FM Global Property Loss Prevention Data Sheets 2-1 May 2001 Page 1 of 19 PREVENTION AND CONTROL OF INTERNAL CORROSION IN AUTOMATIC SPRINKLER SYSTEMS ble of Contents Page 1.0 SCOPE 3 1.1. Changes. os 3 1.2. Superseded Information 3 2.0 LOSS PREVENTION RECOMMENDATIONS. 3 2:1 Introduction 3 2.2 Operation and Maintenance 3 2.2.1 Existing Sprinkler Systems 3 2.3 Protection 4 2.8.1. New Sprinkler Systems 4 3,0 SUPPORT FOR RECOMMENDATIONS. 5 3.1 Microbiologically Influenced Corrosion (MIC) 5 3.1.1 What Is MIC? 6 3.1.2 How MIC Affects Sprinkler Systams 6 3.1.3 Telltale Signs of MIC in Sprinkler Piping 8 3.1.4 Industry Postion and NFPA Requirements 8 32 Test Data enn 8 3.3 FM Global UT Protocal for In-Situ Examination of Pipe Internal Corrosion 9 34 Loss History 12 365 lustrative Losses 12 38:1 Sprinkler Leakage Due to Corrosion in Pipe Coupling 12 3.8.2 Pinhole Leaks From Sprinkler System Over Data Processing Center 12 4.0 REFERENCES 12 4.1 FM Global 2 4.2 NFPA 12 APPENDIX A GLOSSARY OF TERMS: 2 ‘APPENDIX B DOCUMENT REVISION HISTORY 12 ‘APPENDIX C ADVISORY GUIDELINES FOR MIC MITIGATION 12 C.1 Mitigation Pian 13 €.2 MIC Prevention: Advice for New Sprinkler Systeme 1B ©.2.1 STEP 1 ~ Diagnosis of water supply 13 ©.22 STEP 2 - Assessment of possible alternatives 14 C23 STEP 3 - Treatment of the local water with disinfectants or biocides 4 C.24 STEP 4- Installation of clean pipe and care during system acceptance 18 €.3 MIC Control: Advice for Existing Sprinkier Systems 18 ©.3.1 STEP 1 - Diagnosis of the corrosion and of the condition of the piping an 15 C32 STEP 2 - Assessment of possible alternatives 18 C33 STEP 3 - Cleaning of piping 16 €.34 STEP 4- Treatment of local water with disinfectants and biocides 17 C36 STEP 5 - Recharging of the system and acceptance 7 6.4 Some Currently Available Mitigation Tools 17 6.4.1 MIC Test Kits 17 €.42 Chemical Treatment Automatic Delivery Systems 17 €.4.3 Chemical Cleaning of Pipe 9 182001 Facay Mul Insurance Company. All ghis reseed. No prt of bis document maybe repedued, ‘Sed ina teeval system, or anamfed. whol on par. tn ay form ob ey meas, eloctrere mesa, ‘Botoopying. ecaidng. or Oerwse, witout utien pansion Faxon laa eurance Company2-1 Internal Corrosion in Automatic Sprinkler Systems Page 2 FM Global Property Loss Prevention Data Sheets List of Figures Fig. 1. Sample arrangement of wet sprinkler piping to prevent air accumulation in branchiines and other high points of the system. Fig. 2. Schematic development of MIC. Fig. 3. Corrosion at rll groove in a wet pipe system. Fig, 4. Pinhole leak site in cut-away section of pipe. Fig. §. Pinhole leak site on outside surtace, Fig. 6. Localized nodule formation below waterline. Fig. 7. Heavy tubercle formation n a 8 In, (200 mm) sprinkler pipe. Fig, 8. MIC test kit and automatic delivery system — courtesy of Bio Industial Technologies Inc. 18 List of Tables Table 1. Guideline for Retaining Pipe Based on Extent of Corrosion Damage cms sod ‘22001 Factory Mutual Insurance Company. Al gh esevedInternal Corrosion in Automatic Sprinkler Systems 2-1 FM Global Property Loss Prevention Data Sheets Page 3 1.0 SCOPE This document addresses prevention and control of corrosion in automatic sprinkler system piping with particular emphasis on Microbiclogically Influenced Corrosion (MIC), 1.1 changes This is @ new document 1.2 Superseded Information ‘The guidelines for MIC provided in Data Shest 2-8N, Installation of Sprinkler Systems, and Data Sheet 2-B1 Fire Safety Inspections and Sprinkler System Maintenance, are supersecied by this new document 2.0 LOSS PREVENTION RECOMMENDATIONS. 24 Introduction ‘The following recommendations are intended to + Provide proper diagnosis of corrasion cases involving sprinkler systems; + Attempt to Keep existing sprinkler systems affected by corrosion free of piping obstructions; Minimize the exposure from possible water leakage losses resulting from MIC affected sprinkler systems: + Provide advisory guidance on possibe corrosion prevention measures that can be considered for any new "wet, dry and preaction sprinkler systam. Recommendations for new systems should be considered based (on the occupancy and exposure present Locations wishing to pursue further corrosion mitigation than what is being recommended in sections 2.2 ‘and 2.3 should follow the guidelines alven in Appendix C of this document; these guidelines are advisory in nature and provide a systematic approach to corrosion mitigation. While these advisory guidelines may Increase the chances of success in mitigating corrosion, and in particular MIC, they are not intended to rep- resent @ compte solution to the problem. Their primary goal is to ensure that the integrity of the sprinkler system Is not further compromised and to prevent loss of protection or further impairments to the sprin- ler system, 2.2 Operation and Maintenance 2.2.1 Existing Sprinkler Systems 2.2.1.1 Investigate for possible corrosion problems and obstructed waterways any sprinkler system exhibit- Ing pinhole leaks, or other signs of corrosion (such as scale, tubercles and other deposits) in pipes, valves Co sprinkler heads, Investigate possible waterway obstructions caused by biological growth (typically in the {orm of tubercles and biofim) in accordance with Data Sheet 2-81, Fie Safety inspections and Sprinkler Sys- tem Maintenance, Include in this investigation any piping leading to waterflow alarms and water motor gongs. ‘Conduct obstruction investigation promptly as the adequacy of the sprinkler system isin question. 1. Flush sprinkler systems where investigation reveals obstructions of the waterway in accordance with the procedures outlined in Data Sheet 2-81, 2. Replace any section of piping that contains obstructions that cannot become removed by flushing procedures. Note: Replacement pipe also may eventually corrode ifthe causes for corrosion are not addressed. In the par- ticular case of MIC, where a proven and universally acceptable solution is not yet available, replacement Cf pipe and monitoring of corrosion progress is a suitable and less costly alternative to more complex mit- gation options, such as cleaning and treatment, for most occupancies until a better solution Is devised. If galvanized pipe is used in an otherwise black steel pipe system, d-electric unions should be used at the black steel/galvanized steel interface. This will prevent galvanic corrosion between the black steel and the galvanized stee! pipe, 3. Relnvestigate systems for waterway obstruction annually, This wil help to monttor the condition of the ‘sprinkler system and the regrowth of slime, tubercles, and scale in the system, 22001 Factor Mutual surance Company All rts reserved2-1 Internal Corrosion in Automatic Sprinkler Systems Page 4 FM Global Property Loss Prevention Data Sheets 2.2.1.2 Conduct metallurgical examination on a sample of the affected component to determine the type ‘and extent of corrosion mechanism involved. 