Paint and Final

Assembly Systems

Booth Balance

February 2012
 System Air Balance
WHAT IS SYSTEM AIR BALANCE?

When a Durr PSI engineer refers to AIR BALANCE we imply the

following;

How the supply air total relates to the exhaust air total
Supply > Exhaust - System is Pressurized : +ve to outside
Supply < Exhaust - System is De-Pressurized : -ve to outside

We are Air Balanced When ;

The actual Volumetric Flow Readings are confirmed against the

design requirement

When all Air Movement Directions are confirmed against the design
requirement

© Dürr Systems, Inc., PFS_PSA/department, title of presentation, date -2-

 System Air Balance Basic Booth Design
Features : X-Drafts
Cross Horizontal air movement controlled between spray booth zones to
prevent paint spray egress

Too Much and down drafts / spray application will be effected

Too Little and over spray will exit the spray zone silhouettes
X-Draft Magnitudes depend on the application process
Gun Application : X-Draft = 2000 cfm / silhouette
: Aggressive - High paint application velocities
Bell Application : X-Draft = 500 cfm / silhouette
: Non aggressive - Passive paint application velocities

© Dürr Systems, Inc., PFS_PSA/department, title of presentation, date -3-

System Air Balance Basic Booth Design
Features : DOWN DRAFTS – DD’s
Vertical air distribution evenly spread and controlled over the
spray booth zone

DD Velocities Promote: Efficient Overspray Removal :

Maximum Transfer Efficiencies
Too High and paint would not reach the substrate - Low Transfer Efficiency
Too Low and over spray will not be removed - Poor Quality Finish

DD Velocity Magnitudes depend on the application process

Gun Application : 60 to 100 fpm
: Aggressive DD – High Paint Application Velocity
Bell Application : 40 to 60 fpm
: Passive DD – Low Paint Application Velocity

© Dürr Systems, Inc., PFS_PSA/department, title of presentation, date -4-

 System Air Balance Basic Booth Design
Features : SYSTEM PRESSURE
System Pressurization Simply Determined
By Net Gains or Losses
All Zones Operating With VOC’s Usually –
ve For Containment
Total Enclosure Testing - EPA Method 204
Requires -ve 0.007 in.wc
Pressurization Tough to Quantify – Check
with Tapes or Smoke Tube

© Dürr Systems, Inc., PFS_PSA/department, title of presentation, date -5-

System Air Balance Basic Oven
Design Features : INFILTRATION
• Horizontal Air Movement Through the Oven Entry and Exit
Silhouettes
• Caused by the main exhaust fan pulling air out of the oven cavity
• Oven should be –ve to the surrounding processes
• Too Much and the mass flow to secondary equipment can be
excessive
• Too Little and process fumes / heat can escape the oven cavity
• Too Little and excess process condensate can form in the oven

© Dürr Systems, Inc., PFS_PSA/department, title of presentation, date -6-

 System Air Balance
Basic System Features : FANS

• Fans Used to Move Air

• Centrifugal Fan = CONSTANT VOLUME
Same volume regardless of changes in air density
• Volumetric Flow (cfm)
= No of Segments x Velocity x Speed
• Fans Usually Rated in Standard Cubic Feet Per Minute (scfm)
i.e. T=70F, Barometric Press (Sea Level) = 29.92 in.Hg, Density = 0.075ib/cuft & SpG = 1.0.
• Moving Air Acquires a Force or Pressure Component in the Direction of
Travel = VELOCITY PRESSURE (Pv) (in.wc)

© Dürr Systems, Inc., PFS_PSA/department, title of presentation, date -7-

 System Air Balance
Basic System Features : BURNERS

• Burners Used to Heat Air MASS

Burners sized for Air Mass not Air Volume
• Burner = CONSTANT MASS FLOW
Volumetric Flow Across Burner Varies With
Temperature but Mass Flow is Constant.
• Air at 70 F has a density of 0.075 lb/cu.ft.
• When heated to 250 F this becomes 0.056 lb/cu.ft
• AIR EXPANDS Volume changes – Mass is Constant therefore density
drops

© Dürr Systems, Inc., PFS_PSA/department, title of presentation, date -8-

 System Air Balance
Basic System Features : FILTERS
Air Filtration
•20 micron particle visible to human eye
•10 micron particle visible in light stream
•Paint finish damaged if particle ingress above 10 microns
•Filter Resistance (Differential Pressure) Increases With
Debris Loading
•Increase in Resistance Lowers Air Flow.
•Filter Differential Pressure Monitored by Air Pressure
Switches (APS’s) and Magnehelic Pressure Gauges.
•DAILY Checks and Good House Keeping Required to
Maintain Air Balance

