green technologies for paint circulation systems

1

Green Solutions in

Paint Circulation Systems

INDIA SURFACE COATING SHOW NOV 2015

ABOUT PATVIN

Started 27 Years ago in 1987 Mumbai.

Installed our first Large PCS 20 Years ago in 1995.

Installed 2000+ Painting Circulation Systems in the last 20 Years.

Completely ready Paint Circulation and Application lab since 9 Years (2006)

Today we are a force of 200 strong team members dedicated to paint

circulation/ application and raring to go!

PATVIN ACTIVIES

Engineering Design

Turnkey Projects on EPC basis for :

Paint Circulation.

Centralized Sealer Distribution.

Robotic / Manual Glass Glazing.

Coded Cavity Wax Systems

Centralized Lubrication Systems.

Commissioning and Training.

After Sales Service and Annual maintenance

contract.

PATVIN ACTIVIES Engineering Design

P&I Drawing

3D Drawing

PATVIN ACTIVIES


Paint Circulation.

Typical PCS Typical Piping

PATVIN ACTIVIES


Centralized Sealer Distribution.

1000 Kg Sealant Un-loaders Typical Drop Station

PATVIN ACTIVIES


Coded Cavity Wax Systems

Coded Gun

Coded Nozzles

Coded Application

PATVIN ACTIVIES

Commissioning and Training. Service and parts

Green Solution in PCS - Introduction

Q. What is a Paint Circulation System ( PCS ) ?

A . A system that moves paints /coatings from a Can to the part

to be painted without attributing to any defect .

Pumping Module Pipe Network

Heat Exchanger System

Drop Point Station


Flow – If the flow varies or is inadequate painting is affected.

Pressure – Low or High Pressure can affect Painting equipment and finish

quality.

Temperature – Out of range temperature cause paint defects.

Velocity – Paint movement below 60fpm cause shade variations and many

other defects.

Shear – Damages Paint pigments thereby affecting end result.


Maintain uniform color and distribution of pigments, metallic and mica –

Maintain particle velocity 60 ft/ min +

Maintain uniform viscosity by maintaining proper circulation rate ( shear )

and temperature

Meet pressure and flow rate requirements of automatic and manual

stations

Maintain suspension which prevents settling of paint

Provide a low shear system design

Provide the best solution to meet all functional objectives with less energy

consumption thereby lowering cost of operation ( cost per unit produced )

Green Solution in PCS

What is the need for an intelligent fluid handling system?

Many organizations have a growing concern for the environment.

Businesses play a critical role in developing and utilizing environmentally

sound products.

Awareness of the impact fluid handling equipment can have on the

environment to find ways to reduce negative effects.

• Reduction of Energy

• Compliment with governmental regulations

• Customer demands for eco-friendly technology

• Protecting the environment

• Reducing waste


We needed to develop an intelligent fluid handling

system so it was a natural thought to create energy

saving simply by using less energy.

UNDERSTAND NATURAL INTELLIGENCE…

…CREATE ARTIFICAL

INTELLIGENCE

Green Solution in PCS - Logic

BRUSHING YOUR TEETH WITH THE TAP RUNNING

≈ 15 Liters

Green Solution in PCS - Logic

BRUSHING YOUR TEETH TURNING THE TAP ON AND OFF

≈ 1 Liter


Now develop a fluid handling system, capable of…

…“Turning on and off the tap” self sufficient.

The patented SMART control:

”Tap OFF mode” - Open Loop

when paint needs to be circulated but is not required at any take off

point.

”Tap ON mode” - Closed Loop

when paint is required maintain required pressure but only supply the

flow needed at the user points

Green Solution in PCS – Traditional

Green Solution in PCS – Electrical

Pilot BPR

Pressure

Sensor

Green Solution in PCS - Differences

Typical Pulsation of most Paint systems after Surge suppression

Typical Pulsation of a Asymmetrical Design Electrical system


Factors To Consider When Comparing Running Costs

Pneumatic Pump Operation Cost (Indirect Energy Source)

kW to Operate Air Compressor

kW to Operate Air Drier

kW lost due to pipework pressure drops and air leaks

High System Installation & Maintenance Costs

Air Motors may require Heaters to prevent freezing

Electric Pump Operation Cost (Direct Energy Source)

kW to Operate Electric Motor

Low System Installation & Maintenance Costs

Green Solution in PCS – Current

Pneumatic Solutions

Filtration

Pipework

Compressor Drier

Typical Conversion Losses = 75~80%

Ie. A typical Pneumatically driven PCS Pump requires 4x the

amount of power compared to a Smart Electrical Pump System


Smart Control

The ‘Smart’ system design provides for

two modes of operation.

