/
svEPA
United States
Environmental Protection
Agency
Office of Air Quality
Planning and Standards
Research Triangle Park NC 27711
EPA-450/3-88-018
December 1988
Air
Protocol for
Determ!-: ^ the Daily
Volatile organic
Compound Emission
Rate of Automobile
and Light-Duty Truck
Topcoat Operations
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BPA-450/3-88-018
Protocol for
Determining the Daily
Volatile Organic
Compound Emission
Rate of Automobile
and Light-Duty Truck
Topcoat Operations
Emission Standards Division
U.S. ENVIRONMENTAL PROTECTION AGENCY
Office of Air and Radiation
Office of Air Quality Planning and Standards
Research Triangle Park, North Carolina 27711
December 1988
U.S. Environmental Protection Agency
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This report has been reviewed by the Emission Standards Division of the
Office of Air Quality Planning and Standards, EPA, and approved for
publication. Mention of trade names or commercial products is not intended
to constitute endorsement or recommendation for use. Copies of this
report are available through the Library Services Office (MD-35), U.S.
Environmental Protection Agency, Research Triangle Park, NC 27711, or
from the National Technical Information Service, 5285 Port Royal Road,
Springfield, Virginia 22161.
PUBLICATION NO. EPA-450/3-88-018
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TABLE OF CONTENTS
SUBJECT PAGE
1 INTRODUCTION 1-1
2 DEFINITIONS 2~!
3 SYMBOLS 3'1
4 DAILY VOC EMISSION RATE CALCULATION 4-1
5 TOTAL DAILY VOC GENERATED 5-1
6 TOTAL DAILY VOLUME SOLIDS DEPOSITED 6-1
7 TOTAL DAILY BAKE OVEN EXHAUST CONTROL CREDIT 7-1
8 DAILY COATING USAGE . 8-1
9 VOC GENERATED PER GALLON OF AS APPLIED COATING USED 9-1
10 ANALYTICAL VOC CONTENT OF AS APPLIED COATINGS 10-1
11 FORMULATION SOLVENT CONTENT OF AS APPLIED COATINGS 11-1
12 FORMULATION VOLUME SOLIDS CONTENT OF AS APPLIED
COATINGS 12-1
13 DAILY TRANSFER EFFICIENCY VALUES 13-1
14 DAILY INDIVIDUAL BAKE OVEN EXHAUST CONTROL DEVICE
VOC LOADING VALUES 14-1
15 MONTHLY VEHICLE COATING SUMMARY 15-1
16 DAILY VEHICLE COATING SUMMARY 16-1
17 MONTHLY COATING USAGE 17-1
18 TRANSFER EFFICIENCY TEST PROCEDURE - IN PLANT 18-1
19 TRANSFER EFFICIENCY TEST PROCEDURE - PILOT LINE 19-1
20 ALTERNATE TRANSFER EFFICIENCY PROCEDURES FOR
UNTESTED BOOTHS AND/OR COATINGS 20-1
21 TEST PROCEDURE FOR DETERMINING BAKE OVEN EXHAUST CONTROL
DEVICE VOC LOADING FOR SPECIFIC COATING 21-1
22 BAKE OVEN EXHAUST CONTROL DEVICE EFFICIENCY 22-1
23 DELETED 23-1
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SUBJECT PAGE
24 ACCOUNTING FOR CAPTURED PURGED COATING 24-1
25 RECORDS OF WITHDRAWALS OF COATING FROM MIX TANKS OR
CIRCULATING SYSTEM 25-1
26 NOTES ON ALTERNATE WEIGHTING FACTORS 26-1
27 NOTES ON USING COMBINED BASECOAT/CLEARCOAT
TRANSFER EFFICIENCY TEST RESULTS 27-1
28 NOTES ON USING TRANSFER EFFICIENCY TESTS RESULTS WHEN
THE TEST ENVELOPE IS MORE THAN ONE BOOTH LONG 28-1
29 NOTES ON USING COMBINED BASECOAT/CLEARCOAT BAKE OVEN
CONTROL DEVICE VOC LOADING DATA 29-1
30 NOTES ON ACCOUNTING FOR DILUTION SOLVENT ADDED BY THE
COATING MANUFACTURER AT A SATELLITE PAINT PLANT 30-1
31 CALCULATING FORMULATION WEIGHT FRACTION SOLVENT
OF AS SUPPLIED COATING 31-1
32 CALCULATING FORMULATION SOLVENT CONTENT
OF AS SUPPLIED COATING 32-1
33 CALCULATING FORMULATION VOLUME SOLIDS CONTENT
OF AS SUPPLIED COATING 33-1
34 RECORDKEEPING REQUIREMENTS 34-1
35 NOTES ON USING THIS PROTOCOL TO DETERMINE
THE DAILY VOC EMISSION RATE OF AUTOMOBILE
AND LIGHT-DUTY TRUCK SURFACER OPERATIONS 35-1
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ADDED 12/88
SUBJECT PAGE
APPENDIX A EXAMPLE CALCULATIONS A-l
APPENDIX B SUMMARY OF ADDITIONS AND REVISIONS TO
JUNE 10, 1988 VERSION OF PROTOCOL B-l
1 n
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1 - INTRODUCTION
This protocol determines the dally VOC emission rate (pounds of VOC
per gallon of coating solids deposited) for a complete automobile and
light-duty truck topcoat operation. The protocol considers the following
factors:
-Daily usage of each coating
-VOC generated per gallon of each coating used
-Volume solids content of each coating used
-Daily weighted transfer efficiency of each coating used
-Daily weighted bake oven exhaust control credit
The protocol describes how to determine each of these factors,
including the necessary testing and recordkeeping.
The protocol is designed for use in cases where (1) the topcoat
emission limit is stated in units of pounds of VOC per gallon of solids
deposited, (2) compliance is to be demonstrated for each day, and (3) the
entire topcoat operation (i.e., all spray booths, flash-off areas and
bake ovens where topcoat is applied, dried, and cured; except final off-
line repair) is treated as a single entity.
The protocol uses the number of square feet coated on each vehicle
in each booth with each coating as the basis for the daily weighting of
individual transfer efficiency and bake oven exhaust control values.
These data are also used to prorate the total usage of each coating in a
month to each of the production days in that month. This can be done in
lieu of directly monitoring and recording the usage of each category
each day. Therefore, the emission rate for each day in a month is
calculated at the end of that month.
1-1
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REVISED 12/88
Sample information sheets and calculations are provided in Appendix
A. Use of these sample sheets is not required by the protocol. Alternative
data presentation formats may be chosen by the owner/operator. A schematic
drawing of the sample coating line used in the examples is presented in
Figure 1. Some notes on the sample coating line are presented in Figure 2.
The protocol is intended as a living document which will be improved
as experience is gained with its use. The protocol is divided into small
sections which are amenable to changes, addition of new sections and
incorporation into computer programs. The equations are presented in a
form that is amenable to incorporation into computer programs. In some
equations, asterisks ("*") are used to indicate multiplication and slashes
("/") are used to indicate division. The protocol as presented here is
complete and must be used in its current form for compliance determinations.
In using the protocol, the owner/operator must initially identify
various test conditions and parameters, data collection procedures and
data presentation formats. For example, the owner/operator needs to
choose the spray booths and coatings for transfer efficiency test (Sections
18 and 19) and a method of accounting for coating withdrawals (Section
25). These choices are subject to review by the appropriate regulatory
agency(ies). The owner/operator should therefore discuss these choices
with the agency(ies) before tests are performed or data are collected.
Pre-test review, which is a requirement of many regulations and permits,
provides an opportunity to identify and resolve potential issues in
advance and thereby minimize the chances of later questions about the
representativeness or validity of data and the need for retesting or
redesign of data collection procedures or data presentation formats.
The protocol was originally published on June 10,. 1988. This printing
includes changes and additions made in November and December of 1988.
The changes and additions are summarized in Appendix B.
1-2
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2 - DEFINITIONS
Formulation Solvent Content - The weight of photochemical!,/ reactive
organic solvents in a specific volume of coating (pounds per gallon) as
determined using the procedures in Sections 11, 31, and 32. Volatile by-
products of cross-linking reactions (cure volatiles) are not included in
the formulation solvent content.
Mix Tank - A coating reservoir which is connected to the circulating
system which delivers coating to the coating application equipment.
Coating and dilution solvent are added to the circulating system through
a mix tank. If the circulating system is kept full, changes in the
coating level in a mix tank provide useful information for determining
the volume of coating used over a period of time. Totes are mix tanks
when they are plugged directly into the circulating system.
VOC Generated - The amount of VOC released from an as applied coating
under specific application conditions, including cure volatiles released
from those coating solids which are cured in a bake oven, and recognizing
that cure volatiles are not released from coatings solids which are not
cured in a bake oven. (i.e. overspray coating solids)
2-1
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3 - SYMBOLS
Variables
BRFRAC(M,N) - Fraction of the total square footage coated on day N
that is coated in spray booth M and baked in oven M. These are the bottom
row fractions in the daily vehicle coating summary for day N (decimal fraction)
BTE(I,M) - Transfer efficiency for coating I in booth M (decimal fraction)
CA(I,J) - Analytical VOC content of the batch of coating I used in
addition J (pounds of VOC per gallon)
CDE(M) - Efficiency of control device which treats exhaust from bake
oven M (decimal fraction)
CDL(I,M) - VOC loading from coating I to control device which treats
exhaust from bake oven M (pounds of VOC per gallon of solids deposited)
CF(I.J) - Formulation solvent content of the batch of coating I used in-
addition 0 (pounds of solvent per gallon)
CFRAC(I,M,N) - Fraction of total square footage coated in booth M on day
N that is coated with coating I. These are the fractions in the column
for booth M coating summary for day N (decimal fraction)
CP(I) - Volume of coating I that is captured by the purge capture system
in a single purge cycle.
