- Design and operation of equipment
- Understanding how the equipment should work
- Identifying what is not working properly
- Preventing or minimizing paint production stoppages
- Solving common paint defects
- Implementing pollution prevention (P2) strategies at zero or minimal cost
- Working efficiently with two-component coatings
- Working with high solids and water-borne coatings
- Implementing waterborne CARC
- Performing basic calculations for spray booths and paint usage
Who Should Attend This Paint Workshop
- Paint shop managers
- Engineers who fund and purchase painting equipment
- Supervisors
- Lead painters
- Environmental compliance engineers who deal with painting operations
- Pollution prevention (P2) professionals
Who Should Not Attend This Paint Workshop
- Incoming and less experienced painters who might find the class too technical
Calculators
All participants must bring calculators to class.
AGENDA
Introduction
Videos of painting operations
Typical layouts of paint facilities
Nomenclature: paints, coatings, primers, topcoats, enamels, lacquers, basecoats, clearcoats,
liquid paints, powder coatings
Surface Preparation – Chemical Methods
Solvent wiping – how to reduce VOC emissions
Chemical methods for removing oil and grease
Iron phosphating
Zinc phosphating
Conversion coatings for aluminum
New novel pretreatments for aluminum
Surface Preparation – Mechanical Methods
Sanding
Abrasive blasting and various abrasives
Spray Booths
Designing spray booths with common sense
Fans, blowers, VFDs, dampers and other ancillary equipment
Spray booth dry filters
Measuring pressure differentials
When to change filters
Carbon filters for abatement
Water wash spray booths – how they function
Bad designs of spray booths – causes of air turbulence
Why airflow through a spray booth is often inadequate
Regulatory requirements – OSHA and NFPA-33
Spray Guns
Principles of atomization
Compressed air
Conventional and HVLP air atomizing spray guns
Siphon and gravity-fed spray guns
Electrostatic spray guns - the principles
Airless and air- assisted airless spray guns
Electrostatic bells and discs
Setting up a Spray Gun
Functions of: fluid needle, fluid control knob, air regulator on spray gun, fan control knob
Step-by-step approach
Testing for atomization
Measuring fluid flow rate
Preventing runs and sags
Transfer Efficiency (TE)
Principles of Transfer TE
Why TE is so effective in lowering costs
Painting techniques that improve TE
Equipment considerations that improve TE
Liquid Coatings by Curing Mechanism
Solvent evaporation
Auto-oxidation
Baked coatings
Polymers
Two-component coatings
Waterborne coatings
UV curable coatings
Importance of Mixing
Mixing – proper methods
Metering of plural component equipment
Pot life as a function of time
Pot life as a function of temperature
Powder Coatings
What they comprise
Why they emit almost zero VOCs
The solution to hazardous waste
Points of opinion regarding disposal of spent powders
How they are applied
Electrostatic and fluidized bed
Available resins: polyester, epoxy, polyurethane, TGIC and more
Paint Defects
Orange peel, blistering, pin holing, cratering, runs & sags, Benard cells, cracking, chalking,
water spotting, blushing, and more.
Touch-up procedures to repair defects
Quality Control and Commonly used Instruments
Dry film thickness (different instruments)
Wet film thickness
Adhesion (dry and wet)
Hardness
Flexibility
Impact resistance
Drying
Full cure
Color control
Compressors
Shop compressors vs. compressors for paint facility
Size of compressors required for painting?
Dehumidification of compressed air; refrigeration vs. desiccants
Air filters; capture of particle size vs. cost and pressure differential
Regulators - choicesPressure Pots
Single-regulated pressure pots
Double-regulated pressure pots
Pressure cups
Siphon cups
Why Spray Guns are often Starved of Air
Plumbing of compressed air lines
Purchasing the correct air hose
Quick disconnects
Other fittings
Preserving air pressure at the spray gun
Equipment Cleaning – Minimizing Hazardous Waste
Low VOC solvents for equipment cleaning
Flushing fluid hoses and fluid tubes
Pressure pots
Spray gun cleaning using gun washers and distillation units
Depainting (Paint Removal)
Physical methods
Chemical methods
Non-toxic paint removers
Minimizing hazardous waste
Identifying Poor Painting Techniques
Quiz on 20 short video clips
The Value of a Stereo Microscope
How to start an investigation of a paint failure
Range of magnifications
Examples of paint failures on metal, plastic, wood, concrete
Scanning Electron Microscope (SEM/EDS)
What SEM can do
How it works
Range of magnifications
Using EDS
Examples of coating analyses
Introduction to EIS
What is electrochemical impedance spectroscopy?
How to use this tool to evaluate surface pretreatment
How EIS can predict coating corrosion performance
How to use EIS for quality control
How to Identify Paints, Coatings, Adhesives and Sealers Using FTIR
What is FTIR?
What this technique accomplishes
Examples of different coatings
Environmental
What are Volatile Organic Compounds (VOCs)?
How solvent-based paints are regulated by the EPA and state agencies
Waterborne paints
How waterborne paints are regulated
Hazardous Air Pollutants (HAPs)
NESHAP and MACT standards
Break 9:30 am – 9:45 am
Environmental Nomenclature 9:45 am – 10:00 am
RACT, BACT, LAER, MACT, NESHAP,
Title III
Title V – Operating Permits
How to use MSDS and Technical Data Sheets for Calculations 10:00 am – 11:00 am
Percent by weight vs percent by volume
Vapor pressure
CAS numbers
Chemical names of compounds
Examples of poorly written material safety data sheets (MSDS)
Analytical methods to determine VOC, HAP, water and exempt solvents
Calculations
Calculating VOC/HAP of a single component coating
Calculating VOC/HAP of a plural component coating
Calculating VOC/HAP when thinners are added
Calculating VOC/HAP of waterborne coatings
Calculating emissions from spray booths
What to Expect from a Paint Facility Inspection
Record keeping
Permits
Covered containers
Empty cans
Spray booth filters
Spray guns
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