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EPA-600/R-96-117
September 1996
Strategic Environmental Research
and Development Program
Improving Mission Readiness through
Environmental Research
POLLUTION PREVENTION DEMONSTRATION AND EVALUATION OF
PAINT APPLICATION EQUIPMENT AND ALTERNATIVES TO
METHYLENE CHLORIDE AND METHYL ETHYL KETONE
By:
J. M. Elion, J. B. Flanagan, J. H. Turner,
J. T. Hanley, and E. A. Hill
Research Triangle Institute
P.O. Box 12194
Research Triangle Park, North Carolina 27709
EPA Contract No. 68-D4-O120
EPA Project Officer: J. K. Whitfield
Air Pollution Prevention and Control Division
U. S. Environmental Protection Agency
Research Triangle Park, North Carolina 27711
U. S. M. C. Project Officer: D. E. Gillum
Maintenance Directorate
Marine Corps Logistics Base
Albany, GA 31704
Prepared for:
U. S. Environmental Protection Agency
Office of Research and Development
Washington, D.C. 20460
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TECHNICAL REPORT DATA „ ,,
(flease read Instructions on the reverse before complei ||j Hit II fllli! 1! ill II1IIIII 111
1. REPORT NO. 2.
EPA-600/R-96-117
3. ii i iiii ii linn 111 ii ii in ii i in
PB97-104632
4. TITLE AND SUBTITLE
Pollution Prevention Demonstration and Evaluation of
Paint Application Equipment and Alternatives to
Methylene Chloride and Methyl Ethyl Ketone
5. REPORT DATE
September 1996
6. PERFORMING ORGANIZATION CODE
7. authoris) Elion, J, B. Flanagan, J. H. Turner, J. T.
Hanley, and E. A. Hill
8. PERFORMING ORGANIZATION REPORT NO.
9. PERFORMING ORGANIZATION NAME AND ADDRESS
Research Triangle Institute
P. 0. Box 12194
Research Triangle Park, North Carolina 27709
10. PROGRAM ELEMENT NO.
11. CONTRACT/GRANT NO.
68-D4-0120
12. SPONSORING AGENCY NAME ANO ADDRESS
EPA, Office of Research and Development
Air Pollution Prevention and Control Division
Research Triangle Park, NC 27711
13. TYPE OF REPORT ANO PERIOD COVERED
Final; 1-2/95
1*. SPONSORING AGENCY CODE
EPA/600/13
is.supplementary NOTEs^pp^^ project 0fficer is J. Kaye Whitfield, Mail Drop 61, 919/
541-2509.
16. abstractrepOI»t gives results of demonstrations of technologies to prevent or
control emissions of hazardous air pollutants (HAPs) and volatile organic compounds
(VOCs) from processes with high-solvent usage (l) paint stripping using methylene
chloride, (2) cleaning paint equipment with methyl ethyl ketone (MEK), and (3) apply-
ing paint by spraying solvent-borne coatings. In demonstration (1) N-methyl pyrroli-
done was chosen to replace methylene chloride because it effectively removed Chemi-
cal Agent Resistant Coatings (CARCs) in laboratory tests, is nonflammable, and is
not classified as a HAP by EPA. This substitution will lower HAP emissions 11% frorr
1992 levels. In demonstration (2) a blend of 40% propylene carbonate and 60% benzyl
alcohol (PC/BA), by weight, was chosen to replace MEK. This substitution will
lower emissions from HAPs 21% from 1992 levels. The objective of demonstration (3)
was to determine if the amount of paint applied to a vehicle could be decreased by
providing the painters with a real-time readout of the amount of paint they were us-
ing. Results showed that, for identical vehicles, differences up to 30% in the amount
of paint used occurred, indicating that potential exists for significant reductions. No
actual reductions were shown during the demonstration.
17. KEY WORDS ANO DOCUMENT ANALYSIS
a. DESCRIPTORS
b.lOENT!F1ERS/OPEN ENDED TERMS
c. COSATl Field/Group
Pollution Methyl Ethyl Ketone
Paint Removers Monitors
Painting
Chloromethanes
Paint Applicators
Paint Thinners
Benzyl Alcohols
Pollution Prevention
Stationary Sources
Paint Stripping
N-Methyl Pyrrolidone
Methylene Chloride
Paint Equipment Clean-
ing
13 B
11K 14 G
131
07C
HC
18. DISTRIBUTION STATEMENT
Release to Public
19. SECURITY CLASS (ThisReport}
Unclassified
21. NO. OF PAGES
334 ' .
20.SECURITY CLASS (Thispage)
Unclassified
22. PRICE
EPA Form 2220-1 (9-73)
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NOTICE
Tiiis document has been reviewed in accordance with
U.S. Environmental Protection Agency policyand
approved for publication. Mention of trade names
or commercial products does not constitute endorse
ment or recommendation for use.
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FOREWORD
The U. S. Environmental Protection Agency is charged by Congress with pro-
tecting the Nation's land, air, and water resources. Under a mandate of national
environmental laws, the Agency strives to formulate and implement actions lead-
ing to a compatible balance between human activities and the ability of natural
systems to support and nurture life. To meet this mandate, EPA's research
program is providing data and technical support for solving environmental pro-
blems today and building a science knowledge base necessary to manage our eco-
logical resources wisely, understand how pollutants affect our health, and pre-
vent or reduce environmental risks in the future.
The National Risk Management Research Laboratory is the Agency's center for
investigation of technological and management approaches for reducing risks
from threats to human health and the environment. The focus of the Laboratory's
research program is on methods for the prevention and control of pollution to air,
land, water, and subsurface resources; protection of water quality in public water
systems; remediation of contaminated sites and groundwater; and prevention and
control of indoor air pollution. The goal of this research effort is to catalyze
development and implementation of innovative, cost-effective environmental
technologies; develop scientific and engineering information needed by EPA to
support regulatory and policy decisions; and provide technical support and infor-
mation transfer to ensure effective implementation of environmental regulations
and strategies.
This publication has been produced as part of the Laboratory's strategic long-
term research plan. It is published and made available by EPA's Office of Re-
search and Development to assist the user community and to link researchers
with their clients.
E. Timothy Oppelt, Director
National Risk Management Research Laboratory
iii
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ABSTRACT
The purpose of this project was to demonstrate on a foil production scale at the Marine
Corps Logistics Base (MCLB) in Albany, GA, pollution prevention technologies to prevent or
control emissions of hazardous air pollutants (HAPs) and volatile organic compounds (VOCs).
The three processes with high solvent usage selected for demonstration were:
• stripping paint by immersion in methylene chloride,
• cleaning paint equipment with methyl ethyl ketone (MEK), and
• applying paint by spraying solvent-borne coatings.
For the first demonstration, n-methyl pyrrolidone (NMP) was chosen to replace methylene
chloride because it effectively removed Chemical Agent Resistant Coatings (CARC) in laboratory
tests, is nonflammable, and is considered by the EPA not to be a hazardous air pollutant (HAP).
The operators were trained how to operate the new process and equipment, and maintain the
system. For the rest of the demonstration period, the operators used the NMP tank for normal
stripping operations.
The implementation of NMP eliminates a major source of HAP emissions at the MCLB.
The NMP, when heated to 150° ±10°F, was able to remove multiple layers of CARC and strip
parts to the base metal within 3-4 hours. The heated NMP was able to successfully remove
Plastisol®, a plastic coating, from battery tie-down brackets. The NMP was able to soften epoxy-
based topcoats, but removal usually required overnight soaking. The annualized costs for NMP
stripping are lower than for methylene chloride stripping, but implementation requires high capital
investment. This substitution will lower HAPs 11% from 1992 levels.
For the second demonstration, a blend of 40% propylene carbonate and 60% benzyl
alcohol (PC/BA), by weight, was chosen to replace MEK based on the results of laboratory
screening, materials compatibility, and paint removal efficiency tests. MCLB used this solvent as
a direct replacement for MEK. No capital investment was required.
Based on the demonstration, PC/BA cleans green CARC from the pumps as well as MEK,
and cleans epoxy primers better than MEK. Advantages of using PC/BA are lower vapor
pressure, reduced solvent use and reduced labor time for cleaning, and classification of the
hazardous waste as non-RCRA regulated. The disadvantage is a higher cost for the PC/BA blend
than for MEK. This substitution will lower emissions from HAPs 21 % from 1992 levels.
For the third demonstration, the task objective was to determine if the amount of paint
sprayed to paint a vehicle could be decreased by providing the painters with a real-time read out
of how much paint they use. The study began with the design, specification, purchase, and
installation of a paint monitoring system in one of MCLB's paint booths. The system monitors
paint use gravimetrically by continuously monitoring the weight of the 5-gallon paint pot from
which the paint is pumped to the spray guns.
The system proved to work reliably, and paint usage measurements were obtained on a
total of 19 vehicles: 10 HMMWVs, 5 cargo trucks, and 4 other vehicles. The measurements
show that, for identical vehicles, differences up to 30% in the amount of paint used occurred
indicating that potential exists for significant reductions.
This report is submitted in partial fulfillment of Contract No. 68-D4-0120 by Research
Triangle Institute under sponsorship of the U.S. Environmental Protection Agency. This report
covers the period from October 1994 to December 1995.
iv
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TABLE OF CONTENTS
ABSTRACT iv
FIGURES ix
TABLES x
Section 1: Introduction 1-1
Section 2: Demonstration ofN-Methyl Pyrrolidone as a Paint Stripping Alternative .... 2-i
ABSTRACT 2-ii
FIGURES 2-v
TABLES 2-v
ACRONYMS AND ABBREVIATIONS 2-vi
METRIC UNITS 2-vii
ACKNOWLEDGMENTS 2-viii
NOTICES 2-ix
2.1.0 INTRODUCTION ... 2-1
2.1.1 Background 2-1
2.1.2 Objectives 2-3
2.2.0 METHYLENE CHLORIDE STRIPPING PROCESS 2-3
2.3.0 DEMONSTRATION OF NMP PAINT STRIPPING 2-4
2.3.1 Description of NMP Stripping Process 2-5
2.3.2 Retrofit of Existing Equipment 2-6
2.3.3 Operator Training 2-7
2.3.4 Discussion of Parts Stripped with NMP 2-9
2.3.5 NMP Level and Temperature Readings 2-12
2.3.6 Estimate of NMP Losses 2-15
2.3.7 Regulations Affecting NMP 2-16
2.4.0 QUALITY ASSURANCE 2-18
2.4.1 NMP Level Measurements .2-18
2.4.2 Temperature Measurements 2-19
2.4.3 Measurement Problems and Corrective Actions 2-19
2.5.0 IMPLEMENTATION PLAN 2-21
2.5.1 Equipment 2-21
2.5.1.1 Temperature Control 2-21
2.5.1.2 Stripping Bath Recirculation 2-25
2.5.1.3 Rinsing 2-26
2.5.1.4 Distillation 2-26
2.5.1.5 Sensing and Monitoring Devices 2-28
2.5.2 Materials 2-31
v
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TABLE OF CONTENTS (continued)
2.5.3 Safety ..... 2-31
2.5.4 Economic Analysis 2-32
2.5.4.1 OAQPS Control Cost Manual 2-33
2.5.4.2 Obtaining Cost Elements 2-36
2.5.4.3 Unit Costs, Rates, and Assumptions for Economic Analysis .. 2-37
2.5.4.4 Paint Stripping 2-39
2.5.4.5 Return on Investment and Payback Period for NMP Stripping 2-45
2.6.0 DISCUSSION OF OBJECTIVE 2-46
2.7.0 CONCLUSIONS 2-47
2.8.0 REFERENCES 2-48
APPENDICES
2-1: Standard Operating Procedure for Immersion Stripping in NMP 2-49
2-2: Equipment Descriptions 2-57
2-3: Material Safety Data Sheet for NMP 2-101
2-4: Biodegradability and Aquatic Toxicity of NMP 2-107
Section 3; Demonstration of Alternatives for Cleaning Paint Application Equipment.... 3-i
ABSTRACT 3-ii
FIGURES 3-v
TABLES 3-v
ACRONYMS 3-vi
METRIC UNITS 3-vii
ACKNOWLEDGMENTS 3-viii
NOTICES 3-ix
3.1.0 INTRODUCTION 3-1
3.1.1 Background 3-1
3.1.2 Objectives 3-2
3.2.0 TECHNICAL EVALUATION OF ALTERNATIVES TO MEK 3-3
3.2.1 Preliminary Screening 3-3
3.2.2 Material Compatibility .3-13
3.2.3 Paint Removal Efficiency 3-17
3.3.0 ON-SITE DEMONSTRATION OF ALTERNATIVE PAINT EQUIPMENT
CLEANER PROPYLENE CARBONATE/BENZYL ALCOHOL 3-21
3.3.1 Current Process 3-21
3.3.2 Setup of Demonstration 3-21
3.3.3 Demonstration of Alternative Cleaner 3-23
3.3.4 Regulations Affecting Alternative Cleaner 3-28
vi
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TABLE OF CONTENTS (continued)
3.4.0 QUALITY ASSURANCE 3-29
3.4.1 Alternatives Evaluation Phase 3-29
3.4.2 On-Site Demonstration 3-30
3.5.0 IMPLEMENTATION PLAN 3-31
3.5.1 Equipment 3-31
3.5.2 Materials 3-32
3.5.3 Safety 3-32
3.5.4 Economic Analysis 3-33
3.5.4.1 OAQPS Control Cost Manual 3-34
3.5.4.2 Obtaining Cost Elements 3-37
3.5.4.3 Unit Costs, Rates, and Assumptions for Economic Analysis .. 3-37
3.5.4.4 Solvent Substitution 3-39
3.5.4.5 Return on Investment and Payback Period for Cleaning Solvent
Replacement 3-43
3.6.0 DISCUSSION OF OBJECTIVE 3-43
3.7.0 CONCLUSIONS 3-44
3.8.0 RECOMMENDATIONS 3-45
3.9.0 REFERENCES 3-45
APPENDICES
3-1: Material Safety Data Sheets for Coatings 3-46
3-2: Material Safety Data Sheets for MEK Alternatives 3-69
3-3: Materials Compatibility Data 3-101
3-4: Paint Removal Efficiency Data 3-109
3-5: Procedure for Monitoring Cleaning Use 3-111
3-6: Material Safety Data Sheets for Benzyl Alcohol and Propylene Carbonate 3-112
Section 4: Evaluation of Innovative Paint Application Technology 4-i
ABSTRACT 4-M
FIGURES 4-v
TABLES .4-v
ACRONYMS 4-vi
METRIC UNITS 4-vii
ACKNOWLEDGMENTS 4-viii
NOTICES 4-ix
4.1.0 INTRODUCTION 4-1
4.1.1 Background 4-1
4.1.2 Objectives 4-2
vli
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TABLE OF CONTENTS (continued)
4.2.0 TECHNICAL EVALUATION 4-3
4.2.1 Introduction 4-3
4.2.2 Equipment Evaluation and Selection 4-4
4.2.3 Measurement Procedure 4-5
4.2.4 Evaluation of Paint Use Reduction 4-7
4.2.5 Test Variables 4-7
4.2.6 Data Reduction, Validation, and Reporting 4-9
4.3.0 DEMONSTRATION OF INNOVATIVE PAINT APPLICATION TECHNOLOGY
4-9
4.3.1 Baseline Data 4-9
4.3.2 Demonstration Data With Feedback 4-21
4.3.3 Data Evaluation and Discussion 4-23
4.4.0 QUALITY ASSURANCE 4-25
4.5.0 IMPLEMENTATION PLAN 4-27
4.5.1 Equipment 4-27
4.5.2 Installation of the Monitoring System at the MCLB 4-27
4.5.3 Safety . 4-28
4.5.4 Economic Analysis 4-29
4.5.4.1 OAQPS Control Cost Manual 4-30
4.5.4.2 Obtaining Cost Elements 4-32
4.5.4.3 Unit Costs, Rates, and Assumptions 4-33
4.5.4.4 Paint Application Monitoring 4-36
4.5.4.5 Return on Investment and Payback Period for Paint Applicatioiri-40
4.6.0 CONCLUSIONS 4-41
4.7.0 RECOMMENDATIONS 4-42
4.8.0 REFERENCES 4-44
APPENDICES
4-1: Evaluation of ULV Paint Delivery System 4-45
4-2; Painting Procedure Instruction Sheet 4-48
4-3: Summary Data For Paint Demonstration 4-49
viii
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FIGURES
Number Page
2-1. Schematic Illustration of NMP Immersion Paint Stripping 2-5
2-2. Tank Before Retrofitting as NMP Stripping and Rinse Tanks 2-6
2-3. Level and Temperature of NMP in Stripping Tank 2-14
2-4. Piping and Instrumentation Diagram for Tank Retrofit 2-22
2-5. Schematic of Vacuum Distillation Unit 2-27
3-1. Comparison of Screening Results for White Primer 3-9
3-2. Comparison of Screening Results for Tan CARC 3-10
3-3. Comparison of Screening Results for Green CARC 3-11
3-4. Gravimetric Results of Materials Compatibility Tests 3-16
3-5. Paint Removal Efficiency Results of MEK Alternatives 3-20
3-6. Schematic for Monitoring Cleaning of Paint Equipment 3-26
4-1. Schematic of Paint Monitoring System 4-6
4-2. Paint Consumption for Test 1 4-13
4-3. Paint Consumption for Test 2 4-14
4-4. Paint Consumption for Test 3 4-15
4-5. Cumulative Paint Consumption, Test 3 4-16
4-6. Cumulative Paint Consumption, Test 4 4-17
4-7. Cumulative Paint Consumption, Test 5 4-18
4-8. Cumulative Paint Consumption, Test 6 4-19
4-9. Cumulative Paint Consumption, Test 7 . 4-20
4-10. Random Noise in Paint Consumption Data 4-26
ix
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TABLES
Number Page
2-1. Level and Temperature of NMP in Stripping and Rinse Tanks 2-13
2-2. Regulations Impacting the Use of Methylene Chloride and NMP 2-17
2-3. Equipment Used for Temperature Control 2-24
2-4. Equipment Used for Bath Recirculation 2-25
2-5. Equipment Used for Rinsing 2-26
2-6. Equipment Used for NMP Distillation 2-28
2-7. Equipment Used for Monitoring and Recording 2-29
2-8. Vendor List 2-30
2-9. Producers of NMP in the US 2-31
2-10. Threshold Limit Values for NMP and Methylene Chloride 2-31
2-11. Capital Costs for NMP Paint Stripping 2-40
2-12. Annualized Cost Analysis of NMP Paint Stripping 2-41
2-13. Capital Costs for Methylene Chloride Paint Stripping 2-43
2-14. Annualized Cost Analysis of Methylene Chloride Paint Stripping 2-44
2-15. Summary Comparison of Cost Analysis 2-45
2-16. Summary of Hazardous Air Pollut ants Based on 1992 Purchase History .......... 2-46
3-1. Cleaner Blends Screened as Alternatives to MEK 3-5
3-2. Summary of Results of Preliminary Screening 3-7
3-3. Cleaners Selected for Technical Evaluation 3-13
3-4. Percent Weight Change of Materials Immersed 7 Days in Alternative Cleaners 3-15
3-5. Removal of Coatings from Glass Tubes 3-19
3-6. Equipment Used to Monitor Cleaning of Paint Application Equipment 3-23
3-7. Volume and Time to Clean Equipment with PC/BA 3-27
3-8, Volume and Time to Clean Equipment with MEK 3-27
3-9. Regulations Impacting the Use of MEK and PC/BA 3-28
3-10. Chemical Suppliers for PC/BA 3-32
3-11. Annualized Cost Analysis of Cleaning with PC/BA 3-40
3-12. Annualized Cost Analysis of Cleaning with MEK 3-42
3-13. Summary of Hazardous Air Pollutants Based on 1992 Purchase History 3-44
4-1. Project Variables 4-8
4-2. Paint Consumption Data "Without Feedback" 4-21
4-3. Paint Consumption Data "With Feedback" 4-22
4-4. Statistical Data Summary 4-24
4-5. On Site Calibration Check Data for Paint Scale 4-25
4-6. Equipment for the Paint Monitoring System 4-28
4-7. Capital Costs for Paint Application with Flow Monitoring 4-37
4-8. Annualized Cost Analysis for Paint Application with Flow Monitoring 4-38
4-9. Annualized Cost Analysis for Paint Application without Flow Monitoring 4-39
4-10. Summary Comparison of Painting With and Without Flow Monitoring ........... 4-39
x
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SECTION 1: INTRODUCTION
The Clean Air Act Amendments of 1990 (CAAA) and Executive Order 12856 mandate
that military depot activities reduce air emissions. Specifically, the CAAA requires a reduction in
hazardous air pollutant (HAP) emissions for major sources and Executive Order 12856 requires
that military installations reduce HAP emissions by 50% of their 1992 levels. Accordingly, the U.
S. EPA and the U. S. Marine Corps Logistics Base (MCLB), Albany, GA, with sponsorship from
the Strategic Environmental Research and Development Program (SERDP), conducted an initial
evaluation and subsequent demonstration of pollution prevention (P2) technologies for reduction
of HAPs. Processes and related high solvent usage sources were identified and P2
recommendations were made. U. S. EPA and MCLB, the host facility, performed the research.
Research Triangle Institute (RTI) personnel provided contractor support.
MCLB carries out maintenance activities on a wide variety of equipment from small arms
to tanks, trucks, and other vehicles. Much of the maintenance on the vehicles requires removing
existing paint prior to repair procedures and applying new paint once the maintenance has been
performed. The processes for paint stripping, repainting, and cleaning of paint equipment release
significant amounts of HAPs.
The purpose of this research was to demonstrate the P2 technologies on a full production
scale at the MCLB. Three processes with high solvent usage were selected for demonstration:
• stripping paint by immersion in methylene chloride,
• cleaning paint equipment with methyl ethyl ketone (MEK), and
• applying paint by spraying solvent-borne coatings.
For the first demonstration, n-rnethyl pyrrolidone (NMP) was selected as the alternative to
methylene chloride for stripping cured coatings from metal parts. NMP was chosen during a
scoping study for the facility demonstration because it effectively removed Chemical Agent
Resistant Coatings (CARC) in laboratory tests, is nonflammable, and is considered by the EPA
not to be a HAP. Two drawbacks are that the NMP must be heated to be effective, and NMP is
subject to reporting under the Superfund Amendments and Reauthorization Act (SARA).
The first step in preparing for the demonstration was to retrofit an existing tank at the
1-1
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Base. The stripping tank required plumbing to heat the bath with steam, and a recirculating pump
to provide enough agitation to ensure uniform temperature throughout the bath. An adjacent
rinse tank required a pump to draw recycled NMP for rinsing stripped parts. Finally, a vacuum
distillation unit was installed to reclaim used solvent from the stripping bath and provide recycled
NMP for rinsing. After the tank retrofit was completed, the heating and recirculating systems
were tested using water. The stripping tank was then emptied and filled with an initial charge of
32 55-gal. (208 L) barrels of technical grade NMP. An additional 16 barrels was added to the
stripping tank during the course of the demonstration.
The NMP, when heated to 150 ±10°F (66 ±6°C), was able to remove multiple layers of
CARC and strip parts to the base metal within 3-4 hours. The heated NMP was able to
successfully remove Plastisol®, a plastic coating, from battery tie-down brackets. These parts
were previously stripped in a hot alkaline bath, followed by scraping and blasting to remove the
coating. The NMP was able to soften epoxy-based topcoats, but removal usually required
overnight soaking.
For the second demonstration, a blend of propylene carbonate and benzyl alcohol was
chosen to replace methyl ethyl ketone (MEK) for cleaning the paint application equipment
(pumps, hoses, and guns). This demonstration consisted of a preliminary screening to identify
several possible solvent alternatives, testing to select the most effective cleaners, and full-scale
demonstration at the MCLB.
Sixty-five alternative cleaners were tested in preliminary screening for their effect on fully
cured single- and plural-component CARCs and an epoxy primer. From these 65 alternatives, 5
were selected for further testing. The cleaners were tested for their compatibility with materials
that would come in contact with the paints and the cleaner. No measurable weight gain or loss,
pitting, or other signs of corrosion were found between any of the five cleaners or MEK and the
four metals tested: aluminum, stainless steel, nickel, and brass. Material compatibility was also
tested with four plastics (Teflon®, acetal, Nylon®, and Delrin®). Results showed slight weight
changes in all coupons tested with the five cleaners and with MEK. Of the five cleaners, the two
showing the least overall weight gain or loss for the four plastics were evaluated for paint removal
efficiency in a laboratory setting. Overall, both of the cleaners were comparable to MEK for
1-2
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CARC, and both cleaners were better than MEK at removing the white primer.
Based on the test results, the blend of 40% propylene carbonate and 60% benzyl alcohol
(PC/BA) by weight was selected by EPA, MCLB, and RTI for demonstration. Subsequently, four
barrels of this cleaner were shipped to the base and the cleaner was used as a direct replacement
for MEK. No capital investment was required.
Use of the PC/BA cleaner was monitored by weighing the amount of cleaner flushed
through the system. Amounts of cleaner used for the initial prewash, the final wash, and the filter
wash were recorded. Date and time at the start and finish of each step were also recorded.
Results showed that PC/BA cleans green CARC from the paint spray pumps as well as
MEK, and cleans epoxy primers from the pumps better than MEK. Advantages of using PC/BA
are lowered inhalation hazard to workers, reduced cleaner usage and labor time for cleaning.
Other advantages are that the PC/BA is non-RCRA regulated and use of PC/BA significantly
decreases downtime of the primer pumps. The disadvantage is a higher cost for the PC/BA blend
than for MEK. The higher cost may be offset by cleaner recovery and reclamation, and further
waste reduction.
For the third demonstration, the objective was to determine if the amount of paint required
to coat a vehicle could be reduced by providing the painters with a real time readout of how much
paint they use. The study began with the design, specification, purchase, and installation of a
paint monitoring system in a paint booth. The system monitored paint use gravimetrically by
continuously measuring the weight of the 5-gallon paint pot that held the paint to be pumped to
the spray guns. The system included programmable digital scales, a small printer, and large
remote displays visible from within the paint booth. Displays continuously showed the cumulative
amount of paint used.
The initial portion of the test period was devoted to baseline or control measurements
taken "without feedback" of paint consumption. During this period, the displays were not visible
to the painters. After sufficient baseline information had been gathered, the displays were installed
in the paint booth and the painters were instructed in how the displays could be used to control
their usage rate. 'Target" levels for High Mobility Multipurpose Wheeled Vehicles (HMMWVs)
1-3
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and 5-ton trucks were set based on the lowest usage during the baseline period.
The system proved to work reliably, and paint usage measurements were obtained on a
total of 19 vehicles: 10 HMMWVs, 5 5-ton cargo trucks, and 4 other vehicles. The
measurements show that, for one set of identical vehicles (the 10 HMMWVs), paint consumption
differed by up to 30% between the highest and lowest vehicles. This indicates that a potential for
significant reductions may exist. However, during the brief study period, no statistically
significant decrease in paint usage was seen between the baseline (without feedback) and the
experimental (with feedback) portions of the demonstration. This may be due to the short
duration of the demonstration and to the presence of monitoring personnel at the paint booth
during the baseline period. However, the system could still provide reductions in paint usage and
other benefits when used in combination with other strategies such as mixing only the amount
needed for each vehicle rather than the current practice of mixing paint in multiples of 5 gallons.
The system could also be used to assist in training new employees, and to assess the impact of
equipment inspection and maintenance practices on paint consumption.
The recommendation for MCLB is to continue to collect paint usage data for a period of
several months to determine if measurable reductions in paint usage are realized after the staff
becomes accustomed to the equipment.
The MCLB has already replaced 1,1,1 -trichloroethane vapor degreasers with aqueous
parts washers. This change alone will reduce emissions from HAPs by 16%. By eliminating the
methylene chloride for immersion stripping, the MCLB can reduce emissions another 11%. By
replacing methyl ethyl ketone with a propylene carbonate/benzyl alcohol blend for cleaning paint
application equipment, the MCLB can reduce emissions from HAPs an additional 21%. These
three changes combined result in a reduction of emissions of 48%. Tie MCLB plans to replace
solvent-borne CARCs with water-borne CARCs in 1996 to achieve over 50% reduction in
emissions from HAPs.
1-4
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SECTION 2:
DEMONSTRATION OF
N-METHYL PYRROLIDONE AS A PAINT STRIPPING ALTERNATIVE
By:
J. M. Ellon, J. B. Flanagan,
IC»• Hill, and J* II« Turocr
2-i
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ABSTRACT
This section contains the Final Report for the demonstration of n-methyl pyrrolidone
(NMP) as an alternative to methylene chloride for stripping cured coatings from metal parts. It
contains descriptions of both the old and new processes, detailed information on the preparation
of the facilities, and the results of the operational evaluation conducted at the Marine Corps
Logistics Base (MCLB) in Albany, GA. The research was conducted by U.S. EPA with the
contractor services of Research Triangle Institute (RTI). Funding was provided by the Strategic
Environmental Research and Development Program (SERDP).
The purpose of this project was to demonstrate on a full production scale a pollution
prevention technology to replace methylene chloride used for stripping cured coatings from pats
at the MCLB. This base carries out maintenance activities on a wide variety of equipment from
small arms to tanks, trucks, and other vehicles.
NMP was chosen during a scoping study for the facility demonstration because it
effectively removed Chemical Agent Resistant Coatings (CARC) in laboratory tests, is
nonflammable, and is considered by the EPA not to be a hazardous air pollutant (HAP). Two
drawbacks are that the NMP must be heated to be effective and NMP is subject to reporting
under the Superfund Amendments and Reauthorization Act (SARA).
The first step in preparing for the demonstration was to retrofit an existing tank at the
MCLB located near the methylene chloride tank. For successful stripping with NMP, the existing
tank required plumbing to heat the bath with steam available from MCLB, and a recirculating
pump to provide enough agitation to assure uniform temperature throughout the bath. The
adjacent tank required a pump to draw recycled NMP for rinsing stripped parts. Finally, a
vacuum distillation unit was installed to reclaim used solvent from the stripping bath and provide
recycled NMP for rinsing.
After the tank retrofit was completed, the heating and recirculating systems were tested
using water. The stripping tank was then emptied and filled with an initial charge of 32 55-gallon
barrels of technical grade NMP. Additional NMP was added to the stripping tank during the
demonstration.
In parallel, the operators were trained to operate the new process and equipment, and
maintain the system. For the rest of the demonstration period, the operators used the NMP tank
for normal stripping operations, and are still using it as of the writing of this report.
The NMP, when heated to 150 ±10 °F, was able to remove multiple layers of CARC and
strip parts to the base metal within 3-4 hours. The heated NMP was able to successfully remove
Plastisol®, a plastic coating, from battery tie-down brackets. These parts were previously
stripped in a hot alkaline bath, followed by scraping and blasting to remove the coating. The
NMP was able to soften epoxy-based topcoats, but removal usually required overnight soaking.
The implementation of the NMP stripping eliminates a major source of HAP emissions at
the MCLB. This substitution will lower HAP emissions by 11% from 1992 levels.
2-ii
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TABLE OF CONTENTS
ABSTRACT 2-ii
FIGURES 2-v
TABLES 2-v
ACRONYMS AND ABBREVIATIONS 2-vi
METRIC UNITS 2-vii
ACKNOWLEDGMENTS 2-viii
NOTICES 2-ix
2.1.0 INTRODUCTION 2-1
2.1.1 Background 2-1
2.1.2 Objectives 2-3
2.2.0 METHYLENE CHLORIDE STRIPPING PROCESS 2-3
2.3.0 DEMONSTRATION OF NMP PAINT STRIPPING 2-4
2.3.1 Description of NMP Stripping Process 2-5
2.3.2 Retrofit of Existing Equipment 2-6
2.3.3 Operator Training 2-7
2.3.4 Discussion of Parts Stripped with NMP 2-9
2.3.5 NMP Level and Temperature Readings 2-12
2.3.6 Estimate of NMP Losses 2-15
2.3.7 Regulations Affecting NMP 2-16
2.4.0 QUALITY ASSURANCE 2-18
2.4.1 NMP Level Measurements 2-18
2.4.2 Temperature Measurements 2-19
2.4.3 Measurement Problems and Corrective Actions 2-19
2.5.0 IMPLEMENTATION PLAN 2-21
2.5.1 Equipment 2-21
2.5.1.1 Temperature Control 2-21
2.5.1.2 Stripping Bath Recirculation 2-25
2.5.1.3 Rinsing 2-26
2.5.1.4 Distillation 2-26
2.5.1.5 Sensing and Monitoring Devices 2-28
2.5.2 Materials 2-31
2-iii
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TABLE OF CONTENTS (continued)
2.5.3 Safety , 2-31
2.5.4 Economic Analysis 2-32
2.5.4.1 OAQPS Control Cost Manual 2-33
2.5.4.2 Obtaining Cost Elements 2-36
2.5.4.3 Unit Costs, Rates, and Assumptions for Economic Analysis .. 2-37
2.5.4.4 Paint Stripping 2-39
2.5.4.5 Return on Investment and Payback Period for NMP Stripping 2-45
2.6.0 DISCUSSION OF OBJECTIVE 2-46
2.7.0 CONCLUSIONS 2-47
2.8.0 REFERENCES 2-48
APPENDICES
2-1: Standard Operating Procedure for Immersion Stripping in NMP 2-49
2-2: Equipment Descriptions 2-57
2-3: Material Safety Data Sheet for NMP 2-101
2-4: Biodegradability and Aquatic Toxicity of NMP 2--07
2-iv
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FIGURES
Number Page
2-1. Schematic Illustration of NMP Immersion Paint Stripping 2-5
2-2. Tank Before Retrofitting as NMP Stripping and Rinse Tanks 2-6
2-3. Level and Temperature of NMP in Stripping Tank 2-14
2-4. Piping and Instrumentation Diagram for Tank Retrofit 2-22
2-5. Schematic of Vacuum Distillation Unit 2-27
TABLES
2-1. Level and Temperature of NMP in Stripping and Rinse Tanks 2-13
2-2. Regulations Impacting the Use of Methylene Chloride and NMP 2-17
2-3. Equipment Used for Temperature Control 2-24
2-4. Equipment Used for Bath Recirculation 2-25
2-5. Equipment Used for Rinsing 2-26
2-6. Equipment Used for NMP Distillation 2-28
2-7. Equipment Used for Monitoring and Recording 2-29
2-8. Vendor List 2-30
2-9. Producers of NMP in the US 2-31
2-10. Threshold Limit Values for NMP and Methylene Chloride 2-31
2-11. Capital Costs for NMP Paint Stripping 2-40
2-12. Annualized Cost Analysis of NMP Paint Stripping 2-41
2-13. Capital Costs for Methylene Chloride Paint Stripping 2-43
2-14. Annualized Cost Analysis of Methylene Chloride Paint Stripping 2-44
2-15. Summary Comparison of Cost Analysis 2-45
2-16. Summary of Hazardous Air Pollutants Based on 1992 Purchase History .......... 2-46
2-v
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ACRONYMS AND ABBREVIATIONS
APPCD Air Pollution Prevention and Control Division
bbl barrel
Btu British thermal unit
CAA Clean Air Act
CARC Chemical agent resistant coating
CERCLA Comprehensive Environmental Response, Compensation, and Liability Act
CFR Code of Federal Regulations
DMA Depot Maintenance Activity
EPA Environmental Protection Agency
EPCRA Emergency Planning and Community Right-to-Know Act
FTI Finish Thompson, Inc.
HAP Hazardous air pollutant
IWTP Industrial wastewater treatment plant
kW kilowatt
lb pound
MCLB Marine Corps Logistics Base
MSDS Material Safety Data Sheet
NMP N-methyl pyrrolidone
P&ID Piping and instrumentation diagram
P2 Pollution prevention
PP Payback period
PPE Personal protection equipment
QA/QC Quality Assurance/Quality Control
RCRA Resource Conservation and Recovery Act
ROI Return on investment
RTI Research Triangle Institute
SARA Superfiind Amendments and Reauthorization Act
scfrn standard cubic feet per minute
SERDP Strategic Environmental Research and Development Program
TLV Threshold limit value
TRI Toxics Release Inventory
TWA Time-weighted average
Vac Voltage, alternating current
Vdc Voltage, direct current
VOC Volatile organic compound
2-vi
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METRIC UNITS
English units have been included in the report to simplify communication with most of the
intended readership and because they are the primary units used by the Marine Corps Logistics
Base. The multiplying factors for converting from the English units to their metric equivalents are
given in the table below.
METRIC CONVERSION FACTORS (Approximate)
Symbol
When You Know
the Number of
Multiply By
To Find the
Number of
Symbol
LENGTH
in.
inches
2.54
centimeters
cm
ft.
feet
0.3048
meters
m
VOLUME
gal
gallons
3.79
liters
1
MASS '
lb
pounds
0.454
kilograms
kg
PRESSURE
psi
pounds per
square inch
6.89
kilopascals
kPa
TEMPERATURE
op
degrees
Fahrenheit
5/9
(after subtracting
32)
degrees
Centigrade
°C
DENSITY
lb/ft3 pounds per cubic
foot
16.0
kilograms per
cubic meter
kg/m3
FLOW
cfm
cubic feet per
minute
0.472
liters per second
1/sec
2-vii
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ACKNOWLEDGMENTS
The authors gratefully wish to acknowledge the following people at the MCLB, without whose
cooperation and assistance this demonstration would not have been possible:
Steve Allan
Wayne Chauncey
Scott Clements
John Gates
George Hagan
Dave Hudson
Mark Joyner
Gary Holton
Gene Palmer
In addition, the authors thank Mark Waldrop of BASF, Inc., and Pete Scantlebury and Link
Galeza of Finish Thompson, Inc.
The authors would especially like to recognize the contribution of EPA and MCLB's Project
Engineers J. Kaye Whitfield and Dan Gillum to this report. Their project oversight, guidance,
direction, and technical assistance contributed greatly to this research demonstration.
2-viii
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NOTICES
QA/QC requirements apply to this project. Data are supported by QA/QC documentation as
required by USEPA's QA Policy.
The use of trade names and company names in this section does not signify recommendation for
use or endorsement by either the EPA or Research Triangle Institute.
2-ix
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2.1.0 INTRODUCTION
This section reports on the demonstration of n-melhyl pyrrolidone (NMP) as an alternative
to methylene chloride for stripping cured coatings from metal parts. It contains descriptions of
both the old and new processes, detailed information on the preparation of the facilities, and the
results of the operational evaluation conducted at the Marine Corps Logistics Base (MCLB) in
Albany, GA. The Implementation Plan, which is included as Section 2.5.0, contains specifics on
the equipment, piping, and controls installed, information regarding cost savings, and estimated
reductions in hazardous air emissions.
2.1.1 Background
This demonstration was performed at the MCLB. This base carries out maintenance
activities on a wide variety of equipment from small arms to tanks, trucks, and other vehicles.
Much of the maintenance on the vehicles requires removing existing paint prior to the repair
procedures and applying new paint once the maintenance has been performed. The processes for
paint stripping, repainting, and cleaning of paint equipment release significant amounts of
hazardous air pollutants (HAPs). By Executive Order 12856, the MCLB is required to reduce
these air emissions by 50% from 1992 levels. The MCLB desires to accomplish this goal by
implementing pollution prevention (P2) technologies.
Three groups were instrumental in performing the demonstration:
1) U. S. Environmental Protection Agency (EPA)/Air Pollution Prevention
and Control Division (APPCD), Research Triangle Park, NC,
2) Research Triangle Institute (RTI), Research Triangle Park, NC, and
3) MCLB, Albany, GA
The EPA/APPCD initiated this project with funding from the Strategic Environmental
Research and Development Program (SERDP) and provided guidance throughout its duration.
RTI conducted the on-site demonstration in which the alternative paint stripping process was
demonstrated in a production environment. RTI coordinated the project, provided contractor
services (e.g. technical expertise for the design and implementation of the demonstration), and
2-1
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reported to the EPA Project Engineer. The primary responsibility of the MCLB was to support
the demonstration by providing the facilities and production personnel for carrying out the
demonstration. The MCLB technical representative supervised the project at the site and served
as the contact person with EPA and RTI.
The paints used on vehicles at the MCLB are generally considered to be very difficult to
remove. They include primers, undercoatings, and chemical agent resistant coatings (CARCs).
Most of the parts sent to the stripping processes have multiple layers of paint, sometimes as many
as seven layers of CARC over the primer. Most of the coatings used by the MCLB can be
classified as polyurethane-based plural-component and single-component CARCs, epoxy primers,
and undercoatings. The MCLB also uses some epoxy-based topcoats, which also must be
stripped.
One of the stripping processes at the MCLB used methylene chloride. This solvent had a
high priority for replacement not only because it was a HAP, but was also one of seventeen toxic
chemicals identified in the EPA 33/50 Program. The 33/50 Program is a voluntary pollution
prevention initiative to reduce national pollution releases and off-site transfers. The seventeen
toxic chemicals chosen were selected by the EPA because they pose environmental and health
concerns, are high-volume industrial chemicals, and may be reduced through pollution prevention.
The parts stripped at the MCLB mainly consisted of metal vehicle parts such as seats,
fenders, brackets, and housings. The MCLB was already using abrasive blasting processes with
either coal slag, steel grit, or plastic media to remove CARC from most parts. The only parts that
were still being stripped by immersion in methylene chloride were 1) those that would be damaged
by mechanical abrasion, such as parts with bearing surfaces or thin skins, and 2) parts with
complex geometries or blind holes that would be likely to trap the media or be difficult to mask.
This fraction represented less than 3% of all the parts stripped at the MCLB. Even so, the MCLB
purchased an average of 120 55-galIon barrels per year over a three year period from 1992
through 1994. In addition to methylene chloride air emissions, the process generated hazardous
waste in the form of sludge that contained methylene chloride and paint. The MCLB's Depot
Maintenance Activity (DMA) disposed of 8-10 500-lb drums per year of methylene chloride
2-2
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sludge at a cost of approximately $2.80/lb, an estimated yearly cost of $11,200 - $14,000,
N-methyl pyrrolidone (NMP) was chosen as the best alternative from a preliminary
laboratory study at Research Triangle Institute. It effectively removed CARC in laboratory tests,
is nonflammable, and is not considered by the EPA to be a hazardous air pollutant (HAP) under
section 112 of the Clean Air Act (CAA), Two potential drawbacks are that the NMP must be
heated to be effective and NMP was added to the SARA 313 list of reportable compounds for
chronic health effects, effective January 1,1995.
2.1,2 Objectives
The objective of this task was to demonstrate pollution prevention technologies or
processes to reduce the emissions of HAPs resulting from the paint stripping process. This
objective was achieved by replacing the methylene chloride with NMP, a less hazardous and less
volatile solvent. The NMP is also not listed as a HAP under section 112 of the CAA. Data for
this technology was collected on-site at the MCLB from November 1 through December 21,
1995. This process has been implemented and is in use at the Base.
2.2.0 METHYLENE CHLORIDE STRIPPING PROCESS
The first step in the paint stripping process was immersing a metal basket of coated metal
parts in the room temperature methylene chloride for 1-2 hours (depending on the soil loading in
the tank). This was followed by three rinses with tap water; 1) an initial rinse to remove most of
the methylene chloride residue, 2) a pressure wash and pressure rinse to remove any remaining
paint chips, and 3) a final hand rinse. The MCLB estimated the rinsing operations took 10-15
minutes per load. The basket was set aside to allow the parts to air dry. At least two baskets of
parts were stripped per day with this process.
The methylene chloride tank had an approximate surface area of 143 ft2 and was capable
of holding two 48 in. by 48 in. baskets side by side. The depth of methylene chloride in the tank
was approximately 30 in. A layer of water floated on the methylene chloride, serving as a seal to
2-3
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reduce methylene chloride emissions due to evaporation. The water seal was approximately 2-3
in. thick, but was not monitored to maintain a constant thickness. Water from the first rinse was
used to replenish the water seal on the methylene chloride tank; water from the second rinse was
used to replenish the first rinse. Water from the third rinse contained very little methylene
chloride residue and was treated on site at the facility's Industrial Wastewater Treatment Plant
(TWTP).
About every eighteen months, the tank was shut down and cleaned. Most of the paint
chips would settle to the bottom of the tank. MCLB personnel would pump most of the
methylene chloride into 55-gallon barrels. Then the rest of the sludge would be scooped out into
hazardous waste disposal containers, and the methylene chloride from the barrels would be
pumped back into the tank.
This tank was shut down and drained in May 1995, because the methylene chloride failed
to meet chemical specifications. When the tank was drained, severe damage to the tank walls was
discovered. The MCLB decided not to repair the tank, but instead to switch to the NMP process
as soon as it was operational. In the meantime, those parts that would have been stripped in the
methylene chloride were stripped with abrasive blasting. This was a labor-intensive alternative
because these parts required extensive masking to prevent media from becoming trapped, and
usually required multiple passes to remove paint satisfactorily. Other parts, such as the battery
tie-down brackets coated with plastic coating Plastisol®, were soaked in hot alkaline solution
followed by scraping and blasting, also a very time consuming process.
2.3.0 DEMONSTRATION OF NMP PAINT STRIPPING
The first step in preparing for the demonstration was to retrofit an existing tank at the
MCLB located near the methylene chloride tank. Retrofitting involved connecting the steam
supply to the tank heater, installing the recirculating and rinse pumps, and installing the distillation
unit. After the tank retrofit was completed, the heating and recirculating systems were tested
using water in the tank. The stripping tank was then emptied and filled with an initial charge of
thirty-two 55-gallon barrels of technical grade NMP. In parallel, the operators
2-4
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were trained on operating the new process and equipment, and maintaining the system. For the
rest of the demonstration period, the operators used the NMP tank for normal stripping
operations. The following sections describe the new stripping process, and the steps to retrofit
the tank, train the operators, and carry out the rest of the demonstration.
2,3.1 Description of NMP Stripping Process
The first step in the NMP chemical paint stripping process was immersing a metal basket
of painted metal parts in the heated NMP for 2-3 hours (depending on the soil loading in the
tank). The operating temperature range of the NMP was initially 140 ±5 °F, but during the
demonstration, the range was changed to 150 ±5 °F to increase the effectiveness of the solvent
stripping action. After the basket was raised over the stripping tank, the parts were pressure
rinsed with recycled NMP. The pressure rinse removed NMP residue and paint chips, and
allowed the NMP to drain into the stripping tank. The parts were blown with an air gun to
remove additional NMP before the final rinse. The basket was then moved away from the
stripping tank and rinsed with tap water to displace the NMP. This rinse drained to the IWTP.
The MCLB estimates the rinsing operations took 15 minutes per load. The basket was set aside
to allow the parts to air dry. At least two baskets of parts were stripped per day with this new
process. This process is illustrated schematically in Figure 2-1.
&
ft
Recycle and reuse NMP
Immersion rinse
NMP
150°F
2-3 hrs
It
Sludge disposed
as hazardous waste
Pressure wash
NMP
Room temp,
5 minutes
li
Makes up NMP in
immersion tank
Hand wash
Tap water
Room temp.
5 minutes
Wafer treated at
on-site facility
Air dry
Figure 2-1. Schematic Illustration of NMP Immersion Paint Stripping
2-5
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2.3.2 Retrofit of Existing Equipment
The tank designated by the MCLB for retrofitting as a stripping tank was a large stainless
steel tank (see Figure 2-2), about 16 ft. long by 8% ft. wide by 8 ft. deep. It was located in a pit
in the concrete floor (1) with the top edge even with the surface of the floor. There was about a
foot of space (2) between all sides of the tank and the concrete walls. The tank was divided by a
steel wall (3) into two areas, each about 8 ft. long by 8% ft. wide by 8 ft. deep. Lip vent exhausts
(4) were located along the front and rear edge of the tank. It was insulated, but not heated. The
area retrofitted for stripping with NMP had previously contained methylene chloride; the area
retrofitted to hold the recycled NMP for rinsing was previously a caustic tank. A crane was
available over the top of the area to load and unload baskets. The same baskets were used as with
the methylene chloride process.
Stripping tank /
Figure 2-2. Tank Before Retrofitting as NMP Stripping and Rinse Tanks
Drawing is not to scale.
When the tank was rinsed and inspected before starting the retrofit, a small hole was found
in one corner of the tank that was repaired by welding. No other repairs were required. The left
side of the tank in Figure 2-2 was retrofitted as the stripping tank because it was closer to the
existing steam supply. The right side of the tank in Figure 2-2 was used to hold distilled
2-6
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NMP reclaimed from the vacuum distillation unit. TMs side was dubbed the "rinse tank" because
the recycled NMP from this tank was used to rinse stripped parts.
The main changes necessary to retrofit the tank for the NMP process were adding the
capability to heat and distill the NMP in the stripping tank. Pre-existing steam lines were
extended to the platecoil in the tank to provide heat. A recirculating pump was added to
distribute the heat and assure a uniform temperature throughout the NMP. A vacuum still was
plumbed and wired to the tank to distill the paint-laden NMP and provide clean NMP for rinsing.
Level and temperature sensors were added to the stripping and rinse tanks and wired to both
visible digital readouts and strip chart recorders. These sensors measured the NMP usage and
provided input to the controllers for the steam automatic shutoff valve. The details on the
equipment used for retrofitting the tank are discussed in greater detail in Section 2.5.1, including
the complete bill of materials, vendor addresses, costs, and a Piping and Instrumentation Drawing
(P&ID).
All major equipment and the NMP were purchased on the contract. The MCLB provided
the labor and small parts to install and connect all plumbing, steam lines, water lines, and electrical
lines for the tank and distillation unit. The MCLB also fabricated a metal grid stand to place on
the bottom of the tank. The stand was higher than the eductors so that operators would not
accidentally hit the eductors with a loaded basket.
Upon completion of the plumbing and electrical connections for the temperature control
and recirculation pump, the stripping tank was filled with water for a "wet check" of the system.
No leaks were detected, the pump ran properly and the steam heated the water to 140°F. The
tank was drained and filled with thirty-two 55-gallon barrels (14,784 lbs) of NMP to an initial
depth of 40.8 inches. The strip chart recorders were turned on with a recording speed set at 12
cm/hour. The tank was heated to 140°F and was ready to be used for paint stripping.
2.3,3 Operator Training
One of the most important requirements for introducing a new process is training and
gaining acceptance from the operators and maintenance personnel. Upcoming changes were
discussed with the operators while the equipment was being installed. The reasons for the process
2-7
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change were explained and questions were answered about the new solvent and proeess. While
the tank retrofits were being completed, a Standard Operating Procedure for the new process was
written (Appendix 2-1). The operators were trained on the uses and safety protocols for NMP
and on the new stripping procedure during an afternoon classroom training session. A second
training session on the new stripping procedure was conducted at the tank, where safety and
handling a combustible solvent were discussed again. Project personnel were also on site for the
cleaning of the first parts and many other days during the demonstration to inspect parts and
answer questions.
Learning the procedure for chemical stripping with NMP was not difficult for the
operators because it was similar to stripping with methylene chloride. Parts were still loaded in a
48 in. by 48 in. wire basket and positioned relative to each other so as to prevent nesting. The
basket was lowered into the NMP and soaked for about 2-3 hours. The parts were still rinsed,
except that the first rinse was with NMP instead of water. The basket was raised over the
stripping tank while the parts were rinsed so the NMP drained into the stripping tank. The initial
NMP rinse helped make up losses to emissions, dragout, and recycling. Additional NMP was
pumped from barrels or from the rinse tank into the stripping tank to keep the stripping tank at
operating level.
The main differences in procedures were in the operation of the tank. The methylene
chloride process operated at room temperature, but the NMP had to be heated to about 150°F to
be effective on the more difficult coatings such as the Plastisol® used to prevent corrosion on
battery tie down brackets. The heating and recirculation system automatically maintained the
working temperature of the NMP. To reduce NMP loss, the system was turned off during
weekends and long shutdowns over holidays.
The second new area that the operators needed to learn was the operation of the
distillation unit. The methylene chloride was not distilled; instead the paint was allowed to settle
and was removed about every eighteen months as described earlier in this report. The distillation
unit is a vacuum still that was designed to be used with the NMP. The still was installed under a
shelter just outside the area of the cleaning tank and plumbed to the tanks. It can be operated in
batch or continuous mode. Because the amount of paint removed from the parts is small
2-8
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compared to the volume of the tank, the still does not have to operate continuously. It only needs
to be operated when the effectiveness of the NMP decreases. Decreased effectiveness is indicated
by an increase in stripping time or when the paint is not removed as well. Operators, maintenance
personnel, and engineers were trained on the operation of the distillation unit by representatives of
the company that manufactured the still. This training included hands-on operation of the unit,
and instructions on draining the sludge from the still. During the demonstration, the still was
operated after an estimated twenty baskets were stripped, even though the NMP had not yet
reached the point where its effectiveness was decreasing.
A second training session on the operation of the stripping tank was found to be necessary
and was conducted at the stripping tank for the operators. The need for a second training session
was indicated by two instances of tank overheating. The operators were aware that the steam
needed to be turned on, but neglected to close the bypass valve when the temperature was within
the operating range of 150±5°F. An estimated 91 gallons (770 lbs.) of NMP were lost by
evaporation resulting from tank overheating. During this training session, safety protocols and
the use of personal protection equipment were reviewed. The steam supply valve, the bypass
valve, and the control line valve were labeled. Instructions for tank heat up, operation, and
shutdown, contained in the operating procedure, were reviewed. A laminated instruction sheet
was attached to the recirculation pump control panel for easy reference. In addition to a second
training session, an alarm and a shut-off valve were purchased for the steam line. The shut-off
valve would automatically close the steam supply if the temperature of the NMP in the stripping
tank exceeded 160°F. An alarm would also sound if the temperature dropped below 140°F as a
warning to the operators that the stripping bath was below minimum operating temperature.
2.3.4 Discussion of Parts Stripped with NMP
The first basket stripped with the new process was loaded with battery tie-down brackets
and quick disconnects for water pumps. The tie-down brackets were coated with black
Plastisol®, a plastic coating that is very difficult to remove. The disconnects were coated with
several layers of CARC. The basket was observed after one hour immersion at MOT. The
2-9
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Plastisol® was peeling off the battery tie-down brackets, but was not completely removed. Also,
the CARC was softening on the disconnects but was not sloughing off. The basket was left in the
bath for an additional hour. While the basket was over the NMP bath, the parts were blown with
an air gun to force excess NMP back into the tank. The basket was moved away from the tank
and the parts were then rinsed with water. The NMP-stripped parts were examined and found to
have removal of nearly all of the Plastisol® from the tie-down brackets and the CARC from the
disconnects. Some of the remaining coating sloughed off when the parts were handled. On some
parts, the coating had softened but still adhered to the part; in these instances, the coating had
been very thick. Since NMP is absorbed through multiple layers down to the base metal and then
lifts the entire coating, parts with very thick coating or multiple layers would probably need to be
left in the stripping tank overnight.
During the first three weeks of November, MCLB stripped about three or four baskets of
parts. The parts were mostly battery tie-down brackets, disconnects, and filter housings. After
Thanksgiving, MCLB stripped about three or four baskets a week. Of an estimated twenty
baskets stripped over the course of the demonstration, MCLB only reported problems with two
baskets. All the remaining baskets of parts were stripped well enough for the parts to continue
through production.
The project's engineers received reports that two baskets of parts had not teen adequately
stripped with NMP and investigated both reports. The first basket was stripped early in the
demonstration period. The parts were battery tie-down brackets and filter housings that looked
like open-ended shoe boxes. The battery tie-down brackets were coated with Plastisol®; the filter
housings were coated with green CARC over white primer. The parts had been stacked in a 48
in. by 48 in. wire basket and placed in the tank for 2 hours. The NMP tank was at 140°F when
the parts were put in, but had dropped to 127°F when checked l'/i hours later. MCLB personnel
reported that the temperature control valve on the steam line did not open. The valve was
adjusted, and the NMP temperature rose to 140°F. The parts were inspected during the next
site visit. There was indeed paint on the sides of the boxes and some on the supports. When the
nested boxes were pulled apart for visual examination, more paint was left on the inside of the
boxes than the outside. It could not be determined whether there was more paint on one side
2-10
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than the other. The remaining paint was dry and flaky and was removable by brushing with
gloved fingers. The parts were also rusty, which meant they would next be sent through an
abrasive blasting process. The report from one of the area Leadermen was that these parts
normally require 20-30 minutes abrasive blasting on a Roto-Blaster when they do not use
chemical stripping. He thought that the NMP-stripped parts would only need 1-2 minutes in their
current condition, a good improvement in time and personnel effort.
During the second training session, one of the operators mentioned that paint was not
removed from parts that had been left in the tank for a whole day. The parts had already been
sent to abrasive cleaning and were not available for inspection by research project's engineers.
Again, the parts had been stacked in a 48 in. by 48 in. wire basket. The steam supply line had
teen closed and the pump had been shut off the previous day. The steam line had not been re-
opened that morning and the pump was not on when the basket was placed in the tank. Based on
a similar occurrence during startup, the tank temperature had probably dropped from operating
temperature to about 110°F by morning and would have dropped further with the addition of
parts. Without the temperature control valve to allow controlled heating of the tank, the bath
temperature would have continued to drop.
In both instances, incomplete removal of paint was most likely caused by failing to strip
the parts at the correct operating temperature. After the first incident, the operating temperature
range was changed from 140 ± 5 °F to 150 ±5 °F. After the second incident, an alarm and a shut-
off valve was ordered and placed on the steam line.
During the demonstration, a white vapor sometimes developed over the stripping tank. It
was especially noticeable, along with a heavy amine odor, during the two instances when the tank
was over heated. It would usually appear when the recirculating pump was on and disappear
when the pump was turned off, even at operating temperatures. This suggests that the agitation
of the pump is increasing air emissions. The vapor was also obvious when the ventilation and lip
vent exhausts were turned off. The vapor is believed to be primarily NMP, perhaps with some
water present. Lower pump flow rate may help reduce turbulence in the bath and still maintain an
even temperature throughout the bath. Also, the ventilation and exhaust system is to remain on at
2-11
-------
all times, as it is with other tanks at the MCLB containing caustic or other hazardous compounds.
Currently, the operators are stripping one basket in the morning, one in the afternoon, and
occasionally leaving some parts in overnight. MCLB noted that souk parts require abrasive
blasting to remove corrosion after chemical stripping and that loose coatings or small amounts of
coatings remaining on these parts would be easily removed in a single pass.
2.3.5 NMP Level and Temperature Readings
The level and temperature of both the stripping tank and the rinse tank were continuously
plotted on strip chart recorders. The strip charts were collected daily by the project engineers
during site visits. Pens and paper were changed as necessary. Rippling of the agitated NMP
surface caused noise on the level readings that made it difficult to read the levels accurately.
Beginning November 16, 1995, daily readings of the tanks were taken with the recirculation pump
turned off and no basket in the tank when they were on site.
The tank levels and temperatures are summarized in Table 2-1. The data are depicted
graphically in Figure 2-3. The rinse tank remained empty until it was filled with recycled NMP, as
indicated in Table 2-1.
When the steam valves were set properly, the temperature in the stripping tank
maintained a near constant 152+2 °F. A number of factors affected the level readings: agitation
from the recirculation pump, whether a basket of parts was in the tank, temperature of the tank,
and additions of NMP, It was noted following the distillation cycles that the NMP in the rinse
tank is slightly warmer than ambient. This is because 1) the NMP is still warm when it drains
from the still, and 2) heat from the stripping tank transfers through the steel separating wall The
warmer temperature of the rinse tank is not a cause for concern.
2-12
-------
Table 2-1. Level and Temperature of NMP in Stripping and Rinse Tanks
STRIP
STRIP
RINSE
RINSE
TIME
DATE
LEVEL
TEMP
LEVEL
TEMP
COMMENTS
(in)
(°F)
(in)
(°F)
9:00 AM
11/01/95
40.8
92.0
0.0
N/A
Added 32 bblsf of NMP to stripping tank; took initial readings.
9:00 AM
11/02/95
40.0
88.0
0.0
N/A
2:30 PM
11/06/95
38.4
68.4
0.0
N/A
Heat off over weekend; not on when reading was taken.
10:30 AM
11/13/95
40.4
138.0
0.0
N/A
Heat off over weekend; tank not at operating temperature when reading was taken.