© Dürr Systems, Inc., PFS_PSA/department, title of presentation, date -9-

 System Air Balance
Basic System Features : BOOTH SPRAY AREA

• Paint Application Area

• Controlled Environment (Temp & Humidity)
• X-Draft Balanced At Silhouettes – Overspray Containment
• Uniform Air Movement (DD) around Part - Overspray Removal

© Dürr Systems, Inc., PFS_PSA/department, title of presentation, date - 10 -

 System Air Balance
Basic System Features : SCRUBBER
ENVIROJET III SCRUBBER
• Installed on all spray zones.
• Air, water and over spray accelerated through the nozzles
• Paint particles mix with water and are captured as
“PAINT SLUDGE”
• Design Pressure drop : -ve 4.2”wc Minimum, -ve 5.5”wc
Preferred
• Scrubber Efficiency Increases as Pressure Drop Increases
• Pressure Drops above 7.0”wc give no practical gains -
Increased fan HP consumption - Increased Noise
• Water Flow Rates 30 - 35 gpm/ft of spray zone
• Water Flow = System Resistance
• Reduction in Sludge Water = Less Resistance = Increase in Air
Volume
• Air Volume Can Increase by 10% if Sludge Water is Totally Off

© Dürr Systems, Inc., PFS_PSA/department, title of presentation, date - 11 -

 System Air Balance
Basic System Features : DEWATERING BAFFLE

• Separates the Wet and Dry side of the scrubber

• Removes any large Water particles

• Post Baffle the air is approximately 98%RH 68F

• Face Velocities 175 to 280 fpm

• Paint Build Up on the Baffles Increases System
Resistance and Reduces Air Flow

© Dürr Systems, Inc., PFS_PSA/department, title of presentation, date - 12 -

 System Air Balance
Basic System Design Features : BALANCE

Why Does System Balance Vary?

• SUPPLY will vary due to system resistance
changes i.e. Dirty Filters, Leaks, Poor
Maintenance
• EXHAUST will also vary due to system
resistance changes i.e. Sludge Water Flow,
Scrubber Fouling, Leaks, Poor Maintenance
• True Balance is Difficult ! It requires Daily
Checks & Good Housekeeping

© Dürr Systems, Inc., PFS_PSA/department, title of presentation, date - 13 -

 System Air Balance
Balancing Techniques – SPRAY BOOTHS

Balance the Exhaust System First

• Fixed System – No moving parts
• Set Volumetric flow rates (acfm)
• Set Scrubber Pressures (approx 5.5 in.wc)

Balance the Supply System to the Exhaust System

• Manual Dampers, Fan FVD’s = Variables
• Set Volumetric flow rates (acfm)
• Establish X-Drafts – Rough Balance
• Establish DD Distribution – Fine Balance

© Dürr Systems, Inc., PFS_PSA/department, title of presentation, date - 14 -

 System Air Balance
Balancing Techniques – OVENS
Balance the Main Exhaust and Fresh Air Intakes First
• Set MASS Flow Rates Cold in STANDARD Cubic Feet Per Minute
(scfm)
• Recirc Systems Don’t Effect Balance ( In = Out )
• Check Infiltration at Entry and Exit Silhouettes : Must be –ve

Heat Up To Full Operating Temperature

• Check Infiltration at Entry and Exit Silhouettes
• Ensure Oven is Still –ve to the surrounding Process
• If Possible Check Exhaust Volumes at Operating Temperature

© Dürr Systems, Inc., PFS_PSA/department, title of presentation, date - 15 -

Test Equipment
Test Equipment

• Psychrometer
• Manometer
• Electronic manometer
• Pitot tube
• Vane anemometer
• Smoke puffer / Hang tape
• Tachometers
• Sound Meter

© Dürr Systems, Inc., PFS_PSA/department, title of presentation, date - 16 -

Psychrometer
Used to measure psychrometric
conditions
Sling Psychrometer
 Pair of thermometers
 One wet bulb one dry bulb
 Instrument is swung to create velocity across
wet bulb Sling Psychrometer

Electronic Psycrhometer
 Electronic instrument that measures
psychrometric conditions
 Features and function varies

Vaisala Psychrometer
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Test Equipment
Fluid Filled Manometer
 Pressure measurement device
Several types: U-Tube Manometer

U-Tube
 Accurate to ~0.1 in. w.c.
 Primarily for measuring static pressure
Inclined
 Accurate to ~0.01 in. w.c.
 Requires Careful Leveling
 Can be used with Pitot tube to measure air velocity

Inclined Manometer

© Dürr Systems, Inc., PFS_PSA/department, title of presentation, date - 18 -

Test Equipment
Electronic Manometer
For differential pressure measurement
Also Measures
 Airflow (volumetric flowrate)
 Velocity
 Pressures (differential, absolute)
 Temperature.
Ability to store multiple readings and average
Unit accuracy of +/- 3%
Not for use in high
temperature applications
(<60°C). Shortridge – AirDataTM
Multimeter

