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Advances in Plural-Component Equipment Technology

Explore the advancements in two-component equipment for protective coatings applications, including improved ratio assurance systems and dosing technology. Learn about the benefits and considerations when selecting two-component equipment.

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Advances in Plural-Component Equipment Technology

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  1. Advances in Plural-Component Equipment Technology Eric RennerfeldtProduct Marketing ManagerGraco Inc. May 1, 2013

  2. Agenda

  3. Protective Coatings Applications • Shipyards • Rail shops • Tank linings • Oil and gas facilities • Offshore platforms • Steel fabrication • Pipe coating

  4. Plural Component Protective Coatings • Two-Part Materials • Two-part epoxies • Two-part urethanes • Hybrid, quick setting urethanes • Polyureas

  5. Reasons for Hot-Potting • The majority of two-component materials are applied with single-component sprayers • Why? • Smaller up-front equipment investment • Easy to use • Comfort level • Some kits are pre-measured whichgives a level of confidence

  6. Single Component Sprayer • 1 motor drives 1 pump lower to pump pre-mixed material Air Motor Pump Lower Fluid outlet Fluid inlet

  7. Operation of a common 2-Ball Piston Pump Up stroke (Fill stroke) Piston ball checks Lower ball opens Fluid fills the pump 1st - ½ volume is pumped out Down stroke Lower ball checks Piston ball opens 2nd- ½ volume is pumped out

  8. Drawbacks of Hot-Potting • Chance for human error when measuring • Partial kits or forgetting to add the catalyst • High solvent costs • Requires more solvent to flush entire system • High labor costs • Especially for larger projects • Less Ergonomic • Physical strain when mixing

  9. Drawbacks of Hot-Potting • Coating performance • More solvent may be used to thin material and extend pot life • Solvent increases cure time, which reduces productivity • Hot-potting may not be suitable for the most advanced materials • Material waste • Throw away unused mixed material at end of day • Need to flush entire system before every break • Higher VOCs • More solvent in the environment

  10. Coatings are Evolving • Less solvent to help the environment • Faster cure times • Shorter pot life drives need for advanced equipment • Material advancements create better performing end product • Coating performancedrives demand for two-component equipment

  11. Advances in Two-Component Equipment Old Fixed-Ratio Systems New Fixed-Ratio Systems 2 legged system 2 material, 2 pumps Easier to understand • 3 legged systems • 2 materials, 3 pumps • More hardware, more difficult, more wear parts A B A A B

  12. Fixed Ratio Fluid Theory

  13. Advances in Two-Component Equipment • Importance of ratio assurance systems • Failure points will cause a change in pressure • Balanced A & B pressures are necessary for ratio assurance Piston shaft Throat seals Piston ball Piston seals Piston seat Cylinder wall Lower ball Lower ball seat Fluid supply

  14. Advances in Two-Component Equipment • Improved ratio assurance systems monitor both A and B pressures • Capable of preventing coating failures caused by: • Worn seals, plugged filters, running out of material, leaking valves, etc. • New systems are difficult to bypass until problem is fixed

  15. Dosing Technology (Variable Ratio Systems) A and B dosing

  16. Dosing Technology (Variable Ratio Systems) A metering valve B metering valve Mix manifold

  17. Dosing Technology Advancements Advances in Two-Component Equipment Old New Injection (continuous) Dosing A runs continuously while B injects into A at higher pressure Allows for higher flow rates and shorter integration line Higher precision ratio accuracy • Alternating Dosing • A and B alternate back and forth at the same pressure • Okay for lower flow rates • Requires longer integration hose for proper mixing

  18. Advances in Two-Component Equipment • Data Reporting Advances • Standard on many systems • Confidence the job was done right • Diagnostic support USB Port

  19. Advances in Two-Component Equipment • Simplicity • Most manufacturers have out of box solutions to go from hot-potting to two-component systems • Focus on ease of operation and ratio assurance • Accessories • Accessories have evolved to handle higher pressures, temperatures and flow rates • Hoses, heaters, gun and manifolds

  20. Selecting Two-Component Equipment Items to consider: • Properties and type of material being sprayed • Epoxy, Urethane, Hybrid Urethane, etc. • Mix ratio, pot life, solvent content, viscosity • Recommended spray temperature and pressure • Production requirements • Tip size, number of guns, distance to substrate

