ANSI/ISA-71.

04-2103
Environmental Conditions for
Process Measurement and Control Systems:
Airborne Contaminants

Dean Bickerton – ISA New Orleans – The Reynolds Company

Shared content from Chris Mueller – Purafil, Inc.
Presentation Sponsors
ISA 71 Committee
• The purpose of the ISA71 Committee is to promote or develop
standards or guidelines on environmental conditions for
industrial process measurement and control systems, and to
provide technical support for U. S. activities in IEC/TC65.
ISA 71 Committee
ISA 71 Standards
ISA-71.04-2013 - History
• Originally published in 1985 to classify airborne contaminants and
biological influences that may affect electronic hardware.
• The classification system provides users and manufacturers with a
means to specify the type and concentration of airborne
contaminants.
• The 2013 edition contains new features and updates to address RoHS
RoHS - Introduction
 EU directive 2002/95/EC “on the Restriction of the use of certain
Hazardous Substances in electrical and electronic equipment” or
RoHS was implemented in July 2006.
 Eliminated and/or restricted the use of certain hazardous substances in
electrical and electronic equipment.

 RoHS regulations are either in effect or pending in many countries.

Get the Lead Out!
• An aim shared by almost all RoHS legislation is the elimination of lead
in electronic products.
• The main issue for the electronics industry is the use of lead in the
manufacture of components and circuit board assemblies.
• Printed circuit boards (PCBs) have conducting layers on their surface
made of thin copper foil.
• Unprotected copper will oxidize and deteriorate.
• Traditionally, any exposed copper was plated with lead(-based) solder.
Unintended Consequences
RoHS and Reliability
• Products with an immersion silver (ImmAg) surface finish
will creep corrode in high sulfur environments (ISA Class
G2 or higher).
• Data from many different sites show locations with an ISA Class
G1 environment for copper but where the silver corrosion
rates are 10-20 times higher.
• This represents serious concerns for lead-free electronic
equipment.
• RoHS costs have been conservatively estimated at $8
billion (USD) industry-wide.
• Will we yield $8 billion worth of positive environmental
impact?
This wasn’t such a big deal back in the 80’s
ISA Standard 71.04-1985
Severity Copper
Class Comments
Level Reactivity
An environment sufficiently well-controlled such that
G1 Mild <300Å corrosion is not a factor in determining equipment
reliability. 10-10
An environment in which the effects of corrosion are
G2 Moderate <1000Å measurable, and corrosion may be a factor in
determining equipment reliability.
An environment is which there is a high probability that
corrosive attack will occur. These harsh levels should
G3 Harsh <2000Å
prompt further evaluation resulting in environmental
controls or specially designed and packaged equipment.
An environment in which only specially designed &
packaged equipment would be expected to survive.
GX Severe ≥2000Å
Specifications for equipment in this class are a matter of
negotiation between user & supplier.
It is a much bigger deal in the 21st Century

G1 G2 G3 GX
Severity Level
Mild Moderate Harsh Severe

Copper Reactivity Level (Å per 30 days) <300 <1000 <2000 ≥2000*

Silver Reactivity Level (Å per 30 days) <200 <1000 <2000 ≥2000*

 Reactive
But wait there’s more… Compounds

Corrosive environments are formed by: Humidity Heat

• Presence of Reactive Compounds (Sulfides, Chlorides, etc).
• Both Humidity and Heat have an impact on rate and
mechanisms of corrosion
• 50 Deg F temperature increase can more than double destructive chemical
reactions
Corrosive
• High or variable humidity may accelerate corrosive effects even more
Environment
• Electronics can be susceptible to corrosion throughout their life
cycle:
• Storage and transit
• During commissioning
• Normal use in or near process
• Maintenance activities
Unplanned
Downtime
And more…
Why is this causing unplanned downtime?
Challenge with Defining the Problem with Corrosive Gases

Industry Standard Problem not Lack of Clear Solution

Limitations Understood
• Vague definition due to many • Symptoms misdiagnosed or • Multiple layers of protection are
variables affecting corrosion dismissed as product quality often necessary

• Environments with same • Environmental assessment not • Manufacturer recommendations not

classification may not be equal completed or not fully known followed

• Lack of test strategy to validate • Denial of corrosion problem • Staff not trained on
performance proper procedures
Industries Effected

Oil Refineries

Petrochemical Plants

Pulp and Paper Mills

Wastewater Treatment Plants

Power Generation Facilities

Chemical Companies

Steel Mills

Copper Mines

Almost EVERY one of the process industries and heavy manufacturing

industries are plagued by corrosion of process control equipment.
Tire and Rubber Industry
Water/Wastewater Treatment
What is the cost of Corrosion?