2.2.1.3 Where the extent of corrosion damage to remaining pipe needs to be determined, use the FM Glo- ‘bal protocol for in-situ UT examination of piping given in section 3.3 below. Consider replacement of any ‘section of pipe exhibiting prt sites with remaining wall thickness less than shown in Table 1 Jablo 1. Guideline for Retaning Pipe Based on Extent of Comasion Damiage Pipe Schedule % Wall Romaiing in Ary Siglo Pi ‘Schedule 40 25 oF More ‘Schedule 10 30 or mare Schedulo 5 75 oF mo | Tiyrnd Schoaule 75 oF mae Not: The rvormaion In Tble 1 proves a working gute for determing whether jpg shove relaned cr replaced ts based on {zgneetng judgement and en seeral case of crosanexarined by Fatty Multa Resear Ths lace ered lo erly those Stelons of poe whieh. because of fe dep of te i pak ieak coud Gevep a rele shot penod ote However does fl eect te eating wsel te ofa pe 2.2.1.4 Further mitigation in the form or cleaning of the piping or treatment ofthe water isnot presently being recommended. However, in locations wnere these are being considered, follow the MIC Mitigation Guide- lines in Appendix C. 23 Protection 23.1 New Sprinkler Systems 2.3.1.1. Use new, clean pipe for all new sprinkler system installations and retrofts. Over occupancies deemed ‘sensitive to leaks, consider the use of Schedule 40 pipe for wet, dry and preaction systems. 1. Where pipe undergoes fabrication, disinfect the Internal surfaces of the pipe at the fabricator with @ solu tion of IPA (Isopropyl Alcohol) or equivalent disinfectant, After fabrication and disinfecting, cap pipe ends to prevent dirt and other residue trom entering the clean pipe. Caution: Do not use chiorine for disinfecting purposes. While under carefully monitored conditions weak chlo- Fine solutions have been prescribed as biocide for wet systems, a solution of chlorine apalied directly to pipe ‘awaiting installation may induce corrosion 2. Do net to leave open pipe exposed where it could accumulate dust, clit, water and other residue prior to installation. Store pipes on pallets or blocks so that they are at least 1 fo 2 In. (26 to 50 mm) above the ‘ground to prevent foreign material trom entering the pipe prior to installation, 2. Certty disinfecting methods and procedures, as well as the pre-assembly storing condition of pipe in the “Additional Explanations and Notes” section of the Contractor's Material and Tests Certificate for Above- {ground Piping, 2.3.1.2 In wet pipe systems: + Avold repeated cycles of system shutdoxns where the system is drained and recharged. This Is espe- clally needed during renovations and maintenance in the system. Establish a work plan to minimize sprinkler system shutdowns. Keep the systems charged es much as possible and keep Impairments to a minimum. + Avoid air gaps (pockets) within the system, which can expose piping to dry/wet conditions. This is particue larly important for branchiine piping where air pockets tend to form in high points of the system as the system Is charged. Alr gaps can be avoided by provicing means for ar release at the highest point of each branchline as shown in Figure 1. Connect the highest points of branchiines to a minimum Yin. (13 mm) "gang air drain” which is pitched and routed to a safe location outside the building. Provide the gang air drain with a manual ball valve that can be opened for bleeding air out ofthe system. This arrangement also ull serve as a possible re-crculation loop in case treatment of the water is desirable per the advisory mit- gation guidelines below, ‘+ When systems are provided! with alr release valves in conjunction with the gang air drain show in Fige Ure 1, provide a pressure relief valve of not less than % in, (6.4 mm) In size or an auxliary air reservoir ‘22001 Factory Mutual Insurance Company. Al gh esevedInternal Corrosion in Automatic Sprinkler Systems 2-1 FM Global Property Loss Prevention Data Sheets Page 8 to absorb pressure increases caused by thermal expansion. Set the relief vaive to operate at pressures rot greater than 175 psi (12.1 bars) or 10 psi (0.7 bars) in excess of the maximum system pressure when the maximum system pressure exceeds 165 psi (11.4 bars), Val Re Riser ‘Alarm Check Valve ‘&OS8Y Fig. 1. Sample arrangement of wet sprinkler piping to prevent air accumulation i branchines ‘and othor hgh pomts of th system. 2.3.1.3 In dry-pipe and preaction systems: + Avoid the use of roll grooved joints, Roll grooved joints in a dry sprinkler system promote water accumu lation that can result in preferted corrosion sites. + Install plpe with proper pitch to promote drainage of all testing water and water vapor condensate within Piping. + For additional corrosion protection, pressurize the system using dry Nitrogen ({rom cylinders or plant sup- ply) and provide air supply as back up. Altematively, install an air drying system so that the dew point ‘temperature of the supply air is 20°F (-6"C) below the lowest expected room temperature for the loca- tion where the systems willbe installed, Check ar-drying systems at regular intervals as needed, to prevent saturation ofthe drying media and excessive humid air trom entering the system, + Keep low point drains clean and drain condensate as needed to prevent watar accumulation. + Fix air leaks to keep eystem as tight as possible. 