© Dürr Systems, Inc., PFS_PSA/department, title of presentation, date - 19 -

Test Equipment
Pitot Tubes
• probes with ports for measuring static and total pressure
• Used for air pressure and air velocity measurements
• Typically used in conjunction with a manometer (pressure
gauge)
• Various types and lengths are available

S-Type
Pitot Tube

Standard Type
Pitot Tube
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Test Equipment
Standard Pitot Tube Construction
Total
Pressure
Port
Inner
Outer Static Tube
Tube Pressure
Port Pressure
Measuring Tip

Static
Pressure

Connections
Total To Manometer
Pressure
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Test Equipment
Vane Anemometer

• Mechanical instruments used to determine air

velocity.
• Filter face velocities (on any accessible filter face)
can be measured, mapped, averaged, and used to
determine flow rate.
• An alternative to performing Pitot Traverses when
acceptable duct measuring points are not available.

© Dürr Systems, Inc., PFS_PSA/department, title of presentation, date - 22 -

Test Equipment
Tools to verify flow direction through openings
Very useful for flow in/out of oven ends

• Smoke puffer

• Tapes
 Section of lightweight material hung in opening
 Teflon pipe tape works well

© Dürr Systems, Inc., PFS_PSA/department, title of presentation, date - 23 -

Test Equipment
Fan Speed
• Strobe
 Most accurate
 Easy to use

• Photo Tachometer
 Not as reliable – does not
always pick up rotating part

• Contact Tachometer
 Can be difficult to use
 Requires contact with shaft

© Dürr Systems, Inc., PFS_PSA/department, title of presentation, date - 24 -

Sound Level Meter
Measures sound pressure
Normally expressed in dBA
 Type of frequency weighting that corresponds to the
sensitivity of the human ear

© Dürr Systems, Inc., PFS_PSA/department, title of presentation, date - 25 -

Spray Booth Training

2. Test Methods
Test Methods
• Static Pressure
• Airflow
• Air Temperature
• Downdraft Airflow
• Silhouette Airflow
• Sound

© Dürr Systems, Inc., PFS_PSA/department, title of presentation, date - 27 -

Test Methods
Static Pressure Measurements
• Often required for
 Verifying fan performance
 Measurement of airflow
 Measurement of scrubber pressure drop
• Measure using pitot tube
• Connect only static ports
• A plain tube can be used
 Care must be used to avoid velocity
pressure

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Test Methods
Airflow Measurement
• Moving air creates a pressure on
obstructions – velocity pressure
 4000 fpm  1” w.c.
• This pressure can be measured and
used to calculate velocity
• Flow in ducts is usually not at
atmospheric pressure
• The duct pressure – static pressure
must be accounted for
• A pitot tube measures velocity
pressure and accounts for duct static
pressure

© Dürr Systems, Inc., PFS_PSA/department, title of presentation, date - 29 -

Test Methods
Airflow Measurement
• For ducts – velocity varies, this must be accounted for
• A pitot traverse is made to account for variation
 Rectangular duct measurements taken on centers of equal area rectangles
 Round duct measurements taken on centers of equal concentric areas
• Determine ductwork size at measurement location (duct area needed for airflow
calculations)
 Height and Width for rectangular
 Radius for Round
• EPA methods 1-3 are the standard
• EPA rules often can not be strictly followed

© Dürr Systems, Inc., PFS_PSA/department, title of presentation, date - 30 -

Test Methods
Airflow Measurement – Location
• Pitot Traverses: Select measurement point in ductwork
• Straight duct section is free of obstructions (elbows, dampers, size changes,
fans, etc.) is preferred
• EPA Method 1 standards for
 distance from nearest obstruction
 Number of traverse points

Upstream Downstream

Airflow

Measurement
Point

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Test Methods
Airflow Measurement – Traverse Points
• EPA Method 1 requirements

© Dürr Systems, Inc., PFS_PSA/department, title of presentation, date - 32 -

Test Methods
Airflow Measurements
 Rectangular Duct Traverse Grid (20 points)
Duct Width

Equal
Rectangular
Areas

Duct Height
Measurement
Point,
Center of
Area

Pitot Tube Locations Indicated By

© Dürr Systems, Inc., PFS_PSA/department, title of presentation, date - 33 -
Test Methods
Round Duct
Traverse
Locations
% of Diameter
From Inside
Duct Wall

© Dürr Systems, Inc., PFS_PSA/department, title of presentation, date - 34 -

Test Methods
Airflow Measurements
 Round Duct Traverse Points – Example 10 Points

Equal
Concentric
Areas

D a b c d e Distance from
Center
a .316 (R)
b .548 (R)
Measurement
Point, c .707 (R)
Center of
d .837 (R)
Area
Pitot Tube Locations Indicated by: o e .949 (R)
© Dürr Systems, Inc., PFS_PSA/department, title of presentation, date - 35 -
Test Methods
Airflow Measurement

 Measurement Notes and Tips:

 Point pitot tube tip directly into airflow (keep extension tube parallel to flow in all
directions).

