FM Global

Property Loss Prevention Data Sheets 7-6

January 2012
Page 1 of 7

HEATED PLASTIC AND PLASTIC-LINED TANKS

Table of Contents
Page

1.0 SCOPE ................................................................................................................................................... 2

1.1 Changes .......................................................................................................................................... 2
2.0 LOSS PREVENTION RECOMMENDATIONS ....................................................................................... 2
2.1 Construction and Location ............................................................................................................... 2
2.1.1 Tank Construction .................................................................................................................. 2
2.2 Equipment and Processes .............................................................................................................. 2
2.3 Protection ......................................................................................................................................... 3
2.4 Operation and Maintenance ............................................................................................................ 3
2.4.1 General .................................................................................................................................. 3
2.4.2 Electrical Safeguards ............................................................................................................ 4
3.0 SUPPORT FOR RECOMMENDATIONS ............................................................................................... 4
3.1 Introduction ...................................................................................................................................... 4
3.2 Fluid Heating Types ......................................................................................................................... 4
3.2.1 Electrical Resistive Element Heaters .................................................................................... 4
3.2.1.1 Electric Immersion Heaters ....................................................................................... 4
3.2.1.2 External Heaters (also known as Bonded Heaters) .................................................. 4
3.2.1.3 Infrared Heaters ......................................................................................................... 4
3.2.2 Heat Exchangers ................................................................................................................... 4
3.3 Loss History ..................................................................................................................................... 5
3.4 Illustrative Losses ............................................................................................................................ 5
3.4.1 Automotive Parts Plant .......................................................................................................... 5
3.4.2 Aircraft Component Plant ...................................................................................................... 5
3.4.3 Electronics Plant .................................................................................................................... 5
3.4.4 Plating Laboratory ................................................................................................................. 6
4.0 REFERENCES ....................................................................................................................................... 6
4.1 FM Global ........................................................................................................................................ 6
APPENDIX A GLOSSARY OF TERMS ....................................................................................................... 6
APPENDIX B DOCUMENT REVISION HISTORY ....................................................................................... 6
APPENDIX C RELATED STANDARDS ....................................................................................................... 6
C.1 NFPA Standard ............................................................................................................................... 6
C.2 Class 4910 Standard ...................................................................................................................... 6

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7-6 Heated Plastic and Plastic-Lined Tanks
Page 2 FM Global Property Loss Prevention Data Sheets

1.0 SCOPE
This data sheet applies to plastic and plastic-lined tanks that contain heating systems for industrial process
liquids.

1.1 Changes
January 2012. Terminology related to ignitable liquids has been revised to provide increased clarity and
consistency with regard to FM Global’s loss prevention recommendations for ignitable liquid hazards.

2.0 LOSS PREVENTION RECOMMENDATIONS

2.1 Construction and Location

2.1.1 Tank Construction

2.1.1.1 Use noncombustible materials that are compatible with the chemicals being used where possible.
Examples of acceptable materials include stainless steel and quartz.
2.1.1.2 Use plastics that are FM Global Research Listed to the Class 4910 Standard whenever plastic
materials are required for process compatibility reasons.
2.1.1.3 Use noncombustible materials for processes heating ignitable liquids.