2.3.1.4 Further mitigation in the form or cleaning ofthe piping or treatment ofthe water is not presently being recommended. However, n locations where these are being considered, follow the MIC Mitigation Guide- lines in Appendix C. 3.0 SUPPORT FOR RECOMMENDATIONS 3,4 Microbiologically Influenced Corrosion (MIC) ‘Over the past years an increasing number of leaks and other corrosion related problems have been assoc fated with microbial or bacterial activity in fre protection piping. Corrosion influenced by the action of bacteria Is a widely recognized phenomencn in the oll, nuclear, chem cal and sewage industy. This type of corrosion also occurs in domestic water systems. MIC is not a new corrosion mechanism: however, its association to fire protection piping is relatively new. Because ofits nature and the complexity offre protection piping, MIC is not easily controlled in fire protec tion systems. Until very recenty, except for pipe replacement, no other mitigation or treatment options were ‘avaliable that could be viably applied to fre protection systems. In the last few years, the emergence of new ‘22001 Factory Mutual Insurance Company. Al gh eseved2-1 Internal Corrosion in Automatic Sprinkler Systems Page 6 FM Global Property Loss Prevention Data Sheets alternatives In cleaning of pipe and a better understanding of treatment options have made MIC migation attempts possible. However, mitigation efforts in ire protection systems are sill evolving and remain largely ‘empirical at present witn no conclusive available feld data on their long-term success. Conversely, severe ‘cases of MIC left unchecked in sprinkler systems can progress over time leading to an increased number of leaks and possible obstruction of pipes and sprinkler heads. 3.1.1 What Is MIC? [MIC is one of the many forms of corrosion that can affect sprinkler systems. In MIC, the onset of corrosion Ccolls andlor the corrosion rate are influenced by the activity of diferent types of aerobic and anaerobic bac teria and microbes within the piping system. Some of the bacteria and microbes related to MIC include: SRB (Sulfate Reducing Bacteria), SOB (Sulfur Oxidizing Bacteria), APB (Acid Producing Bacteria), IRB (iron Reducing Bacteria), and LNB (Low Nutrient Bacteria). These types of bacteria are naturally occurring and ‘can be found in ground and surface waters: they also are found in soils, particles, oils and other sub- stances that can be present in the piping system prior to installation or that can be carried into the piping system by the local water supply, (MIC almost always occurs concurrently wth other corrosion mechanisms, and itis virtually impossible to sepa- rato them, This isin part due to the fact that microbes help create conditions under which other corrosion ‘mechanisms can occur, such as crevice corrosion, pitting, and under-deposit corrosion. However, there are ‘malor differences between the corrosion induced by bacteria and uniform corrosion within the piping sys- tems, Some of these diffarances are as follows: ‘+ MIC Is usually localized and damages plping through progressive piting corrosion. General corrosion usu- ally results from the oxidation of the Iron on the piping and doas not tend to be localized; the corrosion rate also will diminish once a layer of iron oxide (rust) is formed on the piping wall + MIC affects almost all types of metals, including black and galvanized steel, copper, stainless stee! and other steel alloys, with the possible exception of Titanlum. General corrosion usually Is associated with black stes! pipe. + MIC creates nodules and biofims, while general corrosion will develop scales within the piping ‘Once within the piping system, the bacteria and microbes tend to settle and attach themselves to preferen- tial regions within the pipe wall, such as small imperfections or crevices, The bacterla wil thrive only where nutrients and a favorable environment are available. Their activity in the inal stages Is typically localized within the piping system. Once established, the bacteria start reproducing and, very quickly create large colo- niles. A schematic of the development of MIC Is shown In Figure 2 below. ‘The feeding, or metabolic, cycle of the bacteria produces diferent by-products, such as acids, sulfates, blofims (slime) and nodules, depending on the type of bacteria involved. As these by-products accumula they foster conditions that make the growth of other types of bacteria possible, and influence the develop- ‘ment of localized corrosion celis on the pipe walls. Corrosion cells resulting from MIC are typically covered by nodules or by biofilm created by the metabolic bacterial process, Under a nodule, the pipe wall progres- sively deteriorates by pting or other corrosion processes, untl the wali finaly perforated and a pinhole leak evelops. ‘Athough there have been regions of the United States, such as the Phoenix, Arizona area, where a large num ber of MIC cases have been reported and documented, there is prasently no indication that MIC is confined to any specific geographical area, Reports of MIC have been received from throughout the United States ‘and also trom abroad, 3.1.2 How MIC Affacts Sprinkler Systems ‘MIC can affect any piping within the sprinkler system, however branchlines and risers seem to be more seriously affected, In branchiines, the prasence of alr gaps in wet systems or undrained water in dry pipe sys- tems is believed to be a contributing factor. This is shown on Figure 3. In risers, the higher exposure to ‘oxygenation compared to other parts of the system is believed to be a contributing factor. Piting corrosion is one of the most common MIC characteristics. This can happen throughout the system (see Figures 4 and 5), 22001 Factor Mutual surance Company All rts reservedInternal Corrosion in Automatic Sprinkler Systems FM Giobal Property Loss Prevention Data Sheets. 2-1 Page 7 Attachment Formation: of of Nodules Microbes, Initial and mature corrosion pit Cell Formation PIPE Pinhole / WALL leak Fig. 2. Schematic development of MIC, Fg 3. Conosion a roll groove. wet pipe systom ‘22001 Factory Mutual Insurance Company. Al gh eseved2-1 Internal Corrosion in Automatic Sprinkler Systems Page & FM Global Property Loss Prevention Data Sheets Fig. 4. Pinhole leak ste in cutaway section of pipe Given the nature of some of the aerobic bacteria, MIC generally results In the growth of blofims and nod- les within the piping. The biofim produced wll generally present itself as a black slime that, In certain cases, ‘can be flushed out, Nodules, on the other hand, are hard, well adhered to the pipe wall, and will not sh ‘out. Nodules and biofilm may result in increased fiction oss, and affect the abilty ofthe pipe to carry tha nec- ‘essary flow. Figures 6 and 7 show typical nodules and tubercles formation in a sprinkler pipe sample. In adcttion to the above, WIC also may affect sprinklers and valves, and block water motor gongs and alarm lines and other components ofa fire protection system, 3.1.3 Teltale Signs of MIC in Sprinkler Prping Pinhole leas, reduced flow capacity, nodules or slime deposits in pipes. sulfur ike smell, and other related Items are among the totale signs of MIC. Its important for these signs to be recognized and investigated. 