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How to move up the safety curve
from basic clamps and cables
on a budget
Protecting workers and company assets from ignitions caused by static electricity can’t be left to chance. In facilities where flammable
and combustible products are processed, there’s a very high probability that static electricity is generated by the movement of gases,
liquids and solids. The risks of a fire or explosion caused by a discharge of static electricity in an EX/HAZLOC area are just too significant
to ignore. To emphasise its significance static electricity is identified in North American and European legislation as a potential source of
ignition in potentially flammable and combustible atmospheres.
Although static electricity is regarded as “witchcraft” by many people working in the hazardous process industries, static grounding and
bonding protection methods are anything but complex. Industry guidelines like NFPA 77* and IEC 60079-32-1** identify specific
processes susceptible to discharges of static electricity coupled with practices that can eliminate the threat of ignition.
The most effective and practical means of eliminating the threat of a fire or explosion caused by static electricity is to ensure static charges
are not permitted to accumulate on equipment, vehicles and people. Grounding and bonding presents the most effective and reliable
way of removing static electricity from an EX/HAZLOC atmosphere.
*NFPA 77: Recommended Practice on Static Electricity” (2014).
** IEC 60079-32, Part 1: “Explosive atmospheres – Part 32-1: Electrostatic hazards – Guidance” (2013).
NOTE: Cenelec CLC/TR 50404 “Electrostatics. Code of practice for the avoidance of hazards due to static electricity” (2003) has been
superseded by CLC/TR: 60079-32-1"Explosive atmospheres – Part 32-1: Electrostatic hazards – Guidance” (2015).
Industry approved guidance on controlling static
ignition hazards.
To ensure we are protected from ignitions caused by static
electricity we need to follow some basic rules of engagement
provided in publications like NFPA 77 and IEC 60079-32-1. The
most important benchmark is to ensure we can achieve an
electrical resistance of 10 ohms or less between electrically
conductive plant equipment, including mobile plant, people
and vehicles, and a “ground source” that is verified as a true
earth grounding point. This point will have a low resistance
connection to the general mass of the earth and will transmit
electrostatic charge from equipment to the earth, regardless of
how much static electricity is generated by the process. This, in
turn, removes the static ignition risk from the processing
location.
In order to achieve a safe level of protection from electrostatic
ignitions we must provide an effective means of grounding the
equipment. Historically, the grounding of portable objects like
drums, vessels, and vehicles like trucks and railcars was
achieved with basic clamps that were assumed to make a direct
connection to the equipment.
Figure 1: Traditional plier type basic clamp.
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Author Details:
Mike O’Brien, Managing Director for Newson Gale
If you have any questions relating to the topics discussed
in this article, please contact .Newson Gale
www.newson-gale.com
However, issues like product build-up and protective coatings
that can impede the integrity of grounding clamp connections,
combined with rusted and degraded cable connections,
prompted the industry to develop ground status indicator
systems, particularly for the larger hazards which are typically
reflected in railcar, truck and IBC bulk handling operations.
Ground status indicators (commonly referred to as static
grounding systems) monitor the connection to the equipment at
risk of charge accumulation and provide a visual reference to
workers to indicate if they have a secure ground connection,
which, if green, will indicate that they can proceed with the
process. In addition to providing a monitored grounding circuit
many of these systems contain output contacts that can be
interlocked with the process. Normally the grounding system’s
output contact will be interlocked with the equipment
controlling the flow or processing of the product, thus ensuring
the equipment is grounded before the process that generates
static electricity can begin.
Sourcing and specifying grounding solutions with the
flexibility to meet your specific zoning, installation and
operating requirements.
For somebody tasked with controlling static ignitions hazards,
solutions tend to fall between basic clamps and cables and
static grounding systems. Static grounding systems offer the
most layers of control and protection over static ignitions risks,
particularly as they can monitor the integrity of the connection to
the process equipment, provide a visual indication to operators
of a positive ground connection and shut down the process if
the grounding connection is ever compromised.
Although the majority of solution specifiers would like to have
multiple layers of protection over electrostatic ignition risks it
can be difficult to source the budget for processes where many
items require static grounding protection. In addition, the
processes responsible for generating static electricity may be
operated manually with no means of automating safe controls
over the process. One example of this is facilities that carry out
manual filling operations of large quantities of drums and
smaller containers with flammable liquids.
Bond-Rites provide 2/3 the level of protection of static
grounding system at half the cost.
®The Bond-Rite family of products enable product specifiers
apply additional controls over electrostatic ignition hazards
above and beyond basic clamps and cables, without the
burden of justifying purchases associated with grounding
systems with interlock capability. For 15 years Bond-Rites have
enabled solution specifiers to move up the safety curve from
basic clamps and cables to achieve enhanced levels of safety
by providing workers with a visual means of verifying a solid
electrical connection to equipment for the duration of the
process.
