(188f) Diagnosing Electrostatic Problems and Hazards in Industrial Processes: Case Studies

Electrostatic hazards continue to challenge the safety and reliability of industrial processes, particularly in sectors where flammable materials are handled. This paper presents a comprehensive study focusing on the diagnosis of electrostatic problems and associated hazards in industrial settings and builds on the published paper by the authors “Electrostatic Hazards: Identifying the Early Warning Signs to Reduce Explosion Risk” that was presented at AIChE GCPS 2023. By leveraging investigative methodologies and data-driven insights, the research aims to shed light on practical strategies for early identification of potential electrostatic hazards, diagnosing the root causes of electrostatic incidents and subsequently implementing targeted modifications to prevent their occurrence.

This paper examines two electrostatic incidents that occurred within the chemical and pharmaceutical industrial sectors, one involving ignition of a solvent vapor and the other a dispersed dust flash-fire. Utilizing advanced techniques and materials data the investigating team was able to systematically trace electrostatic pathways, and pinpoint areas of concern within the processes and equipment, where charge generation was most likely to occur. Through systematic analysis of the events, the team then identified key parameters influencing that charge generation, charge accumulation, subsequent discharge mechanisms, and eventual ignition of the flammable/explosible atmosphere. In both cases the events displayed ‘early warning signs’ of static electricity, which if they had been appreciated and understood in advance, could have prevented the incidents. This data-informed approach empowered the team to evaluate the likelihood of ignition scenarios and prioritize mitigation efforts accordingly.

The integration of awareness of the hazards of static electricity, early warning signs, and quantitative data allows for a thorough assessment of ignition risks of all processes.

The outcomes of this study highlight the importance of acting on early warning signs of static electricity and the crucial role of data-driven diagnostic techniques in addressing and controlling those hazards. By dissecting the intricacies of electrostatic phenomena, safety professionals can formulate actionable strategies to modify plant operations and prevent hazards. The success stories presented herein showcase the important role played by implementation of grounded equipment, control of insulating materials, and optimization of process conditions as effective measures to mitigate electrostatic risks.

In conclusion, the findings shared in this paper offer valuable lessons for industries seeking to safeguard personnel and assets, enhance electrostatics safety, and uphold operational integrity.