Note: This booklet was developed by TB&S Consultants under contract to the Propane Education & Research Council Docket Number 12457. For further information regarding propane safety and static electricity, visit www.propanesafety.com.
Propane Education & Research Council 1140 Connecticut Ave. NW Suite 1075 Washington, DC 20036 202.452.8975 www.propanecouncil.org
Table of Contents
1. Purpose and Definitions ............................................................................................................................................................... 1 2. Introduction ..............................................................................................................................................................................................2 3. A Lesson Learned .............................................................................................................................................................................3 4. Static Electricity ...................................................................................................................................................................................4 4.1 What Is Static Electricity and Where Does It Come From? ..............................................................4 4.2 How Does Static Electricity Act? ............................................................................................................................5 4.3 Did You Know? ........................................................................................................................................................................6 4.4 What About Relative Humidity? ................................................................................................................................6
5. Steps to Take to Reduce Static Electricity ................................................................................................................... 7 5.1 Identify the Static Discharge Control Areas .................................................................................................. 7 5.2 Floors and Work Surfaces ............................................................................................................................................. 7 5.3 Footwear.......................................................................................................................................................................................8 5.4 Safety Clothing and PPE ................................................................................................................................................8 5.5 Ground the Equipment......................................................................................................................................................8 5.6 Remove Field Sources ......................................................................................................................................................9 5.7 Friction Creates Static Electricity............................................................................................................................9 5.8 Temperature and Relative Humidity ......................................................................................................................9 5.9 Training....................................................................................................................................................................................... 10 5.10 Interviews and Anecdotal Evidence .................................................................................................................. 10 5.11 Limit Access to Static Discharge Control Areas .................................................................................... 10 Static Discharge Prevention Quick Tips .......................................................................................................................11 Glossary...................................................................................................................................................................................................12 References and Acknowledgments ................................................................................................................................14 Field Evaluation Guide: Static Discharge Hazards .............................................................................................15 Static Discharge Control Quiz ..............................................................................................................................................21 DVD ......................................................................................................................................................................Inside Back Cover Static Discharge Control Quiz Answers ................................................................................Inside Back Cover
2. introduction
Static electricity is electricity at rest, or simply not moving. Other than an attraction to other materials, it is relatively harmless. However, if a conductive path is provided for the static electricity, the resulting static discharge or spark may cause the ignition of propane vapor. When propane mixes with air (2.15 to 9.60% by volume), the resulting mixture can be ignited easily by a static discharge. Static discharge is sometimes cited as the possible cause of fires or explosions. Advances in chemistry and technology have brought us new polymers and synthetics that have increased the likely presence and generation of static electricity. For example: Wood and steel are being replaced with polymeric materials such as high-density polyethylene (HDPE) Polyvinyl chloride (PVC) and stretch wraps are used to cover and secure loads PVC pipes are replacing metal pipes in low-pressure systems Natural fabrics are being replaced by synthetics Automation has brought faster production speeds The study of static electricity has grown exponen-tially over the past decade. However, there is still a vast misunderstanding about how it works where propane is transferred and handled. This guide offers a practical view of static electricity as an ignition source and provides general suggestions to reduce associated risks. It must be noted, we can never completely eliminate static electricity. However, by understanding what static electricity is, where it comes from, and how it behaves, we can more effectively control it.
3. A Lesson Learned
The event:
In July 2006, an employee at a northern California cylinder processing facility reported to his manager what he believed to be a fire during the transfer process. An immediate investigation did not show any signs of ignition or fire.
The outcome:
Once we understood what and why this was happening, it was an issue easy to resolve. A few simple process changes were implemented to keep HDPE trays and other HDPE items outside the transfer area. The employees now wear approved anti-static footwear or heel grounders, and the mats have been changed to anti-static conductive types. Employees were educated on static electricity, static discharge, and their role in controlling static electricity.
Copyright AmeriGas Propane, L.P., February 23, 2007. All rights reserved.
This cylinder processing facility was refilling 20-pound cylinders, filling by weight using a low-emission transfer process.1 The low-emission transfer releases between 2 and 4 cubic centimeters (ccs) of propane at the end of each fill cycle as the fill nozzle is released from the cylinder.
observation:
The only time we notice or pay any attention to static sparks is when they are painful or they ignite fuel. Static sparks too small to be seen or felt can ignite propane!