 Marking pitot tube extension with points prior to traverse increases potential
accuracy and simplifies process.

Pressure  Always check pitot tube ports after completing a traverse; ports become clogged
Measuring Tip
& Airflow
with duct debris very easily.

 Good technique and locations can produce air velocity accuracies of +/- 5%.

© Dürr Systems, Inc., PFS_PSA/department, title of presentation, date - 36 -

 Test Methods
Duct Air Volume Measurement Simplified Calculations
1. Take square root of each velocity pressure measurement ( p)
2. Average the square roots
3. Calculate the density factor (d) using duct temperature (T)

4. Calculate actual velocity (V) using

P in inches water (in w.c.), V in feet per min. (fpm) P in Pascal (Pa), V in meters per second (m/sec)

Standard Pitot Tube S-Type Pitot Tube Standard Pitot Tube S-Type Pitot Tube

Notes:
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Test Methods
Duct Air Volume Measurement Simplified Calculations - Continued
1. Find the duct area (A)

Rectangular ducts

Round ducts

2. Calculate actual volume (acfm) (Q) using

3. Calculate standard volume (scfm) (Qstd) using

© Dürr Systems, Inc., PFS_PSA/department, title of presentation, date - 38 -

Test Methods
Airflow measurement
Other techniques
Ultrasonic
Anemometer
Hot wire anemometer
 Uses heat transfer to measure air velocity
Ultrasonic anemometer
 Uses sound waves to measure air velocity
A traverse must be done as with a
pitot tube to get accurate flow in
ducts
Both technologies offer better
resolution of low air speed
 Pitot traverse limited to ~400 fpm
 Hot wire and ultrasonic accurate at <50
Hot Wire
Anemometer

© Dürr Systems, Inc., PFS_PSA/department, title of presentation, date - 39 -

Test Methods
Air Temperature measurements
Variety of instruments
 Thermocouple
 RTD
 Bi-metallic thermometer
Most reliable in moving airflow depth
Be aware of time response Airflow
 Larger probe responds more slowly
 Faster airflow causes faster response
Probe insertion depth – at least 10 diameter
times the probe diameter
 More if duct is under negative pressure

© Dürr Systems, Inc., PFS_PSA/department, title of presentation, date - 40 -

Test Methods
Downdraft Measurement
 Electronic Micro-manometer
 As previously discussed, but connected to a specialized air velocity averaging grid
(Velgrid) for air velocity measurements.
 Provides direct velocity measurements without additional calculation.

Shortridge – AirDataTM Multimeter Shortridge – Velgrid

© Dürr Systems, Inc., PFS_PSA/department, title of presentation, date - 41 -
Test Methods
Downdraft Measurement
 Analyze zone size and obstructions (machines, equipment, conveyor, etc.) to determine
measurement locations
 Note air conditions, zone name, conveyor travel direction, and obstructions.
 Booth grating typically provides consistent reference points in zones.
 2 – 5 measurement locations typical each side of conveyor (dependent on booth width).
 Perform measurements in target locations and record readings.
 Average total number measurements taken in zone to obtain Zone Average Downdraft
Velocity.
 Compare to System Airflow Schematics.
 Hold the instrument as far away as possible or use a stand when taking measurements
as the operator is an obstruction to airflow.

© Dürr Systems, Inc., PFS_PSA/department, title of presentation, date - 42 -

Test Methods
Downdraft Measurement
 Notes and Tips for spraybooth downdraft measurements:
 Always keep velocity sensing component perpendicular to the oncoming air flow as this
effects measurement accuracy.
 Take measurements at the working level – typically 4 to 6 feet above grating and be
consistent.
 Perform readings based on goals:
 Intermediate/Tuning downdraft checks = 3 measurements per location.
 Final/Complete downdraft checks = 5 measurements averaged per location.
 Spraybooth must be clear of bodies as these present obstructions to airflow.
 Use good technique when performing velocity measurements:
 Always allow time for air stabilization (~1-2 min.) when air has been disrupted prior to
taking measurement.
 Moving objects distort readings i.e. machines, equipment, people, zone doors
opening/closing.

