What is electrostatic discharge?
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An electrostatic ignition source is a discharge resulting from the generation and accumulation of electrostatic charges. Electrostatic charge generation most frequently occurs when any two materials &#; liquids and/or solids &#; make contact with each other and then separate.
For an electrostatic hazard to occur, the following criteria must be fulfilled; there should be a flammable atmosphere which may be gases, vapors, suspended droplets or suspended dusts; there should be a process giving rise to charge generation, the charge must accumulate, the charge accumulation must be large enough to produce an electrical breakdown of the local atmosphere and the electrostatic discharges so produced must be energetic enough to ignite the flammable atmosphere.
Electrostatic hazard assessment is the process of identifying, evaluating, and mitigating risks associated with static electricity in various environments, particularly in industrial settings. The primary aim is to prevent accidents such as fires, explosions, and equipment damage that can result from electrostatic discharges. This assessment involves several key steps:
What are some risks associated with static electricity?
Electric shock due to the flow of current through the body, causing a person everything from an uncomfortable zap to falls, burns, or stopping the heart, Fires or explosions due to the ignition of flammable or explosive mixtures, Production disturbances in the processing of paper, plastics, composites, powder, granules, and liquids, Damage to electronic equipment and components from electrostatic discharge (ESD), and Damage to mechanical components such as bearings due to sparking through the oil films on the bearing surface
How are static electricity charges generated (charge generation)?
When two different materials come into contact, electrons may prefer one material over the other, leading to an electron transfer across the interface. If these materials are separated, the electrons might not fully return to their original material. In cases where both materials are good conductors, the transferred charge will return through conduction at the last contact point, leaving no trace of the charge exchange. However, if one or both materials are insulators, the transferred charge cannot move back easily, resulting in one material becoming positively charged and the other negatively charged
Why should we perform an electrostatic hazard assessment?
Performing an Electrostatic Hazard Assessment in the process industry is vital due to the inherent risks associated with static electricity in environments handling flammable or combustible materials. In industries such as chemical manufacturing, pharmaceuticals, and petrochemicals, static charges can accumulate and, if not properly controlled, lead to ignition of flammable vapors, gases, or dust, resulting in fires or explosions. These assessments help in identifying and evaluating the sources of electrostatic generation, the potential accumulation points, and the effectiveness of existing grounding and bonding systems. By systematically analyzing these factors, industries can implement appropriate safety measures to mitigate the risk of static-induced incidents. This not only ensures compliance with safety regulations but also enhances overall operational safety, protecting both personnel and assets from the potentially devastating consequences of electrostatic discharges.
What are the Preventive Measures of Electrostatic Hazard?
Static hazards are dealt with by avoiding charge generation, preventing charge accumulation or by removing the charge before there is any possibility of a discharge
How can static electricity be controlled?
Ignition hazards from static electricity can be controlled by the following methods:
How can conductive materials be bonded and grounded?
It is generally recommended that fixed conductive surfaces and equipment be grounded such that their resistance-to-ground are less than ten (10) ohms (Ω). However, a resistance-to-ground of as much as 1 x 106 ohms (1 MΩ) can be allowable for rotating and moving conductive parts of mechanical equipment, such as screw feeder screws, blender rotors and conductive probes inside of equipment. A resistance-to-ground of less than 1 x 106 ohms is generally sufficient to prevent the accumulation of a potentially hazardous level of charge on conductive surfaces and equipment. The lower value, 10 Ω, is generally recommended for fixed metallic equipment, however, since it is easily achievable, and a higher resistance generally suggests a problem with the grounding system or pathway. The grounding of conductive surfaces and equipment should be checked regularly by measurement as a part of a safety-critical Mechanical Integrity program.
How can we control static electric charge on personnel?
The human body is a conductor and subject to charge accumulation when isolated from ground. The maximum stored energy on a human body is generally not expected to exceed 30 mJ. However, the grounding of personnel is generally recommended when they may be exposed to a flammable atmosphere having a Minimum Ignition Energy (MIE) of less than 100 mJ. Personnel should be grounded such that their resistance-to-ground is less than 1 x 108 ohms (100 MΩ) to prevent the accumulation of a potentially hazardous level of electrostatic charge. However, their resistance should be no lower than 5 x 104 ohms (50 kΩ) in order to protect them from potential electrocution hazards. Steps to prevent charge accumulation include the use of the following:
What are the applicable standards for static control in flammable and combustible atmospheres?
