NASA SP-5076
CONTAMINATION CONTROL
HANDBOOK
Prepared by Sandia Laboratories under NASA Order Number H-13245A
for Marshall Space Flight Center
Technology Utilization Diuisiolz OFFICE OF TECHNOLOGY UTILIZATION 1969 NATIONAL AERONAUTICS AND SPACE ADMINISTRATION
lVashington, D. C.
For sale by the Clearinghouse for Federal Scientific and Technical Information
Springfield, Virginia 22151 - Price $3.00
FOREWORD
Rigid control of contamination has contributed to the reliability and precision of vehicles and instruments sent out to explore space. Experience gained in the aerospace community also can be helpful in the pharmaceutical, electronic, and many other indus- tries in which extreme cleanliness is important. This is one of three Special Publi- cations issued by the NASA Office of Technology Utilization to help extend and diffuse current concepts and techniques of rigorous contamination control.
The first of these documents, Contamination Control Principles, SP-5045, was issued in 1967 when a NASA Contamination Control Panel called attention to the wide- spread need for guideline information. The George C . Marshall Space Flight Center, the Manned Spacecraft Center, and the John F . Kennedy Space Center were represented on that panel by, respectively, Frederick J. Beyerle, Quintin T . Ussery., and Dr. John Gayle . Since then a number of special courses for technicians and supervisors employed in clean rooms have been given, and the lectures prepared by James W . Useller for one of those courses at the Lewis Research Center have been published in Clean Room Technology, SP-5074.
This handbook deals in more detail with many of the same matters discussed in SP-5045 and SP-5074. It was prepared for the George C . Marshall Space Flight Center under the direction of H. D . Sivinski, Manager of the Planetary Quarantine Department at the Sandia Laboratories and one of the authors of Contamination Control Principles. He was assisted in this work by a team that included D . M. Garst, K . F . Lindell,
\ W . J. Whitfield, and J . A. Paulhamus and their associates at the Sandia Laboratories; Dr. John Beakley and L . Hughes of the University of New Mexico, and Mrs. Dorothee Drury, technical editor.
The authors’ purpose was to assemble in one volume the information and data most -- likely to be of practical help to persons engaged in contamination control in industrial and related operations. Although commercial names have been used, mention of them does not constitute endorsement by the authors or any Government agency. The group respon- sible for this work drew on many sources of information and has included matters about which there may still be controversy, but the information presented has been verified to the extent believed practical.
Ronald J . Philips, Director Technology Utilization Division Office of Technology Utilization
. . . 111
SECTION
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
CONTAMINATION CONTROL HANDBOOK
INDEX
INTRODUCTION TO CONTAMINATION CONTROL
CONTAMINATION CONTROL IN PRODUCT DESIGN
CONTROL OF SURFACE CONTAMINATION
CONTAMINATION CONTROL IN GASES AND LIQUIDS
CONTROL OF AIRBORNE CONTAMINATION
,- MICROBIAL CONTAMINATION AND ITS CONTROL
RADIATION
CLEAN PACKAGING
MAINTAINING PRODUCT CLEANLINESS
PERSONNEL
GLOSSARY
ACKNOWLEDGMENTS
NOTICE COMMERCIAL NAMES AS USED HEREIN ARE FOR IDENTIFICATION ONLY AND THEIR MENTION DOES NOT CONSTITUTE ENDORSEMENT BY THE AUTHORS OR ANY GOVERNMENT AGENCY.
V
TABLE OF CONTENTS
SECTION 1. - INTRODUCTION TO CONTAMINATION CONTROL
1.1 Contaminants
1.2 Environments
Critical Environment General Environment
1.3 The Origin of Contamination - Sources and Types
1.4 The Mechanisms of Contamination Migration -6
1.5 The Mechanisms of Contamination Retention -6
Gravity Electrostatic Charges Molecular Attraction Viscous Surface Coatings Physical Entrapment
1.6 Bibliography I-7
SECTION 2. - CONTAMINATION CONTROL IN PRODUCT DESIGN
2 .l Control of Contaminants Through Product Design
2.2 Performance Levels
2.3 Bibliography II-8
SECTION 3. - CONTROL OF SURFACE CONTAMINATION III-1
3 .i Cleaning of Surfaces -2