© Dürr Systems, Inc., PFS_PSA/department, title of presentation, date - 43 -

Test Measurements
Downdraft Measurement - Example Typical
Grating Piece
Zone Length
Grid
Areas
Robot Robot

Zone Width
Conveyor Travel

Measurement
Point,
Center of
Area
Robot

Measurement Locations Indicated By

© Dürr Systems, Inc., PFS_PSA/department, title of presentation, date - 44 -
Test Methods
Downdraft Measurement - Example
 Spraybooth Downdraft Measurement:
 Example:
 The following grid shows downdrafts taken in a robotic zone.
 Find the average downdraft velocity.

9m

0.365 Robot 0.345 Robot 0.375

0.411 0.432 0.396 0.436 0.406

Note: All
Velocities

6m
Conveyor Travel
in MPS.

0.406 0.406 0.421 0.416 0.401

0.381 0.401 Robot 0.386 0.370

© Dürr Systems, Inc., PFS_PSA/department, title of presentation, date - 45 -

Test Methods
Downdraft Measurement
 Spraybooth Downdraft Measurement Example: – Continued
 Average Velocity:

Add up all measurements

V Average=
Number of measurements taken

V Average= 0.397 MPS

 Zone Flow Rate:

 Q=AxV
 Flow = Area x Volume
 Q = 54 m2 x 0.397 MPS x 3600 s/hr
 Q = 77,177 m3/hr
 Comparing this to the value of 0.4 MPS target downdraft on the airflow diagram indicates
airflow is satisfactory.
 Accuracy for this type of reading is typically +/- 5%.

© Dürr Systems, Inc., PFS_PSA/department, title of presentation, date - 46 -

Test Methods
Silhouette Measurement
Purpose: to determine airflow direction through opening relative to
conveyor travel.
 Plastic streamers hung from top center of opening typically used
 Provides indication of airflow direction and relative velocity – not quantitative
 If quantitative data is required use process similar to downdraft measurement
 Determine area of opening size and shape (curved silhouette, square opening) and
determine measurement locations – see example.
 Use grid format as previously discussed.
 9 - 12 measurement locations typical (dependent on opening size).
 Perform measurements in target locations and record on grid.
 Average total number measurements taken in zone to obtain Zone Average Downdraft
Velocity (MPS) and calculate flow rate through opening using Q=AxV.
 Compare to System Airflow Schematics.
 Generally velocity will be too lower for accurate measurement with the Shortridge and Velgrid
 Vane, hot wire or ultrasonic must be used in these case
 Verify instrument capability before taking readings

© Dürr Systems, Inc., PFS_PSA/department, title of presentation, date - 47 -

Test Methods
 Example Spraybooth Silhouette Recording Grid:
Zone Width
Opening Width
Silhouette

Grid

Opening Height

Zone Height
Areas

Measurement
Point,
Center of
Area
Conveyor

Measurement Locations Indicated By

© Dürr Systems, Inc., PFS_PSA/department, title of presentation, date - 48 -
Sound Measurement

Sound Pressure
 Dependent Upon Sound Source and
Environment
 Typically Expressed in Terms of dBA where,

Pm
dB  20  LOG10
20Pa

Sound Power
 Emitted from a Sound Source
Sound Intensity
 Intensity = Power/Area
 Dependent Upon Source Only
 Vector Quantity
Heat Analogy
Source: Brüel & Kjær Sound Intensity Manual

© Dürr Systems, Inc., PFS_PSA/department, title of presentation, date - 49 -

Decibels
Adding sound pressure from two 25

sources 20

The difference in decibels between the 15

two sources is defined to be
10
20 log (P2/P1) dB        10 times the pressure
 If the second produces twice as much gives +20 dB

Difference in dB
5

pressure as the first, the difference in dB is 20

log10 (P2/P1) = 20 log10 2 = 6 dB. 0
0 5 10 15
 If the second had 10 times the pressure of the -5
first, the difference in dB would be 20 log 10 equal pressure
(P2/P1)= 20 log10 10 = 20 dB. -10 gives 0 dB

 If the second had a million times the pressure -15

of the first, the difference in dB would be 20 ½ the pressure
gives -6 dB
log10 (P2/P1) = 20 log10 1000000 = 120 dB. -20

-25
Ratio of Source Pressure

© Dürr Systems, Inc., PFS_PSA/department, title of presentation, date - 50 -

Methods for Measuring Sound

Sound Intensity Level Meter

 Total Sound Power is Calculated by Multiplying
the Measured Sound Intensity by Surface Area
 Spatial Averaging Technique
 Independently Determine Sound Power Emitted
from Each Source in a Multiple Sound Source
Environment
 Measurements can be Made on a Single
Source Even when Multiple Sources are
Present

Source: Brüel & Kjær Sound Intensity Manual

© Dürr Systems, Inc., PFS_PSA/department, title of presentation, date - 51 -
 Spraybooth Balance
Methods & Procedures

© Dürr Systems, Inc., PFS_PSA/department, title of presentation, date - 52 -

Booth Balance
This section covers typical spraybooth balance philosophies and
procedures including:
 System inspection guidelines and sequence for balancing Spraybooths.
 Performing tests that isolate problems and suggest solutions.