NFPA 58, Establishes a maximum fugitive emissions standard for certain product transfer operations. Low-emission transfer specifications might be employed to comply with environmental regulations or to determine certain minimum distance requirements, 2008 Edition, Section 3.3.37.5 Low-Emission Transfer.
4. Static Electricity
4.1 What is Static Electricity and Where Does it Come From?
We have all seen examples of static electricity. The way our hair flies around when we brush it, the way some garments cling together when they come out of a clothes dryer, or the annoying little zap you feel when you reach for a light switch. Static cling and static sparks are common everyday events. When any two materials touch and separate, one material rips electrons away from the other material creating an imbalance or charge. It happens with all materials. The material that receives the electrons has a negative charge, and the material that gave them has a positive charge. Different combinations of materials will develop different levels of static charge or voltages. Relative humidity, speed of movement, the materials size, and the materials electrical properties are all factors in determining how much static will be generated and how its going to behave. When we walk across a carpet, the soles of our shoes separate from the carpet, there is friction inside our shoes and socks, and our clothes rub against our bodies. These sources of friction generate a static charge. Then, if we reach out to touch a light switch or other conductive material, a spark is emitted. Other examples include fuel flowing at high velocity through a small opening, which can generate enough static electricity in the fuel vapors to ignite them. Also, the friction of a dry wind blowing over cellophane or stretch wrap may energize the wrap. The wrap, in turn, may induce a charge into nearby conductors. A conductor can be any material that an electric current can pass through. Non-conducting materials resist the flow of electric currents.
Static electricity is simply that static: its electricity thats standing still! A material with either too many or too few electrons in its atomic structure has a static electrical charge. Static electricity can come from a number of sources. Atmospheric lightning is the largest and most violent form. Most of the static electricity we experience in our daily lives is not as dramatic. In fact, we usually dont notice it at all, or if we do, we dont pay it much attention. This is the static electricity created or generated by friction, scientifically called tribogeneration. Walking across a loading dock with rubber-soled boots, removing a wool sweater, and wind blowing over stretch wrap are all examples of friction generating static electricity.
Figure 4. Stretch wrap in the wind may generate and induce static on cylinders.
Common materials
Conductors Most metals Human body Wet fabrics Wet concrete Non-Conductors Plastic film High-density plastics Most dry fabrics Dry concrete
Within the effects of the electric field surrounding the charged object.
Higher relative humidity reduces static generation and reduces decay time. Effects of moisture on Static Generation (typical values)
Source Walking on a carpet Walking on concrete Rubbing a plastic bag Brushing hair Below 25% rh 30,000 volts 8,000 volts 20,000 volts Dry 25,000 volts Above 50% rh 1,500 volts 500 volts 1,200 volts Wet0 volts
Humid air also reduces the ability to generate static by depositing a microscopic moisture layer on the materials surface. The moisture is conductive, thereby making the surfaces temporarily conductive. Polymeric materials such as HDPEs, PVCs, and plastic films do not absorb moisture and can charge to extreme voltages, even at 100% relative humidity.4 While one side of the plastic may be wet, the inner surface is dry.
Figure 5. Normally innocuous items may generate and retain incendiary levels of static electricity.
Figure 6. Plastic film remains dry on the inner surface, even when the outer surface is wet.
NFPA 77, Recommended Practices on Static Electricity, 2007 Edition, Section 7.4.2.3.
Figure 7. Some Static Discharge Control Areas are stationary and others are mobile.
The static dissipative range is between 1 x 10 5 and 1 x 10 11 ohms per square. Conductive is less than 1 x 106. Dissipative is between 1 x 106 and 1 x 1011. Non-conductive is above 1011. Static-safe floor coverings and mats are commercially available.
5.3 Footwear
People generate static charges by movement. They can carry the charge a considerable distance before discharging. Static-safe footwear 6 or temporary heel grounders allow the wearer to discharge safely to a static-safe floor or floor mat before the charge levels become great enough to spark. Other grounding methods are available, including conductive wrist bands with cords. Avoid garments that snap and crackle when put on or removed. Flame-retardant, chemical-retardant, and anti-static garments may be required.
Figure 8. Static Discharge Type 1 safety boot and a disposable heel grounder.
Figure 9. Process equipment such as conveyers and roller systems may develop static if they are not bonded and grounded.
Static Discharge Type I, below 100 Meg ohms and Static Discharge Type II, below 1,000 Meg ohms.