3-1
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DAYSQFT(I.N) - Total square footage coated with coating I on day N
(square feet)
DCC(N) - Total bake oven exhaust control credit for day N (pounds of VOC
per gallon of solids deposited)
DENS(I.J) - Density of the batch of coating I used in addition J (pounds
per gallon)
DER(N) - Daily emission rate for the topcoat operation on day N (pounds
of VOC per gallon of solids deposited)
DSD(N) - Total volume of solids deposited on day N (gallons)
DVG(N) - Total mass of VOC generated on day N (pounds)
DVOL (I,J,A) - Density of the volatiles in ingredient A of the batch of
coating I used in addition 0 (pounds per gallon)
END(I) - Volume level of coating I in mix tank at end of month (gallons)
GDAY(I.N) - Volume of coating I used on day N (gallons)
GMON(I) - Volume of coating I used in the month (gallons)
MONSQFT(I) - Square footage coated with coating I in the month (square feet)
NPURGE(I.N) - Number of purge cycles of coating I on day N
PADD(I,J) - Volume of coating I added to mix tank in addition J (gallons)
RADD(I,K) - Volume of dilution solvent added to the mix tank for coating
I in addition K (gallons)
3-2
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RCA(I) - Analytical VOC content of coating I (pounds of VOC per gallon,
as applied)
RCF(I) - Formulation solvent content of coating I (pounds of solvent per
gallon as applied)
RCV(I.N) - VOC generated per gallon of coating I on day N (pounds of VOC
per gallon, as applied)
RD(I,K) - Density of dilution solvent added to the mix tank for coating
I in addition K (pounds per gallon)
RVS(I) - Formulation volume solids content of coating I, as applied
(decimal fraction)
RFRAC(I,M,N) - Fraction of total square footage coated with coating I on
day N that is coated in booth M. These are the fractions in the row for
coating I in the daily vehicle coating summary for day N (decimal fraction)
START(I) - Volume level of coating I in mix tank at start of month (gallons)
TCOL(M.N) - VOC loading to control device which treats exhaust from bake
oven M weighed for day N (pounds of VOC per gallon of solids deposited)
TCP(I,N) - Total volume of coating I which is captured by purge capture
system on day N (gallons)
TE(I,N) - Transfer efficiency for coating I on day N (decimal fraction)
VFS (I,J,A) - Volume solids content of ingredient A added to the batch of
coating I used in addition J (decimal fraction)
3-3
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VOL (I,J,A) - Volume of ingredient A added to the batch of coating I used
in addition J (gallons)
VS(I,J) - Formulation volume solids content of the batch of coating I used
in addition J (decimal fraction)
WITH(I.P) - Volume of coating I removed from mix tank for coating I in
withdrawal P (gallons)
WITHTOT(I) - Total volume of coating I removed from mix tank for coating
I in the month (gallons)
WT (I.J.A) - Mass of ingredient A added to the batch of coating I used in
addition J (pounds)
WTFRSV (I,J) - Formulation weight fraction solvent content of the batch
of coating I used in addition J (decimal fraction)
WTNR (I,J,A) - Weight fraction water or exempt solvent in ingredient A
added to the batch of coating I used in addition J (decimal fraction)
WTSOLV (I.J.A) - Weight fraction solvent content of ingredient A added to
the batch of coating I used in addition J (decimal fraction)
WTVOL (I»J,A) - Weight fraction volatiles content of ingredient A added
to the batch of coating I used in addition J (decimal fraction)
3-4
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Indices. Counters, Limits
A Ingredient index for formulation calculations
B Number of ingredients in the formula for a
coating
BC Base Coat
CC Clear Coat
I Coating Index
j Coating Addition Index
K Dilution Solvent Addition Index
L(i) Number of Additions of Coating I in Month
M Booth or Oven Index
N Day Index
p Withdrawal Index
R(I) Number of Additions of Dilution Solvent to
Mix Tank for Coating I in Month
5(1) Number of Withdrawals from Mix Tank for
Coating I in Month
T Number of Booths/Ovens in Topcoat Operation
V Number of Coatings Used
W Number of (Operating) Days in Month
Y Month Index
3-5
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4 - DAILY VOC EMISSION RATE CALCULATION
The daily VOC emission rate is calculated by dividing the total
pounds of VOC generated that day by the total gallons of solids deposited
that day and then subtracting that day's bake oven exhaust control credit.
On day N, the daily emission rate is:
DER(N) = CDVG(N) / DSD(N)] - DCC(N)
A sample calculation is presented in Figure 20.
4-1
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5 - TOTAL DAILY VOC GENERATED
The total VOC generated each day is calculated by multiplying the
volume of each coating used that day by the pounds of VOC generated per
gallon of that coating and summing the results.
The VOC generated on day N is:
V
DVG(N) = SUM [GDAY(I.N) * RCV(I.N)]
1=1
A sample calculation is presented in Figure 16.
5-1
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6 - TOTAL DAILY SOLIDS DEPOSITED
The total gallons of solids deposited each day is calculated by
multiplying the volume of each coating used that day by its formulation
volume solids content and by its daily transfer efficiency and summing
the results
The solids deposited on day N are:
V
DSD(N) = SUM CGOAY(I.N) * RVS(I) * TE(I,N)]
1=1
A sample calculation is presented in Figure 17.
6-1
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- 7 - TOTAL DAILY BAKE OVEN EXHAUST CONTROL CREDIT
The bake oven exhaust control credit is determined for each day by
weighting together the individual bake oven control device VOC loading
values for that day and the previously determined incinerator efficiencies
The daily weighting factors are the fractions of the total square footage
coated that day that are coated in the spray booth associated with each
bake oven. These weighting factors are the bottom row fractions in the
daily vehicle coating summary.
The bake oven exhaust control credit on day N is:
T
DCC(N) = SUM [TCDL(M,N) * CDE(M) * BRFRAC(M.N)]
M-l
A sample calculation is presented in Figure 19.
7-1
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8 - DAILY COATING USAGE
The volume of each coating used each day can be calculated by
prorating the volume of that coating used in a month to each day in the month,
The prorating factor is the ratio of the total square footage coated with
that coating on the day to the total square footage coated with that
coating in the month.
The volume of each coating used on day N is:
GDAY(I.N) = GMON(I) * DAYSQFT(I.N) / MONSQFT(I)
A sample calculation is presented in Figure 14.
If the owner/operator chooses to make an adjustment for captured
purge coating, then TCP(I.N) should be subtracted from the above result.
The owner/operator may elect to.determine the daily usage of a
coating directly by measuring the start-of-day and end-of-day volume of
the coating in its mix tank, additions of the coating or dilution solvent
to the mix tank, and withdrawals of coating from the mix tank. The daily
usage is equal to:
STARTDAY - ENDOAY + ADDITIONS - WITHDRAWALS
8-1
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9 - DAILY CALCULATION OF VOC GENERATED PER GALLON OF EACH COATING USED
The amount of VOC generated per gallon of each coating used is
calculated each day using the analytical VOC content of the as applied
coating, formulation solvent content of the as applied coating and the
daily transfer efficiency for that coating.
The amount of VOC generated per gallon of coating I used on day N is
RCV(I.N) = RCF(I) * [1 - TE(I,N)] + RCA(I) * TE(I,N)
A sample calculation is presented in Figure 15.
9-1
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10 - ANALYTICAL VQC CONTENT OF AS APPLIED COATING
The analytical VOC content of an as applied coating can be calculated
from records on the additions of coating and dilution solvents to that
coating's mix tanks during the month.
For each addition of coating, the following information is needed:
- Gallons of coating added
- Analytical VOC content by EPA Method 24 (pounds by VOC per gallon)
of the production batch from which the addition was made
For each addition of dilution solvent, the following information is needed.
- Gallons added
- Density (pounds per gallon)
The owner/operator may elect to have the EPA Method 24 analysis
performed by the coating supplier or manufacturer. The owner/operator
may elect to have the dilution solvent density value provided by the
solvent supplier or manufacturer. All other information should be
available from the owner/operator records of additions of coating and
dilution solvent to mix tanks. Sample records are presented in Figure 11;
At the option of the owner/operator, a fixed (maximum) analytical VOC
content value can be used for each coating as long as the use of such
values does not underpredict the emission rate of the topcoat operation.
10-1
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The analytical VOC content of the as applied coating I (pounds of
VOC per gall-on of coating) is equal to:
SUM CPADD(I.J) * CA(I,J)] + SUM [RADD(I.K) * RD(I,K)]
J=l K=l
RCA(I) =
L(I) R(D
SUM PADD(I.J) + SUM RADD(I.K)
J-l K-l
A sample calculation is presented in Figure 13.
For waterborne coatings, if the precision adjustment factors in
Reference Method 24 are used by the enforcing agency, the resulting
analytical VOC content should never be less than the formulation solvent
content. If the adjusted analytical VOC content is less than the formulation
solvent content, then the analytical VOC content should be set equal to
the formulation solvent content. That is:
If CA(I,J) LESS THAN CF(I,J) THEN CA(I.J) = CF(I.J)
10-2
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11 - FORMULATION SOLVENT CONTENT OF AN AS APPLIED COATING
The formulation solvent content of an as applied coating can be
calculated from records on the additions of coating and dilution solvents
to that coating's mix tanks during the month.
For each addition of coating, the following information is needed:
- Gallons of coating added
- Formulation solvent content (pounds of solvent per gallon) of the
production batch from which the addition of as supplied coating was made.
For each addition of dilution solvent, the following information.is
needed:
- Gallons added
- Density (pounds per gallon)
The owner/operator should obtain formulation solvent content data
for the as supplied coating from the coating supplier or manufacturer.
These data should be generated using the procedures described in Sections
31 and 32. The owner/operator may elect to have the dilution solvent
density value provided by the solvent supplier or manufacturer. All
other information should be available from the owner/operator records of
additions of coating and dilution solvent to mix tanks. Sample records
are presented in Figure 11.
At the option of the owner/operator, a fixed (maximum) formulation
solvent value can be used for each coating as long as the use of such
values does not underpredict the emission rate of the topcoat operation.
11-1
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The formulation solvent content of the as applied coating I (pounds
of VOC per gallon of coating) is equal to:
L(D R(I)
SUM [PADD(I.J) * CF(I,J)] + SUM [RADD(I.K) * RD(I.K)]
J-l K-l
RCF(I) =
L(D R(D
SUM PADD(I.J) + SUM RADO(I.K)
J-l K-l
11-2
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12 - FORMULATION VOLUME SOLIDS CONTENT OF AS APPLIED COATINGS
The formulation volume solids content of an as applied coating can
be calculated from records on the addition of coating and dilution solvents
to that coating's mix tanks during the month.
For each addition of coating, the following information is needed:
- Gallons of coating added
- Formulation volume solids content of the production batch from which
the addition of as supplied coating was made.
For each addition of dilution solvent, the following information is
needed:
- Gallons added
The owner/operator should obtain formulation volume solids content
data for the as supplied coating from the coating supplier or manufacturer.
These data should be generated using the procedure in Section 33. All
other information should be available from the owner/operator records of
additions of coating and dilution" solvent to mix tanks. Sample records
are presented in Figure 11.
At the option of the owner/operator, a fixed (minimum) formulation
volume solids value can be used for each coating as long as the use of
such values does not underpredict the emission rate of the topcoat
operation.
12-1
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The volume solids content of the as applied coating I is equal to:
SUM [PADD(I.J) * VS(I,J)]
J-l
RVS(I) =
R(D
SUM PADD(I.J) + SUM RADD(I,K)
J*l K-l
12-2
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13 - DAILY TRANSFER EFFICIENCY
For each coating transfer efficiency shall 6e determined each day by
weighting together the previously determined individual booth transfer
efficiencies for that coating. The individual booth transfer efficiencies
are the values for individual booths [or groups (parallel, and/or series)
of booths] determined by the procedures in Sections 18, 19 and 20.
The daily weighting factors for each coating are the fractions of the
total square footage coated with that coating that day that are coated in
each booth [or group of booths] in which that coating is used. These
weighting factors are the coating row fractions in the daily vehicle
coating summary. These weighting factors provide the relative amount of
solids deposited in each booth. An example calculation is presented in
Figure 10.
The daily transfer efficiency for each coating is calculated by the
following equation.
TE(I.N) =
T
SUM [RFRAC(I.M) / BTE(I.M)]
M-l
Note that since the weighting factors give the relative amount of
solids deposited in each booth, dividing a weighting factor by the
appropriate transfer efficiency tells the amount of solids sprayed.
13-1
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14 - DAILY INDIVIDUAL BAKE OVEN CONTROL DEVICE VOC LOADING VALUES
Bake oven exhaust control device VOC loading values are determined
each day for each bake oven which is vented to a VOC control device by
weighting together the previously determined coating specific bake oven
control device VOC loading values for each coating used in the spray
booth(s) associated with that bake oven. The weighting factors are the
fractions of the total square footage coated that day in the spray booth(s)
associated with the bake oven that were coated with each coating used in
that spray booth(s).
V
TCDL(M.N) = SUM [CDL(I.M) * CFRAC(I,M,N)]
1-1
A sample calculation is presented in Figure 18.