3.1.4 Industry Position and NFPA Requirements MIC Is now an industry wide concer and has gained the attention of groups such as NACE (National ‘Association of Corrosion Engineers), NFPA (National Fire Protection Association), AFSA American Fire Sprin- ers Association) and the NFSA (National Fire Sprinkler Association). NFPA 13 Introduced new language in paragraph 9-1.5 of its year 2000 code. These provisions require that “in areas with water supplies known to have contibuted to MIC of sprinkler system piping, water supplies to be tested and appropriately treated prior to filing and testing of metallic pipe systems.” 3.2 Test Data For the period between 1994 and 2000, the FM Global Metallurgical Laboratory has examined approximately 1185 cases involving failed sprinkler system components. These rangad from pipes of several diameters, ‘materials and pipe schedules as well as other components such as fitings, sprinkler heads and valves. ‘22001 Factory Mutual Insurance Company. Al gh esevedInternal Corrosion in Automatic Sprinkler Systems 2-1 FM Global Properly Loss Prevention Data Sheets Page 9 Fig 9. Pinte leak site on outside surface. Evidence of MIC was present in about 40% of all te cases involving sprinkler system components. The data collected shows no indication that MIC is restricted to a particular geographical area, as MIC was evident in components sampled from different geographical areas within North America and abroad. Also, there is no ‘evidence that MIC |s restricted to certain types of pipes or sprinkler components. MIC was found in corro- sion cases involving both black steel pipe and galvanized pipe of ciferent pipe schedules as well as in cooper piping. MIC also has been found in some cases involving corrosion of sprinkler heads, flexible stee! hoses ‘and other sprinkler components. 3.3 FM Global UT Protocol for In-Situ Examination of Pipe Internal Corrosion Objective: Nondestructive in-situ investigation of both wet and dry pipe systems with the objective of iden- tifying potential sites within the piping systems with advanced pitting corrosion. Uttrasonic Thickness (UT) surveys of wat and cy pipe systems in-situ should be conducted in accordance withthe following protocol 41, Make Uttrasonic Thickness surveys of sprinkler piping systems with Ultrasonic (UT) Examination Systems that incorporate a cathode ray tube or similar display. ‘These UT instruments are regularly referred to as Flaw Detectors. They are designed to detect small flaws within a material. They are capable of displaying information from a reflector that enables an experienced ‘operator to judge the shape, depth, and size of the flaw, 2. Donot use UT thickness devices that display thickness measurements only as a digital numerical reading, ‘These instruments cannot be relied upon to detect and measure pits n a sprinkler pipe. Digital thickness ‘gauges that display only a numeric reading are suitable only for thickness surveys where there is an over- all thinning of the piping wall. Such overall thinning can be caused by erosion, or corrosion. However in the 22001 Factor Mutual surance Company All rts reserved2-1 Internal Corrosion in Automatic Sprinkler Systems Page 10 FM Global Property Loss Prevention Data Sheets Fig. 6. Localized nodule formation below water ine ‘case of corrosion in sprinkler pipes, the condition of the affected surface is more irregular, and usually Involves pitting, In sprinkler piping, corrosion pits are usually localized, and can sometimes be quite deep In relation to their diameter. The evidence of pts Is indicated by a numerical digital UT thickness gauge (if at al) as instabilty of the numerical read out. Because the UT beam is being reflected irregularly by the shape cof a pit, a numerical cigital thickness gauge does not receive a coherent reflection. In such cases, the read- ing by an experienced operator of such a device might stronaly suspect that a pit is being indicated. There {Is no information obtainable regarding the size, shape, or depth ofthe pit, unless it s quite large or large ‘areas of the surface are affected 3. Remove outside paint from the pipe prior to UT scanning, 4, Scan the entire circumference of the pipe in search for pits, with particular focus on the bottom of the plpe between three o'clock and nine o'clock postion. 5. Use any of the following modes of UT flaw detector display: A SCAN, B SCAN or C SCAN. Uttrasonic examination instruments with cathode ray tubes, and more recently developed digital screens, ‘can display the Information from a reflector In a variety of ways. Modes of UT Flaw Detector Display: + ASCAN ASCAN displays are the most commonly used with portable UT flaw detectors. Ultrasonic reflectors are dis- played on the rectangular screen as base line deflection spikes. The horizontal axis represents material thickness, and the vertical axis represents the amplitude of the reflected energy. Other controls and options ‘enable an operator to precisely locate end measure small flav. 22001 Factor Mutual surance Company All rts reservedFM Global Property Loss Prevention Data Sheets Page 11 Fa. 7. Heavy tubercle formation ina 8, (200 mm) sprinkler pipe. + BSCAN B SCAN displays ara becoming vary popular for monitoring thickness of tank and pressure vessal walls. ‘The rectangular screen displays a profile view of a walls thickness, and the shape and depth below the sur- face of a flaw. In tank and vessel examinations, ultrasonic reflection data from all points scanned are recorded ‘and usually stored electronically + CSCAN © SCAN displays data in a plan view. Images of pits would be displayed as round shadovrs on @ flat sur~ face, similar to a radiograph, ‘Any one of these flaw detector displays would be sufficiont for sprinkler pipe thickness survey/pit detection ‘examinations. 