Confirm that a problem exists with the system in question before making
changes.
 Understand that each booth in the paint shop is capable of interacting with adjacent booths.
 Incorrect airflow in one booth may be caused by incorrect operation of nearby units.
 Opening and closing of large paint shop outside doors or improperly operating ovens or
building ASH units disrupt booth balance

© Dürr Systems, Inc., PFS_PSA/department, title of presentation, date - 53 -

Booth Balance
General Balance Philosophy
 Spraybooth air balance should be checked on a routine basis.
 Simple daily checks using streamers quickly verifies basic airflows are correct.
 Balance the air supplied to and exhausted from the Spraybooth enclosure.
 Balancing involves adjusting sub-systems

Typically steps in balancing

Measure Evaluate

Adjust

© Dürr Systems, Inc., PFS_PSA/department, title of presentation, date - 54 -

Booth Balance Procedures
General Balance Philosophy

 3 Critical Values in Booth Balance: DD OK

 Spraybooth downdraft air velocities.

 Spraybooth lateral airflow patterns.

Tack-Off Booth Proper Flash-Off Oven Cooler

Paint Shop
 Overall spraybooth pressurization.
Oven Spraybooth

Cleanroom

© Dürr Systems, Inc., PFS_PSA/department, title of presentation, date - 55 -

Booth Balance Procedures
General Balance Philosophy
 Supply and Exhaust air flow changes affecting Booth balance:
 Supply air will vary due to
Supply Air
system resistance changes:
 Air density
 Dirty filters
IN OUT
 Equipment fouling
(Dirt) (Overspray
 Leaks
& Solvent
Vapors)
 Exhaust air will also vary due to
system resistance changes:
 Water flow
 Scrubber fouling
 Fan fouling / wear Exhaust Air
 Leaks

© Dürr Systems, Inc., PFS_PSA/department, title of presentation, date - 56 -

Booth Balance Procedures
Spraybooth Balance Activities

 Setting up the water supply

 Setting Exhaust Air for proper flow and scrubber pressure
 Setting ASH proper temperature and humidity
 Setting up Supply Air for:
 Correct pressure relationships.
 Correct lateral air flow patterns.
 Correct downdraft air in all zones.

© Dürr Systems, Inc., PFS_PSA/department, title of presentation, date - 57 -

Booth Balance Procedures

Pre-Balance Inspection

 Perform a full system inspection prior to any Spraybooth Balance attempts.

 Broken, malfunctioning, or unavailable equipment/systems complicate achieving good
system balance.
 Correct system deficiencies identified at inspection step before attempting balancing
activities.

© Dürr Systems, Inc., PFS_PSA/department, title of presentation, date - 58 -

Booth Balance Procedures
Pre-Balance Inspection – Continued

 Reference Materials should be available from start of activities:

 Fan speeds, PID settings, and airflow diagrams.

 Airflow diagram information should include:

 Air supplied to each zone from supply house including ductwork branches (m 3/hr).
 Air flow rate (m3/hr) and Downdraft (MPS) for each zone.
 Lateral airflow direction and rate (m3/hr) for booth entry, exit, and all intermediate
silhouettes.

 Operation and Maintenance manuals for specific equipment repair.

© Dürr Systems, Inc., PFS_PSA/department, title of presentation, date - 59 -

Basecoat Booth Flow Schematic

© Dürr Systems, Inc., PFS_PSA/department, title of presentation, date - 60 -

Booth Flow Schematic – Airflow Settings

© Dürr Systems, Inc., PFS_PSA/department, title of presentation, date - 61 -

Clearcoat Booth Schematic (Recirc.)

© Dürr Systems, Inc., PFS_PSA/department, title of presentation, date - 62 -

Booth Balance Procedures
Pre-Balance Inspection – Continued

 Technicians or plant maintenance personnel make a detailed inspection of the following

systems.
 Air Supply Houses
 Spraybooth and Supply Ducting
 Exhaust System
 Sludge System
 The following sections outline the primary systems / components to be inspected for the
above major sub-systems.

© Dürr Systems, Inc., PFS_PSA/department, title of presentation, date - 63 -

Booth Balance Procedures
Air Supply
Pre-Balance Inspection – Continued House

 Air Supply Houses:

 Shutdown dampers functional.

 Filters in place (correctly installed) and in good condition – inspect pressure gauges for
functionality.

 Temperature and humidity control components functioning and responding to control.

 Primary / Secondary Heating
 Humidifier
 Hot and Chilled Coils

 Supply fan is operating and free of excessive noise or vibration.

 Unit and equipment drains/overflows clear of debris and capable of flow.

