Presentation on theme: "Paint Circulation Technology Level 2 - Training Document"— Presentation transcript:
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?
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 SAFETYTote storage rackTote stand for loading materialBulk Storage Tank for Solvent and WasteTypical circulationsystemTypical paint mix room
6 Typical Paint Circulation System Components Transfer PumpSurge ChamberDay TankBPRPumpSupply LineTote TankReturn LineBoothDropsHeat 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 FTube and shell heat exchangerWater supply and return linesWater 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 HeaderRecirculation of the header and drop legs are very importantGravity 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 velocityBall Valves Added to Header to Have the Ability to Power Flush Header for Preventative MaintenancePurge 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 PumpsUtilize (1) Pump for Recirculation and (1) Pump for Empting of the TankNote: 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 LFORMULA ~= .0273ID4~ “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 FORMULAExample:Calculate Pressure Lost Between Drop 1 & Drop 2?50 Feet1” x .065 WALL - 18 GAUGE S.S. TUBINGDrop 1Drop 2Viscosity = 1 PoiseQuantity = 1.84 GPM (1 foot per sec)Length = 50 FeetI.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 FORMULASubstitute numbers into formulaPQ V LFORMULA ~= .0273ID4P1.84 * 1 * 50FORMULA ~= .02734.8750 FeetDrop 1Drop 21” x .065 WALL - 18 GAUGE S.S. TUBINGP= 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 velocityShear (turns through system)
16 Maintain Material Integrity? Material VelocityMaterial 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.
18 Maintain Material Integrity? Material VelocityIf 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 VelocityIf 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? ShearShear 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? ShearGeneral 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 ExampleOver Sized Delivery SystemSmart DesignTank Volume120Flow Rate73Time for 1 Turn (min)17.140.0Time for 1000 Turns (min)1714340000Time for 1000 Turns (days)11.927.8
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.ORRequired 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 SYSTEMTWO PIPE SYSTEMONE PIPE SYSTEMPIGGABLE SYSTEM
25 3-Pipe Systems ~ Advantage: ~ Disadvantage: Circulation thru Color ValveColor valve can be mounted on robot arm (low material waste)~ Disadvantage:Time and material to cleanOld Technology – Does not work well with WB PaintsRegulator Dependent – Have to adjust to make sure system is balancedDifferent velocities throughout systemCostly labor to design & installNot easily expandableSwings in viscosity can cause problems
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 cleanDifferent velocities throughout systemCostly labor to design & installNot easily expandableSwings in viscosity can cause problems
34 No Circulation through Color Valve Material settling at deadend drops Overview1-Pipe Systems~ Disadvantage:~ Advantage:Low volume containmentQuick color changeQuick viscosity adjustmentReduced energyEasily expandableLower install costNo Circulation through Color ValveMaterial settling at deadend drops
35 Color valve cannot be located on robot arm (must be hard mounted) OverviewPiggable System~ Advantage:Low volume containmentNo settlingQuick color changeCapable of being shut downExpandableReduced energyCirculates through color valveLow design engineering costsSimpler operationConsistent velocityLow solvent usage~ Disadvantage:Color valve cannot be located on robot arm (must be hard mounted)
37 MAIN PAINT LINE COLOR 1 MAIN PAINT LINE COLOR 1 COMPRESSED AIR HEADERSOLVENT HEADERMAIN PAINT LINE COLOR 1COLOR CHANGE VALVEMAIN PAINT LINE COLOR 1MAIN PAINT LINE COLOR 1
38 Paint Circulation System Components Transfer PumpSurge ChamberDay TankBPRPumpSupply LineTote TankReturn LineBoothDropsHeat Exchanger
39 Non-Encapsulated Ball Valves FORD SPEC - Full-Encapsulated Ball Valves TYPES OF BALL VALVESNon-Encapsulated Ball ValvesDirt builds up between ballNot easily cleanablePaint can settle outCheaperFORD SPEC - Full-Encapsulated Ball ValvesNo space for dirt build upEasily cleanablePiggableMore Expensive
40 TYPES OF FITTINGS Threaded Fittings Dirt builds up threads Rough inside diameterOil used to cut threadsNot piggableSanitary FittingsUsed in dairy and pharma industryCleanest fittingNo oil used in fabricationPiggable
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 operateOil required for lubricationRadial Piston Air MotorLow SCFM usage (2 – 4 scfm)Low cost to operateOil NOT required for lubricationFORD SPEC - Electric Direct Drive Agitator MotorLowest cost to operateMost expensive to integrate (larger tanks)
43 TANKS FLAT LID TANKS Removal lids for cleaning Larger access openings Not recommended for WB – PaintsDOMED TOP TANKSNot RemovableTypically smaller openingsCondensation builds up and wicks side wallRecommend for WB Paints
44 Description E4-60 & E4-90 16 & 24 GPM Main Pump AssemblyMain Components5 HP Motor & GearboxMain Cam Shaft and Bearings4 Cylinders 8 Ball CheckCarriage and Cam FollowerCarriage 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.StagesImpeller 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 OverviewSmart 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 InputData shows material to be “required”.Data shows material is “not required”.PLCSmart Circ ControlsB) 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.