As an alternative, the source owner or operator may choose to set
V
TCDL(M.N) = MIN CDL(I.M)
1=1
14-1
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15 - MONTHLY VEHICLE COATING SUMMARY
For each month, calculate the total number of square feet coated
with each coating. These values can be calculated by summing the daily
totals from the daily vehicle coating summary for each day in the month.
If the owner/operator elects in Section 16 to use equivalent vehicles
instead of square feet, then equivalent vehicles should be used in this
Section too.
W
MONSQFT(I) = SUM DAYSQFT(I,N)
N-l
A sample monthly vehicle coatiny summary is shown in Figure 5.
15-1
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16 - DAILY VEHICLE COATING SUMMARY
The coatings used and the number of square feet coated with each
coating in each spray booth are determined daily. The square foot figures
are determined from the specifications for each type or style of vehicle
coated.
For each day, the total square feet coated with each coating in each
booth is calculated. The fraction of the total square feet coated in
each booth that is done with each coating and the fraction of the total
square feet coated with each coating that is done in each booth are also
calculated each day. These two items are the coating column fractions
(CFRAC) and coating row fractions (RFRAC) in the daily vehicle coating
summary. The fraction of the total square feet coated each day that is
done in each booth is also calculated. This is the bottom row fraction
in the (BRFRAC) daily vehicle coating summary. A sample daily vehicle
coating summary is shown in Figure 4.
The owner/operator may elect to substitute "equivalent vehicles",
and appropriate documented fractions thereof, for square footage values.
Equivalent vehicle means a typical vehicle selected as the basis for
equating an increase or decrease in the fractional size of all other -
vehicles or portions of vehicles coated in a particular topcoat operation
calculated to the nearest 0.01 vehicle. A sample equivalent vehicle
calculation is presented in Figure 22.
The owner/operator may elect to set the daily number of square feet
of in-line repair work done with each coating equal to 4 percent of total
square footage (excluding in-line repair) coated with that coating on that
day. A sample calculation is presented in Figure 23.
16-1
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A sample of the information needed for each vehicle processed is
provided in Figure 3. The owner/operator may el.ect to record this information
or just use this information to create running daily totals for the daily
vehicle coating summary.
16-2
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17 - MONTHLY COATING USAGE
The monthly usage of each as applied coating can be determined from
the start-of-month and end-of-month volume of that coating in its mix
tank, records of additions of coating and dilution solvent to the mix
tank, and records of withdrawals of coating from the mix tank.
The following equation can be used to determine the monthly usage of
an as applied coating.
L(I) R(D
GMON(I) = START(I) - END(I) + SUM PADD(I.J) + SUM RADD(I,J)
- SUM WITH(I.P)
A sample calculation is presented in Figure 12.
17-1
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REVISED 11/88
18 - TRANSFFR EFFICIENCY TEST PROCEDURE - IN PLANT
Applicability
This procedure can be used to determine by in-plant testing the transfer
efficiency with which specific coatings are applied in an automobile or
light-duty truck topcoat operation. The transfer efficiency of color and
clear coats applied in main color booth(s) must be determined with this
method or with the pilot line test method described in Section 19. The
choice of in-plant or pilot line test is made by the owner/operator. At
the option of the owner/operator, the transfer efficiency of other coatings
applied in main color booth(s) (e.g., blackout) and coatings applied in
other booths (e.g., separate "interior" color booth, tutone or in-line
repair) may be determined by this procedure, by the pilot line test
procedure described in Section 19, or by the alternate procedure described
in Section ZU (Alternate Transfer Efficiency Procedure for Untested Booths
and/or Coatings). The results determined by this procedure, the pilot
line test procedure described in Section 19, and the alternate procedure
described in Section 2U are combined for each coating each day in the
Daily Transfer Efficiency Values section (Section 13).
This procedure for transfer efficiency uses the measured weight of
coating solids applied to vehicles or foiled vehicles in production
facilities.
18-1
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REVISED 11/88
Transfer Efficiency Procedure
A. The owner/operator selects the spray booth(s) to be Included in the
test. A main color booth must be included in the test. Each identical
parallel booth in the same assembly line need not be tested.
B. The owner/operator selects the coatings to be used in the test. This
procedure can be run for each coating used, but it is not necessary to
test every coating. The coatings may be grouped based on processing
sequence. Only one coating need be tested from each group and the result
used for all of the coatings in that group. Some sample groupings are
straight shades, non-metallic basecoats, metallic basecoats, mica basecoats
and clear coats. These sample groupings are not the only possible groupings,
Others may be appropriate based on processing sequence (e.g., the processing
sequence for metallic basecoats and mica basecoats may be the same or
silver basecoat may be applied with only air spray while all other metallic
basecoats are applied with air spray and electrostatic spray). The
owner/operator must explain in the test report the groupings used and the
rationale for choosing a particular coating from each group for testing.
To simplify testing and more closely represent actual process conditions,
basecoat and clear coat can be tested together at the owner/operator
option as noted later in this procedure.
C. Select an area in the facility for the body weighing or foil weighing
which has relatively constant temperature and minimal air movement.
D. Topcoat must be the only coating applied during the test. If the
body is weighed, weight loss from all other materials must be accounted for
in the initial test weight.
18-2
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REVISED 11/88
E. A minimum of two foiled or unfoiled vehicle bodies (or major
subassemblies thereof) are to be weighed to determine weight of solids
applied. The test is considered acceptable if each final weight gain
result is within 10 percent of the average weight gain.
F. Identify and preweigh vehicle bodies or major subassemblies to be
painted to the nearest 0.05 Ib. If foil method is used preweiyh all
available foil and tape. After vehicle is foiled, reweigh all unused
foil and tape to determine beginning weight of test foil and tape by
difference.
G. Isolate selected paint material at each spray station by using an
auxiliary paint system or paint pots. Alternatively, at the owner/
operator option, coating usage may be measured from the main circulating
system tanks.
H. At tne owner/operator option, determination of the amount of material
used during the test may be made by weight or volumetric measurement as
follows:
Weight Measurement
1. Weigh the tank of reduced paint after all supply and return
lines have been filled, to nearest 0.05 Ib.
2. Connect the paint tank to the system and paint the test vehicles
or targets.
3. Reweigh the tank to nearest O.Ob Ib.
lb-3
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REVISED 11/88
4. Determine weight of paint material used by subtracting final
weight of tank from the initial weight of tank.
5. Obtain paint samples for weight solids determination.
6. The initial and final weighings of the paint tank must both
be done with the tank pressurized or both be done with the
tank not pressurized.
Volume Measurement
1. a. Verify diameter of paint tank.
b. Determine level in paint circulating tank prior to test, to
nearest 0 .1 inch.
2. Paint the test vehicles or targets. (It is suggested that the
number of units painted should be chosen to achieve approximately
a 3" to 4" drop in a typical circulating tank.)
3. Determine the paint level after the test to the nearest U.I inch.
Paint usage from a cylindrical tank is determined as follows:
Gallons Paint Used s \ \ r^h - Volume occupied by all other equipment
job 231n in the measured section of the tank.
231 = Cubic inches per gallon
J| = 3.141b
18-4
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REVISED 11/88
r = Radius of tank in inches
h = Drop of paint level in tank in inches
n = Number of vehicle bodies or major subassemblies painted to
achieve the measured liquid level drop in circulating tank
4. Obtain paint samples for testing weight solids fraction and
coating density.
J. Reweigh the painted test vehicles, foil or components to the nearest
U.U5 Ib after paint has cured, and cooled.
K. Determine the weight solids of the paint samples using ASTM-D 2369-86.
L. Determine the coating density using ASTM-D 1475 (Ib/gallon).
M. The transfer efficiency is calculated by dividing the weight of paint
solids applied to the vehicle or foil by the weight of paint solids used.
Calculation for Paint Usage by Weight
Transfer Efficiency - average weight gain of target
(average weight coating consumed per job) x
(weight fraction solids)*
Calculation for Paint Usage by Volume
Transfer Efficiency * average weight gain of target
(average gallons coating used per job) x (density) x
(weight fraction solids)*
The test result for coating I in booth M is referred to in the section on
Daily Transfer Efficiency as BTE(I.M).
18-5
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REVISED 11/88
* If more than one coating Is sprayed on each test vehicle (e.g. basecoat
and clear coat), then the denominator Is the sum of all solids sprayed.
General Comments
At the owner/operator option, separate transfer efficiency values for BC and
CC can be determined directly by coating at least two vehicles with BC only
and at least two vehicles with BC/CC. The average weight gain per job for
CC only can be determined by subtracting the average weight gain per job for
BC only from the average weight gain per job for BC/CC.
Frequency of Certification
Transfer efficiency tests must be conducted for an initial compliance
test. The owner/operator must review the operating conditions annually
thereafter. The most recent test results remain valid as long as the
owner/operator demonstrates that no significant changes have occurred in
paint technology or processing. Significant product, processing, material
or application equipment changes will necessitate reevaluation of the
transfer efficiency of the operations which have been modified. Such
complete reevaluation must be done as soon as practicable (not later than
180 days after start-up) after start-up and stabilization of the new
product, process, material or application equipment. The results of this
reevaluation (i.e., new transfer efficiency values) must be used retro-
actively to the start-up of the new product, process, material or application
equipment. Reevaluation is not necessary for:
A. Model year product changes, unless there are significant changes
in size and shape of the typical vehicle.
B. Processing and material changes such as new model year or special
order colors of the same formula type, minor changes in line
rate, minor changes in processing sequence, minor changes in
equipment types, etc.
18-b
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ADDED 11/88
19 - TRANSFER EFFICIENCY TEST PROCEDURE - PILOT LINE
A - Applicability
This procedure can be used to determine by pilot line testing the
transfer efficiency with which specific coatings are applied in an
automobile or light-duty truck topcoat operation. The transfer efficiency
of color and clear coats applied in main color booth(s) must be determined
with this method or with the in plant test method described in Section
Ib. The choice of in-plant or pilot line test is made by the owner/operator.
At the option of the owner/operator, the transfer efficiency of other
coatings applied in main color booth(s) (e.g., blackout) and coatings
applied in other booths (e.g., separate "interior" color booth, tutone or
in-line repair) may be determined by this procedure, by the in-plant test
procedure described in Section la, or by the alternate procedure described
in Section 20 (Alternate Transfer Efficiency Procedure for Untested Booths
and/or Coatings). The results determined by this procedure, the in-plant
test procedure described in Section 18, and the alternate procedure
described in Section 2U are combined for each coating each day in the
Daily Transfer Efficiency Values section (Section 13).
19-1
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ADDED 11/88
B -
This procedure for transfer efficiency uses the measured weight of coating
solids applied to vehicles or foiled vehicles in pilot line facilities.
The production line process is simulated in the pilot line. The pilot
line data are validated against production line data to verify that a
credible simulation has been carried out. Once the pilot line data have
been validated, the pilot TE results are adjusted to improve the correlation
with production line data.
C - Selection of Spray Booth(s) and Coating(s) to be Tested
1. The owner/operator selects the production spray booth(s) to be simulated
in the pilot line test. Each identical parallel booth in the same assembly
line need not be simulated separately.
