Process plants are getting bigger, more expensive, and more tightly regulated. Semicnoductor facilities for example, can now exceed U.S. $2 billion, with expectations of U.S. $5 billion in the near future.
The rapid increase in process plant cost, particularly in the high tech arena, has led to the development of more effective criteria. Factory Mutual (FM) in particular has been active in these areas. FM has a battery of tests to qualify fume ans smoke exhaust duct materials of construction for use without sprinklers.
Corrosion resistant materials are absolutely required to keep these plants running. Fiscal, as well as legal responsibility, requires use of flame and smoke resistant materials. Building code officials and insurance underwriters have helped raise awareness levels, as well as enforce compliance.
Traditional "Flame Safe" requirements have meant testing demonstrated corrosion resistant materials via the ASTM E-84 tunnel test for flame propagation and smoke generation . A value of less than 25 for flame and 50 for smoke was generally considered a corrosion resistant Class 1 flame and smoke material.
FM 4922
The FM 4922 test protocols qualify duct for use without sprinkler protection.
FM 4922 Horizontal Vertical Test
Sprinklers have many drwbacks, iincluding initial costs associated with installation of supply mains with sprinklers, drain lines towaste treatment procesing areas, and continuous maintenance. While incorporationg a variety of flat panel tests, Factory Mutual goes beyond reliance on ASTM E-84 to test actual duct in real fire situations.
Horizontal Test - a 24-0' horizontal run of 12" diameter duct. This is generally considered the bench mark test for FM.
Horizontal-Vertical Test - a 15' vertical combined with a 24-0" horizontal run of 12" diameter duct. This test is run following successful completion of the horizontal test.
Unlimited Height Test (optional) - The standard qualification by FM limits vert5ical runs to 15'. If a less restrictive listing is desired, then additional testing must be done.
While the set up of the three tests differs slightly, all limit the ultimate temperature to 1000oF (538o C) near the outlet. The lower the temperature, the lower the risk of fire propagation. In addition, any dripping or bur through of the duct is prohibited.
FM 4910
The FM 4910 test protocol qualifies materials for use in clean rooms.
4910 builds upon the results of the 4922 testing using small scale flat panel tests to ensure suitability for clean room installations. The protocol evaluates fire propagation behavior, potential for smoke contamination, and potential for contamination by corrosive products of combustion.
From these tests, Factory Mutual calculates a Smoke Damage Index (SDI) and Flame Propogation Index (FPI).
The SDI is the total mass of smoke generated to the total mass of the material loss. The 4910 upper limit for the SDI is 0.40. FPI values are used for classification of materials as eiether nonpropagating (good, or progagating. The 4910 upper limit for the FPI is 6.0 Pure Guard SS did not ignite in these tests (and as a result has no value for SDI or FPI).
The Solution
Pure Guard SS - Fluoropolymer Coated Stainless Steel
Pure Guard SS is fluoropolymer coated stainless steel duct
0.41 mm (16mil) ECTFE Halar® coating, up to 60% thicker thatn the competition
FM 4922 Approved
FM 4910 Approved
Unlimited Height Approval
Critical Comparisonsof Pure Guard SS to ETFE Coated Stainless Steel
Pure Guard SS is approved for use without sprinklers
It's ASTM E-84 flame spread of 10 and smoke development of 35 meets all Class 1 requirements
Maximum FM horizontal test temperature of 744ºF (396ºC) is much lower than Teflon® ETFE coated duct 850ºF (454ºC), despite Pure Guard SS' much greater coating thickness.
Pure Guard SS provides on average a 50% safety factor versus ETFE lined duct for critical FM duct maximum allowable exit temperatures.
In FM tests to measure critical heat flux, ignition resistivity and chemical heat release rate, Pure Guard SS did not ignite!
Controlled burn of 3.175 mm (125 mil) thick ETFE (left) and ECTFE (right) demonstrating ECTFE's superior resistance to burning and flaming-dripping (courtesy Ausimont)
There is a Difference - Don't Accept Second Best
Pure Guard SS gives you a thicker, tougher, more corrosion resistant exhaust duct, with better flame resistance than the competition
Extra Thick... Pure White...Pure Guard SS -
Your Quality Assurance Guarantee
The Advantage
Halar ECTFE....