Wetting Surface Tens ion Emulsification Saponification Deflocculation Solvent Activity Organic Solvents pH and its Control Buffer Activity’ Alkalinity and Acidity Hard Versus Soft Water Object of Surface Cleaning Soils and Cleaning Methods
Page I-l
-3
-5
-5 -5
-5
-7 -7 -7 -7 -7
II-1
-1
-8
-2 -2 -3 -3 -3 -4 -4 -5 -6 -6 -7 -7
III-7 vii
Page
Generator Transducers Electronic Components Ultrasonic Cleaning Efficiency Hazards
Drying Methods Displacement Drying
3.4.4
3.5 Cleaning Agents
3.5 .l 3.5.2 3.5.3 3.5.4 3.5.5 3.5.6 3.5.7 3.5.8 3.5.9 3.5.9 .l 3.5.9.2
Kauri-Butanol Values Properties and Characteristics Effects on Materials of Construction Effects on Soils Cleaning Agents and Compatible Cleaning Methods Aqueous Cleaning Solutions Solvent Reclamation and Purity Handling and Storage Hazards and Cautions General Cleaning Agent Safety Rules First Aid and Treatment
3.6 Verification of Surface Cleanliness
3.6 .l Classification of Surface Cleanliness Tests 3.6.2 ASTM Test Methods
3.7 Bibliography
SECTION 4. - CONTAMINATION CONTROL IN GASES AND LIQUIDS
4 .I Contaminants in Gases
4 .l.l Description of Gases 4 -1.2 Purity Levels and Grades 4 .1.3 Gas Systems 4 .1.4 Specifications and Analysis of Gases 4 .1.5 Safe Handling of Compressed Gases
4.2 Contaminants in Liquids
4.2 .l Hydraulic Systems
4.2.2 4.2.3
Design Considerations for a Hydraulic Filtration System
Design Considerations for a Cleanable Hydraulic System
Liquid Filtration Contaminant Measurement Methods
Analysis of Contaminants in Liquids Removal of Contaminants from Liquids
Distillation
4.3 Bibliography IV-31
III-52 -54 -54 -54 -60 -60 -62
-62
-63 -64 -65 -65 -65 -101 -101 -102 -103 -110 -111
-111
-112 III-113
IV-l
-1
-2 -2 -7 -10 -14
-15
-17
-17
-17 -19 -20 -20 -26 -28 -28 -28 -28 -30
ix
Page
SECTION 5. - CONTROL OF AIRBORNE CONTAMINATION V-l
Air Supply -1
Activities Within the Controlled Area -3 The Agglomeration Characteristics of Particulate Matter -4
The Sizes of Airborne Particulates -4
5 .l Atmospheric Air Contamination -4
5.2 Classification and Sources of Airborne Contaminants -6
5.2 .l Contaminant Classification -6 5.2.2 Contaminant Sources -8
Petroleum Industry -8 Metallurgical Industry j -8 Organic Solvent Usage -8 Mineral Processing -9 Motor Vehicles -9 Combustion Processes -9 Other Industry -10 ‘. Natural Environment -10
5.3 Control Techniques for Atmospheric Air Contaminants -10
5;3.1 Air-Pollution Control Devices -13 Aerosols -13 Gases -13
5.3.2 Detecting and Measuring Atmospheric Air Contaminants -14
5.4
Methods Applied to Particulates Methods Applied to Gases
5.3.3 Air-Supply Conditioning
Air Filters for Contamination Control Facilities
-21 -21 -21
-28
5‘.4 .I
5.4.2
Weight Test (Synthetic Dust) -29 Discoloration Test (National Bureau of Standards) -29 DOP Test -29
Types of Air Filters -30 Industrial Filters -30 Ventilation Filters -30 Intermediate Efficiency Filters -30 High-Efficiency Particulate Air (HEPA) Filters -31
Selecting Air Filters -31 High-Efficiency Particulate Air (HEPA) Filters -32
5.5 Nonlaminar Airflow Facilities
5.5,1 Nonlaminar Airflow Rooms 5.5.2 Nonlaminar Airflow Work Stations 5.5.3 Fume Hoods
Conventional Hood Streamlined Entrance Hood @pass Hood Balanced or Compensating Hood
x
-34
-37 -38 -39 -39 -39 -39
v-39
Page
5.6
5.7
5.8
5.9
5 .lO
5 .ll
5.12
Laminar Airflow Facilities v-41
5.6.1 Vertical Laminar Airflow (VLF) Rooms -43 5.6.2 Vertical Laminar Airflow (VLF) Portable Curtain Units -46
5 -6.3 Vertical Laminar Airflow (VLF) Work Stations (Benches -47
5.6.4 Horizontal Laminar Airflow (HLF) Rooms -48
5.6.5 Horizontal Laminar Airflow (HLF) Tunnel -50 5.6.6 Horizontal Laminar Airflow (HLF) Work Stations (Benches) -51
5.6.7 Balanced Laminar Airflow Hood -54
Temperature and Humidity in Clean Room Facilities -56
5.7.1 Temperature 5.7.2 Temperature Monitoring 5.7.3 Humidity 5.7.4 Humidity Monitoring
Clean Room Construction Features
5.8 .l Construction Materials 5.8.2 Walls, Ceilings, and Floors 5.8.3 Plenums and Ducting 5.8.4 Airlocks, Doors, and Pass -Thronghs 5.8.5 Anterooms
Clean Room Furniture and Equipment
-56 -57 -57 -57
