Abcaring4safety

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Hazard Recognition and
Intervention Module
Static Electricity (SE)
This module does not cover SE prevention by means of design and construction, nor does it cover prevention of
other spark type ignition sources such as from Hot Work like welding (see HR&IM Work Permitting)
This module deals with the risk for SE incidents, related work practices by process Operators and
maintenance Technicians- and with potential incident prevention Inspiring Work Practices (IWP)
27-02-2014
Free
Draft for review
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Disclaimer and conditions of use
ABCARING4SAFETY
Theo van der Smeede
Rotterdam-Rozenburg, The Netherlands
27-02-2014
Disclaimer:
! Separateness notice: This Hazard Recognition and Intervention Module (HR&IM) is freely available on the
ABCARING4SAFETY website for end-users only. This in an effort of trying to help people improving or maintaining
Health, Safety, Security and Environmental (HSSE) performance at their operations. End-users of this module,
including Incident Prevention Elements (IPE), Lay-outs, Inspiring Work Practices (IWP) and Theo van der
Smeedes Key Lessons provided herein, retain ultimate responsibility for adapting, adopting, and using all or parts
of its contents. End-users take a conscious decision to utilize this module or not, accept full responsibility and
accountability for usage and agree with this disclaimer and conditions of use by utilizing this HR&IM;
! The names, titles and/or content of HSSE Management Systems, Work Practices, Lay-outs and IWP are included
as examples. They do not necessarily match one-to-one with a particular system used by a particular company.
End-users of this information are referred to the relevant documents of the company they work with;
! End-users of this module are responsible and accountable for pictures/videos/illustrations/text if added to this
module and/or used in conjunction with this module by them. This taking into account ownership and copy-right
issues of these items if any;
! Local laws and/or regulations always prevail to anything covered in this module;
! In no event, under no circumstances and under no legal theory or practice, shall ABCARING4SAFETY nor its
founder and owner, Theo van der Smeede be liable to End-users of this module or to any other party/person for
events/incidents including injuries, illnesses, loss of life, environmental pollution, work stoppages, loss of profits,
loss of goodwill, or any other direct, indirect, special, incidental, or consequential deaths, injuries, illnesses,
damages and costs. This includes situations in which the causes of these incidents can be allocated to the use,
less than adequate (LTA) use or misuse of the contents of this module.
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Target audience and expected outcomes
After reviewing this module you should be able to:
! Explain what Static Electricity (SE) is
o Explain how accumulated positive + and negative - ions generate a
voltage difference between two materials / objects / bodies
o Explain how a Spark Bridge between these objects can be dangerous
depending spark energy, flash point / explosive range of the
combustibles / flammables and other conditions
! Explain how process- and maintenance activities shall take this
information into account in order to prevent SE type incidents
The ultimate outcome: NO Fires nor Explosions
The Team leader best reviews this module with the Process Operators and /or
Maintenance Technicians in her / his Team. See also the Dos for these Toolbox
type sessions on the ABCARING4SAFETY website
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1. Static Electricity
1 Definition of Static Electricity (SE)
2 Is Static Electricity dangerous, a HAZARD?
3 How is SE produced / generated?
4 Can Static Electricity (SE) accumulate?
5 Can SE lead to fire / explosions?
6 Incidents
7 Example of SE accumulation / build-up
2. Key Hazard examples
3. Example Inspiring Work Practices (IWP)
Content
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1.1
Example definition of Static Electricity (SE)
Static Electricity (SE) is electricity formed by an
imbalanced situation in between electrical charged bodies.
Example: Charges got stuck on one body* e.g. negative (-) and
on another body* e.g. positive (+) charges / ions
* Body with positive or negative charges can be anything such as a pipe, tank
truck loading arm, liquid inside a storage tank, powder in a storage bin, your
personal body, a bucket, tool and sample- or gauging device
Generation of SE can be caused by several events such as by flow of liquids
through a pipe, filtering, splashing, spraying mist on an object, separating two
different solid materials, contact between two differently charged objects etc.
Think about combing your hair for example. See also the next page
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1.2
YES, SE can be the (ignition) source for fires and explosions!
