Paint Circulation Technology Level 2 - Training Document Subject Matter Expert: Miguel Bahena
Mar 31, 2015
Paint Circulation TechnologyLevel 2 - Training Document
Subject Matter Expert: Miguel Bahena
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.
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?
What Are We Doing?
Point A Point B
5
• 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
PAINT MIX ROOM
Typical paint mix room
Typical circulationsystem
Bulk Storage Tank for Solvent and Waste
Tote stand for loading material
Tote storage rack
Typical Paint Circulation System Components
Tote Tank
Transfer Pump
Day Tank BPR Pump Surge Chamber
Supply Line
Return Line
Booth
Heat ExchangerDrops
7
• 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.
PAINT CIRCULATION HEADER
Typical paint circulation header
8
• 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
PAINT HEATEXCHAGNER SYSTEM
Tube and shell heat exchanger
Water conditioning skid
Water supply and return lines
Recirculation of the header
and drop legs are very
important
Utilize (1) Pump for Recirculation and (1) Pump for Empting of the Tank
Special Cage Inside Tank to Capture 2K Waste Debris From Clogging Pumps
Special Waste Collection Funnel Under Cap Cleaner to Flush Drop Legs and Prevent Debris from Entering Waste Header
Note: Containment Pan Not Shown
Ball Valves Added to Header to Have the Ability to Power Flush Header for Preventative Maintenance
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
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)
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.
Supply Material Fluid Pressure?
• Generally between 80-100 PSI at the drop and 20-60 PSI at the point of atomization.
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”.
Supply Material Fluid Pressure?
DELTA P FORMULA
~ “Change”
FORMULA ~ P
= .0273 Q V L
ID 4
P
~ “Pressure” (Pounds per Square Inch)
Q
~ “Quantity of Flow” (Gallons Per Minute)
V
~ “Viscosity” (Poise)
L
~ “Length” (Feet)
ID ~ “Inside Diameter” (Inches)
DELTA P FORMULA
Example: Calculate Pressure Lost Between 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)
Drop 2 Drop 1
50 Feet 1” x .065 WALL - 18 GAUGE S.S.
TUBING
DELTA P FORMULA• Substitute numbers into formula
FORMULA ~ P
= .0273 Q V L
ID 4
FORMULA ~ = .0273 1.84 * 1 * 50
.87 4 P
Drop 2 Drop 1
= 4.384 psi P
50 Feet
1” x .065 WALL - 18 GAUGE S.S. TUBING
Maintain Material Integrity?
This is the #1 concern for paint circulating system design. Issues include:
• Material velocity• Shear (turns through system)
What Are We Doing?
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.
Maintain Material Integrity?
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
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).
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.
Maintain Material Integrity?
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.
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).
Maintain Material Integrity?
Over Sized Delivery System Smart Design
Tank Volume 120 120
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
Maintain Material Integrity?
Material Integrity Example
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
TYPES OF PAINT CIRC SYSTEMS
What are end user options?• THREE PIPE SYSTEM
• TWO PIPE SYSTEM
• ONE PIPE SYSTEM• PIGGABLE SYSTEM
3-Pipe Systems
• 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
~ Advantage:
Three Pipe System(1) Supply – (2) ReturnsThree Pipe System(1) Supply – (2) Returns
TWO PIPE SYSTEM
• GRADUATED LINE SIZES
• SINGLE BPR (Back Pressure Regulator)
• RECIRCS THROUGH COLOR VALVE MOUNTED ON ROBOT ARM
• HYDRAULICALLY BALANCED OR REGULATOR DEPENDANT
TWO PIPE SYSTEM
2-Pipe Systems
• 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
~ Advantage:
Two Pipe SystemTwo Pipe System
ONE PIPE SYSTEM (Ring Main)
One pipe circles booth. Deadend drops are used to supply color valve with material.
ONE PIPESYSTEMONE PIPESYSTEM
Overview1-Pipe Systems
• Low volume containment
• Quick color change
• Quick viscosity adjustment
• Reduced energy
• Easily expandable
• Lower install cost
~ Advantage:
• No Circulation through Color Valve
• Material settling at deadend drops
~ Disadvantage:
OverviewPiggable System
• Low volume containment
• No settling
• Quick color change
• Capable of being shut down
• Expandable
• Reduced energy
~ Advantage:• 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)
\PIGGABLESYSTEMS
PIGGABLESYSTEMS
MAIN PAINT LINE COLOR 1
MAIN PAINT LINE COLOR 1
SOLVENT HEADER
COMPRESSED AIR HEADER
MAIN PAINT LINE COLOR 1
CO
LO
R C
HA
NG
E V
ALV
E
Paint Circulation System Components
Tote Tank
Transfer Pump
Day Tank BPR Pump Surge Chamber
Supply Line
Return Line
Booth
Heat ExchangerDrops
TYPES OF BALL VALVESNon-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
TYPES OF FITTINGSThreaded 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
DUAL FUNCTION FILTERS
Filter Housing
Cartridge
Bag
Basket Strainer
Centering Ring
TYPES OF AGITATORSVain 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)
TANKSFLAT 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
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
Main Pump Assembly
Description E4-60 & E4-9016 & 24 GPM
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
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.
Turbine Pump Technology
Overview
Smart Pump… every Hz equals flow!
Smart BPR… can be automatically energized or de-energized!
End Result…
Smart Circulating System
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!
Smart Circulating System Flow Chart
Job Queue Input
a) Data shows material to be “required”.
b) Data shows material is “not required”.
A) Material Required:
Signal activates BPR to preset pressure level. Pump is adjusted
to “Flow” or “Pressure” mode depending on system demands.
B) Material Not Required:
Signal de-activates BPR to fully open 0 pressure level. Pump is
adjusted to maintain “Flow” mode at preset levels.
PLC
Smart Circ Controls
– Material integrity.– Pump component wear.– Energy use. – Consistent pressure settings (automated control).– Consistent flow settings (automated control).– Greater process controls.
Why “SMART CIRC”
Thank You