6. While using a flaw detector system to scan a section of piping, continuously monitor its relative thick ness and search for pits. Once pits are detected, stop and measure the pit depth, diameter and the ‘concentration of pits In a given area. Mark the location ofthe pit in the pipe with an indelible marker or paint 7. Prepare a final report with the results of the survey Indicating raglons of the pipe scanned: location and depth of the pits in the sprinkler plan. 22001 Factor Mutual surance Company All rts reserved2-1 Internal Corrosion in Automatic Sprinkler Systems Page 12 FM Global Property Loss Prevention Data Sheets 34 Loss History {A study of sprinkler leakage losses for the period between 1988 and 1997 shows corrosion as the fith larg- fest cause of sprinkler leakage losses by dollar loss, preceded by mechanical injury, freezing, defective ‘equipment and accidental discharge, While loss history has been favorable, it shaw internal corrosion of fire protection piping is a potential source of sprinkler leakage losses and a potential factor aggravating fre losses. 3.5 llustrative Losses 35.1 Sprinkler Leakage Due to Corrosion in Pipe Coupling ‘Abo fora 2 in. (50 mm) grooved pipe coupling rusted to the point that the 75 psi city water pressure caused the bolt to break. This resuited in wet down of 71 pallet loads of pharmaceutical products in a warehouse. ‘The suspected cause for the bolt rusting was a leak in the rubber seal onto the bolt for an extended period of time, 3.52 Pinhole Leaks From Sprinkler System Over Data Processing Center Pinhole leaks developed in a schedule 10 sprinkler piping system protecting a data processing center. The leaks damaged records and computer equipment. This location was not insured with FM Global 4.0 REFERENCES 4.4 FM Global Data Sheet 2-8N, installation of Sprinkler Systems. Data Sheet 2-81, Fire Safety Inspections and Sprinkler System Maintenance. 4.2 NFPA NFPA 13, installation of Sprinkler Systems NFPA 25, Standard for Inspection, Testing and Maintenance of Water-based Fire Protection Systems. APPENDIX A GLOSSARY OF TERMS. MIC: Microblologically Influenced Corrosion. XRD Analyses: X-Ray Detraction Analyses. APPENDIX B DOCUMENT REVISION HISTORY This document does not have any revision history. APPENDIX C ADVISORY GUIDELINES FOR MIC MITIGATION [MIC mitigation is complex. While different companies and! groups are presently undertaking considerable effort to come up with a solution for the problem, mitigation activities remain largely experimental. Proper diag- ‘nosis ofthe problem and a sound evaluation ofthe condition of the afected piping are key to the development cof @ mitigation plan with clear, attainable objectives. For the success of any mitigation activities It algo Is important to constantly monitor the conditions inside the pipe and take corrective action promptly. Factory Mutual Research Is actively Investigating possible detection, damage assessment and mitigation strategies. Research in this area is expected to produce some preliminary results within the next few years. Inthe interim, advisory prevention and mitigation guidelines are included in this appendix. These are intended {28 a source of guidance through the many steps of MIC prevention and control for those locations wish- Ing to pursue further mitigation than what Is recommended above. The goal of thase guidelines Is to help ‘such locations select technologies that will not cause further damage to sprinkler systems; they do not rep resent @ complete solution to MIC corrosion problems, Mitigation guidelines are divided into two distinct groups. The first group includes those activities intended to prevent MIC from developing in new sprinkler systems, particularly for those systems to be installed In areas 22001 Factor Mutual surance Company All rts reservedInternal Corrosion in Automatic Sprinkler Systems 2-1 FM Global Property Loss Prevention Data Sheets Page 13 where the water supply is known to be contaminated with MIC-causing bacteria and microbes. The second, {group includes those activities to help mitigate or control MIC In existing sprinkler systems that are sus- pect or known to have MiC-related problems. CA Mitigation Plan Al mitigation efforts should be under the direction of a registered professional engineer and performed in accordance with a detalled work plan addressing: + Complete dlagnosis of the corrosion problem, + Overall objectives of the mitigation effort + A.complete evaluation of the extent of corrosion damage to the piping, including identification of what sections of pipe will require replacement. + Adstalled description of the processes to be used to mitigate corrosion, identifying suppliers, chemicals and dosages to be used. + A detailed cleaning and treatment plan as outlined in this guideline, + Expected downtime ofthe sprinkler system, + Plans for periodic monitoring and expected results at monitoring intervals, + Environmental impact assessment of the proposed effort. + Periodic monitoring reports should be kept on file for review. €.2 MIC Prevention: Advice for New Sprinkler Systems New sprinkler systems offer a unique opportunty for cost-effective MIC prevention. Such measures also are in line with the requirements of NEPA 13, instalation of Sprinkler Systems, as discussed above. [MIC prevention should include some or all ofthe folowing steps: Step 1 ~ Diagnosis of the water supply. Stop 2 ~ Assessment of possible alternatives. ‘Step 3 ~ Treatment ofthe local water with disinfectants or biocides. ‘Step 4 — Installation of clean pipe and care during system acceptance. C.2.1 STEP 1 ~ Diagnosis of water supply ‘An analysis of the water will help determine whether there is a tendency for corrosion and whether there ‘re nutrients that can support the growth of bacteria, hence MIC. It also will help determine whether there are suficent residual disinfectants in the water supply or if additional disinfectants need to be added, and the type of bacteria that can be encountered in the system. ‘Conduct a chemical analysis of the water to determine how corrosive the water is and whether it can sup- por biological organisms. Important