Unscheduled Downtime – How much

does ONE HOUR of unscheduled
downtime cost?
Example: Pulp & Paper Mill

Produces approximately 680,000 tons

per year of Kraft Pulp
Production value for mill =
$374,000,000 per year
Current Market Price = $550 per ton,
which equates to…
$1,024,657 per day or $42,695 per hour!!
What do you do?

Assess, Control, and Monitor

• Assess outdoor air and the indoor environment to quantify

the corrosion potential based on ISA 71.04-2013

• Develop and specify detailed contamination Control

strategy based on ISA 71.04-2013 severity levels

• Establish real-time environmental Monitoring program

based on the severity levels established in ISA 71.04-2013
Assess
Corrosion Classification Coupons aka
Reactivity Monitoring Coupons
• Each coupon contains one strip of copper and silver
• Performed throughout facility
• Inside enclosure
• Outside enclosure
• Storeroom
• Leave for 30 days then removed and sent in for analysis
• Report detailing corrosion rate observed and classification per ANSI/ISA
71.04-2013, Airborne contaminants – gases
• Multiple other methods including active electronic sensing are
available
• CCC+ - Adds Temperature and Humidity Datalogger to coupon
• Electronic monitors with simple Pass/Fail indication
What can you do? Control it – Layers of Protection
Enclosures
Installation Best Practices
Temperature Control
Humidity and Corrosion Control
More Robust Products

Leading process controls manufacturers

• Control Hardware Planning Guide.
Brand H • “Uncoated boards are rated for mild (G1)
environments.”

• Environmental Data.
Brand A • “Corrosive protection –
Compliant according to ISA-71.04…”

• Hardware Features.
Brand Y • “…corrosion resistance meets the specifications
of ANSI/ISA 71.04 as standard.”
New manufacturing processes
Standard IGBT XT IGBT

Dendrite growth
between high-voltage
conductors

Dendrite growth
eliminated

Copper not darked

Enhanced Coating Processes
Components w/ palladium plated leads after 30 days in accelerated corrosion test
Standard coating Enhanced coating

U25: Less corrosion

using enhanced
coating process

U46: Less
corrosion using
enhanced coating
process
Connector grease

 After test w/o grease  Dielectric Grease • After test w/ grease applied
applied

Test

 Connector grease helps limit the corrosive atmosphere from reaching the base
metals and reduces risk of corrosion
Port plugs / covers

 Ethernet port plug  PCIe female port plug • Fiber-optic transceiver port
plug

Port plugs help limit the corrosive atmosphere from reaching the metals in unused ports
What is required to maintain ISA Class G1 Air?

Room Air Pressurize the room to 0.05-0.10 IWG with Clean Air
Purification ( 3 to 6 air changes/hour)

Humidity Control <55% Relative Humidity, with < 6% Change/Hour

Temperature
70°F (21°C); +/- 2°F Per Change (+/- 1°C)
Control

Room Construction
Well Sealed Room; Airlock Entryways
and Integrity

Room Air
6 to 12 air changes per hour
Recirculation*
Maintaining ISA Class G1 Air
Pressurization air is ducted into the room through the A/C to better control
humidity and temperature. The recirculation air unit is an additional source of
purification.

Recirculation
by CA unit

Supply OA
Pressurization
by DBS unit
+∆p A/C
Monitor –
Visual Inspection
Checklist
Monitor
Summary

3-Step Process for Corrosion Control

Determine the types and levels of corrosion
Assess wherever sensitive electronics are used or
stored

Utlilize layers of protection for your electronics

Control equipment and get air to ISA Class G1 if
possible.

Real-time monitoring options to verify ISA Class

Monitor
G1 air. Examine installations and spent media.