The following elements are needed for an ignition hazard to
be present:
1. A combustible / flammable atmosphere (mixture), (fuel in air);
2. Static Electricity is generated, for example by friction between two materials;
3. The electrical charges are accumulated on the surface of these materials;
" There is a difference in potential / voltage between the two
charges, (+ ions on one material and ions on the other);
4. A gap is created / exists in between the two materials / objects in which a spark
can be created between the + and the bodies;
5. Electrostatic discharge (ESD) takes place including spark formation;
6. Spark has enough energy, some materials ignite at very low spark energy levels.
Is Static Electricity (SE) dangerous?
Combustibles
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1.3
Example activities and processes that produce SE charges:
o Contact and then separating solid materials, (e.g. combing your hair);
o Flowing materials through pipes or hoses;
o Filling a tank truck or land storage tank with refinery products such as gasoline;
o Movement of people, liquids, dust / other isolating (non-conductive) materials;
o Filtering combustible / flammable materials through a metal screen (the smaller the screen
mazes, the higher the SE generation);
o Splashing liquids like loading a tank railcar when the loading arms outlet is not submerged;
o The production of mist like spraying paint / coating;
o Moving liquids, ascending gasses and descending water droplets in e.g. a storage tank;
o Draining, sampling without assuring that all parts are equally connected to each other such
that potential charges flow away / be earthed before a gap / spark bridge is formed .
Message: Waiting periods / times are different! This depending materials handled, their characteristics with
regard to accumulation of electrical charges, the processing method (e.g. filtering), weather conditions and alike.
Electrical charges need to disappear / flow away to earth / equalize.
This should all be made clear to you through formal work practices / procedures and education !
How is Static Electricity (SE) produced / generated?
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1.4
YES, SE accumulates / assembles in particular on isolating materials!
Examples:
1. Refined products such as gasoline, jet fuel, kerosene, solvents like
toluene, xylene, heptanes, diesel, naphtha, polymers and plastics;
2. Many powders used in industry.
Can Static Electricity (SE) accumulate?
Combustibles
Not easy on:
Raw materials like wood, crude oils, bitumen, alcohols, ketones,
water and metals.
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1.4
KEY HAZARD WARNING
Static Electricity can also accumulate on conductors such
as metal if:
You have ungrounded, bad earth connections or insufficient
bonding / connections in between conductors for example.
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Take an open metal bucket with solvent on a rubber /
plastic floor
Other examples of SE hazards:
# Metal fittings with non-conductive hoses (without metal wires inside the rubber);
# Metal scaffold on rubber wheels;
# Floating / flying debris in a vacuum truck tank;
# Corroded connections and people on isolated / non conductive shoes.
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Exercise
Is it true that static electricity charges are accumulated in good
conductors like metal and water?
Is it true that static electricity is always fatal due to electrical
execution?
Is it true that spiral wounded hoses must form a conductive
connection through metal couplings and equipment such that the
whole set is earthed / grounded?
Static electricity can be formed by high pressure cleaning, the use of
steam hoses/lances, spraying paint etc. A fire or explosion may
happen if combustible / flammable materials are also present in air.
Please read the descriptions below and indicate if the statement is
True or False. Discuss in your team after your initial conclusions
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Answer examples
Is it true that static electricity charges are accumulated in good
conductors like metal and water? Normally its not unless metal is
badly grounded / earth connections are corroded etc.
Is it true that static electricity is always fatal due to electrical
execution?
Is it true that spiral wounded hoses must form a conductive
connection through metal couplings and equipment such that the
whole set is earthed / grounded?
Static electricity can be formed by high pressure cleaning, the use of
steam hoses/lances, spraying paint etc. A fire or explosion may
happen if combustible / flammable materials are also present in air.
Please read the answer examples below, clarify to each other,
discuss in your team and determine if you agree or not
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Can SE lead to re or explosions ?