Employing the well-recognised safety principles of GREEN for
“SAFE TO GO”, Bond-Rites utilise a pulsing green LED to
indicate when the equipment (e.g. drum) has a resistance of 10
ohms or less to the site’s verified ground network. All Bond-
Rites continuously monitor the connection to the equipment
until the clamp is removed. The green for “SAFE TO GO”
concept is extremely easy for workers to engage with enabling
them to take responsibility for their own safety and that of their
colleagues.
How to move up the safety curve
from basic clamps and cables on a budget
Page 2 of 6
Figure 2: Traditional wall mounted ground status indicator
system with internal output contacts. Note the green for
‘SAFE TO GO’ indication method.
Figure 3: Bond-Rites
provide operators
with ‘SAFE TO GO’
visual indicators.
www.newson-gale.com Page 3 of 6
The benefit for product specifiers and buyers, particularly for
processes that cannot be interlocked, is that they can enhance
the controls over “their” static ignition hazards to a much higher
level than basic clamps without having to stretch their budget to
the more established interlock-able static grounding systems.
Compared to a traditional static grounding system a Bond-Rite
can provide 2/3 of the level of protection at close to 1/2 of the
cost.
Taking an example of a typical drum filling operation, the normal
mode of static grounding protection will be to ground the drum
with a basic clamp and cable. Electrical isolators like paint
coatings, product deposits and rust can prevent the clamp
teeth from making a solid, reliable connection to the drum.
Following repeated opening and closing cycles clamp springs
can stiffen, losing their capability to close completely thereby
reducing their capacity to make a reliable connection to
equipment.
A Bond-Rite CLAMP or Bond-Rite REMOTE can provide
workers with a visually verified ground connection to the site’s
grounding network. All workers need to do is clamp the drum
and wait for the pulsing green LED to activate. As long as the
green LED is pulsing, the operator can work safe in the
knowledge that he/she has obtained a green light to start the
process and the Bond-Rite will continuously monitor the circuit
ensuring static charge generated by the operation is
transferred from the potentially explosive atmosphere.
Bond-Rites come in various configurations that complement the
ignition control requirements of the product specifier, the
installation flexibility desired by electrical installers and ease of
engagement provided by the GREEN for “SAFE TO GO”
principle for workers.
In compliance with NFPA 77 and IEC 60079-32-1, the
Bond-Rite CLAMP is ideal for applications where the operator
can get an immediate visual verification of a secure 10 ohm, or
less, connection to equipment at risk of accumulating
electrostatic charges. If there’s a chance that the product from
the process could obscure the LED in the Bond-Rite CLAMP
(e.g. coatings mixing operation), the Bond-Rite REMOTE can
be specified. This configuration enables the LED and circuit
electronics to be wall mounted which is more typical of a
traditional ground status indicator station. Both of these
versions are powered by a 9V battery which can easily be
replaced as necessary.
If the site has processes that last for more than an average of 6
hours per day, product specifiers can specify the
Bond-Rite REMOTE EP. This EP power supply takes line / mains
power (230 V AC or 115 V AC) and converts it into an intrinsically
safe power source for each individual Bond-Rite REMOTE
indicator station. Not only can the Bond-Rite REMOTE EP
power supply be mounted in Zone 2/21 areas and Class I, II, III,
Div. 2 locations, it can power up to 10 individual
Bond-Rite REMOTE indicator stations simultaneously. The
Bond-Rite CLAMP and Bond-Rite REMOTE indicator stations
can be mounted in ANY location that is classified as an
EX/HAZLOC atmosphere.
Site verified grounding points
CLAMP mounted
indicator
Wall mounted
indicator
How to move up the safety curve
from basic clamps and cables on a budget
®The Bond-Rite EZ is a portable device that bonds equipment
to ensure they are at the same electrical potential or can be
used to ground objects directly to a verified earth or via other
objects that are connected to earth. The Bond-Rite EZ consists
of a Bond-Rite CLAMP attached to standard or large stainless
steel heavy duty clamp with 2 pole Cen-Stat™ cable.
Green for “SAFE TO GO” vs. RED for not safe to go.
Some equipment providers supply similar products that
provide indication of a positive ground connection with no
visual indicator. The only indication such devices provide
workers with is a red LED to indicate a negative ground
connection. On two counts it’s worth noting that operators
prefer a GREEN for “SAFE TO GO” mode of operation.
Secondly, how does the operator know if the device is in fact
grounding the equipment? It will be virtually impossible for the
operator to know, during a process or manual handling
operation, if the system is actually grounding the equipment or
if the battery, that powers the red indicator when it is not
connected to ground, has simply run out of power.