Open Loop

Back Pressure Regulator „Unloaded‟ to

reduce the paint line pressure and

Pump pressure requirement

Pump motor will be driven to run at a

set minimum speed (Min Paint velocity)

Back Pressure

Regulator

(air pilot)

Closed Loop

Paint pressure maintained by the back-pressure regulator

Pressure sensor monitors System Pressure

Pump speed is controlled to maintain system pressure to the

pre set point value

http://www.binkspce.eu/en/sites/default/files/imagecache/product_image_fullview/1.5_1.png


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Example of Open Loop Control for Basecoat System Colour

Open Loop, Pump Pressure 12 bar System Colour in use with a Flow Rate of 16L/min. during production.

Pressure/Flow set to production requirements.

Typical relationship between vehicle travel through the Spraybooth versus Paint Flow/Pressure.

Hand ‘Touch in’ Basecoat Bells ‘Pick up’ Station

Green Solution in PCS Example of Smart Closed Loop Control for Basecoat System Colour

Closed Loop, Pump 12 bar System Colour in use.

Flow rate varies to meet required system demand

(up to design requirement 16L/min) Closed Loop, Pump 12 bar

System Colour Ready for

use. Flow rate 9.0L/min

Duration

Pressure/Flow

Typical relationship between vehicle travel through the

Spraybooth versus Paint Flow/Pressure.

Hand ‘Touch

in’ Basecoat Bells ‘Pick up’ Station

Product I-Dent reader

Colour requirement

information sent to Mix

Room control panel


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Example of Smart Control for Basecoat System Colour

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Pump Speed

(Hz)

Pump Pressure

(bar)

OPEN LOOP OPEN LOOP CLOSED LOOP

CLOSED LOOP DURING APPLICATION

Pump Speed (Hz)

Pump Pressure (bar)

CONSTANT

PRESSURE

≈ USED

ENERGY

REDUCE ENERGY

USED

Cost kWh 8.00 Average Day/Night Cost Currency INR Utility Company Charge

Power kW 8.05 Pneumatic Pump ₹ 562,598.40 Air Compressor Annual Energy Cost

Power kW 0.25 Smart Controled Electric

Pump

₹ 17,472.00 Annual Energy Cost (0.8kW £594.05)

Annual Saving ₹ 545,126.40 Per Pump

1.00 Pump Mix Room ₹ 545,126.40 Basic Annual Saving

Time

Hours

Power

kW Pressure bar Flow Event Remarks

22 0.22 5 7.5L/min Open Loop Paint not required at spraybooth

1.5 0.50 14 9.0L/min Closed Loop Paint required at spraybooth

0.5 0.80 14 16L/min Closed Loop Paint 'In Use' dynamically at spraybooth

24 0.25 --- --- --- Average Power Used per 24 hr Day

Paint System Energy Costs

• With Smart Control we decrease Power consumption from 0.6 kW 24/7 to

0.25 kW for average power usage of typical Paint system 24/7.

• Further decreasing annual running Costs



Cost Savings by adopting Electric Drive Pump • Reduction in Compressed Air Usage & Maintenance costs

• Lower Power Consumption – Reduction in Running Cost

• Reduction of Pump Speed and Pressure during Non-Production hours.

• Incentives for Energy Saving Investments

Additional Cost Savings by adopting Smart Control • Supply paint at required pressure and flow only when needed for actual

production.

• Further savings on Pump running costs

• Longer life for Pump wear parts

• Reduced maintenance costs

• Potential paint saving due to reduction of shear

• Smart System Control of Individual Pumps

• Smart Controls allows Monitoring of pump performance life and

provides information on Maintenance schedules.

Green Solution in PCS Review on Key Benefits:-

• Savings on Energy Usage v Pneumatic Pumps

• Energy Conversion to Compressed Air

• Air Conditioning Equipment – Driers, Heaters

• Impact on Environment

• No Compressed Air supply requirement – Pipework Installation, Leak

potential

• No Pump Air exhaust

• Ambient Noise Reduction

• Reduced Contamination Risk

• Operation

• Smart Control of Each Pump

• Paint supplied at required pressure and flow only when needed

• Reduced Paint Shear

• Maintenance

• Maintenance of all Compressed air services

• Reduction in Maintenance Tasks

• Reduction in Annual Spare Parts Budget

• Individual Pump Monitoring and data recording

THANK YOU

Mr. Mangesh Pawar.

PATVIN ENGINEERING PVT LTD. Navi Mumbai; INDIA

www.patvin.co.in

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