2.2 Equipment and Processes

2.2.1 Process liquid heating should be done using heat transfer systems that use hot water or other
noncombustible heat transfer media for process liquid heating whenever possible. Steam heated immersion
coils should be considered where practical. Steam coil temperatures can be in the range of 250°F (121°C)
at 15 psig (103 kPa) steam to 300°F (149°C) at 50 psig (345 kPa) steam. Another acceptable option is to
remotely heat the chemicals in a properly designed heat exchanger that is external to the process line.
2.2.2 Where possible, replace electric immersion heaters by other heating methods discussed in this standard
where possible.
2.2.3 Where heaters are used on processes involving plastic or plastic-lined tanks, arrange for the following
features:
a) Mount and secure immersion heaters in a fixed position in accordance with the manufacturers’ mounting
recommendations. This will ensure that proper distance from the walls and bottom of the plastic tank or
liner is provided.
b) Provide FM Approved (see Appendix A for definition) low liquid level sensors or limit
switches interlocked to de-energize the heaters and sound an alarm if the liquid level falls below any
section of the element where heat is produced. The tank heater should not be able to re-start until the
process level sensor is satisfied.
c) Equip tanks that are filled from facility’s bulk supply system with a high level interlock. This interlock
should stop the flow of chemical if the tank is filled above the normal process level.
d) Provide each heated tank with a high liquid temperature limit sensor or limit switch arranged to
de-energize the heater and sound an alarm when the liquid temperature rises 25°F (14°C) above normal
operating temperatures. The interlock should have a manual reset.
e) Provide each heater with a heating element over-temperature sensor, limit switch or snap switch. The
sensor should be located as close as possible to the heater or be an integral part of the heater, and should
be interlocked to shut down the heating system if the pre-set value is exceeded. The pre-set value should
be factory set and not be field adjustable. If not an integral part of the heater, the location of the sensor
should be determined by the heater manufacturer.
f) Provide interlocks for the high temperature limit and the liquid level limit switches outlined above, that
operate independently of normal process controls. Some installations are microprocessor controlled with
integrated liquid level and high temperature cutout. These systems should be evaluated for the proper
application of the limit switches.

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Heated Plastic and Plastic-Lined Tanks 7-6
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g) Turn off power to the heating system serving the tank in question upon actuation of a vessel’s drain
sequence. Power to the heater should be permitted only when the proper process liquid level in the tank
is restored.
h) Provide interlocks that shut down the power to the heating system if the associated process pump is
deactivated and/or liquid flow is interrupted in systems where liquid flow is required for safe operation.
In systems where a mechanical pump is not directly associated with the heater, provide a flow sensing
system using an independent sensor and associated circuitry interlocked to shut off power to the heater
on loss of fluid flow.
i) For bonded or embedded heating systems, any outer enclosure around the heater should be made
of noncombustible material such as stainless steel, quartz, or materials that are Listed to the Class 4910
Standard.
j) Shut off heaters during idle periods when practical.
k) Protect heaters from mechanical damage.

2.3 Protection
2.3.1 Provide automatic sprinklers capable of delivering a density of 0.15 gpm/ft2 (6 mm/min) over 2500 ft2
(233 m2) over all combustible plastic and plastic-lined tanks containing nonignitable liquids. 250 gpm (944
lpm) should be reserved for hose streams. Suitable corrosion resistant sprinkler heads and piping should be
used as necessary.
2.3.2 For tanks (noncombustible) containing ignitable liquids, provide sprinkler protection capable of delivering
a minimum density of 0.30 gpm/ft2 (12 mm/min) over 2500 ft2 (233 m2) 500 gpm (1873 lpm) should be
reserved for hose streams.
2.3.3 For new construction, use FM Approved fume/smoke exhaust duct systems. Where combustible ductwork
or hoods are provided, install automatic sprinklers as outlined in Data Sheet 7-78, Industrial Exhaust
Systems. The fume/smoke exhaust system for the plating area should be independent of other plant areas.
2.3.4 Provide adequate drainage or containment for the area containing the plastic tanks. Drainage should
be capable of removing the largest expected spill in addition to expected sprinkler water flow of one hour
duration.
2.3.5 Provide a minimum 1-hr fire separation between plating areas and other important areas.
2.3.6 Develop a pre-incident plan with the fire department and any other responding agencies to ensure
that an agreeable plan of action is in place in the event of a fire or other incident. Factors that should be
addressed include issues of chemical exposure, potential plating solution reactivity (e.g., with water), and
ignitable liquids handling (if any). The facility should work closely with these agencies to develop the plan to
make certain they are fully aware of the items outlined above, and to ensure proper coordination of
emergency efforts. At least annually, there should be a joint exercise (drill) involving the facility and the public
agencies that would normally respond to emergencies. The plan should be reviewed and updated as
necessary following these exercises.
2.3.7 Provide portable extinguishers in accordance with Data Sheet 4-5, Portable Extinguishers. Do not use
dry chemical or foam extinguishers where contamination of tank contents is a major factor.