11:55 AM
11/14/95
44.8
130.0
0.0
N/A
Added 5 bbls of NMP (used to check out distillation unit); addition of room temp NMP
raised level and lowered temp.
Adjusted thermal control valve to maintain 150°F.
8:00 AM
11/15/95
41.6
152.0
0.0
N/A
10:35 AM
11/16/95
42.0
150.0
0.0
N/A
8:15 AM
11/27/95
42.0
170.0
0.0
N/A
Steam bypass not closed and tank overheated; shut off steam bypass valve.
Added 1 bbl of NMP to makeup losses.
1:00 PM
11/27/95
40.0
122.0
0.0
N/A
(Steam bypass valve locked out to prevent being its left open.)
4:45 PM
11/28/95
40.8
152.0
0.0
N/A
8:15 AM
11/29/95
40.0
152.0
0.0
N/A
8:45 AM
11/30/95
40.0
152.0
0.0
N/A
12:55 PM
12/04/95
40.7
125.0
0.0
N/A
Heat off over the weekend; tank not at operating temperature when reading was taken.
4:05 PM
12/05/95
41.2
154.0
0.0
N/A
4:30 PM
12/06/95
40.7
155.0
0.0
N/A
4:22 PM
12/07/95
40.6
154.0
0.0
N/A
9:00 AM
12/12/95
37.6
156.0
0.0
N/A
1:12 PM
12/14/95
36.9
155.0
0.0
N/A
Reading before adding NMP and before distilling.
2:40 PM
12/14/95
49.6
137.0
0.0
N/A
Reading after adding 10 bbls of NMP and before distilling.
3:15 PM
12/15/95
40.8
152.0
10.4
104
Reading after completing 6 distillation cycles.
t bbl — 55-gallon barrel
-------
PO
I
300.0
250.0
200.0
CD
0)
O)
25.0
- 20.0
50.0
a TEMP (F) ¦ LEVEL (in)
15.0
10.0
10/28 11/2 11 n 11/12 11/17 11/22 11/27 Mil 12/7 12/12 12/17
t bbl — 55-gallon barrel DATE
Figure 2-3. Level and Temperature of NMP in Stripping Tank
-------
2.3.6 Estimate of NMP Losses
Mass balance is a more effective method for measuring total air emissions than measuring
fugitive air emissions in this system, since it will include losses from any leaks in the equipment
and the amount of solvent lost when parts are pulled from the cleaning tank and allowed to dry in
a separate area. All of this material eventually ends up as air emissions. These measurements
need to be taken over a long enough period to show a statistical difference.
Calculating an accurate mass balance is difficult for the following reasons:
• Shortened duration of demonstration period,
• Changes in tank temperature on weekends,
• Presence of parts being cleaned when some level measurements were being taken,
• Failure of the strip chart recorders that required a pro ject engineer/technician to be
present to manually record the temperature and levels, and
• Lack of written records kept of number and type of parts stripped, etc.
The fundamental mass balance equation is as follows:
AM = [M0 + Md ] - Mt
where, AM = mass of solvent lost between times zero and t
M0 = mass of solvent in the tank at time zero
Md = mass of solvent added from drums between times zero and t
M, = mass of solvent in the tank at time t
The quantity [M„ + Md] is known, because forty-eight 55-gallon barrels were added to the
tank in whole increments over the course of the demonstration. Paint dissolved in the NMP was
assumed to be negligible. This assumption was based on the fact that at the end of the
demonstration period, the viscosity of the sludge was below the detection limit of the distillation
unit after completing six cycles. The calculations are shown below:
2-15
-------
AM" [NMP.StartJTntal] i^MPmnaUS)ripping tank + HnuUiiinse mnk ]
= WMPStart/Tota[ )] - l(Atank) *&NMPs) *(P]50«»f) + ^tank )*(ftWFr)*(p10o^)]
= [22,176 lbs] - [(14,708 lbs) + (3829 lbs)]
= 3639 lbs
where A,^ = the surface area of each tank (A^^ ^ = 70 ft2),
hNMP g = the height of NMP in the stripping tank (in feet),
Piso-f - density of NMP at 150°F in the rinse tank (61.8 lb/ft1), and
hNMP r = the height of NMP in the rinse tank (in feet),
Phot = the density of NMP at 100°F in the rinse tank (63.6 lb/ft3).
Over the course of the six week demonstration, approximately 3,640 lbs. were lost to
emissions, dragout, and recycling. At this point, over 95% of these losses may be attributed to
NMP emissions and dragout because only six distillation cycles were run at the end of the
demonstration period. Over time, as the paint sludge accumulates in the still, the MCLB will be
able to determine how much NMP is lost in the still bottoms. At least 25% of this loss may be
attributed to tank overheating. Based on these losses, the MCLB will need to add an estimated 3
barrels of NMP each month to the stripping tank. This amount may vary as the operators become
more experienced with the process. This is a significant reduction over the previous process,
which required the addition of approximately 10 barrels of methylene chloride each month.
2.3.7 Regulations Affecting NMP
Replacing methylene chloride with NMP will reduce the amount of tracking and reporting
for the MCLB for this process. Regulations impacting the uses of methylene chloride and NMP
are summarized in Table 2-2. NMP is subject to some but not all these regulations. Most
importantly, unlike methylene chloride, NMP is not listed as a HAP under section 112 of the
2-16
-------
CAA. Therefore, by replacing methylene chloride with NMP, the MCLB eliminates one source of
air emissions from HAPs. The use of NMP will still result in air emissions from VOCs.
Releases of Comprehensive Environmental Response, Compensation, and Liability Act
(CERCLA) hazardous substances, in quantities equal or greater than their reportable quantity, are
subject to reporting to the National Response Center under CERCLA. Such releases are also
subject to state and local reporting under section 304 of SARA Title III. Methylene chloride is
classified as a CERCLA hazardous substance; its reportable quantity is 1,000 lbs. NMP is not
classified as CERCLA hazardous substances.
Methylene chloride is also classified as a RCRA hazardous waste, but NMP is not. The
hazardous waste code for methylene chloride is indicated in Table 2-2.
Under Executive Order 12856, the MCLB is required to file an annual Toxics Release
Inventory (TRI) of chemicals listed under section 313 of the Superfund Amendments and
Reauthorization Act (SARA) Title III. The TRI includes emissions, transfers, and waste
management data as part of the community right-to-know provisions of SARA Title III.
Methylene chloride is classified as a toxic chemical and is included on the TRI. NMP was added
to SARA Title III, section 313, for chronic health effects and became subject to reporting January
1, 1995. As a result, the MCLB will be required to include NMP on the annual TRI report.
Notice of this requirement was made public in 40 CFR Part 372 in November 1994. By
that time, the scoping study and preparatory work for the demonstration had been completed.
The ramifications of this change were discussed. MCLB confirmed their commitment to continue
with the NMP demonstration since NMP has a much lower vapor pressure than methylene
chloride1, which will minimize the emissions.
Table 2-2. Regulations Impacting the Use of Methylene Chloride and NMP
CAS
CHEMICAL
Section 112,
CAA
Hazardous Substances
CERCLA
RCRA
Code
Toxic Chemical
SARA
75-09-2
Methylene chloride
yes
1,000 lbs
U080
yes
872-50-4
NMP
Not listed
Not listed
Not listed
yes
2-17
-------
2.4.0 QUALITY ASSURANCE
2.4.1 NMP Level Measurements
A non-contact ultrasonic level/distance transmitter, Omega Instruments model LV4G4,
was used to monitor the levels of the stripping and rinse tanks. The digital indicator display has
0.1 in. resolution. The accuracy and linearity of the level sensors were assessed by project
personnel prior to their shipment to the MCLB. A meter stick and a tape measure were used as
the references. The units were then shipped to the MCLB and installed over the tanks. The level
sensor over the NMP stripping tank was rechecked after installation by comparing the level sensor
reading to the distance as measured with a tape measure. After installation, it was found that
there was a problem with the level sensor losing signal over the empty rinse tank, which resulted
in large spikes in the strip chart recorder output and on the digital indicator display. This was
determined to be caused by the signal bouncing off the walls and floor of the empty tank and
scattering. The problem was resolved when the rinse tank was filled with NMP.
A second, smaller problem was the turbulence of the stripping bath with the recirculation
pump on, which caused rapid fluctuations in the signal of up to ±0.5 in. This problem was
eliminated by turning off the recirculation pump during readings so that the surface of the liquid
became less turbulent and noting the reading manually rather than by relying on the strip chart
recorder. This reduced the signal variation on the digital indicator display to ±0.1 in.
Relative decreases in the NMP level would be valid only if the decrease were significantly
larger than this 0.1 in. uncertainty. If the decrease in level due to evaporation had not been
significantly larger than the readability of the instrument, then the maximum probable loss would
have been estimated. This would have provided an upper bound on the evaporation rate of NMP.
To ensure comparable level measurements, temperature must be controlled within ±5°F,
and there should be no foreign objects (such as parts being stripped) in the tank when level
readings are recorded.
2-18
-------
2.4.2 Temperature Measurements
Low noise Type J thermocouples with 304 stainless steel sheaths were used to measure
temperature in the stripping tank and in the rinse tank. These were checked at RTI's facilities
prior to shipment using an ice/water bath (32°F) and boiling water (212°F). Once mounted into
position in the tanks at the MCLB, the thermocouples were rechecked with an ice/water bath and
at ambient temperature. Although temperature is not a critical measurement, it must be controlled
to within approximately ±5°F to avoid errors in level due to thermal expansion of the NMP. On
12/4/95, the RTI QA Officer for the project recorded the NMP level as the temperature rose
during the tank's weekly startup. It was found that between 89 and 125°F the level recorded by
the level sensor changed by approximately 1 in. This confirms the importance of using only level
readings taken close to the target operating temperature of 150°F when making level
measurements to determine solvent loss. Representativeness of the temperature measurements is
ensured by the rapid agitation induced by the recirculating pump.
2.4.3 Measurement Problems and Corrective Actions
Three significant measurement problems were encountered during the study. Both were
rectified satisfactorily. These were as follows:
1. Problem: Excessive noise in level signal due to wave motion of NMP in the stripping
tank.
Solution: Readings were taken only when the recirculating pump was off and the
stripping tank was empty of parts. Residual noise in the signal was approximately
±0.1 inch.
2. Problem: Strip chart recorders failed.
Solution: a) Both strip chart recorders were sent to the manufacturer for repairs.
Strip charts up to the time failure occurred do not suggest drift or other anomaly,
b) Readings were taken by recording the digital readouts of the level meter and
thermocouple.
2-19
-------
3. Problem: Measurements of the NMP level needed to be made temperatures within ±5°F
of the operating temperature of 150°F, but adding NMP changed the temperature
significantly more than that. Because we could not interfere with production by adding
NMP and dropping the temperature during work hours, NMP was often added near the
end of the shift. Therefore, level and temperature readings were often delayed until the
next day.
Solution: Change in level vs. change in temperature was measured several times
and calculated to be approximately 1 in. rise in level for every 40°F. When
possible, readings were taken as soon as NMP was added and after it had come to
temperature. When the temperature change was taken into account, the
calculations between levels for the before and after temperatures were good.
2-20
-------
2.5.0 IMPLEMENTATION PLAN
This section contains the Implementation Plan for the demonstration of n-methyl
pyrrolidone (NMP) as an alternative to methylene chloride for stripping cured coatings from metal
parts. The plan details the equipment purchased under contract to carry out the demonstration,
describes installation of the equipment, and illustrates the plumbing aid instrumentation of the
retrofitted tank. An economic analysis of the new NMP paint stripping process is included and
compared with the previous methylene chloride stripping process.
2.5.1 Equipment
Equipment was required to control the temperature of the stripping bath, circulate the
stripping bath, spray rinse the cleaned parts, distill the used NMP, and monitor the process. The
layout for all the equipment is shown in the Piping and Instrumentation Diagram in Figure 2-4.
More information on the equipment purchased under this contract can be found in Appendix 2-2.
2.5.1.1 Temperature Control
NMP is more effective when it is heated above ambient temperatures. During the bench
scale tests, parts were cleaned at MOT, However, because a basket fully loaded with parts
would cause a sudden drop in the bath temperature when first immersed, the target temperature
during the demonstration was raised to 150 ±5 °F. The stripping tank was heated using steam
available from the MCLB.
Table 2-3 lists the equipment purchased to provide temperature control to the stripping
bath. Contact information for the suppliers listed is given in Table 2-8.
2-21
-------
-C*3
8XT
1/2
A
SB
r * p
rip
r tr „
i
cxi
AUTOMATIC VALVES
CONTROL VALVE
MOTOR BALL VALVE
0 STEAM TRAP
h^l STRAINER
HAND VALVES
NFS
1X3 GATE VALVE
MOD «
NFS
D*3 GLOBE VALVE
MOD i
NPS
D&3 BALI VALVE
MOB «
NPS
h*J CHECK VALVE
HOD #
INSTRUMENT BUBBLES
O LOCAL INSTRUMENTATION
Q LOCAL PANEL-MOUNTED INSTRUMENTATION
LOCAL PANEL ALARM/PILOT LIGHT
Figure 2-4, Piping and Instrumentation Diagram for Tank Retrofit
2-22
-------
HX-103
TANK HEATING COIL
36* X 83*
P—108
RECIRCULATION PUMP
100 GPM 0 58 FTTH
P—114
RINSE PUMP
6 GPM 0 50 PS
I VACUUM I
DISTILLATION 1
AflON
i SYSTEM i
X X X X-X H H M - X X K M
/ST'
v=? W
MAI
HX-103
5 8 5
STRIPPING TANK
RINSE TANK
P-108
P—114
LETTER DESIGNATIONS
P « PRESSURE
T • TEMPERATURE
E - ELEMENT
A = ALARM
t = INDICATOR
R = RECORDER
H = HAND
S » SWITCH
NPS - NOMINAL PIPE SIZE
MOO f = MODEL NUMBER
PIPING SYMBOLS
— MAJOR PROCESS UNE
MINOR PROCESS UNE
ELECTRICAL CONTROL UNE
* x CAPILLARY CONTROL UNE
«¦ FLEXIBLE UNE
-J HAND-HELD SPRAY WAND
r i r
-0— REDUCER
ca EDUCTOR
niwMmr &
—
U :
fc'
*, >¦
2 t"
5 13
^ Z
U>P
z «
A *
a. *»'
5 i j
Sj
o
CLj
> I
II |
li J
ij/u-zn
SS- w
2-23
-------
Table 2-3. Equipment Used for Temperature Control
ITEM
U/M
OTY.
SUPPLIER
MODEL0
Alarm
EA
1
American Mfg.
Custom made
Check valve, 1 in.
EA
1
United
50TLS
Gate valve, 2 in.
EA
2
United
17
Gate valve, 3/4 in.
EA
4
United
17
Gate valve, 1 in.
EA
2
United
17
Globe valve, Vz in.
EA
1
United
81T
Globe valve, 2 in.
EA
2
United
81T
Globe valve, 3/4 in.
EA
2
United
81T
Motor-driven ball valve
EA
1
Watts
C7000
Pressure gage, 2 in.
EA
_
United
1001K
Pressure control valve, 1 in.
EA
1
Spence
ED
Steam trap, 3/4 in.
EA
2
Engrg. Resources, Inc.
3/4 SG-HB-02
Steam coil, 36 in. x 83 in., 12-gauge carbon steel
EA
1
Tranter
POD
Temperature control valve, 3/8 in.
EA
1
Spence
ET14
Temperature switch
EA
1
Murphy
SPL-BP
Y-Strainer with 20 mesh screen, 2 in.
EA
1
Mueller Steam
02.0-11M
Y-Strainer with 20 mesh screen, 1 in.
EA
1
Mueller Steam
01.0-11M
The heater platecoil was suspended over the side of the stripping tank. The remaining
items served to modify the flow of steam into the platecoil. A bypass valve allowed rapid heatup
of the NMP from ambient temperatures. When the temperature of the bath approached operating
temperature, this valve was shut off. The temperature control valve on the steam line kept the
temperature at 150°F ±2°F. The temperature dropped slightly lower when a basket of parts was
lowered into the tank.
An automatic shutoff and alarm system was recommended and ordered to ensure the
correct temperature range. At 160°F, the steam supply will automatically shut off and an audible
alarm will sound. The most likely cause of this condition is neglecting to shut off the steam
bypass valve when the temperature nears 150°F. As temperature increases, the vapor pressure of
NMP increases and more NMP will be emitted into the environment. It will also create a
noticeable amine odor in the work area. Once in operating mode, an alarm will also sound if the
temperature drops below MOT. NMP loses its effectiveness as a CARC stripper at ambient
temperatures, and as the temperature of the bath decreases, the time necessary to strip parts
increases.
2-24
-------
2.5.1.2 Stripping Bath Recirculation
To prevent hot spots from building up and to promote uniform temperature distribution
throughout the bath, a recirculation pump was installed in the stripping tank. The equipment used
to provide recirculation to the stripping tank is shown in Table 2-4, The layout for the equipment
is shown in the Piping and Instrumentation Diagram in Figure 2-4 and contact information for the
X c o o
suppliers listed is given in Table 2-8.
A wire mesh cage was built in the corner of the stripping tank. This cage was intended to
prevent large clumps of paint from being sucked into the pump and clogging the eductors.
Agitation of the pump helped break down large clumps. The pump inlet was located inside the
cage. The distillation unit inlet was also located inside the cage. The pump outlet fed into a
manifold with four eductors. The horizontal manifold was mounted about eight inches from the
bottom of the tank.
Table 2-4. Equipment Used for Bath Recirculation
ITEM
VIM
J2TY
SUPPLIER
MODEL #
Eductors, 3/4 in.
EA
4
Jerguson/Jacoby
JRG-JT TLA 3/4 in.
Self-priming recirculation pump,
316 SS w/Teflon seals
EA
1
R, S. Corcoran
5000
3 ft x 4 ft 4x4 mesh, 0.080 in.
EA
2
McMaster-Carr
9226T447
Pump control panel
EA
I
Mechanical Equipment Co.
Custom made
2-25
-------
2.5.1.3 Rinsing
The parts were rinsed after the basket was raised above the stripping tank. The rinse
pump (separate from the recirculation pump) draws either fresh NMP or recycled NMP from the
rinse tank. The NMP was sprayed onto the parts; excess NMP drained into the stripping tank.
After rinsing, the parts were sprayed with an air gun to minimize dragout. The basket of parts
was moved and then rinsed with water to displace any residual NMP. Because the NMP is
biodegradable and the concentration of NMP in the rinsewater is low, the wastewater can be
treated on-site at the MCLB's I WTP.
Equipment required for the rinsing operation is listed in Table 2-5. Contact information
for the suppliers listed is given in Table 2-8.
Table 2-5. Equipment Used for Rinsing
ITEM
V/M
QTY
SUPPLIER
MODEL §
Air hose assembly, 25 ft.
EA
1
MeMaster-Carr
5313K13
Air blowRun, extended reach
EA
1
MeMaster-Carr
5536K15
Extension tube, 60 in.
EA
1
Spraying Systems, Inc.
9702S-60
Male NPT fittings, 3/8 in.
EA
2
MeMaster-Carr
52515K53
Tip. full cone nozzle
EA
1
Spraying Systems, Inc.
TG-8510
Solvent spray gun, GunJet Model 60
EA
1
Spraying Systems, Inc.
AA-60-3/8-SS
Positive displacement pump (rinse pump)
EA
1
Roian
HD33-BRM-1U4B2
Teflon hose w/SS braided sheath
FT
25
MeMaster-Carr
52515K23
2.5.1.4 Distillation
A distillation unit links the stripping tank and the rinse tank. The unit draws NMP from
the stripping tank when it becomes loaded with paint sludge. Under vacuum, the unit distills the
solvent and separates the sludge. The unit is also equipped with a water diverter since NMP
absorbs moisture from the air. The distilled NMP is drained into the rinse tank, and is used for
rinsing parts. The still operates at a noise level of about 75-80 decibels. The supplier and model
of the distillation unit are provided in Table 2-6. Contact information for the suppliers listed is
given in Table 2-8. A schematic of the distillation unit is shown in Figure 2-5.
2-26
-------
HUB SHrBG TM
OUT tUMT MB—>
ay» EwaiOT®
msjtmr % MBKutecrm ac
ofun mtemm rs
flnBHZHCTEM MSB
tnmji i 3k>
okiit catsrra
BR !>6MnLFY£ MSB
rbsue H.»wn
tULDIj IA19 (3USIET
JOES RWttT Ml
BTOJUAIlOt T*
(MDCWSnUT
WOWmDETNC
toiiunn tUNB
rarraunw kiij
Figure 2-5. Schematic of Vacuum Distillation Unit
{reprinted with permission from Finish Thompson, Inc.)
2-27
-------
Tab lb 2-6. Equipment Used for NMP Distillation
ITEM
U/M
QTY
SUPPLIER
MODEL#
Vacuum distillation system
EA
I
FTI
BCF380
2.5.1.5 Sensing and Monitoring Devices
The equipment used to monitor and record information about the process is listed in Table
2-7, Some of this equipment is necessary for the process; other equipment was only needed to
gather data to calculate mass balance for the demonstration of the new process. The six foot
thermocouple was placed in the stripping tank. A longer thermocouple was placed in the rinse
tank so less NMP could be used to fill it. The level sensors sent an ultrasonic signal to the surface
of the bath. The sensors and thermocouples were mounted in the adjacent back corners on
brackets fabricated by the MCLB. Cables ran from the sensors to the work cabinet which housed
the indicators, recorders, and power supply.
The thermocouples were wired into temperature indicators that provided an LED digital
display of the temperature. The indicators had 0-10 Vdc output to the recorders and were scaled
from 0 to 200 °F. The chart paper had divisions from 0 to 100; actual temperature was twice the
value plotted on the strip chart.
The remote level sensors were wired into the sensor indicator displays. Both displays
were powered with the same 120 Vac to 12 Vdc regulated power supply. The sensor displays
had 0-10 Vdc output to the recorders. Because the sensors sent a signal to the surface of the
NMP in the tank, higher readings on the level sensors corresponded to lower levels of NMP. The
high setting for the sensors was 95 in., which corresponded to an empty tank. The low setting
was 15 in.
Two channel recorders were used to simultaneously plot temperature and level. Because
the recorders would be left on almost continuously, variable chart speeds with slow options were
chosen. Also, the recorders had to accept dual 0-10 Vdc inputs. Replacement paper and pens
were also ordered.
2-28
-------
Table 2-7. Equipment Used for Monitoring and recording
ITEM
UIM
QTY
SUPPLIER
MODEL#
Extension grade thermocouple wire, 100 ft.
EA
1
Omega
EXPP-J-20-TWSH
120 Vac to 12 Vdc power supply
EA
1
Radio Shack
22-120
J-thermocouple, 304 SS sheath, 6 ft.
EA
1
Omega
GIOSS-14(U)-72
J-thermocouple. 304 SS sheath, 7-1/2 ft.
EA
1
Omega
GJOSS-14(U)-90
Non-contact ultrasonic level sensor
EA
2
Omega
LV404-RT(30)
Stripehart recorder, 2-channel flatbed
EA
2
Cole-Parmer
G-08380-82
Replacement paper
EA
1
Cole-Parmer
G-08380-83
Replacement pens, Channel 1 (green)
EA
2
Cole-Parmer
G08380-73
Replacement pens, Channel 2 (red)
EA •
2
Cole-Parmer
G-08380-74
Temp, controller/indicator w/0-10Vdc output
EA
1
Omega
CN76060-PV
Temp, indicator w/0-IOVdc output
EA
1
Omega
DP21-TC-AQ3
Work cabinet, single door
EA
1
Grainger
1W814
2-29
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Table 2-8, Vendor List
Cole-Parmer Instrument Company
7425 North Oak Park Avenue
Nilcs, IL 60714
800-323-4340
Engineering Resources, Inc.
142 Crossen Avenue
Elk Grove Village, IL 60007
312-693-5500
Finish Thompson, Inc.
921 Greengarden Rd.
Erie, PA 16501-1591
800-888-3743
Grainger
6100 Fulton Industrial Boulevard
Atlanta, GA 30336-2852
404-346-7000
Jerguson®/J acoby-T arbox®
16633 Foltz Industrial Parkway
S trongsville, OH 44136
216-572-1500
McMaster-Carr Supply Company
PO Box 740100
Atlanta, GA 30374-0100
404-346-7000
Mechanical Equipment Company
PO Box 16272
Greensboro, NC 27406
919-596-8123
Mueller Steam Specialty
NC Hwy. 20 West
St Pauls, NC 28384
910-865-8241
OMEGA Engineering
PO Box 4047
Stamford, CT 06907-0047
800-826-6342
Paul N. Gardner Company, Inc.
316 NE 1st Street
Pompano Beach, FL 33060
800-762-2478
R.S. Corcoran Company
500 North Vine Street
PO Box 429
New Lenox, IL 60451-0429
815-485-2156
Radio Shack
Local
Rotan
Borneman Pumps, Inc.
2825 Tophill Road
Monroe, NC 28110
704-289-1150
Spence Engineering Company, Inc.
150 Coidenham Road
PO Box 230
Walden, NY 12586
914-778-5566
Spraying Systems Company
PO Box 19444
Charlotte, NC 28219
704-392-9448
Tranter, Inc.
PO Box 2289
Wichita Falls, TX
817-723-7125
United
PO Box 60950
Charlotte, NC 28260
910-498-2661
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2.5.2 Materials
NMP is readily available in large quantities and can be purchased commercially in different
grades. The three producers of NMP in the United States are Arco, BASF, and ISP; contact
information is provided in Table 2-9. There is sufficient production to meet expected needs. For
estimating purposes, high-grade NMP costs roughly S2.00/lb while lower grades cost less.
Producers may provide volume discounts for purchasing bulk quantities.
For this demonstration, 26,740 lbs of NMP were purchased from BASF.
Table 2-9. Producers of NMP in the US
Arco Chemical Co.
3801 West Chester Pike
Newtown Square, PA 19073
610-359-2000
800-321-7000 (orders)
BASF, Inc.
3000 Continental Drive
Mt. Olive. NJ 07828
201-426-4671
800-634-9127 (orders)
800-828-6627 (NMP Hotline)
ISP Technologies Inc.
1361 Alps Road
Wayne, NJ 07470
201-628-4000
2.5.3 Safety
The Material Safety Data Sheet for NMP is included in Appendix 2-3. The threshold limit
value—time-weighted average (TLV—TWA) is the time-weighted average concentration for a
normal eight-hour workday and a 40-hour workweek, to which nearly all workers may be
repeatedly exposed, day after day, without adverse effect. The TLV—TWA for NMP is given
below in Table 2-10. The TLV—TWA for methylene chloride has been included for comparison.
Table 2-10. Threshold Limit Values for NMP and Methylene Chloride
CHEMICAL
CAS
FLASH POINT (eF)
TLV-TWA *" (ppm m)
N-methyl pyrrolidone
872-50-4
195
100
Methylene chloride
75-09-2
none
50
<»' Threshold Limit Value — Time-Weighted Average.
sb) Parts of vapor or gas per million parts of contaminated air by volume at 77°F and 1 atmosphere.
2-31
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NMP is classified as combustible and must be stored in accordance with applicable
regulations. NMP is highly biodegradable and NMP waste may be effectively treated in an
industrial wastewater treatment facility using activated sludge technology. Information on
biodegradability and aquatic toxicity is included in Appendix 2-4. NMP will be classified as
hazardous waste only if it contains hazardous components from the stripped parts.
NMP is a skin and eye irritant. NMP wiU not burn skin on contact, but because of its low
vapor pressure, it will not quickly evaporate either. Personnel are required to wear splash goggles,
butyl rubber gloves and butyl rubber aprons when working with NMP. This personal protection
equipment (PPE) designed to protect the eyes and skin from direct contact is similar to that
required now when working with methylene chloride and MEK. Areas must be properly
ventilated to prevent vapor buildup to levels above the TLV.
As discussed in Section 2.3.7, NMP was added to SARA Title III, section 313, for
chronic health effects. The basis of this decision were animal studies suggesting that NMP may
cause reproductive toxicity. Additionally, there is considerable variation in the reported
toxicology data in the MSDSs prepared by different chemical manufacturers. However, variation
in the toxieological data may result from genetic variation in the species strain or from the models
used to extrapolate the LD50 from the test data. Also, the data reported in Registry of Toxic
Effects of Chemical Substances does not contain information on dosage, which also may greatly
affect the results. Data for the same test may differ by a factor of two or more; even a factor of
ten would not be considered unusual2. Under these circumstances, one would either use the most
conservative figure, which would provide the most protection, or use the most recent data, which
would take into account genetic drift in the species strain.
2.5.4 Economic Analysis
One aspect of changing process operations for pollution prevention purposes is the effect
on capital and annual cost. Pollution prevention changes are more likely to be accepted if these
costs stay the same or decrease. The following sections provide measures of capital and annual
costs for replacing methylene chloride with NMP for paint stripping.
2-32
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The methodology for estimating costs is taken from the EPA methods described in the
OAQPS Control Cost Manual3, which allows a convenient means of comparing different
processes based on their annualized costs. Where actual costs were not known, factors applied to
base equipment costs were used to estimate the remaining costs. These factors have been
developed from a wide variety of sources associated with pollution control systems. The method
provides a study estimate, which is intended to give a cost estimate within an accuracy range of
±30% of the actual cost when all the information affecting the costs is reasonable well known.
This accuracy range is typical for EPA's estimates of pollution control systems when assessing
cost impacts on existing or model facilities. Greater accuracy can be obtained with budget
authorization estimates (±20%), definitive estimates (±10%), or contractor's estimates (±5%).
Improved accuracy of the estimate is obtained only by improving the detailed knowledge of items
that make up the estimate. In the present case, the firm costs obtained for most of the capital
items could lead to a contractor's estimate if no assumptions were required for the remaining
costs. However, unit costs, rates, and consumptions (listed in section 2.5.4.3) are not known with
sufficient accuracy to go beyond a study estimate.
The estimates for NMP costing include most of the capital and annual cost items in the
EPA methodology.
2.5.4.1 OAQPS Control Cost Manual
Analysis of the costs associated with the pollution prevention project is performed such
that comparisons can readily be made between competing processes. A consistent format for
costing is used so that comparisons are valid. To be compatible with EPA. usage, the format in
this report is taken from the OAQPS Control Cost Manual as mentioned above. The
methodology used in the manual divides costs into two major categories, capital costs and annual
costs. For the cost analysis to be meaningful, it must include all elements associated with
implementation of new technologies. An exception is the case in which no new capital costs are
incurred. Capital and annual costs can be further subdivided into the categories shown below:
• Site preparation and buildings
• Equipment
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• Emission controls
• Materials
• Energy and utility requirements
• Labor requirements, including training
• Waste disposal
• Special transportation costs (hazardous materials)
• Recovery credits
• Overheads and capital recovery
• Accommodation costs (for changes in use or behavior forced by the new
technology).
Treatment of each of the cost elements is briefly described below. As used in the OAQPS
Control Cost Manual, the first three items are capital costs, while the remainder are annual costs.
After all the cost elements are collected, they are presented as tables of capital and annual costs.
Capital Costs
Capital cost items are those requiring relatively large expenditures for land, buildings, and
equipment expected to have a lifetime longer than a year (usually many years). Specific items are
collected in the following paragraphs. For those cases in which explicit costs are not available,
the factor method is used to estimate reasonable costs. Factors (as multipliers of the purchased
equipment cost) are available in costing manuals or can be based on engineering judgement.
Site Preparation and Buildings: No site preparation (land clearing and leveling) or new
buildings were required for the pollution prevention project.
Equipment and Emission Controls: Equipment costs include either new purchases
(including add-ons) or modifications for existing items such as stripping and rinse tanks, heaters,
storage tanks, water supply, fans, hoods, ducts, pollution control equipment, waste handling, or
the vacuum distillation for recycling NMP. Costs include installation. These costs are taken
2-34
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from invoices, vendor quotes, or other records where available, or are estimated from cost manual
data.
Indirect Costs: Associated with purchase and installation of equipment are the indirect
costs that include engineering, construction and field expense, contractor fees, start-up,
performance tests, and contingencies. Not all of these items are required.
Annual Costs
Annual costs include expenditures for operating and maintenance labor Mid materials,
utilities, and waste disposal. Indirect costs include overhead, administrative charges, property
taxes (where applicable), insurance, and capital recovery. With the exception of overhead, the
indirect annual costs are related to capital costs. The annual cost elements are described in the
following paragraphs. The sum of the annual costs provides a total annual cost that is useful for
comparison with other systems or technologies.
Materials: Materials include raw materials for operation, and maintenance materials for
repairs and preventive maintenance. Costs and usage rates for materials are obtained from MCLB
records, vendors, or estimates from MCLB or RTI project personnel.
Energy and Utility Requirements: Energy and utility usage rates are taken from MCLB
records, project data, or estimates for the equipment or process being analyzed. Included for this
project are electric power, steam, water, and compressed air.
Labor Requirements: As with materials, labor is divided into operating and maintenance
categories. Operator labor hours are estimated from project records or from observation by
project personnel. Maintenance labor hours are projected based on estimates of project
personnel. Labor hours are also required for supervision and for training.
Waste Transportation and Disposal: Waste disposal costs include wastewater treatment,
solid waste disposal, and hazardous waste treatment or disposal. Transportation costs are
included in the waste disposal costs. Quantities are taken from MCLB records or are projected
from project data.
2-35
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Recovery Credits: Recycling of spent solvents may provide money to offset costs of
operation. For this project, on-site distillation of NMP is analyzed for its contribution to reducing
costs.
Overheads and Capital Recovery; General and administrative overheads, property tax,
and insurance are taken from information provided by MCLB or from estimates by project
personnel. Capital recovery charges are estimated from current EPA usage for interest rates;
equipment lifetimes are based on engineering judgement.
Accommodation Costs: Identifiable costs are included here that are associated with a
changeover to new technology. An example for this project is higher than normal initial solvent
usage while learning to use NMP for paint stripping.
2.5.4.2 Obtaining Cost Elements
Capital Costs
Because the factor method is dependent on base equipment costs for its capital cost
accuracy, special care must be taken to record all of the individual items purchased. For the
present work, each required item is purchased through RTFs purchasing department. All RTI
purchases are posted on a computer operated accounting system that allows identification of each
item associated with the project.
Annual Costs
Annual cost items are largely dependent on the labor, utility, and materials costs
associated with operating a process and on recovery of capital. As with capital costs, accuracy of
the annualized cost estimate depends on the accuracy of the information collected for these cost
elements and also for the usage rates associated with the operating costs. Capital costs remain
important in estimating annualized costs because most of the costs and the capital recovery cost
depend on purchased equipment costs. For the present project, unavailability of some unit costs
and usage rates may affect the accuracy (and the conclusions) of the cost analysis.
2-36
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2.5.4.3 Unit Costs, Rates, and Assumptions for Economic Analysis
Unit Costs and Rates Used Throughout Economic Analysis
The following unit costs and rates were used throughout the cost analysis:
• Operating labor costs are $16.52/hr, taken and updated from the OAQPS Control
Cost Manual, pp. 7-43, April 1991.
• Maintenance labor costs are $ 18.17/hr, taken and updated from the OAQPS
Control Cost Manual, pp. 7-43, April 1991.
• Supervisory labor costs are 115% of operating labor costs, taken from the OAQPS
Control Cost Manual, pp. 7-43, April 1991.
• Training costs are $33.04/hr based on twice the operating labor rate.
• Waste disposal costs for low-end wastes include $0.35/lb for transportation and
$0.80/lb for disposal, based on interpolation from MCLB estimate.
• Waste disposal costs for high-end wastes include 0.35/lb for transportation and
S1.80/lb for disposal, based on interpolation from MCLB estimate.
• Water costs $0.21/1,000 gal, taken and updated from OAQPS Control Cost
Manual, pp. 9-51, July 1992.
• Electricity costs $0.0709/kWh, cited in Chemical Engineering, January 1995.
• Compressed air costs $0.19/1,000 scfm, from example problem in OAQPS Control
Cost Manual, pp. 5-49 (April 1991) and updated with Chemical Engineering (CE)
cost index.
• Steam cost $3.40/1,000 lb based on estimate from MCLB.
• Wastewater disposal or treatment costs $4.75/1,000 gal updated from OAQPS
Control Cost Manual, pp. 9-51, July 1992.
• Methylene chloride costs $0.51/lb based on MCLB records and includes shipping
charges of $0,05/lb.
• NMP costs $ 1.82/lb based on RTI accounting records and includes shipping
charges of S0.05/lb.
2-37
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• State emissions fee of $25/ton required for hazardous air emissions is not charged
because MCLB is below the minimum.
Assumptions Used for NMP Stripping
The following assumptions were used for NMP stripping,
• Capital costs are taken from RTI accounting records. The initial charge of NMP is
included in the capital costs.
• Operator hours are the same as for methylene chloride stripping, but no annual
tank cleaning charge is added.
• Maintenance hours and compressed air usage are the same for methylene chloride
and NMP stripping.
• NMP consumption is 16,632 lbs/yr (3 bbl/month), based on RTI projections.
• Power usage is estimated at 2.8 kW for miscellaneous electrical loads plus the
NMP distillation unit.
« Steam usage is based on 100 lb/hr per FTI boiler specifications, plus 20% for
startups and losses. The still operates 1 shift/ week, 2 hrs/shift. Dip talk heating
is included at a weekly rate of 1,570,000 Btu as estimated by project personnel.
One pound of steam is assumed equivalent to 1,000 Btu.
• Water usage is taken as 20 gal/shift for rinsing plus 7 gal/min for the still (per
Finish Thompson range of 4 to 10 gal/min).
• Waste water disposal taken as 20 gal/shift (all of the rinse water).
• Waste disposal based on same quantity of paint waste sludge as for methylene
chloride stripping. Low-end disposal charge applies.
Assumptions Used for Methylene Chloride Stripping
The following assumptions were used for methylene chloride stripping.
• Capital costs include tank clean out and charging with fresh methylene chloride.
« Operator hours estimated from observation. Annualized charge of $1,588 added
for periodic tank cleaning.
2-38
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• Methylene chloride usage is based on MCLB estimates.
• Power usage is estimated at 2 kW for miscellaneous electrical loads.
• Compressed air usage is estimated at 20 scfm/hr based on 3 scfm/gun x 15 min
use/day.
• Water usage is estimated at 60 gal/shift for rinsing.
• Waste water disposal is based on treating one-third of the rinsing water (the other
two thirds goes into the methylene chloride tank or the first rinse tank).
• Assumes disposal of 10 500-lb drums/yr containing tank sludge, based on MCLB
estimate. High-end disposal charge applies.
2.5.4.4 Paint Stripping
Results of NMP Costing
Tables 2-11 and 2-12 provide estimated capital and annual costs for NMP paint stripping.
Total capital investment is $166,260, with the major items being the purchase of a distillation unit
to recover used NMP and the original charge of NMP. Factors were used to obtain values for
most of the direct and indirect installation costs, which may be conservative.
Annualized cost is $9Q,695/yr, with the largest elements being materials, capital recovery,
labor, and waste disposal.
Discussion of NMP Costing
The short time available for actual operation of the stripping system and the non-
separability of capital cost elements impact the accuracy of the cost estimates. While a study
estimate is typically within ±30% of the true cost, it is likely that such accuracy is not reached for
this project. A relatively modest increase in operating experience and the opportunity to search
MCLB records in more depth should provide a significant increase in accuracy.
One item that can be included under accommodation costs is several hundred dollars for
NMP that was lost while learning how to operate the stripping tank controls.
2-39
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Table 2-11. Capital Costs for NMP Paint Stripping
Direct Costs
Purchased Equipment Costs
System with controls* $141,870
Instrumentation (if not included in controls) $6,131
Sales Taxes $0
Freight $7.093
Purchased Equipment Cost, PEC $155,094
Direct Installation Costs
Foundations and supports $0
Handling and erection $ 1,551
Electrical $1,241
Piping $1,551
Insulation for ductwork $0
Painting $620
Direct Installation Costs $4,963
as required,
as required.
Total Direct Cost $160,057
Indirect Costs (installation)
Engineering $3,102
Construction and Field Expense $0
Contractor Fees $0
Start-up $775
Performance Test $0
Contingencies $2,326
... , , TataLladirect Costs. IC MM?
TOTAL CAPITAL INVESTMENT, TCI $166,260
(~Includes initial NMP charge of $39,153)
Site Preparation
Buildings
2-40
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Table 2-12. Annualized Cost Analysis of NMP Paint Stripping
Direct Annual Costs, DC
Operating Labor
Operator ([2.5 hours/day]*[260 days/year]*[$16,52/hour}) $10,738
Supervisor (15% of operator) $1,611
Training ([8 hours/year/employee[*[$33.04/hour[*fl0 employees}} $2,643
Operating Materials
NMP ([$1.82/pound{*[16,632 pounds/yearI) $30,270
Maintenance
Labor ([0.5 hours/day]*[260 days/year]*[$18.17/hour}) , $2,362
Material (Equal to Maintenance Labor) $2,362
Utilities!
Electricity ([2.8 kWl*[$0.07I/kWhour]*[2080 hours/year]) $414
Steam ([45 pounds/hour]*[$3.40/1000poutids]*[2080 hours/year]) $318
Compressed air ([40 scfin/hour]*[$0.19/1000 $cfm]*[2080 hours/year)) $16
Water ([23.5 gal/hour]*[$0.21/1000 galj*[2080 hours/year]} $10
Wastewater Treatment ([2.5 gal/hour]*[$4.75/1000 gal]*[2080 hours/year}) $25
Waste Disposal ([2.5 tans/yearl*f$2,3Q0/tonl} $5,750
Total Direct Cost, DC $56,519
Indirect Annual Costs, IC
Overhead (60% of sum of labor + maintenance materials) $ 11,830
Administrative charges TCI * 0.02 $3,325
Property taxes TCI * 0.01 $1,663
Insurance TCI *0.01 $1,663
Capital recovery CRF*TCI (CRF=0.Q944) $15,695
Total Annual Cost, TAC (TAC = DC + IC) $90,695
f In calculating the annualized costs, consumption of utilities has been normalized to one eight-hour shift, five days per
week, fifty-weeks per year.
2-41
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Economic Comparison with Methylene Chloride Stripping
Estimated stripping costs with methylene chloride are shown in Tables 2-13 and 2-14.
Capital costs are limited to dip tank preparation and an initial charge of methylene chloride. Most
of the direct and indirect installation costs do not apply in this case.
A summary comparison of the capital and annualized costs is presented in Table 2-15.
Assuming that an existing tank system is either to be cleaned and filled with methylene chloride or
is to be refurbished for use with NMP, capital costs are significantly lower for the methylene
chloride system (about 11 percent of the NMP system). Estimated annualized costs are $86,888,
or about 96% that for NMP. The major cost is for the methylene chloride, which is used in much
larger quantities than estimated for NMP (almost ten times as much). Other significant costs, as
with NMP stripping, are labor and waste disposal.
Given the assumptions of this analysis, NMP stripping is comparable to methylene chloride
stripping on an annualized basis. Taking advantage of NMP depends on being able to acquire the
significantly higher amount of capital required to purchase and install the distillation unit and
heating system.
2-42
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Table 2-13. Capital Costs for Methylene Chloride Paint Stripping
Direct Costs
Purchased Equipment Costs
System with controls*
$17,854
Instrumentation (if not included in controls)
$0
Sales Taxes
$0
Freisht
$893
Purchased Equipment Cost, PEC
$18,747
Direct Installation Costs
Foundations and supports
" $0
Handling and erection
$187
Electrical
$0
Piping
$0
Insulation for ductwork
$0
Painting
$0
Direct Installation Costs
$187
Site Preparation as required,
Buildings as required,
Total Direct Cost
$18,934
Indirect Costs (installation)
Engineering
$0
Construction and Field Expense
$0
Contractor Fees
$0
Start-up
$187
Performance Test
$0
Contingencies
$562
Total Indirect Costs fC
' .8740
TOTAL CAPITAL INVESTMENT, TCI
$19,683
(~Includes cleaning costs of $1,639 and initial methylene chloride
charge of $16,215)
2-43
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Table 2-14. Annualized Cost Analysis of Methylene Chloride Paint Stripping
Direct Annual Costs, DC
Operating Labor
Operator ([2.5 hours/day]*[260 days/year]*[$16.52/hour[) $11,927
+ ([8 hours/day j*[9 days/year} *[$I6.52/hour[) for clean out
Supervisor (15% of operator) $1,789
Training ([8 hours/year/employee[*[$33.04/hourjm[10 employees]) $2,643
Operating Materials
Methylene chloride ([$0.54/poundI *[ 73,000 pounds/year]) $39,420
Maintenance
Labor ([0.5 hours/day]*[260 days/year]*[$18.17/hourJ) $2,362
Material (Equal to Maintenance Labor) $2,362
Utilities!
Electricity ([2.0 k\V)*[ $0.071/kWhour] *[2080 hours/year}) $295
Steam ([0 pounds/hour] *[$3.40/1000 pounds]*{2080 hours/year]) $0
Compressed air ([40 scfm/hourj *[SO. 19/1000 scfmJ "[2080 hours/year]) $16
Water ([7.5 gal/hour]*[$0.21/1000 gal]*[2080 hours/year]) $3
Wastewater Treatment ([2.5 gal/hour] *[$4.75/1000 gal]*[2080 hours/year}) $25
Waste Disposal ([2.5 tons/\earl*l$4.300/toni) $10,750
Total Direct Cost, DC $71,592
Indirect Annual Costs, IC
Overhead (60% of sum of labor + maintenance materials) $ 12,650
Administrative charges TCI * 0.02 $394
Property taxes TCI *0.01 $197
Insurance TCI * 0.01 $197
Capital recovery CRF'TCI (CRF=0.0944) $1,858
Total Indirect Costs. IC $15.296
Total Annual Cost, TAC (TAC = DC + IC) $86,888
t In calculating the annualized costs, consumption of utilities has been normalized to one eight-hour shift, five days
week, fifty-weeks per year.
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Table 2-15. Summary Comparison of Cost Analysis
I PROCESS
CAPITAL COSTS
ANNUALIZED COSTS
Methylene Chloride Stripping
$19,683
$86,888
| NMP Stripping
$166,260
$90,695
2.5.4.S Return on Investment and Payback Period for NMP Stripping
Return on investment (ROI) and payback period (PP) are two common measures for
estimating the profitability of a venture. Return on investment as used for this project is the
average yearly profit divided by total capital investment, expressed as a percentage. The average
yearly profit is taken as the difference in annualized cost between the existing process and its
intended pollution prevention replacement.
Payback period is the total capital investment divided by the sum of profit (as used above)
and depreciation of the pollution prevention equipment. For this project, the straight line
depreciation method is used with a 5 percent salvage value. Depreciation is total capital
investment minus salvage value, all divided by equipment life.
Table 2-15 suggests switching to NMP would result in a yearly loss of approximately
$3800. For this reason, calculations of ROI and PP are not shown here. However, given the
uncertainty in the estimate, the costs should be considered comparable. Also, the largest annual
cost element in switching to NMP is for operating materials. Additional steps taken to further
reduce air emissions, such as covering the tanks when not moving baskets of parts in and out, will
significantly reduce the amount of NMP needed and thus lower the operating material cost.
2-45
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2.6.0 DISCUSSION OF OBJECTIVE
As discussed previously, the MCLB is required to reduce air emissions from hazardous air
pollutants by 50% from 1992 levels. The MCLB provided a summary of their purchase history of
toxic materials for 19924. Table 2-16 shows the hazardous air pollutants from this list.
The MCLB has already replaced 1,1,1-trichloroethane vapor degreasers with aqueous
parts washers. This change alone will reduce emissions from HAPs by 16%. By eliminating the
methylene chloride for immersion stripping, the MCLB can further reduce emissions another 11%.
The MCLB has also replaced methyl ethyl ketone with a propylene carbonate/benzyl alcohol
blend for cleaning paint application equipment, reducing emissions from HAPs an additional 21%.
These three changes combined result in a reduction of emissions of 48%.
Five of the chemicals listed in Table 2-16 are components in paints and coatings used at
the MCLB. The MCLB plans to replace solvent-borne CARCs with water-tome CARCs in 1996
to achieve over 50% reduction in emissions from HAPs.
Table 2-16. Summary of Hazardous Air Pollutants Based on 1992 Purchase History
CONSTITUENT
LBS.
USE
1,1,1 -trichloroethane
49,077
neat - degreaser
ethyl benzene
1,465
component - aircraft thinner
ethylene glycol
75,527
neat - antifreeze
methyl isobutyl ketone
613
component - paints
methyl ethyl ketone
89,787
63,810 lbs. neat for paint cleanup/remainder in paints
methylene chloride
33,700
component - paint stripper
toluene
18,533
component - paints
trivalent chromium
16,801
component - paints
xylene
16,600
component - paints
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2.7.0 CONCLUSIONS
Based on this demonstration, the following conclusions may be drawn;
1) NMP was demonstrated to be an effective replacement for methylene chloride for
MCLB's immersion paint stripping process.
• The NMP, when heated to 150 ±5 °F, will remove multiple layers of CARC and
strip parts to the base metal within 3-4 hours.
• The heated NMP will successfully remove Plastisol®, a plastic coating, from
battery tie-down brackets within 3-4 hours. These parts were previously stripped
in a hot alkaline bath, followed by scraping and blasting to remove the coating.
• The NMP will soften epoxy-based topcoats, but removal usually requires overnight
soaking.
2) Emissions of HAPs from paint stripping was reduced to zero by replacing methylene
chloride with NMP. This is an important achievement for MCLB towards meeting their overall
emissions reduction goals. Air emissions from VOCs are still present, since NMP is a VOC.
3) The distillation unit may provide a convenient method of removing paint sludge. It is
expected that the pump agitation combined with the solvency of the NMP will dissolve paint chips
in the tank; the paint will be separated from the NMP during distillation. It is likely that there will
be no need to drain the tank for paint sludge removal as required with the methylene chloride.
The course of this demonstration was too short to confirm this.
4) Annualized cost of NMP stripping is comparable to stripping with methylene chloride,
although the start-up cost is higher.
The recommendations for MCLB are continued use of NMP as an immersion stripper and
to consider the use of NMP as a stripper in other applications where immersion is the preferred
process.
2-47
-------
2.8.0 REFERENCES
1. Letter from James L. Taylor, USMC, to J. K. Whitfield, US EPA, April 21, 1995.
2. Personal conversation with Dr. Rochelle Tyl, Research Director for RTFs Center for Life
Sciences and Toxicology, July 23, 1995.
3. OAQPS Control Cost Manual, EPA-450/3-90-006 (NTIS PB90-169954), January 1990.
4. Letter from John Woodward, MCLB Albany, GA, to Principal Director, Maintenance
Directorate, June 14, 1993.
2-48
-------
APPENDIX 2-1
STANDARD OPERATING PROCEDURE
FOR
IMMERSION STRIPPING IN
N-METHYL PYRROLIDONE
Prepared By:
Approved By:
Approved By:
Approved By:
Revision
J. M. Elion
E. A. Hill
J. K. Whitfield
D. Gilium
—
2-49
-------
6057001-2
1. SCOPE
I.l- Scope.
This document covers the general requirements for stripping cured chemical agent resistant
coating (CARC) systems from tactical military equipment via immersion in n-methyl
pyrrolidone. It is intended for use as a guide and as a supplement to information available in the
below referenced specifications. This document also includes information regarding health and
safety guidelines, environmental restrictions, and operating techniques.
2. APPLICABLE DOCUMENTS
2.1. Government documents
The following specifications and standards form a part of this document to the extent specified
herein. Unless otherwise specified, the issues of these documents are those listed in the issue of
the Department of Defense Index of Specifications and Standards (DODISS) and supplement
thereto, cited in the solicitation.
MIL-C-53072 Military Specification, Chemical Agent Resistant Coating (CARC) System
Application Procedures and Quality Control Inspection
TT-C-490 Federal Specification, Cleaning Methods for Ferrous Surfaces and
Pretreatments for Organic Coatings
2.2. Order of precedence
In the event of a conflict between the text of this document and the references cited herein, the
text of the specifications takes precedence. Nothing in this document supersedes applicable laws
and regulations unless a specific exemption has been obtained.
3. REQUIREMENTS
3.1. Equipment
3.1.1. Distillation unit
3.1.2. Paint adhesion test kit
3.1.3. Platecoil heater
3.1.4. Recirculation pump
3.1.5. Rinse pump
3.1.6. Spray wands
3.1.7. S tripchart recorder
3.1.8. Thermocouple probes, Type J
3.1.9. Ultrasonic level/distance transmitter
2-50
-------
6057001-2
3.2. Materials
3.2.1. N-methyl pyrrolidone (NMP)
Operators are required to wear butyl rubber aprons, butyl rubber gloves, and butyl rubber boots
to minimize skin contact. Operators are required to wear eye goggles and face shields. The
Material Safety Data Sheet shall be easily accessible to all operators.
Ventilation will be run continuously while NMP is in either the wash tank or the immersion tank.
Operators are to notify their immediate supervisor if there is a noticeable fish-like odor (typical
of NMP). This indicates insufficient ventilation or a possible leak in the tank.
NMP has been added to the SARA Title III list of chemicals and is subject to reporting under
Toxic Release Inventory (TRI) guidelines effective January 1,1995. Although NMP is a volatile
organic compound (VOC), it is not classified as a hazardous air pollutant (HAP).
3.5.1. Removal of paint from finished parts
3.5.1.1. Recirculation pump operation
Turn on the recirculation pump by rotating the breaker located in the upper right corner of the
control panel 90° clockwise from OFF to ON. Turn pump switch from OFF to MANUAL. The
recirculation pump must be operated whenever the tank heater is on. The pump promotes even
temperature distribution throughout the tank and provides agitation to the bath.
3.5.1.2. Tank heatup
Prior to stripping parts, the NMP in the tank shall be heated to 150°F ±10°F. The recirculation
pump must be operating before starting the tank heatup procedure. Heat the NMP from room
temperature by opening the 2" gate valve, the 2" globe bypass valve, and the 1" gate valve near
the temperature control valve (Figure la).
3.4.
3.5.
——T—K
u—iX
2" bypass valve
n T\
¦—L i/*
p K ^ n hv
t-i is w L1 \s
Steam In
2' gate 1' gate
valve valve
1" gate
valve
Pressure Temperature
reducing control
valve valve
Figure la. Valve Configuration for Startup
2-51
-------
6057001-2
When the temperature reaches 140°F, close the 2" globe bypass valve (Figure lb). It will take
approximately 20 minutes to heat from room temperature to 140°?. During routine operation
and shutdown, the 2" and 1" gate valves will remain open.
n N.
u—1/~
Steam in
2" bypass vaive
p —TV
u—1/ F" u—
2" gate
valve
1'gate
valve
Pressure Temperature
reducing control
valve valve
Figure lb. Valve Configuration for Routine Operation
Once the tank is heated, it should be left at operating temperature except for weekends and plant
shutdowns. To shutdown, close the 2" globe bypass valve, the 2" gate valve in the control line,
and the steam supply valve (Figure lc).
2" bypass valve
2" gate
valve
1" gate
valve
Steam In
Pressure Temperature
reducing control
valve valve
Figure lc. Valve Configuration for Shutdown
3.5.1.3. Loading parts
Load parts to be stripped in 4' x 4" wire baskets. Parts shall be loaded in the basket to allow for
easy drainage. Parts should be racked to avoid nesting and to allow the NMP to contact all
surfaces.
3.5.1.4. Immersing parts
Lower the basket of parts into the tank at a sufficiently slow speed to prevent excessive splashing
of the NMP.
2-52
-------
6057001-2
3.5.1.5. Soaking parts
Soak the parts in the heated NMP bath 180 ± 30 minutes. When soaking is complete, raise the
basket and hold it just above the tank to allow excess NMP to drain back into the tank.
3.5.1.6. Primary rinse
With the basket of parts held just above the immersion tank, rinse the parts by spraying with
NMP. Operators will use virgin or recycled NMP to rinse paint sludge and dirty NMP from the
parts. The NMP rinse will used as makeup NMP in the immersion tank. Use caution to avoid
NMP splashback.
3.5.1.7. Air blowoff
Blow off remaining NMP with shop air. Use caution to avoid NMP splashback.
3.5.1.8. Second rinse
Move the basket of parts away from the NMP immersion and recycled reservoir tanks. Rinse the
parts with water. The waste water will be treated by the MCLB's on-site industrial waste water
treatment plant.
3.5.1.9. Dry
Allow parts to air dry before the next process step.
3.5.2. Process maintenance
3.5.2.1. Solvent distillation
The distillation process itself is not part of this operating procedure. The unit will be run in batch
mode on second shift or on weekends and will shut off automatically when the NMP level in the
immersion tank reads 50.00 as indicated on the level sensor. Frequency of operation will be
determined by level of use of the stripping bath.
Rinsing with NMP will deplete the reservoir tank and add to the immersion tank. Distillation
will stabilize the immersion tank level, provide recycled NMP for rinsing, and prevent high
dissolved solids build-up in the immersion tank. The NMP in the immersion tank will be
distilled when any one of the following conditions are met:
1) The NMP level is within 24" of the top of the immersion tank when a basket of parts is
immersed.
2) The heating platecoil is exposed in the stripping bath with no basket present.
3) Parts are not satisfactorily stripped in less than 4 hours. This may indicate a high
concentration of dissolved solids which need to be removed.
3.5.2.2, Immersion tank cleaning
Over time, paint sludge will accumulate on the bottom of the tank. At least once a year, the
immersion tank will be drained by running the distillation unit in a continuous mode. The
recycled NMP will be stored in the reservoir tank. Personnel will wear coveralls, boots, butyl
rubber gloves, goggles, and an appropriate respirator when cleaning out paint sludge. Paint
sludge will be drummed and disposed of as hazardous waste. The immersion tank will be
refilled from the reservoir tank.
2-53
-------
6057001-2
3.5.3. Shut-down procedures
3.5.3.1. Daily
Once the tank is heated, it should be left at operating temperature except for weekends and plant
shutdowns.
Parts with thick coatings or multiple layers of coatings may be left in the tank overnight.
3.5.3.2. Weekly
Turn off heat as shown in Figure 1 c. Turn off recirculation pump by switching pump from
MANUAL to OFF and rotating the breaker 90°counterclockwise from ON to OFF. Remove
basket of parts from tank.
3.5.3.3. Long-term
Turn off heat as shown in Figure lc. Turn off recirculation pump by switching pump from
MANUAL to OFF and rotating the breaker 90°counterclockwise from ON to OFF. Remove
basket of parts from tank.
Temperature and fluid levels in both the immersion tank and recycled NMP reservoir tank are
continuously monitored. The thermocouple in the heated tank is connected to an indicator panel,
which provides the current temperature of the bath. The level sensors provide high and low level
alarms for the distillation unit.
(Data from the thermocouples and the level sensors will also be continuously plotted on strip
chart recorders as part of the demonstration. Data from these sensors are used to calculate a mass
balance for the system and determine emissions.)
The monitoring and control equipment should be checked prior to startup according to the
following procedures. Record all readings and the reference standards used.
4.2.1. Thermocouples
Thermocouples and indicators will be checked prior to the demonstration program by immersing
each thermocouple in a water bath of known temperature. A reference mercury-in-glass
thermometer or other suitable temperature reference will be used. The indicators have been
scaled to provide direct current voltage analog output from 0° to 200°F. The output of the
stripchart recorder should agree with the reading from the reference thermometer within ±1
degree.
4. QUALITY ASSURANCE PROCEDURES
4.1.
4.2.
2-54
-------
6057001-2
4.2.2. Level indicators
Level meters, alarms, and stripchart recorders will be checked prior to the demonstration
program by comparing the output with a graduated rod that extends to the bottom of the tank
(reference zero level). The sensors have been scaled to provide direct current voltage analog
output from 15.0 to 95.0 inches. The output of the stripchart recorder should agree with the
reading from the reference within ±0.5 inches.
4.3. inspection and monitoring
4.3.1. Process controls
The correct configuration for the control panel on the strip chart recorders is shown in Figure 2.
From left to right, the first switch should be on the red circle, the second switch should be on the
point down triangle, the indicator dial should be on the "10/12", the fourth switch should be in
the neutral center, and the fifth switch should be on the "cm/h".