2. The owner/operator selects the coatings to be used in the test. This
procedure can be run for each coating used, but it is not necessary to
test every coating. The coatings may be grouped by the owner/operator
based on processing sequence. Only one coating need be tested from each
group and the result used for all of the coatings in that group. Some
sample groupings are straight shades, non-metallic basecoats, metallic
basecoats, mica basecoats and clear coats. These sample groupings are
not the only possible groupings. Others may be appropriate based on
processing sequence (e.g., the sequence for metallic basecoats and mica
basecoats may be the same or silver basecoat may be applied with only air
spray while all other metallic basecoats are applied with air spray and
electrostatic spray). The owner/operator must explain in the test report
the groupings used and the rationale for choosing a particular coatir
from each group for testing. To simplify testing and more closely
represent actual process conditions, basecoat and clear coat can be
ing
19-2
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ADDED 11/88
tested together at the owner/operator option as noted later in this
procedure. The coatings used in the pilot test must be coatings that are
used in the plant (i.e., same manufacturer, product code and solvent
reduction conditions).
D - In-Plant Survey and Data Collection
1. The owner/operator conducts an in-plant survey of the spray booth(s)
to be simulated in the test to determine the operating parameters.
The following parameters must be noted:
- Number of spray stations
- Type and number of spray guns at each spray station
- Portion of vehicle coated at each spray station
Additional parameters may be noted at the option of the owner/operator.
These additional parameters could include any or all of the following:
(Note: The more parameters that are noted in the plant and faithfully
reproduced in the pilot line test, the greater the likelihood of the pilot
line test producing acceptable results which pass the tests for data validity.)
"Fluid nozzles and tips
°A1r pressures at the heel of guns
••Electrostatic voltage settings
"Reciprocator trigger points
"Fluid delivery rate per gun
"Open gun times
°Paint temperature
"Paint viscosity
19-3
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ADDED 11/88
"Analytical weight solids
°Fan width
°Dry film thickness
°Gun to target distance
"Resistivity of paint
"Line speed adjusted to plant specifications
°Traverse speed (strokes per minute for recips, cycles for bells)
"Contour bar for reciprocators should be designed for vehicle
being sprayed
°Booth balance
°Booth downdraft (Ifpm)
"Booth temperature
"Booth relative humidity
"Bell RPM
°Bell shaping air
"Bell and recip. angles
"Set zone pressure to those at the process of interest
The in-plant values for each parameter noted must be recorded and
presented in the test report. In situations where the coating of interest
is applied in two or more "identical" parallel booths, the noted parameters
must be measured in at least two of these booths. The individual booth
measurements and average measurement must be presented in the test report.
2. For each coating to be tested, the owner/operator determines the
average weight of solids sprayed per vehicle in the production booth(s)
to be simulated. This is to be done either by determining the average
mass of coating used per vehicle and multiplying by the analytical weight
solids content, or by determining the average volume of coating used per
vehicle and multiplying by the analytical coating density and by the
analytical weight solids content.
19-4
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ADDED 11/88
The averaye mass or volume of coating used per vehicle may be
determined from usage on a block of vehicles as in the in-plant TE test,
from direct measurements (e.g., use of temporary in-line meters), or from
gun on times and fluid flow rates. (See Parts L-7 and L-8 of this section.)
In situations where the coatiny of interest is applied in two or more
"identical" parallel booths, coating usage per vehicle must be determined
usiny data from at least two of these booths.
3. For each coating to be tested, the owner/operator determines the
average in-plant dry film build for Class I and Class II areas. This is
to be done by taking before and after dry film build measurements on at
least two vehicles. (See Part L-6 of this section). At least one before
and after dry film build measurement must be made for each square foot
of Class I surface area coated per vehicle. These measurements must be
uniformly distributed over the Class I area of the vehicle, with the same
distribution used for before and after measurements. At least two before
and after dry film build measurements must be made for each square foot
of Class II surface area coated per vehicle. [Large flat interior panels
(e.g., interior of commercial panel vans) may be treated as Class I area
for dry film build measurements.] These measurements must be uniformly
distributed over the Class II area of the vehicle, with the same distribu-
tion used for before and after measurements, (See Part L-5 of this
section.) In situations where the coating of interest is applied in two
or more "identical" parallel booths, the vehicles on which the film build
measurements are made must be coated in at least two of these booths.
4. The owner/operator calculates the overall averaye dry film build by
weiyhtiny toyether tne averaye Class I and Class II film builds by the
square feet of Class I and Class II area coated per vehicle.
ly-b
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ADDED 11/88
E - Pilot Line Set-Up
1. Select an area in the pilot facility for the body weighing or foil
weighing which has relatively constant temperature and minimal air movement.
2. Topcoat must be the only coating applied during the test. If the
body is weighed, weignt loss from all other materials must be accounted
for in the initial test weight.
3. Prepare the pilot line to simulate the in-plant conditions. The pilot
line must use the same number of spray stations or steps as there are in-
plant. At each station the same type and number of gun(s) must be used and
the same portions of the vehicle must be coated. Additional parameters,
documented in-plant are set in the pilot. The pilot line values for each
parameter that was documented in-plant must be recorded and presented in
the test report. Portions of the vehicle which are not designated for
coating in-plant must not be coated to a greater extent in the pilot
facility than they are coated in-plant (i.e., overs pray that unavoidably
lands in these areas in plant is acceptable in pilot, but intentional
excess coating of undesignated areas in the pilot test is not acceptable).
F - Pilot Line Test
1. A minimum of two foiled or unfoiled vehicle bodies (or major subassem-
blies thereof) are to be weighed to determine weight of solids applied.
The test is considered potentially acceptable, subject to pilot line data
validation, if each final weight gain result is within 10 percent of the
average weight gain.
19-6
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ADDED 11/88
2. Identify and preweigh vehicle bodies or major subassemblies to be
painted to the nearest U.Ob Ib. If foil method is used preweigh all
available foil and tape. After vehicle is foiled, reweigh all unused foil
and tape to determine beginning weight of test foil and tape by difference.
3. Isolate selected paint material at each spray station by using an
auxiliary paint system or paint pots. Alternatively, at the owner/operator
option, coating usage may be measured from the main circulating system tanks,
4. At the owner/operator option, determination of the amount of material
used during the test may be made by weight or volumetric measurement as
follows:
Weight Measurement
i. Weigh the tank of reduced paint after all supply and return lines
have been filled, to nearest U.Ub Ib.
ii. Connect the paint tank to the system and paint the.test vehicles
or targets.
iii. Reweigh the tank to nearest O.Ub Ib.
iv. Determine weight of paint material used by subtracting final
weight of tank from the initial weight of tank.
v. Obtain paint samples for weight solids determination.
vi. The initial and final weighings of the paint tank must both
be done with the tank pressurized or both be done with the
tank not pressurized.
Volume Measurement
i. a. Verify diameter of paint tank.
19-7
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ADDED 11/88
b. Determine level in paint circulating tank prior to test, to
nearest 0.1 inch.
ii. Paint the test vehicles or targets. (It is suggested that the
number of units painted should be chosen to achieve approximately
a 3" to 4" drop in a typical circulating tank.)
iii. Determine the paint level after the test to the nearest 0.1 inch.
Paint usage from a cylindrical tank is determined as follows:
Gallons Paint Used = || r2h - Volume occupied by all other equipment
job 231n in the measured section of the tank.
231 = Cubic inches per gallon
|| = 3.1416
r = Radius of tank in inches
h = Drop of paint level in tank in inches
n = Number of vehicle bodies or major subassemblies painted to
achieve the measured liquid level drop in circulating tank
iv. Obtain paint samples for testing weight solids fraction and coating
density.
5. Reweigh the painted test vehicles, foil or components to the nearest
0.05 Ib after paint has cured, and cooled.
6. Determine the weight solids of the paint samples using ASTM-D 2369-86.
7. Determine the coating density using ASTM-D 1475 (Ib/gallon).
19-8
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ADDED 11/88
*
8. For each coating tested, determine the average weight of solids
sprayed per vehicle in the pilot test. This is done either by multiplying
the average mass of coating used per vehicle by the analytical weight
solids content, or by multiplying the average volume of coating used per
vehicle by the analytical coating density and by the analytical weight
solids content.
9. For each coating tested, the owner/operator determines the average
pilot line dry film build for Class I and Class II areas. This is to be
done by taking before and after dry film build measurements on at least
two vehicles. (See Part L-6 of this section.) At least one before and
after dry film measurement must be made for each square foot of Class I
area coated per vehicle. At least two before and after dry film build
measurements must be made for each square foot of Class II surface area
coated per vehicle. The locations for film build measurements must be
uniformly distributed over the Class I and Class II areas on vehicle
with the same distribution used for before and after measurements. (See
part L-b of this section.)
10. The owner/operator calculates the overall average pilot line dry
film build by weighting together the average Class I and Class II film
builds by the square feet of Class I and Class II area coated per vehicle.
G - Pilot Line Data Validation
1. All of the following tests must be met (except as described in Part K)
in order for the pilot data for a particular coating to be considered valid.
If any of the following tests are not met, the pilot data are not valid
and cannot be used to calculate in-plant transfer efficiency. (See Figure
24.)
19-9
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ADDED 11/88
2. The average weight of solids sprayed per vehicle in the pilot test
must be within or equal to ^20 percent of the average weight of solids
sprayed per vehicle in-plant.
3. The overall average dry film build in the pilot test must be within or
equal to +_ 20 percent of the overall average dry film build in-plant.
4. The percent change in weight of solids sprayed per vehicle from plant
to pilot and the percent change in overall dry film build from plant to
pilot must be within 20 percentage points of each other.
If A - Solids sprayed pilot - Solids sprayed plant *100
Solids sprayed plant
and B » Overall film build pilot - Overall film build plant *100
Overall film build plant
then the absolute value of A - B must be less than or equal to 20.
H - Calculation of Pilot Line TE
1. If all the pilot line data validation tests are satisfied, then the
pilot line TE is calculated by dividing the weight of paint solids
applied to the vehicle or foil by the weight of paint solids used.
Calculation for Paint Usage by Weight (See Figure 25.)
Pilot Transfer Efficiency = average weight gain of target
(average weight coating consumed per job) x
(weight fraction solids)*
19-10
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ADDED 11/88
Calculation for Paint Usage by Volume
Pilot Transfer Efficiency = average weight gain of taryet
(average gallons coating used per job) x
(density) x (weight fraction solids)*
*If more than one coating is sprayed on each test vehicle (e.g., basecoat
and clear coat), then the denominator is the sum of all solids sprayed.
I - Adjustment of Pilot Line TE
1. The pilot line TE values must be adjusted based on the differences in
average weight solids sprayed per vehicle and overall average dry film
build between the pilot line and tne plant. (See Figure 26.) The adjusted
values may be used in the section on Daily Transfer Efficiency. The
adjusted pilot line test result for coating I in booth M is referred to
as BTE(I.M).
BTE(I,M) » Pilot TE * Solids sprayed pilot * Overall film build plant
Solids sprayed plant Overall film build pilot
J - Frequency of Certification
1. Transfer efficiency tests must be conducted for an initial compliance
test. The owner/operator must review the operation conditions annually
thereafter. Significant product, processing, material or application
equipment changes will necessitate complete reevaluation of the transfer
efficiency of the operations which have been modified. Such complete
reevaluation must be done as soon as practicable (not later than 18U days
after start-up) after start-up and stabilization of the new product,
process, material or application equipment. The result of this reevaluation
19-11
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ADDED 11/88
(i.e., new transfer efficiency values) must be used retroactively to the
start-up of the new product, process, material, or application equipment.
Reevalnation is not automatically necessary for:
i. Model year product changes, unless there are significant changes
in size and shape of the typical vehicle.
ii. Processing and material changes such as new model year or special
order colors of the same formula type, minor changes in line
rate, minor changes in processing sequence, minor changes in
equipment types, etc.
