Purafil

Purafil Training Webinar:

Corrosion Classification Coupons (CCCs)
Instructor:
Chris Muller, Technical Director
Thursday, March 24, 2016
 Important Notice

COPYRIGHT © 2016 by PURAFIL, INC.

Neither this document nor any part may be reproduced or transmitted in any form or by any means,
electronic or mechanical, including photocopying, microfilming, and recording, or by any information
storage and retrieval system, without written permission from Purafil, Inc.

Corporate Offices: Purafil, Inc.: 2654 Weaver Way, Doraville, Georgia 30340 U.S.A.
Tel: 770.662.8545 Fax: 770.263.6922 Laboratory Fax: 770.263.0520

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 Training Agenda

1 Why use Purafil Corrosion Classification Coupons?

2 What is corrosion?

3 Where are corrosive environments found?

4 What is the impact of corrosion?

5 International regulations and industry standards

6 Purafil’s solution – Corrosion Classification Coupons

7 Installation and use procedures.

8 Reports and results

9 Summary and final thoughts

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 Why use Purafil CCCs?…a quick overview

1. As a survey tool
• Low cost allows for multiple CCCs to be used in a single location or in multiple locations within a facility.
• Provides an assessment as to the types of corrosive contaminants and estimates of concentrations.
• Develop baseline data for the development of a corrosion control strategy.

2. To identify problems
• Once the need for corrosion control has been recognized, the current air quality needs to be determined.
• Identification of “hot spots” within a manufacturing facility.
• Track corrosion “episodes” and the damage caused to materials and products.

3. Evaluate performance of Purafil chemical filtration products & systems

• Place CCCs in the outdoor air or at the inlet to the HVAC / chemical filtration system.
• Place CCCs at the outlet of the HVAC / chemical filtration system.
• Place CCCs at the inlet and outlet of recirculating air handling systems.
• Place CCCs placed a various locations within the protected space(s).

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 Why use Purafil CCCs? …increased sales revenue!

Using coupons will create opportunities, enabling new equipment and/or filter sales.
1. Show potential customers that they risk voiding manufacturers’ warranties.
2. Identification of corrosive species guides proper media selection.
3. Develop new opportunities beyond current markets.

Utilize coupons for replacement media and filter sales.

4. Track the performance of installed Purafil media, filters, and air cleaning systems.
5. Keep track of competitors’ systems
• Identify deficiencies in equipment design.
• Identify deficiencies in media selection and performance.

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 What is corrosion?

For our purposes, corrosion can be defined as a byproduct of chemical reactions between gaseous
contaminants and various types of metal.

In particular, we are concerned with three types of gaseous contaminants: acidic gases, caustic
gases, and oxidizing gases.

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 What causes corrosion?

Of the different classes of contaminants that can cause corrosion, four classes of acidic gases are
the most common and the most harmful.

• Active sulfur compounds

• Hydrogen sulfide (H2S), mercaptans (R-SH), elemental sulfur (S)
• Sulfur oxides
• Sulfur dioxide (SO2), sulfur trioxide (SO3)
• Nitrogen oxides
• Nitric oxide (NO), nitrogen dioxide (NO2), nitrogen tetroxide (N2O4)
• Inorganic chlorine compounds
• Chlorine (Cl2), chlorine dioxide (ClO2), hydrochloric acid (HCl)
• Others
• Hydrogen fluoride (HF), ammonia and derivatives (NH3, NH4+), photochemical species (O3)

With copper and silver, the metals most susceptible to corrosive attack, the byproducts formed are
metal salts that remain on the surface causing mass gain or metal loss.
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 Where are corrosive environments found?

Examples of facilities containing adverse / corrosive environments include, but are not limited to, the
following:
• Pulp and paper processing
• Oil and petroleum refining
• Mining
• Metal foundries
• Chemical manufacturing
• Water / wastewater treatment plants
• Marine/coastal (salt) environments

Corrosive environments are also found in other operations, such as the following:
• Animal confinement areas
• Meat packing plants
• Rendering plants for animal products
• Grain processing

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 Where are corrosive environments found?

