Static Control Evolves with Hardware and Process Changes

Static Control Evolves with Hardware and Process Changes Kelly Robinson, PE, PhD Static Control Evolves with Hardware and Process Changes 1/22

Agenda 1. Introduction Static sparks: a) ignite flammable solvents, b) shock people and machine control systems, c) cause sheets to stick and jam, and d) damage products. 2. Management of Change (MoC) overview. 3. Static Survey to identify charging sources. 4. Include Static Control in MoC. 5. Summary Static Control Evolves with Hardware and Process Changes 2/22

1. Introduction 1. Eliminate ignitions. 2. Prevent shocks to operators. 3. Prevent static problems in customer applications (sheet sticking, process jams). Static Control Evolves with Hardware and Process Changes 3/22

1.4 Introduction Static sparks can damage the silicone release liner causing release failure (PSA label sticks to support). Product Application PSA Label Image courtesy of Release liner Static Control Evolves with Hardware and Process Changes 4/22

2.1 OSHA Mission OSHA's Mission Disabling injuries in the US increased 20% during the 1960 s. Worker deaths in America are down-on average, from about 38 worker deaths a day in 1970 to 13 a day in 2014. https://www.osha.gov/ With the Occupational Safety and Health Act of 1970, Congress created the Occupational Safety and Health Administration (OSHA) to assure safe and healthful working conditions for working men and women by setting and enforcing standards and by providing training, outreach, education and assistance. Static Control Evolves with Hardware and Process Changes 6/22

2.1 MoC Overview Description Item Part Number: 1910 Part Title: Occupational Safety and Health Standards Subpart: H Subpart Title: Hazardous Materials Standard 1910.119 Number: Title: Process safety management of highly hazardous chemicals. Appendix: A, B, C, D GPO Source: e-cfr Purpose: This section contains requirements for preventing or minimizing the consequences of catastrophic releases of toxic, reactive, flammable, or explosive chemicals. These releases may result in toxic, fire or explosion hazards. Static Control Evolves with Hardware and Process Changes 7/22

2.1 MoC Overview 910.119(L) Management of change. (1) MoC Procedures: The employer shall establish and implement written procedures to manage changes (except for "replacements in kind") to process chemicals, technology, equipment, and procedures; and, changes to facilities that affect a covered process. (2) Required Procedures: The procedures shall assure that the following considerations are addressed prior to any change: (i) The technical basis for the proposed change (impact on product quality, manufacturing costs, etc.). (ii) Impact of change on safety and health (spark risk, shock risk, etc.). (iii) Modifications to operating procedures. (iv) Necessary time period for the change. (v) Authorization requirements for the proposed change. Static Control Evolves with Hardware and Process Changes 8/22

2.1 MoC Overview 910.119(l) Management of change. (3) Training: Employees involved in operating a process and maintenance and contract employees whose job tasks will be affected by a change in the process shall be informed of, and trained in, the change prior to start-up of the process or affected part of the process. (4) Documentation: If a change covered by this paragraph results in a change in the process safety information required by paragraph (d) of this section, such information hall be updated accordingly. (5) Documentation: If a change covered by this paragraph results in a change in the operating procedures or practices required by paragraph (f) of this section, such procedures or practices shall be updated accordingly. Static Control Evolves with Hardware and Process Changes 9/22

3.1 Design Principles fault tolerant control Apply 2-layer, fault tolerant design to static control. THREAT (static charge) Failsafe Static RISK (flammable mixture) Control Fault Fault THREAT (static charge) Layer 2 A2 A threat penetrates to a risk only when there are 2 simultaneous faults; one in the 1 ST layer and one in the 2 ND layer. The system effectively shields the risk from a threat even when there is a single fault. Static Control Evolves with Hardware and Process Changes 11/22