NFPA 77 guides on &#;identifying, evaluating, and controlling static electric hazards to prevent fires and explosions. Other applicable codes and standard includes API RP : Protection Against Ignitions Arising Out of Static, Lightning, and Stray Currents and IEC -32-1: Electrostatic Hazards &#; guidance
What is electrostatic hazard assessment?
Electrostatic hazard assessment is the process of identifying, evaluating, and mitigating risks associated with static electricity in industrial and other environments.
Why is electrostatic hazard assessment important?
It is crucial to prevent fires, explosions, and equipment damage caused by electrostatic discharges in industries handling flammable materials or sensitive electronics.
What industries require electrostatic hazard assessments?
Industries such as chemical manufacturing, pharmaceuticals, petroleum, mining, electronics, and food processing often require these assessments.
What are common sources of static electricity in industrial settings?
Common sources include friction between materials, fluid flow through pipes, handling of powders, and movement of conveyor belts.
What is an electrostatic discharge (ESD)?
An ESD is a sudden flow of electricity between two electrically charged objects caused by contact, an electrical short, or dielectric breakdown.
How can static electricity cause fires and explosions?
Static electricity can ignite flammable vapors, gases, or dusts when a discharge occurs, providing an ignition source.
What are some common methods to control static electricity?
Methods include grounding and bonding, humidity control, antistatic agents, conductive flooring, and proper material handling practices.
What is grounding and bonding?
Grounding involves connecting objects to the earth to eliminate charge buildup, while bonding connects two objects to equalize their charge.
How does humidity affect static electricity?
Higher humidity levels increase the conductivity of materials, helping dissipate static charges, while low humidity promotes charge buildup.
What are antistatic agents?
Antistatic agents are chemicals applied to surfaces to reduce static charge accumulation by increasing surface conductivity.
What is a safe threshold for static charge accumulation?
While it varies by material and environment, generally, static charge should be kept below 1 kV to prevent hazardous discharges.
How can clothing contribute to static hazards?
Synthetic fabrics can generate and hold static charge, so antistatic or conductive clothing is recommended in hazardous environments.
What role do footwear and flooring play in static control?
Conductive footwear and flooring help dissipate static charges from personnel to the ground, reducing the risk of discharge.
Can static electricity affect electronic equipment?
Yes, ESD can damage sensitive electronic components, leading to malfunction or failure, making ESD control critical in electronics manufacturing.
What is the purpose of an electrostatic hazard assessment?
To identify potential sources of static electricity, evaluate the associated risks, and implement measures to mitigate those risks.
What are some indicators of a potential electrostatic hazard?
Indicators include frequent small shocks, visible sparks, and the accumulation of dust in areas where it shouldn&#;t be.
How often should electrostatic hazard assessments be conducted?
Assessments should be conducted regularly, especially when there are changes in processes, materials, or equipment.
What standards or guidelines are followed in electrostatic hazard assessment?
Standards include NFPA 77, IEC , and OSHA guidelines, among others, which provide detailed procedures and safety measures.
Can portable electronic devices pose a static hazard?
Yes, portable electronic devices can generate static and should be used cautiously in hazardous environments.
How do you measure static electricity?
Static electricity can be measured using instruments such as electrostatic voltmeters, field meters, and charge plates.
What is an electrostatic discharge protective area (EPA)?
An EPA is a designated area with controls to protect sensitive components from ESD, including grounded work surfaces and tools.
What are the consequences of not addressing electrostatic hazards?
Consequences include fires, explosions, equipment damage, production downtime, and potential injury or loss of life.
What training is required for personnel regarding electrostatic hazards?
Personnel should be trained on static electricity sources, hazards, and control methods, and how to properly use and maintain ESD protection equipment.
Can static electricity be completely eliminated?
It is nearly impossible to eliminate static electricity entirely, but it can be effectively controlled to safe levels.
What are some examples of personal protective equipment (PPE) for static control?
Examples include antistatic wrist straps, conductive shoes, grounding cords, and antistatic clothing.
How do you determine if a material is prone to static buildup?
Material properties like resistivity, humidity sensitivity, and triboelectric characteristics help determine static buildup propensity.
What is the triboelectric series?
The triboelectric series is a list of materials ranked by their tendency to gain or lose electrons, which helps predict static charge generation.
How can you safely discharge static electricity?
