In petrochemical industries, one of the most severe risks is the occurrence of fires and explosions caused by electrostatic discharge. According to incomplete statistics, over the past decade, China's petrochemical companies have experienced more than 20 incidents related to static electricity, resulting in significant financial losses, with some cases costing hundreds of millions of yuan. Therefore, for these enterprises, the primary objective of electrostatic safety management is to prevent such hazardous events from happening.
To effectively control and manage electrostatic fire and explosion accidents, it is essential to first understand the conditions under which these incidents occur. Only then can appropriate protective measures be implemented to reduce the risk.
### 1. Formation Conditions and Characteristics of Electrostatic Fire and Explosion
It is well known that fires and explosions occur under specific conditions. When it comes to static electricity causing such events, four key factors are typically involved:
1. **Static charge generation** must occur.
2. The accumulated static charge must reach a voltage high enough to cause a spark discharge through the surrounding dielectric material.
3. The energy released during the spark must be sufficient to ignite flammable materials.
4. There must be a combustible mixture (such as flammable vapor or gas) present at a concentration capable of igniting upon discharge.
#### 1.1 Characteristics of Electrostatic Fire and Explosion Accidents
Petrochemical environments are particularly prone to electrostatic hazards due to several reasons:
- They provide excellent conditions for static charge generation and accumulation, making dangerous voltages likely.
- A large amount of flammable substances is often present in the production process, and the ignition energy required to start a fire is very low—often below 1 mJ for explosive mixtures.
- These incidents tend to happen suddenly, giving little time for detection or intervention.
#### 1.2 Common Causes of Electrostatic Fires and Explosions
Over the past 30 years, numerous electrostatic-related accidents have occurred in Sinopec enterprises. After analysis, these incidents can be categorized into three main types:
- **Tank float-related discharges**: For example, in Haigaoqiao Petrochemical Company, oil tanks suffered explosions due to discharges between floating floats and tank walls.
- **Accidents caused by improper operations**: Such as using plastic buckets during sampling or rapidly lifting thermometers, which can generate static electricity.
- **Discharges from spraying or friction during loading**: This has been observed in various petrochemical facilities across China.
These accidents often result from outdated technical measures and poor management practices.
### 2. Control and Prevention of Electrostatic Hazards
To prevent electrostatic fires and explosions, the focus should be on both controlling static charge generation and ensuring its safe dissipation.
#### 2.1 Reducing Static Charge Generation
- Ensure pipes and equipment are smooth and free of sharp edges.
- Use new materials and advanced technologies that have good anti-static properties.
- Control the flow speed of liquids to avoid turbulent flow, which can increase static buildup.
- Improve filters, as they are a major source of static electricity in many processes.
- Use gear drives instead of belt drives where possible, and if belts are used, ensure they are anti-static.
#### 2.2 Accelerating Static Dissipation
- Add anti-static agents to improve conductivity and help dissipate static charges.
- Implement proper grounding for all metal equipment, trolleys, and even personnel, using conductive floors made of materials like rubber or marble.
- Allow sufficient "standing time" for static charges to fully leak out after transport.
- Install static eliminators in pipelines to reduce the risk of charge buildup.
In addition to these measures, it’s crucial to minimize the presence of explosive mixtures in the workplace. This can be done by keeping concentrations below the lower explosive limit, replacing flammable substances with non-flammable ones, and reducing oxygen levels in certain areas.
Petrochemical companies often use floating roof tanks and sealed loading systems to prevent the formation of explosive vapors inside storage tanks, thereby enhancing safety during storage and transportation.
By combining these strategies, petrochemical enterprises can significantly reduce the risk of electrostatic fires and explosions, ensuring safer working environments.
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