Leading Litho Plant Repeats Use of CPVC Piping to Reduce Maintenance Costs and Downtime
Past Performance of Corzan® CPVC System Proves Claims of Durability and Cost-Effective Service Life
In 2005 and again in 2006 when a Colorado-based litho plant decided to modify its two aluminum substrate manufacturing lines to increase capacity, there was only one piping material considered by the engineering design team – Corzan® CPVC. That’s because the high-performance material had already proven it could provide an extended service life, improved process utilization and lower life-cycle costs. It had been doing so since 1992 when it was first used on a new fluid handling line at the manufacturing center used for medical x-ray film, photographic papers and aluminum lithographic printing plates.
Nearly 15 years later, that CPVC line is still fully operational, providing the necessary corrosion resistance and mechanical strength necessary to effectively handle the harsh chemicals being pumped under pressures up to 80 psi at temperatures up to 180¢ªF without leaks. The chemicals include a caustic etching solution, 30% nitric acid, 50% sodium hydroxide, 94% sulfuric acid, and 30% hydrochloric acid.
With such aggressive chemicals flowing, management felt it couldn’t afford failures of any kind. There was, however, no need to conduct another materials study, because the manufacturer knew that the Corzan system had previously helped it increase the level
of quality control in its fluid handling system which resulted in maximized plant efficiencies, increased worker safety and higher level environmental protection.
The new $3 million line modifications and addition are designed to help the company increase its overall flow capacity. An older line with larger pumps required upgrading to match the operating capacity of the plant’s other lines. With the enhancement and addition, the company can now make the same products on this new line that it does in other parts of the plant.
Like many manufacturing plants, this litho plate plant strives for continuous production. Downtime due to maintenance issues is costly. In addition to cost issues, leaks in the system can jeopardize worker safety and environmental compliance.
The Corzan CPVC line that was installed in 1992 is still in place and functioning without any problems. Even more important from a productivity standpoint was that when modifications were needed, they were made quickly as a result of the fast, easy installation process used with CPVC piping. In fact, once the system is drained and the change made, the line can be up and running in a maximum of 24 hours.
The CPVC system has proven so effective, in fact, that it is the only piping material specified throughout the plant since the early 1990s. This was partially a result of the maintenance department’s desire to minimize any confusion or error. In plants piped with different materials, the chance of worker error in replacing an incompatible pipe or fitting component is great. With these aggressive chemicals, companies can’t afford the mistake of installing PVC where CPVC is required for temperature properties.
More specific than just CPVC, the company specifies only Corzan CPVC, because of its confidence in Lubrizol, the company that manufactures the CPVC used in the Corzan pipe and fittings, and its ability to handle all of the required testing for its customers.
Lubrizol also features a Quality Assurance Program, which requires Corzan pipe manufacturers to perform rigorous tests on their finished product. These tests are stricter than the required national standards to ensure consistent quality and long-term performance. In addition, Lubrizol creates all the base compounds for the Corzan CPVC components, providing uniform properties throughout the system. This permits engineers to design a system around a consistent property profile.
Criteria for Originally Choosing CPVC
Back in the 1990s, the Colorado litho plant conducted a comprehensive materials study in order to choose a preferred piping material for its new plate manufacturing facility. The company opted to specify a single piping material throughout the entire plant for design efficiency and to minimize maintenance costs. The chosen material needed to meet the plant’s high quality standards and safely handle the aggressive chemicals used in the plate etching process at high temperatures.
Prior to the 1990s, the plant had been using PVC pipe for its fluid handling system.
Metallic pipe was not considered because of the harsh chemicals and the likelihood of corrosion. Not only would the pipe not hold up, but there were concerns that the corrosive chemicals in the air would break down the insulation that’s required around metallic pipe.
Other materials, including polypropylene, had been tried but found to be difficult and costly to maintain, because they required expensive equipment and certified welders on the job.
The PVC pipe previously used solved two problems presented by metallic pipe – it didn’t corrode, and as a thermoplastic which does not transfer heat, it did not require insulation. However, over time, even the PVC pipe had proved inadequate for the harsh demands of this application– even at lower temperatures.
So in 1992, a new fluid handling line, comprised exclusively of Corzan CPVC, was installed in iron pipe sizes from 1” (25mm) up to 12” (300mm), including a wide variety of piping, fittings and valves.
For this demanding application, Corzan CPVC proved to be the best, most effective choice – back in the 1990s, as well as today.