1. Paint Circulation Technology Level 2 - Training Document
Subject Matter Expert: Miguel Bahena

2. What Is A Paint Circulating System
A pressurized vessel used to transport material to various locations. More efficient then manual moving material to individual locations.

3. Sounds simple doesn’t it?
What Are We Doing?
Moving material from point A to point B.
Supply material fluid pressure.
Supply material fluid flow.
Maintain material integrity.
That is all we do!
Sounds simple doesn’t it?

4. What Are We Doing?
Point A
Point B

5. PAINT MIX ROOM Typical paint mix room
The martial that is used for painting the vehicles is a solvent borne material which is extremely flammable. The paint is stored and pumped from a paint mix room.
MIX ROOMS ARE CLASS 1 DIVISION 1 AREAS – NO ELECTRIC ITEMS ARE ALLOWED IN THIS ROOM INCLUDING – (CELL PHONES, FLASH LIGHTS, RADIOS, ETC). UNLESS APPROVED BY FORD SAFETY
Tote storage rack
Tote stand for loading material
Bulk Storage Tank for Solvent and Waste
Typical circulation
system
Typical paint mix room

6. Typical Paint Circulation System Components
Transfer Pump
Surge Chamber
Day Tank
BPR
Pump
Supply Line
Tote Tank
Return Line
Booth
Drops
Heat Exchanger

7. PAINT CIRCULATION HEADER Typical paint circulation header
The paint is pumped from the paint circulation module to the spray booths in what is called a header system. The headers system is constructed from stainless steel pipe/tubing and delivers paint to each robot or manual spray station.
At each robot or manual station, a line tee’s off the header to feed this station. This is called a drop/paint station.
Typical paint circulation header

8. PAINT HEATEXCHAGNER SYSTEM
The paint must be applied to the vehicle at the correct temperature. A paint heat exchanger system is used to maintain a temperature of +/- 2 degrees F
Tube and shell heat exchanger
Water supply and return lines
Water conditioning skid

9. WASTE COLLECTION SYSTEM
Each time the robot or manual station changes color a certain amount of waste is generated. This waste is collected at the paint booth in a waste collection system.
Special Waste Collection Funnel Under Cap Cleaner to Flush Drop Legs and Prevent Debris from Entering Waste Header
Recirculation of the header and drop legs are very important
Gravity Waste Header Fabricated from 2” S.S. Tubing Utilizing Sanitary Fittings for Smooth ID and Ease of Maintenance. Line Installed at ¼” – 3/8” per foot to maintain proper drain velocity
Ball Valves Added to Header to Have the Ability to Power Flush Header for Preventative Maintenance
Purge Solvent Piped to Tank so Virgin Solvent Can be Added for Cleaning. A Catalyst Stop can be Substituted to Prevent the Catalyst from Curing (paint supplier can recommend material)
Special Cage Inside Tank to Capture 2K Waste Debris From Clogging Pumps
Utilize (1) Pump for Recirculation and (1) Pump for Empting of the Tank
Note: Containment Pan Not Shown

10. Supply Material Fluid Pressure?
Generally between PSI at the drop and PSI at the point of atomization.

11. Supply Material Fluid Pressure?
Circulating systems must provide minimum required fluid pressure at all drops.
As material flows through piping friction causes a “pressure loss”. This pressure loss must be calculated in order to ensure the last drop meets the minimum pressure requirement.
Pressure calculations are done via the “Delta P Formula”.

12. P DELTA P FORMULA FORMULA ~ ~ “Change” P
Q V L
FORMULA ~
= .0273 ID 4
~ “Change” P
~ “Pressure” (Pounds per Square Inch) Q
~ “Quantity of Flow” (Gallons Per Minute) V
~ “Viscosity” (Poise) L
~ “Length” (Feet) ID
~ “Inside Diameter” (Inches)

13. 1” x .065 WALL - 18 GAUGE S.S. TUBING
DELTA P FORMULA
Example:
Calculate Pressure Lost Between Drop 1 & Drop 2?
50 Feet
1” x .065 WALL - 18 GAUGE S.S. TUBING
Drop 1
Drop 2
Viscosity = 1 Poise
Quantity = 1.84 GPM (1 foot per sec)
Length = 50 Feet
I.D. = .87 Inches (1” x .065 Wall S.S. Tubing)

14. Substitute numbers into formula 1” x .065 WALL - 18 GAUGE S.S. TUBING
DELTA P FORMULA
Substitute numbers into formula P
Q V L
FORMULA ~
= .0273 ID 4 P
1.84 * 1 * 50
FORMULA ~
= .0273 4
.87
50 Feet
Drop 1
Drop 2
1” x .065 WALL - 18 GAUGE S.S. TUBING P
= psi

15. Maintain Material Integrity?
What Are We Doing?
Maintain Material Integrity?
This is the #1 concern for paint circulating system design. Issues include:
Material velocity
Shear (turns through system)

16. Maintain Material Integrity?
Material Velocity
Material must maintain a certain velocity through all piping and drop hoses.
“Velocity” is measured via ft/sec of material flow through piping and drop hoses.
General rule is WB material must maintain 0.5’/sec and SB 1’/sec.