COMMON EMISSIONS OF NATURAL AND INDUSTRIAL PROCESSES

Industrial Process Emissions
Power generation SO2, C, CO, NOx, hydrocarbons, organics
Automotive combustion SO2, SO3, HCl, HBr, NOx, hydrocarbons, organics, CO, HBr
Diesel combustion CO, NOx, many organics
Fossil fuel processing H2S, S, SO2, NH3, hydrocarbons, other organics, mercaptans
Plastic manufacture All organics, aldehydes, alcohols, NH 3, SO2
Cement plants
Steel blast furnaces SO3, dust, SO2, NOx, CO
Steel electric furnaces H2S, SO2, CO, HF, coal dust
Coke plants H2S, SO2, C, CO
Pulp manufacture H2S, CO, HCN, carbon, dust
Chlorine plants Cl2, SO2, H2S, CO, wood fibers, dust
Fertilizer manufacture Chlorine, chlorine compounds, NaCl
Food processing HF, NH3, CH4, gas, liquids, dust, acids
Rubber manufacture Hydrocarbons, many organics
Paint manufacture H2S, S8, R-SH
Aluminum manufacture
Ore smelting C, hydrocarbons, oxygenated hydrocarbons, dust
Tobacco smoke HF, SO2, C, dust
Gasoline and fuel vapors SO2, CO, H2, dust
Battery manufacture H2S, SO2, HCN, CO, tars and particulates
Hydrocarbons, oxygenated hydrocarbons
SO2, acids, dust
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 What is the impact of corrosion?

INDUSTRIAL – WATER / WASTEWATER

• Damage to / failure of electronic process control systems.
• Loss of in-process products and costly equipment downtime.

MISSION CRITICAL – IT / DATACOM

• Failure of servers, hard drives, networking / switch gear.
• Loss of critical data and network downtime.

CULTURAL HERITAGE
• Damage to paper, metal collections, photographs, electronic media.
• Destruction of irreplaceable cultural treasures and historical documents.

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 What is the impact of corrosion?

The physical environment surrounding a printed circuit

board (PCB) is defined by the temperature, humidity
and gaseous and particulate contamination in the air.

Environmental factors can cause PCBs to fail in two

ways:
• First, electrical open circuits can result from
corrosion, such as the corrosion of silver terminations
in surface mount components.
• Second, electrical short circuits can be caused by:
• copper creep corrosion,
• electrochemical reactions such as ion migration and
cathodic-anodic filamentation, or
• settled, hygroscopic particulate matter reducing the
surface insulation resistance between closely spaced
features on PCBs.

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 International regulations and industry standards

RoHS (lead-free) regulations that took effect since 2006 have changed the landscape with regards
to electronic equipment reliability.

• Electronic equipment has become much more sensitive to environmental factors – especially
gaseous contamination.

• Corrosion failures have increased dramatically with the most common failures being on the
most common components.

• More so than industrial computer systems, commercial datacom and IT equipment were
negatively impacted by the changes brought about by RoHS.

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 International regulations and industry standards

Key standards that provide detailed information on the quality of air required for optimal
performance of electronic equipment:

• ISA Standard 71.04-1985 - Environmental Conditions for Process Measurement and Control
Systems: Airborne Contaminants
• IEC Standard 60654-4 (1987-07) - Operating conditions for industrial-process measurement
and control equipment Part 4: Corrosive and erosive influences
• IEC Standard 60721-3-3 (1994) - Classification of environmental conditions – Part 3-3:
Classification of groups of environmental parameters and their severities – Stationary use at
weather protected locations
• JEIDA Standard 29-1990 - Standard for Operating Conditions of Industrial Computer/Control
System

Since its original publication, ISA Standard 71.04-1985 has been the predominant standard being
used to measure severity levels in industrial environments.

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 Environmental specifications – INDUSTRIAL APPLICATIONS

All leading DCS manufacturers have warranty requirements tied to ISA Standard 71.04.

Honeywell: Guidelines to Maximize Equipment Uptime

Chemical purification systems and verification by reactivity monitoring.

Honeywell: Control Hardware Planning Guide.

“Uncoated boards are rated for mild (G1) environments.”

ABB: Environmental Data.

“Corrosive protection – compliant according to ISA-71.04…”

Yokogawa: Hardware Features.

“…corrosion resistance meets the specifications of ANSI/ISA 71.04 as standard.”

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 Environmental specifications – MISSION CRITICAL APPLICATIONS

ASHRAE Guidelines
“Gaseous contamination should be within the ANSI/ ISA-71.04-2013 severity level of G1-Mild that meets:
A copper reactivity rate of <300 angstroms (Å) per month and a silver reactivity rate of <200 Å per month.

For environments with higher gaseous contamination levels, gas-phase filtration of the inlet air and the air in
the controlled environment is highly recommended.”
iNEMI Guidelines
“Gaseous contamination should meet the conditions of the modified severity level G1 of ANSI/ISA-71.04-
1985, Environmental Conditions for Process Measurement and Control Systems: Airborne Contaminants of:
A copper reactivity rate of less than 30 nanometers (nm) /month, and
A silver reactivity rate of less than 20 nm /month.”