2. If no significant changes occur over a year, the owner/operator must
still revalidate and readjust the pilot test data annually. (See Figure 27.)
This is done by conducting an annual in-plant survey of average weight of
solids sprayed per vehicle and average Class I and Class II dry film
build for each coating previously tested on the pilot line. (These data
should be collected in the same manner as in the initial pre-test survey.)
The pilot line test data are then revalidated against the new in~plant
data as described in Parts G and K of this section. If all the required
tests are passed, then the pilot data are still valid and new adjusted TE
values are calculated as described in Parts I and K of this section. If
the pilot data are no longer valid, then a new TE test must be conducted.
(Note: If a coating that was used in the most recent pilot test is no
longer used in-plant, then the annual revalidation and readjustment may be
done using another coating from the same group of coatings.)
3. Similarly, at the owner/operator option, the effect of minor process
or product changes on transfer efficiency may be taken into account at
19-12
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ADDED 11/88
any time without necessarily having to conduct a complete new pilot line
test. This may be done by following the procedure in part J-2 of this
section. If the pilot test data are still valid compared to the new in-
plant data, then new adjusted TE values may be calculated without performing
a new pilot TE test.
K - General Comments
At the owner/operator option, separate TE values for BC and CC can
be determined directly by coating at least two vehicles with BC only and
at least two vehicles with BC/CC. The average weight gain per job for CC
alone can be determined by subtracting the average weight gain per job
for BC only from the average weight gain per job for BC/CC.
The BC only vehicles and the BC/CC vehicles must meet the within 10
percent weight gain tests (Part F-l) for the test to be considered
potentially valid, subject to pilot line data validation.
The BC/CC vehicles must pass all the pilot line data validation
tests in Part la. The BC only vehicles must pass the test in Part G-2.
The BC only vehicles do not have to be assessed witn respect to the test
in Part G-3, G~4 and G-5 (i.e., there is no need to collect BC only film
build data in the plant).
The adjustments to pilot BC and pilot CC TE should be made as follows;
BTE(BC.M) - Pilot BC TE * BC solids sprayed pilot * Overall BC/CC film build plant
BC solids sprayed plant Overall BC/CC film build pilot
BTE(CC.M) = Pilot CC TE * CC solids sprayed pilot * Overall BC/CC film build plant
CC solias sprayed plant Overall BC/CC film build pilot
19-13
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ADDED 11/88
L - Additional Information and Definitions
1. Each dry film build measurement should be performed consistent with
ASTM B499-87, "Measurement of Coating Thicknesses by the Magnetic Method:
Nonmagnetic Coatings on Magnetic Basis Metals." The number of dry film
build measurements should be as specified in parts D-3 and F-9 of this
section, rather than as specified in part 6.3.4 of ASTM B499-87.
2. Class I means exterior surfaces designated to be coated that are
visible with hood, deck lid and doors closed.
3. Class II means all surfaces designated to be coated that are not
Class I.
4. All weight solids determinations must be done with ASTM D2369-86
5. Dry film build measurements are not required to be made on non-magnetic
substrates (e.g., plastic parts) for which the magnetic instruments
described in ASTM B499-87 cannot be directly used to measure coating
thickness if the total designated coated area (Class I plus Class II) of
these substrates is less than 25 percent of the total area (Class I plus
Class II) coated on the vehicles. The total Class I and total Class II
areas coated (including non-magnetic substrate area) must be used to
determine the number of Class I and Class II dry film build measurements
required and to calculate overall average dry film build. (See Figures
28 and 29.) The dry film build measurements that would normally be made
on a particular part, but are not made because the part is constructed of
a non-magnetic substrate must be made on a corresponding part. For
example, if a vehicle has a 10 square foot Class I plastic front fender
and no dry film build measurements are made on that fender, then the
19-14
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ADDED 11/88
(approximately) 10 measurements that would normally be made on the fender
could be made as additional measurements on a rear quarter panel. Other
examples of corresponding parts are hood and deck lid, engine compartment
and trunk interior, etc.
If 2b percent, or more, of the total area (Class I plus Class II)
coated on the vehicle is on non-maynetic substrates, then in-plant and
pilot line dry film build measurement are required for the non-maynetic
substrates. These measurements can be accomplished by wrapping the non-
magnetic substrates with foil or by attaching magnetic basis metal (e.g.,
steel) shims to the non-magnetic substrates. The film build measurement
device must be calibrated for the foil or shims.
6. The requirement to take before and after dry film build measurements
on at least two vehicles can be met at the owner/operator option by taking
before and after measurements on portions of a greater number of vehicles
as long the equivalent of at least two complete vehicles (i.e., two of
each panel or surface) is measured.
The before and after measurements for a particular panel or surface
must be made on the same vehicle. An example of an equivalent vehicle
would be all before and after measurements from front windshield forward
on one vehicle, all before and after measurements from front windshield
to rear windshield on a second vehicle, and all before and after measurements
from the rear windshield back on a third vehicle. The equivalent vehicle
approach may be helpful when the owner/operator chooses to perform in-plant
dry film build measurements while the vehicles are still in process (e.g.,
on the conveyor) as opposed to removing the vehicles from the production
line.
i9-lb
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ADDED 11/88
7. The method used to determine in-pi ant average mass or volume of coating
used per vehicle is chosen by the owner/operator from the options presented
in Part D-2 of this section. The in-plant determinations of average mass
or volume of coating used per vehicle and Class I and Class II dry film
builds must be made contemporaneously. For example, if coating usage per
vehicle is determined from usage on a block of vehicles, then the vehicles
on which film build measurements are made must be included in that block.
If temporary in-line meters or fluid flow rates and gun on times are used
to determine coating usage per vehicle for manual guns, the metering or
gun on time measurements must include the manual coating of the vehicles
on which film build measurements are made. If temporary in-line meters
or fluid flow rates and gun on times are used to determine coating usage
per vehicle for automatic guns, the metering or gun on time measurements
must be done during the same shift in which the automatic coating of the
vehicles on which film build measurements are made.
8. If gun on times and fluid flow rates are used to determine in-plant
average coating usage per vehicle, caution must be used to account for
fluid flow rate variation during the spray cycle of each piece of equip-
ment. This variation could be caused by partial triggering of manual
guns or fluid pressure changes in automatic guns.
IS-lb
-------
20 - ALTERNATE TRANSFER EFFICIENCY PROCEDURES FOR UNTESTED BOOTHS
AND/OR COATINGS
This section describes an alternate transfer efficiency procedure
that may be used for those parts of the topcoat operation whose transfer
efficiencies are not determined using the test procedure in either Section
19 or 20. These parts may include color and clear coatings applied in
untested booths (e.g. separate "interior" color booth, tutone, or in-line
repair); and other coatings applied in tested booths (e.g. blackout
applied in a main color booth).
The following predetermined transfer efficiency values may be used
by these situations:
Air Atomized Spray 40 percent
Electrostatic Spray . 55 percent
If a particular coating is applied with both types of equipment,
then the two transfer efficiency values should be weighted by relative
square footage coated by each method.
Transfer Efficiency
Air Fraction +' Estatic Fraction
.4 .55
Where Air Fraction + Estatic Fraction = 1
The transfer efficiency for coating I in booth M is referred to as
BTE(I,M) in the section on Daily Transfer Efficiency.
20-1
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-------
21 - TEST PROCEDURE FOR DETERMINING BAKE OVEN EXHAUST CONTROL DEVICE VOC
LOADING FOR SPECIFIC COATINGS
This procedure is used to determine the bake oven exhaust control
device VOC loading for specific solvent-borne coatings used in an automobile
or light-duty truck topcoat operation.
Scope
This procedure simulates the loss of VOC from a freshly painted
surface by weight difference before and after baking. Metal test panels
are subjected to simulated coating film build, flashing and baking sequence.
The weight loss during baking is then related to the volume of solids
deposited on the test panels to compute a control device inlet loading in
pounds VOC per gallon solids applied. Identification of the points at
which painted vehicles would enter oven zones whose effluents are vented
to a control device provides the data needed to determine the oven VOC
loading available for destruction in control device equipped zones.
A baking oven must be used to thoroughly cure the paint film. Gas-fired
ovens are more representative of actual production; however, a vented
electric oven may be used.
Film thickness is to be measured with an instrument, such as an
Elcometer or Dualscope. Ensure that this equipment is capable of
measurements on substrate selected if direct measurements on the panels
are to be taken.
21-1
-------
Process
The processing conditions must be determined prior to beginning the
test, including film thicknesses, flash times, and baking sequence, to
ensure use of values that represent the range of conditions found in the
plant.
Identify all locations in the process sequence in which oven effluent
is vented directly to a control device for VOC destruction. This will
affect the number of panel weight measurements taken and the number of
test panels that need to be run. If more than one oven is vented to a
control device then panels need to be run for each different baking
sequence and ventilation pattern.
Selection of Coatings for Evaluation
This procedure need not be run for each coating used. The coatings used
may be grouped based on similar appearance characteristics, processing
sequences and dry film thicknesses. One coating can be tested from each
group and the result used for all of the coatings in that group. Some
sample groupings are straight shades (colors that do not receive a clear
coat), non-metallic basecoats, metallic basecoats, mica basecoats and
clear coats. In order to more closely represent actual process conditions,
basecoat and clear coat can be tested together at owner/operator option
as noted later in the procedure.
For each coating evaluated, run triplicate test panels for each production
bake oven which is vented to a control device.
21-2
-------
Weight Measurements to be Recorded
Weigh panel before paint is applied (W)
Coat panel according to plant process sequence.
Weigh coated panel at point in bake cycle at which exhaust air is first
vented to the incinerator (Wl).
Weigh coated panel at point in bake cycle at which exhaust air is no
longer vented to the incinerator (W2). (Note: Panel should be cooled to
room temperature before weighing).
If W2 does not represent a fully cured coating film, then a duplicate
painted panel should remain in the oven to complete the full bake cycle.
Cool and weigh this panel (W3). [This weight (W3) should be used to
determine the Gallons Solids Applied (GSA), covered later in this section],
Measurement of Film Thickness
Coupons should be coated and baked along with the test panels for
measurement of film thicknesses of basecoat and clearcoat on the panels.
For straight shade systems, film thickness measurements may be taken
directly on the panels.
Dry film thickness measurements should be recorded for basecoat and
clearcoat for each panel tested.
21-3
-------
Determination of Dry Solids Density
Dry solids density may be calculated as shown below. Information needed
to perform this calculation includes the weight fraction solids, volume
fraction solids, and gallon weight of the coating materials as applied.
These values should be determined using the procedures specified in EPA
Method 24. The one-hour bake should be used in the weight fraction solids
determination. The formulation volume fraction solids value should be
generated using the procedure described in Section 33. Solids density is
calculated using the following equation:
SD = WFS x WGC
VFS
SD = Solids Density (Ibs solids/gal solids)
WFS = Weight Fraction Solids (Ibs sol ids/1 bs paint)
WGC = Weight Per Gallon of Coating (Ibs paint/ gal paint)
VFS = Volume Fraction Solids (gal solids/gal paint)
If base coat and clear coat are applied to the same panel, determine the
weighted average paint solids density by the ratio of film thickness as follows:
WSD = Tl x D + T2 x D
cc
Tl + T2 Tl + T2
WSD = Weighed Solids Density
Tl = BC Film Thickness
T2 = CC Film Thickness
21-4
-------
= BC Solids Density
Dcc = CC Solids Density
Calculations
The following calculations are used to express bake oven control device
loading in pounds VOC per gallon solids applied (GSA).