17. Maintain Material Integrity?
Material Velocity
Material Velocity Chart
Pipe Dia.
1'/sec
0.5'/sec
3/4" Line
1.2 GPM
0.6 GPM
1" Line
1.84 GPM
0.92 GPM
1.25" Line
3.5 GPM
1.75 GPM
1.5" Line
4.5 GPM
2.25 GPM

18. Maintain Material Integrity?
Material Velocity
If velocity is to low then material can settle.
If material settles finished product can have the “appearance” of dirt when in fact it is a settling issue.
Over time this can also lead to restricted or clogged lines (usually return lines).

19. Maintain Material Integrity?
Material Velocity
If velocity is to high then extra energy is being used and material shear levels are higher then necessary.
Higher velocity equates to higher then necessary pump flow rates and turns through paint circulating system.

20. Maintain Material Integrity?
Shear
Shear is caused at any point where force is put on material.
High pressure combined with high flow will cause the highest shear point (i.e. BPR, pump ball checks, regulators…).
The lower the pressure and/or flow the better.

21. Maintain Material Integrity?
Shear
General rule is after 1000 turns through the system material will have visible color degradation.
Material must be replenished or it could be damaged beyond repair.
80/20 Theory: 80% of paint waste costs comes from 20% of material (i.e. low run colors).

22. Maintain Material Integrity?
Material Integrity Example
Over Sized Delivery System
Smart Design
Tank Volume
120
Flow Rate 7 3
Time for 1 Turn (min)
17.1
40.0
Time for 1000 Turns (min)
17143
40000
Time for 1000 Turns (days)
11.9
27.8

23. Total system flow is based on the following:
What Are We Doing?
Supply Material Flow?
Total system flow is based on the following:
Total applicator flow requirements if all applicators are flowing at maximum rate at one time. OR
Required material velocity flow rate needed to maintain material integrity.
WHICHEVER IS HIGHER

24. TYPES OF PAINT CIRC SYSTEMS
What are end user options?
THREE PIPE SYSTEM
TWO PIPE SYSTEM
ONE PIPE SYSTEM
PIGGABLE SYSTEM

25. 3-Pipe Systems ~ Advantage: ~ Disadvantage:
Circulation thru Color Valve
Color valve can be mounted on robot arm (low material waste)
~ Disadvantage:
Time and material to clean
Old Technology – Does not work well with WB Paints
Regulator Dependent – Have to adjust to make sure system is balanced
Different velocities throughout system
Costly labor to design & install
Not easily expandable
Swings in viscosity can cause problems

26. Three Pipe System
(1) Supply – (2) Returns

27. TWO PIPE SYSTEM GRADUATED LINE SIZES
SINGLE BPR (Back Pressure Regulator)
RECIRCS THROUGH COLOR VALVE MOUNTED ON ROBOT ARM
HYDRAULICALLY BALANCED OR REGULATOR DEPENDANT

28. TWO PIPE SYSTEM

29. 2-Pipe Systems ~ Advantage: ~ Disadvantage: Circulation in Color Valve
Color valve can be mounted on robot arm (low material waste)
Not Regulator Dependent
~ Disadvantage:
Time and material to clean
Different velocities throughout system
Costly labor to design & install
Not easily expandable
Swings in viscosity can cause problems

30. Two Pipe System

32. ONE PIPE SYSTEM (Ring Main)
One pipe circles booth. Deadend drops are used to supply color valve with material.

33. ONE PIPE SYSTEM

34. No Circulation through Color Valve Material settling at deadend drops
Overview
1-Pipe Systems
~ Disadvantage:
~ Advantage:
Low volume containment
Quick color change
Quick viscosity adjustment
Reduced energy
Easily expandable
Lower install cost
No Circulation through Color Valve
Material settling at deadend drops

