Understanding

the Generation & Control

of
STATIC ELECTRICITY
to prevent
Fire and Explosion Hazards
Trainer :
Guru Pratap Voleti

22nd June 2024

INTRODUCTION
 Static electricity has been
discovered 2500 years ago.
 600 B.C.
Thales of Miletus writes
about amber becoming
charged by rubbing - he
was describing what we
now call
Static Electricity.
The discovery of Static Electricity
was mankind’s first step toward
learning about electricity.
 GREATEST OPPORTUNITY
TO
PROTECT LIVES
WITH
YOUR KNOWLEDGE

Doc.Ref.4S/ESD/3092/2022-23 Doc.Ref.4STS/0118/2018-19
 STATIC ELECTRICITY

HIDDEN HAZARD
INDUSTRIES FACING ESD ISSUES…
MINING
ELECTRONICS

EXPLOSIVES

Oil-Gas-Petrol PLASTIC
Chemical

Other Areas:
Computer Labs,
Communication
Systems, Medical …
Few Incidents …
1) Empty HDPE Drum – Bottom Valve Spent Discharge – 2
min- Spark Blowup

2) BV Closing – Last Wash – Worker Cleaning - PP Covers

Bundles

3) Liner Bag – Human Body – Powder Loading - 11 the

Bag fire near Reactor MH

4) SS Mug – Heptane (0.24 mj ) – CF washing

5) Sifter – Sieving – Mechanical to Dust Blow-up

6) Powder Handling - PTS - High Velocity transfer-Air

entrapment
Few Incidents …

7) Drum Filling – Hose Nipple – Toluene (0.24 mj)

8) Reactor Sampling Metal rod/pipe – entry in to Dust

9) Valve handle – Human Body contact

10) Tray Dryer – Trays – Static Charge

11) Earth Calmp - Earthing a Drum

12) Dip Rod – Metal Drum – Non Polar solvent

 Static Electricity Regular Electricity

The steady flow of Charge

Buildup of Charges (+/-) between Source point to
Destination

Charge stays at one place

and INFLUENCES the nearest Needs a conductor to flow
available CONDUCTORS through.
resulting in Sparks

Does not need a Circuit Needs a closed circuit

Types of Spark Discharge
 Brush Discharge
 Corona Discharge
 Propagating Brush Discharge
 Cone Discharges
INSULATORS
Insulator Conductor
STAGNATED
EXCITED
ELECTRONS
BUNCH
To understand the subject better
The cause of the May 6, 1937, incident that killed 35 of the
100 passengers and crew members on board was static
electricity,

Hindenburg
Disaster
Doc.Ref.4S/ESD/3092/2022-23
Charge Separation Effect
Static Sparks - Day to Day Life
 TRIBOELECTRICITY
Materials become electrically charged
after they come into frictive contact with
different material
Negatively charged
-
(extra electrons)
- - + - + +
+ - -
- + + -
- +
+ -
+
+ Positively charged
(Less Electrons)

ATTRACTION…
 Positive & Negative charges

Quasi-Static Equilibrium
The charge moving into a region = The charge leaving the region
The amount of charge created by
triboelectric charging is mainly affected by
>> Area of contact,
>> Speed of separation,
>> Relative humidity,
Once the charge is created on a material, it
becomes an "electrostatic" charge (if it
remains on the material). This charge may
be transferred from the material, creating
an electrostatic discharge, or ESD, event.
 How do charges behave?

2 North poles repel each other. But,

a North and a South put together will attract one another.
Opposites Attract, Likes Repel.
 INDUCTION
(Proximity to an electrostatic field)
There are several ways to excite electrons from objects of different
MOC, Shapes & Sizes knowingly & Unknowingly.

Known Methods Unknown Methods

Power Plants Material Handling
All Friction/Separation activities
(Thermal, Tidal,
Nuclear…with Liquid Transfers
Dynamos)
Chemical Reactions
Solar Panel
Machinery Movements
Heat , Light, Pressure
etc.
Piezo electric effect
When pressure or stress is applied to certain crystals, opposite
electric charges collect on the ends of the crystal. By maintaining
the pressure on the crystal, the static electric effects can be
demonstrated.

Piezoelectric effect creates charges near surfaces

Although applying pressure to a piezoelectric crystal is
considered causing static electricity, its use is in creating
an electrical current for many applications.
Pyro electric effect
When heat is applied to certain materials, positive and
negative charges move to opposite ends of the material. By
maintaining the heat on the material, the static electric effects
can be demonstrated.