3.2 Static Survey Objectives Guider Dry Out Dryer Dry In Inspect In Inspect Dancer Chill Out Chill SD Dance Out Wind Span Chill 1 st coat contact Guide Out Wind Coat contact Out Unwind Dance Out CT Out Corona treater CT SB CT SB Out Coat Out Dancer Inspect Out Nip Nip SB Contact roller Wind roll Unwind roll Unwind span Dance In Coat In Coater Take a static reading on each accessible web span including the unwinding and winding rolls. If possible, record the min, max and average reading at each location. These reading accomplish 2 objectives. 1. Identify sources of static charging. 2. Document static performance during this run. Static Control Evolves with Hardware and Process Changes 12/22

3.3 Static Survey Documentation Electrostatic Fieldmeter Readings (KV/in) Date 10/11/2016 # Location Min Max Avg Range Shift 1 Unwind Roll -7.5-2.5-5.0 5.0 #N/A 2 Unwind-Span -1.3 0.0-0.6 1.3 #N/A 3 Dance In -2.0-0.5-1.3 1.5-0.7 4 Dance Out -3.0-1.3-2.1 1.8-0.8 5 Corona Trt Out 12.5 22.5 17.5 10.0 19.6 6 Corona Trt SB Out -1.0 0.0-0.5 1.0-18.0 7 Coat-In -1.8-1.0-1.4 0.8-0.9 8 Coat-Out -1.0 0.5-0.3 1.5 1.1 9 Dry-In -1.5 0.0-0.8 1.5-0.5 10 Dry-Out -15.0-7.5-11.3 7.5-10.5 11 Guide-Out -20.0-12.5-16.3 7.5-5.0 12 Coat Contact-Out 10.0 15.0 12.5 5.0 28.8 13 Chill Out 15.0 20.0 17.5 5.0 5.0 14 Inspect In 2.5 5.0 3.8 2.5-13.7 15 Inspect Out 1.3 3.8 2.5 2.5-1.3 16 Nip In 0.0 2.5 1.3 2.5-1.2 17 Nip Out -10.0-7.5-8.8 2.5-10.1 18 Nip SB Out -1.3 0.0-0.6 1.3 8.2 19 Dance Out -3.8-2.5-3.1 1.3-2.5 20 Wind Span -4.5-3.0-3.8 1.5-0.7 21 Wind Roll -10.0-5.0-7.5 5.0 #N/A Record the Min, Max & Avg reading at each location. The Range is Max-Min. The Shift is Avg N -Avg N-1. Static Control Evolves with Hardware and Process Changes 13/22

3.3 Static Survey Analysis 25 20 High Red Zone; ±15 KV/in < E Stoplight Chart (Avg Readings) Electrostatic Fieldmeter Reading [KV/in] 15 10 5 0-5 -10-15 Moderate Yellow Zone; ±5 < E < ±15 KV/in Low Green Zone; E < ±5 KV/in Corona Treater added + charge. SB OK Static dissipator OK Dryer, guider, idler touching coating & chill roller all added charge. Nip roller added charge. Static dissipator OK -20-25 Static Control Evolves with Hardware and Process Changes 14/22

3.3 Static Survey Analysis Change betwen Fieldmeter Measurements [KV/in] 40 30 20 10 0-10 -20-30 2.2 Survey Analysis Source Chart (Shifts) Corona treater added + charge Static bar dissipated + charge from corona treater Static dissipator needed at 1st roller that touched coated surface. Dissipators needed at Dryer exit and guider exit Chill roller static dissipator OK Shifts > ±3 KV/in indicate significant charging source. Nip roller deposited + charge. Static dissipator neutralized static from nip roller Static Control Evolves with Hardware and Process Changes 15/22