Halar ECTFE has long been recognized as a premium corrosion resistant lining material for chemical process applications. It has found particular acceptance in clean room environments - for wet bench, fume exhaust and other services. These wet bench applications are significant because they require FM 4910 Approval on Halar flat sheet, something that ETFE is unable to achieve.
Critical properties of liners fo flame-smoke-corrosive duct applications include the following data (courtesy Ausimont USA):
Criteria
Halar ECTFE
ETFE
Fire Safety
Superior
Average
Surface Smoothness
Superior
Average
Permeation Resistance at Equivalent Lining Thickness
Equal**
Equal
Chemical Resistance at Equivalent Lining
Thickness
Equal**
Equal
Hardness
Superior
Average
Adhesion
Superior
Average
**Pure Guard SS has a 60% thicker liner than ETFE lined duct, yieolding a more corrosion and permeation resistant duct system
Halar provides excellent corrosion resistance to chemistries commonly encountered in exhaust ducts, including:
Hydrofluoric Acid (HF)
Sulfuric Acid (H2SO4)
Nitric Acid (HNO3)
Piranha
Hydrogen Peroxide (H2O2)
Ozone (O3)
Ammonium Hydroxide (NH4OH)
All Alkaline Chemistries
All Etchants and Strippers
Pure Guard SS manufacturing facility in Phoenix, Arizona
Corrosion resistance of linings is a function of the lining thickness. By providing a liner up to 60% thicker than it's competition, Composites USA Pure Guard SS offers the best assurance for years of successful use. Halar ECTFE, in comparison to Teflon® ETFE (competitive lined stainless steelduct material), is harder to ignite, does not drip like ETFE when exposed to flame, and provides a smother, tougher, more abrasion resistant coating.
...and Composites USA
Experts in the application of Halar to solve process corrosion problemd, Composites USA has been providing quality products to clients worldwide since 1982. We have provided ECTFE sheet lined fiberglass and steel vessels for ultra-high purity applications, and Halar reinforced FRP duct for corrosive exhaust. We are the world's largest consumer of Halar veils for FRP manufacturing applications. Our engineers hold key application patents in this area. Composites USA, with industry recognized Approvals and Listings from Factory Mutual, Underwriters Laboratories, and the U.S. Government, is well poised to be yoour strategic partner.
Corrosion Guard Products
Pure Guard SS - The Best Lined Stainless Steel Corrosion Resistant Fume Exhaust Duct on the Market
Key advantages include:
Factory Mutual (FM) Approved top 4922 Protocol for use as a fume and smoke exhaust duct without internal sprinklers.
Factory Mutual (FM) Approved to 4910 Protocol for use in clean rooms.
Factory Mutual (FM) Approved for unlimited riser height.
Pure Guard SS has the thickes corrosion resistant fluoropolymer liner by far of an FM Approved duct system (up to 60% thicker).
Pure Guard SS in testing at FM had a much lower temperature rise than Teflon® ETFE lined duct.
Pure Guard SS ECTFE liner system is thicker, tougher, more combustion resistant than it's ETFE competition.
Dual Guard 2000 - The Best GRP/Fiberglass Corrosion Resistant Fume Exhaust Duct on the Market
Key Advantages include:
Factory Mutual (FM) Apprpved to 4922 Protocol for use as a fume and smoke exhaust duct without internal sprinklers.
Factory Mutual (FM) Approved to 4910 Protocol for use in clean rooms.
Underwriters Laboratories (UL 181) Listed for use as a fume and smoke exhaust duct without internal sprinklers.
Dual Guard 2000 is the only Listed/Approved duct with fluoropolymer (Halar®) reinforcement in the corrosion liner.
Dual Guard 2000 in testing at FM had a much lower temperature rise than vinyl ester lined duct.
Dual Guard 2000 is easily field modified and mates to all major material altenatives, including Pure Guard SS.
Pure Guard and Dual Guard 2000 - Together an Unbeatable Combination with Single Source Responsibility for Complete Process Systems.
Composites USA, Inc. Solving Corrosion Problems World Wide
Duct for corrosive exhaust - GRP.FRP, lined stainless and lined fiberglass
Dual Laminate Equipment for ultra-high purity and extremely corrosive applications
Fume exhaust scrubbers
Composite tanks, pipes and more
Composites USA, Inc.
One Peninsula Drive, North East, MD USA 21901
Tel: 1-410-287-2700 Fax: 1-410-287-5222
www.compositesusa.com