issues to identiy in a local water test are alkalinty (pH); suspended solids Cr turbclty, total organic carbon, chemicals, including sulfates and residual disinfectant for public water sys- tems. For untreated water it also Is important to determine whether SRB and IRB are present in the water ‘supply. Information about the local water condition should be obtained directly from the plant or from the contract- Ing sprinkier installer. Water authorities normally cary only information about the condition of the water as it leaves thelr treatment facillias but not necessarily about the condition of the water at the point of usa. Infor- ‘mation about the water condition at the point of use remains mostly in the private domain. In addition, test the local water supply to determine the types of MiC-causing bacteria present in the water sup- ply and in the supply piping at the point of connection to the plant. This test for MIC-causing bacteria is relatively simple and inexpensive, and can be accomplished by using portable MIC Test kts or by a quall fied testing laboratory ‘22001 Factory Mutual Insurance Company. Al gh eseved2-1 Internal Corrosion in Automatic Sprinkler Systems Page 14 FM Global Property Loss Prevention Data Sheets C22 STEP 2— Assessment of possible alternatives Based on the results of the water supply analysis investigate other possible costeffectve alternative sup- piles for one that Is superior. This could include wells, lakes and other reservoirs. Generally, the least ‘expensive way of providing water for fire protection is through a direct feed from the public fire main, since pub- lic fre mains typically carry enough pressure andior low to supply the fire protection system without the need for fire pumps and tanks. Ino superior water supply is available or feasible, consider providing continuous treatment to the water sup- ply with blocides (disinfectants) and corrosion inhibitors as described in Step 3 below, ©.23 STEP 3. Treatment of the local water with disinfectants or biocides ‘Water, as it enters the sprinkler system, should be treated with disinfectants (to kill or control the growth of MIC causing bacteria) and with other corrosion inhibitors. The treatment should be evaluated for its corro- sive properties, and a treatment plan should be developed in accordance with the FM Global guidelines given ‘below. All incoming water supply to the sprinkler system should be treated. ‘One of the challenging aspects of treating water to sprinkler systems is that sprinkler systems are typically rnon-recirculating systems. This makes it difficult for treatment chemicals to reach and maintain prescribed ccosages in all ppes within the system, ‘One of the biocides more commonly used in wet systems Is a weak solution of Chlorine (typically no more than 50 ppm), which is effective against MIC bacteria and can be obtained at relatively low cost. Chorine has ‘also been used in several MlC-infected sprinkler systems to date. Other blocides and disinfectant options exist When biocides are used in a sprinkler system, they may create cross-flow conditions, which require the instal- lation of a back-low preventer in the fire protection system. The treatment prescription, including the type ‘and dosage of blocidas should be formalized in the MIC Miigation Plan. ©.2.3.1 FM Global Guidelines for Treatment of the Local Water Supply Use these guidelines where a preventive or post-cleaning treatment plan for sprinkler system water is being considered, 1. Use only NSF (National Sanitary Foundation) approved, noncombustible, chemicals (biocides, disinfec- tants, corrosion Inhibitor or passivating agents). 2. Independent laboratory test data should be provided confirming that the prescribed dosage is effective ‘against the types of MiC-causing bacteria found in the water supply. 3. Plan should address general corrosion of the piping. 4, Delivery devices used to add treatment chemicals to sprinkler systems should be automatic and capable Cf delivering the prescribed maintenance dosage based upon flow in the system. Delivery devices should bbe arranged to sound an alarm In case of trouble or fallure, such as low tank. Devices should be provided with an indicator giving the biocide concentration being delivered, 5. Field test data should be provided showing that with the intended delivery devices the prescribed dosage {is met atthe inspector’ test connection. 6. Data should be provided showing that the type and dosage ofthe selected treatment chemicals is not dam- ‘aging to any of the materials present in piping, valves. or sprinkler watarways, including any elastomeric products used in sprinkler piping. such as those used in gaskets, o-ings, valve seats. 7. Plan should include treatment ofall incoming water to fire protection sprinkler systems. When conduct ing an inspector test, allow enough water flow until biocide is coming out at the other end. & The application rate of the treatment chemicals should be enough to promote the desired concentration throughout the system and to compensate for any decay of biocide concentration overtime, anywhere within the system. ‘8. Treatment plan should identity all necessary periodic monitoring and tests to be conducted 4s well as corrective measures during the life of the system, 22001 Factor Mutual surance Company All rts reservedInternal Corrosion in Automatic Sprinkler Systems 2-1 FM Global Property Loss Prevention Data Sheets Page 18 10. Plan should identity what measures should be taken when system Is flooded with untreated water after fa fre or accidental trp, 11,_ Records detaling the treatment agents, concentration, injection process for the inal treatment as well 28 for all parodic monitoring should be kept on fle and on a summary record sheet displayed on the riser cf each system undergoing water treatment. 