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1.5
Three components of the Fire Triangle
Combustible / ammable materials
such as organic (hydrocarbon) vapor / gas or dust
Some metal dusts / thin shavings are also
combustible
Combustibles
Air because of the
Oxygen (O
2
)
Ignition source such as:
1. Sparks from welding,
grinding, electrical arches
and static electricity;
2. Hot surfaces
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1.5
KEY HAZARD EXAMPLE
Flammable liquids in the form of mist or aerosols may ignite far
below the official flashpoint!
Remember that the official flashpoint laboratory test starts with a colder liquid which
is slowly heated up until the combustible / flammable material produce enough vapor
that can be ignited if an ignition source is present.
When you have small droplets, dense mist and / or aerosols you already have a
combustible / flammable / explosive mixture in the air.
See also HR&IM Fires, Explosions and Bleves
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Incidents
1.6
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Electrical discharge (getting rid of the charge difference (+ and -)
depends on so many factors that settling and waiting times must
be carefully defined with a lot of contingency time and must be
strictly respected.
Even weather conditions like air humidity play a role!
Note: Using an open bucket with
low flash materials is
hazardous anyway!
SE is a so-called hidden hazard; Youll be hit without even seeing it!
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1.7
Example of SE accumulation / build-up
+
+
+
+
+
+
+
Earth connection
A difference in electricity
voltage is created between
the liquid and storage tank
during the emptying /
filling operation of the tank
Hatch
Liquid
positive
Tank wall
negatively
charged
Atmospheric
connection
Accumulation of electrical
charge is worsened by
splashing!
Patience after product movement is KEY !!!
Liquid has to settle out, water droplets need to sink, gas bubbles need to
ascend and the difference in electrical charges need to disappear before any
work is considered near the tank / truck / rail car etc. , (see your local procedure)
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+
+
+
+
+
+
+
Hatch
An example Inspiring Work Practice (IWP) includes that:
1. People are kept away from the tank during transfer of combustible liquid such as filling or emptying a
storage tank. This is also true for storage tanks with (internal) floating roofs with open hatches;
2. Minimum waiting times are defined, after product transfer has been stopped, for each storage tank,
tank truck, railcar tank and ship compartment and for the product type such that static electricity /
electrical potential is equalized / drained to ground. Products differ in conductivity, i.e. accumulate
higher or lower electrical charges;
3. People do not remove clothing near-by open hatches. They use special safety footwear, first touch a
metal / earthed object close to the hatch before opening hatches to equalize potential differences
between their body and the tank;
4. Any equipment such as measuring /gauging devices and sample equipment are selected and used as
per local procedure. This taking into account conductivity of the device material and potential need
for bonding / holding it against the vessel near the hatch if the devices are conductive.
1.7
Example of SE accumulation / build-up
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Exercise
Ignition due to static electricity: Please read the
descriptions below and indicate if the statement is True or
False. Discuss in your team after your initial conclusions
Is it true that the items listed below are all needed for
electrostatic ignition of combustibles / flammables?
Generation of static electricity
Build-up of an electrical charge / accumulation of electricity
A space gap in between 2 differently charged objects/materials
Nitrogen
Spark with enough energy
Combustible / flammable gas, vapor or mist (due to splashing)
Oxygen, for example from air
The concentration of combustibles / flammables above the
flashpoint within the explosive range, (in between LEL and UEL)
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Answer examples
Ignition due to static electricity: Please read the answer
examples below, clarify to each other, discuss in your
team and determine if you agree or not
Is it true that the items listed below are all needed for
electrostatic ignition of combustibles / flammables?
Generation of static electricity
Build-up of an electrical charge / accumulation of electricity
A space gap in between 2 differently charged objects/materials
Nitrogen
Spark with enough energy
Combustible / flammable gas, vapor or mist (due to splashing)
Oxygen, for example from air
The concentration of combustibles / flammables above the
flashpoint within the explosive range, (in between LEL and UEL)
Flashpoint not always true, (think about the page 13 Key Hazard)
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Exercise
Ignition due to static electricity: Please read the
descriptions below and indicate if the statement is True or
False. Discuss in your team after your initial conclusions
Can you imagine static electricity building up, leading to
ignition, when an open bucket is filled with solvent
while electrically isolated from the process equipment?