Figure 2. Correct Configuration shown for Strip Chart Recorder Control Panel
The correct configuration for the channel panel on the strip chart recorders is shown in Figure 3.
Both the level sensors and thermocouple indicators provide 0 to 10 volts direct current analog
input to the strip chart recorders.
During the demonstration period, continuously record the temperature and fluid levels of both the
immersion tank and the recycled NMP reservoir tank while the system is in use. The operator is
responsible for checking the test equipment on a daily basis. The operator will verify that the
recorder has chart paper and the pens are not dried out. The operator should refer to the
operator's manual when changing paper and/or pens. Both channels should be re-zeroed when
the paper is changed.
100 50 20 10 5 2 1
120 60 30 12 6 3 1.2
7\ CM/MIN
V50 20 10 5 2 1
Figure 3. Correct Configuration for Strip Chart Recorder Channels
2-55
-------
6057001-2
Plotting temperature and fluid levels upon completion of the demonstration will be at the
discretion of the MCLB,
4.3.2. Inspection records
At the start of each first shift, the operator will indicate the date and time on the chart paper using
a blue or black ball point pen. The operator should also indicate significant events such as
unscheduled shut-downs on the chart. Whenever possible, the operator should also indicate
routine operations such as immersing a load of parts, running the distillation unit, or adjusting
the temperature.
4.4. Production acceptance tests
Acceptance of the NMP stripping method will be based on achieving successful adhesion of
CARC to the cleaned parts, applied in accordance with MIL-C-53072.
5. NOTES
This standard operating procedure is intended to conform to the requirements of TT-C-490,
Method II.
2-56
-------
APPENDIX 2-2
EQUIPMENT DESCRIPTIONS
2-57
-------
© Copyright 1992 Omega Engineering, Inc. All fights reserved. Reproduced with the permission of Omega Engineering, Inc.,
Stamford, CT 06907
NON-CONTACT ULTRASONIC LEVEL/DISTANCE
TRANSMITTER Series LVm
made IN
1 YEAR
Sensor Construction
Diaphragm: 24K gold on kapton film
Housing: nylon with stainless steel g*
For Recorder* ami
Dataloggers, See Paget
J-41 Thru J-S6.
Remote Senior
"-RT'OpUon
X
Shown tmiller than
actual al»
The LV400 series displays and
transmits the distance of objects
located in front of the sensor in the
open air in the range from 05 to 30
feet with an accuracy of up to 1% of
reading. It is suitable for measuring
liquid levels in tanks open to the air
(0 psig interna]), certain solid levels as
welt as other general distance
measurements- All units feature a
4 digit LED display with 0.1 inch
resolution. Available with alarm
relays, analog outputs, RS-232 or
RS-422 2-way computer
communications, and a remote
transducer. Setting the limits of the
SPECIFICATIONS
Resolution; 007* for analog, RS-232 and
RS-422 outputs, 0.1* display
Temp. Effect: 1% shift in accuracyfevery
18°F away from 6S°F air temperature
when no( using the Auto Temperature
Compensation
Beamwldth: 12 degrees; target should
occupy one square M0 ft of distance for
opfjmal performance.
Range: 05 to 30 feet
Weight: 11 az.
Dimensions: 2.14* X114* X 472*
Output Cable: 24" length
Relay: .25 AMP @ 120 Vac resistive,
SPOT
Analog Output: 0-2M3e, CM0 \«c, or
4-20 mA, 2S6 steps within setpoints,
4-20 mA requires external 5-50 Vdc po#«
suppfy. Max loop resistance = {supply
voitage -5) * S11000 ohms for 24 Vdc
supply. Standard output increases with
increasing distance from sensor face
Power. 7J5 to 12 Vdc @ 500 mA
(LV404 accepts 12 Vdc ONLY!)
Operating Temp: -20°F to 160°f for
sensor; 32"F to 158°F far electronics
Relative Humidity: 5% to95% Noo
Condensing
HIGHLIGHTED MODELS STOCKED FOR FAST DELIVERY
TO Order (Specify Model Number)
alarms and analog output can be
performed manually by presenting
targets at the desired setpoints or by
entering the exact distance value pn
inches) by computer communication.
Alarm setpoints equal the analog
output span.
Temperature compensation for
variations in air temperature is done
automatically by placing a reference
target at an exact distance away from
the sensor.
Mode*
S'i.PWe»5
J
LV401
M2fl
Unit with high relay ONLY
CV402
3OT
Unit with high relay and 4-20 mA output
LV403
3M
Unit with high relay and 0-3 Vttc output
UW04
399
| Unit with high relay and 0-10 \Wc output
far additional lew mlay output, and add $33 to price Addsutkx "-fiS" lo reverse action ofanaM
output (increasing output with decreasing distance from the sensor fees), and add $39 to pnef
Add suffix "-mrJ" for remote sensor, mptaang asterisk with cabte length in IW up to <« v*. .
add $t09 tor firsts'and add $1 per additional hot. Jfo display heigft, reverse the distance d'&V
with option "-A20" and add $2$ k> price for extended range measurement, displays in feet ("J'
up *s SO-tl range, add suffix "-£R"and add $29 topnc# Ordering Example: UMOt-fTT(S],
tor utlrmonie transmitter, wish high relay and remote sensor with SO It cable.
Price: $329 * 109 - $*3&
K-7
-------
Courtesy of Cole-Farmer Instrument Company
RECORDERS
Flatbed
rtrublf, ctmfiet ntatitrt
M3S0-S4 tat 41 tn Htm
let jest KM wwtt
Cempict ttcoritt
MI0&4 thOKIt
vitbpowtr supply
nthirgtr
umfleg
unsmen
tot-tut
200-mm rt carter
120-AND 200-MM
FLATBED RECORDERS
COMPACT 120-MM RECORDERS
These ightweight recorders are avaiatsle in
one- or two-channel models. AH feature
12 chart speeds. wrth fast advance of SO
cnVmin. Inputs f*ng« from 10 mV to 50 V;
variable gatn setting allows fufljcale deflec-
tion between the fined range settings. Use
convenient Knob to manual position paper
ongridmarfcs.
Line powered models operate on 115/230
VAC. W60 Hi (switchablej. include a 7-lt
coOwir
«3M«*
JWo#
*-0&380-«0
M-o*»o-e2
Om
two
115*30 VAC.
S0*CHx
m&.m
1290.00
H-ceaa***
M-QS380-66
O*
IWo
12 VDC
>20 00
1250 00
H-OS3SO-70 Rechargeable NiCd power
•upply {two 6 VDC batteries) .S134.0O
H-OB360-71 Battery recharge*, 110 VAC
operation. for 06380-70 above .$63.00
H-08380-78 Battery recharge?, 220 VAC
operation, for 06380-70 above .*£3.00
H-06380-72 Connector tor hooKup to an
external 12 VDC power source $13.00
H -06380-76 Optional carrying case lor
recorders 08380-64 and-66 1180.00
FULL-SIZE 200-MM RECORDERS
Get one- or two-channel recording on a Ml-
size 200-mm chart width. Recorders faatim
28 chart speeds, with fast advance at 100
crt^min. Vottage settings range from 1 mV to
SO V (full-scaJe) use the gam control to con-
tinuously vary voltage sensitivity between
fixed ranges.
Use convenient knob lo manually position
paper on grid marks. Chart drive provides
forward/reverse direction and external
start/stop control. Recorders also feature an
event marker (on channel one arty. *nd
*100% zero suppression (via itro setting!.
Operate on liS/230 VAC. 50/60 Hi tswfleh-
able) Recorders come with a 7-lt power cord
with plug, chart paper, and pens (one for each
channel).
Cvtatoe
*e el
P9w«r
number
chamets
source
H-o«ao-eo
One
11V200VAC.
$1070.00
H-06380-82
Two
S&GOHz
1630,00
REPLACEMENT CHART PAPER
CftUk*
numb*
WOVx
Lrqw
«x
Mca/pk
«f lOroSt
14-08380-93
H-06380-75
200 mm
120 mm
52ft
53 fl
f&300
34.00
REPLACEMENT FIBER-TIP PENS
Gat»log
nunb«r
C
(nfcsail
C<**
PfitM/pk
Of 5p*m
H-08380-73
H-063&yn
Tvwo (tang)
Gr*m
Rad
$34.00
24.00
Callus tall-free Ml 1-800-323-4340
SPECIFICATIONS
Kimbtr «f t&anMls: one sr two
Oun irttfa
Moats 08380-60. -62. -64.«: 120 mm
Models <*380-80.-82:200 mm
Ckart 05%
200-mm models i0 35%
taps! ImpeJmtc 2 l«J (V); 30 Mfl (mVl
lire nttiai' < 100%
Mauitiea: up to 2.5 times input signal
Pti irtm: poise sens potentiometric
Paimyaew
120-mm models: B.3S strand M-seale
200-mm models: 0 4 second M-seale
Nww
Models 08380-60,-82: 11V230VAC,
S(V60 Kz (switdubk)
Models 06380-64. -68:12 VDC
Plmtplwi
120-rnm models: 10* 1«H*H * 12'4*B
200-mm models 13* 1% 13*0
Shfi M
120-mm models: 17 RH (7 ? kgl
200-mm models 20 Its (91 kg)
1165
2 - 59
-------
McMmter-Carr Supply Catalog No. 102
Courtesy of McMasier-Carr Supply Company
Braided Hose Assemblies
Teflon Hose Assemblies with Stainless Steel Braided Cowers
Reedy U> Insts* for most fluid eppttcetkxw, these ightweight ¦*-
MmbA«i feeture virgin Teflon cor** with super-smooth, nonstick
surfeces. plus Hecfble, corroeio«-«»*»tent Type JM stainless steel
braids. They SAC 100A14 tenements.
Since Teflon Is nonadheslve. hose cart carry mM. dyes. grease,
glue. late*. and paints. There is no cartoon buildup when used on ¦
compressor-disthvge »«ne Teflon hose assemblies are encetlent for
handling many prolan fluids and gases .. acid*. hydraulic fluids,
s(«am. solvents, fue*$, aieonofca, elastomers. coolants, and many
other chemicals. Teflon's nonstick properties make dearang the in-
side surface of the hose easy, too. Teflon is virtually rtonaging and w«
provide «Ktra-iong service we. tts *ow coefficient of friction ensures
continuous tow-pressure drop faring service while ma*nia«*
'A*...,
*A*~.
Mate
Yi* ..
%*....
V,#' ,
w.,.
Ma Mr
¥«*.
Vie".
%"...
%"...
Min.
End Rend
Fittings Radius
Pipm To Male Py» MPT Fating*
W-2? ..T
V-*-l8 .3*
**-1« 4*
V**-U 6%* ...
¥«'*14 TV,"
r -n^„ r
Pif>« To Male £M*on MPT ffttirtgt
... 'V-27 .T
V.M6 JT
H*-18 ,.4*.
K'-U 6%-
V«'.H
i* -n** .. r
Union To Male C/mon MPT Fittings
*'-27 ...r
%*-18 3"
W-18 4m
%M4 .6'A-
¥«M4 rv.*
„r
Mai_
Pressure
Vacuum
Rating
CMeMe.'iriiiV
wMrma* Fitting*
Cach
IneMwfrteV
v/3M SS FHtingm
Each
..3000 psi Hg
.3000 psi Hg
.2500 psi -28'
5522*201
5522*202
5522*203 .
.1500 psi ...28- Hg 5522*204
1200 psi .20* Hg 5S22*205„
1000 ps< 14* Hg 5522*206 .
3000 psi .28* Hg 5240*901..
3000 psi... ...J28* Hg 5240*302..
.2500 psi. 26' Hg $240*303..
1500 psi 29* Hg ,..,.5240*304..
1200 psi.,. 2V Hg S240K9OS..
iOQO psi 14- Hg S240K3Q8..
3000 psi 28* Hg S607K401
3000 psi 28" Hg S607K402..
J?500 psi JF Hg 5607K403..
1500 psi 29* Hg S607K4O4..
1200 psi ^0* Hg S607K405 „
1000 psi 14" Hg .5607K408..
....15.74
.... 7.18
.... 8.78
- .15.10
.20.40
....38.70
.... 8JKI
....10-58
....12rf2
....23.40
...Mm
....47.08
5S22K211..
K22I012..
5522K213...
5522K214...
5522K215..
5522K218...
.*11.78
.. 18J«
1«.70
.. 33.44
.. 40.04
.. 72.18
Ad4*r for Meee
Per Ineh
*0.14
.. .18
- ^0
...1072
17.04
,».S2
....S&28
5240K311 18-40
5240K312....... 29-24
5240K313 28^2
5240K314....... 53-60
5240K31S T7M2
5240K316.. 11SJ29I
5607K421 21,04
S607K422 33.72
S607K423 32.94
5607K424 T3.74
S607K42S 109 JO
5G07K428 100J6
.42
.80
.. .14
.. M
.14
.18
JM
.28
.42
JO
Mah Pipm
ffttktg
Do-It- Yourself Teflon Hose Assemblies
with Stainless Steel Braided Covers
problem* and reduce eouipment downtime.
Smooth-bore hose offers mimmaJ resis-
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Choose from brass and Type 303 stainless
steel f "
srjrc
—,1,11/1 n-f I I
»www rawiy
AUJnBody S*eeve B+e* Hut
cSiDtcgi
Easy essembfy In minutes!
(1) Wrap hose with masting tape at de-
sired eutoff point Place in vise and cut
with hacksaw or cutoff wheel. (2) Slide
beck nut over hose. Remove m*sking
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britid away from hose with a tmall screw-
driver. Push sleeve between braid and
tubing. (41 Clamp main body In vise. Slide
hose end over stem of-main body. <5)
Brtng back nut forward and thread onto
main body until ft m hand tight.
(6) Tighten back nut with wrench.
No spedaf equipment la needed! Jusl cut
the hose length you need and attach the fit-
tings using simple bench tools. This super-
tough, extmded Teflon hose with stainless
steel braid cover handles the most demand-
ing liQuid flow service application*, including
problem fluids such as acids, hydraulic fluids,
steam, solvents, fuels, and dNOTricais. Keep a
supply of hose and fittings on hand so you
can quickly solve your *
Fating Threads Min. < #fe«e —i
Hose Male KPT 37* JIC Send Mu. Vacuum Per Foot
10 Fitting Swivel Radius Pressure Rating 1-24 25-Up
V'** %V-27 %e"-20 r J000 ps» .....29* Hg .,..,.52515*21... «.4f $2*4
V*" ¥,*-18 W -20 r .3000 psi 28* Hg .52515K22... 3.0» 2.53
V..' W-\9 V»«-.i8 4* .„...,^500 psi 29' Hg .52515*23. .. 3^0 2,95
*¥*' VT-14 V«* -16 5Y«" .....2000 psi ......2rHg 52515K24 ... 4^3 3.71
W-U W -14 6%* .....1500 psi 29T Hg 52515*15. 3.51 4.51
V»"»14 rA»M2.....~ 7V«" 1200 psi -2T Hg 525iaC16 ,... 7JS2 0.33
*h' 1- -11% ..1W-12 r ........1000 psi 14" Hg S2515K27 ....10.40 1,67
t'A* VA-.11% . .1V«* -12 16*........ 750 p*i...„.ir Hg.....525l5Kl8 .,.W^5 IS.7«
muss Frmttas tw 303 stainless stl. ftttinqs
Hose Kale Pipe trJWSwtal Mat* Pip* Jr JIC Serfref
IO Eeeli Each Each Each
Vi." ,52515*31....$5,40 S251SK41.,„$5.45 S2S1SK51 .$14.18 S251SK81 J12.S5
V." ... 52515*32.... S.70 52515*42 .. 8A5 S2S15K52.. 1C.50 S2StS*«2.. 14.12
V«* ......... 52515*33,... SJ0 52515*43....11^ft S2SI5K53.. 17A3 S251«*ft3.. 17.43
'V«* . .. 52515*34....12.62 $2515*44 ... 848 S2St5K54.. 27.7$ S2S15*$4„ 28-73
W . ..52515*35....12.87 52515*45 .13,15 52S15K55.. 33.43 52515*65.. 36.38
v.- .......52515*36,...1740 52515*46 20^5 52S15K56.. 42^2 52515K«8 . 52.30
*h* 52515*37....20.87 5251SK47..U26^5 S2515KS7.. $5.«2 52515*67.. 71.07
1H* ...52515*38 ... 43.05 S2515K48 .86.66 S2515KS8..130.87 52St$*88 .134J5
McMASTER#CARR
72
2
-60
-------
McMaster-Carr Supply Catalog No. 102
Courtesy of McMaster-Carr Supply Company
About Safety Blowguns
•« Mmwh wt.ty nozzSM lh»t prr»»ol Hp pr»«-
buM-up fa es It has
a tarnp-er -resistant opening recessed instde the nozzle Featves
a tufi four finger trigger.
Repair Wt for 8 and C blowguns tndudes an extra valve s«al. spnng.
and gasket
Max. Inlet
Description Pressure Each
Adjustable Air Blast 120 psi >450*13 513.06
Extension Nozzle eiowgun ,.120 psi 1450*14 .... 18.5$
Recessed Nozzle Blowgun 150 psi *50*16 .... 16.60
Repair KH (for B and C on^ (450*16 2j»
R^piacairwit 6* Brass Ertension M50*22 Z99
Quiet-Air Blowgun
This gun's unkftte nozzie reduce*
•ir-itr«am vibrations wtthout losing
air velocity. Noisa lereJs are reduced by
6 to 6 decibels when compared to regu-
lar btowguns. The nozzle doesn't have a
Center hole so Static pressure is zero,
even when the nozzie is blocked. The
blowgun body h cast aluminum with a finger-orip trigger. Air iryei
size: V«* female pipe thraad (NPT). Maximum Met pressure: 150 psi
54615*16 Each SllS*
Dual-Connection Blowgun
La Two connections for tw4ce tfn
Top Ccnn&ctfon 9 versatifity: use the top <»nne«
j^B—sAk g for overhead hoses,, and th«
afcJPgll ff bottom connection for bench an>
floor hoses. A plug seals oft th
unused connection. Siowgun bod
is made of high-impact plastic tN
insulates against cotd air. and
has a variawe-flow trigger. Tut*
(soU separately) have a simp'
tvnst-and-4ock bayonet-style cor
nection for f«st chanoes. f
-------
Grainger 1995 General Catalog No. 386
Courtesy of W. W. Grainger inc.
STORAGE .<
EQUIPMENT
SHOP DESKS AND WORK TABLE CABINETS
SHOP DESKS
BolH ta Wail
ll«t> VllwWl
Floor Sp«c«
Cabin*'
Octk
0*lux« Desk
Space saving desks provide (convenient, efficient work area for able T OC. Deluxe desk has locking tray drawer, two full
shop foremen, shipping and receiving clerks, and watchmen. suspension file drawers, and one all-purpose drawer. Opes and
Back met has three op«n compartments, each 3H * 9W x 11 Vi*D; cabinet desks are 53* high overall; deluxe desk is 55H"H
No 4W345 his eight compartments. Desks have a (op locking 14-gauge corner posts. 20-gauge lop and 19-22 gauge panels;
drawer 3HH x 24W z 23*D (keyed differently), mounted on i 16-gauge drawer front. Gray enamel finish. Shipped unassem-
nylon rollers for smooth operation. Open style model has Coot bled. Edsal brand.
rest, cabinet style has locking doors and full sire shelf adjust- .
SHOP DESK SPECIFICATIONS AND ORDERING DATA
U..t
C'KMf
*
0«t
w
¦
(Itii
M*4ft
Stack
*«.
u*
(Ml
IMa
1
Wl.
Walt-Hung
Op«n 0«*S
Cabinet D««k
D«lut« D«»k
37 W
45%'
45 Height frog bottom of bracigt to tap of4«fc (*1 BeigfatfroB ioorto lop »f work
ONE AND TWO DOOR WORK TABLE CABINETS
Top tin fei
movnt«
<*r nvintd .
, t* prorfd* • ,
*mootfC'H*n-
t*s» morfc-',-.
fabl«
I
Provide safe, locked-io storage of valuable tools, merchandise,
arts and serve as a work table with edge-stop on sides and
¦ack. Cylinder locks are built into the T-handle on the door for
added security (keyed differently).
No. 1WS14. 2H sq fl work surface can be mounted to form a 7
deep tray or reversed to provide a smooth, rimless work table.
Mount a drill press, grinder, or other bench tool or use as extra
work space. Posts are 14-gauge steel, door 22-gauge, shelves
22-gauge and panels 24-gauge. Three adjustable shelves inside
the 6 2 cu ft interior provide ample storage space.
No. IWW
No. 1W7QJ
No*. 1 WW?, 1W703. Cabinets have 14-gauge steel corner posts.
Id-gauge steel lop. 20-gauge doors 19-gauge side and back
panels provide 2* deep lip to prevent supplies from falling off
top and can be inverted to obtain a flat surface. Double door
cabinet has G sq ft of work area and 18 cu 11 of storage space,
single door model has 4 sq ft work top and 12 cu ft of storage
space Full site center shelf adjustable on IV centers.
All cabinets have gray enamel finish and are shipped unassem-
bled. Edsal brand.
WORK TAB LI CABINET SPECIFICATIONS AND ORDERING DATA
U»ii
ficierlftUa
BwltliMI
«» W
0
Ta# ScHac*
s, h
Starafa
Call
(laal
Slack
*•.
IM
lack
lata
s
*rt.
Single Deer
Slncl* Door
Oeiibl* Doer
32 21*
35 24
35 36
1SV4*
24
24
IS
4
6
6.3
12
18
630
59242
59243
1W1M
IW909
1W703
1108 90
166 45
21504
$«S,00
% J6.50
176.7$
S84.SS
129.68
167.91
460
80.0
1020
t*i Hut&i froa Soot to top of »ort jurfice.
1866
WHOLESALE PRICES—GRAINGER
2-62
-------
Rotan HD Series
Internal Gear Pumps
m.
Design Parameters |
Capacity Range 1 0 10 750 GPM
Speed ..Up to 1750 RPM
OiHetentiai Pressure Up to 250 PS1 for sizes 26 • Bt
Up to ISO PSi tor sues 101 - 201
Suction Lift Up to 15' Hg vacuum while priming
Up to 24" Hg vacuum while pumping
Viscosity Range 32 to 350.000 SSU (i to 75.000 cSt)
Tempesature Up to 500* f
Jacket P.'essuie Up to 150 PSI as standard
Relief Valve Setting Apprommately 20 PSi a&ove system
design pressure is recommendefl
The
tougher
the application,
the more you need an ...
HD Series pump!
The Rotan HO (Heavy Duty) Series are rugged, cast iron,
interna! gear pumps of modular construction. They are backed
by our 70 years of experience in the design and manufacture of
positive displacement gear pumps. Typical applications include
pumping waste oils, asphalt, molasses, chocolate, soaps,
paints, lacquers, thinners, and other low to medium viscosity
fluids.
In addition !o the cast iron housing, rotor and idler gear. each
pump is equipped with a steel drive shaft and idler pin. in
packed pumps, the idler and main bearings are either cast iron,
bronze, carbon, ceramic, or tungsten carbide sleeve-type
bearings. These internal bearings are typically lubricated by the
pumped fluid, but can be externally lubricated as well. When
supplied with single or double mechanical seals, a ball bearing
serves as the main bearing.
Rotan pumps require little maintenance. However, should
repair or disassembly be required, it is easily accomplished
With our modular design, all pumps can be disassembled and
inspected without removing the casing from the process line
and bolt-on heating jackets and relief valves are simple and
inexpensive options. Complete systems can also be supplied
with the pump, motor, gear reducer (tf required) and couplings
mounted on a common baseplate
?. - 63
-------
Design Principle
The Rotan Series internal Gear Pump is a positive displacement rotary gear pump with only two rotating parts: a main power
rotor driving an internal idler gear. The rotor and idler are arranged in a circular pump casing with both rotating in the same
direction The rotor is mounted on a solid Shalt that passes through a main bearing located in the rear cover A second bearing,
mounted in the rear bracket, supports the free shaft end. The idler gear folates freely on a pin fixed in the front cover A non-
rotating part, the crescent, is positioned between the rotor and idler and separates the suction and discharge sides of the pump
«¦¦¦¦+ | U) 1
Fig 1
As the pump shaft rotates, a finite
amount of liquid enters the pump
through the suction port and fills
the voids between the teeth of the
rotor and idler gears.
As the rotor and idler gears
rotate, the liquid is separated by
the crescent and locked into the
spaces between the gear teeth.
As the liquid moves past the
crescent, the rotor and idler gears
mesh, forcing the liquid out of the
gear teeth and into the discharge
port of the pump.
Design Advantages \
MOST PARTS ARE COMMON AND
INTERCHANGEABLE.
• Shorter lead times & lower cost.
• lower stocking levels.
OESIGNED FOR IN-LINE
INSPECTION/REPAIR.
Simplifies inspection/
repair procedures
saving time and
money.
AXIAL ADJUSTMENT Of ROTOR
ANO SHAFT POSITION IS POSSIBLE
WITHOUT DISMANTLING PUMP.
• Allows pump to be adjusted to
compensate for wear or to
reposition after rebuilding.
Saves maintenance
time and expense.
ONLY TWO MOVING PARTS
WITH ONE SHAFT SEAL
¦ Strong, simple construction.
> Longer life with minimal wear.
IN-LINE OPPOSING INLET ANO
OUTLET CONNECTIONS WITH
OVERSIZED PORTS.
• Self-priming with large suction
capabilities. Low NPSH require-
ments.
• Gentle liquid handling (low
shear design), smooth flow
characteristics.
• Handles lubricating and non-
lubricating liquids equally well
2 - 64
-------
How To Select |
The pump capacity is directly proportional to the pump
speed. The maximum speed of the pump must be reduced
when the following liquid specifications are encountered:
liquids with abrasive particles
Liquids sensitive to mechanical agitation (emulsions)
When the capacity (gpm) and viscosity (cSt) are known, the
pump size and speed can be readily determined using the
Selection Chart on page 5 and the following steps
t. find the point of intersection of the horizontal CAPACITY
(gpm) line and appropriate VISCOSITY (cS)curve.
2 From the point of intersection of the CAPACITY tine and
VISCOSITY curve, move left horizontally until you meet
the first diagonal PUMP curve. Each PUMP curve is
labeled with the corresponding pump size in the box just
above it {for example fisTh.
3. The pump speed is found by dropping straight down
from the point on the selected PUMP curve to the
horizontal SPEED (rpm) zxis.
4. The pump speed, as a percentage of the maximum
allowable speed for the pump size selected, can then be
found by following the VISCOSITY curve to where it
crosses the PERCENT OF MAXIMUM RPM scale. The
percentage of maximum speed will indicate if a larger (or
smaller) pump could possibly be used.
5. The calculated pump speed should then be adjusted
according to the liquid's abrasiveness or shear sensitiv-
ity by multiplying the speed by the appropriate Speed
Reduction Factor (Refer to table at top of Selection
Chart). The chart automatically compensates for
viscosity changes between 400 cSt and 75.000 cSt. For
viscosities below 400 cSt. use the 400 cSt curve. For
applications involving a viscosity greater than 75.000
cSt, please contact your local Rotan distributor.
How to Select £xample ~|
An application involving a clean, non-abrasive liquid ar
design parameters of...
130 gpm and 50,000 cSt
Proceed as follows:
1. Locate the 130 gpm line on the CAPACITY (gpm) axis a
the 50.000 cSt curve on the VISCOSITY (cSt) axis Fir
the intersection of these two curves.
2. In this example, the intersection of the VISCOSITY a
CAPACITY curves occur on the Oft] PUMP curve Ther
fore, the 151 pump size is selected
3. The pump speed is determined by dropping straight dov
from the fisTj PUMP curve to the SPEED (rpm) axis a! ft
bottom of the chart. In this example, the pump speed
approximately 180 rpm.
4. The actual pump speed as a percentage of maximu
recommended speed can then be found by following v
50.000 cSt curve until it intersects the PERCENTAGE <
MAXIMUM RPM scale. In this example the pump
would operate at 32% of the recommended max-
imum speed.
5. The pump speed should then be adjusted to compensa
for the liquid's abrasiveness or shear sensitivity. Sin
this example involves a clean, non-abrasive liquid, n
pump speed remains at 180 rpm.
Additional Information]
In addition to the HD Series, a complete line of internal gear pumps is offered. Contact your local Rotan distributor for
additional product information.
GP • General Puipow
Clow-coupud pamps ol
east iron construction.
CO - Clwmcal Duty
Pumps oi stainless SMI
construction
PO - Ptlioctwmml Duly
Pumps ol carbon sitti
construction (API-676)
MO • Magnetic Owe
IhgatOitn magnetically
coupled pumps avaiiaste
in cist iron, carbon steel,
and stainless steel con-
structions
2 - 65
-------
Selection Chart \
t
<3
5
2
VISCOSITY (cSlI
50.000 21000 3.000 400& below"
75,000 40.000 ; 7.500 1.000
5040 Mitflio* mt§4J MeHpiy *f
Clem, 100
$l*gh% itxisnt liquids 75
Mockiaiety abusnf fcqvxh so
€mufe»o« 1 $0
90 " "1
i
25 35 50 60 75 85 >00 %
PfRCm OF MAXIMUM RPM
&
2
o
5
1
£
60 80 100
150 200 300 400
smofam)
600 800 1.000 1.500
1750
2 - 66
-------
How to Order \
HO 101
Pump Size
26. 33, 41, 51, 66, 81
101. 126. 151, 152. 201
[See Selection Chart - Page 51
Optional Features
nr> nn np
Nhimh SaaMMi
(See Table 2 - Below]
Bearing lubrication
U-Bearings lubricated
by pumped liquid
M-Bearings lubricated
externally
Table 1 - Standard Materials lor Mala Parts
Component
i Material
Casing
l Cast Iron
Front/Rear Covers
Cast Iron
flQtar
: Cast Iron
Idler
i Cast Iron
Idler Pin
1 Hardened Carbon Steel
Shaft
1 Carbon Steel
for other material combinations, consult your
Rotan distributor.
7"
Special Configuration
S- Consult Rotan
Distributor
Primary Shaft Seat
8 - Packing
2 - Single Mechanical Seal
22 - Double Mechanical Seal
Bearings. Idler Pins anil Shaft Materials
(See Table 3 - Below}
Table J - Optimal features
Code 1 Description
1
SuctiorVDischarge connections in-line
(No other options available)
(blank)
Packed pump supplied as standard unless
other seat options are specified
M*
Single mechanical shah seal
MM
Double mechanical shah seal {tandem orientation,
non-pressurized sealing fluid required)
UUP
Ooubie mechanical shaft seal (back-to-back
orientation, pressurized sealing fluid required)
0
Front cover heating jacket
K
Rear cover beating jacket (packed pumps only)
«
One way, pressure relief valve
RR
Two way. pressure relief vatvt
T
Special clearances
I CHD
Chocolate Execution (includes front (0) and rear (K)
heating jackets)
* The Main Searing must be a Ball Bearing when a single mechanical
shaft seal is specified.
Table 3- Material Codes and Standard Combinations for Barings, Idler Pins and Shafts
Code 1
Idler Bearing
! Main Bearing !
Idler Pic
Shan
11
Cast Iron
Cast Iron
Carbon Steel
Carbon Steel
18*
Cast Iron
: Bali Bearing
Carbon Steel
Carbon Steel
22
Bronze
| Bronze
Carbon Steel
Carbon Steel
28*
Bronze
i Ball Bearing
Carbon Steel
Carbon Steel
33
Carbon
| Carton
Carbon Steel
Carbon Steel
38*
Carbon
j Bait Bearing
Carbon Steel
Carbon Steel
41
Ceramic
< Cast Iron
Cr Oxide Coating
Carbon Steel
42
Ceramic
! ¦ Bronze
Cr. Guide Coating
Carbon Steel
44
Ceramic
: Ceramic
Cr. Oxide Coating
Cr. Oxide Coating
53
Carbon
i Carton
Ceramic, Polished
Carbon Steel
58*
Carbon
Ball Bearing
Ceramic. Polished
Carbon Steel
T3
Carbon
Carbon
Tungsten Carbide
Carbon Steel
S4
Tungsten Carbide
Ceramic
Tungsten Carbide
Cr. Oxide Coating
SB*
Tungsten Carbide
Ball Bearing
Tungsten Carbide
Carbon Steel
* The Main Bearing must be a Bad Bearing when a single mechanical shaft seal is specified.
For other material combinations, consult your Rotan distributor.
2-67
-------
Assembly Drawings j
* 8*
« DC SAS8US8A8C 83 CJ BO 88 if BE COO CS Cufii CR C» Bv CA
S ! ' ; '
t
Pump with Packing
*C8Cf !
8V
Af AA 8 DC 5 AS 6U 6 BA ®C BH 8G U 88 » M CO CT CS Cu 32 CG CI Sv CA
Pump with Heating Jackets
a ca a f
6 DCjSASBUBfiAQ BCB8BD CO Ct CS CXI K CS CI BV CA
Pump with Single Mechanical Seat
A C8 C£ F
IntSei el Parts
ttem
Part
A
Pump Casmg
B
Gasket
C
Gasket
D
Bolt
E
Bolt
F
Bolt
G
Pipe Plug
K
Name Plaie
S
Blind Cover
M
Front Cover
A8
Idler
AC
Idler Pm
AO
Idler Bushing
AE
Lube Nipple
AF
Gasket
AJ
Heating Jacket
At
Pipe Plug
AM
Pipe Plug
8A
Rear Cover
BB
Packing Gland/
Bearing Cover
BC
Main Bushing
80
: Stud BoB
BE
i Nut
BF
Washer
BG
Pipe Plug
BH
Bolt
BU
Lube Nipple
BV
Shaft
BY
. Ball Bearing Nut
BZ
Locking Ring
CA
Key
CB
> Key
CE
' Snap Ring
CJ
Packing/
Mechanical Seal
CQ
Beating Bracket
CR
' Bearing Cover
CS
Bearing Cover
CT
' Bolt
CU
. Ball Bearing
2-6S
-------
HO Series Dimensions |
v\
^ Ku—1| !L
^o=^m ;t.
s
_M_
Standard Construction with Optional Pressure Relief Valve
%
k
%
Jacketed Construction
•e ®
*0 mm
u
Pump Sin ; Prtssuri Cm ft C$nnections
26-66 ! 1/4" NPT Female
81-201 ~f 3/8* NPT Female
Pump She
fit ages / Ports
26-41
NPT Female Ports
26-201
ANS1125 U>s. FF Flanges
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-------
Rotan Flexibility |
flexibility is the keyword for Rotan pumps!
The Rotan pump offers the benefit of both our 70
years experience in rotary pump manufacturing
and the advantages of our state-of-the-art modu-
lar design concept This design and our constant
dedication to innovation and improvement are
the key reasons why Rotan pumps are recog-
nized as the most advanced internal gear pump
available in the world today.
The advantages of this design include:
Pump selection is simplified as there
is only one general set of corves for
the entire Rotan Series.
Special pump constructions are pre-
pared as easily as standard pumps.
C^> Customized pumps are fitted exactly
to end-user specifications.
C^> Interchangeably of parts minimizes
stocking requirements, resulting in
lower costs.
A fully computerized Sales and Engineering staff stand ready to assist
you with your most difficult pumping problems.
Short delivery times for all pump
constructions.
Rotan Quality |
To insure a high and constant quality level, every
Rotan pump undergoes both hydrostatic and
performance tests before leaving the factory. A
Test Certificate, attached to each pump before it
ships, documents the performance of the pump
tor the end-user. A copy of each Test Certificate
is kept in our file, an extensive archive that in-
cludes information on all Rotan pumps manufac-
tured since the early 1920's. All Rotan pumps are
designed, built, and tested to general ISO 9000
guidelines.
All Rotan pumps are tested before leaving our factory. TMs is your guar-
antee of a high quality product
2-70
-------
In 198? the engineer* at R. S.
Corcoran Company designed • email
stainless steel centrifugal pump to
replace a cast Iron pump for a friend of
Mr. Corcoran'*. By 1965 several OEMs
were using this and another, some-
what larger, design. By 1881 the com-
pany decided to divest Itself of a]] other
Interests {through the years Corcoran
had been actively involved in the man-
ufacture and distribution of hand tools
and small compressors, proprietary
food products and artesian well-water,
blow-molded bottles, extruded wire
harnesses, military bomb fuses, mate-
rial handling equipment and auxiliary
machinery for plastics processors}. As
of 1985, this multiple divestiture has
been complete and now the R.S.
Corcoran Company manufactures only
corrosion-resistant centrifugal pumps
for the vast Chemical Processing
Industry and OEM markets.
Our design It unique. The shape
of our housings is concentric, not a
"volute". They arc deep-drawn from
special grades of wrought 304L and
316L sheet and hand fabricated from
plate stock, using proven techniques
developed by manufacturers of pipe,
tanks and other process equipment-
Wrought metal has several advantages
over Its cast alloyed counterpart.
Wrought metal Is more uniformly
dense and generally of higher density;
It has better mechanical properties; it
Is less porous; In many Instances the
wrought metal has significantly higher
corrosion resistance.
Corcoran fabricates pumps from
Independently certifiable plate material
In 304L and 316L stainless steel,
Carpenter 20 Cb-3 and Mo-4.
HaHelloy B-2. C-22 and C-276,
Ferrallum 255, Moncl 400, Nickel 200,
commercially pure Titanium and its
alloys. Zirconium, and other metals.
Sizes range from 1/2 through 6 Inch
discharge, three through 14.5 Inch
Impellers and 1/6 through 100 HP.
Corcoran offers a complete line of
Horizontal pumps (close-coupled or
pedestal mounted ANSI 073.1 dimen-
sional) with single seal, double seal,
dynamic seal, or packing... each with a
SELF PRIMER option.
Corcoran also offer* a complete
VERTICAL line: submerged bearings
(Rulon J or Grmphalloy. product or
externally flushed], with four sizes of
thrust bearings and extended lengths
from 6" to 21 feet below the cover
plate. CANTILEVER versions: from
close-coupled for compact design (of-
ten provided with the "rcpclkr* option
for continuous, sealtcss. dry-mount
operation) through heavy duty models
with extensions up to 60* and shads to
4.5* in diameter... each with optional
top suction or the vortex (recessedl
Impeller are available.
In addition, Corcoran manufac-
tures a series of small heavy duty.
Industrial design, 316L stainless steel
and exotic alloyed SUBMERSIBLE
sump pumps available in 1/2 through
l.S inch discharge and 1/2 through 2
HP.
Corcoran offers an adaptable, cus-
tomer-oriented line of corrosion-resist-
ant pumps. Case histories of our near
limitless flexibility and adaptability to
customer requirements arc well docu-
mented: (1) Pumps built to withstand
up to 1000 PS10 system pressure,
close-coupled, and frame mounted; (2)
Pedestal-mounted, packed-box vertical
pairs, each built as the minor-Image
of the other, (3} Left-handed pumps
(the reason for which has long since
been forgotten), close-coupled, frame-
mounted,and vertical; (4) Pumps built
to duplicate dlmenslonally a competi-
tor's discontinued model or to help a
customer move up quickly to a less
expensive, more corrosion-resistant
pump with no piping changes; (S) Non-
sanitary, otherwise standard pumps
provided with sanitary fittings, hand-
polished external welds and other
"ckan-ln-placc" feature*; (8) Pumps
built to meet the demanding, sometimes
questionable but always respected,
design and QA parameters of the mili-
tary. (7) High speed, stainless steel.
Monel 400-fltted, 2" non-clog vertical
Inline sewage pumps; (81 Special heavy
duty cantllevtrcd verticals for nitnscel
lulose, radio-active waste water and
•pink water", which allow no liquid rest
due to be trapped after removal from
the sump or require the pump to be
completely welded Into one solid unit
and guaranteed for 100,000 hours of
non-maintained operation; and (9)
Horizontal in-line stainless steel pumps
for hot. concentrated nitric acid in a
condensing, dripping nitric acid
atmosphere, with a fan-cooled, self
flushing double seal chamber, special
narrow vane impeller for flow limitation,
and 318 stainless steel plasma-sprayed
explosion-proof motors.
There is a little Isolated box In mast
of Corcoran'* brochures which capsulire
our business attitude. It reads:
Corcoran socializes In adapting to
your specific requirements. Call the
factory far Information on an pub-
lished modifications.
Model 2000MD-2, close-coupled. end
suction, 2- stage centrifugal; available in
all Corcoran materials of construction.
wide variety of single Internal mechanical
seals; FNFT. flanged, hose or sanitary
damp connections; and 56C Jrturm rmtors.
heads to 60 PSI and maximum Jlow of 35
GPM
CORCORAN
COMPANY
P.O. BOX 429 * S00 N. VINE ST.
NEW LENOX, 1L. 60451-0429
Phones 815-485-2156 « Fax; 815-485-5840
Toll Free: 800-637-1067
Model 6000D, 6X4
13 dose-coupled, end
suction, horizontal.
316 stainless steel
centrifugal; pumping
brine and walnut
shell slurry at ISO' F".
single Internal non-
flushed, hard face
rubber bellows
mechanical seal;
1450 RPM, 380V.
5OHZ; produces 870
USGPMatBO FeetTH.
2 - 71
-------
•JH&raJHL
~ MODELS
5000-D - Close coupled
5000-F - Pedestal mounted
~ MATERIALS OF CONSTRUCTION
304 Stainless Steel
3)6 Stainless Steel
Carpenter 20 C8-3
Monet
Nickel
~ PORTS AVAILABLE
IPS threoded
ASA flanged
~ MECHANICAL SEAL AND GASKET
Neoprene
Vitoo A .
Teflon
Manganese Steel * *,
Zirconium i
Titanium -•
Tantalum . ' ,,
Hasteiloy 8i C
STANDARD
¦ -f -! • *
¦4,
;ri-ia Kt
V2 - '"-X
2-1/2
J
^•IPS threaded
thfeoAsd
flonged
. *ASA flonoed
. , *"?*:1 5;i^£;'ASA flanged
-¦ *•
~ OTHER MODELS AVAILABLE:
5000-H (Double mechanical seal)
5000-VE (Vertical extended shaft)
5000-VEC (Vertical cantilever shaft)
5000-RS (Rear suction)
5000-2 (Two stage)
5000-FHP (High pressure, High temperature with double balanced seol and
optional seal lubrication system)
MODEL 5000 VE
^ PACKINGS
Braided Teflon
African Blue Asbestos impregnated with Teflon
Asbestos impregnated with Graphite
~ PUMPS AVAILABLE
WITH PACKING GLAND AND
LANTERN RING IF REQUIRED
~ CUSTOM DESIGNED MODELS ARE AVAILABLE fOR PROCESS AND O, E.M. APPLICATION^ WITH
! DELIVERY USUALLY MADE IN LESS TIME THAN pO* COMPETITORS REQUIRE
PUMPS.
JSUALLY MADE IN LESS TIME THAN pU* COMPETITORS REQUIRE
^ CORCORAN COMPANY
2 - 12
-------
F.N.P.T. PORTS
MODEL 5000D
F.N.P.T. ¦
DISCHARGE
—F.N.P.T.
SUCTION
FF
EE
DIMENSIONS OF MODEL 5000D F.N.P.T. PORTS
For planning purposes only. Do not use for construction unless certified.
*For Motor Dimensions J see Motor Dimensions Table.
MOTOR
FMMC
Silt
9
EE
FT
WMS
A
8
G
H
143IC
3,5
5.5
4
1% * 1
10.44
5.47
362
2.68
2x1ft
10 44
5.16
3.62
2.16
3 111k
10.44
S.18
362
2.H
145TC
s
3 «2
10.44
4.77
3.62
2.66
4*3
13 62
4.37
5.44
2.16
U2TC
4 5
4.5
1ft *1
2* 1*
3 11*
3*2
4x3
10.67
5.47
3.62
3.62
10 87
5 16
362
362
10.1?
5 16
3.62
3.62
184TC
55
1087
4 77
3 62
362
14.06
4 37
5.44
3.62
213TC
5 25
15
55
1* 11
2x1%
3x1*
3x2
4x3
11.37
5.47
362
4.50
11-3?
5.16
362
4.50
11.37
5.16
3.62
450
21STC
7
It.37
4 77
3 62
450
14 56
4.37
5 44
450
254TC
6 25
10
625
1* 11
2x1ft
3x1ft
3*2
4 <3
12.37
5.47
3.62
4.50
12.37
5.16
3.62
4.50
12.37
5 16
3.62
4.50
256TC
10
12.37
4.77
3.62
4.50
15.56
4.37
5.44
4.50
2MTC
284TSC
7
It
«
1ft x 1
2*tft
3*1%
3x2
4*3
12 50
5.47
362
5.00
12.50
5,16
3.62
5.00
12.50
516
362
5.00
12.50
4.77
3.62
5.00
15.69
4.37
5.44
500
MOTOR
FRAME
SIZE
B
ff
NRTS
A
B
G
H
2I6TC
7J6TSC
7
11
11
1% X 1
2x1*
3x1%
3x2
4x3
1250
S.47
3 62
500
12.50
5.16
3.62
500
1250
5.16
3.62
5.00
12.50
4.77
3.62
SOO
15.63
4.37
5.44
5 00
324TC
324TSC
«
125
10.5
1* • 1
2x1*
3*1%
4x3
1331
547
3.62
5.50
1331
5.16
362
550
13 31
516
362
5.50
13 31
4 TT
365
550
16.50
4 37
544
550
326TC
326TSC
*
12.5
12
1ftxl
2x1*
3x 1ft
3x2
4x3
13 31
5.47
3.62
550
1331
5.16
3.62
5.50
13.31
5.16
3.62
550
13.31
4.77
3.62
5.50
16.50
4.37
5.44
5.50
364TC
3G4TSC
S
14
1125
1ft x 1
2x 1ft
3 i 1*
3x2
4*3
14,12
5.4?
3.62
6 12
14.12
5.16
362
6.12
14.12
5.16
3.62
6.12
14.12
4.77
3.62
612
17.31
4.37
5.44
6.12
365TC
365TSC
t
14
12.25
1ft x I
2x1ft
3x1%
3x2
4x3
14.12
5.47
3.62
612
14.12
5.16
362
6.12
14.12
5.16
3.62
6.12
14.12
4.77
362
6.12
17.31
437
5.44
6.12
jjpfcjrt D''Jl'Skl -500.Old Hiciiory Rcf/ •'Ne'Wlenisffl!i;;"6^45iK
%#BTI *Ti,I?hone 8t5/485*2156 "Telex: 72-3422" \ £-.'C
2-73
-------
FLANGED PORTS
MODEL 5000D
DISCHARGE
HOUSING n
DIA.145/16"
SUCTION
~
0
DIMENSIONS OF MODEL 5000D FLANGED PORTS
For planning purposes only. Do not use for construction unless certified.
'For Motor Dimensions J see Motor Dimensions Table.
MOW
«**£
sia
9
a
If
KMTS
A
8
G
H
1*. * 1
11.44
5.47
462
266
143TC
1
2x1*
11 *4
5.16
4 62
2.88
3* 1%
11.44
5.16
462
2.88
3.5
5.5
3x2
11.44
4 77
4 62
288
14STC
4x3
14.16
4.37
£00
288
5
6k «
14 16
3 67
600
2.88
6x5
14 56
3.34
600
288
1ft xt
11.81
5.47
4 62
362
182TC
4.5
2x1*
11.88
5.16
4.62
3.62
4.5
3x 1ft
11.88
516
462
3.62
7.5
3x2
11.IS
4 7?
4 62
3.62
184TC
5,5
4x3
14.59
4 37
600
3,62
6x4
14.59
387
600
362
6x5
15 00
3 34
600
362
1% * 1
12.37
5.47
4 62
4.50
213TC
IS
2x1*
1237
5.16
462
4.50
5.25
3 x 1ft
1237
5 16
4 62
4.S0
85
3x2
12.37
4.77
462
4.50
215TC
4x3
15.09
4.37
600
4.50
?
6x4
1509
317
600
4.50
6x5
1550
3 34
600
4.50
1ft x 1
1288
5 47
462
4 50
2&4TC
125
2 x 1ft
12 68
5 16
4 62
4.50
3 x 1ft
12 88
5 16
4 62
4.50
6 25
10
3x2
12 88
4 77
4 62
4 50
256TC
to
4x3
15.59
4.37
600
4.50
6x4
1559
3 87
6.09
KM
6x5
16,00
3 34
600
450
1ft x 1
1350
5.47
462
500
284TC
2x1*
13.50
5 16
462
5.00
3x1*
1350
5 16
4.62
500
—
J
11
ts
3x2
1350
4 77
462
5.00
264TSC
4x3
16.22
43?
6.00
500
6x4
1622
3 8?
600
5.00
6x5
16.621
334
600
5.00
M01SR
FMME • a ft
SIS
PORTS
A
B
6
H
1ft tl
13 50
5.47
4.62
i 00
286TC
2» 1ft
1350
5.16
4 82
500
3x1*
13.50
5.16
462
5.00
7 11 11
3x2
13 50
4.77
482
5 00
2861SC
4i3
1622
4.3?
600
500
6x4
1622
3.87
600
500
6x5
1662
3.34
6.00
5.00
1ft x1
14.31
5.4?
4.62
5.50
324TC
2x1*
14.31
5.16
4 62
5.50
3*1*
1431
5.16
4.62
5.50
8 12.5 10.5
3x2
1431
47?
462
550
324TSC
4x3
17.03
4.3?
600
550
6x4
1703
387
600
550
6x5
17.44
3.34
6.00
550
1ft x 1
14.31
547
4 62
550
326TC
2*1*
14.31
5.16
4.62
5.50
3x1*
14.31
5.16
4.62
550
8 12 5 12
3x2
14.31
4.7?
462
5.50
326TSC
4*3
1703
4.37
6.00
550
6*4
17.03
387
6.00
5 50
6x5
17.44
3 34
6.00
550
1ft x 1
15.12
5 47
4.62
612
36
-------
MOTOR DIMENSIONS
MOTOR DIMENSIONS FOR 4000D AND 5000D
M.f
nr.*
Mi,
met
FMKE
J
1
1725
1
OOP
56C
10 00
1
1725
3
OOP
56C
900
1
1725
1
T£f C
56C
11 25
1
1725
3
TEFC
56C
10 25
1
1725
1
XP
56C
13 IS
1
1725
3
XP
56C
12 31
1
3450
1
0 0*
56C
It 31
't
3450
"3
OOP
560
« 19
1
3450
1
T tf C
sec
1125
1
3450
3
?Cf c
56C
9 31
1
3450
1
XT
56C
1311
1
34 50
3
XP
sec
12.31
1 5
>725
1
OOP
56C
10.00
1 5
1725
3
OOP.
see
900
1 5
1725
1
TEfC
sec
12 12
1 5
1725
3
IfIC
56C
10 25
1 5
1725
3
XP
sec
12 31
15
3450
1
0 0 P
56C
13 IS
15
3450
3
OOP.
sec
9.00
1.5
3450
l
T E f.C.
560
11.25
1.5
3450
3
T.E.F.C.
56C
10,25
( 5
3450
3
XP
M3IC
12-31
2
1725
l
OOP
145TC
11 81
2
1725
3
OOP
560
to.oo
2
1725
1
TEFC
1S2TC
1394
2
1725
3
TEFC
sec
11.25
2
1725
3
XP
56C
14.1*
2
3450
1
OOP
56C
1000
2
3450
3
OOP
56C
900
2
3450
1
t£f C
56C
12 «
2
3450
3
HfC
56C
11 25
2
3450
3
IP.
145TC
13.19
3
1725
1
OOP.
1#4IC
12 37
3
1725
3
OOP
182TC
11.00
3
1725
1
T.£f C
184TC
15.44
3
1725
3
I.E.F C
182IC
1256
3
1725
J
XP.
182TC
14.19
5
1725
3
OOP
164TC
12 37
H.P.
ft.PM
PH,
cm.
FRAME
J
5
1725
3
TEfC
184IC
13.94
5
1725
3
XP
1f4IC
17 67
S
3450
1
OOP
1821 C
1237
5
3450
3
TE.f C
1641C
1394
5
3450
3
XP
184TC
16 25
75
172$
3
OOP
2UIC
1394
75
1725
3
I If c
21JTC
15.56
71
1725
3
XP
213TC
16.19
75
J450
3
OOP
184 JC
12.37
75
3450
3
I If c
1«4TC
1544
75
3450
3
XP.
184TC
17 75
10
1725
3
OOP
2151C
13 94
10
1725
3
T tf C
2151C
1669
10
172S
3
XP
2l$tC
17 56
10
3450
3
OOP,
215TC
17 31
10
3450
3
T.E.f.C
215TC
15 56
IS
1200
3
T.E.F C
284TC
19 31
15
1740
3
T If C
2S4TC
1931
IS
3500
3
T E.f C
2S4TC
19 31
20
1200
3
UK
286TC
25 06
20
1740
3
T £ f C
2561C
1931
20
3500
3
TEFC
254TC
19 31
25
1140
3
TEfC
324IC
2369
»
17«0
3
TEfC
2S4IC
1931
25
3500
3
TE.f C
284TSC
1931
30
1140
3
TEFC
326TC
23.69
30
1740
3
T.E.f.C,
286IC
25 06
30
3500
3
TEfC
286TSC
25 06
40
1140
3
TEfC
364TC
26.81
40
1740
3
T.E.f.C
324TC
23 69
40
3500
3
TEfC
324TSC
23.69
50
1140
3
TEFC
365TC
26,81
50
1740
J
T.E.f.C.
326TC
23 69
SO
3500
3
T.Ef.C
326TSC
23.69
60
1740
3
T.I.F.C.
364TC
26.81
60
3500
3
T.E.f.C.
364TSC
26 81
75
1740
3
TEfC
265TC
2681
75
3500
3
TE.f C.
365TSC
2611
• Tolerance * 0.12
• AH motors are 60 hertz. Single phase motors are 115-208/230 volts A C. Three phase motors are
206-230/460 volts A C Single phase XP motors are 115/230 volts A C.
• OOP = Open Orip Proof; TEFC - Totally Enclosed Fan Cooled; XP = Explosion Proof.
• FNPT - internal national pipe thread (tapered).
• All dimensions are Inches.
• Discharge may be turned In 90* Increments. Dimension 8 remains the same o!f the center line.
S Q
-------
-J
120
LU
LU
a
<
LU
X
<
H
O
SERIES 5QQQ
MODEL A60-2
SIZE* _3x2_
MOTOR RPM 1725
IMP. EYE AREA _9.97 Sq. In
MAX. SOLIDS .63
* Self-Pnmer 3x3
10.56
CURVE NO. 5-0302-17
s
hp:i
7-1/2 HP
150 200 250
CAPACITY - GALLONS PER MINUTE
450
-------
R.S. CORCORAN CO.
ANSI B73. 1 PUMP SPEC SHEET #00 1
00
OO
GROUP
THRUST
BEARING
"T"
RADIAL
BEARING
"R*
*
-------
BULLETIN PO-26
TRANTER, Inc., Texas Ofritlon, P.O. Boi 2289. Wlehtta F«H», T«i«* TOO?
Phot*: i1)r/7?3-7t?* T»u,- TX»-iin /•.». »->«
2 - 78
-------
f»0-2«C
P»Q* 2
Platecofl
simplifies a
tank hearing
and,
cooling
promsms.
IMMEDIATE DELIVERY FROM .
WAREHOUSE STOCKS GAINS
VALUABLE PRODUCTION TIME
Over 300 stock sizes and styles of
PLATECOIL irieet most lank heat-
ing and cooling needs. You can get
delivery in a matter of fays, putting
new installations into production
faster and cutting down time on
replacement jobs. PLATECOIL is
delivered to you factory-f ested. You
can install them knowing that opera-
tion will not be held up by leaks.
Installation is fast, with hangers and
brackets provided/ ";.
79
-------
INCREASES TANK CAPACITY FOR PRODUCTION
WORK
A 22" X 47" PLATECOIL provides the
same heat transfer at 32 ft. of 1VV pipe
requiring approximately 30" * 60".
RIGID STRUCTURAL DESIGN
*, PLATECOIL*! structural rigidity permits
its use ii walls, baffles, or partitions. It
can be used in many applications where
pipe coil is impractical.
WEIGHS ABOUT 1/2 AS MUCH AS EQUIVALENT
PIPE COIL
Lightweight PLATECOIL units are handled
easily by one or two men — no need for
hoisting machinery.
QUICK REPLACEMENT
No need to empty a tank to change
PLATECOIL; just set new unit* in on
"Quick Change" hangers. Thu allows
double sets of PLATECOIL to be rotated
quickly between shifts for cleaning with
no production downtime.
EASY TO INSTALL
"Quick Change Hangers" make PLATE-
COIL installation in open tanks easy. It
takes just minutes to place the handles of
the PLATECOIL units on the hanger
hooks and bend the top of the hangers
over the edge of the tank.
NO THREADEO JOINTS IN TANK
Welded and pressure tested, PLATECOIL
units have no threaded joints to corrode or
leak. Both connections can be located
above the liquid level of the tank, free
from contamination.
LOW FIRST COST
In most instances, users find it costs less to buy PLATE-
COIL than to fabricate pipe coils. Reduced installation
time saves, too.
EASY TO CLEAN
The streamlined design of PLATECOIL
makes it unusually simple to clean. Exper-
ience also has proved that deposits tend to
form less readily on PLATECOIL than
on pipe coils.
HIGH BUILT IN SAFETY FACTOR
Laboratory tests to destruction have dem-
onstrated a built-in safety factor of more
than S to I. Every PLATECOIL is factory
tested.
EXTRA CORROSION RESISTANCE
All stainless steel PLATECOIL are fully annealed for
maximum corrosion resistance at no extra cost as a
standard feature. (Only Tranter, inc. supplies this feature.)
2-80
-------
P*g*«
How to
r
MULTI-ZONE PLATECOIL
PIPE SIZES — ALL MULTI-ZONE STYLES
. ; Steam inlet 1", Jor 2" MPT -
- Condensate outlet %" or 1* MPT depending
on PLATECOIL size, i
REFER TO PAGE 5
•; for sizes and specifications.
¦ Vr
STYLE 70 AD
PLATECOIL
STYLE90D PLATECOIL <}¦
.^;/^6TYUE70DPU^EC:CWL\:J:^c^k.: ,
V ^ Very useful
For use in long shaUow tank. • / ,
: V ; * For piping through the end of ~
^ for short,
All pipe connections above the solution. -".7
; > the tank and for use In banks.? * ; "
V-.'v V deep tanks.
2-81
-------
MULTI-ZONE PLATECOIL
have been specially designed for use with steam. They have
replaced pipe coils in thousands of plating and metal
processing plants. The patented zoned headers have proven
superior in heat transfer rales and condensate removal. This
results in faster heat-up to get production started sooner.
Refer to chart on Page 6 for details concerning use of Multi-
jone PLATECOIL when used with steam.
Most Style 9QD Multi-ione PLATECOIL in the sizes
indicated below are available in carbon steel or Type 316
fully annealed stainless steel as stock items ready for
immediate shipment. Other Multi-zone styles are also available
from stock in various sues. Contact factory for size and style
needed.
SfRPtKTWI PLATE COIL
are particularly designed for use with liquids and refrigerants
and generally used for cooling purposes. The pass configur-
ation results in the best possible heat transfer rates due to
high internal velocities. The serpentine design also prevents
short circuiting with refrigerants.
Refer lo Page 7 for details on selecting Serpentine PLATE-
COIL when used to remove heat from plating solutions, etc
Most Style 60D and Style 50D Serpentine PLATECOIL in
the sizes indicated below arc available in carbon steel or
Type 316 fully annealed stainless steel as stock items ready
for immediate shipment.
EUECTItOfKHJSH
This is an economical electrochemical surface finish for
stainless stee' PLATECOIL which greatly reduces the
tendency for scaling in phosphatizing and other similar
solutions.
Some Style 9QD Electropolished PLATECOIL are available
as stock items ready for immediate shipment.
HANGERS
Standard PLATECOIL hangers hold the PLATECOIL at
the optimum distance from the tank wall for best chimney
effect which improves heat transfer. Just bend the hanger
over the edge of the lank at the desired height. Two hangers
are used per PLATECOIL except 12* wide 70A and 60A
where only one banger is needed.