0.24 STEP 4— Installation of clean pipe and care during system acceptance ‘The last step in MIC prevention for new sprinkler systems is to ensure that al piping installed is disinfected, ‘and that proper hydrostatic test procedures are used. This step should be taken to minimize the possibilty that bacteria or microbes are present in the new piping to be insted or are Introduced into the systam accl- ertally during hydrostatic test or other acceptance procedure. Regardless of the condition of the water supply, all piping to be installed should comply with recommenda- tion 2.3.1.1 above. Piping that is rusted or weathered should not be installed. \Where the water supply Is treated, all hydrostatic tests and other acceptance test procedures should be done using treated water in accordance with the guidelines established in Step 3 above. €.3 MIC Control: Advice for Existing Sprinkler Systems ‘Mitigation of MIC In existing sprinkler systems can be complex and costly, Because nodules, tubercles and ‘other deposits on the internal surfaces ofthe pipe can shield microbial colonies and corrosion cells, biocide treatment of the incoming water alone may net suffice to control MIC. Therefore, before treatment is applied to the water, the piping should be thoroughly cleaned. Cleaning of pipe should be aimed at removing all epostts to bare metal ‘Cleaning existing pipe to bare metal can be challenging depending on the amount and type of deposits. Where Cony partial or non-uniform cieaning of the pipe can be achieved, microbes can re-colonize in the pipe trom these partially cleaned areas, Subsequent water treatment to partially clezned pipe may be able to con- trol the bacteria count, Keeping the corrosion in check and helping extend the Ie ofthe piping system. Mitigation activities in existing sprinkler systems should include one or all ofthe following steps: ‘Step 1 ~ Diagnosis of the corrosion and of the condition of the piping. Step 2 — Assessment of possible alternatives. Step 3 ~ Cleaning of piping Step 4 - Treatment of the local water with disinfectants and biocides, Step 5 — Recharging of the system and acceptance, ©.3.1 STEP 4 ~ Diagnosis of the corrosion and of the condition of the piping ‘The fist step involves determining the nature of corrosion in the ping and conducting a corrosion dam- age assessment of the piping to determine extent of corrosion damage and feasibly of further treatment. Diagnosis of the corrosion should be conducted per recommendation 2.2.1 above. Preferably, piping should 'be sent in for metallurgical examination in the "as removed” condition, without any cleaning or removal of Intermal deposits or substances, so that a metallurgical lab can analyze the nature of the residuals found in the piping. ‘Assasement of the condition of remaining piping should be conducted per recommendation 2.2.2 above. ‘Any sactions of piping that are damaged o that do not meet the criteria given in Table 1 should be replaced prior to cleaning. Remaining piping should then be cleaned as outlined in Step 3 below. 22001 Factor Mutual surance Company All rts reserved2-1 Internal Corrosion in Automatic Sprinkler Systems Page 16 FM Global Property Loss Prevention Data Sheets C32 STEP 2— Assessment of possible alternatives ‘Similar to what is done with new sprinkler systems, it is important to determine to what extent an existing ‘sprinkler system Is exposed fo MIC. Information about the local water condition should be obtained directly {rom the plant or from the contracting sprinkler installer. Water authorties normally provide only informa: tion about the concition of the water as itleaves thelr treatment facilities but not necessarily about he condition Cf the water atthe point of use. Information about the water condition atthe point of use remains mostly in the private domain, In most cases, however, the condition ofthe local water supply with respect to MIC is not known by plant per ‘sonnel orby the installing contractor. In those cases, the local water supply should be tested for the presence cof MiC-causing bacteria, This testis relatively simple and inexpensive, and can be accomplishad by using portable MIC test kits or by a qualified testing laboratory. It the local water supply Is free of MIC-causing bacteria, then it could be used in the existing system. If the local water supply is determined to carry the MIC-causing bacteria, then it may become necessary to explore ‘one or more of the following options: ‘Option 1 - Investigate other possible cost-effective alternative supplies for one that is free of MIC-causing bac- teria and microbes. This could include wells, lakes and other reservoirs. Normally, the least expensive way Cf providing water for fre protection Is through a direct feed from the public fre main, This Is because pub- lic fire mains normally carry enough pressure and/or low to supaly the fre protection system without the need {or fre pumps and tanks, For most sprinkler systems, public water supplies can be used directly or in con- Junction with easter pumps to Increase supply pressure to meet the demand of a fre protection system, Puble water supply systems also may require the installation of a back-fow-preventer to eliminate cross connec- tion problems. As other alternative supplies are explored, the cost of providing water for fire protection may Increase. The increased cost may be offset by the additional costs for the continuous treatment necessary {or a supply that is known to carry MlC-causing bacteria. ‘Option 2 - Provide continuous treatment to the water supply with biocides o disinfectants to eliminate or con- trol the growth of the MlC-causing bacteria, as outined above for new systems. C33 STEP 3~ Cleaning of piping Cleaning may become a key step in mitigating MIC in existing sprinkler eystoms. Cleaning should be done so that all internal surfaces within the piping are cleaned to bare metal. Advances in chemical clean- Ing methods have now made it possible for piping to be cleaned in place. The folowing guidelines should apply to-any cleaning method ©.3.3.1 FM Global Guidelines for Cleaning of Sprinkler Piping 1. Awritten cleaning pian should be developed identifying + how cleaning will be conducted, which methods, chemicals or other cleaning agents will be used, {an outline of the process and the process sequence, the concentration of any chemicals to be used, ‘the duration of the cleaning process, disposal of cleaning solutions. 