Pyroelectric effect creates charges near surfaces

Although the separation of charges is considered static

electricity, the usual applications of the pyroelectric effect is
to create electric current for various devices.
Direct & Indirect Reasons for
Static Sparks

FRICTION SEPARATION

INDUCTION PRESSURE

LIGHT HEAT
 ATOM!!
An atom is one of the basic units of
matter. Everything around us is made
up of atoms.
An atom is a
Million times smaller
than the thickest human hair.

The diameter of an atom ranges from

about 0.1 to 0.5 nanometers.
(1×10-10 m to 5×10-10 m).
FRICTION
SEPARATION
Friction & Separation
Friction & Separation
High Voltage Sparks
 More Studies…More Findings…

Light - Wave length - Energy

STATIC CHARGE
Ex. 350nm – UV Freq.
 CHARGE SEPARATION
DUE TO
ELECTRIC FORCE
(The attraction or repulsion between electric charges )

Negative
Positive
If the "excess charges" are in a conductor then they
are, by definition, free to move. If there are excess
charges distributed throughout the conductor then
they will be compelled to move by any electric field
within the conductor.

The electrons in a conductor are free to move.

Therefore if there is any potential gradient in a
conductor the electrons will move along it.
 MOST IMPORTANT

ICC MANTRA

Reason for most of the ESD

incidents.
 STATIC FIELD - IMPACT

II IC CC
I : INSULATOR
C : CONDUCTOR
 IC Combination

+ -
Static Field +
+
C-
-
+ -

I : INSULATOR
C : 1st CONDUCTOR – Without Earth Connection
 ICC FORMULA…

+ -
+ -

I +
+
C -
-
C

I : INSULATOR
C : 1st CONDUCTOR – Without Earth Connection
C : 2nd CONDUCTOR – with / without Earth Connection
 I
One Field – Many Conductors around
Free Electrons
Free Electrons
C: With
Capacitance

C: Without
Capacitance
ICC Sparks practically
 ICC Sparks practically -
-
-
-
- -
-
- -- - -
- -
- - - - --
- - - -
- - -
- - - -
- - - -
- - - - - -- - - -
- - - -
- - - - - - - - -
-
- - - -
-
- -
-- + + + - - -
- - -- - - - + + + - - -
- - - -- -
- - -- -
- - - - - - + + - --
- - -- - - - - - ++ + -
-- -
-
- - - - - - - - - ++ + - - -
-
- - +
- - - - - - - ++ + - - -
-
- - +
- - - - - - - ++ - - -
- - - - - - - ++ +
-- - - + + + - - -
- - - - - -
- - - - - + - -
- - -
- - -
- -
- -
-

I C
-
-
C
ICC Sparks practically…

+ -
+ -
+ -
+ -

I C C
IC Combinations

1 mj 2 mj

1 mj
Spark risk from Metal objects
Chemical Hose with Metal Ends
IBC
Moving Static Field

I CC
Approaching
Static Field

IC C
I : INSULATOR
C : CONDUCTOR
 ICC FORMULA…

I : INSULATOR
C : 1st CONDUCTOR – Without Earth Connection
C : 2nd CONDUCTOR – with / without Earth Connection
 Approaching
Static Field

IC C
I : INSULATOR
C : CONDUCTOR
 Types of Sparks
due to
CHARGE SEPARATION

EXIT SPARK
ENTRY SPARK
 INSTANCES of SPARKS…

in ICC combination
- From a CONDUCTOR inside STATIC field while
in Physical contact with INSULATOR.
- From CONDUCTOR inside STATIC field while
NOT in Physical contact with INSULATOR.
- From Charged CONDUCTOR outside STATIC Field.
- When Field approaching Tow or more Conductors placed nearby.
- When Two conductors together moving towards STATIC Field
- When Two conductors leaving field after static spark.
Other Situations:
- Ionization path between two powder / solvent vapor partials
 _ _
_ _
_ _ _ _ + - ELECTRICALLY
_ _
_
_
_
_ _ _ + - 1 BALANCED BODY
_ _ _ _ (CONDUCTOR)
_ _ + -
ELECTRICALLY
_ _
CHARGED BODY + - +
DUE TO
It will take
FRICTION, +
SEPERATION, Electrons
_ _ + - from Ground
INDUCTION. +
_ _
_ _ + -
+
_
_
_
_
+ -
2 4
_ _
+ -
+ -
_ _ + + - And becomes
_ _ Neutral
+ -
_
_
_
_
+ 3
+ -
_
_
_
_
+ 5
+
 MIE
vs
PARTICAL SIZE
 MIE for Aluminum Dust at respective concentrations
Dust sample Dust concentration