2.4 Operation and Maintenance

2.4.1 General
2.4.1.1 Establish a regular maintenance and inspection program for all tanks and heater equipment.
Maintenance and inspection reports should be available for review.
2.4.1.2 Operators should be fully trained in operating and maintenance procedures, and should have access
to written procedures whenever possible. Training should include the correct operation of the heaters and
the reliable operation of safety interlocks for liquid level and over-temperature.
2.4.1.3 Visually check electrical and mechanical components, heater supports, operating controls, and all
safety devices every week.

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7-6 Heated Plastic and Plastic-Lined Tanks
Page 4 FM Global Property Loss Prevention Data Sheets

2.4.1.4 For immersion heaters, test low liquid level and high temperature interlocks at least monthly to ensure
proper operation. All other heater types should have these interlocks tested quarterly.

2.4.2 Electrical Safeguards

2.4.2.1 Incorporate a manual reset into the over-temperature interlocks so that when the system shuts off
the power to the heating element, a manual reset is needed to re-energize the system.
2.4.2.2 The interlock that interrupts power to the heater(s) upon over-temperature, low liquid level, ground
fault condition, or fire detection should be a hardware component. The component should be wired in such
a manner that a fault signal should shut off power to the heaters and place the system into a safe condition.
2.4.2.3 Annually, physically check for tightness of connections, or alternatively conduct an infrared scan of all
electronic components.

3.0 SUPPORT FOR RECOMMENDATIONS

3.1 Introduction
Plastic (usually polypropylene, polyethylene, polyvinyl chloride or glass-fiber-reinforced plastic) and plastic-
lined tanks are used extensively in the electronics industry for cleaning, plating, and etching of circuit boards
and electronic components. They are also used in metal finishing and electroplating operations.
Although the plating solutions in these tanks are generally nonignitable, fire involving the combustible tank
and/or tank lining can cause considerable damage to contents and surroundings. The solutions generally
contain precious and semi-precious metals or alloys of extremely high purity, which are easily contaminated
by smoke or water. Often these tanks have associated plastic piping and ductwork for fume removal. A fire in
such apparatus may spread to other areas and involve in-process or stored electronic components. The
tank heaters can become an ignition source under low liquid level or over-temperature conditions.

3.2 Fluid Heating Types

3.2.1 Electrical Resistive Element Heaters

These types of heaters use the energy generated by the resistance to the passage of electrical current through
a conductor to directly heat a liquid.
These of heaters can be either non-flow or flow systems. Non-flow systems do not require agitation or flow
in order to operate properly and safely. Flow systems require forced convection through either flow or
agitation of the liquid being heated to prevent overheating of the liquid.

3.2.1.1 Electric Immersion Heaters

An outer sheathing that acts as a corrosion and electrical barrier typically protects the heating element on
these heaters. This type of heater transfers energy to the liquid by means of conduction.

3.2.1.2 External Heaters (also known as Bonded Heaters)

External heaters are normally bonded to the outside of the tank. This type of heater also transfers heat to
the liquid by conduction.

3.2.1.3 Infrared Heaters

These are heaters that emit infrared energy and heat the liquid by absorption of radiant energy. Infrared
heaters are generally resistive element devices that are separated from the liquid by a nonconductive material,
typically quartz glass.

3.2.2 Heat Exchangers

The most common type of heat exchanger uses a separate heating device that may be remote from the
heated tank. This heat source may use a heat transfer fluid that is delivered by noncombustible tubing to
the tank and then recirculated back to the heater. A similar design uses a dual loop system and counter-flow
type heat exchanger.