Safe discharge methods include grounding, using ionizing equipment, or controlled discharge through resistive paths.
What is an ionizer and how does it work?
An ionizer neutralizes static charge by emitting positive and negative ions that attract and neutralize charges on nearby surfaces.
What role do process modifications play in electrostatic hazard control?
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Modifying processes to reduce friction, control flow rates, and avoid static-prone materials can significantly reduce electrostatic hazards.
What Services does Prime Process Safety Center offer
Prime Process Safety Center offers the following Combustible Dust Consulting Services; Combustible Dust Hazard Analysis (DHA), Ignition Sources Assessment, Electrostatic Hazard Assessment, Hazardous Area Classification, Fire and Explosion Hazard Analysis, Explosion Prevention and Protection Consulting Services, Fire and Building Code Services, Incident Investigation, Expert Witness and Litigation. Moreover, Prime Process Safety Center offers the following combustible dust testing services Go/No Go Explosibility Screening, Burn Rate / Fire Train Test, Dust Explosion Severity (Kst/Pmax/dP/dt), Minimum Explosible Concentration (MEC)/Lower Explosible Limit (LEL), Limiting Oxygen Concentration (LOC) Test, Minimum Ignition Energy (MIE), Minimum Autoignition Temperature-Cloud (MAIT &#; Cloud), Layer Ignition Temperature of Dust (LIT), Volume Resistivity, Surface Resistivity, Charge Decay (Relaxation) Time, Breakdown Voltage, Flexible Intermediate Bulk Containers (FIBC), Electrostatic Chargeability Testing, Basket Self-Heating, Grewer Oven Test, Air Over Layer/Powder Layer Test, Bulk Powder Test, Aerated Powder Test
Electrostatic discharge is a threat that manufacturers of electronic products shouldn&#;t underestimate as it can damage or even kill products and should influence how your product is designed and manufactured. As we&#;re a contract manufacturer who often produces electronic devices for our customers, we know the risks, so here are answers to some of the common questions about ESD and its risks for you.
If you are manufacturing electronic products, this one is a must&#;
10 FAQs we often get about electrostatic discharge and its risks
Here are 10 FAQs about electrostatic discharge that will bring you up to speed based on a recent discussion we had about ESD and ESD testing on our group&#;s podcast:
1. What is Electrostatic Discharge and why is it dangerous for electronic devices?
Electrostatic Discharge (ESD) is the same as naturally occurring lightning. It can occur on a smaller scale in the factory, the office, or the home, and is an electrical charge that passes between two electrically charged objects, such as your hand and an electronic device. The discharge can cause a short which damages or &#;fries&#; sensitive electronic components resulting in the product failing. If you&#;ve ever been &#;zapped&#; when touching a metallic object or brushing past another person, that&#;s an electrostatic discharge.
2. How can ESD damage electronic components?
An ESD spark, for example, could be at a high enough voltage to result in a current that can break microchips, melt the silicon in circuits, and short our electronic products. Here are a few examples of ESD damage:
Overpowering components: Many electronic components are designed to handle specific voltage levels. ESD events, which can reach thousands of volts, can be way above this limit. This surge of electricity can fry the delicate circuits within the component.
Short circuits: ESD can create unintended electrical connections between different parts of a circuit that shouldn&#;t be connected. This can disrupt the normal flow of electricity and damage the components involved.
Latent damage: Sometimes, ESD damage isn&#;t immediately obvious. The zap might weaken the component, making it more likely to fail prematurely down the road. This can be a nightmare for manufacturers as it can lead to field failures after the product is sold.
The unpredictable nature of a discharge could be enough to cause lasting damage to unprotected products which is why they need to be tested for resilience against it and protected accordingly. One way will be to include ESD protection circuitry (we&#;ll come on to that later).
3. How can products be designed to avoid ESD damage?
ESD should be in the product designer&#;s mind, as the final product needs to be resistant. Starting by following international ESD protection standards, such as ANSI/ESD S20.20-: Protection of Electrical and Electronic Parts, will set you up for success.
There are two main approaches to designing products to avoid ESD damage:
1. Grounding and Shielding
This involves creating a path for ESD current to safely flow away from sensitive components and preventing static charges from building up in the first place.
Grounding: This involves connecting all conductive parts of the product to a common ground plane. This plane acts as a pathway for ESD current to travel directly to earth ground, bypassing sensitive components.