"A" Dimension:
12*
STANDARD WIDTHS AIL STYLES
18" 22* 26*
29*
36"
43"
STANDARD LENGTHS ALL STYLES
"8" Dimension:
23"
29" 35" 47"
59"
71*
83"
95" 107" 119*
131*
143*
PLATECOIL arc also available la non-standard dimensions and la materials otber thin carbon steel and Type 314 ililaltii tied. Refer to
PLATECOIL Product Data Manual No. £43 for detaS*.
-------
TO-»G
Pag««
How to
calculate
Piatecoil area.
STEAM HEATING WITH MULTI-ZONE PLATECOIL
FIG. t MULTI-ZONE HEATING CURVES
X
3"
W
X
m
z,
2
<
a
i u j i < Minn » x m «» ttnmiom mm w mm
SATURATED STEAM PRESSURE - pat m
NOTE: The above charts basedMeae hour heaM|>gf(W(UsytoltKioflfro
-------
P(
Pt
HOW TO USE MULTI-ZONE HEATING CURVES (Fig. 1)
EXAMPLE: Determine the total square feet of
FLATECOIL required to heat a watery solution
from 60F to I80F using 100 psig steam. The tank
measures 10' x 5' x 5", and the solution depth is 4'.
SOLUTION: I. Calculate the solution volume: V=I0'
x 3' x 4' = 200 cubic feet. {This is equivalent to 200 x
7.5 gal/cu ft = 1500 gal.)
2. Enter the bottom of the chart at the 100 psig steam
pressure line. Follow the line up to the curve for 180 F
final temperature. From this intersection, move
horizontally to read 31.8 gal heated per sq ft of
PLATECOIL, or 4.24 cu ft heated per $q ft of
PLATECOIL
COOLING WITH SERPENTINE PLATECOIL
FIG. 2. HOLDING TEMPERATURE IN PLATING SOLUTIONS
Watts Removed
PtrSqM
OPM/SqFt
Cooling Watar
Cooling WMar
InM Tamparatura
Solution HokHag
Tampafatura
Btu/hr FUmovad
PwSqfl
1146
.4
SO
100
3000 '
irw
M
80
120
2320
M
SO
140
7900 "
ese
3
eo
"100
2900
1440
S
m
120
2020
.7
m
140
mm
410
2
70
100
1900
1140
A
m
120
9990
1730
*
n
140
NOTE: Tfcj abort <*Mc k IwIm a"tl* tain* sf 1M Bla/kr/aq R t lor a nitr) aafatfoa ud a coots* vaUr la^atMt rtar «f appro idMtrfj MF tfcraatk
du J4 (1 of nofal Mba, atwal iaaaitr rtATXeoa mj It MrtMi. hp 71 «f Mm lunaa r»0 D UCT DATA MAKVAl #i« «H toMplcU
prauvt tnp M.
HOW TO USE THE TABLE (Fig. 2)
EXAMPLE: Maximum current input into a 4'x 6'x
4' liquid level Cyanide Copper plating bath is 30,000
watts. Determine the size of PLATECOIL required
to hold 120 F operating temperature using 60 F
cooling water.
SOLUTION: I. Entering the table at 60 F cooling
water and 120 F solution temperature, a PLATECOIL
capacity of 4900 Btu/hr/sq ft or 1440 Watts/sq ft is
noted.
FIG. 3. HEAT TRANSFER AREA IN SQUARE FEET for ALL Double Embossed PLATECOIL Styles.
(
3. Divide the result of step (I) by the result of step (2)
to obtain the required PLATECOIL area:
200 1500 - ,
or 47.2 sq ft
4.24 31.1
4. Select the appropriate PLATECOILsizefrom the
area table Fig. 3. Either a 26* x 119" or 29" x 107"
PLATECOIL will do the Job.
2. Divide input by PLATECOIL capacity to obtain
the required PLATECOIL area.
30,000 _ 20.8 sq ft
1,400 " PLATECOIL Area
3. Select the appropriate PLATECOIL size from the
area table Fig. 3. A 22" x 59" PLATECOIL will do
the job, utilizing 20.8 x.5= 10.4 OPM cooling water.
Nominal
Width
Inchaa(A
dSmanalon)
LENGTH in INCHES {B ¦
.*sit.:
¦"»*
41M
454 .
60JB
28
M
H.T
14.1
tu
23 J -
2M
m >;
-***
4M
mjs -
.2
srs>
29
1QJS
13.2
18.0
21.8
WjO
32J
38.0.•
• 48.0
MJ
ma
asr
38
iza
MJ
18.7
284
. 40.1
«7J .
.774.1 i
>.80J»>
43
15.4
IftS
23.8
ate
«a.r
<7 M
88 J *
n.i
V«M
2-84
-------
¦ -.j**¦
¦: Prwm *
1
1
Ji Ptmmi*
; NomI
~ HomOMcr4p6oil '^¦ ¦*'
V^--.-v*PproK.m>IA«, •;
-i.* «** witbHoM*
' WW***,'
- - - »¦ --
... VVQwt# ".'-fl
IM
«PfN
SINGLE RfHQ . •'
• CLAMP-ON
HINGED
ESS *
."" essfi ' '-Si
iso psta
¦i> ••;»!%* sariKMM '
OM h Jumper hOM .
W
50
SINGLE RING"
CLAMP-ON . v
SP«ING OKN 'A.
WITHOUT HINGES
ESSNH
ESSNHHV
. «r
':*¦ m psig
^ ^ -
" 2-Vje2T hoM* ' .
M
SO
^#>rwN<» -m*;
CLAMP-ON
HINGED
•' ¦ :
p^isopsie
¦ ktmm mmmcM
; htpdni w«h Km la prauM*
w«1 wM
' n
130 -
SADDLE "*•
TYPE
HSW
SS5WH "
150PSIG
"¦*.** a-«*x4rhoMw '
M
12$
IMMERSION
x-r. type • ;• •-
1-#1
t-riH
2SOPSIO
2~%** ¦ 42* li«Mt wHti Mrifd .
- __ adaptor ,
«S
. ts
TRANTER, inc., Texas Division, P.O. Box 2289, Wichita Falls, Texas 7630?
Phone: 817/723-7125 TELEX; 734410 FAX: 817/723-5131
Manufactured in Great Britain by Senior PlATECOiL Ltd., P.O. Bo* 30, CaWervale Road, Wakefield West Yorkshire, WFI5PF England
ORDER LOCALLY FROM:
PLATECOIL
~by
tranter
2-85
-------
A WIDE RANGE OF SPECIFICATIONS
PIATECOIL STYLES
800 Mufti-Zoo«*
70AD Multi-Zone*
900 Multi-Zone*
700 Multi-Zone*
60 AD Serpentine
2-86
PLATECOIL AREAS & WEIGHTS
DOUBLE EMBOSSED SURFACE AREAS
TABLE 1 ALL STYLES IT1 SQUARE fECT
Nom. Width
Inchfli
A. DM.
Hou»MtjENcrmMMCHes &mm.
a « k « n n n k t» in m -
11
4j 14 u u 11.1 tu is.s <7j 20.1 22a 24.4 2
11
•4 as 104 1U 17.4 214 24J 28.1 314 352 38.7 <
n
84 10,1 121 144 204 244 28.0 3X2 37A 41J 454 5
»
M 11.7 14.1 1U 234 2M 33J MJ A3J2 4&.D UJ 5
a
105 134 1«4 21J 274 325 38,0 435 494 545 804 6
as
11# I4J 11.7 2&5 3U 40.1 <6.9 S3.7 605 67J 7«1 ft
43
114 US 235 114 39.7 474 SSJ «44 7X1 MJ BL3 S
AREAS OF FLAT SIDE ONLY FOR
SINGLE EMBOSSED
TABLE2 allsmesmsquareitct
Mom. WMfi
Irtchaa
A.M1
M0MW*L LENGTH WWCHE* &0ML
23 29 35 47 59 71 83 »S 107 11» til 1.
11
14 *4 UU1IUUI4UUHIti
1t
34 14 U 11 7.7 »J 104 12.4 144 155 17.1 1t
xt
14 44 54 74 .4.1 114 124 14? 184 184 2L2 22
w
4.1 U U 84 104 12.7 144 1S4 18.1 J« 234 2J
a
43 14 7.1 U 114 144 184 1*4 214 24.1 2&5 »
as
5.7 72 a? 11.7 14.7 17.7 20.7 217 26.7 29.7 J2.7 35
43
«4 M 104 144 174 21.1 24.7 284 314 354 314 4a
QUICK DQJVERY OF 2-3 WEEKS for ainglaafliboaseclPUCTECOB.
CM b* auppOad in limited quantKiea lor
In 14 ga. carbon at««L Flat aid* oI PLATECOtL can t>a c*i»tom
des&MdfortNcknefaM up to 10 ga. Coawnortf* aingta emtxwsad
PLATECOIL la UMd at damp-on to th# aMa wal of tank* or far
appScaBona requiring one flat tkta.
PLATECOIL INTERNAL OPERATING PRESSURE
(MOM ASMCCOOC)
Gauge
CARSON STEE-
304,3041, 31S, 3161, VOXEL
Ooubfe Embcmd
PS
PSI
it
180
250
14
aoo
330
12
400
400
Sfciol* Emfcoasad
Embootnfl
Companion
pa
PSI
H
1<
190
ISO
If
14
14$
190
1*
It
180
205
14
11
20S
240
. 14
-cJ-.14 '• • j
»40
14
12
21S
270
I
•;.rtf*o#ar>
•* <*2M :
to '•» '
12
12te*ar
205
300
-------
QUICK SELECTION CHARTS
«Tfl. i QUAwrrrrorsoumonniMxopersorrvs steamprcssuu: tu*«ion<*»«t>o««i>e*iu»i8mrftora«or(U=t50tHtt't.r*jitri
m .
Hg. t
EXAMPLE lUJUSTRATirtG THE USE OT THE CHART
Octcrmirx the total sq 11 of PLATCCOtl needed to heat a
walery solution from 60T to 10OT In one hour with steam
at 100 psig. The tank measures 10**5 *5' and U* solution
depth Is 4 . Also determine pounds of steam condensed.
1 Calculate solution volume V= I0"i3'i4' = 200 cu ft
(This is equivalent to 200*7.5 gal/cu H=t50Q gallons.!
2, Enter the bottom of fig I at the tine for 100 psig steam
pressure, follow it vertically to the curve for ISQf operating
temperature, from this Intersection, move horijonlally to
the (eft and read- 30 aal heated per sq ft of PIATCCOIL or
move right and read I cu ft heated per sq ft of PlATf.COil
3. Divide result of Step I by result of Step 2 to obtain
PIATCCOIL AREA = 200 or 1500 = 47.2 sq ft
4.24 314
t Select the appropriate silt St)te 90 PLATECOIL from
Table I on page 7. A 26 * i 19." will provide 48 sq ft
and will be the most economical choice
mwtuam steam pressure-***
rtQ.2
MOW TO USE THE HOLDING TEMPERATURE
CHART
CXAMP1X- Maximum current input Into a 4 *6 *4" liquid
level cyanide copper plating bath is 50.000 watts
Determine the site of PLATCCOIL required to how 120f
operating temperature using 60f cooling water.
SOtUTIOfl: 1. Cntertng the chart at 60f cooling water and
120f solution temperature, a PIATCCOIL capacity of 4900
Btu/hr/sq It or 1440 watts/sc) ft is noted.
2. DMde input by PtATECOtl capacity to obtain the
required PLATCCCML area.
50.000 s 203sq#
1440 PIATCCOIL area
3. Select the appropriate PLATCCOIL size from the surface
area chart in Table 1 on page 7. A 22"*S9" FLATECOIL
wfll do the job. utilizing 20&5= 10.4 QFM cooling water.
MOLDING TEMPERATURE IM PLATING SOLUTIOftS
fig. 2 Cooling With Serpentine PIATCCOIL
Vtettsfivncv4
PmS*n
GfWSqR
Cooing Wvtar
- ¦
Coo/wVWmm
MtW
SoWfonKoMns
Wiparatura
etu/hr Hamooed
f%r Sqift
1140
,4
SO
toe
3900
1?30
1
SO
1*0
S90Q
2320
J
to
140
r#oe
•SO
2
m
100
2900
1440
S
m
120
4900
9020
.7
*0
140
woo
410
2
re
100
1400
1140
.4
70
120
3900
1 m
4
n
140
5900
HOT|; Tha aboM toM % baaed «« • 0 wlua of «0 Stu/fcr «q ft f tat an agRaM wtmy wMio"
andaeiMBngwatirtamiMratvraflaaolapptMiiMMirSOFOwsughaiafUITECOft.. Gcnaratr
e*tf wtef pmaura ** tuppty nJequite codkg aortar tar a Sfyta 10 or SO KJffECCM. u(> to about
30 K a ^ tank* raquiring rnan than 30 «] ft of cooling (Wtae*. *«y*>«t tmallar RATI COC
may b«efvA
f0>40-7Q
1M$
50-m
1V2S
«49
Iftdhpn sulphur
«0^0-70
3MS
IMS
4-1$
90>»
T SUM
IWUft ptftAft
f&^O-TO
3$4|
4S-SS
2$4S
40-10
i.SbMM
tey|ini
9049-79
34 •
V« "
1-4 ¦
44
t If am
Watww* er eem tfiw
2*40
70-99
1M9
4049
1ft. Mgfi tain*. faaf water
WaWy kokJtion*
4&.S040
•0-104
100-22$
1W-1O0*
f 10-140*
Ttf Qf
M-9&49
12-30
IS4S
1949
20-10
12.
laroriM^Mft
40-9040
IV»
S&40
1J-I0
20-10
GOOUWS *miCATVXS
CQL&SKX.
Hcrrsoc
13.WM«r
HMnVMWtoR
7»>l«0
90-140
1049
•0-140
U. Water
Owmehei
40-S&44
10-11
H49
r-w
19-2S
iS.Wvtar
%tyvy*Q
4-12
304Q
$-4
10-20
and with caicuMadanMdoubMMturity (actor • Sm cutvm «« pa^a <6 o< PLATECOtL Data Uanual tor mora 4 • - - -
" Por low velocity air or ?af.
2-87
-------
OPL SERIES PRESSURE SWICHGAGE®
AND MURPHYGAGE®
Bulletin OPL-65
Revised 2-!-
Catalog Section
4.5 in/114 mm Dial Diameter; Bourdon
TUbe Actuated Movement; Ranges From
30" Vacuum to 20,000 psi; OPL <£|
Approved; OPL-BP 0 Listed
DESCRIPTION
The OPL series SWICHGAGE* is a mechanical, analog
gauge with adjustable high and low pressure limit con-
tacts. The visible limit contacts are self-wiping tor posi-
tive switching and are rated pilot duty (or limit switch
activation of alarms and/or equipment shut-down.
Gauge pointer closure with either contact makes a
circuit.
A bourdon tube sensing element actuates the stain-
less steel, geared movement to translate pressures into
accurate dial readings: inches of mercury, kilo-Pascals
or psig. The MURPHYGAGE is a gauge-only version of
this series.
APPLICATIONS
The OPL series are used to protect, to start and stop,
to automate systems and equipment, such as pumps,
• steam generators, air and gas compressors. Through
use with Murphy relays, magnetic switches, or trans-
former relays, the OPL can become a controller for most
engine or electric motor applications involving pressure
control.
TYPICAL OPL INSTALLATION
OPL SWICHGAGE:®
3 Instruments in 1
• Accurate/Rugged
Mechanical Gauge
• Low Pressure Limit
Switch
• High Pressure Limit
Switch
Use It To Alarm,
Control, or Shut-Down
OPL SWICHGAGE®
Marxi* in-line tfsconnec*
swnch for low side contact
NPTF
Flagged case
standard
to
iocatm tins*
Kisiue i«n
tfcCidivUa
Dual Scale
USWeWe
Knorted
knobs
% MPT base connect
(thru 1000 psit>.89 MPa)
Hinged cas* tof Inspection*
end wiring coootctiort*
A FULL 2 YEAR WARRANTY is carried by all Murphy SWK
GAGES* against detective parts and/or workmanship.
BASIC MODELS: OPL Series Pressure SWtCHGAGES*
Models Description Models
OPL Standard OPL SWICHGAGE* Standard Case OPL-BP
OPL-C Standard OPL w/ungrounded contacts
OPL-F SWICHGAGE*, Round/Flush Case OPL-G
OPL-FC SWICHGAGE* w/ungrounded contacts, OPL-FG
Round/Flush Case
Description
(^Listed Controller, Standard Case OPL
w/Control Relay
Gauge Only, Standard Case
Gauge Only. Round/Flush Case
2 - 88
-------
STANDARD DIMENSIONS
OPL: Standard Cam OPL-F: Panel/Flush Mount Ca««
® 31 OlA()) MOi.£S v '¦» "• ) t)ii| f i¦ Jil
\ I I I H 2^32
***« M
'\h~ —| f- -
' 1 ^
• lit I
4*11
• 7 li
t'2 CONDUIT
*€0 *
J
L
•LACK «« "
1
A
r
B
_L
SCHEOULE
RANGE
A
e
Thru 1000 PSI
1/4 NPT
1-1/16
2000-20,000 PSI
1/2 NPT
1-7/8
1U
OIM
STANDARD ELECTRICAL DIAGRAMS
OPL PRESSURE SERIES.
THESE DIAGRAMS ARE SHOWN WITH PRESSURE POINTER IN NORMAL OPERATING RANGE.
OPL
OPL-C
OPL-F
OPL-FC
OPL-F OS
Red Green Black Red White Stack Red Black Red White Black
OPL-BP
YEUOW
BROWN
iP*
SET
t—120 VAC
\ oil Qa
\ <»1« Ba
2 BLACK
LOW
RESET
a.
/ ( \q s SET
i.-A. !
REMOTE START
WIRING CONNECTION
OPL & OPL-C: terminal block: 1/2" conduit connect
OPL-F & OLP-FC: wire leads
OPL-f OS: open terminals
OPL-FC OS: 1/2 NPTM conduit & wires (epoxy filled)
OPL-BP: terminal block/ 1/2" conduit
STANDARD SPECIFICATIONS
(See also OPTIONS LIST)
Dial: 4,5" (114 mm), white on black, psi A kPa
Case: die cast aluminum: standard OPL is flanged. OPL-F has
a flush case for panel mounting
Gauge Connection: V* NPT thru 1000 psi (6-89 MPa). 1/2-NPT
for models 2000-20.000 psi (13.8-138 MPa)
Sensing Element: bourdon tube: bronze to 1000 psi (6.89
MPa); Stainless Steel 2000 psi (13.8 MPa) and up
Gauge Movement: Stainless Steel w/pointer calibration hub
Gauge Accuracy: * 1% in the Operating Range {mid 1/3 ol
scale)
SWICHGAGE* Contacts: SPOT: pointer and limit contacts:
N.C. when a pressure limit is met; N.O. when gauge is operat-
ing between limits. Contact Area: pointer is nickel silver with
line silver contact area: stationary contacts are heavy silver;
current carrying areas are gold flashed.
Contact Rating: 2 A @30 VAC, resistive (pilot duty)
Limit Contact Adjustment: full range by knurled knobs
Disconnect Switch: standard case has an in-line switch for
low side disconnect.
Shipping Weight: std. 6 Its. (2.7 kg); F models 4 lbs (1.8 kg)
2-89
-------
TYPICAL PANEL MOUNT INSTALLATION
OPL-F-OS-60 V
OIL SEALED SPECIFY: OS
For corrosive environments, the OPL-F can be filled with an
inert, non-toxic oil. then sealed. The oil dampens
vibration/pulsation, reduces corrosion, suppresses contact
arcing, and lubricates parts.
OPL-SA-1000
SEMI-AUTOMATIC LOCKOUT SPECIFY: SA
A manually actuated lockout replaces the low limit line switch.
The push button on the limit knob automatically resets, to arm
the low limit circuit, as the pointer lifts off the limit contact.
OPL-E-2OO0
Mounted
in A
MURPHYMATIC®
Pressure
Controller
See Bulletin PC-7119
OPL-BP
The OPL-BP is designed to start and stop electric motor driven
pumps, and air compressors. The pilot duty limit switches are
connected to an internal control relay (10 A @ 120 VAC) for
ON/OFF automation, either directly or through a motor starter.
As can be seen in the OPL-BP wiring diagram (see page oppo-
site), when the SWICHGAGE* pointer touches the low contact,
the magnetic latching relay RESETS (shipped in reset posi-
tion}. If pressure increases to the high contact, the relay SETS.
Once latched into either side, the relay will remain in that
position until the opposite limit is met, even if a power outage
occurs.
Exampkk Pumps are to be started at the low pressure limit and
remain in operation until the high limit contact is made: wire
the RESET side of the relay {low contact) to close a circuit and
start the pumps; when the pressure rises to the high contact,
the relay will SET and open the circuit to stop the pumps.
OPL OPTIONS
£
OPL-BP: PRESSURE CONTROLLER
AIR COMPRESSORS — PUMPS
2-90
-------
OPL Series Pressure SWICHGAGE® & MURPHYGAGE®
1. Select SWICHGAGE* or
MURPHYGAGE*
2. Specif/ case type: standard or
panel mount
3. Specify options
4. Specify Dial Range (your
operating pressure should fall
into the center 1/3 of the dial
range)
EXAMPLE:
OPL— F —OS —0-2000 psi
1* 2 3 4
HOW TO ORDER
Vacuum/pti
30" vac-0 psi
30* vac-15 psi
30" vac-30 psi
30" vac-100 psi
30r vac 200 psi
30r vac-300 psi
0-15 psi
0-30 psi
0-60 psi
0-100 psi
0-160 psi
DUAL PRESSURE SCALES
fcPa/MPA
—101 kPa-0 kPa
—101 kPa-103 kPa
—101 kPa-207 kPa
—101 kPa-689 kPa
—101 kPa-1 38 MPa
—101 kPa-2 07 MPa
0-103 kPa
0-207 kPa
0-414 kPa
0-689 kPa
0-1.1 MPa
P«»
0-200 pst
0-300 psi
0-400 psi
0-600 psi
0-1000 psi
0-1500 psi
0-2000 psi
0-3000 psi
0-5000 psi*
0-10.000 psi
0-20.000 psi'
MPa
0-1 3# MPa
0-2 07 MPa
0 2 76 MPa
0-4 14 MPa
0-6.89 MPa
0-103 MPa
0-13 8 MPa
0-20 7 MPa
0-34 5 MPa
0-66.9 MPa
0-138 MPa
•OPL-BP above 5000 psi. and stc! OPt s 30 000 thru 60.000 psi special o'de'
OPTIONS LJST
Bourdon TUbe: For ammonia service or other corrosive gases
in gauges under 1000 psi (6.89 MPa), specify "SS tube'
Ungrounded Insulated Contacts: 1A @ 125 VAC, order models
with "C" designation.
Semi-Automatic Disconnect: Button with dust boot on low
adjustment knob, manual disconnect will reset after sufficient
pressure increase, specify "SA"
Pressure Line to Gauge Connection: Back Connect available
for applications where std. Base Connect hinders: specify
Back Connect."
Bourdon TUbe Stop: Allows 100% overpressure without dam-
age to the tube or movement, specify " Bourdon Tube Slop
Tamperproof Adjustment: Allen wrench adjust specif,
"Tamperproof'
Oil Sealed: Flush case only in corrosive atmospheres adc
OS" to F models
Controller: For latching relay start/stop order OPL-BP. sei
wiring diagram, available in ranges 30 in. hg (—101 kPa) thrL
5000 psi (34 5 MPa)
CUSTOMER REPLACEABLE PARTS
05-00-0041 TUBE. MOVEMENT. DIAL 4 POINTER
ASSEMBLY (SPECIFY RANGE)
05-00-0060 GLASS. RING 4 GASKET ASSEMBLY
See also bulletin 45-584
MURPHY PULSATION DAMPENERS
• Eliminate pointer contact flutter on pressure indicat-
ing SWlCHGAGES*, which are subject to pulsating
pressure from reciprocating pumps or compressors.
• Allow close high-low contact settings for more accu-
rate pressure indication and equipment control.
• Decrease wear on SWICHGAGE* geared movement
increasing the life of your instrument — by eliminating
excessive strain and unnecessary pointer movement
• See bulletin PD-6811
PD-8183
HOmomC£,nASA-T4t4T,USJL
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2 91
-------
Pressure
SWICHGAGES'
The OPL is an accurate indicating guage. a high pressure
switch and a low pressure switch, it is designed to initiate
high-low pressure safety shutdown or start/stop signals.
The Murphy OPL has beer* applied to protecting and automat-
ing tasks on pumps, steam generators, air and gas com-
pressors, etc. for over twenty years. Satisfactory service and
trouble free operation throughout the world give the instru-
ment proven reliability.
When a change in pressure occurs, this causes the instru-
ment's pointer-contact to touch contacts at either end of your
predetermined operating range. A circuit is completed and a
signal can be sent to sound an alarm, flash a light, cause a
switch or valve to open or close, signal the engine controller
or relay to operate,
ADJUSTABLE CONTACTS
The OPL features fingertip adjustable contacts which allow
you to 'dial' your 'operate or shutdown* pressure (thru 100%
scale of the dial). These contacts are also gold flashed to resist
corrosion from H2S and other damaging gases.
OPL accuracy is better than 1 % in the normal operating range
and readings are indicated on a large, 41/2" dial. The instru-
ments precision movement is actuated by a heavy duty bour-
don tube.
INSTRUMENT ENCLOSURE
A Die-Cast Aluminum Enclosure sealed with long-life
Neoprene gaskets protects the OFT. from weather, dust, and
other environmental hazards. The hinged cover provides easy
access to the terminal block assembly for installation wiring
and maintenance.
Also, a 112" conduit connection is provided with each instru-
ment along with a 1 12" conduit knock-out on the backside of
the enclosure for installation versatility. (For Explosion Proof
enclosures see Murphy Bulletin EX-7038).
ADAPTABILITY
The OPL connects to Murphy Nerve Centers for automation of
engines, motors, and valves and is also compatible with other
installations. See the following Murphy bulletins for indicated
applications:
OPERATE MAGNETIC SWITCHES .., M-Series (Magnetic
Switches)
START & STOP ENGINES... A-Series (Murphymatic Engine
Controllers)
START & STOP MOTORS.,. TR-Series (Transformer Relay
Assemblies) or PC Series (OPL & TR-Series as a unitized
package).
OPEN AND CLOSE VALVES ...MVA SV-Series (Magnetic
& Solenoid Valves)
OPL WARRANTY
Like all Murphy SWICHGAGES®, the OPL carries a full one year
limited liability warranty against defective materials and
workmanship. Should trouble occur, contact the Murphy Ser-
vice department.
Bulletin OPL-6573
Revised 3-15-78
Catalog Section 5
Class C
OPL-SERIES
Z instruments in one
mmm
fumiltumf Mf B MC
•ox mumiUWi*
CUtifi&HlEt -
c5-~"
v:
Hj
WIPING CONTACT
A. Contact Arm-Flex
B. Contact Arm „ ' "j
C. Pointer Contact /
D. Initial Point of Contact y
As the force of the pointer causes the Flexible Contact arm to
"tilt," a wiping or scraping action takes place. This assures
reliable contact as It clears away any film or corrosion which
may have formed on the contact surfaces.
2-92
-------
SPECIFICATIONS
CASE: Oie -cast alluminum, weather and dust tight, with
ncoprene gaskets, hinged cover, '/«*' conduit connection RH
Side, and knock-out back side
CONTACTS; Indicating pointer-contact is nickel silver with
fine silver contact area. Molded Lexan window assembly car-
ries both high and low heavy silver contacts. All current carry-
ing parts of contact assembly are gold plated.
CONTACT RATING: Standard OPL has S.P.D.T. with common
ground. Adjustable differential. 2 amperes @ 30 volts AC
resistive.
MOVEMENT: Geared movement with special link and spring
lo compensate for arrested movement of pointer contact in
operation. Movements are bronze and stainless steel com-
bination. Pointer-contact has recalibrating hub.
BOURDON TUBE: Bronze thru 1.000 PSI, stainless steel
2,000 PSI and up.
DIAL: 4V»" laminated Synthane. White figures silk screened
on black background, reverse optional on special order
PRESSURE CONNECTION: Lower male pipe thread V."
thru 1.000 PSI. '/« • 2,000 PSI thru 20,000 PSI, Special order
above 20.000 PSI.
ACCURACY: Exceeds ASA standard for Grade A gauges
Accuracy is better than 1% in operating range
SHIPPING WEIGHT: 6 pounds. DIMENSIONS: 8V." *
8V." x 2s/.".
IMPORTANT
A. Always select an instrument with twice the pressure range
of your normally expected pressures. This will prevent bour-
don tube fatigue, over pressures, distortion, give you the most
accurate readings, and multiply the life of your instrument.
6. We recommend that the instrument be mounted off of
vibrating machinery. Use shock mounts anywhere excessive
vibration is present.
C. Pump pulsations, which will destroy geared movements on
any pressure gauge, should be dampened out. Murphy pulsa-
tion dampeners give mircometer adjustment of pulsation dam-
pening and act as a shutoff valve when required.
MODEL PRESSURE RANGE
OPL-30V 30" vac-0 PSI
OPL-30V15 30" vac-15PSi
OPL-30V-3Q 30" vac-30 PSI
OPL-30V-100 30" vac-100 P SI
OPL-3QV-200 30*vae-200PSi
OPL-30V-300 30" vac-300 PSI
OPL-15 0-15 PSI
OPL-30 0-30 PSI
OPL-60 0-60 PSI
OPL-100 0-100 PSI
OPL-160 0-160 PSI
OP1-200 0-200 PSt
OP1.-300 0-300 PSI
OPL-400 0-400 PSI
OPL-600 0-600 PSI
OPL-1000 0-1.000 PSI
OPL-2000 0-2.000 PSI
OPL-3000 0-3,000 PSI
OPL-S000 0-5.000 PSI
OPL-10000 0-10,000 PSI
OP t--20000 0-20,000 PSI
OPL-30.000 thru 60,000 PSi are made on special order only. Ask for
prices, specifications and delivery.
OPTIONAL EXTRAS
Stainless Steel or Ammonia Service Tube for ranges under
2,000 PSI Specify "Stainless Steel Tube" (stainless steel
tubes are standard on 2.000 PSI and up). Stainless steel
movement & link available on all pressure ranges. Specify
"Stainless Steel Movement"
Oil Seated Case for highly corrosive environment, Specifity
Oil Sealed ("F" Case only)
Ungrounded Insulated Contact* rated 1 amp @ 125 volt AC
resistive. Specify "C
Bourdon Tube Stop allows 100% overpressure without
damage to tube or movement Specify "Bourdon Tube Stop "
Dial with black figures prinled on white background available
on special order Specify 'Dial-White Background."
Tamperproof Contact Settings are available on special
order. Adjustable with Alien head wrench. Specify "Tam-
perprool . (Noi available m C Model)
Pulsation Dampener. See bulletin for prices on sizes and
materials.
faun-Mr
mi ram twneitt
I rr*nr i|c
©b mm
€
ttiur
"DEVELOPING SOLUTIONS TO YOUR MONITORING 4 CONTROL PROBLEMS"
Write us today for a no-obligation recommendation
P.O. BOX 45248 • TULSA. OKLAHOMA • 74145 • 918 (627-3550)
MFfi. INC.I
tno.4»«
*Q imtrn MiliK «***>
"iKfi Miikiiiiii -*1
2-93
-------
The SteamGarcf System.
SOME COMMON QUESTIONS
Question:
How does it work?
Answer:
STEAMGARD operates on the
physics law known as two-phase
flow. This means that steam and
condensate are both fighting to
pass through the same small
orifice. The reason STEAMGARD
works effectively is because
much more condensate can pass
through this orifice than steam.
This means that an orifice
discharges fluid by volume. At 10
PSIG, one (1) pound of steam
takes up close to 17 cubic feet.
One cubic foot of condensate
weighs over 59 pounds. This
volume ratio means that our
model SG-B-10 would discharge
as follows:
Psi Vs/Vw Condensate/Hour
10 980 236#
50 380 521#
100 220 728#
Question:
Where can STEAMGARD be
used?
Answer:
STEAMGARD can be used on a
variety of applications in many
different types of facilities:
• Saturated steam distribution
lines.
• Superheated steam distribution
lines. (Up to 2000 PSIG and
950° F)
• Steam tracing,
• Tank heating.
• Radiators/convectors.
• Plating
coils/degreasers/embossed
coils.
~ ft* NX
SUMMER
BASKET INSERT-
" ' ~ "
,> CONOENSWESS*,
:. - .V return -V":v
- PLUG OR 8L0W0FF VALVE
FOR CLEANING s •; ¦>
7/16 SteamganT" System is a combination of a stainless steal
condensate drain orifice, a special protective strainer assembly, and
some very Important applications engineering know-how rarely used
when applying conventional steam traps.
The stainless steel drain, which comes In 25 nozzle configurations,
Inch, % Inch and 1.0 Inch pipe sixes (NPT, BSPT, or Welded} can
handle steam pressures to 2000 PSI and condensate toads to more
than 95,000 pounds per hour.
%
• Steam heated dry
cans/cylinders.
• Humidifiers.
• Flash tanks.
• Sterilization equipment.
• Cooking kettles.
STEAMGARD can also be used
on applications that utilize a
modulating steam control valve:
• Air heating coils.
• Shell/tube heat exchangers.
• Domestic water heating tanks.
• Instantaneous water heaters.
• Batch process tanks.
• Steam absorption coolers.
• Process heating equipment.
Question:
Won't STEAMGARD only work
on constant load applications?
F§4
Answer;
If the conditions in a
condensate system are not
constant, STEAMGAHO can still
effectively discharge condensate
while inhibiting excessive steam
loss.
Let's look at a common
example: STEAMGARD Model
SG-B-10 can discharge 288 lbs.
of condensate/hour at 15 PSI. If
this same SG-B-10 sees only 144
lbs. of condensate/hour (50% of
capacity) the steam loss is only
02 lbs/hour.
If this same SG-B-10 sees only
43 lbs. of condensate/hour (15%
of capacity) the steam loss is still
only 1.9 IbsJhour, This Is still
lower than the approximate 2
-------
The Figure shows the steam loss curve under partial loadt. Using thit
curve and the capacity tables steam losses under any load conditions
can be determined.
FALLACY, LAMINAR PLOW ONLY
ACTUAL
Ibs./hour of live steam that an
efficient steam trap will lose
The above example illustrates
how STEAMGARQ can efficiently
work on many applications that
have varying condensate
conditions without any means of
steam control.
Question:
How can STEAMGARO
operate on applications such as
heat exchangers and heating
coils when condensate loads
fluctuate?
Answer.
Steam equipment which
consumes large amounts of
steam always requires some
method of controlling the steam
flow. One of the most common
and energy efficient methods is
the use of a pressure modulating
steam control valve.
Our applications experience
has proven that STEAMGARO
will remove condensate quickly
and completely with a very small
amount of live steam loss on
applications utilizing a
modulating steam control valve.
Over a wide range of
condensate/pressure variations,
the orifice of the properly sized
STEAMGARO will be occupied
by condensate so that steam
losses are usually too small to
measure. Example: Steam
absorption chillers, large
convenors, air pre-heat coils.
It is important to realize that a
conventional steam trap, with its
own compensating mechanism,
tends to complicate and defeat
the modulating steam control
which results in inefficiency and
substantial steam losses.
Question:
Won't STEAMGARO plug up if
my system is dirty?
Answer:
Any type of steam trap can
plug or hang up. STEAMGARO
minimizes the plugging problem
two ways:
E ©
m
a: 7
o
3
M
o 3
a
~
j
«
u
** i
m I
® ° O 10 20 30 40
* CONDENSATE C
1. The unit is to be installed in
conjunction with a special 40
mesh stainless steel strainer
insert. This insert is designed
to trap any particles or
contaminants before they
reach the drain nozzle. This
strainer should be blown down
or cleaned as often as you
would clean the strainers in
front of your existing steam
traps.
2 The drain nozzle in all
STEAMGARO units is
manufactured with a staged
discharge. This design, which
is totally different from the
"simple" orifices found in
many steam traps and orifice
plates, facilitates the continual
discharge of contaminants
generally found in condensate.
This continual discharge
allows CO?, air and non-
condensables to be passed
continually (unlike "sub-
cooling" or "intermittent
discharging" traps.}
I 60 70 80 90 JOO
ITY CX US OR * MM I
Question:
How can STEAMGARO be
used on a distribution line when
ambient conditions change?
Answer:
STEAMGARO units are in
service on outside distribution
lines all over the world. Here's an
example of how STEAMGARO
would be applied on a
distribution line that sees
dramatic changes in ambient
conditions.
A common outdoor distribution
line may have the following
characteristics:
• 8"IPS
« 1" Fiberglass insulation
• 300 Linear feet between drain
points
• Distributing 150 PSlG steam
• 20° F Minimum ambient in
winter
• 70° F Ambient in summer
When ambient is -20° F. this 8"
line will generate 41 lbs. of
condensate/hour. The
STEAMGARD model
STEAM LOSSES UNDER PARTIAL LOADS.
1. - Q5
-------
recommended must be able to
dischange a minimum of 41 lbs.
of condensate/hour at 150 PSIG.
The model selected. SG-B-03,
has a condensate capacity of 106
Ibs./hour at 150 PSIG. The steam
loss during -20° F conditions is
only 0.28 lbs /hour.
This same 8" line at 90' F
ambient will now generate 20 lbs.
of condensate/hour. Our SG-B-03
still has a condensate capacity of
106 Ibs./hour. How does this
reduction in condensate affect
steam loss?
The reduction in condensate
load causes the steam loss to
increase 0 62 Ibs./hour. This
"loss" is significantly less than
steam loss figures stated by most
steam trap manufacturers for
their brand new traps.
Question:
Will STEAMGARD work on a
vacuum return system?
Answer:
STEAMGARD is becoming a
very popular replacement for
steam traps on vacuum return
systems for two reasons:
1. STEAMGARD cannot fail
* open" like conventional steam
traps usually do. This failure
many times results in the
introduction of an excessive
amount of live steam into the
vacuum return. This live steam
will result in vacuum loss and
sometimes in pump failure.
By eliminating the excessive
live steam losses inherent in
conventional steam traps,
STEAMGARD helps to
maintain consistent
condensate return
temperatures and a level
vacuum.
2. STEAMGARD'S continuous
and complete condensate
discharge will dramatically
reduce heat up times in
systems utilizing a vacuum
return system.
Question:
Can STEAMGARD be applied
in a return system that is
experiencing back pressure
problems?
Answer:
Let's look at our 150 PSiG
distribution line example for an
answer.
Our model SG-B-03 must be
able to discharge a maximum of
41 lbs. condensate/hour under
minimum ambient conditions. At
150 PSIG differential, this is no
problem because the SG-8-03
has a capacity of 106 lbs.
condensate/hour. If system back
pressure increases as high as
80% <120 PSIG) the model SG-8-
03 can still discharge 48 lbs.
condensate/hour at the reduced
pressure differential.
Question:
How does STEAMGARD vent
air, CO, and other non-
condensables?
Answer:
The continuous venting of air,
CO, and other contaminants is an
important requirement of any
steam trap. The key to
performing this vital function is
continuous and complete
condensate removal. Unlike many
steam traps that operate
"intermittently", STEAMGARD'S
continuous discharge allows
continuous air venting (even at
low pressures).
STEAMGARD'S complete
discharge also results in no "sub-
cooling" of condensate. This
"sub-cooling", which is a
characteristic of many steam
traps that introduce an upstream
water seal, can cause dangerous
CO? build-up. This CO, formation
causes serious corrosion
problems.
Question:
Won't a trap replacement
program require a large number
of different STEAMGARD
models?
Answer:
Even though STEAMGARD
must be sized for each specific
application, our applications
experience has proven that many
large facilities require a
Surprisingly limited number of
STEAMGARO models
A major midwestern refinery
standardized on two different
STEAMGARD models to
complete a 300 trap conversion
of its existing steam traps.
Question:
Won t it be difficult to select
the correct STEAMGARD model
sizes''
Answer:
Selecting the appropriate
STEAMGARD models does
require a certain basic knowledge
of the lines and equipment to be
trapped
Early in STEAMGARD'S
development. ERI realized that
the majority of plant and facilities
engineers do not have time to
spend on sizing steam traps Our
engineers also realized that in
order for STEAMGARD to
operate more efficiently, the trap s
proper sizing was imperative.
This need for proper sizing
resulted in extensive research
into the multitude of factors that
effect the operation of
STEAMGARD and steam traps.
1. The STEAMGARD" System
Applications & Selection Guide
This guide can assist the
engineer in selecting
STEAMGARD for applications
where sizing information or
condensate flow rates are
available. The guide makes it
simple to select a
STEAMGARO model because
safety factors are already
included.
2. The STEAMGARD'" System
Field Sizing Survey
ERI and its field engineers can
also assist customers in
selecting STEAMGARD models
through a field trap survey
performed at the facility.
Trained ERI field engineers will-
make a complete list of all
existing traps that are to be
replaced. They will also gather
appropriate sizing information
for each application.
2 - %
-------
The customer receives a
computerized survey that lists:
• Location of existing steam traps
by tag number,
• Working steam pressure,
• Sizing applications information,
• STEAMGARD model selections.
In the Installation above, The SteamGard System has replaced three
steam traps. The remaining two traps are no longer used.
mSNEERING RESOURCES, NC.
International Tower Building
6550 W Bryn Mawr Ave
Chicago Illinois 60631
(312t 693-5500
Telex: 25-6259
Contact your representative
12/82
2-97
-------
THE STEAMGARD SYSTEM®
SERVICE INSTRUCTIONS
Typical STEAMGARD® Assembly
D=r> STEAMGARD®
Flow
Strainer
Basket Insert
Blowdown Device for Cleaning
Slowdown Procedure
1. Wear safety glasses, protective clothing and gloves.
2, Position a bucket to receive debris from blowdown device and stand
away from the direction of the flow from the blowdown device.
3 Open blowdown device three full turns.
4. Leave device open until debris is no longer present in flow (typically 10-
15 seconds).
5. Close blowdown device with a small wrench. When device seats, give 15°
turn to seal (equivalent to 30 ft.-lbs.; less than 1/16 turn). For units
equipped with ball valves (available to handle up to 150 psig), open valve
1/4 turn (no wrench required).
CAUTION; IF STEAM IS HIGH PRESSURE AND BLOWDOWN UNIT IS
IN A SMALL ENCLOSED SPACE ONLY BLOWDOWN FOR PERIODS OF
10 SECONDS OR LESS.
DO NOT OVER-TORQUE.
DAMAGE WILL RESULT.
SB
IMPORTANT: AFTER INSTALLATION IT IS IMPORTANT TO PERFORM AN INITIAL
STRAINER BLOWDOWN TO CLEAR THE LINE OF DIRT, METAL CHIPS, CORROSION
BY-PRODUCTS, AND ACCUMULATED CONDENSATE BEFORE RETURNING TO
NORMAL SERVICE. THE BLOWDOWN PROCEDURE SHOULD THEN BE REPEATED
FOR EACH UNIT ON A BIANNUAL BASIS.
1-800-258-6771 li
FOR SERVICE IN ILLINOIS CALL 1-600-826-1043
ftCSOUIICH. IMC.
SEE OTHER SIDE FOR IMPORTANT
WARRANTY INSTRUCTIONS
The STEAMGARD SYSTEM* is a patentees development of Engmeefing Resources !nc
Copyright < 1989 Engineering Resources trie.
2-98
-------
me oieamciara oysiem
INSTALLATION INSTRUCTIONS
The SteamGard" System requires no special orientation or leveling. The central device
may be Installed horizontal, vertical, diagonal or as shown below. The SteamGard*" System
can replace existing traps which are physically much larger and may utilize larger pipe
diameters. Bushings or reducers may be used as required to reduce pipe size down to
SteamGard** pipe size, keeping runs short.
THE STEAMQARO'- SYSTEM MUST 06 INSTALLED WITH AN ERIARPROVEO
STRAINER AS REQUIRED UNOCfl WARRANTEE. EACH ERI STRAINER IN-
CLUDES A CUSTOM 40 MESH STAINLESS STEEL BASKET INSERT, INSPECTEO
PRIOR TO SHIPMENT FOR INSTALLATION ANO FIT.
Tha Staan»Qa«J~ SytlMn require* no apaciat orianlatlon or ianbng Tha cantfat davtca
may b« fnitaiM horizontal, vertical,diagonal o< at thoarn baloo Tha StaamGard"" Syf lai*
Can laplaca tmlmfl trap* which art physically much larpar and may ulitna iargar pip*
dlamatars Bushings 0' raduean may b* vsad ai raquwad to raouca p
-------
CD
TMIHO ANOLC
MOJICTION
1
(NO NO
ENG STD 201
STEAMGARD® INSTALLATION INSTRUCTIONS
E>=E>
FLOW
mz.
FLOW
?zzzzzzz&%
STEAMGARD®
CONDENSATE RETURN
STEAM
STRAINER
BASKET INSERT
PLUG OR BLOWOFF VALVE FOR CLEANING
STEAMGARD MUST BE INSTALLED DOWNSTREAM OF A" Y" STRAINER WITH
A BASKET INSERT WITH 0.020" MAXIMUM OPENINGS (40 MESH)
pmtwiON twowN mimc/PHPO
UNkIM OTHtRWIM IMCirilO
TOltftANCI:
MtTNIC INCH
i PiACia
i £
1 'LACKS i
~
1 PLACI ±
ANQULAM
•
DO NOT tCALC ORAWINO
oma
ChK O
•Y
• T
rim
INSTALLATION
ItfCl
b*5#*ewn© resources, nc.
Inlerrvfltional Tower Building
OAT(
T or
(NO NO
ENG STD 20 1
TT7JT
-------
APPENDIX 2-3
MATERIAL SAFETY DATA SHEET
FOR NMP
2-101
-------
BASF Corporation
BASF
Material Safety Data Sheat
Page • i
BASF CORPORATION
3000 CONTINENT*! DRIVE
MT. OLIVE# NJ 07828
(201) 426-4671
Original Data:
Revision Data:
12/21/1993
06/07/1995
Emergency Telephone: (800) 424-S300 (CHEMTREC)
(800) 832-HELP (BASF Hotline)
BOTH NUMBERS ARE AVAILABLE DAYS, NIGHTS, WEEKENDS, & HOLIDAYS.
SECTION 1 - PRODUCT INFORMATION
NMP TECH ' " "
Product IDs NCI 597000
Common Chemical Name:
NMP TECHNICAL
Synonymss
N-METHYLPYRROLIDONE TECHNICAL
Molecular Formulas
C (5) H (9) NO
Molecular Wt.s 99.1
Chemical Family: Cyclic Amines
SECTION 2 - INGREDIENTS
Amount
» 97.8 X
0.3 X
* 2.0 %
Chemical Name: . CAS
2-PYRROtIO'MQME, 1-NETHYl 873-50*4
rei/TlV HOT ESTABLISHED
UATER 7732-18-5
PEl/TIV NOT ESTABLISHED
GAXHA 8UTTROIACTONE 96-48-0
PEl/TIV HOT ESTABLISHED
SECTION 3 - PHYSICAL PROPERTIES
Colo*: Clear
Form/Appearance: Liquid
Odor s Amine
Odor Intensity: Mild
Specific Gravitys
Bulk Density:
pH:
pH method:
Typical
NOT AVAILABLE
1.028
100 G/L H20
Low/High
7.7
tJ.O.M.
G/CC
su
Boiling Pt:
Freezing Pt:
Decomp. Tmp:
Low/High
Typical
202
-25
„ NOT AVAILABLE
Solubility In Water Descriptions Complete
Vapor Pressure: < 1 MILLIBARS
Deg.
C
C
9
760
760
3000 Continental Dow - North, Mount Of««, New Jersey 07828-1234 (201) <26-2600
2 - 102
Pressure
MM HG
MM HG
20
DEG. C
-------
unoi wwi putauvi <
NMP TECH Page j 2
NCI 597000
SECTION 3 - PHYSICAL PROPERTIES (coat)
Typical Low/High 17.O.K. ® Temperature
Vapor Density (Air ¦ 1)s 3-4
%
SECTION 4 - FIRE AND EXPLOSION DATA '
Typical Low/High Deg. Method
Plash Pointi 91 C ASTM D9373
Autoignitlon; 270 C DIN 51794
Flam. Limits; 1.3 - 9.5 %
Extinguishing Media:
Use water fog, foam, C02 or dry chemical extinguishing media.
Fire Fighting Procedures:
Firefighters should be equipped with self-contained breathing
apparatus and turn out gear.
Unusual Hazards:
Low when exposed to heat or flames. It can react with oxidizing mat -
j]L> .
SECTION 5 - HEALTH. EFFECTS
Routes of entry for solids and liquids include eye and skin
contact, ingestion and inhalation. Routes of entry for gases
include inhalation and eye contact. Skin contact may be a route
of entry for liquified gases.
Acute Overexposure Effects!
Contact with the liquid results in moderate eye irritation and may
cause temporary corneal clouding. Skin contact results in mild
irritation. Prolonged skin contact may result in redness and
dermatitis.
Inhalation of the vapors of NMP may result in respiratory irritation.
Accidental ingestion of the liquid causes gastric disturbances.
Nausea and vomiting may result.
Chronic Overexposure Effects!
In animal studies in rats and mice, N-methylpyrrolidone (NMP} was
embryotoxic by the oral and intraperitoneal routes at very high dose
levels which were close to the LD(50). In a dermal exposure study
with rats, NMP was only embryotoxic at the high dose level; this
effect was attributed to maternal toxicity. Several inhalation
studies in rats did not reveal any indication of maternal toxicity or
embryotoxicity. In a 2 year inhalation study, NMP did not cause any
life-shortening or carcinogenic effects in rats at 0.04 or 0.4 mg/1
(10 and 100 ppm respectively)
First Aid Procedures - Skins
Wash affected areas with soap and water. Remove and launder
contaminated clothing before reuse. If irritation develops,
get medical attention.
First Aid Procedures - Eyess
Immediately rinse eyes with running water for 15 minutes. If
irritation develops, get medical attention.
First Aid Procedures - Ingestion:
If swallowed, dilute with water and immediately induce vomiting.
3000 Continental Drive - North. Mount Olive. New Jersey 07828-4234 (201) 426-2600
2- 103
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BASF Corporation
NMP TECH
NCI 597000
Never give fluids or induce vomiting if the victim is unconscious or
having convulsions. Get immediate medical attention.
First Aid Procedures - Inhalation]
Move to fresh air. Aid in breathing, if necessary, and get
immediate medical attention.
First Aid Procedures - Notes to Physicianss
Not applicable.
First Aid Procedures - Aggravated Medical Conditions:
No data is available which addresses medical conditions that are
generally recognized as being aggravated by exposure to this product.
Please refer to Section 5 (Effects of Overexposure) for effects
observed in animals.
First Aid Procedures - Special Precautions:
Not applicable.
SECTION 6 - REACTIVITY DATA
Stability Data:
Stable
Incompatability:
Oxidizing reagents and strong acids.
Conditions/Hazards to Avoid:
See Reactivity - Incompatibility section.
Hazardous Decomposition/Polymerizations
Hazardous decomposition products: CO, C02 and NOx.
Polymerization: Does not occur.
Corrosive Properties:
Not corrosive.
Oxidizer Properties:
Not an oxidizer
SECTION 7 - PERSONAL PROTECTION
Clothing:
Manufacturer recommends the use of butyl rubber or FEP teflon gloves,
coveralls, apron, and boots as necessary to prevent skin contact.
Eyes:
Chemical goggles,- also wear a face shield if splashing hazard exists.
Respiration:
If vapors or mists are generated, "wear a NIOSH/MSHA approved organic
vapor/mist respirator or an air-supplied respirator as appropriate.
Ventilation:
Use local exhaust to control to recommended P.E.L.
Explosion Proofing:
See Section 4 - Fire and Explosion Data.
Other Personal Protection Data:
Eyewash fountains and safety showers must be easily accessible.
Shower after handling.
SECTION 8 - SPILL-LEAK/ENVIRONMENTAL
General:
Spills should be contained, solidified and placed in suitable
containers for disposal in a licensed facility. This material is not
3000 Continental Drive - North, Mount CXiv* New Jersey 07828-1234 {201} 426-2600
BASF
Page t 3
SECTION 5 - HEALTH EFFECTS (cont)
2 - 104
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DAor ^orpofitiio«i
DMor
NMP TECH Page i 4
NCI 597000
SECTION 8 - SPILL-LEAK/ENVIRONMENTAL (cont)
regulated by RCRA or CERCLA ("Superfund"). Wear appropriate
respiratory protection and protective clothing and provide adequate
ventilation during clean-up.
Waste Disposal:
Incinerate or bury in a licensed facility. Do not discharge into
waterways or sewer systems without proper authority.
Container Disposal:
Dispose of in a licensed facility. Recommend crushing or other means
to prevent unauthorized reuse.
Environmental Toxicity Teat Data:
Elimination (method not specified) - > 90 PERCENT
Readily Biodegradable
Golden Orf e, static 96 hr LC50 - 4 000 MG/L
Insignificant Hazard
Daphnia magna, 24 hr LC50 - > 1000 MG/L
Insignificant Hazard
Acute Algal Toxicity, 72 hr. EC/LC50 - > 500 MG/L
Practically Nontoxic
Toxicity to Bacteria - > 9000 MG/L
Insignificant Hazard
Biological Oxygen Demand, 5 day - 1,100 MG/L
TEST RATING NOT FOUND
Chemical Oxygen Demand - 1,600 MG/L
TEST RATING NOT FOUND
SECTION 9 - STORAGE AND HANDLING
General:
Avoid exposure to moisture; this product is hygroscopic.
Other Storage and Handling Data:
Consult other sections of this MSDS for information on reactivity and
flammability.
SECTION 10 - REGULATORY INFORMATION
TSCA Inventory Status
Listed on Inventory: YES
SARA - 313 Listed Chemicals:
CAS: 872-50-4 AMOUNT; 97.8 %
NAME: 2-PYRROLIDINONE, 1-METHYL
RCRA Haz. Waste No.:
CERCLA: NO Reportable Qty. : (If YES)
NMP is subject to the reporting requirements of SARA Title III,
Section 313 and 40CFR372.
Hazard Ratings:
Health: Fire: Reactivity: Special:
HMIS 12 0 NA
SECTION 11 - TRANSPORTATION INFORMATION
DOT Proper Shipping Name:
REFER TO BASF BILL OF LADING
3000 Continental Drive - North, Mount Olive. New Jersey 07828-1234 (201) 4262600
2 - 105
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BASF Corporation
NMP TECH
KCI 597000
SECTION 11
DOT Technical Name:
REFER TO BASF BILL OF LADING
DOT Primary Hazard Class:
REFER TO BASF BILL OF LADING
DOT Secondary Hazard Class:
REFER TO BASF BILL OF LADING
DOT Label Required?
REFER TO BASF BILL OF LADING
DOT Placard Required:
REFER TO BASF BILL OF LADING
DOT Poison Constituent:
REFER TO BASF BILL OF LADING
BASF Commodity Codes: NA NA UN/NA Code: NONE E/R Guide:
Bill of Lading Description:
FOR THE MOST UP-TO-DATE D.O.T. SHIPPING DESCRIPTION, PLEASE REFER TO
THE BASF BILL OF LADING!
WHILE BASF CORPORATION BELIEVES THE DATA SET FORTH HEREIN ARE
ACCURATE AS THE DATE HEREOF, BASF CORPORATION MAKES NO WARRANTY
WITH RESPECT THERETO AND EXPRESSINGLY DISCLAIMS ALL LIABILITY FOR
RELIANCE THEREON. SUCH DATA ARE OFFERED SOLELY FOR CONSIDERATION,
INVESTIGATION, AND VERIFICATION.
END OF DATA SHEET
BASF
Page i 5
- TRANSPORTATION INFORMATION (cont)
3000 Continental Drive
- North. Mount Oiiva New Jersey 07828-1234 (201) 426-2600
2- 106
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APPENDIX 2-4
BIODEGRADABILITY AND AQUATIC TOXICITY OF NMP
2- 107
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front "Technical Information; N-Methyl Pyrrolidone Handling and Storage" reprinted with permission from BASF, inc.
BIODEGRADABILITY AND AQUATIC TOXICITY
i. INTRODUCTION
Biodegradation refers to the biological (usually bacteria) catalyzed breakdown of organic
chemicals. When dissolved oxygen is present as it typically is in a biologically healthy
stream or river, the end products are carbon dioxide and water. In practice, complete
oxidation is rare. More commonly, a partial breakdown occurs resulting in the formation
of C02. H20, and metabolites.
Most chemicals will cause environmental damage if released untreated. The damage can
take many forms depending on the chemical involved. Direct toxic effects may take the form
of:
a. poisoning of aquatic species through short single dose exposure (acute toxicity)
b. poisoning of aquatic species due to persistent non-degraded toxicants (chronic
toxicity)
c. poisoning of higher members of the food chain through bioaccumulation in aquatic
species
Indirect toxic effects may take the form of:
a. oxygen demand overloading causing dissolved oxygen levels in the water to be de
pleted below levels needed by typical species of fish
b. high algal growth rates resulting in lake eutrophication
Prevention of future damage requires minimizing both the amount and toxicity of those
wastewater discharges.
The need for treatment of chemicals prior to their release is obvious. In turn, this makes the
need for a means of predicting the degree of treatment obvious. However, considering the
wide range of circumstances that could be applicable, the form of the measurements
needed to make these predictions is far from obvious. Our measurement, biodegradability,
is not an absolute intrinsic property. Its value, and the method involved in determining that
value, is dependent on the anticipated conditions which have necessitated the treatment.
For example, a chemical which might be inadvertently released to a receiving water (a spill)
would have different properties of interest than a chemical intentionally released to a waste-
water treatment plant (aquatic toxicity vs. BOD). Similarly, the levels of treatment required
and the ultimate efficiency of treatment achieved would differ as would the tests required to
measure them.
II. MEASURES OF BIODEGRADABILITY
Biodegradability is a function of the type and amount of bacteria available, the structure of
the chemical being treated, various environmental factors (oxygen, pH, etc.), and the con-
tact time. Different treatment situations will involve different combinations of the above.
Thus, it is understandable that many different types of tests exist
2- 108
-------
Primary biodegradability was an early test method established to measure the loss of a par-
ticular property of interest (surface tension or foaming). This test used high concentrations of
acclimated bacteria. Contact times are on the order of one day. Since oily a small structural
change is required in the test chemical to cause loss of a physical property, this type of test
generally gives very extensive biodegradability even though most of the molecular makeup
of that chemical remains untouched. For this reason, this type of test has fallen out of use
The familiar BOO (Biological Oxygen Demand) test is an example of a respiromeiric (oxy-
gen consumption) measurement of biodegradability. By measuring oxygen consumption,
these tests provide a belter indication of the extent of degradation of the chemical structure
than does loss of a property of the chemical. These tests are often reported as percentages
of theoretically complete oxidation (ThOD); accordingly, the biodegradability values are gen-
erally lower even though the extent of treatment may often be greater. This type of test
varies in the conditions under which it is run, however, it is generally run with low concen-
trations of bacteria which may or may not be acclimated (adapted to the chemical) and con-
tact times on the order of 1-5 days. The BOD test is the most commonly used test to de-
scribe wastewater treatment plant performance.
A third general type of test takes the respirometric test a step further by increasing the con-
tact time to 30 days or longer (virtually insuring that the bacteria are acclimated). The objec-
tive of this test is to measure the ultimate biodegradability (greatest possible extent of de-
gradation). This testing simulates the environmental fate of chemicals in a receiving water.
The biodegradability values are usually higher than the shorter term BOD type tests.
Biodegradability can also be measured by monitoring other properties or descriptions of the
test chemical. Chemical Oxygen Demand (COD) measures (for practical purposes) the
complete oxidation of a chemical to C02 and H20. Thus, biodegradability measured by COD
is generally lower than by any other test. The ratio of the BOD to COD gives the per-
centage of the molecule that can be biologically oxidized. A value of 0.3 or greater is
considered good.
Total Organic Carbon (TOC) is sometimes used to describe a molecule. Values of bio-
degradability obtained by monitoring this parameter generally lie between BOD and COD
values.