Examples of the electrical isolation:
1.) Bucket is equipped with a plastic handle and hung-up
on the drain valve;
2.) Bucket is handhold by the Operator without any
conductive bonding with the process equipment.
An Operator was severely burned over his
whole body when solvent vapors were
ignited during draining / flushing into an
open bucket
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Answer examples
Ignition due to static electricity: Please read the answer
examples below, clarify to each other, discuss in your
team and determine if you agree or not
Can you imagine static electricity building up, leading to
ignition, when an open bucket is filled with solvent
while electrically isolated from the process equipment?
Examples of the electrical isolation:
1.) Bucket is equipped with a plastic handle and hung-up
on the drain;
2.) Bucket is handhold by the Operator without any
conductive bonding with the process equipment.
$
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Exercise
Is the description below True or False? Discuss in your team
after your initial conclusions
Static electricity is a so called hidden hazard, you dont see
it but its there. Thats one of the reasons why its so
important to follow safe work practices, procedures and
safety rules to the letter / without any deviations.
Youll be hit by the hazard without even seeing it!
A Tank truck loader was killed during sampling,
after loading and before the electrical charge
was drained to ground. The highly
combustible / flammable vapors ignited
Earth connection
+
+
+
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Answer examples
Please read the answer examples below, clarify to each
other, discuss in your team and determine if you agree or
not
Static electricity is a so called hidden hazard, you dont see
it but its there. Thats one of the reasons why its so
important to follow safe work practices, procedures and
safety rules to the letter / without any deviations.
Youll be hit by the hazard without even seeing it!
Earth connection
+
+
+
$
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2
KEY HAZARD EXAMPLES
- Static Electricity accumulators such as refined oil products and powders
- Combustible mist, small droplets lowering the ignition temperature to < flashpoint
- Dust clouds, transferring combustible powders with air
- Moving materials, turbulence in liquids, splashing, spraying liquids
- gas bubbles ascending from liquids, water droplets sinking
- Steam jets
- Filters and even more, partly plugged / small screen filters are increasing charge
- Peoples activities such as moving, sampling, (un)loading, draining, flushing
- Peoples activities such as using hoses, buckets, ropes and isolated tools
- Lack of good earth connections, lack of conductive bonding of all equipment
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- Combustible / flammable atmosphere with aerosols, dust, gasses or vapors
Example Inspiring Work Practices (IWP)
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Describing exactly what the hazards are and how to deal with them step-by-step. The IWP
takes contingencies (e.g. extra waiting times) into account and spells out, e.g.:
1. What equipment to use for activities such as sampling or draining;
2. Assuring that conductors are not isolated by non-conducting materials (also true
for hoses and tools);
3. The work method / how to do the job, including how to check and assure
conductive bonding, grounding and earth connections of all equipment and tools;
4. People based rules like for expected behaviors, clothing and footwear etc.;
5. Waiting times before approaching potentially hazardous areas and before doing
any work.
3
Describing exactly how emptying / filling trucks, railcars, ships, storage tanks is done (e.g.):
1. Proper bonding / grounding of all equipment involved;
2. No splash filling, no spraying;
3. Bottom filling / loading arm extended to the bottom of the truck / railcar
4. Varying flow rates, slow until fill nozzle is fully submerged;
5. No modifications without proper risk assessment by subject matter experts,
review and approval by management. Not adding filters for example!
6. Dedicated and well selected equipment for sampling / gauging;
7. Adherence to waiting times and other subjects in work practices / procedures;
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Target audience and expected outcomes
Are you now able to:
! Explain what Static Electricity (SE) is
o Explain how accumulated positive + and negative - ions build up a
voltage difference between two materials / objects / bodies
o Explain how a Spark Bridge between these objects can be dangerous
depending spark energy, flash point / explosive range of the
combustibles / flammables and other conditions
! Explain how process- and maintenance activities shall take this
information into account in order to prevent SE type incidents
The Team leader best reviews this module with the Process Operators and /or
Maintenance Technicians in her / his Team. See also the Dos for these Toolbox
type sessions on the ABCARING4SAFETY website
Please raise / resolve questions and discuss how
to use the information in day-to-day activities