 Check ductwork for leaks

© Dürr Systems, Inc., PFS_PSA/department, title of presentation, date - 64 -
Booth Balance Procedures
Pre-Balance Inspection – Continued
 Supply and Enclosure:
 Check supply ductwork control dampers are functional.

 Check plenum filters and/or distribution media in place (correctly installed).

 Inspect pressure gauges for functionality.

 Check for paint build-up on

Supply
distribution media and grating.
Ductwork

 Verify ductwork/plenum, and booth Plenums

access door seals/latches functional
and doors are closed. Spraybooth
Enclosure

© Dürr Systems, Inc., PFS_PSA/department, title of presentation, date - 65 -

Booth Balance Procedures
Pre-Balance Inspection – Continued

 Scrubber and Exhaust System:

Stack
 Exhaust fans operating and free of excessive noise or vibration.
 Inspect inlet cone for deterioration and proper gap to wheel.
 Inspect wheel for paint build-up on blades and blade pitting.
 Exhaust ductwork control dampers are functional (if present).
 Check exhaust / recirc. filters (if present).

Exhaust
Ductwork

Scrubber
© Dürr Systems, Inc., PFS_PSA/department, title of presentation, date - 66 -
Booth Balance Procedures
Pre-Balance Inspection – Continued
 Scrubber and Exhaust System (Liquid):
 Inspect scrubber for paint build-up and blockages to air or water return flow.
 Dewatering baffles clear to allow airflow.

Stack
 Dewatering baffles weep holes clear to allow drainage.
 All scrubber and exhaust ductwork access door seals/latches functional and
doors closed.
 Unit and equipment drains clear of debris and capable of flow.
 Appropriate test points available and in suitable condition to perform
measurements.

Exhaust
Ductwork

© Dürr Systems, Inc., PFS_PSA/department, title of presentation, date

Scrubber - 67 -
Booth Balance Procedures
Pre-Balance Inspection – Continued
 Booth Water and Sludge Collection System (Liquid):
 Check water flow in wet pans.
 Sufficient and even distribution.
 Insufficient flow indicators of clogged piping, pump deterioration, or
misadjusted valves.
 No dry spots around scrubbers.
 No obstructions in wet pans (paint islands, debris, etc.) forcing water to flow around
and not directly to the scrubbers.

Supply Sludge
Piping Collection
Return
Piping
Return
Booth Water Piping
Supply
Piping
© Dürr Systems, Inc., PFS_PSA/department, title of presentation, date - 68 -
Booth Balance Procedures
Pre-Balance Inspection – Continued

 Booth Water and Sludge Collection System:

 Booth water pumps operating and free of excessive noise or vibration.
 Inspect flow meters / pressure gauges for functionality.
 Sludge water acceptably free of floating sludge.
 Sludge water clarity is reasonable
 Consolidation valves, strainer, and controls functional.

Supply Sludge
Piping Collection
Return
Piping
Return
Booth Water Piping
Supply
Piping
© Dürr Systems, Inc., PFS_PSA/department, title of presentation, date - 69 -
Booth Balance Procedures
Pre-Balance Inspection – Continued

 Booth Water and Sludge Collection System:

 Check for sludge build-up in sluiceways and sludge pit.
 Unit and equipment drains clear of debris and capable of flow.
 Bleed-off / blow-down capable of flow.
 Chemical feed equipment operational.

Supply Sludge
Piping Collection
Return
Piping
Return
Booth Water Piping
Supply
Piping
© Dürr Systems, Inc., PFS_PSA/department, title of presentation, date - 70 -
Booth Balance Procedures
Pre-Balance Survey

 It is often helpful to perform a pre-balance system airflow survey after repairing deficiencies
and making no further changes to determine problem areas in system.
 Survey measure spraybooth – Collect:
 Exhaust air volume
 Scrubber pressure drop – each zone
 Temperature and humidity – 1 zone from each ASH
 Downdrafts – complete set all zones
 Silhouettes – complete set all openings
 Lateral balance – all zones
 Spraybooth overall pressurization to surrounding systems.
 Cleanroom, Oven, Heated Flash-Off, Building.