Obviously, it is essential that the test conditions be specified when citing biodegradability
numbers. When comparing values from different sources it is vital to insure that the values
are describing the same test.
. MEASURES OF AQUATIC TOXICITY
The harmful effect of a chemical released into a receiving water is dependent on its concen-
tration in that water. All chemicals are toxic if their Concentration is high enough. Therefore,
it is necessary to determine a *safe" concentration. The tests for doing this generally use
various forms of aquatic life as indicators of toxicity. The values reported usually show the
chemical concentration at which 50% of the test organisms would be expected to die. The
common term for this is the LD-50. Because the life forms used in this testing vary greatly
in their sensitivity to chemicals. Hie tests results also vary greatly. Again, it is important to
specify the conditions used in the test and to make sure that conditions are identical when
comparing values. In general, LD-50 values <1 0 ppm are considered toxic. Values between
10 and 100 ppm are somewhat toxic and values >100 ppm are "non-toxic."
2 - 109
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IV, NMP BIODEGRADABILITY
River die-away tests were conducted by Chow & Ng (1), These tests simulate the fate of a
compound in a receiving water. Using an initial concentration of 100 ppm NMP, they found
95% removal as measured by specific compound analysis and 45% removal as measured
by COD. These determinations were conducted after two weeks exposure. The low COD
removal compared to the specific compound removal indicates a high degree of molecular
modification (probably nitrogen-carbonyl bond splitting) and a lesser amount of mineral-
ization (conversion to CO* and HjO). Thus, while the compound was no longer present as
NMP, the compound was still present as modified fragments.
An additional test by the same people using a semi-continuous activated sludge system
acclimated for five days showed 7 day biodegradability of 95% by specific analysis.
In similar tests, Matsui (2) used a semi-continuous system to measure TOG, COD, and spe-
cific compound (by GC) removals. These results all showed >92% removal (regardless of
the parameter being measured) within 24 hours starting with concentrations ranging from 92
ppm to 210 ppm NMP.
Rowe and Tutlos (3) studied biodegradability of NMP in acclimated and unacclimated. static
and continuous flow, laboratory activated sludge systems. The tests were run at 300 and
1000 ppm of NMP; the continuous cells had an 18-hour hydraulic residence time. The re-
sults indicate that NMP was largely degraded (more than 98 percent destruction with 90
percent TOC reduction in the continuous cells), and that significant acclimation is easily
achieved (more than 75 percent TOC reduction in 24 hours in unacclimated static tests).
Respirometric tests provided by BASF show a BOD-5 (acclimated) of 1.2 wt/wt. Compared
to the Theoretical Oxygen Demand (ThOO = COD) of 2,18, this gives a BOD/COD ratio of
0.55 which is quite biodegradable.
As an indication of the impact of NMP on an activated sludge treatment system, the Hand-
book of Environmental Data (3) lists a no-effect level (LD-O) for NMP using the bacterium
Pseudomonas as 5 g/1. This demonstrates that NMP is non-toxic to treatment systems
even at fairly high concentrations. BASF AG tests indicate that activated sludge wastewater
treatment systems will continue to function efficiently at NMP concentrations at least as high
as 2000 ppm.
BOD tests conducted by BASF show that using unacclimated bacteria, NMP is bio-
degradable (BOD-5 = 0.76). rtowever, acclimation significantly increased the biode-
gradability; BOD-5 = 1.15 wt/wt Long term BOD tests show substantial biodegradability
BOD-20 = 1.2 wt/wt.
Alt of the above tests show that in acclimated systems or systems that could acclimate
during the normal contact time (as in the case of a spill to a receiving water), NMP is
readily biodegradable. There are indications that in unacclimated, short contact time
systems (single dose exposure in municipal treatment plants) NMP would not be
significantly degraded.
2 - no
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V. AQUATIC TOXICITY
GAF data tor various species of fish list the LC-50 as ranging from 832-3048 ppm. Even the
lowest value is well within the "non-toxic" range,
VI. CONCLUSIONS
NMP is nearly non-toxic to most aquatic life and can be readily degraded by typical waste-
water treatment plant organisms. It is. accordingly, an advantageous solvent to use when-
ever any possibility of discharge with an aqueous stream exists.
REFERENCES
(1) "The Biodegradation of N-Methyt-2-PyrroIidone in Water by Sewage Bacteria," S. T.
Chow and T. L Ng, Water Research, Vol. 17, pp. 117-118 (1983).
(2) "Activated Sludge Degradability of Organic Substances in the Waste Water of the
Kashima Petroleum and Petrochemical Industrial Complex in Japan." S. Matsui, T.
Murakimi, T. Sasaki, Y. Hirose, and Y. Iguma, Progress in Water Technology» Vol. 7,
Nos. 3/4, pp. 645-659 (1975).
(3) "Lube Solvents No Threat to Waste Treatment," E. H. Rowe and L. F. Tullos, Jr.. Hydro-
carbon Processing, 59, pp. 63-65 (October 1980).
(4) Handbook of Environmental Data on Organic Chemicals. 2nd Ed., Karel Verschueren,
Van Nostrand, ReinhoW Co., N.Y. 1983. p. 873.
2-111
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SECTION 3:
DEMONSTRATION OF
ALTERNATIVES FOR CLEANING PAINT APPLICATION EQUIPMENT
By:
J, M. Elion, J. B. Flanagan,
E. A. Hill, and J. H. Turner
3-i
-------
ABSTRACT
The purpose of this project was to demonstrate on a full production scale a pollution
prevention technology to replace methyl ethyl ketone (MEK) for cleaning the paint application
equipment (pumps, hoses, and guns) at the Marine Corps Logistics Base (MCLB) in Albany, GA.
The research was conducted by U.S. EPA with the the contractor services of Research Triangle
Institute (RTI). Funding was provided by the Strategic Environmental Research and
Development Program (SERDP).
This demonstration consisted of a preliminary screening to identify several possible solvent
alternatives, testing to downselect the most effective cleaners, and finally full-scale demonstration
at the MCLB.
The preliminary screening tested 65 alternative cleaners for their effect on fully cured
single and plural component Chemical Agent Resistant Coatings (CARCs) and an epoxy primer.
From these 65 alternatives, 5 cleaners were selected for further testing. These cleaners were
tested for their compatibility with materials that would come in contact with the paints and the
cleaner. The project researchers found no measurable weight gain or loss, pitting, or other signs
of corrosion between any of the five cleaners or MEK and the four metals tested: aluminum,
stainless steel, nickel, and brass. Material compatibility was also tested with four plastics
(Teflon®, acetal, Nylon®, and Delrin®). Results showed slight weight changes in all coupons
tested with the five cleaners and with MEK. Of the five cleaners, the two showing the least
overall weight gain or loss for the four plastics were evaluated for paint removal efficiency in a
laboratory setting. Overall, both of the cleaners were comparable to MEK for CARC, and both
cleaners were better than MEK at removing the white primer.
Based on the test results, the blend of 40% propylene carbonate and 60% benzyl alcohol
(PC/BA), by weight, was selected for demonstration at the base. Four barrels of this cleaner were
shipped to the MCLB. MCLB used this cleaner as a direct replacement for MEK. No capital
investment was required.
Use of this cleaner was monitored by weighing the amount of cleaner flushed through the
system. The amounts of cleaner used for the initial prewash, the final wash, and the filter wash
were recorded. The date and time at the start and finish of each step was also recorded.
PC/BA cleans green CARC from the pumps as well as MEK, and cleans epoxy primers
from the pumps better than MEK. Advantages of using PC/BA are lowered inhalation hazard to
workers, reduced cleaner use and reduced labor time for cleaning, and classification of the
hazardous waste as non-RCRA regulated. The disadvantage is a higher cost for the PC/BA blend
than for MEK. The higher cost may be offset by cleaner recovery and reclamation, and further
waste reduction. The use of PC/BA significantly decreases downtime of the primer pumps. This
substitution will reduce emissions from HAPs 21% from 1992 levels.
3-ii
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TABLE OF CONTENTS
ABSTRACT 3-ii
FIGURES 3-v
TABLES .. 3-v
ACRONYMS 3-vi
METRIC UNITS 3-vii
ACKNOWLEDGMENTS ............. 3-viii
NOTICES 3-ix
3.1.0 INTRODUCTION 3-1
3.1.1 Background 3-1
3.1.2 Objectives 3-2
3.2.0 TECHNICAL EVALUATION OF ALTERNATIVES TO MEK 3-3
3.2.1 Preliminary Screening 3-3
3.2.2 Material Compatibility 3-13
3.2.3 Paint Removal Efficiency 3-17
3.3.0 ON-SITE DEMONSTRATION OF ALTERNATIVE PAINT EQUIPMENT CLEANER
PROPYLENE CARBONATE/BENZYL ALCOHOL 3-21
3.3.1 Current Process 3-21
3.3.2 Setup of Demonstration 3-21
3.3.3 Demonstration of Alternative Cleaner 3-23
3.3.4 Regulations Affecting Alternative Cleaner 3-28
3.4.0 QUALITY ASSURANCE 3-29
3.4.1 Alternatives Evaluation Phase 3-29
3.4.2 On-Site Demonstration 3-30
3.5.0 IMPLEMENTATION PLAN 3-31
3.5.1 Equipment 3-31
3.5.2 Materials 3-32
3.5.3 Safety 3-32
3-iii
-------
TABLE OF CONTENTS (continued)
3.5.4 Economic Analysis 3-33
3.5.4.1 OAQPS Control Cost Manual 3-34
3.5.4.2 Obtaining Cost Elements 3-37
3.5.4.3 Unit Costs, Rates, and Assumptions for Economic Analysis .. 3-37
3.5.4.4 Solvent Substitution 3-39
3.5.4.5 Return on Investment and Payback Period for Cleaning Solvent
Replacement 3-43
3.6.0 DISCUSSION OF OBJECTIVE 3-43
3.7.0 CONCLUSIONS 3-44
3.8.0 RECOMMENDATIONS 3-45
3.9.0 REFERENCES 3-45
APPENDICES
3-1: Material Safety Data Sheets for Coatings 3-46
3-2: Material Safety Data Sheets for MEK Alternatives 3-69
3-3: Materials Compatibility Data 3-101
3-4: Paint Removal Efficiency Data 3-109
3-5: Procedure for Monitoring Cleaning Use 3-111
3-6: Material Safety Data Sheets for Benzyl Alcohol and Propylene Carbonate 3-112
3-iv
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FIGURES
Number Page
3-1. Comparison of Screening Results for White Primer 3-9
3-2. Comparison of Screening Results for Tan CARC 3-10
3-3. Comparison of Screening Results for Green CARC 3-11
3-4. Gravimetric Results of Materials Compatibility Tests 3-16
3-5. Paint Removal Efficiency Results of MEK Alternatives 3-20
3-6. Schematic for Monitoring Cleaning of Paint Equipment 3-26
TABLES
3-1. Cleaner Blends Screened as Alternatives to MEK 3-5
3-2. Summary of Results of Preliminary Screening 3-7
3-3. Cleaners Selected for Technical Evaluation 3-13
3-4. Percent Weight Change of Materials Immersed 7 Days in Alternative Cleaners ...... 3-15
3-5. Removal of Coatings from Glass Tubes 3-19
3-6. Equipment Used to Monitor Cleaning of Paint Application Equipment 3-23
3-7. Volume and Time to Clean Equipment with PC/BA 3-27
3-8. Volume and Time to Clean Equipment with MEK 3-27
3-9. Regulations Impacting the Use of MEK and PC/BA 3-28
3-10. Chemical Suppliers for PC/BA 3-32
3-11. Annualized Cost Analysis of Cleaning with PC/BA 3-40
3-12. Annualized Cost Analysis of Cleaning with MEK 3-42
3-13. Summary of Hazardous Air Pollutants Based on 1992 Purchase History . 3-44
3-v
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ACRONYMS
APPCD
Air Pollution Prevention and Control Division
CAA
Clean Air Act
CARC
Chemical agent resistant coating
CERCLA
Comprehensive Environmental Response, Compensation, and Liability Act
DMA
Depot Maintenance Activity
EPA
Environmental Protection Agency
EPCRA
Emergency Planning and Community Right-to-Know Act
HAP
Hazardous air pollutant
MCLB
Marine Corps Logistics Base
MEK
Methyl ethyl ketone
MSDS
Material Safety Data Sheet
P2
Pollution prevention
PC/BA
Propylene carbonate/benzyl alcohol
PP
Payback period
QA/QC
Quality Assurance/Quality Control
RCRA
Resource Conservation and Recovery Act
ROI
Return on investment
RTI
Research Triangle Institute
SARA
Superfund Amendments and Reauthorization Act
SERDP
Strategic Environmental Research and Development Program
VOC
Volatile organic compound
3-vi
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METRIC UNITS
English units have been included in the report to simplify communication with most of the
intended readership and because they are the primary units used by the Marine Corps Logistics
Base. The multiplying factors for converting from the English units to their metric equivalents are
given in the table below.
METRIC CONVERSION FACTORS (Approximate)
Symbol
When You Know
the Number of
Multiply By
To Find the
Number of
Symbol
LENGTH
in
I
inches 1 2,54
cm
centimeters
VOLUME
gal
gallons
3.79
liters J 1
MASS
lb
pounds 0.454
kilograms
kg
PRESSURE
psi
pounds per
square inch
6.89
kilopascals
kPa
TEMPERATURE
°F
degrees
Fahrenheit
5/9
(after subtracting
32)
degrees
Centigrade
°C
DENSITY
lb/ft3
pounds per cubic
foot
16.0
kilograms per
cubic meter
kg/m3
FLOW
cfm
i
cubic feet per | 0.472
minute |
liters per second
Vsec
3-vii
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ACKNOWLEDGMENTS
The authors gratefully wish to acknowledge the following people at the MCLB, without whose
cooperation and assistance this demonstration would not have been possible:
Steve Allan
Dave Baxter
Wayne Chauncey
Scott Clements
Clarence Clyde
Larry Fountain
John Gates
George Hagan
Duke Bellinger
Dave Hudson
Mark Joyner
Willie Walker
In addition, the authors acknowledge Tom Marquis of Huntsman Chemical for his assistance with
the preliminary screening.
The authors would especially like to recognize the contribution of EPA and MCLB's Project
Engineers J. Kaye Whitfield and Dan Gilium to this report. Their project oversight, guidance,
direction, and technical assistance greatly contributed to this research demonstration.
3-viii
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NOTICES
QA/QC requirements apply to this project. Data are supported by QA/QC documentation as
required by USEPA's QA Policy.
The use of trade names and company names in this section does not signify recommendation for
use or endorsement by either the EPA or Research Triangle Institute.
3-ix
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3.1.0 INTRODUCTION
This section reports on the demonstration of solvent alternatives for cleaning paint
application equipment (hereafter referred to as the "MEK alternatives demonstration"), performed
at the Marine Corps Logistics Base in Albany, GA, with funding provided by the Stategic
Environmental Research and Development Program (SERDP). It contains detailed descriptions
of the technical evaluation, including the preliminary screening tests, and the operational
evaluation conducted at the MCLB, Information regarding cost savings and estimated reductions
in hazardous air emissions is contained in the Implementation Plan (Section 3.5,0).
3.1.1 Background
The demonstrations in this project were performed primarily at the Marine Corps Logistics
Base (MCLB) in Albany, GA. This base carries out maintenance activities on a wide variety of
equipment from small arms t o tanks, trucks, and other vehicles. Much of the maintenance on the
vehicles requires removing the existing paint prior to the repair procedures, and application of
new paint once the maintenance has been performed. The processes for paint stripping,
repainting, and cleaning of paint equipment release significant amounts of hazardous air pollutants
(HAPs). By Executive Order 12856, the MCLB is required to reduce these air emissions by 50%
from 1992 levels. The MCLB desires to accomplish this goal by implementing pollution
prevention (P2) technologies.
The coatings used by the MCLB can be classified as polyurethane-based plural-component
Chemical Agent Resistant Coatings (CARCs) and single-component CARCs, epoxy primers, and
undercoatings. The four coatings used in this evaluation were dual-component green CARC
(NSN 8010-01-160-6742); single-component tan CARC (NSN 8010-01-276-3640);
undercoating (NSN 8030-01-127-3683); and epoxy primer (NSN 8010-001-193-0517). Material
Safety Data Sheets for these four coatings are included in Appendix 3-1.
The MCLB primarily uses air-assisted airless spray systems to apply paint; cup sprayers
are used for touch-up paint.
3-1
-------
The current process used to remove the partially cured paint from the paint application
equipment is to flush methyl ethyl ketone (MEK) through the equipment into an open bucket.
When the MEK looks clean, the lines are flushed for three minutes or less with additional fresh
solvent. The systems are cleaned at least twice daily; at the ends of the day shift and the night
shift. The systems are also cleaned between color changes. The waste paint and MEK from the
prewash is collected in a bucket that is later emptied into a hazardous waste barrel. The barrel is
then disposed of as hazardous waste. The MEK from the final rinse is used for the next prewash
cycle.
MEK needs to be replaced because it is a hazardous air pollutant and is one of seventeen
toxic chemicals identified in the Environmental Protection Agency (EPA) 33/50 Program The
33/50 Program is a voluntary pollution prevention initiative to reduce national pollution releases
and off-site transfers. The seventeen toxic chemicals chosen were selected because they pose
environmental and health concerns, are high-volume industrial chemicals, and may be reduced
through pollution prevention technologies.
3.1.2 Objectives
The objective of this task was to demonstrate a process for cleaning the paint application
equipment that would reduce the emissions of HAPs resulting from cleaning the paint application
equipment. This objective was achieved by replacing the MEK with a less hazardous, less volatile
solvent and a combination of work practices. These technologies and work practices were tested
at a laboratory facility and then demonstrated on-site at the MCLB over a four-week period. The
MCLB continued to use the new process after completion of the demonstration.
3-2
-------
3.2.0 TECHNICAL EVALUATION OF ALTERNATIVES TO MEK
3.2,1 Preliminary Screening
The first step in finding a replacement solvent was to test the efficacy of a group of
solvents that was most likely to be capable of removing the CARCs and primer. The list of
capable solvents and solvent mixtures was narrowed to those that best met environmental, cost,
and safety criteria. These criteria included high flash point, low vapor pressure, and removal of
coatings at ambient use temperature.
Four aluminum 6 in, x 6 in. x 0.060 in. panels were sent to the MCLB, where they were
each coated with one of four coatings: one-component Chemical Agent Resistant Coating
(CARC), two-component CARC, epoxy primer, or undercoating. The panels were returned to
RTFs laboratory. The panel coated with the undercoating arrived in poor condition and was not
included in the preliminary screening. Each of the other panels was sheared into ¥i in. x Vi in.
squares. The square coupons were sent to Huntsman Specialty Chemical Corporation in Austin,
TX, for preliminary screening tests.
Preliminary screening consisted of visual examination of the effect of different solvent
formulations on the three coatings. Although the coatings cleaned at MCLB are usually uncured
or only partially cured, the preliminary screening was conducted on fully cured coatings to ensure
that a robust cleaner would be selected. Sixty-five different cleaners were tested. The cleaners
were various proportions of propylene carbonate and other compounds, including methyl isoamyl
ketone, n-methyl pyrrolidone (NMP), dibasic esters, and benzyl alcohol. A list of the sixty-five
cleaners is provided in Table 3-1.
For each test, one test square coated with one-component CARC was placed in a test vial,
one test square with two-component CARC was placed in another test vial, and one test square
with epoxy primer was placed in a third test vial. Approximately 2 milliliters (ml) of the test blend
was placed in each of the three vials. This was repeated for all sixty-five cleaners. MEK was also
included to provide a baseline for comparison. Each coupon was visually inspected after twenty-
four hours and again after forty-eight hours. The results are shown in Table 3-2. Samples were
rated "L" for little or slight attack as evidenced by small pock marks or blisters in the coatings.
3-3
-------
Samples were rated "M" for moderate attack as evidenced by wrinkling or blistering of the
coating. Samples were rated "S" for severe attack, indicated by heavy blistering, wrinkling, or
removal of the coating. No rating indicates no observed effect on the coating. MEK, the current
cleaner, had no observed effect on the three coatings.
The photograph in Figure 3-1 shows a comparison of the white primer as coated and after
severe attack following 48 hours immersion in one of the cleaners. The coating was heavily
wrinkled on both sides. The photograph in Figure 3-2 shows a comparison of the tan CARC as
coated, after moderate attack following 48 hours immersion in cleaner #2, and after severe attack
following 48 hours immersion in cleaner #58. The coating was severely blistered on one side of
the test square and completely removed from the other side. The photograph in Figure 3-3 shows
a comparison of the green CARC as coated, following 48 hours immersion with no noticeable
effect, and severe attack following 48 hours immersion. The coating shows a large blister.
3-4
-------
Table 3-1. Cleaner Blends Screened as Alternatives to MEK
(Compositions Given by Weight Percent)
RTI #
PC
MIAK
NMP
DBE
DPM
N-AMYL
BENZYL
OTHER
acetate
alcohol
1
25
25
50
2
20
40
Diisobutyl ketone - 40
3
25
50
25
4
20
80
5
40
60
6
25
50
25
7
20
20
20
40
8
20
40
20
20
9
25
75
10
25
25
25
25
11
25
25
50
12
20
30
50
13
14
21
35
30
14
8
12
20
60
15
25
30
25
20
16
17.5
21
17.5
14
30
17
10
12
10
8
60
18
25
15
20
Limonene - 40
19
17.5
10.5
14
30
Limonene - 28
20
10
6
8
60
Limonene - 16
21
28
35
Ethylene glycol butyl ether acetate - 37
22
19.6
24.5
30
Ethylene glycol butyl ether acetate - 25.9
23
11.2
14
60
Ethylene glycol butyl ether acetate - 14.8
24
24
35
5
Diacetone alcohol - 36
25
16.8
24.5
3.5
30
Diacetone alcohol - 25.2
26
9.6
14
2
60
Diacetone alcohol - 14.4
27
40
35
12
Methyl amyl acetate - 13
28
28
24.5
8.4
30
Methyl amyl acetate - 9.1
29
16
14
4.8
60
Methyl amyl acetate - 5.2
30
44
35
12
Isobutylisobutyrate - 9
31
30.8
24.5
8.4
30
Isobutylisobutyrate - 6.3
(continued)
-------
(Table 3-1, continued)
32
17.6
14
4.8
60
Isobutylisobutyrate - 3.6
33
50
20
25
Limonene- 5
34
35
14
17.5
30
Limonene - 3.5
35
20
8
10
60
Limonene - 2
36
15.2
8
10.8
60
Tripropylene glycol - 6
37
26.6
14
11.2
30
2-Ethoxyl acetate - 18.2
38
15.2
8
6.4
60
2-Ethoxyl acetate - 10.4
39
49
7
20
24
40
34.3
4.9
14
16.8
30
41
19.6
2.8
8
9.6
60
42
30
20
34
Ethylene glycol diacetate - 16
43
21
14
23.8
30
Ethylene glycol diacetate -11.2
44
12
8
13.6
60
Ethylene glycol diacetate - 6.4
45
55
45
46
38.5
31.5
30
47
22
18
60
48
10
19.2
60
y-Butyrolactone - 10.8
49
18
17.2
60
Furfiiryl alcohol - 4.8
50
32.2
29.4
30
Triethylene glycol - 8.4
51
18.4
16.8
60
Triethylene glycol - 4.8
52
28
28
30
Diethylene glycol butyl ether - 14
53
16
16
60
Diethylene glycol butyl ether - 8
54
17.5
17.5
17.5
17.5
30
55
10
10
10
10
60
56
13.3
13.3
13.3
60
57
10
10
10
10
60
58
13.3
13.3
13.3
60
59
20
20
20
20
20
60
14
14
14
14
14
30
61
8
8
8
8
8
60
62
17.5
17.5
17.5
17.5
30
63
10 *
10
10
10
60
64
33.3
33.3
33.3
65
50
50
Texadd S-200
PC - Propylene carbonate
MIAK - Methyl isoamyl ketone
NMP - N-methyl Pyrrolidone
DBE - Dibasic esters
DPM - Dipropylenc glycol methyl ether
-------
Table 3-2. Summary of Results of Preliminary Screening
Effects of cleaners on coatings after 24 and 48 hours,
GREEN CARC
TAN CARC
WHITE EPOXY PRIMER
Panel#
24 hours
48 hours
24 hours
48 hours
24 hours
48 hours
1
L
L
M
M
S
S
2
s
S
3
L
S
L
M
• s
s
4
L
L
S
S
M
s
5
M
s
M
s
6
L
L
L
L
S
s
7
L
L
L
L
M
s
8
L
M
L
L
S
s
9
S
S
L
L
s
s
10
M
s
11
L
L
M
s
12
L
L
L
S
s
13
L
L
M
s
14
L
M
s
15
L
M
s
16
L
M
s
17
L
M
s
18
L
L
L
L
M
s
19
S
s
20
S
S
M
s
21
L
M
s
22
L
S
s
23
L
L
L
M
s
24
L
L
s
25
L
L
s
26
L
L
L
L
s
27
L
L
M
s
28
L
L
L
M
s
29
M
M
L
M
M
s
30
L
L
s
31
M
s
32
L
L
• s
33
s
34
L
s
35
S
S
M
s
36
S
s
37
L
L
M
s
38
L
M
M
s
39
L
L
M
40
L
L
s
(continued)
3-7
-------
{Table 3-2, continued)
41
M
s
s
S
S
42
L
L
L
43
M
S
44
L
S
S
45
L
L
L
L
46
L
M
L
M
47
L
S
S
48
L
S
M
S
s
S
49
L
S
S
s
s
50
L
L
L
M
51
L
L
L
S
S
52
L
L
L
s
53
L
L
S
s
54
L
M
s
55
S
r l
S
s
56
M
s
L
M
57
L
L
M
S
58
S
S
S
s
59
L
* S
s
60
L
s
s
61
L
M
s
s
62
L
s
s
63
S
S
M
s
64
M
M
65
M
M
MEK
L - Little or slight effect
M - Moderate effect
S - Severe effect
Blank spaces indicate no observed effect
3-8
-------
Figure 3-1. Comparison of Screening Results for White Primer
Photograph shows test squares as coated and after severe attack following 48 hours immersion.
3-9
-------
Figure 3-2. Comparison of Screening Results for Tan CARC
Photograph shows test squares as coated (on the left), after moderate attack following 48 hours
immersion in cleaner #2 (in the middle), and after severe attack following 48 hours immersion in
cleaner #58 (on the right). The coating is severely blistered on one side of the test square; the
square directly above is the removed coating from the other side of the same test square.
3-10
-------
Figure 3-3. Comparison of Screening Results for Green CARC
Photograph shows test squares as coated (on the left), after slight attack following 48 hours
immersion in cleaner #1 (in the middle), and after severe attack following 48 hours immersion in
cleaner #3 (on the right).
3-11
-------
Only one screening formulation, #48, severely attacked all three coatings after forty-eight
hours. Three other formulations severely attacked two of the three coatings and moderately
attacked the third. Based on the results of the screening study, five formulations were selected for
further tests. Formulations with high percentages of n-methyl pyrrolidone (NMP) or benzyl
alcohol appeared to have the highest solvency. For this reason, formulations #5 and #48 were
chosen as likely candidates to replace MEK. Noting that the screening study with cured panels
was a "worst-case" condition, formulation #64 was chosen to determine whether a formulation
with a lower percentage of benzyl alcohol would prove effective. Formulation #65 was chosen to
represent the propylene carbonate/NMP blends. Propylene carbonate (PC), as the common
constituent, was also included for further testing, even though screening tests were not done with
100% PC.
Huntsman Specialty Chemical Corporation had Material Safety Data Sheets available for
several of the screened cleaners, designating the formulations with letters or names instead of
numbers. (Formulation #65 was selected over #3 and #9 because the MSDS was already
available.)
These five formulations shown in Table 3-3 were used for materials compatibility testing
and more cleaning tests, Half-gallon samples were submitted for further
technical evaluation. The Material Safety Data Sheets for these are included in Appendix 3-2.
3-12
-------
Table 3-3. Cleaners Selected for Technical Evaluation
Product
Formulation
Paint Remover H
(RTI #64)
Propylene carbonate (33-1/3%)
Dibasic esters (33-1/3%)
Benzyl alcohol (33-1/3%)
Paint Remover L
(RTI #5)
Propylene carbonate (40%)
Benzyl alcohol (60%)
Paint Remover N
(RTI #48)
Propylene carbonate (10%)
Dibasic esters (19.2%)
¦y-Butyrolactone (10.8%)
Benzyl alcohol (60%)
Texadd S-200
(RTI #65)
Propylene carbonate (50%)
N-Methyl pyrrolidone (50%)
Propylene Carbonate
Propylene carbonate (100%)
3.2.2 Material Compatibility
The choices of materials for compatibility testing were based on wetted materials in the
paint application pump systems then in use at the MCLB. The MCLB provided the instructions
and parts list for the Graco plural component mixer manifold then in use to spray coatings. The
manifold parts that would come in contact with the paint and paint cleaner included chrome alloy,
303 stainless steel, Delrin®, Nylon®, and Teflon®. The test materials chosen were aluminum,
brass, nickel, 303 stainless steel, acetal, Delrin®, Nylon®, and Teflon®.
Test coupons measuring 3/4 in. by 2 in. by 1/8 in. thick were made for each material.
Each coupon was weighed to the nearest 0.01 mg and the weight recorded. Replicate coupons of
each material were placed in three separate test vials. Approximately 4 ml of cleaner were added
to each vial, which covered about half the coupon. This allowed exposure of the coupon to the
liquid phase, the liquid/vapor interface, and the vapor phase of each cleaner. Each vial was then
capped and stored at room temperature. The test coupons were removed and weighed after one
day immersion. They were returned to the cleaner vial and reweighed after three days immersion
and again after seven days immersion. A fourth coupon, the control, was also reweighed to the
nearest 0.01 mg after one day, three days, and seven days exposure to ambient conditions.
3-13
-------
When the coupons were removed from a cleaner to be weighed, they were patted dry with
absorbent towels for 60 seconds and then immediately weighed. Excessive contact with air am!
delays in weighing were avoided. Coupons were returned to their individual vials as soon as
possible after weighing. Weight changes indicate loss of material or absorption of cleaner.
Visual examination of the test coupons during weighing indicated no pitting, flaking,
discoloration. No signs of corrosion were visible on the metal coupons. No shape distortion was
visible on the plastic coupons.
The results of the materials compatibility gravimetric testing are summarized in Table 3-4.
The full experimental data are in Appendix 3-3. A comparison of the five cleaners and MEK is
shown graphically in Figure 3-4. This figure shows only the plastics because, as can be seen from
the data in Table 3-4, there was no significant change in the weights of any of the metals with any
of the cleaners. The data in Figure 3-4 indicate that Teflon is the most stable of the plastics over
the seven-day exposure. It absorbed a small percent of MEK, but not the other cleaners. Percent
change for other cleaners are very close to the limits of detection for the method. The Delrin®
absorbed the most cleaner for each of five cleaners and absorbed more MEK than any of the other
cleaners. The acetal also absorbed a small percentage of cleaner, although not to the degree
shown by the Delrin®. The data indicate that nylon lost a small weight percentage upon seven-
day immersion to the five cleaners. Cleaner formulations L and N were chosen for further
evaluation because they showed the least variation of weight gain/loss for the four plastics.
3-14
-------
Table 3-4. Percent Weight Change of Materials Immersed 7 Days in Alternative
Cleaners
MATERIALS TESTED
CLEANERS
MEK
PC
L
H
N
T
Metals
Aluminum
-0.02
0.03
0.00
0.00
-0.01
-0.01
Brass
-0.01
0.00
-0.01
-0.01
-0.02
-0.02
Nickel
0.00
0.00
0.00
0.00
0.00
0.00
Stainless Steel
-0.01
0.00
-0.01
-0.01
-0.01
0.00
Plastics
Teflon®
0.11
-0.02
-0.04
-0.04 *
-0.04
-0.03
Delrin®
1.36
0.48
0.60
0.77
0.64
0.54
Acetal
1.02
0.29
0.32
0.49
0.43
0.36
Nylon®
0.13
-0.71
-0.13
-0.35
-0.19
-0.83
CONTROLS!
Metals
Aluminum
0.00
0.00
0.00
0.00
0.00
0.00
Brass
0.00
0.00
0.00
0.00
0.00
0.00
Nickel
0.00
0.00
0.00
0,00
0.00
0.00
Stainless Steel
0.00
0.00
0.00
0.00
0.00
0.00
Plastics
Teflon®
0.00
0.00
0.00
0.00
0.00
0.00
Delrin®
-0.04
-0.04
0.03
-0.01
-0.01
0.00
Acetal
-0.02
-0.02
0.00
0.00
0.00
0.00
Nylon®
-0.07
-0.07
0.05
-0.02
-0.02
0.01
f Controls not exposed to solvents
3-15
-------
1.75 -
1.25 -
0.75 --
MEK
PC
L
Solvent
H
N
Acetal * Delrin Nylon
Teflon
Figurh 3-4. Gravimetric Results of Materials Compatibility Tests
3-16
-------
3.2.3 Paint Removal Efficiency
Cleaners L (40% propylene carbonate/60% benzyl alcohol) and N (10% propylene
carbonate/19.2% dibasic esters/10.8% y-butyrolactone/60% benzyl alcohol), selected from the
material compatibility study, were evaluated further for paint removal efficiency. MEK was used
as a baseline for comparison.
In this test, cleaner was pumped through tubes that had been contaminated with the
coatings in such a way as to simulate the way the hoses for the paint spray equipment are flushed
at the MCLB. A small section of glass tubing was connected between two sections of hose to
allow visual examination and gravimetric analysis of the paint removal by the cleaners. In this set
of tests, paint was not allowed to cure before removal to more closely reproduce actual cleaning
conditions at the MCLB.
The 3 in. long glass tubes had an inside diameter of 0.220 in. and an outside diameter of
0.375 in. All the tubes were precleaned and weighed to the nearest 0.01 mg to obtain The
paints were stirred before use. For the dual-component CARC and epoxy primer, the two
components were mixed according to the manufacturer's instructions. Paint was applied to the
interior of each glass tube using a cotton swab. The tubes were reweighed to the nearest 0.01 mg
to obtain the coated weight, Wcoated. The tubes were contaminated, reweighed, and cleaned one at
a time to minimize paint curing. To clean, approximately 200 ml of the appropriate cleaner was
flushed through each glass tube from a 50 psig pressure pot. The tubes were dried overnight and
reweighed to the nearest 0.01 mg to obtain the cleaned weight, Wcleane<1. Each paint was tested
with three replicates and a control for each cleaner. The raw data are included in Appendix 3-4.
The average paint removal efficiency was calculated as follows, for n=3:
Average Paint Removal Efficiency = ^a'nt Removed * jqO
Paint Applied
n
y
^cleaned( ^
2Lmt
1 = 1
coated i
- W }
initial. '
n
3-17
-------
The averaged data are summarized in Table 3-5, For each of the four coatings, the
cleaners are listed in order of decreasing effectiveness. The same data are shown graphically in
Figure 3-5. Overall cleaner performance was determined by averaging all samples for a given
cleaner. Both of the cleaners were significantly better than MEK at removing the epoxy primer
(white). Formulation L was nearly as effective at removing the dual-compOnent CARC (green) as
MEK. Neither of the two cleaners was as good at removing the single-component CARC (tan) or
the undercoating (black) as MEK. Further discussions with the MCLB revealed that the black
undercoating is thinned before applying and sometimes heated to reduce its viscosity. These
factors would significantly effect its ability to be cleaned.
Although MEK is the current standard at the MCLB, it did not successfully remove all
four coatings as expected. The MEK removed more of the tan CARC than of the other three
coatings, but a residue was still visible on the glass tubes. Based upon visual examination, none of
the three cleaners removed any noticeable amount of the black undercoating. The MEK did not
remove any noticeable amount of the white epoxy primer; the two cleaners, L and N, removed
most of the primer and left a faint residue behind.
Based on this data, formulation L, the blend of propylene carbonate and benzyl alcohol,
was chosen for demonstration at the MCLB. The formulation is a custom-made blend with no
commercial name. To avoid confusion, it will be referred to through the rest of this report as
PC/BA (propylene carbonate/benzyl alcohol) rather than L.
3-18
-------
Table 3-5. Removal of Coatings from Glass Tubes
Coating
•
Average Cleaning Efficiency
(%)
Standard Deviation
m
Black underrating
MEK
76.49
16.76
N
55.54
3.08
L
53.39
17.24
Green CARC
MEK
99.58
0.7
L
97.86
1.17
N
96.76
1.55
Tan CARC
MEK
99.97
0.02
L | 82.21
8.56
N
77.23
15.18
White primer
L
95.82
1.62
N
90.23
5.3
MEK
71.34
20.5
~Data are intentionally listed in order of decreasing cleaning efficiency for each coating
3-19
-------
I
*s
i
a
110.00
100.00
90.00
80.00
70.00
60.00
1 50.00
| 40.00
Sjj 30.00
S3
2 20.00
10.00
MEK
¦mek; ^ ^
f
N
iMEX
|N
0.00
^4
a
ca
s
m
%
S
c
-------
3.3.0
ON-SITE DEMONSTRATION OF ALTERNATIVE PAINT EQUIPMENT
CLEANER PROPYLENE CARBONATE/BENZYL ALCOHOL
3.3.1 Current Process
More than 60,000 lbs. of MEK was purchased by the MCLB in 1992 for cleaning paint
application equipment. Equipment is cleaned at the end of each shift and between color changes.
Previously used solvent is flushed through the equipment following paint application to clean the
hoses and guns of remaining paint as a prewash. The equipment is flushed with prewash solvent
until no paint is visible in the wash effluent. The prewash is collected in a hazardous waste
container which is later emptied into a hazardous waste barrel. The paint pickup tube then is
placed in a container of fresh solvent for a final wash. Fresh solvent is flushed through the hoses
and guns and collected in the prewash bucket. The pump filter is then backfiushed with fresh
solvent and the waste disposed of in the hazardous waste container. Finally, fresh solvent is
recirculated through the system for several minutes.
In discussions with the area's Leadermen, it was learned that the cleaning process takes
two operators using five gallons of MEK about fifteen to twenty minutes per paint spray system
to clean the equipment. Data collected for verification indicate less MEK is actually used and the
cleanup process takes less time.
3.3.2 Setup of Demonstration
Before the official on-site demonstration phase was started, a meeting was held with the
MCLB painters to describe the test results and new cleaner, and answer any questions. The
painters' main concerns were that the new cleaner would not remove the paint as well as MEK or
that it would work so well that it would cause large chunks of paint to be released from the hoses
that would plug the pumps and cause them to seize. Preliminary tests were conducted at the
MCLB with the cooperation of the painters. The painters first sprayed a sample of the cleaner
through the pumps to check that the cleaner could withstand the high pressures with no adverse
reactions.
Next, three pumps were cleaned prior to the quantified portion of the demonstration. The
first pump was located in Building 2200. The pump, a Graco Senator, had been flushed with
3-21
-------
MEK and was considered clean by the operators. The area Leaderman placed a filter in line in
one of the hoses to see if the new cleaner would cause sloughing of chunks of paint. About five
gallons of PC/BA were continuously recirculated through the pump for about two hours. The
PC/BA removed additional paint from the equipment, but there were no large chunks caught in
the filter that might have caused the pump to seize up. Some paint residue was left on the main
filter, and the in-line filters were clean. A catch sample taken from the bucket showed small green
particles in suspension, which later settled. The cleaner wanned slightly when recirculated for
over an hour and heated the pump slightly as well. The area Leaderman did not consider this a
problem as the cleaning process generally takes less than half an hour. Air pressure of 45 psi was
required to circulate the cleaner at the beginning of the test. Required air pressure increased to 60
psi after half an hour. At the end of the test, only 40 psi was required. The painters were pleased
that the new cleaner was able to remove paint left behind by the MEK and that it broke down the
old paint residue into small pieces that did not seize the pumps.
The second pump cleaned, also a Graco Senator, was located in Building 2222. It had
recently been torn down, thoroughly cleaned, and rebuilt. The spray system was used for a single
shift and then cleaned with PC/BA. The cleaning procedure was the same as that for cleaning
with MEK. The dirty PC/BA from the first pump served as the prewash for the second pump. A
final wash of fresh PC/BA was recirculated through the lines. Again, the cleaner removed the
paint from the pump satisfactorily and did not cause any large clumps of paint to be released that
might cause the pump to seize.
A third pump, a Graco 5-gallon model used only for spraying primer, was also cleaned
with PC/BA. The cleaner dissolved the paint and flushed it completely. A catch sample taken
from the waste container showed no settling or paint flakes; instead, the white primer appeared to
dissolve completely.
The painters and the project's engineers were pleased with the results of these tests and
proceeded to the full-scale demonstration of replacing MEK with PC/BA for cleaning the paint
spray equipment.
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3.3.3 Demonstration of Alternative Cleaner
The paint monitoring system used for the paint application demonstration was used to
monitor the amount of cleaner and paint flushed through the system. The WI-130 Rate of Flow
Monitor System is designed to monitor and display the rate of flow of paint and the amount of
paint used from a scale using a Weigh-Tronix WI-130 indicator display. Accessories to the
system included a tape printer, a remote Tare and Print push-button station, and a multiport
controller. The remote displays used for the paint application demonstration were not used for
this demonstration. The system was used for analysis purposes only and is not required to
implement the new cleaner. The equipment used is listed in Table 3-6 and was purchased from J.
A. King & Company in Greensboro, NC,
Table 3-6. Equipment Used to Monitor Cleaning of Paint Application Equipment
ITEM
MODEL NO. •
OTY.
Base scale
Weigh Tronix BSA02020-200
2
Programmable controller
Weigh-Tronix Model WI-130 with;
Extended memory
2-base interface
Opto-22 Modules (2)
Special Software
Interface cable
Multi-port controller
1
Tape printer
Weigh-Tronix Motel WP-233
2
Remote tare and print push-button station
NA
I
Keyboard
Weigh-Tronix keyboard for WI-130
1
Interface cable to remote printer
NA
150 ft
25 lb. calibration weight
NA
2
The procedure for using the system is included in Appendix 3-5. The painters were
trained in the new procedure during a site visit November 27-30, 1995. Because the software
was designed for the paint application demonstration, the procedure for gathering cleaning data
was adapted to fit the existing software. Upon start-up, the WI-130 prompted the painter to enter
the following information:
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"Enter Vehicle ID Number",
"Enter Vehicle Code",
"Enter Coating Code",
"Enter Your ID Number",
"Enter Partner's ID Number",
"Enter Target Amount",
"Enter Pounds per Gallon for Coating",
"Enter Scale".
For each entry, the previous value was displayed which the painter could accept by simply
pressing or replace by entering a new value. To collect the data for the cleaning, the
vehicle ID and vehicle code were not relevant. Painters were instructed to accept the existing
entry. For coating code, painters were instructed to enter P for primer coatings and C for
CARCs. Painters were instructed to enter the shift for "Your ID Number" and identify the
cleaning solvent, either MEK or PC/BA, for "Partner's ID Number". There was no prescribed
target amount for cleaning, so painters accepted the existing entry. For pounds per gallon for
coating, painters entered the pounds per gallon of the cleaner, 6.71 for MEK or 9.18 for PC/BA.
This block of data, headed by the date and time, was printed whenever the painters pressed
.
Collecting data did not interfere with the painters' ability to clean the equipment. The
cleaning procedure is shown schematically in Figure 3-6. For the prewash, the painters placed the
hazardous waste container on the scale and pressed to zero the display. The painters
continued the prewash as normal, with the paint pickup tube in the prewash container. The
painters flushed the cleaner through the hoses and guns into the hazardous'waste container on the
scale until the cleaner was visibly free of paint. For the final wash, the painters switched the paint
pickup tube from the prewash bucket to the final wash bucket. Then they replaced the hazardous
waste container on the scale with the prewash bucket, and pressed . The filter wash used
fresh cleaner from the final wash bucket, but the waste was dumped into the hazardous waste
container, not the prewash bucket. Some painters included the filter wash in the prewash by
simply switching the paint pickup tube from the prewash bucket to the final wash and leaving the
hazardous waste container on the scale. Other painters took the extra step of switching the
prewash bucket with the hazardous waste container again and pressing . Either was
acceptable since it was the total amount used that was recorded. Painters printed the
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data block before and after the prewash, the final wash, and the filter wash, totaling the amount of
cleaner flushed through the system.
All data were collected from one booth in Building 2222. Both tan and green CARC are
sprayed in this booth. However, during the course of data collection, only green CARC was
used. The painters also continued to use PC/BA to clean the white epoxy primer from the Graco
5-gallon pumps.
The amount of PC/BA used to flush the Graco Senator clean of green CARC is shown in
Table 3-7. The operators consider the Senator to be clean when no paint is visible in the wash
solvent as it comes out of the spray gun. Because the printer included the date and time with each
data block, it was also possible to determine how long the new cleaner took to flush the
equipment. Some painters included the filter wash as part of the prewash, as described earlier.
This is indicated by an asterisk in the filter wash column in Table 3-7. Cleaning data for the
training sessions is included in averaging the amount of cleaner used to flush the equipment clean.
However, the time for the training sessions is not included in the average for process time. The
training sessions took longer than the normal cleaning procedure because time was taken to
answer questions as they arose.
Although data were not collected for the Graco 5-gallon pump used only for spraying
primer, the operators have used the blend to clean it since November 14, 1995.
The amount of MEK used to flush the Graco Senator clean of green CARC is shown in
Table 3-8. As can be seen from the table, these data were collected after the completion of the
demonstration. Although area Leadermen reported that the cleaning process takes two operators
using five gallons of MEK about fifteen to twenty minutes per paint spray system to clean the
equipment, data collected for verification indicate less MEK is actually used and the cleanup
process takes less time. Because data for MEK usage were collected after the PC/BA
demonstration, it is possible that the operators had gotten used to using less solvent and less time
to clean the pumps. For this reason, the figures in Table 3-8 may be artificially low.
The values in Tables 3-7 and 3-8 form the basis of assumptions regarding usage in the
economic analysis.
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SPRAY GUN
PRINTER
DISPLAY
PUMP
SCALE
SPRAY GUN
Iqp—
PRINTER DISPLAY
Final wash
b. For final wash, paint pickup tube is placed in final wash bucket of fresh cleaner. Prewash bucket is on scale.
SPRAY GUN
PRINTER
PUMP
Final wash
©
Prewash
g. For Alter wash, paint pickup tube is placed in final wash bucket of fresh cleaner. Hazardous waste container is on scale.
figure 3-6. Schematic for Monitoring Cleaning of Paint Equipment
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Table 3-7. Volume and Time to Clean Equipment with PC/BA
DATE
START
STOP
PREWASH
(gallons)
FINAL
(gallons)
FILTER
(gallons)
TOTAL
(gallons)
ELAPSED TIME
(h:mm:ss)
11/28/95
3:21:03 PM
3:30:13 PM
0.90
0.65
*
1.55
0:09:10**
11/29/95
3:17:17 PM
3:26:38 PM
1.22
0,34
0.30
1.86
0:09:21**
11/30/95
3:26:08 PM
3:30:24 PM
1.45
0.27
*
1.72
0:04:16
12/05/95
3:33:31 PM
3:44:35 PM
0.86
1.16
*
2.02
0:11:04
12/13/95
3:23:51 PM
3:28:54 PM
1.00
0.62
0.29
1.91
0:05:03
12/14/95
10:26:35 AM
10:30:33 AM
1.21
0.57
2.75
0:03:58
12/14/95
3:25:43 PM
3:34:23 PM
0.83
0.59
0,56
1.98
0:08:40
12/15/95
11:32:28 AM
11:35:22 AM
1.24
0.69
0.72
2.65
0:02:54
AVERAGE:
2.06
0:05:59
STANDARD DEVIATION:
0.43
0:03:11
» Indicates filter wash was included with prewash
** Not included in average and standard deviation because the operators stopped to ask questions
Table 3-8. Volume and Time to Clean Equipment wrra MEK
DATE
START
STOP
PREWASH
(gallons)
FINAL
(gallons)
FILTER
(gallons)
TOTAL
(gallons)
ELAPSED TIME
(h:mm;ss)
12/19/95
3:23:09 PM
3:36:53 PM
1.19
0.34
0.95
2.47
0:13:44
^ 12/20/95
3:18:59 PM
3:24:11 PM
1.15
0.53
1.17
2.85
0:05:12
12/21 /95
3:17:51 PM
3:23:49 PM
1.27
0.57
0.46
2.30
0:05:58
03/06/96
4:34:35 PM
4:38:56 PM
1.75
0.98
0.48
3.21
0:04:21
03/06/96
9:22:07 AM
9:26:07 AM
1.34
0.60
0.50
2.44
0:04:00
03/06/96
1:06:22 PM
1:11:51PM
1.41
0.72
0.52
2.65
0:05:29
03/07/96
4:27:56 PM
4:34:24 PM
1.60
1.41
0.57
3.57
0:06:28
AVERAGE:
2.79
0:06:27
STANDARD DEVIATION:
0.46
0:03:19
Feedback from the painters was generally positive. The painters reported that the new
cleaner did not have an objectionable odor like MEK. They believed it removed the white primer
from the Graco 5-gallon pumps much more effectively than MEK. They also believed that the
"oily" nature of the PC/BA blend would reduce the binding that occurs when pumps are cleaned
with MEK. The Senators still must be torn down approximately every two weeks; as paint builds
up between the seals and packing, it causes the pump to seize up. However, the new cleaner was
just as effective at cleaning the components of the torn-down pump as MEK. As of
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mid-March 1996, the MCLB reported that the Graco pump for primer has not required
maintenance.
On the negative side, the operators were concerned about unknown health risks. They
also did not like the fact that they cannot thin the CARCs with it. Material Safety Data Sheets
(MSDSs) for the individual components of the blend were provided to the MCLB Safety and
Health. These MSDSs were more detailed than the MSDS developed for the blend. (The
MSDSs are included in Appendix 3-6; Safety issues are discussed in Section 3.5.3) The blend is
not intended to be used as a thinning agent; it is to be used for cleaning only. The MCLB uses
only approved thinning agents with CARC paints.
3.3.4 Regulations Affecting Alternative Cleaner
Replacing MEK with PC/BA decreases the burden of tracking and reporting for the
MCLB. MEK is listed as a Hazardous Air Pollutant (HAP) under the Clean Air Act (CAA) Title
III, section 112. Neither benzyl alcohol or propylene carbonate are classified as HAPs. Other
regulations impacting the use of MEK are summarized in Table 3-9. Benzyl alcohol and
propylene carbonate are not subject to these regulations.
Table 3 -9. Regulations Impacting the Use of MEK and PC/BA
CAS
Chemical Name
Hazardous Substances
CERCLA
Toxic Chemical
SARA
RCRA
Code
CAA, Title 01
Section 112
78-93-3
Methyl ethyl ketone
5,000 lbs.
313
U159
yes
100-51-6
Benzyl alcohol
Not listed
Not listed
Not listed
no
108-32-7
Propylene carbonate
Not listed
Not listed
Not listed
no
MEK is subject to reporting requirements under Title III of the Superfund Amendments
and Reauthorization Act (SARA). Releases of CERCLA hazardous substances, in quantities
equal or greater than their reportable quantity, are subject to reporting to the National Response
Center under CERCLA. Such releases are also subject to state and local reporting under section
304 of SARA Title III. MEK is classified as a CERCLA hazardous substance; its reportable
quantity is 5,000 lbs. Neither benzyl alcohol nor propylene carbonate are classified as CERCLA
hazardous substances.
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MEK is also classified as a toxic chemical under SARA Title III, section 313. Emissions,
transfers, and waste management data of MEK must be reported annually as part of the
community right-to-know provisions of SARA Title III. Neither benzyl alcohol nor propylene
carbonate are classified reportable under SARA Title HI, section 313.
Because MEK is flammable, it is classified as a RCRA hazardous waste. The hazardous
waste RCRA code for MEK is indicated in Table 3-9. Neither benzyl alcohol nor propylene
carbonate are subject to RCRA. Because the paint used at the MCLB is not RCRA-regulated
either, the PC/BA-paint waste stream is not RCRA-regulated.
3.4.0 QUALITY ASSURANCE
3.4.1 Alternatives Evaluation Phase
Calibration and Standardization of Laboratory Balance; Evaluation of the alternative
cleaners after the initial qualitative screening relied on data from a precision balance at the
laboratory (Mettler Model AT261, Serial Number N71359). This balance is calibrated yearly by
an outside service. The digital output of the balance is readable to the nearest 0.01 mg. The
balance was leveled and zeroed before each weighing. Calibration was checked daily with a
1000.00 mg weight prior weighing samples.
Materials Compatibility: Materials coupons were weighed to the nearest 0.01 mg.
Control coupons were weighed along with the experimental coupons used to assess the cleaners.
A summary of weight changes for test coupons and control coupons is provided in Table 3-4.
Control coupons were never wetted by cleaner. After weighing they were immediately returned
to their container. For the metals and Teflon®, which show virtually no effects due to cleaner,
the very small variability of the controls is comparable to the variability of the coupons. Control
coupons for Delrin®, acetal, and Nylon® showed much greater weight changes than did the
metals and Teflon®. Even for the plastics, however, the controls' weight changes were less than
the weight changes for the cleaner-treated coupons. Changes in humidity could have contributed
to some weight variability for the controls.
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Paint Removal Efficiency: Table 3-5, which gave the removal effectiveness for several
combinations of coatings and cleaners, shows individual standard deviations of up to about 20%.
Assuming an average paint weight of approximately 8000 mg, a standard deviation of 20%
corresponds to 1600 mg, which is much larger than the estimated error intrinsic in the balance.
Most of the observed variability must be ascribed to real variations from a variety of causes.
Controls were used during the removal efficiency assessments (see Appendix 3-4). These
controls showed weight gains (no losses) between 0.01 and 0.33 mg. The controls' weight
variations were negligible. Averaged over four different coatings, MEK has a slightly higher
cleaning efficiency; however the differences between the cleaning efficiencies for the three
cleaners reported in Table 3-5 are not statistically significant.
3.4.2 On-Site Demonstration
The primary Quality Assurance (QA) goal for the on-site portion of this project was to
estimate and control the net error in the estimates of solvent usage for MEK and the MEK
substitute. These estimates were derived from weighings taken with the Weigh-Tronix Flow
Monitoring System model Wf-130 that was installed at one paint booth. The chief sources of
error, uncertainty, and variability included the following:
• errors in the balance - zero offset, nonlinearity, and instrument noise,
• ambient vibration and noise, and
• variability of amount paint used between cleanings.
The balance was set up at the site according to the manufacturer's specifications. This
included assuring that the feet had solid support (concrete floor) and that the balance transducer
was level. The accuracy and linearity of the electronic balance were assessed using a 25-pound
weight supplied by the manufacturer. The accuracy and linearity of the balance were checked
following setup of the scales at the MCLB by using the 25 lb. weight that had been independently
checked at RTI's laboratory facilities. Accuracy and linearity were checked daily during site visits
by the project's engineers throughout the demonstration period. The balance, as installed, was
accurate within the resolution of the scale, and the linearity was also good.
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Random noise experienced by the balance was evaluated in another task under this project.
Approximately one hour's worth of data was acquired at one minute intervals from the balance
while it was unused and there was no activity in the area. This provided an estimate of the scatter
in data that may be attributed to the combined sources of noise affecting the balance. These
included electrical and instrumental noise, as well as the effects of wind and ambient vibrations.
The noise level was found to be approximately 0.02 gallons. This amount of noise is very small
compared with the amount of cleaner typically used in a single cleaning.
The average amount of PC/BA used for six cleanings performed by the MCLB painters
during the demonstration was 2.06±0.43 gal. The uncertainty in this cleaner usage estimate is
clearly dominated by operational variability rather than by instrumental accuracy and precision.
Prior to the start of the demonstration, area Leadermen reported that the cleaning process
takes two operators about fifteen to twenty minutes and about 5 gallons of MEK per paint spray
system. The average amount of MEK used for six cleanings performed by the MCLB painters
was 2.79+0,46 gallons; the time was about 6.5 minutes. The measured amounts were
approximately half the estimated amounts. It is unclear, and cannot be determined, whether the
Leadermen overestimated how much cleaner is actually used or whether the operators became
used to using less cleaner over the course of the demonstration, resulting in lower figures. These
two factors affect the accuracy of the usage numbers by as much as 50%.
3.5.0 IMPLEMENTATION PLAN
3.5.1 Equipment
Since the replacement cleaner was used as a direct substitute, capital investment required
was minimal. A hand pump to fit on the 55-gallon drum was purchased. The pump was the same
type as other hand pumps used at the MCLB. If available, one of these other hand pumps could
have been used. Painters can pump from the drum into smaller 5-gallon buckets if desired.
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3.5.2 Materials
The cleaner blend used in this demonstration is not available as a single commercial
product. However, the components, propylene carbonate and benzyl alcohol, are commercially
available. The product was ordered as a custom-made blend from a chemical products company,
Eldorado Chemical Company, Inc., in San Antonio, TX, The company has assigned the product
number ES-120 to this blend for identification purposes. It is likely that arrangements could be
made with other vendors to blend the material. A list of chemical suppliers follows in Table 3-10.
The components, propylene carbonate and benzyl alcohol, can be purchased from other
sources. Propylene carbonate typically costs about $0.90/lb and benzyl alcohol is normally
$1.5()/Ib. At the time of demonstration, availability of benzyl alcohol was limited and the price
was closer to $2.00/lb. No special expertise is required for blending. The formulation is a simple
ratio by weight. The components may purchased separately and blended on-site.
3.5.3 Safety
The Material Safety Data Sheets for the components, propylene carbonate and benzyl
alcohol, have been included in Appendix 3-6. These MSDSs are more detailed than the MSDS
for the blend itself.
Table 3-10. Chemical Suppliers for PC/BA
Alchem
5360 Tulane Drive
Atlanta, GA 30336
404-696-9202
Baychem, Inc.
3200 Moon Station Road
Kennesaw, GA 30144
404-429-1405
American Industrial Chemical
1819 South Cobb Industrial Boulevard
Smyrna, GA 30082
770-434-8300
Eldorado Chemical Company, Inc
PO Box 34837
San Antonio, TX 78265-4837
210-653-2060
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The cleaner is less toxic and has a much lower vapor pressure than MEK and so poses less
of an inhalation hazard than MEK. However, proper ventilation is still necessary to prevent
buildup of vapors. Also, lower vapor pressure means it will not evaporate quickly if accidentally
splashed on skin. Gloves should be worn when handling the cleaner to prevent skin contact.
Benzyl alcohol is a severe eye irritant. Safety glasses are necessary to prevent eye contact with
the cleaner. Operators should also wash their hands before smoking or eating.
The MSDS for benzyl alcohol warns against mixing with isocyanates. Some of the
CARCs contain isocyanates. This warning does not refer to any formation of hazardous
compounds. The alcohol will affect the curing properties of the paint. Polyisocyanates consist of
a polyol catalyzed by an isocyanate. Polyols have two or more OH (hydroxyl) functional groups,
which serve as crosslinking sites, on the chain. The more functional groups available on the chain,
the higher the crosslinking density and the better the chemical resistance. An alcohol such as
benzyl alcohol, with only a single OH functional group, would act as a chain stopper because it
has only one crosslinking site. A high proportion of alcohol would prevent the coating from fully
crosslinking and achieving a full cure. For cleaning purposes, this is an advantage. However, the
painters must discharge paint from the gun to flush the cleaner completely before painting
vehicles.
3.5.4 Economic Analysis
One aspect of changing process operations for pollution prevention purposes is the effect
on capital and annual cost. Pollution prevention changes are more likely to be embraced if these
costs stay the same or decrease. The following sections provide measures of capital and annual
costs for replacing MEK with PC/BA.
The methodology for estimating costs is taken from the EPA methods described in the
OAQPS Control Cost Manual1, which allows a convenient means of comparing different
processes based on their annualized costs. Where actual costs are not known, factors applied to
base equipment costs are used to estimate the remaining costs. These factors have been
developed from a wide variety of sources associated with pollution control systems. The method
provides a study estimate, which is intended to give a cost estimate within an accuracy range of
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±30% of the actual cost when all the information affecting the costs is reasonable well known.