Most of the world’s leading IT and datacom equipment manufacturers have changed their warranties
to include requirements for the control of corrosion to ISA Class G1 levels.

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 ISA Standard 71.04-2013

As with the original 1985 version, the current edition still classifies four levels of environmental
severity for electrical and electronic systems.
• Now incorporates silver corrosion rates as a required metric for determining severity levels.
• The higher of the two reactivity rates sets the overall severity level.

Most of the major electronic process controls manufacturers, IT/datacom equipment manufacturers,
and those in related industries already have or will be updating specifications to reference the 2013
version of ISA 71.04.

Severity Copper Silver

Class Comments
Level Reactivity Reactivity
G1 Mild <300Å <200Å Corrosion is not a factor in determining equipment reliability.
Corrosion effects are measurable and corrosion may be a
G2 Moderate <1,000Å <1,000Å
factor. OSP and ImSn PCB surface finish failures.
High probability that corrosive attack will occur. ENIG and
G3 Harsh <2,000Å <2,000Å
ImmAg PCB surface finish failures.
GX Severe ≥2,000Å ≥2,000Å Only specially designed and packaged equipment will survive.

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 Air quality guidelines – CULTURAL HERITAGE APPLICATIONS

Guidelines have also been established for the protection of paper, paintings, metals, and historical
artifacts in museums, libraries, galleries and archives.
• Reactivity monitoring has been in continuous use in museums for more than 25 years to gauge the
aggressiveness of the ambient environment towards materials and artifacts.
• It has been the de facto environmental monitoring technique for many institutions.
• Joint research by the Government Buildings Agency (Netherlands), the Comitato Termotecnica Italiano,
the Swedish Corrosion Institute, and Purafil, Inc. has shown that reactivity monitoring can be used as a
viable alternative to direct gas monitoring in preservation environments.

Copper Reactivity Silver Reactivity

Air Quality Corrosion Rate Air Quality Corrosion Rate
Class Class
Classification (per 30 days) Classification (per 30 days)
C1 Extremely Pure <90Å S1 Extremely Pure <40Å
C2 Pure <150Å S2 Pure <100Å
C3 Clean <250Å S3 Clean <200Å
C4 Slightly Contaminated <350Å S4 Slightly Contaminated <300Å
C5 Polluted ≥350Å S5 Polluted ≥300Å
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 Measuring Corrosion

Reactivity (Corrosion) Monitoring

• Involves placement of specially prepared copper and silver
metal coupons in the subject environment.

• Purafil laboratory analysis measures film thickness, film

chemistry, and/or weight loss.

• International standards reference measurement of film

thickness by coulometric (electrolytic) reduction.

Allows for the direct correlation

between corrosion and reliability!

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 Purafil’s solution – Corrosion Classification Coupons

CCCs are used to indicate the presence of many chemical contaminants

such as H2S, SO2, NO2, Cl2, O3, and others.

Both copper and silver CCCs are required to provide the most accurate
environmental assessment.

Purafil’s CCCs have the sensitivities required to measure low levels of

corrosive contaminants in all applications.

Chemical Class Chemical Types Detection Limits

Active sulfur compounds H2S, mercaptans, elemental sulfur <3 ppb
Sulfur oxides SO2, SO3 (sulfurous acids) <10 ppb
Inorganic chlorine compounds Cl2, HCl <1 ppb
Nitrogen oxides NO, NO2, N2O4 <50 ppb
Strong oxidants O3, ClO2, HNO3 <2 ppb
Halogen acids F2, HF, HBr, HI <1 ppb
Ammonia and derivatives NH3, NMP, amines 200-500 ppb Company Confidential 19
 Installation and use procedures

Follow these basic steps to insure the validity of the CCC test results:
1. Within 30 days of receipt, place the CCC in the protected space.
2. Remove the CCC from the plastic bag. Keep the bag for return mailing to Purafil's laboratory.
3. Completely fill in the transmittal label with the required information.
• Company Name & Address
• Room/area identification
• Date and time installed
• Application type

DO NOT…
• Touch the copper or silver strip
• Place the coupon outdoors unless protected from weather, dust, insects, and wildlife.
• Place the coupon inside the control cabinet

IMPORTANT: A report cannot be provided without a date and time of installation.

