James R. Dralle, President

1
Selecting the Best Overspray Collection System
for Aerospace FacilitiesPricing versus
Performance

• Presented By
• James R. Dralle, President
• A. J. Dralle, Inc.

2
Selecting the Best Overspray Collection System
for Aerospace FacilitiesPricing versus
Performance

• There Are Two Types of Paint Booth Filtration
• Supply Filtration and Exhaust Filtration

3
Selecting the Best Overspray Collection System
for Aerospace FacilitiesPricing versus
Performance

• Supply Side Efficiency Levels Are Governed By
• - Paint Quality Finish Requirements

4
Selecting the Best Overspray Collection System
for Aerospace FacilitiesPricing versus
Performance

• Exhaust Side Efficiency Levels Are Governed By
• - Litigation
• - Liability
• - Corporate Conscience
• - Maintenance and Environmental Expense

5
Selecting the Best Overspray Collection System
for Aerospace FacilitiesPricing 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.

6
Selecting the Best Overspray Collection System
for Aerospace FacilitiesPricing 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

7
Selecting the Best Overspray Collection System
for Aerospace FacilitiesPricing 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)

8
Selecting the Best Overspray Collection System
for Aerospace FacilitiesPricing 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)

9
Selecting the Best Overspray Collection System
for Aerospace FacilitiesPricing 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

10
Selecting the Best Overspray Collection System
for Aerospace FacilitiesPricing 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?

11
Selecting the Best Overspray Collection System
for Aerospace FacilitiesPricing 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

12
Selecting the Best Overspray Collection System
for Aerospace FacilitiesPricing 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

13
Selecting the Best Overspray Collection System
for Aerospace FacilitiesPricing versus
Performance

• E.P.A. Method 319 Test Procedure Two-Stage
  Existing Booth

14
Selecting the Best Overspray Collection System
for Aerospace FacilitiesPricing versus
Performance

• E.P.A. Method 319 Test Procedure Three-Stage New
  Booth

15
Selecting the Best Overspray Collection System
for Aerospace FacilitiesPricing 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

16
Selecting the Best Overspray Collection System
for Aerospace FacilitiesPricing 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

17
Selecting the Best Overspray Collection System
for Aerospace FacilitiesPricing 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

18
Selecting the Best Overspray Collection System
for Aerospace FacilitiesPricing versus
Performance
E.P.A. Method 319 Test Examples
19
Selecting the Best Overspray Collection System
for Aerospace FacilitiesPricing versus
Performance
E.P.A. Method 319 Test Examples
20
Selecting the Best Overspray Collection System
for Aerospace FacilitiesPricing versus
Performance
E.P.A. Method 319 Lab Certification Letter
21
Selecting the Best Overspray Collection System
for Aerospace FacilitiesPricing versus
Performance

• THE BOTTOM LINE
• MEETING E.P.A. METHOD 319 IS A
• FILTER SYSTEMS FIRST STEP.
• NOW THE SYSTEM MUST PROVE HOW WELL
• IT PERFORMS IN A REAL WORLD SETTING.

22
Selecting the Best Overspray Collection System
for Aerospace FacilitiesPricing 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

23
Selecting the Best Overspray Collection System
for Aerospace FacilitiesPricing 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

24
Selecting the Best Overspray Collection System
for Aerospace FacilitiesPricing versus
Performance
Paint Arrestance Test Report A Chart I of II
25
Selecting the Best Overspray Collection System
for Aerospace FacilitiesPricing versus
Performance
Paint Arrestance Test Report A Chart II of II
26
Selecting the Best Overspray Collection System
for Aerospace FacilitiesPricing versus
Performance
Paint Arrestance Test Report B Chart I of II
27
Selecting the Best Overspray Collection System
for Aerospace FacilitiesPricing versus
Performance
Paint Arrestance Test Report B Chart II of II
28
Selecting the Best Overspray Collection System
for Aerospace FacilitiesPricing versus
Performance
29
Selecting the Best Overspray Collection System
for Aerospace FacilitiesPricing versus
Performance
30
Selecting the Best Overspray Collection System
for Aerospace FacilitiesPricing versus
Performance
31
Selecting the Best Overspray Collection System
for Aerospace FacilitiesPricing versus
Performance