-57
-58 -58 3
-59 -59 -60
-60
5.9.1 Chairs or Stools -60 5.9.2 Benches and Work Surfaces -60 5.9.3 Equipment -61
Clean Room Garments -61
5 .lO .l Fabrics 5 .10.2 Garment Construction 5 .lO .3 Soiling and Laundering
Monitoring
Gases Aerosols Combinations or Mixtures of Gases and Aerosols
5.11.1 Air Sampling and Collection Methods Grab Sample Continuous Sample
5 .11.2 Analytical Methods and Instrumentation 5 .11.3 Filter and Filter Bank Testing 5 -11.4 Nonlaminar Airflow Facilities 5.11.5 Laminar Airflow Facilities
Specifications for Laminar Airflow Clean Rooms
5.12 .l General Specification Guidelines Dimensions and Location Type of Room Room Occupancy Operations and Equipment Portability Electrical Power Load
-61 -62 -63
-63
-63 -63 -63 -65 -65 -65 -67 -72 -78 -80
-83
-84 -84 -84 -84 -85 -85 -85
xi
5.12.2 Performance Requirements
5.12.3
, 5.12.4 5.12.5
5.12.6
5.X2.7
5.13 Bibliography v-95
Air-Cleanliness Class Airflow Temperature Humidity Lighting Noise and Vibration
Design and Construction Requirements General Requirements Walls Ceiling - Vertical Laminar Airflow Ceiling - Horizontal Laminar Airflow Ceiling - Perforated Floor - Perforated or Grating Floor - Solid Plenum - Air Supply Plenum - Exhaust Air Ducts Doors
Equipment Requirements Electrical Requirements
Distribution Points Wiring Wire Types and Sizes Conduit Systems Lighting - Fluorescent Motor Controls Electric Motors Switches
Air Filtration and Control System Rough or Ventilation Filters Prefilters Final Filter - High Efficiency Particulate
Filter (HEPA) Clean Room Filter Bank Pressure Gage
Flex-Tube Manometer Inclined-Tube Air-Filter Gage Magnehelic Pressure Gage
Air Conditioning Applicable Standards
Yage
V-85 -85 -85 -86 -86 -86 -86 -86 -86 -87 -87 -88 -88 -88 -88 -88 -88 -89 -89 -89 -90 -90 -90 -90 -90 -91 -91 -92 -92 -92 -92 -92
-92 -93 -94 -94 -94 -94 -94
xii
Page
SECTION 6. - MICROBIAL CONTAMINATION AND ITS CONTROL VI- 1
6 .l Characteristics of Microbial Contamination -3
6.1.1 Physical -3
6 .1.2 Metabolic or Nutritional Types -6
6.1.3 Microbial Flora of Selected Environments -10
Clean Rooms -10
Various Body Areas -10
Jet Fuel -13
Microbes in the Earth’s Atmosphere -16
6.2 Control of Microbial Contamination -16
Before Treatment Actual Treatment Recovery
-18 -18 -18
6.2.1 Deactivation -18
Heat -18
Chemical -20
Radiation -29
6.2.2 Removal -32
6.2.3 Isolation -32
6.3 Monitoring Methods for Microbial Contamination -33
6.3.1 Air and Gases -34
6.3.2 Liquids -36
6.3.3 Solids -36
6.3.4 Surfaces -36
6.4 Bibliography VI-37
SECTION 7. - RADIATION VII-1
7 .l Radiation as a Contaminant -1
7.2 Control of Radiation Contamination -2
7 -3 Radiation Monitoring -2
Light,. X-ray, Infrared -2
Particles (Alpha Particles, Electrons, etc .) -3
Sound and Vibration -3
7.4 Bibliography VII-4
. . . x111
SECTION 8. - CLEAN PACKAGING VIII- 1
8.1 Preparation for Clean Packaging -2
8 .l.l Determination of Cleanliness Levels 8.1.2 Preparing the Item to be Packaged 8.1.3 Selecting or Preparing the Packaging Material 8.1.4 Packaging Facilities, Equipment, and Personnel
-2 -3 -3 -4
8 .2 Packaging Materials -4
8.2 .l
8.2.2
8.2.3
8.2.4
Barrier Materials Structural Type Package Application
Ancillary Materials and Accessories for Clean Packaging Tape, Adhesive-Backed Ribbons and Ties (Nonadhesive) Identification Labels and Tags Desiccants and Humidity Indicators Purging Gases Integrity Seals Intermediate Package Material
Characteristics and Properties Strength Permeability Formability Resistance to Oil and Grease Temperature Range Sealability Transparency Cleanability Sloughing or Shedding Static Charge Flammability Interaction with Hazardous Materials
Evaluation of Plastic Films Polyethylene Polyamide (Nylon 6) Fluorohalocarbon (Aclar) Polyester (Mylar) Aluminum Foil
\ Composite Films
8.3 Closure and Packaging Methods
8.3 .l Intimate Cushioning Taping the Cushioning to the Item Taping Only Over thecushioning Tying the Cushioning to the Item
-5 -5 -6 -7 -7 -7 -7 -7 -8 -8 -8 -8 -8 -8 -8 -8 -8 -9 -9 -9 -9 -9 -11 -11 -11 -11 -12 -13 -13 -13 -18
-18
Material
-19 -19 ~ -19
VIII-20
xiv
