevent Hazards of Static Charge


Measurement of Static Electricity

Static Electricity can be measured using Electro Static voltmeter.


Presence is demonstrated by sparks, shocks or attraction/repulsion Measurement is important for comparing it with Minimum Ignition Energy of combustible material present in surrounding.

Control Measures to Prevent Hazards of Static Charge Follow standard procedures / practices
Standard procedures & practices are to be followed while handling static charge generating materials. Plastic drums are not to be used Earthing is to be provided to drums while manual loading/unloading.

Control Measures to Prevent Hazards of Static Charge

Conclusion
Mainly following points/conditions are to be considered for avoiding hazards of Static Electricity
Avoid / Reduce Static charge generation by use of conductive material. Provide proper earthing / bonding for discharge of Static charge generated Avoid Explosive mixture formation in areas where chances of Static charge generation

Case study

Case study

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