We cannot call you for this information due to the large number of CCCs received for analysis.
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 Installation and use procedures

Basic steps continued…

4. Place the CCC in the area of concern in a vertical orientation or with the label side up.
5. Corrosion is defined in terms of corrosion film thickness, which builds up within one month of exposure.
However, due to varying environmental conditions, a visual inspection of the coupon should be made.
In a harsh environment, a coupon may become highly tarnished before 30 days, and should be
returned sooner.
If a CCC shows little to no discoloration, it should remain for an additional period of time up to 90
days.
If inspection is not possible and the severity of the environment is unknown, return the CCC at 90
days.
6. After the specified time has passed, remove the coupon from the test area. Mark the label with the date
and time of removal. This information is critical – the lab cannot produce an analysis without it!
7. Place the CCC in the plastic bag being careful to seal the bag. Return to Purafil.
8. Purafil will issue an Environmental Corrosivity Report classifying the severity level of the subject
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 Reports and results

Purafil offers four different reports based on the application.

1. Purafil Environmental Corrosivity Report – check “Industrial” on the CCC label.
• All process industries: pulp & paper, oil & gas, chemicals, metal manufacturing
• Water and wastewater treatment plants
• Medical devices and others

2. Purafil Data Center Assessment Report – check “Data Center” on the CCC label.
• Data centers, server rooms, battery rooms
• Other mission critical applications

3. Purafil Environmental Reactivity Report – check “Semiconductor” on the CCC label.

• Semiconductor fabs, hard disk drive manufacturing
• Other microelectronics

4. Purafil Environmental Reactivity Report – check “Preservation” on the CCC label.

• Museums, libraries, galleries, archives

Each report provides information relevant to the application.

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 Environmental corrosivity report

The results of Purafil's environmental

analysis are issued in a comprehensive
report. Key features of the report include:
Page 1
• Photograph of the CCC panel showing
coupons and transmittal label.
• The measured ISA severity level – G1
through GX.
• The total corrosion film thickness observed
on each coupon in Angstroms / 30 days.
• Information on general classes of gases
present, estimated concentrations, and
humidity effects.
• Local Purafil representative information.

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 Environmental corrosivity report

The results of Purafil's environmental

analysis are issued in a comprehensive
report. Key features of the report include:
Page 2
• Corrosion film thickness in angstroms for
each of the corrosion products identified,
normalized to 30 days and extrapolated
over 1 and 5 years.
• Graphical representation of corrosion film
thickness and corresponding ISA Severity
Level.

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Environmental corrosivity report

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 Reports and results – SURVEY of semiconductor fab site

Source Copper Corrosion Silver Corrosion

CCC Location of Air Cu2S Cu2O Cu-Unk Total AgCl Ag2S Ag-Unk Total

Boundary line (outside air) Outdoor 16,195 634 0 16,380 192 83 0 275
Central Utilities Building (roof) Outdoor 15,759 577 0 16,336 256 124 0 380
Loading dock (east) Outdoor 8,033 144 0 8,177 133 86 39 259
Loading dock (south) Outdoor 6,058 144 0 6,202 149 55 63 268
Fab MUAH - Intake Outdoor 15,348 350 0 15,698 298 76 0 375
Fab MUAH - common plenum Supply 0 252 0 252 104 98 63 265
DD Recirculation 0 259 0 259 162 304 44 509
Etch Bay (1) Recirculation 0 210 0 210 43 179 111 332
Etch Bay (2) Recirculation 121 248 0 369 177 114 44 334
Films Recirculation 0 198 0 198 11 254 126 391
MVA Recirculation 364 117 0 481 353 76 44 473
Sub-Fab, Diffusion Recirculation 0 216 0 216 21 199 118 339
Sub-Fab, WETS area Recirculation 0 196 0 196 33 183 49 266
Sub-Fab, Photolithography Recirculation 0 179 0 179 19 153 84 256
Rooftop air intake Outdoor 406 87 59 553 116 46 0 163
Ground-level air intake (1) Outdoor 388 159 59 606 378 38 0 416
Ground-level air intake (2) Outdoor 249 167 0 436 247 66 129 442
Inspection Building Outdoor 0 227 0 227 59 398 65 523
Probe & Test Building Supply 101 189 0 290 173 39 15 Company227
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 Reports and results – SURVEY of semiconductor fab site