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Heated Plastic and Plastic-Lined Tanks 7-6
FM Global Property Loss Prevention Data Sheets Page 5

3.3 Loss History

From 1985 through 1999, there were 52 losses involving plastic and plastic-lined tanks. The losses occurred
at locations with a process/occupancy of metal plating, circuit board manufacturing/assembly and
semiconductor manufacturing.
Electrical immersion heaters caused 61% of the losses. Immersion heaters are normally submerged in the
processing solution. If the tank leaks or if the liquid level drops below the heater and the heater is left
energized, the tank wall or liner can be ignited. Most fires occurred when heaters were either left energized
during idle periods or were activated by a timer several hours before the beginning of operations. A major
factor in most of the losses was the malfunctioning of low-liquid level interlocks and/or high temperature limit
switches. These interlocks were often poorly maintained and as a result did not function properly when
needed.

3.4 Illustrative Losses

3.4.1 Automotive Parts Plant

Washers and nuts for the automotive industry were plated in four lines consisting of zinc, chrome and
phosphate applications. A fire originating in an electrical distribution cabinet that provided power to the plating
line destroyed the plating operations. The electrical cabinet was located adjacent to the zinc plating line.
The plating lines did not contain any heaters, however the plating building was unsprinklered.
Infrared scanning was performed on the distribution cabinet in January with corrective actions reportedly
taken in October. The fire occurred in November.
The volunteer fire brigade was able to bring the fire under control after 3.5 hours.
The building suffered structural damage caused by the fire. Building and contents also suffered severe smoke,
soot and corrosion damage created by acid vapors generated by the fire.

3.4.2 Aircraft Component Plant

A fire originated in the unsprinklered plating room of an aircraft component manufacturing plant at
approximately 3:00 p.m. The 2500 ft2 (233 m2) plating room contained four plating lines (two tin plating, one
nickel plating and one gold/silver) plating. Some of the plating tanks were heated using immersion heaters;
all were reportedly equipped with high temperature and low-level alarms and interlocks. The fire occurred
over the Labor Day Holiday weekend so there were limited operations taking place at the plant. It was normal
procedure for the plant to leave the plating equipment operating even when the plant was unoccupied.
Sprinklers had recently been installed in the building, though not in the plating room due to the plant’s fear
of sprinkler water reacting with cyanic solutions in the baths and creating toxic gases. The local fire
department (part paid) reportedly conducted annual pre-fire planning visits to the facility.
The fire was spotted by an employee who notified an on duty policeman who was conducting hourly rounds
of the plant as mandated by the local Fire Marshal Office since the newly installed fire alarms were not yet
connected. The fire department responded to the location at 3:15 p.m. and connected a pumper truck to
the fire department connection. No further fire fighting efforts were initiated by the fire department, reportedly
due to the nature of chemicals located in the plating area (cyanides and acids) and the possibility that when
combined with water cyanide gas could be evolved. The fire was allowed to burn until 11:00 p.m. when Hi-Ex
foam concentrate and associated equipment was brought on-site from a neighboring fire department.
The fire resulted in severe damage to the plating room area and contents. An adjacent cleanroom used for
assembly and packaging suffered smoke and soot damage.
The likely cause of the fire was determined to be the ignition of the polyethylene-plating tank by an immersion
heater.

3.4.3 Electronics Plant

The plating wafer booth of a semiconductor manufacturing plant contained two 12 by 26 in. (300 by 660
mm) tanks, 7 to 12 in. (180 to 300 mm) deep. Pumps continuously circulated gold cyanide solution. The tanks
were equipped with 1000-watt electric immersion heaters and with a low liquid level cutoff. Exhaust at the
polypropylene tank top was through a slot into a 10 to 12 in. (250 to 300 mm) diameter polypropylene duct.

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7-6 Heated Plastic and Plastic-Lined Tanks
Page 6 FM Global Property Loss Prevention Data Sheets

The electric heaters were turned on by the operator who later went home ill. At 4:00 p.m. the fire department
responded to a waterflow alarm and found two sprinklers containing the fire to the booth. The booth, tank
equipment, and exhaust ducting were severely fire damaged. Electronic equipment was water damaged.
Substantial smoke damage occurred in the surrounding cleanroom.
Evidence indicated that the low liquid level switch had not operated and the immersion heaters had ignited
the polypropylene tank.