Shielding: Sensitive components can be encased in conductive materials like metal enclosures or conductive coatings. This creates a barrier that weakens the electric field and prevents static charges from reaching the components. This is commonly known as a Faraday cage.
2. Component Selection and Circuit Design
Careful selection of components and circuit design practices can also help mitigate ESD risks.
ESD-tolerant components: Look for components with high ESD voltage ratings. These components can withstand higher voltage spikes without getting damaged.
Protection devices: Incorporate transient voltage suppressor (TVS) diodes or other ESD protection devices into the circuit. These devices act as a sacrificial element, absorbing the ESD current and protecting sensitive and sometimes critical components.
Circuit layout: PCB layout plays a role too. Minimize loop areas in the circuit to reduce the potential for induced currents. Keeping ground planes close to signal lines also helps dissipate ESD efficiently.
4. What are the common types of ESD testing?
There are 3 common types of ESD testing to test that the product will be resilient against ESD and that measures put in place, such as implementing ESD protection circuitry, are effective:
5. What are typical voltages used in ESD testing for different devices?
Your testing laboratory will advise you on your best options for your electronic product, but in general we suggest these ranges:
6. When should Electrostatic Discharge testing be done?
ESD testing should be done throughout the NPI process, as you need to ensure that your design, prototypes, and finished products are all resistant to ESD due to its damage risks. Basically, ESD testing needs to be a part of your general testing plan along with reliability, and more, if you manufacture electronic products. After the products are on sale, you may also do some ESD testing as a part of your Ongoing Reliability Testing procedure, too, just to be sure that future batches remain resilient to ESD damage and nothing has crept into the production process that could be causing the damage.
7. How else can ESD cause problems for a business?
As we have discussed, ESD can damage electronic products, but for the businesses selling them it is also a risk of:
8. How can a manufacturer reduce the risks of ESD damage during production?
Products can be damaged by ESD in the factory long before they get to consumers.
To safeguard electronic components from electrostatic discharge (ESD) throughout the production process, manufacturers should implement a multi-faceted approach. One crucial aspect involves properly grounding personnel. Operators wear ESD-safe smocks, gloves, and conductive wrist straps. These straps connect them to a common ground point, ensuring any static charge they accumulate is safely dissipated.
Another key element is environmental control. Production areas maintain controlled temperature and humidity levels. Lower humidity reduces the generation of static electricity, while slightly higher humidity helps dissipate existing charges.
ESD-safe tools are another line of defense. These tools are manufactured with conductive or dissipative materials, like rubberized handles. This design minimizes the transfer of static charges between the tool and the components.
Furthermore, ESD-safe packaging is used throughout production, not just for final shipment. Static-resistant bubble wrap, shielded bags, and conductive foam all play a role in protecting components during various production stages.
The work surfaces themselves are also crucial. Grounded workbenches and ESD mats further minimize static buildup around the product as it&#;s being assembled.
Air ionizers are another weapon in the fight against ESD. These devices neutralize static charges present in the air, significantly reducing the risk of ESD events occurring during production.
Finally, a well-trained workforce is vital. Manufacturers provide regular training to personnel on ESD risks and proper handling procedures for ESD-sensitive components. By understanding these principles and implementing the necessary precautions, employees play a vital role in ensuring the quality and functionality of the finished product.
9. Should you work with an ISO -compliant manufacturer to produce your electronic devices?
Not necessarily, as ISO is rather vague and many of the auditors lack an understanding of what is important in the production and handling of electronic products. A knowledgeable auditor will raise the topic of ESD prevention with the factory, but there is no assurance that they will fail the audit because of that point.
Suppose you&#;re making electronic products susceptible to electrostatic discharge damage. In that case, the key is to work with a manufacturer who knows what they are doing and is experienced in manufacturing electronics.
You may also audit them before you start working with them, a best practice that many importers follow, and check that they have implemented ESD prevention and are using some of the techniques mentioned earlier (such as controlled environment, ESD-resistant tools, appropriate uniforms, etc).
10. Can Electrostatic Discharge damage occur after the sale?
Yes, as mentioned, consumers may become electrostatically charged and cause ESD damage to products in, say, the home. Aside from testing the products to ensure that they can survive, there may be certain advice for reducing the risks of ESD that you can/should provide to the customer, perhaps in the operating manual.
Next steps
If you need help with testing your products or have specific questions about ESD testing for your electronic devices, get in touch and we&#;ll offer you our advice based on your situation and needs.
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