© Dürr Systems, Inc., PFS_PSA/department, title of presentation, date - 71 -

Booth Balance Procedures
Analyzing Data / Results
Experience in troubleshooting booths air balance is
the key factor in determining the corrective actions
required.
 Must be familiar with system arrangement, condition, Measure Evaluate
and equipment capabilities
 After collecting all data, analyze the results and
determine exactly what needs to be changed to
balance the system.
 After the decision is made to alter an existing Adjust
condition, analyze what this change would do to the
rest of the system, and if any other system
compensation is required.
 After making a change, re-check the measurements to
verify that the desired effect has been gained

© Dürr Systems, Inc., PFS_PSA/department, title of presentation, date - 72 -

Air Balance

Spraybooth Balance
Methods & Procedures

© Dürr Systems, Inc., PFS_PSA/department, title of presentation, date - 73 -

Spraybooth Balance
The following sequence applies more to newly
commissioned systems, but may be applied to
existing systems having undergone major rework or
special cases where starting over is the best option
1. Setup and measure water distribution to wet pans.
 Measuring bucket or impact pond fill timing test
 Bucket test is more accurate and can be performed at several points
in the zone to verify distribution allong the length of the zone
2. Turn on surrounding building ASH, heated flash, and
ovens systems
3. Turn on the booth ASH and rough set to correct
temperature and humidity

© Dürr Systems, Inc., PFS_PSA/department, title of presentation, date - 74 -

Spraybooth Balance (continued)
4. Setup exhaust system airflow and scrubber pressure
 Make scrubber adjustments for correct exhaust airflow and underfloor depression
(static pressure).
 Measure underfloor depression, exhaust airflows (typically within 10% of design), and
fan pressure / amps.
 If the “scrubber pressure drop,” is low, and the air volume is high, close the
scrubber orifice gap
 If the “scrubber pressure drop,” is high , and the exhaust air volume is low, open
the scrubber orifice gap
 If the “scrubber pressure drop,” is low and the exhaust air volume is low, an
analysis of the exhaust fan capacity is the correct course of action. Nothing will
be gained by changing the scrubber gap dimension. A possible increase in
performance may be needed (fan speed).
 If the “scrubber pressure drop,” is high and the exhaust air volume is high, an
analysis of the exhaust fan capacity is the correct course of action. A possible
reduction may be needed (fan speed).

© Dürr Systems, Inc., PFS_PSA/department, title of presentation, date - 75 -

Spraybooth Balance (continued)
5. Set ASH temperature and humidity.
 Test temperature and humidity to verify controls / monitoring.
6. Hang streamers from spraybooth zone silhouettes
7. Proportion main ASH supply air branches air for correct
pressurization
 Adjust supply distribution dampers and / or ASH VFD for correct lateral balance zone to
zone
 Adjust pressurization to Cleanroom, Booth entrance, Heated Flash-Off, and Booth exit.
8. Adjust plenum air distribution and presentation to Booth
 Measure downdrafts
 Fine adjust plenum air distribution and presentation to Booth
 Move filters in plenum or adjust baffles / perforated distribution plates
 Repeat fine adjustments and measurements until downdraft distribution goals achieved
 Verify filter pressure drops against design

© Dürr Systems, Inc., PFS_PSA/department, title of presentation, date - 76 -

Spraybooth Balance (continued)
9. Complete final measurements
 Exhaust air volume
 Scrubber pressure drop – each zone
 Temperature and humidity – 1 zone from each ASH
 Downdrafts – complete set all zones
 Silhouettes – complete set all openings
 Lateral balance – all zones
 Spraybooth overall pressurization to surrounding systems.
 Cleanroom, Oven, Heated Flash-Off, Building.
10. Evaluate data for consistency
 Compare booth downdraft measurements to exhaust volume
 Should be 10%
 Compare other measurements to design values

© Dürr Systems, Inc., PFS_PSA/department, title of presentation, date - 77 -

Booth Balance
Characteristics of a Balanced Booth
Air supplied is at proper temperature and relative humidity.
 Booth airflow is correctly controlling overspray.
 No excessive downdraft affecting paint application nor insufficient downdraft promoting
swirling and fog.
 Correct pressurization between zones.
 No unwanted lateral drifts.
 Correct pressure relationships to other systems / areas.
 Cleanroom enclosure slightly positive to building.
 Spraybooth slightly negative to Cleanroom.
 Spraybooth positive at exit flash-off zone prior to oven.
 Oven slightly negative to building and spraybooth.

© Dürr Systems, Inc., PFS_PSA/department, title of presentation, date - 78 -

Booth Balance
After balance process is complete – document booth operation
 Water flow rates for each zone or scrubber.
 Scrubber pressure drop
 Scrubber gap dimension.
 Exhaust fan operating volume, Amps, speed, suction and discharge pressures.
 Water eliminator pressure drop when clean.
 Exhaust filter pressure drop, if installed.
 Supply fan operating volume, Amps, speed, suction and discharge pressure.
 Supply air damper positions.
 Supply air duct pressures.
 Supply air filter operating pressures
 Zone downdraft data
 Overall spray booth pressure in relation to external influences.
 Zone pressure in relation to external influences.

© Dürr Systems, Inc., PFS_PSA/department, title of presentation, date - 79 -

Typical Booth Downdraft Data Sheet

© Dürr Systems, Inc., PFS_PSA/department, title of presentation, date - 80 -