Weight of coating solids applied = coated panel weight after full bake
minus panel weight before coating application.
WPS W3 - W or
WPS = W2 - W if W2 represents a fully cured paint film
where WPS = weight of coating solids applied
Weight of VOC available for control equals panel weight at point which
all exhaust air is vented to control device minus panel weight at point
which exhaust air is no longer vented to the control device.
WSA = Wl - W2
where WSA = weight of VOC available for control
Set up the following ratio for each panel measured:
weight of VOC available for control/weight of paint solids applied
RATIO = WSA/WPS
21-5
-------
Convert this ratio to units of pounds VOC available for control per gallon
of coating solids applied by multiplication of this ratio by paint solids
density.
CDL = RATIO x WSD
where CDL = VOC loading expressed in terms of pounds VOC per gallon
solids applied.
WSD = weighted solids density expressed in terms of pounds solids
per gallon solids
Frequency of Certification
Bake oven exhaust control device VOC loading must be determined for an
initial compliance test. The owner/operator must review the operating
conditions annually thereafter. The most recent test results remain valid
as long as the owner/operator demonstrates that no significant changes
have occurred in coating technology or processing. A significant change
in coating technology is considered to be a major difference in the
generic nature of the coating chemistry. Annual variations in color
palette or routine minor solvent blend adjustments for processing, quality,
or other reasons do not constitute significant changes in coating tech-
nology. Significant process changes may include changing ducting to the
incinerator, or major size modifications to spray booths, flash tunnels,
or ovens.
Equipment
Use triplicate aluminum or thin steel panels with a minimum area of 20
square inches for each coating evaluated.
For weight measurements, use a balance with accuracy to O.OOlg.
21-6
-------
Coating is to be applied in a laboratory spray booth with booth air velocity
representative of production conditions.
Coating materials must be the specific formulations (in as-applied condition)
as used in the plant whose control device VOC loading is to be determined.
21-7
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22 - BAKE OVEN EXHAUST CONTROL DEVICE EFFICIENCY
The efficiency of a bake oven exhaust control device (incinerator
destruction efficiency) should be determined using the following methods
for the inlet and outlet streams:
(a) EPA Method 25 to determine VOC concentration;
(b) EPA Method 1 or 1A for sample and velocity traverses;
(c) EPA Method 2, 2A, 2C, or 2D for velocity and volumetric
flow rates;
(d) EPA Method 3 for gas analysis;
(e) EPA Method 4 for stack gas moisture.
Three runs of EPA Method 25 should be made for each stream. The EPA
Method 25 results for both streams may be adjusted by the result generated
by rumnng a blank (zero air or nitrogen) stream through the sampling
train.
-------
23 - DELETED
23-1
-------
-------
24 - ACCOUNTING FOR CAPTURED PURGED COATING
At the option of the owner/operator, the coating collected by a
purge capture system may be subtracted from the amount of each coating
used each day. To do this, records must be kept of the number of purge
cycles for each coating each day and the standard amount of each coating
captured in a purge cycle. The standard amount of coating captured may
be established by direct measurement or by calculation of the volume of
as sprayed coating in the line(s) being purged.
The total volume of a coating that is captured by the purge capture
system on a particular day is:
•TCP(I.N) = CP(I) * NPURGE(I.N)
24-1
-------
-------
25- RECORDS OF WITHDRAWALS OF COATING FROM MIX TANKS OR CIRCULATING SYSTEMS
If the owner/operator elects to deduct from topcoat usage any quantity
of coating that is not consumed in the topcoat operation, then the following
documentation is required.
Records must be kept of each withdrawal of coating from mix tanks or
circulating system. Withdrawals include discrete removal of coating from
the mix tanks or circulating system in ways other than spraying or purging,
and coating continuously supplied through the circulating system to
operations other than topcoat. Examples of the first type of withdrawal
are coating removed for use in final off-line repair or because of quality
considerations. An example of the second type of withdrawal is coating
supplied through the circulating system to a fascia coating or wheel
coating operation.
The records for each coating must include the date of each discrete
withdrawal and the volume of coating withdrawn. A sample record is
provided in Figure 11. Continuous withdrawals must be accounted for
either by establishing standard values for the volume of coating sprayed
per part outside of topcoat (e.g. fascia or wheel) or by extending the
daily and monthly vehicle coating summaries to include the coating done
outside of the topcoat operation.
If the owner/operator chooses not to document withdrawals of topcoat
materials not consumed in the topcoat operation, then the quantity of
such withdrawals may not be excluded from the calculation of daily topcoat
emission rate.
25-1
-------
-------
26 - NOTES ON ALTERNATE WEIGHTING FACTORS
The weighting factors presented earlier in this procedure are based
on the square footage coated on each vehicle with each coating in each
booth. These factors should give an accurate weighting of individual
transfer efficiency and bake oven control device VOC loading values in
most cases.
If a source owner or operator desires, weighting factors based on
the square feet - mils (i.e. surface area coated times dry film build)
coated on each vehicle with each coating in each booth may be used. Such
weighting factors could be slightly more accurate than weighting factors
based solely on square footage.
In cases where there is a separate "interior" color booth in which
coating is applied to edges and interior surfaces at a significantly
lower dry film build than coating is applied to exterior surfaces in the
main color booth, it may be to the sources' advantage to use weighting
factors based on square feet - mils. In cases where "interior" coating
is done in the main color booth, it is probably to the owner or operator's
advantage to use weighting factors based only on square feet coated.
Weighting factors based on square feet - mils should not be used in
Sections 27 and 29. Weighting factors based on square footage coated
should be used in Sections 27 and 29.
26-1
-------
-------
27 - NOTES ON USING COMBINED
BASECOAT/CLEARCOAT TRANSFER EFFICIENCY JEST RESULTS
As noted In the Transfer Efficiency Test Procedure (Sections 18 and 19),
some transfer efficiency tests may result in a measured transfer efficiency
value for BC/CC combined, rather than individual values for BC and CC.
In this case the measured values may be directly used for each BC. That
is, for each BC, BTE(I.M) should be set equal to the measured transfer
efficiency value for BC(I)/CC. For CC, BTE(CC, M) must be calculated
each day from the daily weighted average of the measured transfer efficiency
values for each BC/CC combination weighted by the fraction of the total
square footage coated in booth M on day N with each BC. These weighting
factors are the coating column fractions in the daily vehicle coating
summary. On day N:
SUM CFRAC (I.M.N)
ALL BC
BTE(CC, M) =
SUM [CFRAC (I,M,N)/BTE(I,M)]
ALL BC
A sample calculation is presented in Figure 21.
27-1
-------
-------
28 - NOTES ON USING TRANSFER EFFICIENCY TEST RESULTS WHEN THE TEST
ENVELOPE IS MORE THAN ONE BOOTH LONG
Some transfer efficiency tests may span more than one spray booth. For
example, an interior color booth and main color booth may be covered by a
single test. If a transfer efficiency test spans booths M and M1, then
BTE(I.M) and BTE(I.M') must be set equal to the test result for coating I.
28-1
-------
-------
29 - NOTES ON USING COMBINED BASECOAT/CLEARCOAT BAKE OVEN
CONTROL DEVICE VOC LOADING DATA
As noted in the Test Procedure for Determining Bake Oven Exhaust
Control Device VOC Loading for Specific Coatings, at the owner/operator
option, control device VOC loading values may be determined for BC/CC
combined, rather than individual values for BC and CC. In this case, for
each basecoat, set CDL(I,M) equal to the measured value for that basecoat/
clearcoat. For clearcoat, CDL(CC,M) must be calculated each day. CDL(CC,M)
should be set equal to the daily weighted average of the measured control
device VOC loading values for each basecoat/clearcoat weighted by the
fraction of the total square footage coated in booth M on day N with each
basecoat. These are the coating column fractions in the daily vehicle
coating summary.
SUM [CDL(I,M) * CFRAC(I,M,N)]
ALL BC
CDL(CC.M) = SUM [CFRAC(I.M.N)]
ALL BC
A sample calculation is presented in Figure 8.
As noted in the section on Daily Individual Bake Oven Control Device
VOC Loading Values (Section 14), as an alternative, TCDL(M.N) can be set
equal to the minimum value measured by the test procedure. In this case
there would be no need to calculate a separate value, CDL(CC,M), for
clearcoat.
29-1
-------
-------
30 - NOTES ON ACCOUNTING FOR DILUTION SOLVENT ADDED BY THE COATING
MANUFACTURER AT A SATELLITE PAINT PLANT
Some assembly plants have nearby satellite paint plants at which the
coating manufacturer may add dilution solvent or other ingredients
to coatings before delivering them to the assembly plant. Satellite
paint plants frequently deliver coatings to the assembly plant in ready-
to-spray condition (i.e. no solvent additions are made at the assembly
plant) on a just-in-time basis.
The satellite paint plant must maintain records of all dilution
solvent additions and all other additions made before shipping coatings
to the assembly plant. The satellite paint plant must also adjust the
analytical VOC content, formulation solvent content and volume solids
content of each container (drum, tote, etc.) of coating shipped to the
assembly plant to account for these additions. These adjustments should
be made using calculations similar to those presented in Sections 10, 11
and 12.
30-1
-------
-------
31 - CALCULATING FORMULATION WEIGHT FRACTION SOLVENT AS OF SUPPLIED COATING
This section describes the calculations which should be performed to
determine the formulation weight fraction solvent content of an as supplied
coating. These calculations should be based on the coating manufacturer's
formula and batch production records at a point in the coating manufacturing
process at and beyond which coating ingredients are mixed or blended only.
(No more chemical reactions should take place in the coating manufacturing
process.) All materials added before packaging for shipment (e.g., for
tinting and adjusting to receive quality control approval) should be
included in-these calculations.
1 - Set B equal to the number of ingredients in the formula for coating
I, including those ingredients added to tint or adjust the coating.
2 - Set WT(I.J.A) equal to the pounds of ingredient A added to the batch
of coating I used in addition J. [For ingredients added by volume,
WT(I,J,A) can be calculated by multiplying the volume (gallons) added by
the density (pounds per gallon) of the ingredient as in Steps 2 through 4
of Section 33. Density should be determined using ASTM D-1475. For dry
materials, actual density, not bulk density, should be determined
analytically. The density analysis may be performed by the supplier of
the ingredient.]
3 - For each ingredient in the formula, determine the weight fraction
volatiles, WTVOL (I.J.A), using the appropriate portion of ASTM D-2832.
(Note that weight fraction volatiles equals 1 minus weight fraction
nonvolatiles.) This information may be provided to the coating manufacturer
by the supplier of the ingredient.
31-1
-------
4 - For each ingredient in the formula which contains water or exempt*
solvents, determine the weight fraction water or exempt solvent, WTNRU.J.A)
This information may be provided to the coating manufacturer by the
supplier of the ingredient.
5 - For each ingredient in the formula, calculate the weight fraction
solvent, WTSOLV(I,J,A), using the following equation:
WTSOLY(I,J,A) = WTVOL (I.J.A) - WTNR (1,0, A)
6 - Calculate the formulation weight fraction solvent content of the as
supplied coating WTFRSV(I.J), using the following equation:
WTFRSVd.J)
B
SUM vrrsoLVd.j.A) * WKI.J.A)
B
SUM WT(I,J,A)
*Exempt solvent means organic solvents which are determined by the
Administrator of the EPA to have negligible photochemical reactivity and
which are similarly recognized in the particular regulation with which
compliance is being determined using this procedure.