Source Copper Corrosion Silver Corrosion

CCC Location of Air Cu2S Cu2O Cu-Unk Total AgCl Ag2S Ag-Unk Total

Boundary line (outside air) Outdoor 16,195 634 0 16,380 192 83 0 275
Central Utilities Building (roof) Outdoor 15,759 577 0 16,336 256 124 0 380
Loading dock (east) Outdoor 8,033 144 0 8,177 133 86 39 259
Loading dock (south) Outdoor 6,058 144 0 6,202 149 55 63 268
Fab MUAH - Intake Outdoor 15,348 350 0 15,698 298 76 0 375
Fab MUAH - common plenum Supply 0 252 0 252 104 98 63 265
DD Recirculation 0 259 0 259 162 304 44 509
Etch Bay (1) Recirculation 0 210 0 210 43 179 111 332
Etch Bay (2) Recirculation 121 248 0 369 177 114 44 334
Films Recirculation 0 198 0 198 11 254 126 391
MVA Recirculation 364 117 0 481 353 76 44 473
Sub-Fab, Diffusion Recirculation 0 216 0 216 21 199 118 339
Sub-Fab, WETS area Recirculation 0 196 0 196 33 183 49 266
Sub-Fab, Photolithography Recirculation 0 179 0 179 19 153 84 256
Rooftop air intake Outdoor 406 87 59 553 116 46 0 163
Ground-level air intake (1) Outdoor 388 159 59 606 378 38 0 416
Ground-level air intake (2) Outdoor 249 167 0 436 247 66 129 442
Inspection Building Outdoor 0 227 0 227 59 398 65 523
Probe & Test Building Supply 101 189 0 290 173 39 15 Company227
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 Reports and results – EVALUATE Purafil system performance

CUSTOMER
REQUIREMENTS: Purafil Side Access
ISA Class G1 air for System with Purafil
both copper and silver Select and Puracarb to
and with no evidence of remove H2S, SO2 and Cl2
H2S or Cl2.

Purafilter SPB-500 to
remove H2S, SO2 and Cl2

EXAMPLE SHOWING POSSIBLE LOCATIONS OF PURAFIL CCCs

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 Reports and results – EVALUATE Purafil system performance

Copper Reactivity Data Silver Reactivity Data

CCC Location ISA IS
Cu2S Cu2O Cu-Unk Total AgCl Ag2S Ag-Unk Total
Class Class
Fresh Air Inlet 818 464 0 1,282 G3 137 943 609 1,689 G3
Chemical Filter - 1st stage 0 280 0 280 G1 0 197 519 715 G2
Chemical Filter – 2nd stage 0 264 0 264 G1 0 118 90 208 G2
Mechanical Room 0 255 0 255 G1 0 79 113 191 G1
Cleanroom 0 239 0 239 G1 0 118 180 298 G2

Copper Corrosion ISA Silver Corrosion ISA

CCC Location
Reactivity Reduction Class Reactivity Reduction Class
Fresh Air Inlet 435 G2 362 G2
Chemical Filter Discharge 21 95.16% G1 9 97.58% G1
Mechanical Room 57 86.97% G1 28 92.24% G1
Control Room 11 97.49% G1 23 93.62% G1

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 Summary

What controls manufacturers are saying…

Honeywell: The Environment in Control and Equipment Rooms: How Important Is It, and What To
Look For?
• “We recommend the chemical filtration be handled by a 3rd party, such as Purafil. Real time, active and
passive monitors, are available to help monitor the effectiveness of chemical filtration. Optimized filtration
can be monitored using either Purafil’s On-Guard systems, or reactivity monitoring, including silver and
copper coupons.”

Schneider Electric: Electrical Equipment and Components in Adverse/Corrosive Environments

• “…data collected by Purafil® have shown that using copper corrosion alone as a gauge for equipment
reliability can seriously understate the corrosive potential of the local environment.”
• “Purafil® has established the shortcomings of direct gas monitoring and why the use of corrosion
monitoring for environmental classification is being used as a replacement.”
• “If you suspect a corrosive environment… we suggest that you contact an environmental consulting or
corrosion engineering firm, such as Purafil®.”

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 Summary (cont.)

What can Purafil’s CCCs do for you?

The use of coupons will create opportunities, thus enabling new equipment and/or filter sales.

“We’re not creating the problem, RoHS did that for us!”

1. Show potential customers that they risk voiding manufacturers’ warranties by exceeding the
specified ISA severity level.
2. Identification of corrosive species guides proper media selection.
3. Allows you to look beyond your current markets.

Utilize coupons for replacement media sales.

• Track the performance of installed Purafil media, filters, and air cleaning systems.
• Keep track of competitors’ systems and identify deficiencies in media selection and
performance and/or equipment design.

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 Final Thoughts

With many manufacturers now using

silver corrosion as a required
environmental metric, and it being
much more sensitive to corrosion, there
are increased concerns over equipment
reliability.

Purafil can track CCC activity by the

number of coupons sold, number of
reports generated, type of industry,
number of individual companies,
number of individual monitoring sites,
etc. to help you identify and focus on
the opportunities for new and follow-up
sales.

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 Q&A

Questions?

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