This accuracy range is typical for EPA's estimates of pollution control systems when assessing
cost impacts on existing or model facilities. Greater accuracy can be obtained with budget
authorization estimates (±20%), definitive estimates (±10%), or contractor's estimates (±5%),
Improved accuracy of the estimate is obtained only by improving the detailed knowledge of items
that make up the estimate. In the present case, the firm costs obtained for most of the capital
items could lead to a contractor's estimate if no assumptions were required for the remaining
costs. However, unit costs, rates, and consumptions (listed in section 3.5.4.3) are not known with
sufficient accuracy to go beyond a study estimate.
The estimates for cleaner substitution costing have only a few elements that must be
considered.
3.5,4,1 OAQPS Control Cost Manual
Analysis of the costs associated with the pollution prevention project is performed such
that comparisons can readily be made between competing processes. A consistent format for
costing is used so that comparisons are valid. To be compatible with EPA usage, the format in
this report is taken from the OAQPS Control Cost Manual as mentioned above. The
methodology used in the manual divides costs into two major categories, capital costs and annual
costs, as described below. For the economic analysis to be meaningful, it must include all
elements associated with implementation of new technologies. An exception is the case in which
no new capital costs are incurred. Capital and annual costs can be further subdivided into the
categories shown below:
• Site preparation and buildings
• Equipment
• Emission controls
• Materials
• Energy and utility requirements
• Labor requirements, including training
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• Waste disposal
• Special transportation costs (hazardous materials)
• Recovery credits
• Overheads and capital recovery
• Accommodation costs (for changes in use or behavior forced by the new
technology).
Treatment of each of the cost elements is briefly described below. As used in the OAQPS
Control Cost Manual, the first three items are capital costs, while the remainder are annual costs.
After all the cost elements are collected, they are presented as tables of capital and annual
costs.
Capital Costs
Capital cost items are those requiring relatively large expenditures for land, buildings, and
equipment expected to have a lifetime longer than a year (usually many years). Specific items are
collected in the following paragraphs. For those cases in which explicit costs are not available,
the factor method is used to estimate reasonable costs. Factors (as multipliers of the purchased
equipment cost) are available in costing manuals or can be based on engineering judgement.
Site Preparation and Buildings: No site preparation (land clearing and leveling) or new
buildings were required for the pollution prevention project.
Equipment and Emission Controls: Equipment costs include either new purchases
(including add-ons) or modifications for existing items. Costs include installation. These costs
are taken from invoices, vendor quotes, or other records where available, or are estimated from
cost manual data.
Indirect Costs: Associated with purchase and installation of equipment are the indirect
costs that include engineering, construction and field expense, contractor fees, start-up,
performance tests, and contingencies. Not all of these items are required.
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Annual Costs
Annual costs include expenditures for operating and maintenance labor and materials,
utilities, and waste disposal. Indirect costs include overheads, administrative charges, property
taxes (where applicable), insurance, and capital recovery. With the exception of overheads, the
indirect annual costs are related to capital costs. The annual cost elements, are described in the
following paragraphs. The sum of the annual costs provides a total annual cost that is useful for
comparison with other systems or technologies.
Materials: Materials include raw materials for operation, and maintenance materials for
repairs and preventive maintenance. Costs and usage rates for materials are obtained from MCLB
records, vendors, or estimates from MCLB or RTI project personnel.
Energy and Utility Requirements: Energy and utility usage rates are taken from MCLB
records, project data, or estimates for the equipment or process being analyzed. Included for this
project are electric power, steam, water, and compressed air.
Labor Requirements: As with materials, labor is divided into operating and maintenance
categories. Operator labor hours are estimated from project records or from observation by
project personnel. Maintenance labor hours are projected based on estimates of project
personnel. Labor hours are also required for supervision and for training.
Waste Transportation and Disposal: Waste disposal costs include'wastewater treatment,
solid waste disposal, and hazardous waste treatment or disposal. Transportation costs are
included in the waste disposal costs. Quantities are taken from MCLB records or are projected
from project data.
Recovery Credits: Recycling of spent cleaners may provide money to offset costs of
operation.
Overheads and Capital Recovery: General and administrative overheads, property tax,
and insurance are taken from information provided by MCLB or from estimates by project
personnel. Capital recovery charges are estimated from current EPA usage for interest rates;
equipment lifetimes are based on engineering judgement.
Accommodation Costs: Identifiable costs are included here that are associated with a
changeover to new technology.
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3.5.4.2
Obtaining Cost Elements
Capital Costs
Because the factor method is dependent on base equipment costs for its capital cost
accuracy, special care must be taken to record all of the individual items purchased. For the
present work, each required item is purchased through RTI's purchasing department. All RTI
purchases are posted on a computer operated accounting system that allows identification of each
item associated with the project.
Annual Costs
Annual cost items are largely dependent on the labor, utility, and materials costs
associated with operating a process and on recovery of capital. As with capital costs, accuracy of
the annualized cost estimate depends on the accuracy of the information collected for these cost
elements and also for the usage rates associated with the operating costs. Capital costs remain
important in estimating annualized costs because most of the costs and the capital recovery cost
depend on purchased equipment costs. For the present project, unavailability of some unit costs
and usage rates may affect the accuracy (and the conclusions) of the economic analysis.
3.5.4.3 Unit Costs, Rates, and Assumptions for Economic Analysis
Unit costs and Rates Used Throughout Economic Analysis
The following unit costs and rates were used throughout the economic analysis. Sources
for unit costs and rates are cited.
• Operating labor costs are $16.52/hr, taken and updated from the OAQPS Cost
Control Manual, pp. 7-43, April 1991.
• Maintenance labor costs are $18.17/hr, taken and updated from the OAQPS Cost
Control Manual, pp. 7-43, April 1991.
• Supervisory labor costs are 115% of operating labor costs, taken from the OAQPS
Cost Control Manual, pp. 7-43, April 1991.
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• Training costs are $33.04/hr based on twice the operating labor rate.
• Waste disposal costs for low-end wastes include $0,35/lb for transportation and
$0.80/lb for disposal, based on interpolation from MCLB estimate.
• Waste disposal costs for high-end wastes include $0.35/Ib for transportation and
$ 1.80/lb for disposal, based on interpolation from MCLB estimate.
• Electricity costs $0.0709/kWh, cited in Chemical Engineering, January 1995.
• Compressed air costs $0.19/1,000 scfm from example problem in OAQPS Cost
Control Manual, pp. 5-49 (April 1991). Updated with Chemical Engineering
(CE) cost index.
• MEK costs $3.88/gal based on MCLB records for early 1995.
• The replacement cleaner PC/BA costs $ 12,60/gaI based on the prices of the two
components and assuming the MCLB blends the cleaner on-site.
• Permit charge of S25/ton for air emissions is not required, based on MCLB
information.
Assumptions Used for PC/BA Cleaning
The following assumptions were used for cleaning with PC/BA.
• No new capital costs are incurred for switching to PC/BA.
• Actual time for cleaning is based on 0.10 hrs/cleaning x 1 cleaning/day x 2
operators/booth x 4 booths.
• Usage is 2.0 gallons PC/BA/cleaning.
• Maintenance hours are primarily for pumps; 0.5 hr/pump/month for 4 booths.
• Air consumption is 60% of the amount required for MEK based on shorter
cleaning time.
• Waste disposal is based on 95% of the PC/BA going to disposal and 5 percent to
evaporation. Low-end disposal charge applies.
Assumptions Used for Cleaning with MEK
The following assumptions were used for cleaning with MEK.
3-38
-------
• No new capital costs are incurred for using MEK.
• Time for cleaning is based on 0.15 hrs/cleaning x 1 cleaning/day x 2
operators/booth x 4 booths, based on observation of area Leadermen.
• Annual usage based on average of neat MEK purchased over 3-year period.
• Maintenance hours are primarily for pumps; 1.0 hr/pump/month for 4 booths,
• Power usage is estimated at 0.4 kW for miscellaneous electrical loads.
• Air consumption is based on 22 scfm/gun x 2 guns/booth x 3.4 min/cleaning [when
gun has air going through it] x 1 cleaning/day x 4 booths.
• Waste disposal is based on 25 percent of the MEK going to disposal and 75
percent to evaporation. High-end disposal charge applies.
3.5.4.4 Solvent Substitution
Results of Costing for Solvent Substitution
Table 3-11 shows the estimated annualized costs for using PC/BA as a replacement
cleaning solvent for MEK. Because this is a direct substitution of one solvent for another, no
capital costs are shown. The total amount is about $97,094/yr with the top three elements being
the cost of the solvent, labor hours for using the solvent (including overheads), and disposal costs.
3-39
-------
Table 3-11. Annualized Cost Analysis of Cleaning with PC/BA
Direct Annual Costs, DC
Operating Labor
Operator ([0.8 hours/day]*[260 days/year]*($16.52/hour]) $3,436
Supervisor (15% of operator) $515
Training ([4 hours/year/employee]*[$33.04/hour}*[32 employees]) $4,229
Operating Materials
PC/BA ([$12.60/galfan]*{4,160 gal/year]) $52,416
Maintenance
Labor ([0,0125 hours/day]*[260days/year]*[$18.17/hour]) $59
Materia] (Equal to Maintenance LaborJ $59
Utilities
Electricity ([3.2 kWj*[$0.071/kWhour[*[23.3 hours/year]) $5
Compressed air ([10560 scjm/hour]*[$0,19/1000 scfmj*[23.3 hours/year]) $47
Waste Disposal ([13.63 tons/year]*f$2.300/ton J) $31,349
Total Direct Cost, DC $92,115
Indirect Annual Costs, IC
Overhead (60% of sum of labor + maintenance materials) $4,979
Administrative charges TCI * 0.02 $0
Property taxes TCI * 0.01 $0
Insurance TCI * 0.01 $0
Capital recovery CRF*TCI (CRF=0.1424) $0
Total Annual Cost, TAC (TAC = DC + IC) $97,094
3-40
-------
Comparison with Current Solvent
Table 3-12 shows the estimated annualized costs for using MEK as a cleaning solvent.
Total annualized cost is about $93,947 or about 97 percent of the cost for PC/BA. The major
costs elements are for the solvent and its disposal.
PC/BA is a less polluting cleaner, is as effective at cleaning, and reduces maintenance on
pumps. However, because it costs over 3 times that of MEK, the annualized cost for PC/BA is
higher than that of MEK. Returning the waste cleaner to the manufacturer for reclaiming, even at
zero credit, would reduce the annualized cost of using PC/BA below that of MEK. Buying the
PC/BA from a chemical supplier will cost almost 50% more than blending the cleaner on-site;
these savings have been figured into the cost estimate. More cost savings could be realized by
filtering and reusing the cleaner.
Other advantages of PC/BA are lower usage rate and lower disposal costs (lower
quantities and lower unit cost). Reduced time for cleaning may also be indicative of long-term
savings in equipment costs due to longer equipment life.
3-41
-------
Table 3-12. Annualized Cost Analysis of Cleaning with MEK
Direct Annual Costs, DC
Operating Labor
Operator ([1.2 hours/day]*[260 days/year]*[$16.52/hour]) $5,154
Supervisor (15% of operator) $773
Training ([4 hours/year/employee]*[$33.04/hour}*[32 employees]) $4,229
Operating Materials
MEK ([$3.88/gal] *[10,175 gal/year]) $39,479
Maintenance
Labor ([0.025 hours/day]*[260 days/yearj*[$18.17/hour]) • $118
Material (Equal to Maintenance Labor) $ 118
Utilities
Electricity ([3.2 kW] *[$0.071/kWhour] *[38,9 hoursfyear]) $9
Compressed air ([10560 scfin/hourj*[ $0.19/1000 scfm]*[38.9 hours/year]) $78
Waste Disposal (18.78 tom/yearl*[$4,300/tm1) $37,754
Total Direct Cost, DC $87,712
Indirect Annual Costs, IC
Overhead (60% of sum of labor + maintenance materials) $6,235
Administrative charges TCI * 0.02 $0
Property taxes TCI *0.01 $0
Insurance TCI *0.01 $0
Capital recovery CRF*TCI (CRF=0.1424} $0
Total Indirect Costs. IC $6.235
Total Annual Cost, TAC (TAG = DC + IC) $93,947
3-42
-------
3.5.4.5 Return on Investment and Payback Period for Cleaning Solvent Replacement
Return on investment (ROI) and payback period (PP) are two common measures for
estimating the profitability of a venture. Return on investment as used for this project is the
average yearly profit divided by total capital investment, expressed as a percentage. The average
yearly profit is taken as the difference in annualized cost between the existing process and its
intended pollution prevention replacement.
Payback period is the total capital investment divided by the sum of profit (as used above)
and depreciation of the pollution prevention equipment. For this project, the straight line
depreciation method is used with a 5 percent salvage value. Depreciation is total capital
investment minus salvage value, all divided by equipment life.
Because the replacement of one cleaning solvent with another requires no capital
investment, neither ROI or PP can be estimated. However, one may compare the total annualized
costs for the existing cleaner and for its pollution prevention replacement as given in the previous
section.
3.6.0 DISCUSSION OF OBJECTIVE
As discussed previously, the MCLB is required to reduce emissions from hazardous air
pollutants by 50% from 1992 levels. The MCLB provided a summary of their purchase history of
toxic materials for 19922. Table 3-13 shows the hazardous air pollutants from this list.
The MCLB has already replaced 1,1,1 -trichloroethane vapor degreasers with aqueous
parts washers. This change alone will reduce emissions from HAPs by 16%. By eliminating the
MEK used for cleaning purposes, the MCLB can further reduce emissions from HAPs another
21%. The MCLB has also replaced methylene chloride with n-methyl pyrrolidone for immersion
paint stripping, reducing emissions from HAPs an additional 11%. These three changes combined
result in a reduction of emissions of 48%.
Five of the chemicals listed in Table 3-13 are components in paints and coatings used at
the MCLB. The MCLB plans to replace solvent-borne CARCs with water-borne CARCs in 1996
to achieve over 50% reduction in emissions from HAPs.
3-43
-------
Table 3-13, Summary of Hazardous Air Pollutants Based on 1992 Purchase History
CONSTITUENT
LBS.
USE
1,1,1 -trichloroe thane
49,077
neat - degreaser
ethyl benzene
1,465
component - aircraft thinner
ethylene glycol
75,527
neat - antifreeze
methyl isobatyl ketone
613
component - paints
methyl ethyl ketone
89,787
63,810 lbs, neat for paint cleanup/remainder in paints
methylene chloride
33,700
component - paint stripper
toluene
18,533
component - paints
trivalent chromium
16,801
component - paints
xylene
16,600
component - paints
3.7.0 CONCLUSIONS
Based on this demonstration, the following conclusions may be drawn:
• PC/BA cleans green CARC from the pumps as well as MEK.
• PC/BA cleans epoxy primers from the pumps better than MEK.
• PC/BA removes additional paint from pumps previously cleaned with MEK.
• The inhalation hazard to workers is reduced with the use of PC/BA.
• The use of PC/BA neither increases or decreases downtime of the pumps used for
applying CARC.
• The use of PC/BA decreases downtime of the pumps used for applying primer.
• The use of PC/BA does not cause clumps of paint to form, which could cause the
pumps to seize.
• The raw material cost for the PC/BA blend is higher than for MEK. The higher
cost may be offset by recovery and reclamation of the PC/BA.
Other advantages of PC/BA for the MCLB are
• replacing MEK with PC/BA will reduce the HAP emissions at MCLB by 21%,
thus achieving over 40% of their overall goal with this one process change.
• PC/BA-paint waste generated at the MCLB is not RCRA regulated. (The waste
may be subject to RCRA regulations if the paint contains high concentrations of
metal pigments.)
3-44
-------
• PC/BA is not subject to SARA Title III reporting, and is not a HAP under the
CAA, Title III, section 112.
* PC/BA does not dry out the seals and packings of the pumps between maintenance
as did MEK.
3.8.0 RECOMMENDATIONS
The first recommendation is to extend the use of this cleaner to the other paint booths.
Also recommended is reclamation of the used cleaner to extract the benzyl alcohol, the more
expensive of the two components in the cleaner. MCLB has already taken steps in this direction
by sending a gallon sample of the used solvent to Eldorado Chemical. It is not cost effective to
reclaim the propylene carbonate.
Although MEK is used at the MCLB for both thinning and cleaning, the project's
objective was in demonstrating a pollution prevention alternative, in this case PC/BA, for cleaning
purposes only. Therefore, pursuing approval from the coatings manufacturer to thin with this
cleaner is not recommended since thinning with this cleaner will adversely affect the curing
properties of the coatings.
3.9.0 REFERENCES
1. OAQPS Control Cost Manual, EPA-450/3-90-006 (NTIS PB90-169954), January 1990.
2. Woodward, John. MCLB Albany, GA. Letter to Principal Director, Maintenance
Directorate, dated June 14, 1993.
3-45
-------
APPENDIX 3-1
Material Safety Data Sheets
for Coatings;
Page
Tan Chemical Agent Resistant Coating (CARC) 3-47
Green Chemical Agent Resistant Coating (CARC), Part A 3-51
Green Chemical Agent Resistant Coating (CARC), Part B 3-55
White Epoxy Primer, Part A 3-58
White Epoxy Primer, Part B 3-62
Black Undercoating 3-65
3-46
-------
..ATT * LAMBERT 316-733-1361
_odustriil Coating* Di*.
P.O.. .Box 2153 ;
B.M.I.S
Tht*t rating* •Hoeld N uiwf only
part of fully >«ptf«nttd H.N.I.S. progra
wlchita, KM "67201
!8o8g5?S<:J.Sr5K' » «,
CORPORATE CONTACT 716-873-6000 (M-F B AM-3 Ml CZ)
MATERIAL SAFETY DATA SHEET
SECTION X
t
PRODUCT CLASS iOVERNMUIT SUC. BAT
TRADE MAKE C0ATJN«,ALIPH.P0LYUR.TAN 666 * .
MANUFACTURER COOK I.D. 70S 111 8 7
DATE OP PREPARATION 6/07/95
33**6 MIL-C-S3039A AH 2
ssctxok zt - mtmrns xkorebiehxs
INGREDIENT
METHYL IJOBUTYL
KETONE
SOLVENT NAPTHA,HEAVY
AROMATIC
K-BUTU ACETATE
ACETATE ESTER
ALCOHOL
XYLENE
TOLUENE
1 BY CAB HO.
HOT
ALLOWABLE
EXPOSURE LEVEL
PPM MO/CU.K.
10
s
s
5
5
108-10-1 TLV-TWA
TLV-STEL
OSHA-PEL
OSHA-STEL
LFL 1
6*7*2-94-5
SO
n
100
n
20S
100
*10
300
0 UFL 8.0
NONE ESTABLISHED
123-86-4 TLV-TWA
TLV-STEL
OSHA-PEL
0SNA-STE|
150 710
200 950
150 710
200 950 „
UFL 7.6
108*19-32-5
NONE ESTABLISHED
1330-20-7 TLV-TWA 100 *3J
TLV-STEL 150 655
OSHA-PEL 100 *35
OSHA-STEL 150 655
LFL 1.0 UFL 7.
108-88-3 TLV-TWA SO 147
OSHA-PEL 100 375
OSHA-STEL 150 560
LFL 1.7 UFL 7.
SILICA, CRYSTALLINE-
QUARTZ
<
1
01
0
m
1
<*
0
1
"4
TLV-TWA
OSHA-PEL
0.1000
0.1000
SILICA, CRYSTALLINE-
CRISTOBAL1TE
10
1**64-46-1
TLV-TWA
OSHA-PEL
0.0500
0.0500
SILICA, AMORPHOUS-
D1ATOBACEOUS EARTH
5
68855-54-9
TLV-TWA
OSHA-PEL
10
6
SILICA, CRYSTALLINE
5
1*808-60-7
TLV-TWA
OSHA-PEL
0.1000
0.1000
TITANIUM DIOXIDE
10
13463-67-7
TLV-TWA
OSHA-PEL
10
10
IS0PH0R0NE
DIISOCrANATE
<
5
4098-71-9
TLV-TWA
OSHA-PEL
0.0050
O.OOSO
0.0*50
0.0200
DIBUTYL TIN
SILAURATE
<
1
77-58-7
TLV-TWA
OSHA-PEL
0.1000
0.1000
POLYMERIC HEXANETH-
YLENE DI1SOCYANATE
25
28182-81-2
MFR
1
SOLVENT NAPTKA ,
LIGHT AROMATIC
<
5
6*7*2-95-6
NONE ESTABLISHED
1,6 MEXANE METHYLENE
DIISOCYAHATE
<0.
100
822-06-0
TLV-TWA
NFR
O.OOSO
0.0050
0.0350
LFL - LOVER FLAMHABILITY LIMIT PERCENT
UFL - UPPER FLAMHABILITY LIMIT PERCENT
SKIN - SKIN ABSORPTION MUST BE CONSIDERED AS A
C-CEILI*«» ALLOW. EXPOSURE LEVEL SHOULD NOT BE *
MFR « MANUFACTURER RECOMMENDED EXPOSURE LIMIT
STCL > SHORT TERM EXPOSURE LIMIT
3 -
47
MPPCF
s;
SKIN
VP
HI Hq
30 DEC
16
10
SKIN X 22
20
SKIN
SKIN
SKIN
ROUTE Of
EXCEEDED
EXPOSURE
FOB ANY TIRE
PERIOD
-------
VAQS 2
4V3141 »7 PATE 6/07/>5
SECTIQW II r HAZARDOUS IKQREDIEKTfi; (COMTIMUBP) •
S ARA 113 • CHEMICAL IS SU8JECT TO REPORTING RE8UIREHENTS OF SECTION 313
or title in of s. * , r . a . id em nut $72
;(• sbctiok hi - health inforkatioh - :: - .
Brrzcis or short term overexposure
SWALLOWINO
Hay b• fatal If swallowed.
Can causa gii t rglntti t I ««( IrrltMfon, mmii, and yoaiting. Asgiretien of
smudlfj M^a I into lung aay ciuii cheaical pmuaonttti which can be fatal.
WARNING vapor and spray slit harifal. Overexposure sajr causa tuna dangt.
Hay causa lung Irritation and allaroti raapl ratory ruction. If foots aay
bi p«fiinint.
Nay causa respiratory tonii tIlaii on (potential for i I I org I c reaction).
Hay causa n o s a or throat Irritation, high concentrations a ay causa acuta
tontrol nervous ivitaa dtpritifon characterized b y headaches, <1ulntss,
nausta and confusion.
EYE
Nay causa severe aya irrltition.
SKIM
Liquid utirI a I aay b a absorbed through t h a skin in htrsful oiounti .
Prfaery skin irritant.
Hay causa skin iiaiIt111tton (allergic raactlon).
Hay causa severe skin irritation.
Jay causa severe skin i
BFPscrs or repeated oviriiposure
Repeated and prolonged occupational overexposure to crystelline silica aay
causa silicosis,- a progretitvily disabling lung disaaia.
Ovaraipotura to tylana aay causa injury to t h a li»ar, M dnayo f and
blood.
Tha 01H A Peraissible Exposure L 1 a i t for aaorphous silica is 20 Itppcf or
ftl« 80 as / R3
XS182
Repeated overexposure to toluene aay causa liver daaage.
Repeated exposure to dl 1 socyanates aay result in respiratory smsitiiation
in soae individuals. Respiratory sensitivity results in astnaa-like
syaptoas on subsequent exposure at concentrations even below tha Tiv.
^resisting respiratory conditions aay be aggravated by exposura to
crystalline silica.
Reports have associated prolonged and repeated occupational overexposure
to solvents with perasnent brain and nervous systei daaaga. Intentional
•isuse by deliberately concantrating and inhaling tha contents aay be
siGNirtaufT Laboratory data hits possible relevancs to soman health.
Titaniua dioxide IS NOT listed as a potential carcinogen by the National
Toxicology Prooraa, the International Agency for Research on Cancer, OIHA,
or A.C.S.i.H, Titaniua dioxide in a 24-aontn inhalation study with rats
revealed a significant increase in benign and Malignant lung tuaors in the
?r o u p exposed to 2S0ag/R3 respirabla T102 dust. At lower exposure levels,
his significant effect was net observed. The noraal clearance aachanisas
of the lungs aay have been overwfielaed at the ZSOag/HS exposura level, and
this aay have contributed to the tuaor foraation. These results aay not
ba directly relevant to the workplace where occupational exposure liaits
are observed. At the TIV the TiOZ aanufacturar concludes that there ft no
significant houro for a a n .
Toluene has been found to cause kidney, lung and spleen daaaga in labora-
tory aniaals.
Laboratory studies involving rats indicates that Methyl Isobutyl Ketone aay
dlooge the kidneys.
The International Agency for Research on Cancer considers crystalline
silica to have tiaited evidence of carcinogenicity in huaans and sufficient
evidence in eiperiae ntat aniaals 1 1>RC Croup 2 A ) .
SECTION IV - FIRSI AID AND EMERGENCY PROCEDURES
SWALLOW!MO
If swallovsd do not induce voaiting. Call poison control (entor, hospital
INHAlATIOlf * n c y r ° 0 ¦ ° r physician iaaediataly.
Reaove to fresh air iaaediataly. If breathing has stopped, give artifi-
cial respiration. Keep wara and quiet. Get aedical attention iaaediataly.
flush with large aaounts of water, lifting upper and lover lids occasional-
ly. Continue tor at least IS ainutes. Set aedical attention.
SKIM
Reaove contaaineted clothing, tlash affected area with soap and water.
Obtain aedical attention If irritation persists.
NOTES TO PHYSICIAN
Any treetaent that sight be required for overexposure should ba
directed at the control of s yaptoas and the clinical cond 1 t1o n a .
SECTION V - PHYSICAL DATA
BOILINO RANOB 210 D E G . f . I
VAPOR aottlff than air.
EVAPORATION RATI
Slower than diethyl ether.
HBIGBT LB./GAL. 10.S
SPECIFIC 6 RA V I T r 1.3
99 DEG . C . ) TO 419 »EG . F.<
% VOLATILE BT VOLUHS 4 9
VOC 3.50 lb/gnl lc« votar t lefts'
VOC 6.89 lb/grit mMM
215 6EG.C . >
4 2 0 g/I leu MKtCTC ALCULATEO
82 7 g/1 M3&SOB CALCULATED
3-48
-------
»n«» SSS8 ./8,/»
I > BBCTIOK V - ramciu. B«» (COmmUtD) .
VOC #«!&•¦ itportfd ear* ir« vtrlilM Ef UIN i
JMQ. C.) 760 ¦¦ >9
caportad bara art »ar IH.3 e; ASIM aathod D-3960
SECTIOH VI - riRE AND KXPLOSIOU DAT*.
NFPA FLAMMABILIT* CLASSIFICATION ftAHKAitt LIBUIft - CLAII ]g
FLASHPOINT *» Hi.*, C * •iS.C,! CAI.eyi.ATIP
EXTINGUISHING MEDIA
U • • (f M C I • * • ¦ M ri ti t 1 nga I ihir i (carbon di »« td« . all purpen dry cNi < '
e a I or alcohol f o a a ) designed to (itlnguls h f Uiiabl• liquid fires. Poly-
a•r foaa 1* preferred for large f 1 r e•.
UNUSUAL FIRE AND 8XPIX38IOK HAZARDS * j
Purlng eaergencv conditions, overexposure to decoapostion product* aajr
cause a health haiard. lyaptoas nr not be laaedletely apparent. Obtain
a e d I c a I attention.
WASHING 1 riAHXABlE.
SPECIAL FIRS FIQHTINO PROCEDURES
firefighter* should wear self-contained breathing apparatus.
Hater a a y he ineffective, but aay be used to cool exposed containers to
prevent pressure build-up and possible a u t o - 1 g n 11 I o n or explosion when
* itposed to extreae heat. If water Is used, fog mil In ere preferable.
SECTION VII - REAGfiVlSf'DATA
STABILITY
Noraally stable
Noraally stable.
CONDITIONS TO AVOID
A v o Id i«t e it 1 w_e_ htit C > 1 1 S f (46 CI and sources of Ignition.
Avoid excessive neat Oils
INCOKFATABILITY (MATERIALS TO AVOID)
Strong acids or alkaline aaterlals.
O*IdI:i ng Materials.
HAZARDOUS DECOMPOSITION PRODUCTS
Burning, Including when heated by welding or cutting, will produce saoke,
carbon aonexide and carbon dioxide.In addition, oxides ot nitrogen
.>iy be genereted.
the reaction of Isocyenates with water aay produce carbon dioxide gas which
aay result in container pressurization.
HAZARDOUS POLYMERIZATION
will not occur
CONDITIONS TO AVOID
Hone known
ibforhatioh
STEPS TO BE TAKEN IF MATERIAL IS RELEASED OR SPILLED
The use of a niosh/nsha approved, TC19C, air-supplied breathing apparatus
aay be required. Consult with a qualified occupational health and /or
safety professional.
Iiaar respirators, aye, hand, and body protection appropriate for the
size of the spill and the exposures encountered
Keep spectators away, flialnate all ignition sources (flaaes, hot
surfaces, and sources of electrical, static or frictlonal sparks),
tike and contain spill with Inert aaterial (e.g. sand, earth). Transfer
liquids to covered aetal containers for recovery or disposal, or reaovs
with Inert absorbent. Use only non-sparking tools. Place absorbent diking
aaterlals In covered aetal containers for disposal. Prevent contsaination
of sewers, struts, and groundwater with spilled aaterial or used
absorbent.
HASTE DISPOSAL
Dispose In accordance with federal, state and local regulations.
RCRA CLASSIFICATION
This product, If discarded directly, would be classified a hazardous waste
based on Its I g n1t a b I I 1 t y characteristic, i.e. has a flash point of 140
ENVIRONMENTAL BAZARD^ ' ' °r * * * " proper IC k A classification would be 1001.
Hone known
SECTIOK IX - PERSONAL PROTECTION ZHFORMATXOX
RESPIRATORY PROTECTION
Hear an appropriate properly fitted positive pressure air supplied
respirator
-------
PAOB 4
•I DATE 6/0 7/tS
, " ""I I Ill II I. , . ' . ,1 . Ill.t[l. I'
SECTION IX ~ PERSONAL PROTECTIOH INFORMATION? (CONXINtfKD)
SYS PROTECTIOH
eaullavent).
OTHER PROTECTIVE EQUIPMENT
Eyewash facility, iifity shower.
As raqu 1 rod to prevent >Hn contact
SBCSZOH X - SPECIAL PRECAUTIONS
PRECAUTIOUS TO BE TAKEN IN BUNDLING AND STORAGE
oo not Hon ibovt 115 defl.F (46 dta.c) store large qmntltln In
coieltinea with OSH* 29CFrT»10.100.
OTHER PRECAUTIONS
Bo not dkt Internally. CUn container a f t a r a • c h use.
Bo not breathe sanding dust.
This product should not b a used by parsons Mho have hod chronic (long
t a ri) breathing problaas or reactions to Isocyanatea. to not. breath vapor
spray or ¦ I 11. Jo not oat 1n eyes, on skin, or clothing. Bash thoroughly
• ftar handling. Kaap away froa hait spark* or 1 I til . (Ill only with
adequate ventiation.
Eapty contalnars oust not bo washed and ra-uiad for any pwrposs.
Containers should ba groundad and bonded to t h a receiving container,
bo not Maid, braie or cut on eapty container.
»«>er use pressure to eapty. Brua Is not a pressure vassal.
SECTION XX - OTHER INFORMATION
THE INFORMATION CONTAINED HEREIN IS BASES ON DATA CONSIDERED TO BE
ACCURATE. WHILE THE INFORMATION IS BELIEVED TO 8E RELIABLE, HO WARRANTY IS
EXPRESSED OR 1MUED REGARDING THE ACCURACY OF THIS DATA 01 THE RESULTS TO
IE OBTAINED FRO* THE USE THEREOF. SINCE THE USE OF THIS INFORMATION AND THE
CONDITIONS AND USE Of THIS PRODUCT ARE CONTROLLED BY THE USER, IT IS THE
USER'S OIL ISAT10N TO DETERMINE THE CONDITIONS OF SAFE USE OF THE PRODUCT.
The Corporate Safety and Envlronatntal Affairs Departient 1*
responsible for the preparation of this Material Safety Data Sheet.
RESEARCH TRIAHOLE INSTITUTS
3040 CORNWALL!S RB.
RESEARCH TRIANGLE PARK NC
2770»
ATTN! JSNNX ELION
3-50
-------
RATT C XAKBSRT
in,
Hichl
f^onMxiMtCraora>^o^ -5 PM C!)
CORPORATE CONTACT 716-873-6000 <*-P * AN-S P* C*J
B.M.Z.S.
JBiitfW" I'
ihasa ratings should b« usad only
u part of fully «apteoantad H.N.I.S. program.
MATERIAL SAFETY DATA SHEET
SECZXOW I
PRODUCT CLASS BOVERNNENT SPEC. NAT
TRADS NAME C 0 A T I N S , P 0 L Y U R E THANE IIIEN 383,34094
MANUFACTURER CODS I.D. 754217 87
DATS OF PRBPAXATZON « / 0 7 / 9 5
II1L - C - 4 6 1 6 B B t N T * N 2
SECT20K It - HAZARDOUS IHGREDIEBTS
ZXQREDIENT
PROPYLENE 6LYC0L
METHYL ETHER ACETATE
XYLENE
¦ETHYL ETHYL KETONE
M-BUTYL ACETATE
I BY CAS MO.
WOT
ALLOWAJRIJ5
BZPOSURB LEVEL
20
101-65-6
PPN MO/CU.M.
NONE ESTABLISHED
MPPCP SKIN
1330-20-7 TLV-TVA
TLV-STEL
OSHA-PEL
OSHA-STEL
LFL 1.0
78-93-3 TLV-TVA
TLV-STEL
OSMA-PEl
OSHA-STEL
LFL 2.0
123-86-4 TLV-m
TLV-STEL
OSHA-PEL
OSHA-STEL
LFL 1.7
200
300
200
300
150
200
loo
UFL
UFL
UFL
435
65 S
435
655
7.0
ajvfo
2
"'5
70
10
7.6
SILICA, CRYSTALLINE-
CRtSTOBALITE
10
14464-46-1
TLV-TVA
OSMA-PEL
0.0500
0.0500
SILICA. ANORPHOUS-
B1AT0NACE0US EARTH
5
68855-54-9
TLV-T«A
OSHA-PEL
10
6
SILICA, CRYSTALLINE- <
OUARTZ
1
14808-60-7
TLV-TVA
OSHA-PEL
0.1000
0.1000
SILICA, CRYSTALLINE- <
TRIPOLI
1
1317-95-9
TLV-TVA
OSHA-PEL
8; iooo
SILICA, CRYSTALLINE
15
14808-60-7
TLV-TVA
OSHA-PEL
S:io8o
CHROMIUM lit OXIDE
10
1308-38-9
TLV-TVA
OSHA-PEL
oJooo
TOLUENE
5
108-88-3
TLV-TVA
50 147
20
OSHA-PEL
OSHA-STEL „
LFL 1.7
UFL
§75
560.
X
SKIN X
22
7.1
LFL « LOVER FLAH
UFL - UPPER FLAN
«K]R • SKIN ABS0R
C-CE1L1N6- ALLOW.
IIFI ¦ MANUFACTURE
STEL " SHORT TERN
X-SARA 313 " CHEN
OF TITLE III OF I
¦ABILITY LIMIT PERCENT
NA B I L I TV LINIT PERCENT
PTION NUST BE CONSIDERED AS A ROUTE OF EXPOSURE
EXPOSURE LEVEL SHOULB NOT BE EXCEEIEB FOR ANY T
R RECONMENBEB EXPOSURE LIMIT
EXPOSURE LINIT
I CAL IS SUBJECT TO RfPORTINS REQUIREMENTS OF SEC
. A . R.A. 40 CFR PART 372
IKE PER
TION 31
I OB
3
TERM OVEREXPOSURE
gastrointestinal Irritation, nauiaa, and voa1t1ng. A s e I r a t 1
ft t o I ufif aay causa chailctl pneusonltla vM eh can b a fatal.
R R • • f%# t h f O I t {ppitat^AR U I A K PANPtR*»B*lAaa ¦ . u ...... _ _
EFFECTS OP SBORX TERM OVEREXPOSURE
SHALLOWIHO
Can citit
IKWLLATIoi** 1 '
Mijf tivii non o r .
ciRtril nervous svstia
nausaa and confvsio
srs
Nay causa savsra ays Irritation
t irritation. High tonciMritIons aay causa ac
dijiriistsn character! iid by Natftckti, ditzlna
on of
lit a
as.
3 - 51
-------
nun- -tr— gggj t/hn*
: ';,V SlCTIOIf III — HEALTH INFORMATION? CCOWTIMUID) y -¦ - ¦-
SKIM
Liquid a a t a r 1 e I aay b e ibierbid through t h • akin In tiirifyl a a o u n t a .
..Hey causa nun itin irrltitlon.
BPFBCXS or repeated overexposuke
I>P«i ltd and prolonged occupational omrtiiimri to cryetelline ¦ 1 M e a say
causa 11( I cot11, • progr•i•1 *ely disabling lung disease.
Ottriipomri to ivlini nr causa Injury to t h • t 1 w • r , kidneys, and
b I ood .
The OSHA Perelstible Exposure L 1 ¦ f t for eaorphous allies 1* 20 M p p c f or
mi- -fsTii*5
lapaatad ovirntoiura to toluene aay tama 11 * a r d a a a g a •
Frexisting ratalratory conditions ¦ a y b a aggravated by exposure ta
crystalline silica.
Exposure to Methyl Ethyl Ketone aay 1 n h a a c e tha neurotoxicity of n-Hexane
and II11 h y I - n-Bg t y I Katona. This synergistic effect hat resulted In
terlpheral neuropathy In huaant.
aports h a v a astoelatad prolongad and rapaatad occupational overexposure
to itlvanti with peraanent brain and nervous syitai d a a a g a . Intentional
alsuse by deliberately concentrating and Inhaling the contents aay be
haraful or fatal.
SIGNIFICANT LABORATORY DATA WITH POSSIBLE RELEVANCE TO HUKAN ESALTB.
toluene has been found to causa kidney, lung and spleen d a a a a e 1n labora-
tory snlsalt
Laboratory studies Involving rats Indicate soae evidence that Methyl ithyl
Ketone aay b• nbrjotoiic. Tetotoxle and teratogenic.
The International Agency for Research o n Cancer considers crystalline
silica to have Halted evidence of carcinogenicity In huaens and sufficient
evidence 1n nitrlatntal a n i a a I a ( I A R C Croup 2 A) .
The Chrotiui ill Oxide supplier has concluded that Chroaiua 111 Oxide 1s
not carcinogenic by OSHA definitions or by the evidence presented by the
International Agency for Research on Cancer (IARC). ( 1ARC has listed
"Chroaiua and Certaln Chroaiua Coapounds* as Sroup 1 carcinogens.)
SECTION IV - FIRST AID AND EHERGEHCT PROCEDURES
SWALLOWING
If s w e I lowed do not Induce v o a i t1n g . Call poison control center, hospital
INHAIAlfaiP *oe a or physician laaedlately.
Reeove to fresh air iaeedietely. If breathing has stopped, give a r t i f i-
BYE e ' * ^ respiration. Keep vara and quiet. Set aedical attention iaaediately.
Flush with large eaounts of water, lifting upper and lover lids occasional-
ly. Continue for at least 1 $ ainutes. Sat aedisel attention.
SKIN
Reaove contaainated clothing, uash affected area with soap and water.
Obtain aedical attention if irritation persists.
NOTES TO PHYSICIM
Any treataent that aight be required for overexposure should be
directed at the control of syaptoas and tha clinical conditions,
SECTION V - PHYSICAL PM*
SOILING RANGE 17 5 P E 6 . F . ( 79 DES.C.) TO 2 81 0 £ 6. F. ( 138 BEG.C.)
VAPOR MNSXCr than air. « VOLATILE BY VOLUME 61
EVAPORATION RATE VOC * . 6 5 lb/g*l loss Wfcar S tifiS* 5 S 8 g/1 less MBtarC ALCULATEC
Slower than diethyl ether.
WEIOIT LB./GAL. 11.7 VOC 12,18 Ili/opl aolida 1 462 a/1 acdida CALCULATES
SPECIFIC GRAVITY 1,*
All Physical data determined at 68 DEO. P. (20 DEO. C.> 760 mm Eg
* Negligibly Photochemical It Reactive Hitsrlsll
VOC values reported hare art verified by AS IN aiathod D-3960
SECTIOH VI - FIRE AMD SXPLOSIOH DATA
NFPA fUUOaBILITT CLASSIFICATION FLAMMABLE LlSUtt - CLASS IB
FLASHPOINT 24BE6.F, < -*0iS.C,} CALCULATE#
BITINOTISHINO media
Use NFPA Class S Fire extinguishers (carbon dioxide, all purpose dry cheal
cat or alcohol f o e a) designed to extinguish flsaaabla liquid fires. Foly-
Curing emergency conditions, overexposure todecoapoatlon products aay
cause a health knird. Syaptoas aay net be iaaediately apparent. Obtain
aedical attention.
WARN IMS I FLAMHAILE.
SPECIAL PIKE PIOBTINQ PROCEDURES
Hater aey be ineffective, but aay be uead to eooI exposed containers to
prevent pressure build-up and possible auto- 1gn111 en or explosion when
exposed to extrsashest. If water iiu a a d , fo§ noti I a» a r epr efa r a b I a .
V::i::::'-'V/: I*.;-?:
- SECTION VII - REACTIVITY DATA
STABILITY
Moraally stable.
3 - 52
-------
ww "»""¦* kh
1 asaaaaagspaaaaWMIIISMMIJIIMIsa . ¦¦« ¦ W—A—¦—
SBCTIOiVlI - REACTIVITl DATAj (COHTHTOBP)
CONDITIONS TO AVOID „ , , .
INCOWaIaBILITX '(MATERIALS *TO 1v""~5" ' ( *4 ?} *n<< ,OUf "* *f iBn1t1on-
11 r o n g a c I'd • o> "TT kV11V**0* a t a r 1 a I a .
HA2ARDOUS DECOilpOBITION PRODUCTS « , ,
Burning, Including vhin heated by w• 1d1nB or cutting, will produce saoke,
carbon a o n o i t d a and carbon dioxlda.ln addition, a * 1 a a « of ckroifua
,aay ba flanaratad. . .
V« I d I n a , brailng, or torch cutting latarlall eoatad with t h1 a product oar
produce lata I oildai. Overexposure to than a a t a I oxide* fay result In
1" e t a I f taa Fever". Syaptoaa Include a flu-tfka 1 I I n a » a with favir. chill*,
and cough. *n air purifying or auppl i ad air respirator aay ba required
depending upon lavala of exposure . Consult a qua I 1 f1 ad health and safety
orofesslonat .
BASA1&OUS POLYXERI1ATION
Kill not occur
CONDITIONS TO AVOID
Nona known
SECTION vtn- environmental information
STEPS TO BS TAKEN IF MATERIAL IS RELEASED OK SPILLED
Keep ipictitori away. Eltainata all ignition sources C f I a a a * , hot
ivr ficn, and • o u r c a • of electrical, static or frictlonal sparks),
(
-------
75iil7'" D*l« *^T/
9S
jgCf IOW II »' OTHER IKFORMATIOH/ fCOHTIWUKD)
THE JHfOHHATIOH CONTAINIS HEREIN I $ BASES ON BIT* J 0* 11£E|fD T0 ¦E
ACCURATE. UHILI THE IHf0* * AfI 0N IS BELIEVE* TO IE RELIABLE . N 0 V A R R A N T T IS
EXPRESSES 0* IMLIK RESARBIH8 THE ACCURACT 0? TH I S , J A T A 0ft T H | » E S «L T t TO
¦ E OBTAINED fROH THE USE THEREOF. SINCE THE USE 0 £ I H I S IHfO}J ATt0N ANt THE
C0NB1TI0AS ANS USE 0* THIS PROBUCT ARE COHTROILE# »Y THE UJER.IT IS THE
USER'S OBLIGATION TO 6 E T E R H I H E THE CONOITIONJOFIAFE l/SI 01 Tfti MOJUC T .
The Corporate Safety indCnvlreniiiiiil A f f a 1 r a Btpartaont i*
ri«;«AiltU for the pripiritlon of thli mttrlit Safety Data tNit.
RfSEJUtCB TRIAHOIJS IK8TITUT*
SoIoCORlWMAI* JUJ.
RESEARCH TRIAKOLE *NftJQ9 *C
ATTUj jsnmi slzom
3-54
-------
PRATT S.LAKBEAI, 316-7
Induatria1 Coating» Di*
Wi&it.? M #7201
316-733-1341
a,M.I,«.
HEALTH
rLAMMABtLITY
REACTIVITY
These rating* should be used only
m part of fully iapletntsd H.W.I.S. prograa.
DOT EXEROENCY CHSHTBL IfOO)2S9-3934 (24br«l
INFORMATION PHONE NO. 3l<-?31-13tl (*-F ft AM-S PM CT)
CORPORATE CONTACT 716-873-6000
-------
i:isav— PAOE ,1
7 54 201 52 DATS t/0T/9$
...... -¦:•» , ¦*>- ¦ . ... ¦¦> . —
SKCTIOW IV - FIRST AID XKD EMERflENCT PROCEP17REB; (COHfItfUED}
SKIN
MOTES° TO VsYSICIAIl' - 1 tttldtiefl ff IrrUltlon persists.
Any triitiint that alflht be riqutrid fop overexposure should b*
dlrteud at the control of syaptoaa ind the tHalfl conditions,
SECTION V - PHYSICAL DATA
BOILXMQ RANOE 260 »16 . F . { 127 016. C . >
VAPOR MMSMnr than air. I VOLATILE 8T VOLUME SO
EVAPORATION HATS VOC 2.21 Ibfad 1MB *mtmc & ICRS* 2 # I f/l tea WftarC ALCULAT18
(lower than diethyl ether.
MSIOBT LB./OAL. 8.8 VOC 3.16 lb/gal aalida IM0 aollA CALCULATED
SPECIFIC 6 * * V J T T 1.1 '
All Physical data determined at €8 DEO. P. (20 DEO. C.) 7(0 m Kg
* Htglulblr PhotochealcalIt (Utariill
VOC values reported bar* art verified by ASTM aatbod D-3960
SECTION VI - FIRE *itl> BIPiOSIOM DATA
NFPA FXAMHABILITY CLASSIFICATION FLAMRASLi LIQUID - CLASS It
HiiSSSISIlNO KEDIA « 22 0E5.C,)
U « • HFPA C lut ¦ Flu iitfngulthiri < carbon dioxide. all p u r p o a • dry efceal-
cil or alcohol foaa) designed to extinguish flsaeebl* liquid fires. Poly
aer foaa 1 » prefsr r«d for lirgi (1 n» ,
UNUSUAL FIRE AMD EXPLOSION HAZARDS
(uring emergency conditions, ovar•*p0 *ur• to dtcoapostlon product* ¦a y
cium a health n a s a r d . Syaptoas say not b a iaaediately apparant . Obtain
aedital ittmtltii.
WARNING! FLAMKASie.
SPECIAL FIRE FIGHTING PROCEDURES
firtf(jhter* should wear self-contained breathing apparatus.
Vitir ny b a iniffictitt, but aay b a used to cool ttpoitd containers to
prevent pressure b u 1 I d - u p and possible a ti t o - 1 g n 1 t 1 on or explosion whan
¦exposed to axtfaia heat. If water 1s und, fog natilti ara prtfarab l e .
BECTIOir VII - REACTIVITY DATA
STABILITY
Noraalty atabla.
CONDITIONS TO AVOID
Avoid a x e a a a1v e haat (>115 f (46 C) and lourcai of Ignition.
IWCOMP AT ABILITY (MATERIALS TO AVOID)
Strong acids or alkaline aatarlala.
0* 1 d 1 * 1 ng_ aatarlala.
HAZARDOUS DECOMPOSITION PRODUCTS
Burning, Including whan h a a t a d by voiding or cutting, will treduca aaoki,
carbon a o n 0 x i d a and carbon diotldi. In addition, oxides of nitrogen
,aay ba ganaratad.
The r a a c t ion of Isocyanatas with water aay produce carbon dioxide gat which
HAIAI&Sis POLYKBR 1IATION* l*'n,r P •" « » « u f * * • * * 0 " •
Kill not occur
CONDITIONS TO AVOID
Nona known
SECTION VIII - EHVIROHXEHTAL INFORMATION
STEPS SO BE TAKEN IP KATERIAL IS RELEASED OR 8PILLED
Tht usa of a NIOSH/MSHA approved, TC1»C, tl r-uppl l id braathlng apparatus
aay ba ripl rad. Consult with a qualified occupational haaltb and /or
safety prof «u1ofii I .
Keep spectators away. Eliainate all ignition aourcn (flaaea, hot
surfaces, and soureaa of electrical, static or frlctlonal sparks).
Oike and contain spill with inart aatarlal (e.g. sand, earth), Transfer
liquids to covered a a t a I containers for recovery or disposal, or reaove
with inert absorbent. Usa only non-sparking toola. Place absorbent diking
aatarlala in covered a a t a I «onta 1nar• fpr disposal. Prevent tontaal nation
of aewers, streaas, and groundwater with a p1 lied aaterlal or used
absorbent.
MAST* DISPOSAL J t ^ J
U eordanca with federal, stata and local regulattone .
If discarded directly, would.be clasalflfd p hazardous waste
ts l - -
ARX>i
Hone known
Dispose in ac
RCRA GLASSIPICATION
baledPonSlfta'lgi«1tabiIity"eharieterlatiij"lTf."hii"a'flisl» pi?it~of~lio"
¦NVIRONflEHTAx/sASAilD j ' ,r 'M*' proper 1(11 classification would ba 0 001.
' " * * " ' \ » IV * 1
SECTION It - PERSONAL PROTECTION INFORMATION -i-:-
RESPIRATORY PROTECTI OS
Hear an appropriate properly fitted positive pressure air supplied
3-56
-------
fglgsi" »"«»»*' Slg| «/3,/,»
SBCTIOW IX - PERSOWAL PROTECTIOH IMFORMATIOK} (COKTIirUED)
RESP1RATORY PROTECTION x k ,
ri!t
-------
PRATT ft LAMBERT
laguBirial.Coatings Div
316-733-1361
Industrial Cos
SichltS* &• 67301
BOX BKEROEMCY CBSMTBL IfOO)255-3924 f241ir»)
INFORMATION PHOKK NO. }i«-733-ll6i E « N I L - P - $ 3 0 2 2 I T Y I
MANUFACTURER CODE Z.D. 72(700 1 4
sbctiok xi —.hazardous ihorediehts
XMGREDIEJ^T
TOLUENE
BISLYCI9YL ETHER
OF BISFHEHOL-A RESIH
TITANIUM DIOXIOE
PROPYLENE GLYCOL
MONONETHYL ETHER
METHYL ETHYL KETONE
TALC
SILICA, CRYSTALLINE
N-BUTYL ALCOHOL
% BT
WT
10
CAS NO.
101-88-3 TLV-TVA
OSHA-PEL
OSHA-STE
LFL
1.1
50
100
150
UFL
147
375
S60
25 25068-38-6
NONE ESTABLISHED
20 13*63-67-7 TLV-TUA
OSHA-PEL
5 107-98-2 TLV-TUA
TLV-STEL
OSHA-PfL
OSHA-STEL
15 78-93-3 TLV-TUA
TLV-STEL
OSHA-PEL
OSHA-STEL
LFL 2.0
15 14807-96-6 TLV-TUA
OSHA-PEL
1 14808-60-7 TLV-TUA
OSHA-PEL
5 71-36-3 TLV-TUA
TLV-STEL
OSHA-CEIL
LFL 1.4
m
100
150
200
300
ALLOWABLE
EXPOSURE LEVEL
PPM MO/CU.M.
7.1
10
10
540
360
540
590
88S
590
885
UFL 10.0
2
2
0.1000
0.1000
50 150
150 *55
50 150
UFL 11.2
KPPCP
SARA
113
SKIN
SKIN X
VP
20
22
11
70
15
20
skin X
SKIN
SKIN
LFL » LOVER FLANRABILITY LIBIT PERCENT
UFL « UPPER FLANRABILITY LIMIT PERCENT
SKIN « SKIN ABSORPTION MUST BE CONS 10ERE6 AS A ROUTE OF EXPOSURE
C-CE1LIN6* ALLOW. EXPOSURE LEVEL SHOULB NOT BE EXCESSES FOR ANY TINE PERIOD
MF« ¦ MANUFACTURER RECOMMENDED EXPOSURE LIMIT
STtL ¦ SHORT TERM EXPOSURE LIMIT
X-SARA 313 « CHEMICAL IS SUBJECT TO REPORTIN6 REQUIREMENTS OF SECTION 313
OF TITLE III OF S.A.R.A. 40 CFR PART 372
SECTIOH XII - HEALTH IKPORMATIOM
bf!
)ration
• t a I .
EFFECTS OF SHORT TERM OVEREXPOSURE
SWAIOjOWINO
Can causegastrointastinal Irritation, nausea, and vo a 1t1ng
¦ at•r 1 a I into lung aay cause eDtileii pneumonitis which can
XifHAXAXXOIf
Nay causa noil or throat Irritation. High concentration* aey cauta acuta
cantral aifvoiii ijritii depression characterized by htidichti . dUiiniM,
n a u * a a and confusion. it,
KTS
Hay
«» .
Liquid aatirlal aey be absorbad through the akin
Nay causa skin sensitization (allergic reaction)
Nay cause defattinj end irritation of the skin.
EFFECTS OF REPEATED OVEREXPOSURE
Repeated end prolonged occupational overexposure to crystalline
cause iI I 1 colli, a progressively disabling lung disease.
Repeated overexposure to toluene aay cause liver deaage.
Repeated contact aay cause deraatitis.
Prexisting respiratory conditions aay be aggravated by exposure to
o f
cause severe eye irritation,
in h a r a f uI aiounts
silica aay
3-58
-------
fflfoica TRir01-'
-T/' SECriOM III » HEALTH IHrORMATIOIT; (COHTIHUID) ' V' r
EFFECTS OP REPEATED OVZRZIPOSURS
tryitilUm silica.
Exposure to Kithgrl Ethyl Kitoni aay Inhinci the neurotoxicity of n-Haxane
and N a t h yI -n-i u t y I Ketone. Thl* synergistic iff designed to extinguish flaaaable liquid fires. Poly-
• er f o a a 1s Preferred for large fires.
UNUSUAL FIRS AND EXPLOSION KASARDS
During eaergtncy conditions, overexposure to decompaction products aay
cause a health hazard. Syaptoas aay net be laaediately apparent. Obtain
aedlcal attention.
U A IN I MS ! F LANHABLE .
SPECIAL FIRE FIGHTING PROCBD0RBS ,
Mater asy be Ineffective, but aay ba used to c00 I a«pot ad container* to
prevent pressure build-up end possible aut0- 1gn11Ion or explosion whan
exposed to extreae heat . If water I* used, f og no** las are preferable.
t " sBcno* vix » 'f'»*»".
STABILITY
Hazardous oolyaerlzatlon aay occur with the addition of excess hardener.
CONDITIONS TO AVOID
Avoid excessive heat (> 111S F <44 C) and .ource* of ignition.
INCOMPAXASILITY (MATERIALS TO AVOID)
Alkalis I A a i n•s
3-59
-------
3ff?§§c" "»»"¦ datI *,h,
9 3
8ECTI0H VII - REACTIVITI DATA) (COHTIHTJBD)
•y
INCOKFATABILITY (MATERIALS TO AVOID)
Strong icldi or alkaline aaterlals.
0i< d1 i < n a materials.
Icciliritori .
HASAXDOUS DECOHPOSITION PRODUCTS
turning. Including when heated by welding or cutting, Mill product aitii,
carbon a o n o x 1 d a and carbon dioxide.
EASAXDOUS POLYMERIIATIOM
Dill not occur
CONDITIONS TO AVOID
Hon* known
SECTION VIII - EKVIROKXEKTAJu jUFORMftf10*
STEPS TO BE TAKEN If MATERIAL IS RELEASED OR SPILLED
Kn» tpictateri away. EUilniti all Ignition sources ((lain, hot
mrticii, and lourcn of tltetrlctl, italic or frictlonal ipirki).
Bike and contain spill with 1 nar t a a t • r I a I ( a . g . sand, a e r t h } . tramtir
liquid* to covered uta I containers for recovery or d jipoi( 1 , or r e a o v e
with fnart abtorbant . Ilia only non-aparklng tool*. Place abiorbint diking
• atirlali In covered ¦a t a I contalnara for a 4 s p o s e I . Prevent conta a 1nation
of sewers, itrtan, and groundwater with ip I lied aatarial or uaad
absorbent.
HASTE DISPOSAL
Mipoit in accordanca with federal, itata and local ragulationt.
RCRA CLASSIFICATION
This product. If discarded directly, would be classified a hazardous waste
based on it* ignitabtllty characteristic, l.a. has a flash point of 1*0
d e g. r. (60 d e a . C ) or lass. The proper t C I A classification would be 8001.
ENVIRONMENTAL BA1ARDS
None known
SECTION IX - PERSONAL PROTECTION INFORMATION
RESPIRATORY PROTECTION
Proper selection of respiratory protection depends upon aany factors
including duration/level of exposure and conditions of us*, tn general
exposure to organic cheaicals such as those contained in this product as y
not require the use of respiratory protection 1f used In wall ventilated
areas. In restricted ventilation areas a N 10 S H approved chsaical cartridge
respirator aay be required, under certain conditions, such as spraying, a
aecnanical prefilter aay also be required. In confined areas use a NIOIH/
ft $ H A approved air supplied respirator. If the TLV's listed in Section II
are exceeded use a properly fitted niosm/nsha approved respirator with an
appropriate protection factor. Refer to 6 S N A 29 t f I 1910.136 " R e s p 1 ritery
Protection", and "Respiratory Protect ion A Manual And Guideline, I a e r i c a n
Industrial Hygiene Assoc.*
VENTILATION
Provide local exhaust ventilation in sufficient volute and pattern so as to
Maintain exposures below nuiianca dust I 1 a 1t s and paralssible exposure
liaits which aay be listed in lection II. Refer to Industrial Ventilation -
A Manual for Recoaaended Practice - Aaerican Conference Of Governmental
Industrial Hyglenists.
HAND PROTECTION
Solvent iaperaeable gloves are required for repeated or prolonged contact,
m PROTKCTIOK " 1 r r
B 3L mm • * Ca W A 4k WJra
Wear safety spectacles and c h a a Ie a I splash goggles (ANSI 187.1 or
e gu1lavent).
OTHER PROTECTIVE EQUIPMENT
Eyewash facility, safety shower.
1' ' SECTION X - SPECIAL PRECAUTIONS
PRECAUTIONS TO BE TAKEN IN HANDLING AND 8X0RAQB
Io not stora above 11$ degrees I (44 C > .
OTHER PRECAUTIONS
Be not take Internally. Close container after each use.
Keep away iroi children.
•o not breathe sanding dust.
Avoid skin contact.
Eapty containers oust not be washed and re-used for any purpose.
Containers should be grounded and bonded to the receiving container.
Bo not weld, braze or cut on eapty container.
>1 e v e r use pressure to eapty. Brua Is not a pressure ve s s e I .
SECTION XI ~ OTHER INFORMATION
, .SSiiK:;.?,
MISCELLANEOUS INFORMATION
The contents of this package mat be blended with other components before
the product can be used. Any mixture of components will have the ha cards
of a U components. .Before opening the packagaa, read all warning labels,
follow all precautions.
THE INFORMATION CONTAINED HEREIN IS BASED OR PATA CONSIDERED TO BE
3
- 60
-------
7§f!o§Ca TRJ5NOtB XNITZTUTI ?*0f
DATI
:s; • sgCTiow xt ~ OTOHji iitroimiio»f icoiitiiiuKa) ;is^ , ~
ACCURATE. UN I II TNI INFORHATION It ¦CHIVE I TO M RCLIABLE. NO tillUTT IS
EIMESSER OR IRPLIEO ICItlttNt TNI ACCURACY 0 f THI $ »ATA 0( THE RC I ULTS TO
• ( OITAINCB r«OD T MI USE THEREOF. SINCE THE USE Of TMI J |Nf9 RiATIOM A¦• THE
CONDITIONS AMI USE Of TNIf P * 0 D U C T ARE CONTROLLER IT THE USER, IT IS THE
USER'S 0 S L 1 6 A T I ON TO •ETERNINE THE C0* 0 ITI 0*S_0f iAF§ USE Of THE MOIUCT.
