How Smart Electrostatic Grounding Helps you Avoid Risks

When sparks are flying, that is not necessarily a good thing. In industry, uncontrolled electric discharges are one of the most frequent causes of explosions and fires. Long-term studies have shown that they are the third-ranking hazard source when combustible substances are moved. These include mineral oil products, disinfectants, adhesives or solvent-based paints and varnishes in filling plants, paint stores and print shops.

What can we do for you?

The most frequent causes for explosions of combustible media

Spontaneous combustion
Overheating of moving parts
Electrostatic discharge sparks

“Usually there are no
problems during grounding!”

“Nothing bad has
happened so far”

“You can count on me, boss.
I always ground correctly”

Don’t make the mistake of relying on such statements! The sources of error in electrostatic grounding are often not visible to the naked eye. Incorrect grounding attempts often give production employees a false sense of security. Tragically so, because this increases the risk of an explosion or fire.

One example: In practice, barrels and containers such as BigBags or tank trucks are frequently found to have well-intentioned but faulty grounding. For example, unsuitable tools such as battery clamps or welding guns are used. Thus the users have no chance to check if the contactor is able to pierce through paint or a layer of dirt, if the cable has an internal break or if a grounding point is really connected to potential equalization.

Six common mistakes to avoid during electrostatic grounding

Fastening the grounding tool to the wrong place on the vessel – for example, to the insulated plastic shell instead of directly to the metal tank.

Using an old or defective clamp, thus preventing the contact from being made.

Attaching the clamp to a dirty location on the metal tank.

Using a defective cable between the clamp and the grounding point – with the defect often being inside the cable and thus not visible.

Using a ground contact with insufficient ground or none at all despite the marking.

Using a clamp with insufficient clamping force. The pressure drops during the transferring process.

Don’t wait until the case of damage has occurred. Act now! Using an Eltex ground monitoring system eliminates all of these potential hazard sources.

Why is electrostatic grounding so important?

Electrostatic energy occurs when solid or liquid surfaces rub against each other. For example, when pumping non-conducive explosive media through a pipeline. Ions of one potential are deposited on the vessel/inside pipe wall, while ions of the opposite potential are diffusely distributed in the medium being moved.

As a result of the movement, the charge carriers on the tube are separated from those in the liquid. The latter becomes charged – and when it flows out of the pipe, it releases the charge uncontrollably into the collection container. If this container is not grounded, it acquires an electrostatic charge. If you then move this container close to grounded machine part, there will be a sudden flow of charge. The resulting discharge spark can ignite the existing gas/air mixture and thus cause a fire or explosion.

It is imperative to avoid this effect and the risk it incurs.

Intelligent grounding with system.
TERRASMART

Discover now

Uncontrolled electrostatic discharges can have fatal consequences. In industry and production, they are one of the most frequent triggers for explosions and fires. With the new TERRASMART, we are countering these risks with the most modern grounding system currently available.” Our goal: to make industrial processes permanently safer, regardless of the industry. We have therefore deliberately developed our TERRASMART system in such a way that it can be individually configured for use in a wide variety of areas.

The result: a high-quality, efficient and reliable system for numerous applications.

„TERRASMART is the best and safest grounding system currently available thanks to its outstandingly well-coordinated components.“

Ready to connect: Intelligently networked
With TERRASMART, the smart entry into Industry 4.0 is also possible for grounding systems. The system can be coupled with our multifunctional control unit Eltex Connected Control ECC. In this way, we make intelligent networking and convenient control of processes possible. The graphic interface of the ECC shows at a glance which grounding devices are active or inactive. And most importantly, whether the systems are operating without interference. So that you can work safely and without risks.

TERRASMART
advantages at a glance

robust and easy to use
safe and permanent ground connection
low maintanance – quality Made in Germany
Ex approvals such as ATEX, IECEx and UL as well a SIL2 certificate
optional: capacitive object detection

TERRASMART
with ELTEX CONNECTED CONTROL – ECC

Industry 4.0 ready through intelligent networking of up to 128 TERRASMART grounding devices
adaptable measuring ranges for optimum process reliability
processing of documents to prove compliance with legal regulations

Three industries, three examples. How to ensure smart grounding

Grounding of BIG-BAG’s (FIBC’S).