31-2
-------
32 - CALCULATING FORMULATION SOLVENT CONTENT OF AS SUPPLIED COATING
This section describes the calculations which should be performed to
determine the formulation solvent content, CF(I,J), of an as supplied
coating.
1 - Determine the density of the coating, DENS(I.J), using ASTM D-1475.
(Note, this is the same density analysis made in determining the analytical
VOC content of the coating.)
2 - Calculate the formulation solvent content, CF(I,J), of the as supplied
coating using the following equation:
CF(I,J) = WTFRSV(I.J) * DENS(I.J)
32-1
-------
-------
33 - FORMULATION VOLUME SOLIDS CONTENT OF AS SUPPLIED COATING
This section describes the calculations which should be performed to
determine the formulation volume solids content of an as supplied coating.
These calculations should be based on the coating manufacturer's formula
and batch production records at a point in the coating manufacturing
process at and beyond which coating ingredients are mixed or blended
only. (No more chemical reactions should take place in the coating
manufacturing process.) All materials added before packaging for shipment
(e.g., for tinting or adjusting to receive quality control approval)
should be included in these calculations.
1 - Set B equal to the number of ingredients in the formula for coating
I, including those ingredients added to tint or adjust the coating.
2 - For ingredients added by weight, set WT(I,J,A) equal to the pounds of
ingredient A added to the batch of coating I used in addition J. For
ingredients added by volume, set VOL(I,J,A) equal to the gallons of
ingredient A added to the batch of coating I used in addition J.
3 - Determine the density, DEN(I,J,A), of each ingredient A in the batch
of coating I used in addition J using ASTM D-1475. For dry materials,
actual density, not bulk density, should be determined analytically. The
units for DEN(I,J,A) are pounds per gallon. This information may be
provided to the coating manufacturer by the supplier of the ingredient.
4 - For ingredients added by weight, calculate the volume (gallons) of
ingredient A added to the batch of coating I used in addition J using the
following equation:
VOL(I,J,A) = WT(I,J,A) / DEN(I.J.A)
33-1
-------
For ingredients added by volume, calculate the weight (pounds) of
ingredient A "added to the batch of coating I used .in addition J using the
following equation:
WT(I,J,A) = DEN(I,J,A) * VOL(I,J,A)
5 - For each ingredient in the formula, determine the weight fraction
volatiles, WTVOL(I,J,A), using the appropriate portion of ASTM D-2832.
(Note that weight fraction volatiles equals 1 minus fraction nonvolatiles.)
This information may be provided to the coating manufacturer by the
supplier of the ingredient.
6 - For each ingredient in the formula, determine the density of the
volatiles in that ingredient, DVOL(I,J,A). The units for DVOL(I,J,A)
are pounds per gallon. This information may be provided to the coating
manufacturer by the supplier of the ingredient.
7 - For each ingredient in the formula, determine the volume fraction
solids, VFS (I,J,A) using the following equation:
VFS(I,J,A) = 1 - WTVOL(I.J,A) * WT(I,J.A)
DVOL(I,J,A) * VOL(I,J,A)
8 - As an alternative to steps 5 through 7, the volume fraction solids of
an ingredient may be determined directly. This would be particularly
useful for ingredients which contain no solids (e.g., solvents) or no
volatiles (e.g., dry solids). Ingredients which are thought to be; pure
liquid resins should be checked as in step 5 to ensure that there are no
volatiles (e.g., low molecular weight olig-imers) present before concluding
that they contain only solids. This information may be provided to the
coating manufacturer by the supplier of the ingredient.
33-2
-------
REVISED 11/88
9 - Calculate the formulation volume solids content of the as supplied
coating using the following equation:
VS(I,J)
B
SUM VFSd.J.A) * VOL(I.J.A)
B
SUM VOLd.J.A)
33-3
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34 - RECQRDKEEPING REQUIREMENTS
The source owner or operator must maintain at the source, for the
time period required by the applicable regulation, all records and
calculations used to determine daily YOC emissions from each topcoat
operation.
34-1
-------
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35 - NOTES ON' USING THIS PROTOCOL TO DETERMINE THE DAILY VOC EMISSION
RATE OF AUTOMOBILE AND LIGHT-DUTY TRUCK SURFACER OPERATIONS
This section reserved for instructions on how to use this protocol
to determine the daily VOC emission rate of automobile and light-duty
truck surfacer operations.
35-1
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-------
APPENDIX A
EXAMPLE CALCULATIONS
A-l
-------
Figure 1
Spray Booth and Bake Oven Layout for Example Calculations
To Incinerator
Interior
Color
Booth
Oven
Main Color
Booth #1
Main Color
Booth §2
[n-Line
tepair
Booth
To Incinerator
-------
FIGURE 2
Notes on sample coating line and sample calculations
Coatings Used
Red
White
Blue Metallic
Clear Coat
(R) straight shade
(W) base coat
(B) base coat
(CC)
Body Styles
2-door
4-door
Tutones
About half of the red vehicles
receive B/CC accent color in tutone booth.
Daily Production
About 800 vehicles per
day
The daily calculations are presented for July 14, 19XX. The index (14)
indicates the 14th day of the month.
-------
FIGURE 3
(See Section 16)
Individual Vehicle Coating Records - July 14, 19XX
Vehicle
Interior
Main Color #1
ID/Style
07140001-2
07140002-2
07140003-2
07140004-4
Color Sq Ft
R 42.0
U 42.0
B 42.0
B 44.0
Color Sq Ft CC Sq
R 150.0 150.0
B 150.0 150.0
Main Color 12
W 150.0 IbU.O
B 160.0 160.0
Tutone
B 70.0 70.0
In-line Repair
B 25.0 25.0
07140780-4 R 44.0
R 160.0 160.0
B 70.0 70.0
-------
FIGURE 4
Coating
R
W
B
CC
Total
Interior
17200(.213)
(.513)
10320(.213)
(.308)
6020(.142)
(.179)
O(.OOO)
(.000)
33540(.136)
(1.000)
Dally Vehicle
Main til
46500(.575)
(.625)
6200(.128)
(.083)
7750(.182)
(.104)
13950(.187)
(.188)
74400(.302)
(1.000)
(See Section 16)
Coating Summary -
Main #2
15500(.192)
(.147)
31000(.639)
(.294)
13950(.328)
(.132)
44950(.602)
(.426)
105400(.428)
(1.000)
July 14, 19XX
Tutone
O(.OOO)
(.000)
O(.OOO)
(.000)
14000(.330)
(.500)
14000(.188)
(.500)
28000(.114)
(1.000)
Repair
1600(.020)
(.317)
960(.020)
(.190)
760(.018)
(.151)
1720(.023)
(.341)
5040(.020)
(1.000)
Total
80800(1.000)
(.328)
48480(1.000)
(.197)
42480(1.000)
(.172)
74620(1.000)
(.303)
246380(1.000)
(1.000)
Square Feet Coated (Row Fraction)
(Column Fraction)
-------
FIGURE 5
(See Section 15)
Monthly Vehicle Coating Summary - July 19XX
Coating Square Feet Coated
R 1,535,200
W 1,018,080
B 849,600
CC 1,641,640
-------
FIGURE 6
(See Section 18)
Transfer Efficiency Test Results
Coating Main Color TE
R .68
W .b7
B .47
CC .74
Each coating was tested because each coating is processed
differently. CC was tested separately. See Figure 21
for example with CC tested together with BC.
-------
FIGURE 7
(See Section 20)
Untested Transfer Efficiencies
Coating
R
W
B
CC
Interior
.40
.40
.40
NA
Tutone
NA
NA
.40
.55
Repair
.40
.40
.40
.55
All interior coating Is done with air spray. Straight shades
and basecoats are applied by air spray In tutone and repair
booths. Clearcoat is applied by electrostatic spray in tutone
and repair booths.
-------
FIGURE 8
(See Section 21)
Bake Oven Exhaust Control Device VOC Loading - Panel Test Results
Coating Main Color Tutone
R 2.0 NA
W/CC 2.3 NA
B/CC 2.1 2.0
Calculation of separate value for main color CC for July 14, 19XX.
(See section 29.)
Main II Main #2
(2.3)(.083) t (2.1)(.104) (2.3)(.294) + (2.1)(
_ = 2.2 _ = 2.2
.083 + .104 .294 + .132
-------
FIGURE 9
(See Section 22)
Bake Oven Exhaust Incinerator Efficiency Test Results
Main #1 96%
Main #2 96%
Tutone 94%
-------
FIGURE 10
(See Section 13)
Daily Weighted TE for July 14. 19XX
,213 + .575 + .192 + .020
74TT .68 .68 .40
1.710
.585
W
.213 + .128 + .639 + .020
T40~ 757" 75T~ .40
1.928
.519
.142 + .182 + .328 + .330 + .018
747" ~37~ T4TT ~4lT
= .433
2.31
CC
= .690
.187 + .602 + .188 + .023
774" 774" T?5~ .55
1.45
-------
FIGURE 11
(See Section 10, 11, 12 and 25)
Monthly Additions for Red - July 19XX
Start 1510
End 1210
Coating
Date
7/1
7/3
7/7
7/9
7/12
7/15
7/18
7/21
7/24
7/28
7/30
Batch
A
A
A
B
B
C
C
C
D
D
D
Gal
PADD
1000
600
850
1000
850
800
700
1000
900
1000
1000
Formula
CF
3.70
3.70
3.70
3.60
3.60
3.80
3.80
3.80
3.60
3.60 .
3.60
Analytical
CA
4.00
4.00
4.00
3.90
3.90
4.20
4.20
4.20
3.90
3.90
3.90
Formula
Vol Solids
VS
.47
.47
.47
.48
.48
.46
.46
.46
.48
.48
.48
9700
Diluent
Gal
RADD
50
60
6U
6U
50
60
340
Density
RD
6.8
6.8
6.8
6.8
6.8
6.8
Withdrawals for Red - July 19XX.
Date Gal Destination
77TI 50 Final repaTF
-------
FIGURE 12
(See Section 17)
Monthly Coating Usage
Coating Gallons Formula
(RCF)
R 10290 3.78
W 3500 4.11
B 3400 4.49
CC 4200 3.31
- July 19XX
Analytical*
(RCA)
4.10
4.32
4.72
3.65
Vol Solids
(RVS)
.456
.423
.359
.527
For red. monthly usage = 1510 - 1210 + 9700 + 340 - 50 = 10290
The data for this calculation came from Figure 11.
* See Figure 13 for sample calculation.
-------
FIGURE 13
(See Section 10)
Analytical VOC Content of as Applied Red Coating - July 19XX
Coating Additions
Diluent Additions
Gallons x
PADD(I.J)
1000
600
850
1000
850
800
700
1000
900
1000
1000
9700
Test VOC
CA(I.J)
4,
4,
4.
3.
3.
4.
4.
4.
3.
3.
00
00
00
90
90
20
20
20
90
90
3.90
= Total VOC
Gallons
PADD(I,K)
50
60
60
60
50
60
340
Density =
RP(I,K)
6.8
6.8
6.8
6.8
6.8
6.8
Total VOC
340
408
408
408
340
480
2312
RCA(I) = 38825 + 2312 = 4.10
9700 + 340
-------
FIGURE 14
(See Section 8)
Coating
I
R
W
B
CC
Month's Usage
GMON(I) x
10290
3500
3400
4200
Day's Sq. Ft.