3.4 Common Charge Sources Neutralize static at each charging source. Sparks occur when field > ±15 KV/in Source Field (KV/in) Lamination Nips ±600 Corona Treaters ±150 Unwinding Rolls ±50 Tacky Roller Web Cleaners ±50 Polymer Nip Rollers ±45 Drive / Pull Rollers ±40 Heated / Cooled Rollers ±40 Spreader / Bowed Rollers ±25 Dryer / Oven Idler Rollers ±25 Registration Compensation Rollers ±10 Dancer Rollers ±5 Metal Idler Rollers ±0.5 Static Control Evolves with Hardware and Process Changes 16/22

4.1 Include Static Control in MoC Establish criteria for assessing the impact on static control (low, medium, high). High impact changes might be: 1. New Classified area (C1/2, D1/2) 2. Adding a winder / unwinder 3. Introducing a new charging source; tensions control nip, corona treater, oven/dryer/curing equipment, etc. 4. Running a metallized web for the first time on a line. Low impact changes might be: 1. New idler roller 2. Changing unwind orientation; over unwind to under unwind. 3. Running a new web polymer. Medium impact changes might be: 1. Adding / moving / removing a static dissipator. 2. Changing unwind orientation; over unwind to under unwind. 3. Running a new web polymer. Static Control Evolves with Hardware and Process Changes 18/22

4.2 MoC Triggers Action High impact triggers a static survey to assess static control and needed changes. 1. Complete a static survey of existing process (probably already done). 2. Complete a dry (no solvents) static survey of new process. 3. Assess static control, identify charging sources. 4. Implement best practice static control. 5. Complete a second dry static survey to verify static performance. Low impact may require no / minimal action. 1. Review results of most recent static survey. 2. Assess proposed changes given known charging sources and existing static control system. Medium impact triggers assessment. 1. Review results of most recent static survey. Or, complete a new survey on the existing process. 2. Modify existing static control system in light of known and new charging sources. Static Control Evolves with Hardware and Process Changes 19/22

4.2 Document Assessment and Actions 1. Machine Drawings: Revise machine drawings and checklists of existing static dissipators. 2. Operating Procedures: Revise operating procedures to include changes to the static control system; visual inspections, actions levels for audits of incoming/finished rolls, etc. 3. Training: Update training to include changes. Static Control Evolves with Hardware and Process Changes 20/22

Summary 1. Introduction Static risks to safety, health, and product quality 2. Management of Change (MoC) overview. 1) MoC is part of OSHA Process Safety Management 2) Static control fits within the technical basis and impact on safety (ignitions) and health (shocks). 3. Static Survey 1) Identify sources of charging 2) Assess / document current static of static control. 4. Include Static Control in MoC. 1) Assess impact (high, medium, low) 2) MoC triggers appropriate action Static Control Evolves with Hardware and Process Changes 21/22

THANK-YOU! Questions? Comments? Kelly Robinson, PE, PhD, IEEE Fellow Owner, Electrostatic Answers Tel: 585-425-8158 Kelly.Robinson@ElectrostaticAnswers.com Static Control Evolves with Hardware and Process Changes 22/22

Speaker Introduction Kelly Robinson, PE, PhD, Owner Electrostatic Answers LLC Kelly.Robinson@ElectrostaticAnswers.com 585-425-8158 www.electrostaticanswers.com Business Owner - Founded Electrostatic Answers, an engineering consulting company dedicated to eliminating injury and waste from static electricity. Industrial Experience working over 25 years solving static problems in web conveyance and solvent handling manufacturing operations. Award Winning Engineer US Nat l Fire Protection Assoc. (NFPA), Member - Static Electricity Committee IEEE Fellow - for contributions to electrostatic performance of mfg. processes Electrostatics Society of America - Distinguished Service Award AIMCAL - John Matteucci Award, excellence in technical presentations PhD Electrical Engineering - Colorado State University Inventor with 14 US patents. Associate Editor for the Journal of Electrostatics, a leading peer reviewed technical journal (Elsevier publication) Contributing Editor, Paper Film & Foil Converter, author of Static Beat column on static control. Static Control Evolves with Hardware and Process Changes 23/22