3.4.4 Plating Laboratory

The plating laboratory contained approximately 70 polypropylene and polypropylene-lined solution tanks with
electric immersion heaters without high temperature and liquid level interlocks. The heaters are actuated
by a seven-day timer at 4:00 a.m. Monday through Friday. The timer and heaters for water and caustic tanks
were left energized without supervision.
At approximately 7:40 p.m. on a Sunday, a neighbor heard an alarm bell and notified the police department.
The police responded and called the volunteer fire department. When they arrived at the plant it was found
that five sprinklers had controlled the fire. Four tanks and 50 ft (15.3 m) of ducts were burned and two tanks
were melted. Extensive smoke damage was limited to the laboratory. Cleanup and production restoration were
scheduled for three to four weeks.

4.0 REFERENCES

4.1 FM Global
Data Sheet 4-5, Portable Extinguishers.
Data Sheet 7-78, Industrial Exhaust Systems.

APPENDIX A GLOSSARY OF TERMS

FM Approved: references to ‘‘Approved’’ in this data sheet means the product and services have satisfied
the criteria for Factory Mutual Research Approval. Refer to the Approval Guide for a complete listing of
products and services that are Factory Mutual Research Approved.
Ignitable Liquid: Any liquid or liquid mixture that is capable of fueling a fire, including flammable liquids,
combustible liquids, inflammable liquids, or any other reference to a liquid that will burn. An ignitable liquid
must have a fire point.

APPENDIX B DOCUMENT REVISION HISTORY

January 2012. Terminology related to ignitable liquids has been revised to provide increased clarity and
consistency with regard to FM Global’s loss prevention recommendations for ignitable liquid hazards.
September 2000. The document has been completely revised to include additional recommendations for
tank construction, electrical safeguards, heating system interlocks, updated loss information and descriptions
of different heating system types.
January 2000. This revision of the data sheet was reorganized to provide a consistent format.
June 1986. This revision of the data sheet emphasized that the high temperature limit switches and the
electrical contactor should be independent of the normal operating controller and electrical contactor. Also,
the loss experience was updated.

APPENDIX C RELATED STANDARDS

C.1 NFPA Standard

There are no NFPA standards on this particular subject. There are no known conflicts with related NFPA
standards.

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Heated Plastic and Plastic-Lined Tanks 7-6
FM Global Property Loss Prevention Data Sheets Page 7

C.2 Class 4910 Standard

FM Global Research has developed a specification test standard that can determine the fire hazard of
materials. The test standard is titled Factory Mutual Research Cleanroom Materials Flammability Test
Protocol (Class 4910) as it was originally applied to lower loss potentials in semiconductor cleanrooms. This
standard evaluates the fire hazard of materials used in environments which are highly sensitive to thermal
and nonthermal damage.
The protocol uses three small-scale tests and a large-scale validation test if needed. Small-scale tests
performed in the FM Global Research Flammability Apparatus are:
Ignition Tests
Fire Propagation Tests
Combustion Tests
This is a performance-based test protocol. Based on results of the three small-scale tests, the following
indexes are determined for each material tested:
1. Fire Propagation Index (FPI): this index is determined based on the fire propagation tests conducted and
represents the rate at which the surface of the material is involved on fire. Nonpropagating materials have
FPI values at or below 6.0 (m/s 1⁄2 )/(kW/m)2⁄3.
2. Smoke Development Index (SDI): this index is defined as the product of the FPI index and the yield of
smoke for a given material. SDI is an indicator of the smoke contamination of the environment expected during
fire propagation. Materials expected to limit smoke contamination have SDI of 0.4 [(m/s 1⁄2 )(g/g)(kW/m)2⁄3
]or less.
Materials that are FM Global Research Specification Tested to meet the flammability protocol criteria
require high heat fluxes to be ignited; once ignited these materials may burn locally in the ignition area, but
they will not propagate a fire beyond the ignition zone. Smoke and corrosive products generated from the
combustion of these materials is reduced, minimizing nonthermal damage.

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