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Selecting the Best Overspray Collection System

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					Selecting the Best Overspray Collection System
            for Aerospace Facilities
          “Pricing versus Performance”


                Presented By
           James R. Dralle, President
               A. J. Dralle, Inc.
Selecting the Best Overspray Collection System
            for Aerospace Facilities
          “Pricing versus Performance”

There Are Two Types of Paint Booth Filtration:
Supply Filtration and Exhaust Filtration
Selecting the Best Overspray Collection System
            for Aerospace Facilities
          “Pricing versus Performance”

Supply Side Efficiency Levels Are Governed By:
  - Paint Quality Finish Requirements
Selecting the Best Overspray Collection System
            for Aerospace Facilities
          “Pricing versus Performance”

  Exhaust Side Efficiency Levels Are Governed By:
  - Litigation
  - Liability
  - Corporate Conscience
  - Maintenance and Environmental Expense
Selecting the Best Overspray Collection System
            for Aerospace Facilities
          “Pricing versus Performance”
 In an effort to reduce hazardous emission levels, the

 E.P.A. established National Emission Standards for

 Hazardous Air Pollutants (NESHAP), which detailed

 specific guidelines for facilities that manufacture or

 rework aerospace vehicles and/or components, and

 paint with chromate/cadmium primers.
Selecting the Best Overspray Collection System
            for Aerospace Facilities
          “Pricing versus Performance”
NESHAP Emission Guidelines for “Major Source”
Aerospace Rework Facilities:

Hazardous Paint Formulation (HAPs) Limits per Source

-   Source emits greater than 10 tons of one HAP
-   Source emits greater than 25 tons of all HAP
Selecting the Best Overspray Collection System
            for Aerospace Facilities
          “Pricing versus Performance”
NESHAP Emission Guidelines for “Major Source”
Aerospace Rework Facilities:
Volatile Organic Emission (VOCs) Limits per Source
Primer
   - VOC Content Limit: 350 g/l (2.9 lb/gal)
   - Organic HAP Content Limit: 350 g/l (2.9 lb/gal)
Selecting the Best Overspray Collection System
            for Aerospace Facilities
          “Pricing versus Performance”
NESHAP Emission Guidelines for “Major Source”
Aerospace Rework Facilities:
Volatile Organic Emission (VOCs) Limits per Source
Topcoat
  - VOC Content Limit: 420 g/l (3.5 lb/gal)
  - Organic HAP Content Limit: 420 g/l (3.5 lb/gal)
Selecting the Best Overspray Collection System
            for Aerospace Facilities
          “Pricing versus Performance”
 Major Source Sites Filtration System Requirements:

 For Booths Installed Prior to June 1994 (“Existing”):
   - Utilization of two-stage air filtration system

 For Booths Installed After June 1994 (“New”):
   - Utilization of three-stage air filtration system
Selecting the Best Overspray Collection System
            for Aerospace Facilities
          “Pricing versus Performance”
 In order to make an informed buying decision, arm yourself
 with relevant data, including:
 1)   Does the filter meet Method 319 standards?
 2)   Has the system been tested utilizing paint?
 3)   What services does the supplier provide?
 4)   Where is the background documentation?
Selecting the Best Overspray Collection System
            for Aerospace Facilities
          “Pricing versus Performance”
1)   Does the filter meet Method 319 standards?
     If so, the supplier must provide:
     - A complete set of test data from an independent lab
     - A certification letter from the lab, stating it performs
       filter testing in accordance with Method 319
       specifications
Selecting the Best Overspray Collection System
            for Aerospace Facilities
          “Pricing versus Performance”
The E.P.A. Method 319 test sets minimum filtration efficiency
levels for “New” and “Existing” sources based on particle size
ranges, using chemical substitutes to simulate wet and dry
paint overspray:
    - Potassium Chloride for dry overspray
    - Oleic Acid for wet overspray
 Selecting the Best Overspray Collection System
             for Aerospace Facilities
           “Pricing versus Performance”
E.P.A. Method 319 Test Procedure: Two-Stage Existing Booth