The Problem …

In many industries, flammable materials, such as plastics, pigments, BPA, etc., are delivered, transported, emptied, or filled in BIG-BAG’S. These operations often take place in areas where explosive atmospheres are present. For this reason, it is absolutely necessary that the BIG-BAG’s are reliably grounded during filling or emptying.

Only a permanent equipotential bonding during the entire process ensures the safe discharge of electrostatic charges and thus prevents the risk of uncontrolled electrostatic spark discharges, which can lead to the ignition of existing gas/air mixtures.

Grounding with simple ground clamps without monitoring the ground connection is a considerable safety risk! The clamps can fall off unnoticed when handling the BIG-BAG’s. The use of a non-permitted or damaged BIG-BAG, which is not or no longer conductive, cannot be detected either.
The Solution …
With the new TERRASMART, Eltex offers a device variant that is especially suitable for the ground monitoring of BIG-BAG’s. The possible activation of a reliably detects that the ground clamp(s) has been connected to a BIG-BAG and not to a metallic conductive plant part. To further increase safety, there is a variant of the BIG-BAG grounding with 2 ground clamps. Here, the complete BIG-BAG is integrated into the monitoring circuit, so that even if an incorrect, non-conductive type is used or a BIG-BAG that is no longer conductive due to aging and/or pollution, no safety risk can arise. In addition to the optical display, it is also possible to integrate the TERRASMART grounding device into an existing process control system via potential-free contacts or a BUS system, thus enabling processes only after grounding has been verified.
- Smart grounding with Eltex

Ground Monitoring in Paint Shops

The Problem …

Electrostatic charges are created when refilling paints and solvents and when blending these components. The only way to prevent this is by grounding both the paint container/mixing container and the pump/mixer. Especially when handling paints, there is a high risk that one of the containers will become contaminated with dried paint that adheres to it with an insulating effect. If an unsuitable ground clamp is now attached, it is entirely possible that it will not be able to penetrate the paint layer, thus causing the container to not be grounded. The user has no control whatsoever unless they remeasure the resistance to ground during each grounding procedure. Generally, though, few users bother to do this. The lack of grounding can result in an electrostatic discharge spark, igniting the existing “solvent cloud” and causing massive injury and property damage.
The Solution …
Using a grounding system enables you to identify any unsafe ground and/or monitor the presence of a safe connection for the long term.The Eltex TERRALIGHT makes this possible without major installation effort. The battery-operated ground monitoring device, in combination with the TERRACLAMP ground clamp, offers an optimal system for safe and permanently monitored grounding in these kinds of manual transfer or mixing processes. If connected and handled correctly, incorrect grounding is no longer possible. After connecting the ground clamp, the user obtains corresponding feedback immediately via the signal lamp on the TERRALIGHT. With a corresponding version of the TERRACLAMP, the user can even see directly on the ground clamp whether the grounding operation was successful.
- Smart grounding with Eltex
  
  Industrial painting
  
  Mixing and decanting of paints/lacquers
  
  TERRALIGHT

Ground Monitoring in Gravure Print Shops

The Problem …

When delivering solvents and inks using tankers and when transferring inks and solvents from IBCs and barrels to smaller containers, all conductive tanks have to be grounded to prevent electrostatic charging. In many cases, this is done with a simple clamp connected to a presumably conductive grounding point. However, the user cannot tell if a potential equalization has actually occurred as a result of applying the ground clamp to the object being grounded. However, if taking this measure does not ensure grounding of the object, this incurs the risk that electrostatic discharge sparks will trigger a fire or explosion.
The Solution …
All portable conductive or dissipative containers that are brought into an Ex area must be grounded and should be monitored. However, only ground monitoring offers maximum safety here. The ideal solution for ensuring safe grounding and keeping the maintenance and testing effort down to a minimum is the battery-operated TERRALIGHT grounding unit from Eltex. Along with the TERRACLAMP, this grounding system provides maximum protection against unwanted electrostatic discharges and their consequences. Another advantage of the system is that the user can see immediately whether a ground connection is present by means of a signal light.
- Smart grounding with Eltex
  
  Passive grounding of paint container
  
  Mobile grounding at pump station
  
  TERRALIGHT

Our expert will be pleased to advise you on electrostatic grounding

Walter Schwarzwälder, Sales Manager Grounding: “Electrostatic energy is the third largest explosion hazard in industry. Controlling it protects production employees – and is much cheaper than fixing damage. In real-life applications, we often see inadequate attempts at grounding. We would be glad to provide advice or carry out an on-site assessment of your production system.”