250 g/m 3 500 g/m 3

Aluminum 100 nm 100 mJ < MIE < 200 mJ 33 mJ < MIE < 51 mJ
Aluminum 70 nm 10 mJ < MIE < 33 mJ MIE < 10 mJ
Aluminum 40 nm MIE < 5 mJ MIE < 5 mJ

The MIE values for aluminum nanopowders in diameter of 100nm, 70 nm and 40

nm measured in the experiments decreasing with their respective diameters at two
different concentrations; 250 g/m3 and 500 g/m3. The research shall conclude as
follows:
a) MIE value for Al-40 nm is less than 5 mJ at both concentrations; 250 g/m3
and 500 g/m3.

b) MIE value for Al-70 nm is between 10 mJ and 33 mJ at concentration equals

to 250 g/m3 and less than 10 mJ at concentration equals to 500 g/m3.

c) MIE value for Al-100 nm is between 100 mJ and 200 mJ at concentration

equals to 250 g/m3 and between 33 mJ and 51 mJ at concentration equals
to 500 g/m3.
International Journal of Automotive and Mechanical Engineering ISSN: 2229-8649 (Print); ISSN: 2180-1606 (Online)Volume 15, Issue
2 pp. 5285-5294June 2018 © Universiti Malaysia Pahang, Malaysia.
ELECTRO STATIC
DISCHARGE
(ESD)
Control Methods
ESD Control Methods
Awareness & Training

Humidity Control & Relaxation

Proper Sequence when

Material Handling & Providing
Earth clamps
Electrically Semi-Conductive
Material & EARTHING
Regular ESD Testing & Auditing
 ANTI-STATIC

CONDUCTOR – SEMI CONDUCTOR

Conductor - Semi-Conductor - Insulator

Conductor
 ESD CONTROL MEASURES
Type Charge Behaviour Charge Transfer Heat Usage
When earth is not Not Advisable if
provided, Charge High Heat on the not provided
Separation within is Instant, very fast path during Bonding /
Conductor Possible in the Charge Transfer sudden charge Grounding from
presence of Static transfer the beginning of
Field any activity
When earth is not
provided, Charge Low / negligible
Semi- Separation within is Medium Fast amount of Heat Good for all ESD
Conductor Possible in the Charge Transfer on the path Applications.
presence of Static possible
Field
Itself creates Static
Field around the
Charge Transfer is
Insulator object and
not possible
NA No Use
influences Metals
nearby
Typical areas where ESD Protection is required

Material Receiving
Test & Inspection /QC
Stores & Warehouses
Processing / Assembly
Research & Development
Packaging
Field Service Repair
Offices
Laboratories
Clean Rooms
 Charge generation
• Flowing / Flow velocity • Filtering
• Filters, valves, obstacles • Cleaning of Hydrocarbon
• Turbulence tanks
• Filling • Water entrainment
• Emptying • Switch Loading
• Stirring • Gauging and Sampling
• Mixing
• Sampling
• Atomization
• Liquid jet cleaning
Solvent Free Fall
Solvent Droplets…
BONDING & EARTHING
TO

MAN
M3 MATERIAL
MACHINERY
 Methods to Control Static Electricity
• Rh%
• Avoid Free electrons with proper earthing
• Continues wet Mopping at Manhole
• Wet Mopping on the trolley path
• Dress Code - Employees
• Earth Clamping (Make n Break )
• Field reduction (PP Covers Folding etc.)
• Conductive Outer Cover (Faraday cage) method
• CGP – Common Ground Points
• Earth Clamps – ES Field
10 Points for ESD Safety
1. Handling Material’s Electrical Parameter
2. Personnel Grounding – ESD Pad, Wristband, ESD
Apron, Footwear, Gloves.
3. Visitors /Supervisors
4. Humidity
5. Flooring/Wheels
6. Insulators - Surface area, Outer surface preparation
7. Conductors - Small in Size, Bonding Multi Segments
of Eqp., Bonding & Earthing, “Make & Break Earth
Connections”
8. Earth Connectivity / Healthiness Monitoring
9. Material Handling, Flow velocity, Relaxation Time,
Handling Qty., Earthing procedures.
10. Nitrogen Inerting, Purging.
BONDING & EARTHING
TO

M3 MAN
 Human Body is an Electric Conductor
A capacitor – That Stores Energy
Collects Voltages from Charged body

…More than
70% ESD
Accidents

Need ESD awareness!!

HUMAN – Source of Ignition

Human body is a good electrical conductor.

Ignitable discharges are possible when body is charged.