                  E.P.A. Method 319
                  Filtration Efficiency   Aerodynamic Particle
                  Requirement, %          Range, um
  LIQUID PHASE            > 90                   > 5.7
                          > 50                   > 4.1
                          > 10                   > 2.2
  SOLID PHASE             > 90                   > 8.1
                          > 50                   > 5.0
                          > 10                   > 2.6
Selecting the Best Overspray Collection System
            for Aerospace Facilities
          “Pricing versus Performance”
E.P.A. Method 319 Test Procedure: Three-Stage New Booth
                 E.P.A. Method 319
                 Filtration Efficiency   Aerodynamic Particle
                 Requirement, %          Range, um
LIQUID PHASE             > 95                   > 2.00
                         > 80                   > 1.00
                         > 65                   > 0.42
SOLID PHASE              > 95                   > 2.50
                         > 85                   > 1.10
                         > 75                   > 0.70
Selecting the Best Overspray Collection System
            for Aerospace Facilities
          “Pricing versus Performance”
The minimum efficiency requirements for “new” sources are
dramatically higher than “existing” sources under Method 319:
Example:
   - An existing source, two-stage system has a minimum
     efficiency of 10% on a particle size of 2.6 micron of dry
     challenge
Selecting the Best Overspray Collection System
            for Aerospace Facilities
          “Pricing versus Performance”
The minimum efficiency requirements for “new” sources are
dramatically higher than “existing” sources under Method 319:
Example:
   - A new source, three-stage system has a minimum
     efficiency of 95% on a particle size of 2.5 micron of
     dry challenge
Selecting the Best Overspray Collection System
            for Aerospace Facilities
          “Pricing versus Performance”

Due to so much misleading information in the marketplace,
many people are unaware that:
    - Neither the E.P.A. nor NESHAP “approve” nor
      “certify” filters
    - E.P.A. Method 319 does not test actual paint
      emissions
Selecting the Best Overspray Collection System
            for Aerospace Facilities
          “Pricing versus Performance”
         E.P.A. Method 319 Test Examples:
Selecting the Best Overspray Collection System
            for Aerospace Facilities
          “Pricing versus Performance”
         E.P.A. Method 319 Test Examples:
Selecting the Best Overspray Collection System
            for Aerospace Facilities
          “Pricing versus Performance”
E.P.A. Method 319
Lab Certification Letter:
Selecting the Best Overspray Collection System
            for Aerospace Facilities
          “Pricing versus Performance”

             THE BOTTOM LINE:
      MEETING E.P.A. METHOD 319 IS A
       FILTER SYSTEM’S FIRST STEP.
 NOW THE SYSTEM MUST PROVE HOW WELL
  IT PERFORMS IN A REAL WORLD SETTING.
Selecting the Best Overspray Collection System
            for Aerospace Facilities
          “Pricing versus Performance”

2) Has the system been tested utilizing paint?
  If so, the supplier should provide independent lab test
  data which includes:
    - Filters’ holding capacities for each of the stages in
      a two or three-stage system
    - Filter pressure drop increases versus paint gain in
      chart and graph form
Selecting the Best Overspray Collection System
            for Aerospace Facilities
          “Pricing versus Performance”
2) Has the system been tested utilizing paint?

  If so, the supplier should provide independent lab test
  data which includes:
    - Filter performance data for each stage in sequential
      order, demonstrating how system performance is
      inter-related
Selecting the Best Overspray Collection System
            for Aerospace Facilities
          “Pricing versus Performance”
     Paint Arrestance Test Report ‘A’: Chart I of II
Selecting the Best Overspray Collection System
            for Aerospace Facilities
          “Pricing versus Performance”
    Paint Arrestance Test Report ‘A’: Chart II of II
Selecting the Best Overspray Collection System
            for Aerospace Facilities
          “Pricing versus Performance”
     Paint Arrestance Test Report ‘B’: Chart I of II
Selecting the Best Overspray Collection System
            for Aerospace Facilities
          “Pricing versus Performance”
    Paint Arrestance Test Report ‘B’: Chart II of II
Selecting the Best Overspray Collection System
            for Aerospace Facilities
          “Pricing versus Performance”
Selecting the Best Overspray Collection System
            for Aerospace Facilities
          “Pricing versus Performance”
Selecting the Best Overspray Collection System
            for Aerospace Facilities
          “Pricing versus Performance”
Selecting the Best Overspray Collection System
            for Aerospace Facilities
          “Pricing versus Performance”

Individual overspray collection systems can exhibit
widely-different performance efficiencies on different
paints:
Selecting the Best Overspray Collection System
            for Aerospace Facilities
          “Pricing versus Performance”
A. J. Dralle’s 2-Stage System: Dexter Paint
Selecting the Best Overspray Collection System
            for Aerospace Facilities
          “Pricing versus Performance”
 A. J. Dralle’s 2-Stage System: Dexter Paint
Selecting the Best Overspray Collection System
            for Aerospace Facilities
          “Pricing versus Performance”
 A. J. Dralle’s 2-Stage System: Baked Enamel (high solids)
Selecting the Best Overspray Collection System
            for Aerospace Facilities
          “Pricing versus Performance”
      A. J. Dralle’s 2-Stage System: Dexter Paint
Selecting the Best Overspray Collection System
            for Aerospace Facilities
          “Pricing versus Performance”