PAYSQFT(I.14^ t
80800
48480
42480
74620
Month's Sq. Ft.
' MONSOFT(I)
1535200
1018080
849600
1641640
Day's Usage
GDAY(I,14)
541.6 .
.
166.7
170.0
190.9
-------
FIGURE 15
(See Section 9)
VOC Generated per Gallon of as Applied Coating Used - July 14, 19XX
Coating Formula 1-TE Analytical TE VOC Gen
I RCF(I) x + RCA(I) x TE(I.14) = RCV(I,14)
R 3.78 .415 4.10 .585 3.97
W 4.11 .481 4.32 .519 4.22
B 4.49 .567 4.72 .433 4.59
CC 3.31 .310 ' 3.65 .690 3.55
-------
FIGURE 16
(See Section 5)
Total Dally VOC Generated - July 14. 19XX
Coating
I
R
W
B
CC
Total
Gallons
GDAY(I.H) x
541.6
166.7
170.7
190.9
VOC/Ga1
RCV(I,14) *
3.97
4.22
4.59
3.55
VOC Generated
(Pounds)
2150.2
703.5
780.3
677.7
4311.7 = DVI
-------
FIGURE 17
(.See Section 6)
Total nally Volume Solids Deposited - July 14. 19XX
Coating
I
R
U
B
CC
Gallons
GDAY(I.M) x
541.6
166.7
170.0
190.9
Vol Solids
RVS(I) x
.456
.423
.359
.527
Dally TE
TE(I,14) =
.585
.519
.433
.690
Solids Dep
^Gallons)
144.5
36.6
26.4
69.4
Total
276.9 = DSD(14)
-------
FIGURE 18
(See Section 14)
Dally Individual Bake Oven Exhaust Control Device VOC Loading Values
Main 01 2.0(.625) + 2.3(.083) + 2.1(.104) + 2.2(.188) = 2.07
Main n 2.0(.147) + 2.3(.294) + 2.1(.132) + 2.2(.426) = 2.19
Tutone = 2.00
-------
FIGURE 19
Booth/ Oven
Main n
Main #2
Tutone
Total Dally Bake Oven
VOC Loading
TCDL(M,14)
2.07
2.19
2.00
(See Section 7)
Exhaust Control
Control Eff
CDE(M)
.96
.96
.94
Credit - July 14, 1988
Wtg Factor Control Credit
BRFRAC(M,14)
.302 .60
.428 .90
.114 .21
Total
1.71 = DCC(14)
-------
FIGURE 20
(See Section 4)
Dally VOC Emission Rate Calculation - July 14, 19XX
DER(14) = [DV6(14)/DSD(14)] - DCC(14)
= [4311.7/276.9] - 1.71
= 13.86 pounds VOC per gallon solids deposited
-------
FIGURE 21
(See Section 27)
Calculating CC TE from combined BC/CC Transfer Efficiency Test Results
TE test results
W/CC .640
B/CC .580
CC TE for July 14, 19XX
Main Color Booth #1
BTE(CC, Main 1) = .083 + .104 = .187 = .605
.083 * .104 .309
7BW 7550
Main Color Booth 12
BTE(CC, Main 2) = .294 + .132 = .426 = .620
.294 + .13? 7657
76W 75W
-------
FIGURE 22
(See Section 16)
Sample Calculation of Equivalent Vehicles
Vehicle Process Step Square Feet Coated Equivalent Vehicles
2-Door Sedan Main Color 184 0.92
Tutone 10 0.05
4-Door Sedan Main Color 200 1.00
Tutone 12 0.06
Station Wagon Main Color 229 1.15
TUtone 17 0.09
In this sample, the "base vehicle" is the 4-Door Sedan Main Color step.
(200 square feet coated is equated to 1.00 equivalent vehicle.)
-------
FIGURE 23
(See Section 16)
Sample Calculation of 4 Percent Standard Dally Repair Rate
Using data for red (R) coating In Figure 4:
Booth Square Feet Coated
Interior 17200
Main II 46500
Main 12 15500
Total (excluding /9200
repair)
Repair Square Feet Coated = 79200 * 0.04 « 3168
Total (Including repair) - 79200 + 3168 = 82368
-------
FIGURE 24
(See Section 19)
Pilot Line TE Test Data Validation
ADDED 11/88
Wt solids sprayed/vehicle
Average Class I film build
Average Class II film build
Overall average film build
In-Pi ant
2.80 Ibs
2.20 mils
1.30 mils
1.90 mils
Solids sprayed test 3.10 - 2.80 * 1UO = +9.7% OK
3.10
Overall film build change 1.83 - 1.90 * 100 = -3.7% OK
1.90
Consistency of solids sprayed ABS[9.7 - (-3.7)] = 13.4 Ł20 OK
and overall film build
Pilot
3.10 Ibs
2.00 mils
1.50 mils
1.83 mils
-------
ADDED 11/88
FIGURE 25
(See Section 19)
Calculation of Pilot Line TE
Weight solids sprayed per vehicle (pilot) 3.10 Ibs
Weight solids deposited per vehicle (pilot) 1.98 Ibs
Pilot TE = 1.98 = 0.64
3.10
-------
ADDED 11/88
FIGURE 26
(See Section 19)
Calculation of Adjusted Pilot Line TE
Weight solids sprayed per vehicle (pilot) 3.1U Ibs
Weight solids sprayed per vehicle (plant) 2.80 Ibs
Overall average dry film build (pilot) 1.83 mils
Overall average dry film build (plant) 1.90 mils
Pilot TE = 0.64
Adjusted Pilot TE =0.64 * 3.10 * 1.90 =0.74
2.80
-------
ADDED 11/88
FIGURE 27
(See Section 19)
Annual Revalidation and Readjustment of Pilot Line TE Test Data
New In-Plant Old Pilot
Wt solids sprayed/vehicle 3.20 Ibs 3.10 Ibs
Average Class I film build 2.0 mils 2.0 mils
Average Class II film build 1.3 mils 1.5 mils
Overall average film build 1.77 mils 1.03 mils
Solids sprayed test 3.10 - 3.20 * 100 = -3.1% OK
3.20
Overall film build change 1.83 - 1.77 * 100 = +3.4% OK
1.77
Consistency of solids sprayed and
overall film build ABS(-3.1 - 3.4) = 6.7 <_ 20 OK
New Adjusted Pilot TE =0.64 * 3.10 * 1.77
1720" OT
= 0.60
-------
ADDED 11/88
FIGURE 28
(See Section 19)
Determination of Required Number of Dry Film Build Measurements for
Vehicle with Plastic Parts
Square Footage Coated
"Magnetic"
(Steel)
111)
70
180
•ea 50 * 100
"Non-Magneti c"
(Plastic)
40
10
50
= 22% < 25%
Total
IbO
80
230
Class I
Class II
Total
Percent non-maynetic area 50
230
Therefore, dry film build measurements are not needed on non-magnetic areas.
The required number of before and after measurements per vehicle are:
IbO on 110 square feet of magnetic Class I area
IbO on 70 square feet of magnetic Class II area (160 = 80 * 2)
-------
ADDED 11/88
FIGURE 28 (Continued)
Square Footage Coated
"Magnetic"
(Steel)
90
70
"Non-Magnetic"
(Plastic)
60
10
Total
150
80
Class I
Class II
Total 160 70 230
Percent non-magnetic area 70 * 100 - 30% > 25%
•210
Therefore, dry film build measurements are required on non-magnetic areas,
The required number of before and after measurements per vehicle are:
IbO on 150 square feet of Class I area
160 on 80 square feet of Class II area
-------
ADDED 11/88
FIGURE 29
(See Section 19)
Calculation of Overall Average Dry Film Build
Square Feet Coated
Class I 150
Class II 80
Total 230
Overall average dry film build equals:
average Class I dry film build * 150 + average Class II dry film build * 80
230 230
-------
APPENDIX B
SUMMARY OF ADDITIONS AND REVISIONS TO JUNE 10, 1988 VERSION OF PROTOCOL
B-l
-------
Revised Section 18 added November 1988.
Scope moved from page 18-2 to 18-1.
New language in paragraph B on page 18-2.
No changes on page 18-3.
New item 6 at top of page 18-4.
One line moved from page 18-4 to 18-5, and
one sentence moved from page 18-6 to 18-5.
New language in Frequency of Certification
on page 18-6.
B-2
-------
CO
CO
O
v«
d)
Q)
'o
•o
I
ft
-------
D*
Pag
-------
r
fit
*< ,
'^j
,:;
-------
New Figures 24 - 29 added November 1988.
These figures illustrate new Section 19 also added
November 1988.
B-5
-------
New page iii added December 1988.
Adds Appendix A (Example Calculations)
and Appendix B (Summary of Additions and Changes) to
table of contents. The example calculations were
previously in a separately bound volume.
B-6
-------
Revised page 1-2 added December 1988.
New language in first sentence to indicate that example
calculations are in Appendix A.
Adds paragraph about agency review of owner/operator
selected conditions and parameters.
Adds paragraph which notes that changes and additions
from original June 10, 1988, version are summarized
in Appendix B.
B-7
-------
TECHNICAL REPORT DATA
(Please read Instructions on the reverse before completing)
1. REPORT NO. 2.
EPA-450/3-88-018
4. TITLE AND SUBTITLE
Protocol for Determining the Daily Volatile Organic
Compound Emission Rate of Automobile and Light-Duty
Truck Topcoat Operations
7. AUTHOR(S)
David Salman (MD-13) (919) 541-5417
9. PERFORMING ORGANIZATION NAME AND ADDRESS
U.S. Environmental Protection Agency
Chemicals and Petroleum Branch
Office of Air Quality Planning and Standards
Research Triangle Park, NC 27711
12. SPONSORING AGENCY NAME AND ADDRESS
U.S. Environmental Protection Agency
Emission Standards Division
Office of Air Quality Planning and Standards
Research Triangle Park, NC 27711
3. RECIPIENT'S ACCESSION NO.
5. REPORT DATE
December 1988
6. PERFORMING ORGANIZATION CODE
8. PERFORMING ORGANIZATION REPORT NO.
10. PROGRAM ELEMENT NO.
11. CONTRACT/GRANT NO.
13. TYPE OF REPORT AND PERIOD COVERED
14. SPONSORING AGENCY CODE
15. SUPPLEMENTARY NOTES
16. ABSTRACT
This protocol determines the daily VOC emission rate (pounds of VOC per gallon
of coating solids deposited) for a complete automobile and light-duty truck topcoat
operation. The protocol is designed for use in cases where (1) the topcoat emission
limit is stated in units of pounds of VOC per gallon of solids deposited, (2) complianc
is to be demonstrated for each day, and (3) the entire topcoat operation (i.e., all
spray booths, flash-off areas and bake ovens where topcoat is applied, dried, and
cured; except final off-line repair) is treated as a single entity.
17. KEY WORDS AND DOCUMENT ANALYSIS
a. DESCRIPTORS
Automobile Topcoat
Light-Duty Truck Topcoat
Volatile Organic Compound Emissions
18. DISTRIBUTION STATEMENT
Release Unlimited
b. IDENTIFIERS/OPEN ENDED TERMS
19. SECURITY CLASS (This Report)
20 SECURITY CLASS 1 This page)
c. COSATI Field/Group
21. NO. OF PAGES
22. PRICE
EPA Form 2220-1 (Rev. 4-77) PREVIOUS EDITION is OBSOLETE
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