Figure 12. Any process that requires movement may generate static electricity.
Figure 10. HDPE stacking trays may develop extreme levels of static electricity. Because trays are stacked, air flow cannot neutralize the charge on the trays in the center of the stack.
Figure 11. Packing materials and wraps should be removed and stored away from Static Discharge Control Areas.
Some polymeric materials may be made anti-static by adding conductive elements in the formulation process or coating with topical, anti-static compounds.
5.9 Training
There is no single tool or material that can control all static electricity. Instead, by understanding what static electricity is and where it comes from, we can apply simple means to reduce and control it. We should examine our processes and equipment to determine if they are part of the problem or part of the solution. Take note of the observations of people who work in Static Discharge Control Areas. They are the ones who witness static discharge events first hand and thus are the first to be aware of potential ignition risks.
5.11 Limit Access to Static Discharge Control Areas 5.10 interviews and Anecdotal Evidence
People working inside Static Discharge Control Areas and other personnel often observe situations and conditions that may indicate the presence of static electricity. They are aware of changing conditions and situations often before management or safety officials. By limiting access to Static Discharge Control Areas to those individuals necessary to conduct normal business activities, we can limit the number of potential charge carriers. Casual observers and retail customers may not be equipped with the appropriate PPE or be aware of static discharge hazards.
Figure 13. Static Discharge Control Areas include areas where hoses and connections are coupled and decoupled and there is the potential for the presence of vapors. It includes railheads, bulk transfers, and cylinder filling areas.
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GLoSSArY
bond electrically connect two or more conductive materials to ensure they are at the same voltage level, not necessarily earth ground; to achieve equal potential conductive the property of a material that allows for the flow of electrons conductor a material that allows the flow of electrons; common examples include most metals and the human body ground the reference point from which voltages are measured; it is the return path for electrical current to earth; a direct physical connection to earth high-density polyethylene (HDPE) dense, economical, hydrocarbon-plastic having good moisture barrier and chemical resistance; commonly used for bags, bottles, and other household products induction the method by which an electrically charged object can create an electrical charge in a second object without physical contact between the two objects insulator see non-conductor ionization the process by which a neutral atom or molecule loses or gains electrons, thereby acquiring a negative or positive net electrical charge; when electrons are gained, it is known as a negative ion; a positive ion has lost electrons joules a unit of heat, energy, or work; there are 4.184 joules in a calorie, and 1,055 joules in a British thermal unit (Btu); a watt is a joule/second millijoules (mJ) 1/1000 joule non-conductive the property of a material that resists the flow of electrons non-conductor a material that resists the flow of electrons; common examples include plastics, vinyls, and dry fabrics polymeric materials popular usage describes materials composed of molecules with large molecular mass typical of polypropylene and common plastics; polymers with covalent chemical bonds polyvinyl chloride (PVC) polyvinyl chloride, a polymer of vinyl chloride used to make a wide range of consumer products such as stretch wrap and low-pressure pipes; commonly known as vinyl PPE personal protective equipment; personal attire, tools, and materials designed to protect the user from the normal hazards associated with the current activity; common examples include static-safe safety boots, face shields, and gloves resistance the quality of a material that resists or impedes the flow of electricity
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resistivity surface resistivity; the electric resistance of the surface of an insulator, in ohms per square, as measured between the opposite sides of a square on the surface, and whose value in ohms is independent of the size of the square or the thickness of the surface film static discharge the rapid equalization of static electricity; electricity in motion static discharge footwear footwear designed to discharge static electricity through static dissipative materials in the shoe soles; static discharge footwear may be designated as static discharge Type 1 (below 1 x 108) and static discharge Type 2 (below 1 x 109); other common designations include static safe, static dissipative, static control, and ESD (electrostatic discharge) safe static dissipative the property of a material that reduces the speed of static discharge; a material with a surface resistivity between 1 x 105 and 1 x 1011 ohms per square static electricity an electrical charge on the surface of a material created by an excess or a deficiency of electrons; electricity at rest stretch wrap a thin, plastic, stretchable wrapping material applied to the outside of a finished load or pallet to protect against dust and moisture, and to reduce load shifting during transit
tribogeneration the generation of static electricity through the friction of contact and separation of two dissimilar materials volts the unit of electrical pressure required to cause one ampere of current to flow through one ohm of resistance
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references
NFPA 77, Recommended Practices on Static Electricity, 2007 Edition. NFPA 58, Liquefied Petroleum Gas Code, 2008 Edition. Jonassen, Niels, Electrostatics, Chapman & Hall, 1998. PERC, Dispensing Propane Safely, 2005. S.A.H. Rizvi and P.R. Smy, Characteristics of incendive and non-incendive spark discharges from the surface of a charged insulator, 27, Journal of Electrostatics, 267282, (1992).