Summary
Now in its 15th year since its launch the Bond-Rite family of
grounding and bonding solutions provide product specifiers
with a cost effective option that enhances the safety of
processes at risk at discharging electrostatic parks. The range
of installation and portable options provided by the flexibility of
the Bond-Rite means specifiers can virtually match the
installation and operating requirements of everyday
EX/HAZLOC operations. Most importantly the green for “SAFE
TO GO” principle is the clearest message that workers can
have to proceed with an operation or process that could be a
static ignition risk.
®Bond-Rite EZ
www.newson-gale.com Page 4 of 6
Figure 5: The Bond-Rite REMOTE EP power supply can
power up to 10 Bond-Rite REMOTEs simultaneously.
Figure 6: In this example the truck has a verified ground
®connection with the Earth-Rite RTR static grounding
system. The gravity fed metal IBC (tote) is grounded via the
truck with the portable Bond-Rite EZ.
How to move up the safety curve
from basic clamps and cables on a budget
www.newson-gale.com Page 5 of 6
Bond
®
-Rite CLAMP
ü Patented static grounding clamp with green LED indicator
and grounding circuit mounted in a rugged stainless steel
clamp.
ü Attention grabbing green LED pulses continuously
indicating a continuous connection to ground.
ü LED positioned in ideal position for operator to verify a
good ground connection.
ü Replaceable 9V battery.
ü Simple installation.
ü Can be operated in all EX and HAZLOC areas.
Bond ®-Rite REMOTE
ü Wall mounted indicator station with heavy duty stainless
steel 2 pole standard and large sized grounding clamps.
ü Ideal for processes (e.g. coatings mixing) where product
®has the potential to obscure the LED on the Bond-Rite
CLAMP.
ü Attention grabbing green LED pulses continuously
indicating a continuous connection to ground.
ü Battery operated version can be installed and running in
less than an hour.
ü Replaceable 9V battery.
ü Can be operated in all EX and HAZLOC areas.
ü Indicator station available in static dissipative GRP and
stainless steel.
Bond
®-Rite REMOTE (EP)
ü Wall mounted indicator station with heavy duty stainless
steel 2 pole standard and large size grounding clamps.
ü 230 V AC / 115 V AC power supply that can be mounted in
Zone 2/21 and Class I, II, III / Div. 2 atmospheres.
ü The EP version powers up to 10 individual indicator
stations meaning 10 individual pieces of plant equipment
can be grounded simultaneously.
ü Attention grabbing green LEDs pulse continuously
indicating a continuous connection to ground.
ü Ideal for processes where the production process is
intensive and equipment requires continuous ground
verification for periods lasting longer than 6 hours per day.
ü Can be operated in all EX and HAZLOC areas.
ü Indicator station available in static dissipative GRP and
stainless steel.
How to move up the safety curve
from basic clamps and cables on a budget
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Bond
®
-Rite EZ
ü A portable bonding verification device consisting of a
Bond-Rite CLAMP attached to standard or large stainless
steel heavy duty clamp with 2 pole Cen-Stat cable.
ü Ideal for bonding portable equipment.
ü Attention grabbing green LED pulses continuously
indicating a continuous connection bond between
portable equipment.
ü Replaceable 9V battery.
ü Can be operated in all EX and HAZLOC areas.
Two Pole Clamps and Cable
ü FM / ATEX certified static grounding clamps compatible
with all Bond-Rite REMOTE and Bond-Rite EZ.
ü VESX90-IP large clamp ideal for connecting to large
objects like railcars and IBCs.
ü VESX45-IP standard clamp ideal for clamping onto
205 litre (1 gallon) drums and smaller containers.
ü System of quick connects enable connection of different
lengths of 2 pole Cen-Stat cable, supplied in standard
lengths of 10 ft, 16 ft, 32 ft and 50 ft (3 m, 5 m, 10 m and
15 m).
How to move up the safety curve
from basic clamps and cables on a budget
www.newson-gale.com
United Kingdom
Newson Gale Ltd
Omega House
Private Road 8
Colwick, Nottingham
NG4 2JX, UK
+44 (0)115 940 7500
[email protected]
Deutschland
IEP Technologies GmbH
Kaiserswerther Str. 85C
40878 Ratingen
Germany
+49 (0)2102 5889 0
[email protected]
South East Asia
Newson Gale S.E.A. Pte Ltd
136 Joo Seng Road, #03-01
Singapore
368360
+65 6704 9461
[email protected]
United States
IEP Technologies, LLC
417-1 South Street
Marlborough, MA 01752
USA
+1 732 961 7610
[email protected]
How to move up the safety curve from basic clamps and cables on a budget
Protecting workers and company assets from ignitions caused by static electricity can’t be left to chance. In facilities where flammable and combustible products are processed, there’s a very high probability that static electricity is generated by the movement of gases, liquids and solids. The risks of a fire or explosion caused by a discharge of static electricity in an EX/HAZLOC area are just too significant to ignore. To emphasise its significance static electricity is identified in North American and European legislation as a potential source of ignition in potentially flammable and combustible atmospheres.
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