In general the energy of a charged capacitor is given by

W =1/2 CV2 in joules.
The average capacitance of human being is 200 pF.
And pf =10-12 Farads.

It is a common experience that Electric Discharges from

a person to ground of over 2 KV are felt as shocks.

This potential of 2 KV [2000 V] with Cman = 200pF.

According to the above formula W = 0.4 mj.

W = 1/2 x 200 x 10-12 x 2000 x 2000 = 0.0004 joules.

= 0.4 Milli Joules.
ESD TOUCH PAD

Meant for dissipation of accumulated Static Charges on the

personnel entering a Static Sensitive Area.
ESD Testers for Human Body
 PTGS
Personnel Tester & Grounding System

Doc.Ref.4S/ESD/3092/2022-23
Wrist Straps Grounding
Cards
 ESD APRON

ANTI – STATIC FABRIC AND APRON :

CONDUCTIVE FABRIC, WHICH SHIELDS ELECTRIC, MAGNETIC

FIELDS AND ULTRA - HIGH FREQUENCY.

PREVENTS THE INDUCTION EFFECT FROM/TO MACHINERY AND

PROTECTS HUMAN BODY .
Conductive & Static Dissipative
Shoes
Conductive & Static Dissipative
Shoes / Gloves
ESD PVC Flooring System
ESD FLOORING
ESD Conductive Flooring
ESD Semi Conductive Flooring

Doc.Ref.4S/ESD/3092/2022-23
ESD Epoxy Flooring

We must also test for Resistance to Ground

BONDING
ESD EQUIPMENT
GROUNDING CLAMP

Meant for dissipation of accumulated Static Charges from the

equipment Static Sensitive Area.
ESD EQUIPMENT
GROUNDING CLAMP
BI-DIRECTIONAL EARTH PIT
 Equi-Potential
CGP – Common Ground Point
CGP…
ESD Poly bags
 CONDUCTIVITY OF SOME TYPICAL LIQUIDS
CONDUCTIVITY
pS/m (10⁻¹² S/m.)

Acetone 6 x 10 6 Conductive
N-Butyl Alcohol 2.0 x 10 7
Conductive

Ethyl Acetate 2.9 x 10 4

Conductive
Methyl Alcohol 4.4 x 10 7 Conductive
Gasoline (leaded) 100 Semi Conductive
Isopropyl Ether 500 Semi Conductive
Toluene <1 Non Conductive
Gasoline (unleaded) < 50 Non Conductive

Xylene 0.1 Non Conductive

AVOID using Insulated Material Max.
Possible

Ordinary Conductive
Plastic Plastic
Bucket Bucket

Ordinary Conductive
HDPE HDPE
Drums Drums

Poly Bags

ESD Poly
Bags
 Conductive Plastic
Bucket / Mugs must
always be used with
Earth Connection.
Model: 4S-AE0419
Minimum Ignition Energies of Flammable
0
Gases and Vapors at 1 bar and 20 C
_________________________________________________________________
Substance Minimum Ignition Energy - Mill Joules
Mixture with Air
Acetaldchyde 0.37
Acetone 1.15
Acetylene 0.017
Acrolein 0.13
Acrylonitrile 0.16
Benzene 0.2
1.3 Butadiene 0.13
Butane 0.25
Carbon disulfide 0.009
Cyclohexane 0.22
Cyclopentadiene 0.67
Cyclopentane 0.54
Cyclopropane 0.17
Diethyl ether 0.19
Dihydropyran 0.36
Diisobutyiene 0.96
Diisopropyl ether 1.14
2,2-Dimethyl butane 0.25
Dimethyl ether 0.29
2,2-Dimethyl Propane 1.57
Substance Minimum Ignition Energy - Mill Joules

Ethene 0.24
Ethyl acetate 1.42
Ethylamine 2.4
Ethylene 0.07
Ethylleneimine 0.48
Ethylene oxide 0.06
Heptane 0.24
Hexane 0.24
Hydrogen 0.011
Hydrogen sulfide 0.068
Methane 0.28
Methanol 0.14
Methyl ethyl ketone 0.53
Methylbutane 0.25
Methylcyclohexane 0.27
i-Octane 1.35
i-Pentane 0.21
n-Pentane 0.22
Substance Minimum Ignition Energy - Mill Joules