• Individual overspray collection systems can
  exhibit
• widely-different performance efficiencies on
  different
• paints

32
Selecting the Best Overspray Collection System
for Aerospace FacilitiesPricing versus
Performance
A. J. Dralles 2-Stage System Dexter Paint
33
Selecting the Best Overspray Collection System
for Aerospace FacilitiesPricing versus
Performance
A. J. Dralles 2-Stage System Dexter Paint
34
Selecting the Best Overspray Collection System
for Aerospace FacilitiesPricing versus
Performance
A. J. Dralles 2-Stage System Baked Enamel (high
solids)
35
Selecting the Best Overspray Collection System
for Aerospace FacilitiesPricing versus
Performance
A. J. Dralles 2-Stage System Dexter Paint
36
Selecting the Best Overspray Collection System
for Aerospace FacilitiesPricing versus
Performance

• Overspray collection systems, manufactured by
• different companies, can exhibit widely-different
  
• performance efficiencies

37
Selecting the Best Overspray Collection System
for Aerospace FacilitiesPricing versus
Performance
A. J. Dralles 2-Stage System
Other 2-Stage System
38
Selecting the Best Overspray Collection System
for Aerospace FacilitiesPricing versus
Performance

• To Fairly Compare and Evaluate Filter Systems
• Based on Price
• - Filters with lower paint-holding capacities
• may initially appear less expensive

39
Selecting the Best Overspray Collection System
for Aerospace FacilitiesPricing 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

40
Selecting the Best Overspray Collection System
for Aerospace FacilitiesPricing 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

41
Selecting the Best Overspray Collection System
for Aerospace FacilitiesPricing versus
Performance

• To Fairly Compare and Evaluate Filter Systems
• Based on Price
• - A filter system that is priced lower doesnt
• make it less expensive

42
Selecting the Best Overspray Collection System
for Aerospace FacilitiesPricing versus
Performance

• To help determine how a filter system will
• perform at your location, independent lab
• testing, provided by the supplier, must
• demonstrate the systems performance and
• efficiency with the paint currently utilized in
• your facilitys day-to-day operations.

43
Selecting the Best Overspray Collection System
for Aerospace FacilitiesPricing versus
Performance

• 3) What services does the supplier provide?
• Is the supplier available for on-call system
• evaluation, on-site inspections and
• troubleshooting?

44
Selecting the Best Overspray Collection System
for Aerospace FacilitiesPricing 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

45
Selecting the Best Overspray Collection System
for Aerospace FacilitiesPricing 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

46
Selecting the Best Overspray Collection System
for Aerospace FacilitiesPricing 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

47
Selecting the Best Overspray Collection System
for Aerospace FacilitiesPricing 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)

48
Selecting the Best Overspray Collection System
for Aerospace FacilitiesPricing 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.

49
Selecting the Best Overspray Collection System
for Aerospace FacilitiesPricing versus
Performance

• Laboratory versus Actual Filter Performance May
• Vary
• - All filter stages load at different rates

50
Selecting the Best Overspray Collection System
for Aerospace FacilitiesPricing 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

51
Selecting the Best Overspray Collection System
for Aerospace FacilitiesPricing versus
Performance
52
Selecting the Best Overspray Collection System
for Aerospace FacilitiesPricing versus
Performance
53
Selecting the Best Overspray Collection System
for Aerospace FacilitiesPricing versus
Performance

• The most effective overspray collection system
• Low ? Medium ?? High ?? ? Absolute Efficiency

54
Selecting the Best Overspray Collection System
for Aerospace FacilitiesPricing versus
Performance

• Filter Monitoring Frame

55
Selecting the Best Overspray Collection System
for Aerospace FacilitiesPricing versus
Performance

• Filter Monitoring Frame Placement

56
Selecting the Best Overspray Collection System
for Aerospace FacilitiesPricing versus
Performance

• Questions Before My Ride Leaves?