35. Color valve cannot be located on robot arm (must be hard mounted)
Overview
Piggable System
~ Advantage:
Low volume containment
No settling
Quick color change
Capable of being shut down
Expandable
Reduced energy
Circulates through color valve
Low design engineering costs
Simpler operation
Consistent velocity
Low solvent usage
~ Disadvantage:
Color valve cannot be located on robot arm (must be hard mounted)

36. \
PIGGABLE SYSTEMS

37. MAIN PAINT LINE COLOR 1 MAIN PAINT LINE COLOR 1
COMPRESSED AIR HEADER
SOLVENT HEADER
MAIN PAINT LINE COLOR 1
COLOR CHANGE VALVE
MAIN PAINT LINE COLOR 1
MAIN PAINT LINE COLOR 1

38. Paint Circulation System Components
Transfer Pump
Surge Chamber
Day Tank
BPR
Pump
Supply Line
Tote Tank
Return Line
Booth
Drops
Heat Exchanger

39. Non-Encapsulated Ball Valves FORD SPEC - Full-Encapsulated Ball Valves
TYPES OF BALL VALVES
Non-Encapsulated Ball Valves
Dirt builds up between ball
Not easily cleanable
Paint can settle out
Cheaper
FORD SPEC - Full-Encapsulated Ball Valves
No space for dirt build up
Easily cleanable
Piggable
More Expensive

40. TYPES OF FITTINGS Threaded Fittings Dirt builds up threads
Rough inside diameter
Oil used to cut threads
Not piggable
Sanitary Fittings
Used in dairy and pharma industry
Cleanest fitting
No oil used in fabrication
Piggable

41. DUAL FUNCTION FILTERS Cartridge Basket Strainer Filter Housing Bag
Centering Ring

42. TYPES OF AGITATORS Vain Air Motors High SCFM usage (15 – 30 scfm)
High cost to operate
Oil required for lubrication
Radial Piston Air Motor
Low SCFM usage (2 – 4 scfm)
Low cost to operate
Oil NOT required for lubrication
FORD SPEC - Electric Direct Drive Agitator Motor
Lowest cost to operate
Most expensive to integrate (larger tanks)

43. TANKS FLAT LID TANKS Removal lids for cleaning Larger access openings
Not recommended for WB – Paints
DOMED TOP TANKS
Not Removable
Typically smaller openings
Condensation builds up and wicks side wall
Recommend for WB Paints

44. Description E4-60 & E4-90 16 & 24 GPM
Main Pump Assembly
Main Components
5 HP Motor & Gearbox
Main Cam Shaft and Bearings
4 Cylinders 8 Ball Check
Carriage and Cam Follower
Carriage Support Shaft and Linear Ball Bearing Bushes

45. Turbine Pump Technology
Use multi stage chambers each with a “impeller” blade that centrifugally create pressure and flow.
Each chamber will create shear and increase paint temperature as the impeller blade abuses material.
Temperature increase demonstrates the inefficiency of the pump…temperature increase is lost energy.
A large 10 to 20 HP motor is needed to supply necessary power to impeller blades.
End result is a costly pump that shears material and needs a heat exchanger installed on the circulating system to function properly.
Stages
Impeller Blade

46. Turbine Pump Technology
Typical turbine pumps will use a 10 to 20 HP motor to supply required pressure & flow.
Smart Pumps will require a 1.5 to 5 HP to supply same pressure & flow.
The extra “energy” required for turbine pumps is transferred into the material in the form of heat (30° to 50°). This heat transfer requires Temperature Controls to be used to cool material to an application temperature.
The Temperature Controls may not be required for the Smart Pump as heat transfer is minimal (2° to 5°).
If required in order to maintain material temperature due to changing ambient temperature, the footprint and energy consumption is much lower.

47. Smart Circulating System
Overview
Smart Pump… every Hz equals flow!
Smart BPR… can be automatically energized or de-energized!
End Result…
Smart Circulating System

48. What is “SMART CIRC”
Existing circulating technology maintains operating pressure 24 hours a day even though material is not in demand…
SMART CIRC automatically adjusts system pressure and flow to meet the demands at the applicator!

49. Smart Circulating System Flow Chart
A) Material Required:
Signal activates BPR to preset pressure level. Pump is adjusted to “Flow” or “Pressure” mode depending on system demands.
Job Queue Input
Data shows material to be “required”.
Data shows material is “not required”.
PLC
Smart Circ Controls
B) Material Not Required:
Signal de-activates BPR to fully open 0 pressure level. Pump is adjusted to maintain “Flow” mode at preset levels.

50. Why “SMART CIRC” Material integrity. Pump component wear. Energy use.
Consistent pressure settings (automated control).
Consistent flow settings (automated control).
Greater process controls.

51. Thank You