Propane 0.25
i-Propyl alcohol 0.65
i-Propylamine 2.0
i-Propyl chloride 1.55
n-Propyl chloride 1.08
Propylene 0.28
Propylene oxide 0.13
i-Propyl mercaptan 0.53
Tetrahydrofuran 0.54
Tetrahydropyran 0.22
Thiophene 0.39
Tri ethylamine 0.75
2,3-Trimethylbutane 1.0
Vinyl acetate 0.7
Vinylacetylene 0.082
Unleaded Gasoline 0.29
Substance Minimum Ignition Energy - Millijoules

b) in admixture with Oxygen

Acetylene 0.0002
Ethylene 0.0009
Diethyl ether 0.0012
Hydrogen 0.0012
Methane 0.0027
Propane 0.0021

c) in admixture with Nitrogen monoxide

Hydrogen 8.7
Methane 8.7
Few Incidents … Reason
1) Empty HDPE Drum – Bottom Valve Spent Discharge – 2
min- Spark Blowup

2) BV Closing – Last Wash – Worker Cleaning - PP Covers

Bundles

3) Liner Bag – Human Body – Powder Loading - 11 the

Bag fire near Reactor MH

4) SS Mug – Heptane (0.24 mj ) – CF washing

5) Sifter – Sieving – Mechanical to Dust Blow-up

6) Powder Handling - PTS - High Velocity transfer-Air

entrapment
Few Incidents … Reason
1) Empty HDPE Drum – Bottom Valve Spent Discharge – 2
min- Spark Blowup

2) BV Closing – Last Wash – Worker Cleaning - PP Covers

Bundles

3) Liner Bag – Human Body – Powder Loading - 11 the

Bag fire near Reactor MH

4) SS Mug – Heptane (0.24 mj ) – CF washing

5) Sifter – Sieving – Mechanical to Dust Blow-up

6) Powder Handling - PTS - High Velocity transfer-Air

entrapment
Few Incidents … Reason

7) Drum Filling – Hose Nipple – Toluene (0.24 mj)

8) Reactor Sampling Metal rod/pipe – entry in to Dust

9) Valve handle – Human Body contact

10) Tray Dryer – Trays – Static Charge

11) Earth Calmp - Earthing a Drum

12) Dip Rod – Metal Drum – Non Polar solvent

Story behind the photo: workers at Cochran Chemical in Wewoka, Oklahoma (USA) were
mixing chemicals in this plant when a spark from static electricity caught the
chemicals on fire. The employees sprinted out of the building and immediately called the fire
department. But the chemicals were exploding already. Hundreds of barrels inside the
warehouse began popping, and flying hundreds of feet into the sky
CSB Finds Static Spark Set Off Fire and Explosions
at Barton Solvents Des Moines Facility,
Investigation Finds Equipment Not Intended for
Flammable Service or Properly Bonded and Grounded
CSB Issues Final Report on Barton Solvents Explosion,
Calls on OSHA and Trade Associations to Improve
Material Safety Data Sheets for
Nonconductive Flammable Liquids
 Static electricity that destroyed a Mini Van in
Yankton, - a city in Yankton County, South Dakota, US.

The fire was ignited by an electrostatic charge that had collected on Mrs.
Shager as she sat in the truck. When she reached for the nozzle, the charge
grounded, igniting the gas vapors around the pump.
“You should never re-enter a vehicle during fueling”
BONDING & GROUNDING
 FIRE
TRIANGLE
Source of Ignition
(Spark)

ESD
TRIANGLE
Induction
(Proximity to an electrostatic field)
Please remember !!!

LUCK MAY PROTECT

YOU ONCE…

But, PROPER SAFETY

PROTECTS YOU
ALWAYS…
 ESD Damage

VOLTS RESULT

< 10 Damage or Partial Degradation of ICs, EPROMS etc.

> 12 Explosion Hazards

> 500 Major Dust and Lint Pick-Up Problems

> 1000 Malfunctions on Computer Sub Systems.

> 2000 Personal Shocks, Inevitable SPARKS.

> 3000 Handling & Packing Problems with Films and

Laminations, Plastic Products.
> 5000 Bio Electrical Stress
ESD Latent Damage
 ESD Damage

A PCB scan indicates areas that are susceptible to

secondary ESD effects. Red indicates highest
susceptibility. Courtesy of University of Missouri-Rolla.
ESD Workstation
 For
 SAFETY TRAININGS
 THIRD PARTY SAFETY AUDITS
 RISK ASSESSEMENTS / GAP ASSESSMENTS
 HAZOP STUDIES
 SUPPORT IN SAFETY ASSESSMENT / AWARDS
 HARA REPORTS

GURU PRATAP. VOLETI

Safety Consultant
ISO 45001 Lead Auditor
34 Yrs of Industrial Experience
Two Years in Safety Auditing

E-mail: vgpratap68@gmail.com
thambigp@gmail.com +91 98493 29164
+91 96665 82805