  21. Selecting Two-Component Equipment More items to consider: • Material handling • Container size? 5-gal (20L) or 55-gal (200L) drums • Does the material need to be pre-heated or agitated? • Will it require a transfer pump from the container? • Fixed ratio or variable ratio? • Fixed – ideal when dedicated to one material • Variable – change ratios quickly or hit odd ratios • Safety requirements • Hazardous location approvals

  22. Selecting Two-Component Equipment More items to consider: • Frequency of use • Is this equipment for one job or many jobs? Rent or buy? • Is this a 24-7 operation? Is it a simple job that happens 1-2 times a month? • Ratio assurance • If off-ratio conditions exist, is auto shutdown important? • Am I required to verify that the coatings were applied properly and on ratio? • Am I required to provide a report? • Technical support • Will my crew ever need technical support?

  23. Basic Unheated System • Ideal for long pot life materials • No heat system • Lowest investment (about 2 times the price of a large airless rig) Gravity Feed B MIX S Proportioner Mix line A Note: Static mixer size and placement may change depending on application and proportioner type (pertains to all systems)

  24. Basic Heated System Gravity or pump feed • Good for heat-assisted spray • Shorter pump-to-substrate distances • Medium investment B Mix line MIX S Proportioner Fluid Heaters A Spray Gun

  25. Heated – Remote Manifold System • Ideal for material requiring heat to spray • Longer pump-to-substrate distances • Higher investment Gravity or pump feed B MIX S Dual Heated hose Mix line Proportioner Fluid Heaters Spray Gun Max length depends on pot-life Volume-balanced hoses A

  26. Heated Supply, Remote Manifold System Gravity or pump feed heated supply • Higher production heated applications • Longer pump-to-substrate distances • Higher investment B Dual Heated hose MIX Mix line Proportioner S Fluid Heaters Max length depends on pot-life A Spray Gun Volume-balanced hoses

  27. Mix-at-gun applications • Ideal for similar viscosity, fast setting materials • Short or long pump-to-substrate distances • Higher investment Gravity or pump feed heated supply B GUN Dual Heated hose S Proportioner Fluid Heaters Static mix or impingement gun A Volume-balanced hoses

  28. Who Benefits From 2-Component Equipment? • Owners • Improved productivity • Higher quality • Less material waste • Environment • Less material waste • No thinning required • Lower VOCs • Painters • Consistent pattern • Less fatigue • Spray at lower pressure • No hand-mixing required • Mechanics • Easier repair • No catalyzed material in pumps • Longer pump life • Coating Suppliers • Confidence in quality

  29. Case Study - Epoxy for Water Tanks • Producer of high quality water tanks • 5-gal kits are mixed by hand and sprayed with airless pump • Material: 2-part epoxy • Pot-life: 4-hrs at 75F • Results • Material savings • Day one resulted in 69% decrease of waste • Annual savings estimate was $15,000 • Improved quality • Improved mixing accuracy • Consistent and repeatable coating thickness • Lower spray pressure with less overspray • Reduced the number of coatings from two to one

  30. Benefits of Two-Component Equipment • Spraying materials accurately and on ratio results in: • Less rework – more even coating • Faster curing – heated coating • More even film builds, less sagging • Coating flows better on substrate • No surging or high spots • Ensures coating suppliers that their materials achieve the desired results

  31. Make more money! • Expand your business • Allows you to bid on projects that require advanced fast-curing materials • Reduce costs • Less paint waste - mix only what you need • Less solvent waste • Increased productivity • Finish jobs sooner, less cleanup at the end • Less downtime rebuilding and cleaning pumps • Reduced liability • Rework costs due to off-ratio mistakes

  32. Summary • In recent years, two-component equipment has evolved to meet the demands of advanced two-component coatings • The majority of protective coatings are two-component, yet the majority of equipment used to apply them is single component • Advances in two-component equipment technology: • Allow for simplified, reliable use of two-component sprayers • Provide confidence that two-part materials are applied accurately and on-ratio • Improve overall profitability

  33. Questions?

  34. Thank you!

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