Acknowledgments
The authors of this booklet would like to gratefully thank the following people for their valuable assistance, contributions, and comments in the preparation of this document: Mike Walters AmeriGas Propane, L.P. Jerry Lucas Heritage Propane Carlton Revere Revere Gas and Appliances Eric Kuster Fairmount Specialty Eric Leskinen Griffith Energy Phil Applegate Targa Resources Randy Warner Ferrellgas Stuart Flatow PERC Vincent Sibilia PERC
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This static discharge field evaluation guide may be used as an initial facility evaluation or as part of regularly scheduled safety or quality management evaluations. If your company has established procedures regarding static discharge control, please comply with those policies. This field evaluation guide is intended to help propane companies identify and reduce the possibility of static discharge in the workplace. Observations are to include all deviations from the recommendations noted in the checklist. Corrective Actions are to include the remedial actions proposed to reduce the possibility of static discharge.
YES Observations:
NO
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YES Observations:
NO
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3. Footwear
All personnel who enter SDCAs should be equipped with static-safe footwear or temporary heel grounders. Entrance to SDCAs should be limited to authorized personnel equipped with the required footwear. Are all personnel who enter SDCAs equipped with static-safe footwear or temporary heel grounders?
YES Observations:
NO
4. Safety Clothing
Clothing has proven to be a source of static electricity and static sparks. Some fabrics generate more static electricity than others. For critical applications, specialized static-safe clothing and fabric treatments are available. Here are some guidelines: Cotton and cotton blends generate less static than most synthetic blends. 100% nylon, 100% polyester, and wool clothing should be avoided. Garments such as sweaters or coats should never be removed or put on inside SDCAs. Avoid garments that snap or crackle when put on or removed. Flame-retardant, chemical-retardant, and anti-static garments may be required.
Do all personnel who enter SDCAs wear safety clothing that follow these guidelines?
YES Observations:
NO
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YES Observations:
NO
6. Field Sources
Remove all plastics and other synthetic materials from the SDCA. Store these materials (stacking trays, trash barrels, plastic wraps, etc.) at least 25 feet away from SDCAs. Are all of these types of materials unnecessary to the operation in progress removed from the area?
YES Observations:
NO
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7. Process Observations
All processes that require movement and the separation of materials are capable of generating a static charge. Have processes, process changes, and new tools been evaluated for static generation?
YES Observations:
NO
8. Training
All employees involved with the transfer of propane should be aware of the hazards of static discharge. Have all employees involved in the transfer of propane been instructed on the hazards of static discharge and appropriate mitigation measures?
YES Observations:
NO
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9. Employee Observations
Employees are the eyes and ears of safety. Are employees actively encouraged to share their observations and concerns regarding static discharge safety?
YES Observations:
NO
Additional Observations:
Signed:
Date:
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Name:
Date:
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Static Discharge Control Quiz...continued 9. All personnel who enter Static Discharge Control Areas should be grounded properly with static-safe footwear or temporary heel grounders. ___ True ___ False 10. It is safe to put on or remove clothing inside a Static Discharge Control Area. ___ True ___ False 11. More static electricity is generated on a rainy day than on a dry day. ___ True ___ False 12. Removing plastic sleeves from cylinders can generate static electricity. ___ True ___ False 13. Which places are NOT usually considered Static Discharge Control Areas? ___ Bulk transfer connections ___ Cylinder filling operations ___ Storage and recovery areas ___ General office ___ Any area where there is the likelihood of the presence of propane vapor 14. What materials should be removed from Static Discharge Control Areas to help reduce the threat of static discharge? ___ Plastic stacking trays ___ Trash barrels ___ Plastic wraps ___ All of the above ___ None of the above 15. Who is responsible for static discharge safety? ___ Plant managers ___ Safety managers ___ Bobtail drivers ___ Any employee who is in an area where propane is present All of the above
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1. 2. 3. 4. 5.
6. 7. 8. 9. 10.
False True General office All of the above All of the above\
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