Til# Corporate Safety and En»1 ronif ntil Affair* | a p a r t ¦ a n t 11
rtiptnt 1 bIt for t h• prtpiritIon of thlt Notarial Safety lata Slieet.
HESEARC* TRIANOU5 INSTITUTE
SsIaicowiwaLiB
RX SEARCH TRIANQXM P*W,0, NC
ATTMl JZMNI BLIOM
3-61
-------
ERT 316-733-1361
fttings Oiv.
H.M•%« S•
These rating* should be ml only
M part Of fuUy iaple—nted M.w.l.i. progrse.
wichita, KB #7201
DOC EMERGENCY CHEKTKL 19001359-3924 (2«bra)
INFORMATION PEONS NO. lli-7JI-13«J (N-P i AN-3 FN CI)
CORPORATE CONTACT 716-873-6000 (M-F « AM-S FN CT)
MATERIAL SAFETY DATA SHEET
SECTION t
PRODUCT CLASS 60VERNHENT tHC. NaT DAT1 OF PREPARATION * / 0 7 / 9 S
TRADE NAME P* IHIR,tP0XT CIt, CORRlNHIB,LEAD • CMt *RfI HI L-P-§ J022 I T* t
MANUFACTURER CODS I.O. 724701 28
SECTION XI - HAZARDOUS IHORBPIENXS
INGREDIENT
ALIPHATIC AH2KE
AODUCT
I IT
MOT
CAS NO.
ALLOWABLE
EXPOSURE LEVEL
SARA
313
25 31326-29-1
FPK MO/CU.M.
NONE ESTABLISHED
MPPCF SKIN
VP
_mm 8g
20 DEO.
H-BUm ALCOHOL
15
71-36-3 TL¥-TMA
TLY-STEL
0SHA-CE1L
LFL 1.4
ooo
1/IIAtA
UFL
150
455
150
11.
C
C
2
SKIN
SKIN
SKIN
X
«
PROPYLENE GLYCOL
HONOMETHYL ETHER
SO
107-98-2 TLV-TUA
TLV-STEL
OSHA-PEL
OSHA-STEL
100
1S0
100
150
360
540
360
540
11
TOLUENE
5
108-88-3 TLV-TMA
OSHA-PEL
OSHA-STEL
LFL 1.7
50
100
150
UFL
147
375
560
7.
.1
SKIN
X
22
OIETHYLEHETRIARINE
S
111-40-0 TLV-TMA
OSHA-PEL
1
1
4
4
SKIN
1
2-NETH0XY-1-PROPANOL <
$
1589-47-5 NONE ESTABLISHED
If L I.J UFL 10.
9
LFL « LOME* FLARNABILITV UNIT PERCENT
UFI. - UPPER FLAKNABILITY L I R I T PERCENT
SKIN « SKIN ABSORPTION DUST IE CONSIDERED AS A ROUTE OP EXPOSURE
C-CE1UN6* ALLOW. EXPOSURE LEVEL SHOULD NOT SE EXCEEDED FOR ANT TIRE PERIOD
HFR * MANUFACTURER RECONHENDEO EXPOSURE LIBIT
STEL - SHORT TERR EXPOSURE LIH1T
X-SARA 313 a CHEMICAL IS SUBJECT TO REP0RTIN6 RE0U IRENENTS OF SECTION 313
OF TITLE III OF S.A.R.A. *0 CFR PART 372
SECTION III - HEALTH INFORMATION
EFFECTS OF SHORT TERM OVEREXPOSURE
shallowxho
Can causa gutrslntittiiiil irritation, mutt*. and yoif ting. Aspiration of
• a t a r 1 a I Into lung iijr catiu chealcal pneuaon 1 tit which can be fatal.
INHALATION
Kay c a u (« respiratory itniltjiatjin (potential for ilUrolc r«act(on) .
Ray e a u i a n oia or throat irritation. Nigh concentrations a a y cause acuta
central nirvom iritti depression charactarltcd by headaches, dizziness,
n a u•a a and confusion.
EYE
May causa severe ara Irritation and corneal daiaga.
SKIN "
in hiritul aaoun t a.
Liquid aatarlal ¦ a y b a absorbad through t h a a k 1 n 1
Nay cause * k 1 n sensitization < a I I a r g 1 Z reaction).
Hay causa severe akin Irritation,
EFFECTS OF REPEATED OVEREXPOSURE
Repeated ovaraipoigra to toluene say causa liver diitgt.
Raptatid contact lay causa diraitltti.
Itports have associated prolonged and repeated occupational overexposure
to solvents with parianant brain and nervous aystaa daaaga. Intentional
hififll or fitat"1 eon can t ra t i ng and Inhaling tha contents aay ba
SIGNIFICANT- LABORATORY DATA Win POSSIBLE RELEVANCE TO SOMAN HEALTH.
Toluene has bean found to cauta kidney, lung and splaan dsiage in labora-
tory sniaals. r ¦
sectzoa iv » jpiksy Aifr aw feMEROEgci ftoemms: '
^.. X?—. ,
SHALLOWING
If swallowed do not induce voa1t1n g. give 1 or 2 glasses of water to dilute
3-62
-------
E
HIWI"' EJ?!
;4.. . . ¦ —* — : ——— _____ ... .. ! I*
* SECTION IV - FIRST AID HHP EHEROENCI PROCEDURES? (COWTIWUEDV
SWALLOWING
(Never give a n y h t I n g by south to •n unconscious person) . (all Pol ton
HIALUIOI emif , NoiptUl Eaergency too*, or Physician laaedlataly.
ftaaove tofresh air 1 a a • 4 i a t a I y . If breathing has stooped, give artifi-
e 1 a I riiptritlen, Kaap vara and qulat. Gat ndlcal attention (andtttilr
BIB
SKIM
Hmh with laroi a a o u n t * of vatir, lifting upper and lower lids eccai loot t -
ly. Contfnui for at laait l! alnutes. Sit sedical attantion.
laaediately flush the contaminated area vith I a rae aiouati of water. fteaove
eonraa 1nat;d clothing a* water 1» applied. Consult a physician.
NOTES 10 PHYSICIAN
Any treatment that alght be required for overexposure should be
directed at the control of syaptoas and the clinical condition*.
I • : 'giCTlO^ . / • ;*> . '.
BOILING HANGS 2 3 1 0 E G . F . ( 111 0 16. C.J TO 405 0E6.F . ( 20? 6 16.C.J
VAPOR SEVSICY than air. % VOLATILE BY VOLUME 77
EVAPORATION RATE VOC $ . 6 5 ltyspl IMS Mftar i MM* C 7 a g/l less latere ALCULATEB
Slower than diethyl ether.
MBXOBT LB./OAL. 8.0 VOC 2 S . 21 lb/gal aolida 3032 g/l Blldl CALCULATED
SPECIFIC SUAVITY 1.0
All Phyaical data detsreiaed at <8 DEO. P. t20 DBS, C.) 760 mm B§
• Negligibly Photochoelcally Reactive Materials
VOC values reported here ark ~•rifled by ASTM eethod D-3960
SECTION VI - FIRE AND EXPLOSION DATA
NPPA PLAMMABIL1TY CLASSIFICATION FLAHNA6LE LIQUID - CLASS IS
FLASHPOINT 4 0 B E 6 . F , ( 4 &E6.C,) CALCULATE#
EXIINOU1SBINO MEDIA
Use KfFA Cliti B Fire extinguisher* (carbon dioxide, all purpose dry c h•¦1
c a I or alcohol f o a s ) designed to extinguish flaeeible liquid fires. Poly-
e*r foaa is preferred for large fires.
UNUSUAL FIRE AND EXPLOSION HAZARDS
t During eaergency conditions, overexposure to decoapostion products aay
cause a heelth fiuerd. Syaptoas aay not be iaaediately apparent. Obtain
aedical attention.
WARNING ! FLANN ABLE.
SPECIAL FIRS PIQSTINO PROCEDURES
Mater aey be ineffective, but aay be used to cool exposed containers to
prevent pressure build-up and possible auto-ignition or explosion when
e xposed to extreae h eat. I f water is used, fog noiiles are prefer a b I e.
SECTION VII - REACTIV2XX DATA
STABILITY
Hazardous poly
CONDITIONS TO AVOID
Avoid excessive heat (>115 f (46 C > and sources of Ignition.
XMCOMPATABILITY (MATERIALS 10 AVOID)
Strong acids or alkaline aaterlals.
Oxidizing aaterlals.
Accelerators.
HAZARDOUS DECOMPOSITION PRODUCTS
•urning, including when heated by welding or cutting, will produce seeke,
carbon aonaxide and carbon dioxide.
BAZARDOOS POLYMERISATION
Vill not occur
CONDITIONS TO AVOID
Hone known
SECT I OH VIII - ENVIRONMENTAL INFORMATION
STEPS TO BE TAKEN IF MATERIAL IS RELEASED OR SPILLED
Keep spectators away. Eliainata all Ignition sources (flaaas, hot
surfaces, and sources of electrical, static or frtctlenal sparks),
tike and contain spill with inert aaterial (e.g. sand, earth). Transfer
liquids to covered aetal containers for recovery or disposal, or raaove
with inert absorbent. Use only non-spark1ng tools. Flies absorbent diking
aaterlals in covered aetal containers for disposal. Prevent contaainat ion
of sewers, streaas, and groundwater with spilled aaterial or used
absorbent .
WASTE DISPOSAL „ , ...
Dispose in accordance with federal, state and local regulations.
RCRA CLASSIFICATION
This product, if discarded directly, would be classified a ha ta rdous waste
based on Its ignitabi tlty characteristic. I.e. has a flash point of 140
d e a. F.C60 deg.C) or less. The proper R C ft A classification would be 6 0 0 1.
ENVIRONMENTAL HAZARDS
None known
SECTION IX - PERSONAL PROTECTION ''INFORMATION %:
RESPIRATORY PROTECTION ,
proper selection of respiratory protection depends upon aany factors
3-63
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R|gEARCH TRjANOLl INSTITUTE g»Oi t/$1f93
BECTIOH IX - PCR90MAL PROIBCTIOM XMrORHATIOIt; (CO»HIIWfD>
RESFIRATORT PROTECTION
Including duration and level of tiptiufi and condition* cf dm, In general
upiiuri to organic chut ctli iuih n those contained in th i product aay
not require the u •« of respiratory trgticl Ion 1 f «ltd 1 n w • I t v e n t 1 Land
a r a ai. In trial of rtitrletid mnlllatIon a N I 0 S H approved organic vapor
raipfrator aay 6a required. Under ctrtain eond111 ons . a«ch aa spraying, a
a e c h a n 1 eat trif I Itar aay a 1 • o b a required. In conflnad inn or In h 1 g n
exposure situation* a ItlOSH/iSHA approvad air t u p p I 1 ad ratpl rator aay b •
raqulrad. If tha TLV's or pIL*• Uitid in taction II ara exceeded use a
properly fitted NIOSH/NSHA approvad respirator with an appropriate
protection factor, lilir to OSHA at C f * 1910.11* "Respiratory Protection*,
and 'Respiratory Protection a Hanual and Guideline, A a a rIe a n Induitrfal
vumtJlf iofcB
Provide general dilution and local exhaust ventilation In sufficient votuac
and oat te rn to keep concentrations «f haurdeui Ingredients listed In
Section II below thi lowest exposure I 1 a 1 t stated. Reaove dacoapositlon
products that ara generated whan welding, cutting, or brazing objects
costad with this product. Refer to 'Industrial Ventilation • A Hanual of
_ Recoaaended Practice * AC6IH .
8AMZ) PROTECTION
Solvent iaperaeable gloves ara required for repssted or prolonged contact.
STB PROTECTION "
Wear safety glasses Beating the specifications of ANSI 18?,1 where no
contact with tha eye is anticipated. Cheaical safety goggles a te t fng the
specifications of ANSI 287 . 1 snolud ba worn whenever fhera Is a possibi I t y
o f splashing or other contact with tha eyas.
fc -ate AaAa* jmm—m * • — 9
OTHER PROTECTIVE EQUIPMENT
Eyewash facility, safety shower
SECTION X - SPECIALPRECAUTIOR8
PRECAUTIONS to be taken in handling ah» storage
Bo not store above 115 degrees F (46 £).
OTHER PRECAUTIONS
Do not take intarnally. Close containar aftar each usa.
Keep away froa children.
Avoid skin contact.
iopty containers aust not be washed and re-used for any purpose.
Containers should ba grounded and bonded to the receiving containar.
to not weld, braze or cut on aapty containar.
Ntvtf usa prtnart to « a p t y . D r u a Is not a prniura vasial.
1 SECTIOM XI ~ OTHER IMFORKATIOtt ' , j
MISCELLANEOUS INFORMATION
Tha contents of this package aust ba blended with other coaponents before
the product can ba used. Any ilitura of coaponents will have the hazards
of all coaponents, ¦•fori opening the packages, read ail warning labels.
Follow all precautions.
THE INFORMATION CONTAINED HEREIN IS BASES ON DATA CONSIDERED TO BE
ACCURATE . WHILE THE INFORMATION IS BELIEVES TO BE RELIABLE, NO WARRANTY IS
EXPRESSED OR 1N P L I E 0 RESAR0 I N6 THE ACCURACY Of THIS DATA OR THI RESULTS TO
¦E OBTAINED FROM THE USE THEREOF. SINCE THI USE Of THIS INFORMATION AND THI
CONDITIONS AND USE OF THIS PRODUCT ARE CONTROLLED BY THE USER, IT IS THE
USER'S OBLIGATION TO DETERMINE THE CONDITIONS OF SAFE USE OF THE PRODUCT.
The Corporate Safety and Env1ranaenta I Affairs Departeent is
responsible for the preparation of this Material Safety Data Sheet.
RESEARCH TRIANGLE INSTITUTE
3040 CORNWALLIS RS.
RESEARCH TRIANGLE PARK HC
27709
ATTN! JENNI ELIOH
3 - E4
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•LIST
PAGE I OF 4
•••••••••• MATERIAL SAFETY OATA SHEET •••••••••«••••«••••••••••••••••••
ZPG Manufacturing
26S00 Capitol avenue
Bedford, Michigan 48239
24 Hour Emergency Contact: CHEMTREC 1-000-424-3300
Corporate Emergency Telephone: 1-313-937-0710 M-F 8:00 - 5:00
DUNS • 006-006-019
Canadian contact:
Ziebart Canada Inc.
ISO Oakdala Avenue
Downsview, Ontario M3N 1W1
Emergency Telephone: 1-416-742-6613
•<••••«••• SECTION 1 - PRODUCT IDENTIFICATION ••••••••••«•»••••••••••••
PRODUCT NAME/NUMBERXL5-G
FORMULA NUMBER; ..MB# 0140
CHEMICAL FAMILY; MIXTURE
CAS NUMBER; UNASSIGNED
HMIS: 2-2-1-H
••••««••»• SECTION 2 - HAZARDOUS INGREDIENTS *•»»•»««••••»••••••••»••••
ALIPHATIC HYDROCARBONS (STODDARD SOLVENT). CAS i 8052-41-3
PERCENTAGE BY WEIGHT: 15-40.
PEL: 100 PPM. TLV: 100 PPM.
LISTED IN NTP, IARC or OSHA 1910{z): YES, OSHA Z-1-A, HOT CARCINOGENIC
OXIDIZED ASPHALT. CAS • 64742-93-4
PERCENTAGE BY WEIGHT: 5-10.
PEL: 100 PPM. TLV: 100PPM.
LISTED IN NTP, IARC or OSHA 1910U): NO
ALIPHATIC PETROLEUM DISTILLATES. CAS • 64742-53-6
PERCENTAGE BY WEIGHT: 1-5.
PEL: AS OIL MIST 5 MG/M3. TLV: AS OIL MIST 5 MG/M3.
LISTED IN NTP, IARC OR OSHA 1910(Z): NO
**•••••••* SECTION 3 - PHYSICAL OATA
PHYSICAL FORM:
APPEARANCE AND OOOR:
PH:
BOILING POINT; F (C):
FREEZING POINT; F (C):
VAPOR PRESSURE; (mm Hg):
VAPOR DENSITY; (AIR=1):
SOLUBILITY IN WATER;
SPECIFIC GRAVITY; (WATER=1):
EVAPORATION RATE; (BUAC=1):
PERCENT VOLATILES-VOLUME:
PERCENT SOLIDS-WEIGHT:
VOLATILE ORGANIC COMPOUNDS:
LIQUID.
BLACK WITH PETROLEUM OOOR.
NEUTRAL.
>350 (>177).
32 (0).
<10.
4.8
SLIGHT.
0.9
0.2
45.
61.
2.9 lb./gal. (minus water)
3-65
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.PAGE 2 OF 4
XL5-G
•••••••••• material, safety data sheet
•••••••••• SECTION * - FIRE AND EXPLOSION OATA
AUTOIGNITION; F (C): >410 (>210)
FLASH POINT; F (C), METHOD: 101 (38), PMCC.
LOWER EXPLOSIVE LIMIT; 0.8*
UPPER EXPLOSIVE LIMIT: 6.0*
EXTINGUISHING MEDIA: FOAM, ORY CHEMICAL, WATER FOG, C02.
SENSTIVE TO IMPACT: NO.
SENSTIVE TO STATIC DISCHARGE: NOT AVAILABLE.
HA2ARD0US COMBUSTION PRODUCTS: OXIDES OF CARBON, NITROGEN AND SULFUR.
FIRE FIGHTING PROCEDURES: USE SELF CONTAINED BREATHING APPARATUS. REMOVE
ALL SOURCES OF IGNITION. COOL EXPOSEO DRUMS
WITH WATER SPRAY.
FIRE & EXPLOSION HA2ARDS: VAPORS ARE HEAVIER THAN AIR AND MAY FLOW TO
DISTANT IGNITION SOURCES.
*•«•••••«• SECTION 5 - REACTIVITY DATA •«»*•••••••••••••••••••••••~••••»••
CHEMICAL STABILITY: YES.
MATERIALS TO AVOID: STRONG OXIDIZERS AND ACIDS.
HAZARDOUS DECOMPOSITION PRODUCTS: OXIDES OF CARBON, NITROGEN AND SULFUR.
HAZARDOUS POLYMERIZATION: WILL NOT OCCUR.
•«••«••••• SECTION 6 - HEALTH HAZARD OATA ~•*••»»••¦••••»•*•••*«•»*»«»•»»•
PRIMARY ROUTES OF ENTRY: INHALATION, SKIN CONTACT.
EFFECTS OF OVEREXPOSURE (ACUTE & CHRONIC): MILO DEPRESSION, CONVULSIONS
AND LOSS OF CONSCIOUSNESS. SKIN CONTACT CAUSES
BURNING, IRRITATION, DEFATTING AND DERMATITIS.
EXPOSURE LIMITS: PETROLEUM DISTILLATES: TLV 100 PPM.
PEL 100 PPM.
OXIDIZED ASPHALT FUMES: 5 MG/M3.
ALIPHATIC PETROLEUM DISTILLATES: PEL: 5 MG/M3 AS OIL MIST.
TLV: 5 MG/M3 AS OIL MIST.
IRRITANCY OF PRODUCT: EYE IRRITATION, DRAIZE TEST: MODERATE.
SENSITIZATION TO PRODUCT: NOT AVAILABLE.
CARCINOGEN: NO.
TERATOGEN: NO.
REPRODUCTIVE TOXICITY: NO.
MUTAGEN: NO.
SYNERGISTIC PRODUCTS: NOT APPLICABLE.
*•*•«*•*•* EMERGENCY AND FIRST AID PROCEDURES »«»*»»«»•»#»»»•»»»***•»¦»*»*
SKIN CONTACT: REMOVE AND LAUNDER CONTAMINATED CLOTHING BEFORE REUSE.
DISCARD SHOES IF SEVERLY CONTAMINATED, WASH SKIN WITH SOAP
AND WATER.
EYES: FLUSH WITH WATER FOR 15 MINUTES LIFTING UPPER AND LOWER LIDS,
CONTACT PHYSICIAN.
INHALATION: REMOVE TO FRESH AIR, GIVE OXYGEN IF BREATHING IS DIFFICULT.
CONTACT PHYSICIAN.
INGESTION: DO NOT INDUCE VOMITING, GIVE WHITE MINERAL OIL. CONTACT
PHYSICIAN. 00 NOT ATTEMPT TO GIVE ANYTHING BY MOUTH TO AN
UNCONSCIOUS PERSON.
3-66
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PAGE 3 OF 4.
XL5-G
*•••*•••«« material safety data sheet
.......... SECTION 6 - HEALTH HAZARD DATA (CONTINUED) ••**••••**#•««•••**•
TOXICOLOGY INFORMATION ......
PETROLEUM DISTILLATES: LD50, ORAL-RAT, >5 GM/KG.
LC50, 4 HOUR-RAT, >5500 MG/M3.
OXIDIZED ASPHALT; LD50, NOT AVAILABLE.
LC50, NOT AVAILABLE.
ALIPHATIC PETROLEUM DISTILLATES: LDSO, NOT AVAILABLE.
LCSO, NOT AVAILABLE.
.......... SECTION 7 - SPILL OR LEAK PROCEDURES •••••••••••*•••« ...»
LEAK AND SPILL PROCEDURES: REMOVE ALL SOURCES OF IGNITION, PROVIDE
ADEQUATE VENTILATION, ABSORB WITH VERMICULITE
OR OTHER ABSORBENT.
WASTE DISPOSAL METHOD: REFER TO LOCAL, STATE AND FEDERAL EPA REGULATIONS.
CERCLA REPORTABLE QUANITY: NOT LISTED.
RCRA HAZARDOUS WASTE NO.: NONE (40 CFR 281.33).
SECTION 8 - PERSONAL PROTECTION INFORMATION
RESPIRATORY PROTECTION: USE AIR PURIFYING RESPIRATOR WITH ORGANIC VAPOR
CARTRIDGE >TLV IF LIMITS ARE EXCEEDED.
PROTECTIVE GLOVES: BUNA-N-RUBBER.
EYE PROTECTION: SAFETY GLASSES OR GOGGLES.
VENTILATION: EXPLOSION PROOF LOCAL EXHAUST IS RECOMMENDED. MAINTAIN
ADEQUATE AIR TRANSFER VELOCITY TO REMOVE VAPORS.
CLOTHING REQUIREMENTS: STANDARD INDUSTRIAL HYGIENE SHOULD BE PRACTICED.
OTHER PROTECTIVE EQUIPMENT: BUNA-N-RUBBER APRON IS RECOMMENDED. EYE WASH
AND SAFETY SHOWER IS SUGGESTED. WASH BEFORE
EATING, DRINKING OR SMOKING.
•••••••••• SECTION 9 - SPECIAL PRECAUTIONS •••••••••••••••••••••••••••••••
STORAGE REQUIREMENTS: STORE IN COOL, WELL VENTILATED AREA AWAY FROM ALL
SOURCES OF IGNITION
HANDLING PROCEDURES: PREVENT PROLONGEO/REPEATEO SKIN CONTACT AND AVOID
BREATHING VAPORS.
SECTION 10 - SHIPPING INFORMATION (HM-181 )
PROPER SHIPPING NAME: PETROLEUM DISTILLATES N.O.S.(STODDARD SOLVENT)
HAZARO CLASS/DIVISION: 3
UN MNUMBER: UN-1268
PACKING GROUP: III
LABELS REQUIRED: FLAMMABLE LIQUID (3.3)
CANADA: TOXIC "T" (D.2.B)
IMDG CODE: page 3375
3-67
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•PAGE 4 OF 4.
XL5-Q
••«•••••«• MATERIAL SAFETY DATA SHEET
•••••••«•« SECTION 11 - OTHER REGULATORY ••»»•••«••*•«*••*•»*•*»•*••»•*»»#
TSCA; ALL COMPONENTS ARE ON THE TSCA INVENTORY.
SARA TITLE III, SECTION 313. THIS PRODUCT CONTAINS (OR IS) A TOXIC
CHEMICAL FOR ROUTINE ANNUAL TOXIC CHEMICAL RELEASE REPORTING UNDER
SECTION 313;
SARA TITLE III, SECTIONS 31 1 AND 312. THIS PRODUCT CONTAINS A CHEMICAL
SUBSTANCE THAT IS CONSIDERED, UNDER APPLICABLE DEFINITIONS, TO MEET THE
FOLLOWING CATAGORIES:
*•*•«••••• SECTION 12 - PREPARATION **•*»*••••*•»•••••••**••*•«••«•••¦¦•••
THE INFORMATION GIVEN AND THE RECOMMENDATIONS MADE HEREIN APPLY TO OUR
PRODUCTS ALONE AND NOT COMBINED WITH OTHER PRODUCTS. SUCH ARE BASED ON
OUR RESEARCH AND ON DATA FROM OTHER RELIBLE SOURCES AND ARE BELIEVED TO
BE ACCURATE, NO GUARANTY OP ACCURACY IS MADE. IT IS THE PURCHASER'S
RESPONSIBILITY BEFORE USING ANY PRODUCT TO-VERIFY THIS DATA UNDER THEIR
OWN OPERATING CONDITIONS AND TO DETERMINE WHETHER THE PRODUCT IS SUITABLE
FOR THEIR PURPOSES. THE INFORMATION HEREIN IS PRESENTED IN GOOD FAITH AND
BELIEVED TO BE ACCURATE AS OF THE EFFECTIVE DATE SHOWN ABOVE. HOWEVER,
NO WARRENTY, EXPRESS OR IMPLIED, IS GIVEN. REGULATORY REQUIREMENTS ARE
SUBJECT TO CHANGE AND MAY OIFFER FROM ONE LOCATION TO ANOTHER; IT IS THE
BUYER'S RESPONSIBILITY TO ENSURE THAT IT'S ACTIVITIES COMPLY WITH FEDERAL,
STATE OR PROVINCIAL, AND LOCAL LAWS. THE ABOVE INFORMATION IS MADE FOR
THE PURPOSE OF COMPLYING WITH NUMEROUS FEDERAL, STATE OR PROVINCIAL, AND
LOCAL LAWS AND REGULATIONS.
NONE
A FIRE HAZARD
PREPARED BY:
TITLE:
CREATION DATE:
SUPERCEDES;
REASON FOR REVISION:
GORDON POL IQUIN
LABORATORY MANAGER
10-27-33
4-29-33
UP DATE SECTIONS 2, 10 AND 11
ADDITIONAL INFORMATION
3-68
-------
APPENDIX 3-2
Material Safety Data Sheets
for
MEK Alternatives:
Page
Paint Remover Formulation H 3-70
Paint Remover Formulation L 3-72
Paint Remover Formulation N 3-74
Texadd S-200 3-76
Jeffsol PC 3-78
Methyl ethyl ketone 3-93
3-69
-------
Date Issued: 06112195
HUNTSMAN EXPERIMENTAL PRODUCT D»te Created: 06/01/95
MATERIAL SAFETY DATA SHEET
NOTE: This MSDS it valid for six month* from the date of issue. Use, dispose of material or request new MSDS when six
months has expired. ___
1. PRECAUTIONARY STATEMENT
WARNING! EXPERIMENTAL PRODUCT? IMPORTANT: The chemical, physical and toxicological properties
of this experimental product have not been fully investigated, and its handling or use may be hazardous.
EXERCISE DUE CARE.
NFFA Code: Health I Flammability J Reactivity 0 Special
HM1S Code: Health / Flimmability 1 Reactivity 0 Protection
2, CHEMICAL PRODUCT AND COMPANY IDENTIFICATION
Huntsman Corporation
Austin Research Laboratories
P.O. Box 15730
Austin, TX 78761
ARL CODE: fAML 9506-011
PRODUCT NAME: PAINT REMOVER FORMULATION H
CHEMICAL NAME/CLASS: Solvent Mixture
EMERGENCY CONTACT
Resile T. Bade (512) 483-0147 (Business hours)
Port Necbes, TX (409) 727-0831 (24-hourj)
3. TRANSPORTATION AND OTHER REGULATORY INFORMATION
D.O.T.
Proper Shipping Name: Not Regulated
Hazard Class: None
Identification f: None
Emergency Guide Response #: None
O.S.H.A.
Component
Benzyl alcohol
Propylene carbonate
Dibasic Ester
WararHnits Characteristic^) CAS # Range
Irritating to skin and eyes (severe) 000100-51-6 20-90
No exposure limit established
None Known 000108-32-7 5-40
No exposure limit established
Flammable; Skin and eye irritant Mixture 5-40
Admissible exposure limit 10 mg/mS (8 hr TWA)
T.S.C.A.
Status: Commercial
3-70
-------
ARL CODE: fARL 9506-011
PRODUCT NAME: PAINT REMOVER FORMULATION H
Dale Issued:
Date Created:
06/12/95
06/01/95
4. FIRST AID MEASURES
Eye Contact
Flush eyes with plenty of water for at least IS minutes: [X]
Get medical attention: [X]
Skin Contact
Wash skin with soap and water: tXJ
Get medical attention: (X]
S. EXPOSURE CONTROLS/PERSONAL PROTECTION
The following persona! protection is recommended:
Safety Glasses [X] Protective Apron [XJ
Chemical Goggles [X] Coveralls [X]
Face Shield (X] Respirator/Hood (X)
Gloves, Chemical Resistant fX) Supplied Air Mask (for large spills or
confined spaces) [X]
6. PHYSICAL AND CHEMICAL PROPERTIES
Color: Light Volatility: Low (< 100}
Odor: Mild Physical State: Mobile Liquid (< 100)
pH, 1% Solution: 6.9 Boiling Point, *F: > 95
Density, g/ral: 1.07 Melting Point, *F: N.D.
1. STABILITY AND REACTIVITY
This material Reacts Violently with: (If others is checked below, see comments for details)
Air [ ] Heat [ ] Others PQ
Water { ] Strong Oxidizer [ ] None of These [ ]
Comments:
This material reacts violently with [Strong acids, bases, oxidizers /
Hazardous Polymerizations: Do Not Occur
«. DISPOSAL CONSIDERATIONS
Contain spill. Avoid personal contact. Wipe up or absorb on suitable material for disposal. Dispose of unused material
in a suitable manner.
R.C.R.A. Classification: Not Regulated
Water Solubility: Appreciable (> 10%)
Flash taint-Closed Cup, *F: 213
3-71
-------
HUNTSMAN EXPERIMENTAL PRODUCT
MATERIAL SAFETY DATA SHEET
Date Issued:
Date Created:
06/nm
06/06/95
NOTE: This MSDS i* valid for six months from die date of issue. Use, dispose of material or request new MSDS when six
months has expired.
I. PRECAUTIONARY STATEMENT
WARNING! EXPERIMENTAL PRODUCT! IMPORTANT: The chemical, physical and toxicologies! properties
of this experimental product hare not been fully investigated, and its handling or use Buy be hazardous.
EXERCISE DUE CARE,
NFPA Code:
HM1S Code:
Health 1
Health J
Flammability J
Flammtbility J
Reactivity 0 "
Reactivity 0
Special
Protection
2. CHEMICAL PRODUCT AND COMPANY IDENTIFICATION
Huntsca«a Corporation
Austin Research Laboratories ¦
P.O. Box 15730
Austin, TX 78761
ARL CODE:
PRODUCT NAME:
CHEMICAL NAME/CLASS:
EMERGENCY CONTACT
Reo&T. Bade (512) 413-0147 (Business hour
Port Necbea, TX (409) 727-0831 (24-hours)
(AXL 9506-05J
PAINT REMOVER FORMULATION L
Solvent Mixture
3, TRANSPORTATION AND OTHER REGULATORY INFORMATION
D.O.T.
Proper Shipping Name: Not Regulated
Hazard Class: None
Identification #: None
Emergency Guide Response #: None
O.S.H.A.
Component
Benzyl alcohol
Propylene carbonate
Wa/ardmts Characteristic^
Irritating to sMit and eyes (severe)
No exposure limit established
Now Known
No exposure limit established
OOOlQO-SI-t
Ranf
25-a?
000108-32-7 15-71
T.S.C.A.
Status: Commercial
3-72
-------
s
ARLCODE: /aML 9506-05/ , Date issued; 06/12/95
PRODUCT NAME; PAtNT REMOVER FORMULATION' L Due Created: temm
4. FIRST AID MEASURES
Eye Contact
Flush eyes with pleaty of water for at least IS minutes: (X)
Get medical attention; PQ
Skin Contact
Wash skin with soap and water PQ
Get medical attention: [X]
5. EXPOSURE CONTROLS/PERSONAL PROTECTION
The following personal protection is recommended:
Safety Glasses
PQ
Protective Apron
PQ
Chemical Goggles
PQ
Covenlls
PQ
Face Shield
PQ
Respirator/Hood
PQ
Gloves, Chemical Resistant
PQ
Supplied Air Mask (for large spills or
confined spaces)
PQ
i. PHYSICAL AND CHEMICAL PROPERTIES
Color: Light Volatility: Low (< 100) Water Solubility: Appreciable (>10%)
Odor: Mild Physical Slate: Mobile Liquid (< 100}
pH, IS Solution; 6.8 Boiling Point, *Fs > 95 flash Point-Closed Cup, *F: 213
Density, g/mi: 1.10 Melting Point, *F: N.D.
7, STABILITY AND REACTIVITY
This material Reacts Violently with: (If others it checked below, see comments fat details)
Air [ ] Heat [ ] Other* [X]
Water [ ] Strong Oxidizer [ ] None of These [ ]
Comments:
This material reacts violently with {Strong acids, bases, oxidizers]
Hazardous Polymerizations: Da Not Occur
8. DISPOSAL CONSIDERATIONS
Contain spill. Avoid personal contact. Wipe up or absoife on suitable material for disposal. Dispose of unused material
in a suitable manner.
R.C.R.A. Classification: Not Regulated
3-73
-------
Date Issued: 06111195
HUNTSMAN EXPERIMENTAL PRODUCT Date Created: 06/06/9!
MATERIAL SAFETY DATA SHEET
NOTE: This MSDS is valid for six months from the due of issue. Use, dispose of material or request new MSDS when sis
months has expired.
I. PRECAUTIONARY STATEMENT
WARNING! EXPERIMENTAL PRODUCT! IMPORTANT: The chemical, physical and toxicologies! properties
of this experimental product have not been fully investigated, and its handling or use may be hazardous.
EXERCISE DUE CARE.
NFPA Code: Health 1 Flammability 1 Reactivity 0 Special
HM1S Code: Health 1 Flammability I Reactivity 0 Protection
2. CHEMICAL PRODUCT AND COMPANY IDENTIFICATION
Huntsman Corporation
Austin Research Laboratories
P.O. Box 15730
Austin, TX 78761
EMERGENCY CONTACT
Renfo T. Bade (512) 483-0147 (Business hours)
Port Neches, TX (409) 727-0831 (24-houn)
ARLCODE
PRODUCT NAME
CHEMICAL NAME/CLASS
{ARL 9506-07]
PAINT REMOVER FORMULATION N
Solvent Mixture
3. TRANSPORTATION AND OTHER REGULATORY INFORMATION
D.O.T.
Proper Shipping Name: Not Regulated
Hazard Class: None
Identification #: None
Emergency Guide Response f: None
O.S.H.A.
Component
Hazardous Characteristic^)
CAS#
Range
Benzyl alcohol
Irritating to skin and eyes (severe)
No exposure limit established
000100-51-6
20-85
Propylene carbonate
None Known
No exposure limit established
000108-32-7
5-25
Dibasic Ester
Flammable; Skin aid eye irritant
Admissible exposure limit 10 mg/m3 (8 hr TWA)
Muaure
Butyrolaaone, gamma
May cause irritation
No Exposure limit established
000096-48-0
5-25
T.S.C.A.
Status:
Commercial
3-74
-------
ARL CODE: fARL 9506-07]
PRODUCT NAME: PAINT REMOVER FORMULATION N
Dite Isfuod:
[Me Created:
06/12/95
06/06/95
4, FIRST AID MEASURES
Eye Contact
Flush eyes with plenty of water for at least IS minutes: PQ
Get medical attention: [X]
Skin Contact
Wash skin with soap and water [X]
Get medical attention: [X]
5. EXPOSURE CONTROLS/PERSONAL PROTECTION
The following personal protection is recommended:
Safety Glasses [X] Protective Apron [X]
Chemical Goggles [X] Coveralls [X]
Face Shield (X) Respirator/Hood [X]
Gloves, Chemical Resistant [X] Supplied Air Marie (for large spills or
confined spaces) [X]
6. PHYSICAL AND CHEMICAL PROPERTIES
Color: Light Volatility: Low (< 100) Water Solubility: Appreciable (> 10%)
Odor: Mild Physical State: Mobil* Liquid (<100)
pH, 1% Solution: 6.9 Boiling Point, "Fx > 95 Flash Point-Closed Cup, *F: 209
Density, g/ml: 1.07 Melting Point, "F'.N.D.
7, STABILITY AND REACTIVITY
This material Reacts Violently with: (If others is checked below, see comments for details)
Air [ ] Heat [ ] Others [X]
Water [ ] Strong Oxidizer [ ] None of These [ J
Comments:
This material reacts violently with /Strong acids, bases, oxidizers/
Hazardous Polymerizations: Do Not Occur
8. DISPOSAL CONSIDERATIONS
Contain spill. Avoid personal contact. Wipe up or absorb on suitable material for disposal. Dispose of unused material
in a suitable manner.
R.C.R.A. Classification: Sot Regulated
3 - 75
-------
Date Issued: 06! 12195
HUNTSMAN EXPERIMENTAL PRODUCT Date Created: 06/10/94
MATERIAL SAFETY DATA SHEET
NOTE: This MSDS is valid for six months from the dais of issue. Use, dispose of material or request new MSDS when six
months has expired.
1. PRECAUTIONARY STATEMENT
WARNING! EXPERIMENTAL PRODUCT! IMPORTANT: The chemical, physical and toxicologies! properties
of this experimental product ha*e not been fully investigated, and its handling or use may be hazardous.
EXERCISE DUE CARE.
NFPA Code: Health 2 FIsmmsbility / Reactivity 0 Special
HM1S Code: Health 2 Flammability I , Reactivity 0 Protection
2. CHEMICAL PRODUCT AND COMPANY IDENTIFICATION
Huntsman Corporation
Austin Research Laboratories
P.O. Box 15730
Austin, TX 78761
EMERGENCY CONTACT
Ren£e T. Bade (512) 483-0147 (Business hours)
Port Neches, TX (409) 727-0831 (24-bours)
ARLCODE
PRODUCT NAME
CHEMICAL NAME/CLASS
I AM. 9406-03}
TEXADD S-200
Solvent Mixture
3. TRANSPORTATION AMD OTHER REGULATORY INFORMATION
D.O.T.
Proper Shipping Name:
Hazard Class:
Identification #:
Emergency Guide Response #:
Not Regulated
None
None
None
O.S.H.A.
Component
Hazardous Characteristic^)
CkM
Ranee
Metkyl-2-pyrrolidinont. 1-
Combustible;Eye (severe),skin/respiratory irritant
000872-30-4
23-75
No exposure limit established
Propylene carbonate
None Known
000108-32-7
25-75
No exposure limit established
T.S.C.A.
Status; Commercial
3-75
-------
ARL CODE:
PRODUCT NAME:
t ARL 940*031
TEXADDS-200
Date Issued:
Date Created:
06/12/95
06/10/94
4. FIRST AID MEASURES
Eye Contact
Flush eyes with plenty of water for at least IS minutes: [X]
Get medical attention: [X]
Skin Contact
Wash skin with soap and water: [X]
Get medical attention: [ ]
S. EXPOSURE CONTROLS/PERSONAL PROTECTION
The following personal protection is recommended:
Safety Glasses [XJ Protective Apron [ J
Chemical Goggles [X] Coveralls [ ]
Face Shield [X) Respirator/Hood [ J
Gloves, Chemical Resistant [ ] Supplied Air Mask (for large spills or
confined spaces) [ ]
6. PHYSICAL AND CHEMICAL PROPERTIES
Color: Colorless Volatility: Low (< 100)
Odor: Mild Physical State: Mobile Liquid (< 100)
pH, 1% Solution: ~ 7 Boiling Point, *F: N.D.
Density, g/ml; 1.10 Melting Point, *F: N.D.
7. STABILITY AND REACTIVITY
This material Reacts Violently with: (If others is checked below, see comments for details)
Air I ] Heat ( ] Others [X]
Water [ ] Strong Oxidizer (X] None of These [ ]
Comments:
This material reacts violently with [Strong acids & bases/
Hazardous Polymerizations: Do Not Occur
8. DISPOSAL CONSIDERATIONS
Contain spill. Avoid personal contact. Wipe up or absorb on suitable material for disposal. Dispose of unused material
in a suitable manner.
R.C.R.A. Classification: Not Regulated
Water Solubility: Appreciable (> 10%)
Flash Point-Closed Cup, *F: 200
3-77
-------
JSFFSOL pc
HtJKTSMAN CHEMICAL CO.
PRODUCT CODSi 75436
DATE ISSUED> 10*31-94 Supersedest 07*01*94
ItXXBRIAL SAPETY DATA SHEET
This USDS was printed utilizing access to Huntsman's CD-ROM USDS Database.
Due to variations is printer dependent character styles, fonts and computer
control codes, the appearance may differ froa that of the centrally printed
Huntsvan USDS.
MOTSi Read and understand Material Safety Data Sheet before handling or
disposing of product.
1. CHEMICAL PRODUCT AND COMPANY IDENTIFICATION
MATERIA!. IDENTITY
Product Code and Haw:
75*36 JEFFSOt PC
Chemical Kmc and/or family or Description:
Alkylene carbonate
Manufacturer's Name and Address:
HUNTSMAN
P.O. Box 27707
Houston, TX 77227-7707
Telephone umbers:
Transportation Emergency-Coapeny : (409} 727-0831
CHERTREC ; (800) 424-9300
Health Emergency •Company : (914) 831-3400
General HS0S Assistance : (713) 231-4432
Technical Information : (512) 459-6543
2. COMPOSITION/INFORMATION OK INGREDIENTS
THE CRITERIA FOR LISTING COMPONENTS IN THE COMPOSITION SECTION IS AS FOLLOWS:
CARCINOGENS ARE LISTED WHEN PRESENT AT 0.1 X OR GREATER,' COMPONENTS WHICH ARE
OTHERWISE HA2AR0OUS ACCORDING TO OSHA ARE LISTED WHEN PRESENT AT 1.0 Z OR
GREATER; HON - HAZARDOUS COMPONENTS AM LISTED AT 3.0 X OR GREATER. THIS IS NOT
INTENDED TO IE A COMPLETE COMPOSITIONAL DISCLOSURE. REFER TO SECTION 14 FOR
APPLICABLE STATES' RIGHT TO KNOW AMD OTHER REGULATOR* INFORMATION.
Product and/or Coa£onent(a) Carcinogenic According ts:
OSHA IARC NTP OTHER NONE
X
Composition: (Sequence Number and Chemical Rama]
Seq. Chamical Nane CAS Nuiwr Range in t
PAGE i 1
N.D. - NOT DETERMINED N.A. - NOT APPLICABLE N.T. - NOT TESTED
< - LESS THAN > - GREATER THAN
3-78
-------
JEFFSOL PC
HUNTSMAN CHEMICAL CO.
PRODUCT CODEi 75436
DATS ISSUED* 10-31-94
PRODUCT CODSt 7543C Dal:* Iiiuadi 10-31-9'
NAMBi JBFFSOL PC SlXp«r8«d6fli 07-01-9'
2. COMPOSITION/INFORMATION OH INGREDIENTS (CONT)
01 • 1,3-dio*olan-2-one, «thyl- 108-32-7 100.00
PRODUCT IS HAZARDOUS ACCORDING TO OS HA (1910.1200).
• COMPONENT IS HAZARDOUS ACCOM) 1KB TO OSHA.
Exposure Unit* rtf«r«wtd by Sequence Ninber In the Conposition Section
S«q. Lfnit
None
3. HAZARD IDENTIFICATION
EMERGENCY OVERVIEW
Appearance
Calories* liquid
Odor:
Slight odor
UARNimi STATEMENT
CAUTION « NAT CAUSE ETE IRRITATION
ASPIRATION HAZARD If SHALLOWED •
CAN ENTER IUNCS AND CAUSE DAMAGE
CONTAMINATION MAT RESULT IN DANGEROUS CXU PRESSURE «U1L6-UP
NMIS NFPA
Health: 1 Reactivity: 0 Health: 1 Reactivity: 0
rinowbility: 1 Special ; - flanaability: 1 Special : -
POTENTIAL HEALTH EFFECTS
ETE SKIN INHALATION INGESTION
Primary Route of Exposure: XX *
EFFECTS OF OVEREXPOSURE
Acute:
Eyes:
May cause irritation, experienced a* aitd discoafort and seen as slight
excess regies* ef the eye.
PAGEt 2 .
N.D. • NOT DETEIMINED ST.A. - MOT APPLICABLE M.T. - HOT TESTED
< - LESS THAN > - GREATER THAN
3-79
-------
JBFFSOL PC
HUNTSMAN CHEMICAL CO.
PRODUCT CODEt 75436
DATE ISSUEDj 10-31-94
PRODUCT CODEt 7S436
NAMEj JSPPSOL PC
Data Xsauadt 10-31-f
Supersede*« 07-01-9
3. HAZARD IDENTIFICATION (COMT)
Skin:
irief contact is not irritating. Prolonged contact, a* iiith clothing
wetted with material, My cause defatting of skin or irritation, (ten u
local redness with possible a»i Id discomfort.
Other than the potential skin irritation effect* noted above, acute (short
ter») adverse effects are not expected froai brief skin contact! see other
effects, below, and Section It for information retarding potential long'
tera effects.
Inhalation:
Vapors or aist, in excess of peraissible concentrations, or in unusually
high concentrations generated from spraying, heating the material or •>
from exposure in poorly ventilated areas or confined spaces, wy cause
irritation of the nose and throat, headache, nausea, and drowsiness.
Ingestion;
If more than several nouthfult are swallowed, abdoainal discoafort, nausea,
and diarrhea My occur. Aspiration nay occur during swaltowing or waiting
resulting in lung damage.
sensitization Properties:
This product is not expected to be a hunan skin sensitizer based on aniaal
data.
Chronic;
Ha adverse effects have been documented in hunan* as a result of chronic
exposure. Section 11 My contain applicable aniMl data.
Medical Conditions Aggravated by Exposure:
There is no evidence that this product aggravates an existing Mdical
condition.
Other Remrks:
None
M.S.
<
MOT DETERMINED
LESS THAN
PAGEi 3
N.A. - HOT APPLICABLE
»• - GREATER TEAM
M.T. - MOT TSSTSD
3-80
-------
JEFFSOL PC
HUNTSMAN CHEMICAL CO.
PRODUCT COClt 75436
OATB ISSUEDi 10*31*94
PRODUCT CODSi 75436
Sat# Xc«u*di
10-31-9
Utllf, .tlfVQAT. DO
BIAIIfii vAcCSwii fw
Supersedest
07-01-9
4 * wXRS^ir AZu SmsAjSukxS
lyes:
Imtdietely flush eyes with plenty of wtir for at lust IS minutes. Hold
eyelids apart while flushing to rinse entire surface of eye and lids with
water. Oat aedical attention.
Skin:
Hash akin with plenty of soap and water for several minutes. Cat medical
- attention if akin Irritation develops or persists.
Ingestions
If person is conscious and can swallow, give two siestas of water (16 oi.)
but do not induce vaulting. If vaulting occurs, give fluids again. Nave
medical personnel determine if evacuation of stomach or induction of
vomiting is necessary. Do not give anything by snuth to an unconscious or
convulsing person.
Infcatation:
If irritation, headache, nausea, or drowsiness occurs, reaeve to fresh air.
Get Medical attention if breathing becomes difficult or respiratory
irritation persists.
Other I Detractions!
Aspiration of this product during induced emesis stay result In severe ting
injury. If evacuation of stomach Is necessary, use method least likely to
cause aspiration, such as gastric lavage after endotracheal imitation.
Contact a Poison Canter for additional treatment information.
5. FIRE - FIGHTING MEASURES
Ignition Taaperature (degrees F>:
not determined,
flash Point (degrees F):
275 (CC)
Flammable limits (X):
lower: 2.3
Uppers Not determined.
lecoMMnded Fire Extinguishing Agents And Special Procedure*:
Use water spray, dry chemical, foam, or carton dioxide to extinguish
flanes. Use water spray to cool lire-exposed containers. Water or
foam aay cause frothing.
PAGBt
N.D. - HOT DETERMINED M.K. - MOT APPX.XCJUBU N.T. - NOT TSSTSD
< - LESS THAN > • GREATER THAN
3-81
-------
JEFFSOL PC
HUNTSMXN CHEMICAL CO.
PRODUCT CODIi 75436
DATS ISSUEDi 10-31-94
PRODUCT CODEI 7543C
NAKEs JEFFSOL PC
Data Iaauadt
Suparsadaat
10-31-94
07-01-9'
5. FIRE-FIGHTING MEASURES (CONT>
Unusual or Exploit** Hazards >
Nan*
Special Protective Equipment for Firefighters:
U«ar full protective clothing and positive pressure breathing apparatus.
6. ACCIDENTAL RELEASE MEASURES (Transportation SpillsI CHQCTREC (800)424-9300;
Procedure* in Cass of Accidental leleasa, Ireakaga or leakage:
Contain spill if possible, contain with absorbent aaterlsls such a* clay or
soil, and shovel ip. Avoid skin and eya contact.
If acre than 10,000,000 poinds of product is spillad, than report spill
according to SAM 304 and/or CEICUk 102(a) requireaenta, idlest product
qualifies for the petroleus exaction (CERCU Section 101(1«».
7. HANDLING AND STORAGE
Precautions to be Taken in
Handling:
Miniaui feasible handling ta^aeratures should be aaintalnad.
Storage:
Periods of exposure to M0t te^eraturas should be •iniaized. Water
contamination should b* avoided.
Alkyl carbonates my decompose in the presence of Hater, acids, bases,
salts, or aatal oxides sucfc as somen rust to causa a pressure butld-ip in
processing or storage vessels. This say lead to mature of th* container.
Pressure-relief devices are rece—ifidud on such containers.
8. EXPOSURE CONTROLS /PERSONAL PROTECTION
Protective Equipment (Type)
Eye/face Protection:
Safety glasses, chaaical type goggles, or face shield recoawoded to
prevent eye contact.
— ¦ PAGBt 5
N.D. - NOT DETERMINED N.A. - NOT APPLICABLE N.T. - NOT TESTED
< - LESS TEAN > - GREATER THAN
3-82
-------
JSFFSOL PC
HUNTSMAN CHEMICAL CO.
PRODUCT CODSi 7543«
DATE ISSUEDt 10-31-94
Cats Zaauadi 10-31-94
Suparaadeat 07-01-94
6. EXPOSURE CONTROLS/PERSONAL PROTECTION (COST)
PRODUCT CODSi 75436
NAME: JEFFSOL PC
Skin Protection:
Workers ahould aash exposed skin several tlaes dolly widi soap and water.
Soiled work clothing should bo I under ed or dry-cleerad.
tespiratory Protection: .
Airborne concentration* should be kept to lowest levels possible. If
vapor, Rist or dust 4* generated and the occupational exposure Unit of the
product, or any component of the product, is exceeded, mm appropriate
kiosk of MSM approved air purifying or afr stcplled respirator after
dcteraining the airborne concentration of the contaminant. Air supplied
respirators should always be Horn rihen airborne concentration of the
contaarinant or oxygen content is uiknowi.
Ventilation:
local exhaust ventilation recoamended if generating vapor, dust, or aist.
if exhaust ventilation la not available or inadaqwta, use HSKA or KtOSH
approved respirator as appropriate.
Exposure tiait for total Product:
None established for product.
9• PHYSICAL AND CHEMICAL PROPERTIES
Appearance:
Colorless liquid
Odor:
Slight odor
¦oiling Point (degrees F):
468
Helting/Freeting point (degrees f):
-56
Specific Gravity (uater«1):
1.203
pK of todiluted product:
r
* PAGE < 6
M.D. - NOT DETERMINED N.A. - HOT APPLICABLE H.T. - HOT TESTED
Uadd * n n ii # vKaIIIbX> *aabi
3-83
-------
JEFFSOL PC
HUNTSMAN CHEMICAL CO.
PRODUCT CODEi 75436
DA'i'js ISSukui 10*31 *94
PRODUCT CODE« 75436
Dat« Zasu«di 10-31-9
HAKE« JEFFSOL PC
8up«ra«das t 07*01-9
9 » PHYSICAL AND ^msfltlCAL PROPERTIES (CONTJ
Viper Pressure:
.02 unHg at 68,0
Viscosity:
1.6 e$t at 43.3 C
VOC Content:
Not determined.
Vapor Density (eir«1):
3.5
Soliijility In Utter (X):
1 - 10
. other: Nana
10. STABILITY AND REACTIVITY
This Material React* Violently With:
(if Othar* it checked below, tee comwnti for details)
Air water Neat Strong Oxidizers Others None of These
X
Cements:
Nona
Products Evolved Wien subjected to Neat or Confcustion:
Toxic levels of carbon Monoxide, carbon dioxide, irritating aldehydes and
ketones nay be formed on burning. Keating in air aay produce Irritating
aldehydes, acids, and ketones.
Hazardous Polarizations: 00 HOT OCOX
11. TOXZOOLOGICAL INFORMATION
TOXtCOLOGICAL INFORMATIOIKANINM. TWICITT DATA)
Median Lethal Cose
Oral:
1850 » 5.00 g/kf (rat) practically non-toxle
— FAGIi 7
N.D. - NOT DETERMINED N.A. - HOT APPLICABLE M.T. - NOT TESTED
< - LESS THAN > - GREATER THAN
3-84
-------
jeffsol fc
HUNTSMAN CHEMICAL CO.
PRODUCT CODBi 75436
DATS ZSSTIlSt 10-31-94
PRODUCT CODSi 75436
NAME > JEFFSOL FC
D«fc« X*8U6di 10-31-94
Supari«d«at 07-01-94
11. TOXICOLOGIC*!. INFORMATION (COOT)
Inhalation:
laI laved to be practically nan-toxic
Derail:
LOSS > 1.00 g/kg (rabbit) practically non-texle
Irritation Indti, Estimation of Irritation (Species)
Skin:
(Oralit) .20 /S.O (rabbit) no appreciable effect
tyess
(Oraize) 12.50 /HO (rabbit) slightly Irritating
Sensitization:
(luehler) Negative • skin (guinea pig)
Otheri
This product ¦ay contain residual (last than 100 ppaj cancantrationa of
propylene oiide. There I* evidtnee that propyl ana oxide causes tuners in
laboratory animals.
12. DISPOSAL CONSIDERATIONS
Uasta Disposal Mathodt
this product has been avaluatad for ftCM characteristics and doe« not staet
tha eritaria of a hazardous uasta if discarded in Its purchased form.
Undar (CM, it ia tha responsibility of tha usar of tha product to datar-
¦irw at tha tiaa of disposal, Mhathar tha product seats (CU eritaria for
hazardous waste. this is becauae product uses, transforsatiom, ¦ixtures,
processes, etc. eey render tha resulting aateriala hazardous.
Ramarfcs
Nona
13. TRANSPORT INFORMATION
Transportation
DOT:
Proper Shipping Naaa:
Not regulated
IKS:
Proper Shipping Naae:
Mot evaluated
PAGE) 8
N.D. - NOT DETERMINED N.A. - HOT APPLICABLE N.T. - NOT TESTED
< - LESS THAN » - GREATER THAU
3-85
-------
JEFFSOL PC
SONTSXAH CHEMICAL CO.
PRODUCT CODBi 75436
DATE ISSUEDi 10*31-94
PRODUCT CODEi
75436
Date I««ued»
10-31-94
NAME> JEFFSOL
PC
Supersede*«
07-0i.fi
13. TRANSPORT
INFORMATION (CONT)
ICAO:
Proper Shipping Hum:
Not evaluated
TOGS
Proper Shipping Name:
Nat regulated
14. REGULATOR* INFORMATION
Federal Regulations:
SAM Title III:
Section 302/304 Extreeety Hazardous S instance*
Seq. Chemical Nam CAS Nunber Range in X
01 Residual propylene oxide (typical) 75-56-9 0.001
Section 302/304 Extremely Xazardous Siiatances (CQHT)
Seq. TPS M
01 10000 100
Section 311 Hazardous Categorization:
Acute Chronic Fire Pressure Reactive It/A
X
Section 313 Toxic Chaaical
Cheaical Mae CAS Nunfeer Concentration
Hone
CERCIA 102(a)/D0T Hazardous Sitetances: {~ indicates DOT Hazardous Substance)
Seq. Chosical Dane CAS Number Range in X
01* Residual propylene oxide (typical) 75-54-9 8.001
CERCLA/DOT Kaiardous Sifcttances (Sequence Rtabera and RO's):
Seq. 80
01* 100
PAGEi 9
N.D. - NOT DETERMINED N.A. - NOT APPLICABLE N.T. - NOT TESTED
< - LESS THAN > - GREATER THAN
3-86
-------
JEFFSOL PC
HUNTSMAN C8EMICAL CO.
PRODUCT CODEi 7543C
DATS ISSUEDi 10-31*84
PRODUCT CODSi 7543$ D«t* Ia«u«dt 10-31-9
NAMEt JEFFSOL PC 8«p«rHdlli 07-01-9
14. REGULATORY INFORMATION (CONT)
TtCA Inventory Status:
This product tt Mated an the faxic Sifcstaree Control Act (TIC*} Oiearfcal
Sliistance Inventory.
Other:
- Hoot.
State Regulations:
C«l iform* Proposition 65:
The follouing detectable caaponsnts of this product are sttxtanees,
or belong to classes of siJsstances, knotm to the State of California
to cause cancer and/or reproductive toxicity.
Chemical Name CAS Umber
Residual propyl"* oxide (typical) 75-56-9
States tight-to-fcnou letutations;
Cheaical Name State Right-to-knoii
Hone
State lilt; CT (Connecticut), Fl (Florida), II (Illinois), HI (Hichitan)
U (Louisiana], HA (Massachusetts), IJ (Nan Jersey),
M (Pennsylvania), RI (Rhode island).
International Regulations:
Export notification (TSCA-12fa):
This product say be si4>Ject te export notification wider TSCA
section 12(b); contains:
Residual propylene oxide (typical)
tnwis Classification:
lot refulated
Canada Inventory Status;
Alt eosponents are listed en the Canadian Donestie Substance List (SSL).
PAGEs 10-
H.D. - NOT DETERMINED N.A. - NOT APPLICABLE N.T. - NOT TESTED
< - LESS THAN > • GREATER THAN
3-87
-------
JEFFSOL PC
80NTSMAN KM ICAL CO *
PRODUCT CODBt 75436
DATS ISSUEDt 10-31-94
PRODUCT CODSt 75436 Dat« Xflauad* 10-31-S
NAME: JIFFSOL PC Sup«ra»d«s» 07-01-9
14. REGULATORY INFORMATION (CONT)
CINECS Inventory Status:
All canporwntj ara listed art th* European Inventory of Existing Chemical
Substances (CINECS}.
Australia Inventory Statu*:
All components ara listed art the Australian inventory of Chemicat
Substances (ACIS).
Japan Inventory Status:
All components ara listed on the Japanese HIT I inventory.
15. ENVIRONMENTAL INFORMATION
Aquatic Toxicity:
Not determined.
nobility:
Not determined.
Persistence and liodegradabititys
Mot determined.
Potential to lisaccuiulate:
Not determined.
Remarks;
Nana
16. OTHER INFORMATION
Propoxylated products say contain residual amounts of fret propylene oxide.
Residual propylene oxide can accvuulate In the container headspaee and be
released into the anient envirorasent. This process is enhanced irftan the
product is agitated, at during tank car loading and unloading, and blending
operations. There is evidence that propylene oxide causes tumor* fn
laboratory animals. The OSMA and ACGIN eight-hour time mighted average
exposure limits are both 20 ppm. The Huntsman internal standard is 19 ppm
for an eight-hour time weighted average exposure.
