Electrostatic Hazard Risk Assessment Case Study – ZCL Chemicals, Ankleshwar

Project Number: 23-674.50.01-zc-akv-hse

Electrostatic Hazard Risk Assessment Serial No.: 01

1. Project Overview

An Electrostatic Hazard Risk Assessment (EHRA) Study was conducted for ZCL Chemicals Limited at its manufacturing facility located in Ankleshwar, Gujarat. The objective of the study was to evaluate the potential for electrostatic charge accumulation and its associated ignition risks during handling of flammable liquids, gases, and combustible powders.

The study focused on identifying operations and equipment where electrostatic discharge could act as a potential ignition source. A structured assessment methodology was applied in accordance with IS 7689 (Guide for Control of Undesirable Static Electricity) and NFPA 77 (Recommended Practice on Static Electricity).

The assessment included detailed evaluation of process steps, equipment, and materials to develop effective mitigation strategies for controlling electrostatic hazards.

1. Objective
2. To identify electrostatic ignition hazards in process operations
3. To assess risks associated with flammable liquids, gases, and combustible dusts
4. To evaluate equipment and process conditions for static charge accumulation
5. To recommend control measures aligned with IS 7689 and NFPA 77
6. To enhance safety and prevent electrostatic ignition incidents.

1. Methodology

Study Preparation

The study involved detailed data collection and analysis, including:

• Process and operational details
• Chemical inventory (flammable liquids, gases, powders)
• Equipment details (GLR, SSR, transfer systems, storage systems)
• Existing safety practices and controls

The collected data was structured into product-wise and equipment-wise evaluation matrices.

EHRA Methodology

A systematic methodology was followed:

• Identification of hazardous chemicals capable of generating static charge
• Preparation of product-wise hazard mapping
• Preparation of equipment-wise hazard mapping
• Evaluation of electrostatic charge generation mechanisms:
• Liquid transfer
• Powder handling
• Mixing and agitation
• Assessment of ignition potential based on Minimum Ignition Energy (MIE)
• Review of existing bonding, grounding, and control systems
• Benchmarking against IS 7689 and NFPA 77 requirements
• Development of recommendations for electrostatic hazard control
• Reporting & documentation

1. Key distinctive characteristics of Emergency Action Plan:
2. Comprehensive Electrostatic Risk Coverage – Evaluation across liquids, gases, and powders
3. Dual-Level Assessment Approach – Product-wise and equipment-wise hazard identification
4. Standards-Based Evaluation – Alignment with IS 7689 and NFPA 77 guidelines
5. Large-Scale Recommendation Framework – Extensive set of actionable recommendations developed
6. Focus on Ignition Prevention – Detailed analysis of static discharge as ignition source.

1. Key Outcomes
2. Systematic Identification of Electrostatic Risk Areas across key operations and equipment.
3. Alignment with IS 7689 and NFPA 77 ensuring adherence to recognized safety standards.
4. Improved Understanding of Electrostatic Ignition Risks within process activities.
5. Opportunities for Enhancing Control Measures such as bonding, grounding, and safe handling practices.
6. Comprehensive Recommendations Developed to strengthen electrostatic hazard management.

1. Conclusion

The Electrostatic Hazard Risk Assessment Study for ZCL Chemicals Limited provides a comprehensive evaluation of electrostatic ignition risks in a pharmaceutical manufacturing environment. The study successfully identifies critical scenarios where static charge accumulation may occur and establishes a structured approach for mitigating associated risks.

The findings highlight the importance of integrating electrostatic hazard control measures into routine operations, supported by proper grounding, bonding, and safe operating practices. Implementation of the recommendations will significantly enhance process safety, reduce ignition risk, and ensure compliance with international standards.