Overspray collection systems, manufactured by
different companies, can exhibit widely-different
performance efficiencies:
Selecting the Best Overspray Collection System
            for Aerospace Facilities
          “Pricing versus Performance”
A. J. Dralle’s 2-Stage System:   Other 2-Stage System:
Selecting the Best Overspray Collection System
            for Aerospace Facilities
          “Pricing versus Performance”
To Fairly Compare and Evaluate Filter Systems
Based on Price:

    - Filters with lower paint-holding capacities
      may initially appear less expensive
Selecting the Best Overspray Collection System
            for Aerospace Facilities
          “Pricing versus Performance”

To Fairly Compare and Evaluate Filter Systems
Based on Price:
- But shorter filter life translates to higher overall
  operational costs:
    - Purchase more filters due to change outs
    - Labor costs associated with filter change outs
    - Booth downtime due to change outs
Selecting the Best Overspray Collection System
            for Aerospace Facilities
          “Pricing versus Performance”
To Fairly Compare and Evaluate Filter Systems
Based on Price:
   - Filters with high paint-holding capacities mean
     longer filter life and less filter changes,
     translating to lower operational costs for
     the facility
Selecting the Best Overspray Collection System
            for Aerospace Facilities
          “Pricing versus Performance”

To Fairly Compare and Evaluate Filter Systems
Based on Price:

   - A filter system that is priced lower doesn’t
     make it less expensive
Selecting the Best Overspray Collection System
            for Aerospace Facilities
          “Pricing versus Performance”

To help determine how a filter system will
perform at your location, independent lab
testing, provided by the supplier, must
demonstrate the system’s performance and
efficiency with the paint currently utilized in
your facility’s day-to-day operations.
Selecting the Best Overspray Collection System
            for Aerospace Facilities
          “Pricing versus Performance”

3) What services does the supplier provide?
   Is the supplier available for on-call system
   evaluation, on-site inspections and
   troubleshooting?
Selecting the Best Overspray Collection System
            for Aerospace Facilities
          “Pricing versus Performance”

4) Where is the background documentation?
  Obtain a complete product manual which includes:
   - Clearly defined filter specifications and
     schematic drawings
   - All independent test summaries
   - UL Listings on all filter media
Selecting the Best Overspray Collection System
            for Aerospace Facilities
          “Pricing versus Performance”

4) Where is the background documentation?

  Obtain a complete product manual which includes:
   - MSDS sheets for all filters and their
     component parts
   - Step-by-step procedures for filter changeouts
     based on pressure drop increases
Selecting the Best Overspray Collection System
            for Aerospace Facilities
          “Pricing versus Performance”
To Fairly Compare and Evaluate Filter Systems:
   - Ensure all the filter systems have met E.P.A.
     Method 319 Standards
   - Review the filter systems’ efficiencies and
     paint-holding capacities utilizing the paint
     used at your facility
Selecting the Best Overspray Collection System
            for Aerospace Facilities
          “Pricing versus Performance”

Establish Performance Standards for Your Facility:
   - Preliminary Method 319 Test (for aerospace)
   - Spray Removal Efficiency and Paint Holding
     Capacity
   - Paint Fractional Efficiency (optional)
   - Breech Test (optional)
Selecting the Best Overspray Collection System
            for Aerospace Facilities
          “Pricing versus Performance”

Establish Performance Standards for Your Facility:
   - Filter and/or paint suppliers should provide
     independent test lab with filter and paint
     supplies, and pay for the testing itself.
Selecting the Best Overspray Collection System
            for Aerospace Facilities
          “Pricing versus Performance”

Laboratory versus Actual Filter Performance May
Vary:
   - All filter stages load at different rates
Selecting the Best Overspray Collection System
            for Aerospace Facilities
          “Pricing versus Performance”
Laboratory versus Actual Filter Performance May
Vary:

   - Lab tests demonstrate relationship between
     filter stages
   - As the first filter stage becomes dirty, the
     second and third stages have only gained
     a few grams of paint
Selecting the Best Overspray Collection System
            for Aerospace Facilities
          “Pricing versus Performance”
Selecting the Best Overspray Collection System
            for Aerospace Facilities
          “Pricing versus Performance”
Selecting the Best Overspray Collection System
            for Aerospace Facilities
          “Pricing versus Performance”

The most effective overspray collection system:

Low  Medium  High   Absolute Efficiency
Selecting the Best Overspray Collection System
            for Aerospace Facilities
          “Pricing versus Performance”
Filter Monitoring Frame:
Selecting the Best Overspray Collection System
            for Aerospace Facilities
          “Pricing versus Performance”
Filter Monitoring Frame Placement:
Selecting the Best Overspray Collection System
            for Aerospace Facilities
          “Pricing versus Performance”
Questions Before My Ride Leaves?

				
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posted:9/14/2011
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