2. Acleaning test should be conducted in at least three sections of pipe, removed respectively from the ‘ser, a mic-system branchiine including a riser nipple for a sprinkler and inspector test connection. Al plp- Ing should be sampled from the actual sprinkler system to undargo cleaning, ‘3. Metallurgical examination should be conducted on all sample piping subjected to the cleaning test to ‘assess the extent and uniformity of cleaning, the Internal condition of the piping with respect to corrosion dam- ‘age including the depth ofthe piting and the lass of piping wall during the cleaning process. Wall thickness prior to testing should be benchmarked by UT or equivalent testing, Results of the analysis should be Included as part of the cleaning plan, 4, Ail sprinkler heads should be removed from the system prior to cleaning. Cleaning agents or solutions ‘should be circulated through all riser nipples and drops to sprinklers. Used sprinkler heads should not be rein- stalled in the system, 22001 Factor Mutual surance Company All rts reservedInternal Corrosion in Automatic Sprinkler Systems 2-1 FM Global Property Loss Prevention Data Sheets Page 17 ‘5. Cleaning agents should circulate throughout the system to promote complete cleaning of all piping, Includ- ing all branchiines, pipe drops and sprig-ups, all isers, feedmains and crossmains. 6. After cleaning, metallurgical examination should be conducted on at least three more samples of piping remaved from the riser, mid-branchlines and inspector test connection. This examination should determine the ‘extent and uniformity of cleaning performed. 7. Chemical cleaning solutions should be NSF epproved. 8. Cleaning agents should not result in damage to any of the metals present in sprinkler piping or damage tonatural or synthetic rubber, silcone, or any other elastomeric products used in gaskets, valve seats, o-rings ‘and other nonmetallic parts in a sprinkler system. ‘8. No rasidual cleaning agents or solutions should be left in the system after cleaning, 410. Any cleaning should be immediately folowed by a treatment of the water. The treatment plan should bbe In accordance with FM Global Guidelines for Water Treatment for Sprinkler systems, given above. 0.3.4 STEP 4 Treatment of local water with disinfectants and biocides Al systems undergoing cleaning should be treated afterward. Cleaning wll leave exposed fresh metal with ‘open pits. If treatment is not provided promptly and continuously these exposed surfaces will rapidly cor- rode. Hence, iis equally important for the treatment plan to address the MIC problem as well as general and piling corrosion within the exposed tresh pipe. Treatment plan should follow the FIM Global Guidelines for Treatment of the Local Water Supply. C.3.5 STEP 5— Recharging of the system and acceptance ‘The last step in MIC mitigation is to ensure that existing system piping Is recharged properly. Proper hydrostatic test procedures should be used any time sections of piping have been replaced and after clean- Ing. In order to minimize the possiblity thet bacteria or microbes are reintroduced into the new piping during hydrostatic testing, this test should be conducted using properly treated water. ‘system should be recharged with water that has been treated following the guidelines established above. Past experience has shown that after cleaning is completed some pinhole leaks were encountered in the pip- ing. This is because the cleaning process is micly corrosive or abrasive and can open up pits. Leaking pipe should be replaced. If treatment is effective, pinhole leaks should stop after a few weeks. C4 Some Currently Available Mitigation Tools Ths section aiscusses some of the currently available MIC technologies in the United States. The intent of this section is to provide information and general comments about technologies available Reference to a particular technology does not represent FIM Global or Factory Mutual Research endorse- iment of a particular company, procedure or technology. 04.1 MIC Test Kits MIC Test kits and portabie kits can be used to test the local water for MIC bacteria. These kits Include @ ‘number of small vals with the nutrient for the diferent bacteria being tested. With a pipete or syringe, a water ‘sample is collected from the sprinkler system injected into the diferent vials. After an incubation period of sev- feral days, resuits on the type and count of bactaria are raad clractly from the vials, by the change in color of the diferent vials. MMIC test kits should not be raliad on as the sole source of diagnosis for MIC, but as just one of the informa tion components of the diagnosis. The kits also should not be used as the sole means of monitoring the effectiveness of mitigation measures in the field (©.42 Chemical Treatment Automatic Delivery Systems ‘These are new products intended to automatically deliver water treatment solution to a sprinkler system, Delivery systems consist of a reservoir where the chemicals are Kept, a small injection pump that starts auto ‘matically when there is water flow in the system and an alarm to indicate trouble with the unit. Chemical delivery systems are typically fixed systems permanently connected to the riser. The system wll deliver the 22001 Factor Mutual surance Company All rts reserved2-1 Internal Corrosion in Automatic Sprinkler Systems Page 18 FM Global Property Loss Prevention Data Sheets prescribed dosage of treatment solution to the system automatically upon flow in the system. The cost of these delivery systems varies but should be in the range of US $3,500 for well-equipped delivery systems. uninstalled Fig 8 MIC lst kt and auton ovary system — courtesy of Bio Indust Technologies Inc 22001 Factor Mutual surance Company All rts reservedInternal Corrosion in Automatic Sprinkler Systems 2-1 FM Global Property Loss Prevention Data Sheets Page 18 C43 Chemical Cleaning of Pipe Chemical cleaning is aimed at removing build-up end cortesion scale from the inside walls of the pipe. The process involves the circulation within the plping of chemical solutions at prescribed concentrations, It Tequires establishing a temporary re-rculation loop between the chemical supply unit and the sprinkler sys- tem. Typicaly a sprinkler system can be clean in one day. The riser as well a the end of branchiines {and sprinkler head outlets needs to be tapped so that re-ceultion hoses can be connected to system. The cost of the procedure varies according to werk schedules, cccupancy types, quantity and type of system, ‘22001 Factory Mutual Insurance Company. Al gh eseved