Diagnosing electrostatic problems and hazards in industrial processes: Case studies

Abstract Static electricity is a phenomenon commonly encountered yet often misunderstood and underestimated in terms of its hazard potential; it continues to challenge the safety and reliability of industrial processes, particularly those involving flammable substances. This paper delves into the critical issue of electrostatic hazards in industrial settings by presenting two flash fire/explosion case studies, one involving biphenyl dust and the other gasoline vapor; both linked to electrostatic discharges. The first case study examines an explosion in a flaker and pack‐out hopper during biphenyl flake manufacturing. The investigation reveals the role of electrostatic charges in the incident and how well‐intentioned equipment changes created warning signs of increased risk that were missed. The second case study discusses a gasoline vapor flash fire, highlighting the common yet overlooked hazard of static electricity during the transfer of flammable liquids. It underscores how common activities involving people can generate sufficient electrostatic charge to ignite flammable vapor–air mixtures in industry. The outcomes of these studies 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 adapt plant operations and prevent hazards from static electricity. The paper advocates for a proactive approach to identifying and mitigating electrostatic risks in industrial settings beginning with process hazard analyses that incorporate static electricity hazards analysis and continues through employee training to ensure that early warning signs are identified, understood, and acted upon. It stresses the need for comprehensive safety measures, including proper grounding and bonding, use of static dissipative materials, and regular maintenance of safety equipment, to prevent incidents. Through these case studies, the paper contributes to understanding of electrostatic hazards in industrial processes and highlights the importance of integrating electrostatic safety measures into routine industrial operations.