PAGE: 11
N.D. - NOT DETERMINED N.A. - NOT APPLICABLE N.T. - NOT TESTED
< - LESS THAN > - GREATER TSAN
3 - 88
-------
JBPFSOL PC
HUKTSKAN CHEMICAL CO.
PRODUCT CODSi 75436
DATS ISSUEDt 10-31-94
Data laauadi 10-31-94
Supariadaai 07-01-94
16. OTHER INFORF.^TIOH (CONT)
PRODUCT CODSt 7S436
MAKEi JBFFSOL PC
THE INFORMATION CONTAINED HEM IN IS RELIEVES TO tf ACCURATE. IT II PROVIDED
independently of ur iale of the product for purpose or hums comunication
AS MKT Of HUNT SHAM'S PRODUCT SAFETY PROGRAM. IT IS HOT INTENDED TO CONSTITUTE
PERFORMANCE INFORMATION CONCERNING THE PRODUCT. NO EXPRESS WARRANTY, OR
IMPLIED WARRANTY OF MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE IS
HADE WITH RESPECT TO THE PRODUCT OR THE INFORMATION CONTAINED HEREIN. DATA
SHEETS ARE AVAILABLE FOR ALL HUNTSMAN PRODUCTS. YOU ARE URGED TO OR? A IN DATA
SHEETS FOR ALL HUNTSMAN PRODUCTS TOU RUT, PROCESS, USE OR DISTRIBUTE AND YOU
ARE ENCOURAGED AND REQUESTED TO ADVISE THOSE UNO MAY COME IN CONTACT WITH
SUCK PROOUCTS OF THE INFORMATION CONTAINED HEREIN.
TO DETERMINE APPLICABILITY OR EFFECT OF ANY LAU OR REGULATION WITH RESPECT TO
THE PRODUCT, USER SHOULD CONSULT HIS LEGAL ADVISOR OR THE APPROPRIATE
GOVERNMENT AGENCY. HUNTSMAN DOES NOT UNDERTAKE TO FURNISH ADVICE OH SUCH
NATTERS.
Date; 10-31*94 Nan X Revised, St^wrsedes: 07-01-94
Inquiries regarding MSDS should be directed to:
Huttsaan
Coordinator, Product Safety
P.O. Box 27707
Houston, TX 77227-7707
PLEASE SEE NEXT PAGE FOR PRODUCT UkSEL
<
PAGEi 12-
M.D. - HOT DETERMINED H.A. - NOT APPLICABLE H.T. - HOT TESTED
• LESS TEAK > - GREATER THAN
3-89
-------
JEFFSOL PC
tnjyf SMxy csocMticyihJCi co •
PRODUCT CODEi 75436
DATE ISSUEDi 10-31-94
PRODUCT CODIi 75436
Dat« Iaau«dt
10-31-5
KAKEt JEFFSOL PC
Supiriidui
07-01-9
17. PRODUCT LABEL
READ MB UNDERSTAND MATERIAL SAFETY BAT* SHEET IE FORE HANDLING OR DISPOSING
Of MOOOCT. TNIS IAIEL COMPLIES U1TN THE RETIREMENTS OF THE OSNA NA2AR0
COMMUNICATION STANDARD (29 C« 1910.)200) FOR USE IN TNE WORKPLACE. THIS
LABEL IS NOT INTENDED TO IE USED WITH PACKAGING INTENOEO FOR SALE TO CONSUMERS
ANO NAT NOT CONFORM WITH THE REOUIREICNTS OF THE CCMSIWR PR0OUCT SAFETY ACT
OR OTHER RELATES REGULATORY REQUIREMENTS.
75436 JEFFSOL PC
WANING STATEMENT
CAUTION I MAT CAUSE EYE IRRITATION
ASPIRATION HAZARD IF SWALLOWED •
CAN ENTER LUNGS AND CAUSE OAKAGE
CONTAMINATION HAT RESULT IN DANGEROUS C02 PRESSURE KJILD-UP
PRECAUTIONARY MEASURES
-Avoid prolonged breathing of vapor, afst, or (aa.
-Avoid contact with eyes.
-Keep container closed.
-Wash thoroughly after handling.
FIRST AID
Eye Contact:
tmedistely f luah eyes with plenty of water for at leaat 15 alnute*. Moid
eycUda apart tfiila flushing to rinse antira surface of «yt and lids with
water. Get Medical attention.
Skin Contact:
Wash skin with plenty of soap and water for several airutes. Get aedfeal
attention if akin Irritation develops or persist*.
Ingestion:
If person Is conscious and can swallow, give two glasses of water (16 ox.)
but da not induce vaulting. If voaiting occurs, give fluids again. Nave
aedical personnel deteraine if evacuation of atoaeeh or induction of
malting is necessary. Do not give anything by aouth to an unconscioua or
convulsing person.
Inhalation:
If irritation, headache, nausea, or drowsiness occurs, raaove to fresh air.
Get aedical attention if breathing becuaei difficult or respiratory
irritation persists.
PAGE* 13-
H.D. - NOT DETERMINED N.A. - HOT APPLICABLE H.T. - HOT TESTED
< • LESS TEAM » - CREATES, THAH
3 - 90
-------
JBFFSOL PC
HUNTSMAN CHEMICAL CO*
PRODUCT CODEt 75436
DATS ISSUEDt 10-31-94
PRODUCT CODEs 75436
KJUCEi JBFFSOL PC
D«t« lasuadi
Supersedest
10-31-94
07-01-94
i»i t>Bnr>rrr«r t itvr.
A# • lrK.UwvvT Li AC all \wUJM f|
Met* to Physician:
Aspiration of this product during induced aaesfs My result in severe ling
injury. If evacuation of stomach fa necessary, uaa method toast likely to
causa aspiration, such at gastric lavage aftar endotrecheal intimation.
Contact a Poison Canter for additional treatment information,
fill
In case of fire, u>e water apray, dry cfcemical, foam or carbon dioxide,
water nay cause frothing, use water spray to cool fire-exposed containers.
If sore than 10,000,000 pounds of product is spilled, than report spill
according to SARA 304 and/or CER&A 102(a) requirements, uitess product
qualifies for the petroleum exeaption (CtRCIA Section 101(H)).
OiMiical Name CAS Nuifeer Range in I
* 1,J-dioxolan-2-one, methyl* 108-12*? 100.00
PRODUCT IS HAZARDOUS ACCORDING TO OS HA (1910.1200).
• COMPONENT IS HAZARDOUS ACCORDING TO CSKA.
Pennsylvania Special Hatardoua SubatanceCs) CAS KuMbar Range in X
Hone
HMIS NFPA
Health: 1 Reactivity: 0 Health: t Reactivity! 0
Flatmabilitys 1 Special : - r I Mutability: 1 Special : -
Transportation
DOT:
Proper Slipping
Hot regulated
PASS: 14-
H.D. - NOT DETERMINED N.A. - NOT APPLICABLE M.T. - HOT TESTED
< - LESS THAN > - GREATER TEAM
3-91
-------
JSFFSOL PC
ttUHU'SKAH QKDCICWE# CO •
PRODUCT CODIt 75436
DATS ISSUEDt 10-31-94
PRODUCT CODSi 75436 Date Iaiuedi 10-31-94
HAMSI JKFPSOL PC Supersede*t 07-01-94
17. PRODUCT LABEL (CQMT) ~~ *
CAUTION: Hisusa of aapty containtra can ba hatardoua. fapty eont»inar« can
ba hazardous If ustd to stera toxic, flammobtt, or raacttva
Mtarials. Cutting or Mtdfng ot amply contairwrt aiaht causa
lira, axploaien ar toxic fuaas fraa raciduaa. Do not prassurUa
ar expo** to apart flaat or liaat. Keap eontainar cloud and driai
bungs in plac*.
Kanuftcturar'* Nana and Address:
huh raw*
*.0. lox 27707
Houston, TX 17227-7707
TRANSPORTATION EMERGENCY Company: (409) ?2f-0U1
CNEHTIECs (BOO) 424-9300
HEALTH EMERGENCY Cmpmt: (914) 831-WOO
3 -.92
-------
MATERIAL SAFETY DATA SHEET
fiCHt :>V : „ IIOfAS Df DATOS
SIGNAL ETtQUE DE SECURI0AO
4 Q*mktnt0UmKnchfait 9*ktt. toe
-T-.— _ « — 2219** %rfv*J Im
J.T.Baker *>«i>pt~r,,Nio»»»s
24-Hour bntrgmry T«t«phonc »0*«59itSl
' National teporo* C«m«* §00-4?*~If Oi
® Onntttc »00 4?4«J00
National Rupees* m Canada
CANUTEC 6H 9W-MM
Outlid, U S. «td C*iad*
Oiamrcc isz-w J-Hlt
WOTi: CHIMTKC CANIJTK and National Iciponw CwKtf tmtrgeney numtwn art ID Im tnttf arty hi
fcc cwrit af chr«nkf«, HOWit 9f »clkStfit hwMi
AH noo-tmtryrey quttUom Ihcotd bt tHrtmd to Cialamtt Swrtct (IJWjtmm) let
M4628 -05
Effective: 01/04/94
Methyl Ethyl Ketone*
Page: 1
Issued: 05/29/96
Mallinckrodt Baker,Inc., 222 Red School Lane, Phillipsburg, NJ 08865
SECTION I - PRODUCT IDENTIFICATION
Product Name: Methyl Ethyl Ketone
Common Synonyms: 2-Butanone; MEK; Ethyl Methyl Ketone; Methyl Acetone
Chemical Family: Ketones
Formula:
CHgCOCHgCHg
Formula Wt.: 72.11
CAS No.: 78-93-3
NIOSH/RTECS No.: EL6475000
Product Use: Laboratory Reagent
Product Codes; 5385,3323,9214,9319,5808,Q531,9211
PRECAUTIONARY LABELING
BAKER SAF-T-PATA* System
ICftLTH
ROCT1WTY COHTflCT
2 A4 2 2
Laboratory Protective Equipment
U.S. Precautionary Labeling
DANGER!
CAUSES IRRITATION. EXTREMELY FLAMMABLE. HARMFUL IF SWALLOWED OR INHALED.
LABORATORY TEST RESULTS INDICATE MATERIAL MAY BE TERATOGENIC.
Keep away from heat, sparks, flame. Avoid contact with eyes, skin, clothing.
Avoid breathing vapor. Keep In tightly closed container. Use with adequate
ventilation. Wash thoroughly after handling. In case of fire, use alcohol
foam, dry chemical, carbon dioxide - water may be ineffective. In case of
spill, soak up with sand or earth. Flush spill area with water.
(*) COPYRIGHT 1996 MALLINCKRODT BAKER, INC. (reproduced with permission)
3-93
-------
MATERIAL SAFETY DATA SHEET
flCllt , HOJAS DE DATOS
SIGHALETIOUE DE SECUR1DAD
IT Baker Nitionji tmpam* In Cmissa**t«ta«s«ca*s**aat*K*i>i*i»c**aiat«tBS>>«IBItiaiSSKSSIIIBtZtltBBSeKtBBS>axZSSC*>Z
SECTION II - COMPONENTS
Component CAS No. Weight % OSHA/FEL ACGIH/TLV
Methyl Ethyl Ketone 78-93-3 99-100 200 ppm 200 pptn
SECTION III - PHYSICAL DATA
e«SS«SSSSSSSSSSKKaSKSSCS«aS9eKSaSSSSSWWBSBBSBBBSSSSXS*SS«B«BBSBBBXaSSSSS35SSaB
Boiling Point: 8G*C (176"F) Vapor Pressure (mmHg): 78
(at 760 mm Hg) (20*C)
Melting Point: -87*C (-124*F) Vapor Density (alr-1): 2.5
(at 760 mm Hp)
Specific Gravity: 0.81 Evaporation Rate: 5.7
(HgO*!) (Butyl Acetate * 1)
Solubility(H20): Appreciable (>10*) * Volatiles by Volume: 100
(21*C)
pH: N/A
Odor Threshold (ppm): N/A Physical State: Liquid
Coefficient Water/Oil Distribution: N/A
Appearance & Odor: Clear, colorless liquid. Ketone-like odor.
3-94
-------
MATERIAL SAFETY DATA SHEET
note • . hojas de datos
SIGNALETIQUE * ' " DE S6GURIOAD
IT Bak#r NiUorul tMponHlnCjn«dj
S totoe,* CANlJliCtl».W««
- 111 Krd Vhnrt law OuWdtU.5
J.T.Baker w»wp»«x*9.niwms o*«r*t« aoi-«u7tu _
~" W M-Mtmir bnargmcy Ttkphon* St NOTt: CHIMT «£C CANUTIC mA N»#imai *««pom« C«nt«r emergency numtw* *• to bt tnc4 only In
NjQdtijI I*ipon*« CerHfT #00 A 24.f 80J In rveot BlrtwwkilBtiiumdw ItwroMftg * Iwfc, fc*. fjwot or «cddwit ThwJc^t
" Qwmlrtc »00-#i4 »W0 A> nwi-cfnttgtncy quCTUont dwuM H» OkI«< to Ci»t«B«f >«r»4c« (1 -iOOITBAKtg) ft M*%hlMK€
M4628 -05 Methyl Ethyl Ketone Page: 3
Effective: 01/04/94 Issued: 05/29/96
SECTION IV - FIRE AND EXPLOSION HAZARD DATA
Flash Point (Closed Cup): -B*C (20*F) NFPA 704M Rating: 1-3-0
AutoIgnition Temperature: 403*C (7S9*F)
Flammable Limits: Upper - 11.4 % Lower - 1.8 %
Fire Extinguishing Media
Use alcohol foam, dry chemical or carbon dioxide. (Water may be
ineffective. )
Special Fire-Fighting Procedures
Firefighters should wear proper protective equipment and self-contained
breathing apparatus with full facepiece operated In positive pressure
mode. Move containers from fire area if it can be done without risk. Use
water to keep fire-exposed containers cool.
Unusual Fire & Explosion Hazards
Vapors may flow along surfaces to distant Ignition sources and flash back.
Closed containers exposed to heat may explode. Contact with strong
oxidizers may cause fire.
Toxic Gases Produced
carbon monoxide, carbon dioxide
Explosion Data-Sensltlvlty to Mechanical Impact
None identified.
Explosion Data-Sensitivity to Static Discharge
None identified.
SECTION V - HEALTH HAZARD DATA
Threshold Limit Value (TLV/TWA): 590 mg/m* (200 ppm}
Short-Term Exposure Limit (STEL): 885 uig/in* (300 ppm}
Permissible Exposure Limit (PEL): 590 mg/m* (200 ppm)
Toxicity of components
Oral Rat LDgg for Methyl Ethyl Ketone 2737 mg/kg
3-95
-------
MATERIAL SAFETY DATA SHEET
I ICItt - . ;.... NNAS DE DATOS
SIGNAIETIQUE DE SEGURIDAD
I T Baker Nittaul Roponwiri Caruid#
/OnjHonrfMrtntMsirfctaii 6x GWUItC HI 9W-MM
-I-_ _ , _ MJUfd Vtinrtlaw Oihi00 Mi non-emergency quevttom *»uM bt directed to Customer Vervlce (HtOO-|lg*Btlt) lof ««frt«K«.
M4628 -05 Methyl Ethyl Ketone Page: 4
Effective: 01/04/94 Issued: 05/29/96
• ***ai«**iiiKia««aM««»ii«v*BaaaatiBBaHSBBBBaavKBBaBaaBS«BBBB»«Ka«atta«««»«aa«ii««aa«aa
SECTION V - HEALTH HAZARD DATA {CONTINUED)
ltllKjlsi«»a»ftBttaMi»s«BBaaflasKaassi«l«K«a«aisilias>aliaa«aiB>iHa»st«aaa«aaBSai
Intraperitoneal Mouse LD^q Tor Methyl Ethyl Ketone 616 mg/kg
Skin Rabbit LD^q for Methyl Ethyl Ketone 13 g/kg
Carcinogenicity: NTF: No IARC: No , Z List: No OSHA Reg: No
Carcinogenicity
None identified.
Reproductive Effects
Tests on laboratory animals indicate material may be teratogenic.
Effects of Overexposure
INHALATION: headache, nausea, vomiting, dizziness, drowsiness,
irritation of upper respiratory tract, unconsciousness
SKIN COOTACT: irritation, prolonged contact may cause dermatitis
EYE CONTACT: irritation, nay cause temporary corneal damage
SKIN ABSORPTION: none identified
INGESTION: headache, nausea, vomiting, dizziness, gastrointestinal
irritation, central nervous system depression
CHRONIC EFFECTS: central nervous system depression
Target Organs
nasal septum, lungs, eyes, skin, mucous membranes, in animals: liver,
kidneys, lungs, spleen, brain
Medical Conditions Generally Aggravated by Exposure
respiratory system disease, skin disorders
Primary Routes of Entry
inhalation, ingestion, eye contact, skin contact
Emergency and First Aid Procedures
INGESTION: CALL A PHYSICIAN. If swallowed, do NOT induce vomiting.
INHALATION: If inhaled, remove to fresh air. If not breathing, give
artificial respiration. If breathing is difficult, give
oxygen. Prompt action is essential.
3-96
-------
MATERIAL SAFETY DATA SHEET
IICHC • . i- . MCMAS DE DATOS
SIGNAL ETIQUE OE SEPUHIDAP
| T Ditaf NaUonrf Hcsporae in Canada
ABMm •*MmHrntn*t kw. tot CANUttC *11-WKW
T—, _ . Q#*«*) lor mhiant
M4628 -05 Methyl Ethyl Ketone Page: 5
Effective: 01/04/94 Issued: OS/29/96
SECTION V - HEALTH HAZARD DATA (CONTINUED)
SKIN CONTACT: In case of contact, flush skin with water.
EYE CONTACT: In case of eye contact, immediately flush with plenty of
water for at least 15 minutes.
C4DA /TTTf D fit UiT A nn jr> >U'PmPTPg Kl.j| it CTC
9nKn/ X X JtUC« 111 itA/JiivlJ La 1 CwiJKJLLj 3IF1C1 Li3 i<9
Acute: Yes Chronic: Yes Flammablllty: Yes Pressure: No Reactivity: No
Extremely Hazardous Substance: No
CERCLA Hazardous Substance: Yes Contains Methyl ethyl ketone CRQ » i LB)
SARA 313 Toxic Chemicals: Yes Contains Methyl Ethyl Ketone
Generic Class: Generic Class Removed from CFR: 7/1/91
TSCA Inventory: Yes
SECTION VI - REACTIVITY DATA
Stability: Stable Hazardous Polymerization: Will not occur
Conditions to Avoid: heat, flame, other sources of ignition
Incompatible*: strong oxidizing agents, strong bases, caustics,
mineral acids, amines and ammonia, halogens, plastics,
rubber
Decomposition Products: carbon monoxide, carbon dioxide
sBssssKBB««BiimaiiK»KKaaiaasa»R«RBiB«««iiaac*««asa«BCSBBB««*BasK)iBKsa*Kafliii«aaa«a«Ba
SECTION VII - SPILL & DISPOSAL PROCEDURES
Steps to be Taken in the Event of a Spill or Discharge
Wear self-contained breathing apparatus and full protective clothing. Shut
off ignition sources; no flares, smoking or flames in area. Stop leak if
you can do so without risk. Use water spray to reduce vapors. Take up
with sand or other non-combustible absorbent material and place into
container for later disposal. Flush area with water.
B
J. T. Baker SOLUSORB solvent adsorbent is recommended for spills of this
product.
3-97
-------
J.T. Baker
4 fetor* inc.
-|--i p| | 222 Red Srtwid [jnc
JT.Baker *i o««$
24-Hour Emergency r«fcphonr 90I1S9.?H1
NaUonJ ftespom* C«nt«r S00-424-KS01
Ot«rr«r*t » 00-424-9 jog
MATERIAL SAFETY DATA SHI
NMIonJ Resporae In Cml Wre. "powrt oc accldertt frtvoMtm chcmkdi.
AJI non-emergent^ gue»tloni ihguld be directed to Cmoroer Semite (l-»00-|T>*m») Im mMMKt.
N4628 -OS
Effective:
01/04/94
Methyl Ethyl Ketone
Page: 6
Issued: 05/29/96
SECTION VII - SPILL & DISPOSAL PROCEDURES (CONTINUED)
Disposal Procedure
Dispose in accordance with all applicable federal, state, and local
environmental regulations.
EPA Hazardous Waste Number; U159 (Toxic Waste)
SECTION VIII - INDUSTRIAL PROTECTIVE EQUIPMENT
Ventilation; Use general or local exhaust ventilation to meet TLV
requirements.
Respiratory Protection: Respiratory protection required if airborne
concentration exceeds TLV. At concentrations up to
100O ppm, a chemical cartridge respirator with organic
vapor cartridge Is recommended. Above this level, a
self-contained breathing apparatus is recommended.
Eye/Skin Protection: Safety goggles, uniform, apron, butyl rubbergloves are
recommended.
SECTION IX - STORAGE AND HANDLING PRECA17TI0NS
SAF-T-DATA* Storage Color Code: Red (flammable)
Storage Requirements
Keep container tightly closed. Store in a cool, dry, well-ventilated,
flammable liquid storage area. Isolate from incompatible materials.
Special Precautions
Bond and ground containers when transferring liquid.
SECTION X - TRANSPORTATION DATA AND ADDITIONAL INFORMATION
Domestic (D.O.T. )
Proper Shipping Name: Ethyl Methyl Ketone
Hazard Class: 3
UN/NA: UN1193 Reportable Quantity: 5000 LBS. Packaging Group: II
3 - 98
-------
^J3aKgr
|.T. Baker
4 *Httt Inc
77? In) !Wtwri Unf
PhMpsb^NIOittS
?4Mour Emwgmry Tdrphor* 90SS59-J151
Htfond Uipomm Cmtm *00^J4-M02
Chcmt/ec f 00-424 9100
MATERIAL SAFETY DATA SHf
NdUoruri Response in Cjrtsd*
CANUIK il j.996 6666
Oubidv U.S. er«t CmtsJs
Chtrnrsc 202-415 7ftH
NOTI: CHCMTRIC. CANUTIC mtd N«4wul Rcfenii Center ctncrgcniy reanberi arc 10 be ml ortyiti
Iht cwfit of chgmkji tmgi}endr< inyoMnq * mH Iwt. Bft, wpwun oc ittMwt ln»tthilnj chtwk^
AI nonemergency c|»eU)
-------
J.T. Baker
A Drm«yt ould be directed lo Cu*tower SefMct (1-MO-f lll*i*MQ lor mhl
-------
APPENDIX 3-3
Materials Compatibility Data
MEK
06/13/95
06/14/95
06/16/95
06/20/95
ID
Description
Initial
Day I
Day 3
Day 7
wt. in mg.
wt. in mg.
wt. in mg.
H't. in mg.
M Ai I
Aluminum 2024-T3
2269.91
2269.57
2269.56
2269.55 ;
MAI 2
Aluminum 2024-T3
2217,87
2217.59
2217.57
2217.55 :
MAI 3
Aluminum 2024-T3
2292.73
2292.33
2292.27
2292.27 '
M Br 1
Brass CDA-360
6341.98
6341.43
6341.40
6341.54
M Br 2
Brass CDA-360
5895.79
5895.16
5895.17
5895.26
M Br 3
Brass CDA-360
6002.47
6001.75
6001.73
6001.71
MNi 1
Nickel N-200
6892.23
6891.88
6891.89 ;
6891.90 |
M Ni 2
Nickel N-200
6912.86
6912.51
6912.52 :
6912.47 !
MNi 3
Nickel N-200
6920.14
6919.93
6919.91 !
6919.89
MSS 1
Stainless Steel 303
6184.46
6184.04
6183.98
6183.96 :
MSS2
Stainless Steel 303
5934.49
5934.16
5934.08
5934 09
MSS 3
Stainless Steel 303
5995.94
5995.58
5995.51 i
5995.53
MAc I
Acetal
1345.22
1350.14
1353.86 j
1358.87 i
MAc 2
Acetal
1344.27
1349.12
1352.84 !
1357.98 [
M Ac 3
Acetal
1343.91
1348.79
1352.43 i
1357.54 |
MBu 1
Buna-N
496.44
1090
1093
944
M Bu 2
Buna-N
494.40
1089
1088
1031
MBu 3
Buna-N
492.26
1079
1094
1063
MDe 1
Delrin
1391.71
1397.79
1403.11
1410.44
M De 2
Delrin
1388 78
1394.76
1399.99 '
1407.53 :
MDe 3
Delrin
1383.26
1389.53
1394.87 i
1402.43 1
MNy 1
Nylon
539.68
539.77
539,80
540.49
MNy 2
Nylon
539.63
539.67
539.74 :
540.25 i
MNy 3
Nylon
540.63
540.72
540.79 I
541,30 :
MTe 1
Teflon
1062.24
1062.61
1062.83 ;
1063.32 i
M Te 2
Teflon
1045.33
1045.90
1046.16 !
1046.63 ;
,M Te 3
Teflon
1057.82
1058.19
1058.43 1
1058.88 i
3-101
-------
Jeffsot PC
06/13/95
06/14/95
06/16/95
06/20/95
ID
Description
Initial
Day I
DayS
Day 7
wt. in mg.
wt, in mg.
•
wt. in mg.
wt. in mg.
JA1 1
Aluminum 2024-T3
2212.98
2213.95
2213.24
2213.56
JA12
Aluminum 2024-T3
2196.45
2197.29
2197.24
2196.94
J AI 3
Aluminum 2024-T3
2177 06
2178.33
2177.56
2177 82
J Br i
Brass CDA-360
5937.62
5938,03
5938.16
5937.76
J Br 2
Brass CDA-360
5922,00
5922.tl
5922.17
5921.55
J Br 3
Brass CDA-360
5860.88
5860.92
5860.98
5860.57
J Ni I
Nickel N-200
6949.88
6950.34
6949.92
6949.77
J Ni 2
Nickel N-200
7055.87
7056.44
7055.91
7055.97
J Ni 3
Nickel N-200
7166.33
7167.18
7166.41
7166.45
JSS 1
Stainless Steel 303
6028.70
6029.78
6028.62
6028.52
JSS 2
Stainless Steel 303
6203.53
6204.41
6203.79
6203.36 :
JSS 3
Stainless Steel 303
6123.63
6124.09
6123.69
6123.62
J Ac 1
Aeetal
1345.13
Hl346J3H
1347.15
1348.81 ;
J Ac 2
Acetal
1347.90
1348.93
1350.51
1351.77
J Ac 3
Acetal
1344.67
1345.82
1347.32
1348 95
J Bu 1
Buna-N
494.84
705.09
736.00
742.98
J Bu 2
Buna-N
490.39
673.81
705.61
727.77
J Bu 3
Buna-N
493.71
702.99
736.13
745.32
JDe 1
Delrin
1396.08
1398.04
1400.22
1402.85 :
J Del
Delrin
1389.87
1392.31
1393.84
1396.10 ;
J De 3
Delrin
1386.56
1388.52
1390.23
1393.79 j
JNy 1
Nylon
538.62
537.08
535.47
534.58 |
JNy 2
Nylon
540.59
538.87
537.34
536.39
JNy 3
Nylon
539.80
539.07
536.69
536.48
JTe 1
Teflon
1047.52
1047.44
1047.41
1047.32
J Te 2
Teflon
1048.35
1048.21
1048.17
1048.13
JTe 3
Teflon
1054.54
1054.61
1054.39
1054.33 i
3-102
-------
I Formulation L
06/20/95
: 06/21/95
06/23/95
06/27/95
ID Description
Initial
Day 1
Day 3
Day 7
wt. in mg.
wt, in mg.
wt. in mg.
wt. in mg.
LAI 1
Aluminum 2024-T3
2169.93
: 2170.01
2169.91
2169.91
LAI 2
Aluminum 2024-T3
2155.42
2155.50
2155.50
2155.49
LAI 3
Aluminum 2024-T3
2170.59
2170.83
2170.56
2170.79
L Br 1 Brass CDA-360
5831.69
5831.45
5830 90
5830.73
L Br2
Brass CDA-360
6111.42
6111.20
6110.84
6110.64
L Br 3
Brass CDA-360
6062.17
6061.79
6061.92
6061.60
LNi 1
Nickel N-200
7089.95
7090.32
7089.95
7089.88
L Ni 2
Nickel N-200
6991.14
, 6991.79
6991.18
6991.25
LNi 3
Nickel N-200
7055.13
: 7055.28
7055.21
7055.23 :
LSS 1
Stainless Steel 303
6052.28
6052.18
6052.27
6052.06
LSS2
Stainless Steel 303
6059.85
6059.76
6059 84
6059.60
LSS 3
Stainless Steel 303
6118.70
i 6118.22
6118.25
6117.96 ;
LAc 1
Acetal
1346.40
i 1347.73
1349.52
1350.81
L Ac 2
Acetal
1345.79
; 1347.09
1348.94
1350.65
L Ac 3
Acetal
1347.96
; 1349.59
1350.61
1351.74 ;
LBu 1
Buna-N
493.95
; 1U6.I5
1140.38
1168.63
L Bu 2
Buna-N
491.69
1093.85
1114.71
1133.41
LBu 3
Buna-N
490.31
j 1082.21
1111.37
1136.57 (
L De 1
Delrin
1384.56
| 1387.13
1390.17
1393.02 |
L De 2
Delrin
1391.07
j 1394.12
1396.23
1399.28 |
L De 3
Delrin
1387.28
! 1390.04
1392.43
1395.76 !
LNy I
Nylon
539.04
; 538.20
538.15
538.39
L Ny 2
Nylon
540.12
! 539.25
539.21
539.61
L Ny 3
Nylon
538.82
S 538.02
537.76
537.87
LTe I
Tenon
1032.15
i 1032.21
1031.98
1031.86
L Te2
Teflon
1072.55
j 1072.25
1072.09
1072.02 :
LTe 3
Teflon
1057.08
; 1056,73
1056.62
1056.64 :
3-103
-------
1
iFormulation H
: 07/10/95
07/11/95
07/13/95
07/17/95
ID
Description
initial
Day 1
Day 3
Day 7
wt. in mg.
wt. in mg.
wt in mg.
wt. in mg.
H Al 1 Aluminum 2024-T3
2107.26
2107.11
2107.53
2106.99
.H A1 2
Aluminum 2024-T3
2169.12
2169.61
2169.44
2169.05
HA! 3
Aluminum 2024-T3
2137.46
2137.86
2137.38
2137.66
H Br i
Brass CDA-360
6593.77
6593.76
6593.08
6593.02
H Br2
Brass CDA-360
5894.67
5894.66
5894.51
5894.23
H Br 3
Brass CDA-360
6113.29
6113.15
6112.99
6112.37
HNi 1
Nickel N-200
7147.23
7147.03
7147,55
7147.01
HNi 2 ]Nickel N-200 ¦
7089.52
7089 69
7089.59
7089.07
HNi 3
Nickel N-200
7232.69
7232.68
7232.34
7232.58
HSS 1
Stainless Steel 303
6533.04
6533.41
6533.00
6532.81
HSS2
Stainless Steel 303
6210.44
6210.19
6209.76
6209.69
1HSS3
Stainless Steel 303
6471.20
6471.58
6471.61
6470.92
|h Ac 1
Acetal
1312.74
1315.36
1316.72
1319.53
H Ac 2
Acetal
1314.82
1317.61
1319.35
1321.40
;H Ac 3
Acetal
1314.25
1316.16
1318.44
1320.00
H Bu 1
Buna-N
485.84
1005.87
1017.19
1028.20
H Bu 2
Buna-N
488.34
1027.32
1038.38
1046,79
H Bu 3
Buna-N
487.20
1074.64
1087.36
1090.16
HDe 1
DeLrin
1347.90
1351.90
1355.56
1357.65
H De 2
Delrin
: 1344.22
1348.99
1351.61
1355.32
HDe 3
Delrin
! 1343.45
1347.11
1349.12
1353.59
HNy 1
Nylon
: 533.88
532,95
532.09
531.84
H Ny 2
Nylon
536.97
535.96
535.76
535.18
jHNy 3
Nylon
536.01
535.07
534.59
534,21
HTe I
Teflon
1044.42
1044.27
1044.24
1044.09
HTe2
Teflon
1039 69
1039.59
1039.41
1039.24
HTe 3
Teflon
1029.32
1029.11
1029.10
1028.86
3-104
-------
jFormulation N
07/10/95
07/11/95
07/13/95 07/17/95
ID
¦ Description
Initial
Day I
Day 3 i Day 7
wt. in mg
wt. in mg
wt. in mg.
wt . in mg.
N Al i
! Aluminum 2024-T3
2110.35
2110.71
2110.53
2110.11
N Al 2
Aluminum 2024-T3
2177.07
2177.33
2176.90
2176.78
NAI3
Aluminum 2024-T3
2182.24
2182.33
2182.62
2182.17
N Br !
Brass CDA-360
6498.09
6498.53
6498.22
6498.18
N Br 2
Brass CDA-360
6667.59
6667.23
6666.81
6666.29
M Br 3
Brass CDA-360
6607.79
6605.93
6606.55
6605.80
NNi 1
Nickel N-200
7033.92
7034.14
7034.24
7033.91
N Ni 2
Nickel N-200
6970.80
6970.72
6970.95
6970.75
NNi 3
Nickel N-200
7231.63
7231.71
7231.34
7231.18
NSS 1
Stainless Steel 303
5911.88
5911.73
5911.74
5911.30
NSS2
Stainless Steel 303
6439.00
6438.81
6438.83
6438.69
NSS 3
[Stainless Steel 303
6199.77
6199.17
6199.16
6198.90
N Ac 1
Acetal
1311.75
1313.55
1314.99
1317.02
N Ac 2
Acetal
1315.26
1317.13
1319.12
1321.36
N Ac 3
Acetal
1316.80
1319.13
1320.51
1322,56
NBu 1
,Buna-N
487.83
1090.62
1102.24
1131.51
N Bu 2
Buna-N
485.82
1066.59
1074.96
1085.58
NBu 3
Birna-N
489.13
1059.95
1075.69
1100.87
NDc 1
'Delrin
1349.63
1352.41
1354.46
1357.53
N De 2
IDelrin
; 1348.82
1351.56
1354.17
1357.30
N De 3
jDelrin
1349.39
1352.78
1355.40
1358.94
NNy I
1
Nylon
536.92
536.48
536.20
536.21
N Ny 2
Nylon
535.93
534.75
535.13
534.73
NNy 3
SNylon
538.74
537.76
537.74
537.60
NTe !
Teflon
1041.37
1040.97
1041.09
1040.90
N Te 2
Teflon
1047.88
1047.99
1047.85
1047.62
NTe 3
'Teflon
1024.41
1023.87
1023.93
1023.90
3-105
-------
Formulation T
07/11/95
07/12/95
, 07/14/95
07/18/95
m
Description
Initial
Day I
Day S
Day 7
wt. in mg.
wt. in mg.
wt. in mg.
wt in mg.
TAl 1
Aluminum 2024-T3
2165.68
2165.71
2166.49
2165.91
TA12
Aluminum 2024-T3
2144.62
2144.67
, 2144.90
2144.37
TAl 3
Aluminum 2024-T3
2184.48
2184,65
2184.02
2184.14
T Br 1
Brass CDA-360
6344.78
6343.06
6342.85
6342.82
T Br2
Brass CDA-360
6414.84
641334
6413.28
6413.29
T Br 3
Brass CDA-360
6569.35
6568.48
6568.32
6568.42
TNi 1
Nickel N-200
7295.98
7295.39
7295.70
7295.61
TNi2
Nickel N-200
7148.85
7148.67
7148.66
7148.75
TNi 3
Nickel N-200
7280.80
7280.09
7280.25
7280.75
TSS i
Stainless Steel 303
6402.90
6402.89
6402.62
6402.86
TSS2
Stainless Steel 303
6202.52
6202.56
6202.61
6202.46
TSS 3
Stainless Steel 303
6424.69
6424.61
6424.40
6424.76
TAc 1
Acetal
1346.60
1347.88
1349.86
1351.13
T Ac 2
Acetal
1341.75
1342.99
1344.30
1346.69
TAc 3
Acetal
1313.94
1315.89
1316.44
1318.76
TBu 1
Buna-N
494.42
1039.18
1050,67
1055.26
T Bu 2
Buna-N
488.19
831.89
874.83
917.76
TBu 3
Buna-N
493.46
1047.04
, 1048.42
1064.07
TDe t
Delrin
1380.05
1382.45
! 1384.86
1387.70
T De 2
Delrin
1392.24
1394.45
i 1396.75
1399.42
TDe 3
Delrin
1344.21
1347.26
; 1349.13
1351.73
TNy 1
Nylon
540.77
538.88
537.68
536.35
TNy 2
Nylon
532.49
530.60
529.50
528.13
TNy 3
Nylon
541.86
539.96
538.60
537.20
TTe 1
Teflon
1066,00
1065.76
1065.63
1065.62
TTe 2
Teflon
1075.42
1075.33
1075.21
1075.13
TTe 3
Teflon
1040.25
1039.95
; 1039.94
1039.90
3-106
-------
id
Control/MEK <£ PC
Description
06/13/95
Initial
06/14/95 06/16/95
Day I
Day 3
Control
Control
ControL
Control
Control __
Control Buna-N
Aluminum 2024-T3
Brass CDA-360
Nickel N-200
Stainless Steel 303
AcetaS
wt. in mg.
2145.25
6247.96
1345.32
494.46
Control
Delrin
1390.61
wt, in mg. hi in mg.
2145.24
6247.94
2145.22
6247.93
7128.72 ' 7128.67
6089.26
6089.24
7128.67
6089.22
1345.06
493.93
1390.24
1344.87
493.81
1389.98
06/20/95
Day 7
wt. in mg.
2145.21
6247.95
7128.68
6089.23
1345,02^
494.07
1390.11
Control
Control
Nylon
539.34
539.05
Teflon
1052.90
1052.91
538.84
1052.90
538.98
1052.90
.Control/L
06/20/95
06/21/95 ¦ 06/23/95
06/27/95
ID
Description
{ Initial
Day I
Day 3
Day 7
1
J wt. inmg.
wt. in mg.
wt. in mg.
wt. inmg.
Control
;Aluminum 2024-T3
\ 2145.23
2145.22
2145.25
2145.22
Control
Brass CDA-360
t 6247.93
6247.96
6247.96
6247.93
Control
Nickel N-200
| 7128.68
7128.68
7128.68
7128.64
Control
;Stainless Steel 303
! 6089.21
6089.25
6089.21
6089.22
Control
^Acetal
j 1345.04
1345.07
! 1345.00
1345.10
Control
Buna-N
494.10
494.12
i 494.03
494.19
Control
Delrin
' 1390.15
1390.25
! 1390.27
1390.52
Control
'Nylon
i 539.05
539.09
; 539.09
539.31
Control
'Teflon
i 1052.91
1052.92
; 1052.90
1052.87
3-107
-------
Corurol/H £ N
07/10/95
07/11/95
07/13/95
07/17/95 •
ID
Description
Initial
Day /
Day 3
Day 7 \
my. in nig.
wt, in mg.
wt in mg.
wt. in mg.
Control
Aluminum 2G24-T3
2145.27
2145.29
2145.27
2145.26 :
Control
Brass CDA-360
6247.96
6247.97
6247.99
6247.98
Control
Nickel N-200
7128.71
7128.74
7128.69
7128.73
Control
Stainless Steel 303
6089.27
6089.30
6089.25
6089.28
Control
Acetal
1345.22
1345.16
1345.12
1345.18
: Control
Buna-N
494.06
494.00
494.00
494.07 !
"Control
Delrin
1390.68
1390.61
1390.59
1390.56
Control
Nylon
539.64
539.55
539.51
539.54
Control
Teflon
1052.88
1052.88
1052.91
1052.86
Corttrol/T
07/11/95
07/12/95
07/14/95
07,-18/95
ID
Description
Initial
Day I
Day 3
Day 7 i
; i
J 1
Ht in mg.
kt in mg.
wt. inmg.
j wt. in mg. ]
iControl
Aluminum 2024-T3
2145.29
2145.27
2145.25
I 2145.27 j
'Control
Brass CDA-360
6247.97
6247.98
6247.93
1 6247.93 !
Control
Nickel N-200
7128.74
7128.75
7128.72
! 7128.66 !
IControl
Stainless Steel 303
6089.30
6089.29
6089.28
; 6089.22 :
IControl
Acetal
1345.16
1345.18
1345.12
1345.12 1
IControl
Buna-N
494.00
494.04
493.99
! 494.10 ,
j Control
Delrin
1390.61
1390.62
1390.51
1390,55 !
'Control
Nylon
539.55
539.53
539.47
: 539.58 ;
iControl
Teflon
1052.88
1052.9
1052.88
; 1052.90 j
3-108
-------
APPENDIX 3-4
Paint Removal Efficiency Data
TWO-COMPONENT CARC - GREEN i
! , ~ ; | PAINT " PAINT
INITIAL
WET
CLEANED
BEFORE !
AFTER
ID
SOLVENT
wt in mg
wt in mg
wt in mg
wt in mg
wt in mg
14
MEK
8061.88
8149.77
8061.88! 87,89
0.00
15
MEK
8095,64
8181.37
8095.66
85.73:
0.02
16
MEK
7983.40
8027.22:
7983.94
43.82
0.54
17
MEK Control
8060.08
N/A
8060.10
0.00
0.02
18
L
8057.87
8137.92
8059.75
80,05
1.88
19
L
8070.20
8124.57
8071,94
54.37;
1.74
20
L
8097.01
8152.74:
8097.50
55.73
0.49
21
L Control
8076.72
N/A
8076.96
0.00|
0.24
22
N
8070.81
8156.68
8073.87
85.87
3.06
23
N
8062.56
8130.33
8065.68
67,IT
3.12
24
N
8142.22
8231.40
8143.61
89.18
1,39
25
N Control
8061.39
N/A
8061.60
0.00
0.21!
ONE-COMPONENT CARC - TAN !
; ;
1
PAINT
PAINT
i INITIAL
WET
CLEANED
BEFORE !
AFTER
ID
SOLVENT
wt in mg
wt in mg !
wt in mg
wt in mg j
wt in mg
1
MEK
7975.70
8199,39;
7975.80
223.69
0.10
2
MEK
8031.68
9369.071
8031.87
I33?,39i
0.19
3
MEK
8043.32
8416.92:
8043.46
373.60!
0.14
4
MEK Control
8067.88
N/A
8067.96
0.00!
0.08
5 !L
8057.25
8354,50,
8080.76
297.25
23.51
6 Sl
8075.43
8388.38!
8147.39
' 312.95
71.96
7
L
8102.38
8597.67
8213.66
495.29!
111.28
8
L Control
8112.67
n/a :
8112.84
o.ooi
0.17
9
N
8084.93
8464.34;
8209.27
379.41,
124.34
10
N
8071.87
8342.84;
8086.26
270.97:
14.39
11
N
8070.94
8330.69
8149.47
259.75!
78.53
12
N Control
8092.03
N/A 1
8092.13
o.oo!
0.10
3-109
-------
UNDERCOATING ~ BLACK
PAINT
PAINT
INITIAL
WET
CLEANED ;
BEFORE
AFTER s
ID
! SOLVENT 1
wt in mg
wt in mg
wt in mg \
wt in mg :
wt in mg
37
MEK.
8126.27
8264.72
8132.12;
138.45
5.85
38
MEK
8071.24
8245.67
8131.531
174.43
60.29
39
MEK
8082.17
8300.06
8151.331
217.89
69.16
40
M E K Control
8149.84
N/A
8149.94;
0.00
0.10
41
!L
8037.06
8228.86
8092.49
191.80
55.43:
42
L
8126 90
8340.46
8228.52
213.56
101.62,
43
L !
8126.65,
8267.33
8215.76!
140.68
89.11 j
44
:L Control
8033.35
N/A
8033.48;
0.00'
0.13|
45
N
8030.66!
8211.59
8112.63!
180.93!
81.97'
46
|N |
8078 82!
8262.86
8165.37-
184.04
86.55;
47
;N 1
8062.38]
8316.23
253.85 j
104.19i
48
N Control ]
8045.29!
N/A
8045.54!
o.ooi
0.25 j
PRIMER
-WHITE
: ! Ill
PAINT |
PAINT
]
INITIAL
WET
CLEANED
BEFORE j
AFTER
ro
SOLVENT
wt in mg
wt in mg
wt in mg
wt in mg |
wt in mg
13
MEK
8120.73
8176.69
8143.08
55.96i
22.35
26
MEK
8056.55
8091.84
8071.03
35.29!
14.48
27
MEK
8063.29
8116.32
8065.94
53.03
2,65
28
MEK Control
8087.34
N/A
8087.35
0.00!
0.01
29
L
8088.85
8135.84
8090.79
46,99;
1.94
30
L
8020.50
8070.73
8021.80
50.23;
1.30
31
L
8057.06
8112.09
8060.27
55.031
3.21
32
L Control
8038.15
N/A
8038,48
0.00;
0.33
33
N
8061.28
8107.00
8063.87
45.72!
2.59
34
N
8054.80
8094.55
8057.94
39.75!
3.14
35
N
8103.35
8138.64
8108.91
35.29'
5.56
36
N Control
8146.49
N/A
8146.62
o
o
©
0.13
3-110
-------
APPENDIX 3-5
Procedure for Monitoring Cleaning Use
CLEANING PAINT EQUIPMENT
* Use keyboard for data entry.
* Make sure printer is on! (Red light will glow.)
1) Press (Start)
2) Enter data when prompted by display:
Display Prompt Code ; Operator entry
Vehicle ID (VID) Press
Vehicle Code
(V)
Press .
Coating Code
(C)
Enter P (Primer) or C (CARC), press .
Your ID
(PI)
Enter 1 (1st shift) or 2 (2nd shift), press .
Partner ID
(P2)
- Enter MEK (ketone) or L (L), press .
Target Amount
(T)
Press .
Pounds per gallon
Enter 6.71 for ketone or 9.18 for L, press .
Scale
(SCL)
Enter 1 (outside) or 2 (inside), press .
3) Screen will prompt "Start Flow Monitor?" Press (Yes)
* The bucket used to collect the cleaner as it is flushed from the hoses and guns is the solvent catch bucket.
Depending on the wash, it may be the hazardous waste bucket, the prewash bucket, or the final wash
bucket. The solvent catch bucket is what goes on the scale!
PREWASH
4) Place solvent catch bucket on scale.
5) Press (yellow button on remote box).
6) Press (blue button on remote box).
7) Clean equipment.
8) When equipment is ready for next step, press .
FINAL WASH
9) Repeat steps 4, 5, 6, 7, & 8.
FILTER WASH
10) Repeat steps 4, 5,6, 7, & 8.
11) To stop, press (Stop); then (Yes).
12) When all data has printed, give data strip to Leaderman.
* Data will print every thirty seconds continuously starting at Step 3.
* Total weight for cleaning will be negative. This is OK!
IMPORTANT: DO NOT HIT WHILE CLEANING!!
To Correct .Errors During Data Entry (Step 2):
Use for current entry.
Use
3-1 ii
-------
APPENDIX 3-6
Material Safety Data Sheets
for
Benzyl Alcohol and Propylene Carbonate
3-112
-------
REPOar NUMBER I 703
USDS NU; FI323VS
EFFECTIVE DATE i 03/31/94'
PRODUCT j BENZYL ALCOHOL
ORDER NO; 136970
PROO NO s 500S8S
WAN WATERS t ROGERS INC. pA0F, 0
MATERIAL SAFETY DATA SHEET
VERSION: O
HUNTSMAN CORPORATION
7114 NORTH LAMAR BLVD
AUSTIN ,TX 787612310
VAN WATERS 4i ROGERS INC. . SUBS CDIARY OF UNIVAR (206)889-3400
6100 CARILLON POINT , KIRKLAND , UA 98033
EMERGENCY ASSISTANCE —
FOR EMERGENCY ASSISTANCE INVOLVING CHEMICALS CALL - CHEHTREC
< 800 >424-9300
************** **** ******** ****** ***** # **
PRODUCT IDENTIFICATION
******************************** ** ******** ****************** ***+ ******** *** *
PRODUCT NAME: BENZYL ALCOHOL
HSOS #s P1325VS
OATE ISSUED; 1-1-94
ISSUED BY: 008547
MANUFACTURER'S MSOS
**************************************£***************************£** ****** *
******************** ** **************** ******** ************** ***•%* *** * *##**•*- «
I PRODUCT INFORMATION
*****************************************************************************
- CHEMICAL NAME? BENZYL ALCOHOL
SYNONYM
-------
REPORT NUMBER I 703 . MAN UATERS & ROGERS INC. PAGE; C
MSOS NOi P1325VS MATERIAL SAFETY DAT* SHEET
EFFECTIVE DATE: 03/31/94 VERSION; 0
PRODUCT! BENZYL ALCOHOL
ORDER NO I 136970
PROD NO s 300585
II SUMMARY OF HAZARDS
WARNING
CAUSES Ere IRRITATION - is a severe eye irritant
EXPOSURE TO VAPORS MAY CAUSE HEADACHE, DIZZINESS, ANO NAUSEA
OVER-EXPOSURE HAY CAUSE CENTRAL NERVOUS SYSTEM DEPRESSION
rift* CAUSE SKIN IRRITATION
HARMFUL IF SUALLOUEO
******************************»******************************************«.*,t
III PHYSICAL PROPERTIES
~¦i-**##*#*##** •*• ~ ~ ill 4fA"ir*4r <% A 4k*i4it+f4k A
APPEARANCE arid ODORi Colorless liquid with an aromatic odor.
BOILING POINT: 401 Oe«. F (205 Org. C>
MELTING POINT! #4.5 Oe§. F t-15.3 Oeg. C>
VAPOR PRESSUREj < 0.1 ia Hg 9 20 Deg. C (68 Oeg. F)
SPECIFIC GRAVITY: 1.045 S 77 0*9. F (H20 - 1)
WEIGHT PER GALLON: S.7*
VAPOR DENSITY! 3.7 (Air - l>
SOLUBILITY IN UATER: Moderate (appro*. 4-3X1
X VOLATILE) 100
EVAPORATION RATE: <0.01 (Butyl acetate - 1)
****************************************************************************
IV FZRE AND EXPLOSION HAZARD INFORMATION
****************************************************************************.
FLASH POINT tTCPi 210 Oeg. F <90.9 0*9, C>
FLAMMABLE LIMITSi Not determined
AUTQIGNITION TEMPI 017 Oeg. F (434 Oeg. C>
DECOMPOSITION TEMPi Not determined
FIRE and EXPLOSION HAZARDSi Decomposition under firm conditions will generat
carbon mono xide and way generate other toxic vapors.
'FIRE FIGHTING INFORMATION: Use C02, foaa, or dry cheeical to extinguish fire
¦ Uater can be used to cool a fir*, but for extingu isheent, foa* or dry chetiic
are preferred, Avoid spreading liquid and fire by water flooding, Uear
self-contained, positive pressure breathing apparatus and full firefishting
protective clothing. Use water to keep containers cool.
3 - 114
-------
REPORT NUMBERi 703 . VAN WATERS & ROGERS INC. PAGE: 0<
MSGS NO I P1S25VS . MATERIAL SAFETY DATA SHEET
EFFECTIVE OATEs 03/31/94 VERSION: 0?
PROOUCT: BENZYL ALCOHOL
ORDER NO: 136970
PROO NO i 3005U3
V HAZARD RATINGS FOR BENZYL ALCOHOL
** ** ***¦**'11?*****# *** A****************** AdkifeAAlfc*'************'******* * * £ * * *
NFPA HEALTH 2 HMIS HEALTH 2
HflZARO FLAMMARILITY 1 RATINGS FLAMWABILITY \
RATINGS REACTIVITY 0 ! 1230 ma/kg
THRESHOLD LIMIT VALUE CTLV): TLV has not been established by the ACGIH.
CARCINOGEN : No
NOTEi Health studies have shown that exposures to chemicals pose potential
health risks which may vary fro* person to person. Exposures to liquid*,
vapors, mists, or fumes should always be minimixed.
ACUTE HEALTH HAZARDS;
Inhalation! Inhalation of concentrated vapor way irritate the nose and thr^i
Overexposure to vapors causes headache, vertigo, nausea, vomiting, and
diarrhea. Over-exposure can cause central nervous system depression.
Eye Contacti Causes eye irritation. Is a severe eye irritant.
Skin Contact! Hay cause skin irritation.
Ingestion: Harmful if swallowed. See L050 data.
CHRONIC HEALTH HAZARDSI
Pro longed contact may cause defatting of the skin.
No other chronic health haztrd information is available,
MEDICAL CONDITIONS GENERALLY AGGRAVATED BY EXPOSURE! None known
EMERGENCY FIRST AIOi
Inhalation! If overcome by exposure, remove to fresh air immediately. 6iv«
oxygen or artificial respiration as needed. Get immediate medical attention.
Eve Contacti In case of eye contact, flush eyes with Plenty of water for *t
least IS minutes, Cet immediate medical attention.
3 - 115
-------
REPORT NUMBER: 703 • UAH UATERS 4, ROGERS INC. PAG«: Ot
MSD5 NO: P1S23VS , . MATERIAL SAFETY DATA SHEET
EFFECTIVE OATEi 03/31/94 VERSION:
PRODUCT: BENZYL'ALCOHOL
ORDER NOi 134970
PROO NO i 500S85
Skin Contact t la case of skin contact, flush skin with plenty of water. Remo
contaminated clothing, Call a physician if irritation develop®. Uash clathin
before reuse,
Ingestion* If swallowed, call a physician immediately. Induce vomiting only
advice of medical personnel. Never give anything by mouth to an unconscious
person.
<.***~¦********»*******¦* ~ '~A****-*********************************************** -
VII PROTECTIVE EQUIPMENT AND EXPOSURE CONTROL METHODS
£4*4-44 * * * 4 -A A 4»* JtA***A4**A*** *********** **** ********** &************»*** -
Use with adequate local enhaust ventilation. In confined or enclosed'space*»
use NIOSH approved respiratory protection. Use chenical resistant apron,
glove?, and other impervious clothing to avoid skin contact.
Us# splash giggles and face shield when ey# contact eay occur. Provide sufct
showar, equipped with an eye wash fountain in the immediate vicinity of »ny
potential exposure! Use goad personal hygiene practices. Uash hands before
eating, drinking, sr seoking, or using toilet facilities. Pronptly remov«
contaminated clothing and wash thoroughly before reuse.
** **********************************************AAA******************** » * » * *
VIII REACTIVITY DATA
****************#*A4******A*****!************************************* **»» + * +
STABILITY! Stable
HAZARDOUS POLYMERIZATION! Uill not occur,
INCOMPATIBLE MATERIALS: Alcohols can react violently in contact with strong
oxidizing agents, isucysnates, aretaldehyde. LiA14, aluminum alkyl compounds
ard strong mineral acids,
HAZARQQUS DECOMPOSITION PRODUCTS! Incomplete combustion will produce carbon
monoxide and ether potentially toxie and/or poisonous vapors.
4 A ************************************ ******************************** ****** *
IX SPILL on LEAK PROCEDURES
****************** ****** ********** ****** ***********'***** ********** ******* ******
'Remove sources of ignition, stop release, and provide adequate ventilation.
Prevent flow to sewer and public waters. Recover free product, if possible.
Cover spill with inert, non-combustible absorbent raterial and remove to
disposal container. Report spill as per regulatory requirements.
Leaking drum should be emptied or placed into an oversiied {recovery $ drum.
3 - 116
-------
REPORT NUhOERi 703 . VAN UTTERS & ROGERS INC. F*nt; v
HSOS NO ( P152SVS , MATERIAL SAFETY DATA SHFET
EFFECTIVE OATE! 03/31/94 % VERSION: C
PRQOUCTr BENZYL ALCOHOL
ORDER NO; 136970
PROD NO : 500SB5
-**«a*****************************************************
X UASTE DISPOSAL
Disposal wust be made in accordance with applicable governmental regulation-.
Do not contaminate any streans, lakes, or ponds.
4«*«**«** + *«***. Benzyl Alcohol is considered hazardoi
under the OSHA Standard.
Benzyl Alcohol is net listed as an Extremely Hazardous Substance under Sect.
302 of SARA Title III.
As a OSHA hazardous substance, Benzyl Alcohol is subject to the reporting
requirements of Sections 311 or 312 of SARA Title III.
Benzyl Alcohol does not contain lna*sdi*nts Cat a level of IX or more) en tf
-List of Toxic Chemicals in Section 313 of SARA Title III.
Benzyl Alcohol is included in the current TSCA Inventory List.
****************************** *************************************** *****< •
XII TRANSPORTATION INFORMATION
3 - 117
-------
REPORT NUMBER: 703 VAN UATERS 4 ROGERS INC.
rtSOS WO: P1S25VS MATERIAL SAFETY DATA SHtET
EFFECTIVE DATEi C3/31/*4
PRODUCT: BENZYL ALCOHOL
ORDER NOs 134770
PROD NO ! 500535
**A* ************ *« ********* ********* ********** ******* *4'** ******** ******** * *
Benzyl Alcohol .Is NOT regulated as s hai srdeus material und»r the regulit ia
of the United States Department of Transportation,
— — poR ADDITIONAL INFORMATION ¦ —-
CONTACT! MSQS COORDINATOR WAN UATERS A ROGERS INC,
DURING BUSINESS HOURS, PACIFIC TIME (206>889-3400
06/14/93 14:52 PHOOUCT; 500505 CUST NO; 333244 ORDER NO; 136?;
NOTICE
** VAN UATERS i, ROGERS INC. ("VU&R") EXPRESSLY DISCLAIMS ALL EXPRESS OR
IMPLIED UARSANTIES OF MERCHANTABILITY AND FITNESS FOR A PARTICULAR PURPOSE,
UITH RESPECT TO THE PRODUCT OR INFORMATION PROVIDED HEREIN, AND SHALL UNDER
NO CIRCUMSTANCES BE LIABLE FOR INCIDENTAL OR CONSEQUENTIAL DAMAGES.**
PARE: t
VERSION: <
ALL INFORMATION APPEARING HEREIN IS 8ASED UPON DATA OBTAINED FROM THE
MANUFACTURER AND/OR RECOGNIZED TECHNICAL SOURCES. WHILE THE INFORMATION IS
BELIEVED TO SE ACCURATE. VU&R HAKES NO REPRESENTATIONS AS TO ITS ACCURACY Ofi
SUFFICIENCY. CONDITIONS OF USE ARE BEYOND VUfcRS CONTROL- AND THEREFORE USKRr:
ARE RESPONSIBLE TO VERIFY THIS DATA UNDER THEIR OUN OPERATING CONDITIONS TO
DETERMINE UHETHER THE PRODUCT IS SUITABLE FOR THEIR PARTICULAR PURPOSES AND
ASSUME ALL RISKS OF THEIR USE, HANDLING, AND DISPOSAL OF THE PRODUCT, OR FRC
THE PUBLICATION OR USE OF, OR RELIANCE UPON , INFORMATION CONTAINED HEREIN
THIS INFORMATION RELATES ONLY TO THE PRODUCT DESIGNATED HEREIN, ANO DOES NO!
RELATE TO ITS USE IN.COMBINATION UITH ANY OTHER MATERIAL OR IN ANY OTHER
PROCESS.
* * * END OF HSOS * * *
3 - 118
-------
JEPFSOL PC
ETOTSMAN CHEMICAL CO.
PRODUCT CODSi 7543C
DATS ISSUEDi 10-31-94 Superaedeai 07-01-94
KAT5RXAL SAFETY DATA SHBST
This USDS waa printed utilising aceeaa to Buataman'a CD-ROM MSDS Database.
Due to variations in printer dependant character atylea, fonta and computer
control codes, the appearance may differ froa that of th# centrally printed
Huntsman USDS.
NOTEi Raad and understand Material Safety Data Sheet before handling or
diaposing of product.
1. CHEMICAL PRODUCT AND COMPANY IDENTIFICATION
MATERIAL IDENTIT?
Product Coda and Nan*:
75434 JEFFSOL K
Chemical Naae and/or Fam'ly or Owcrtotioo:
Mkylane carbonate
Manufacturer'* Dane and Addrest:
HUNTSMAN
0.0. iox 27707
Houston, T* 77227-7707
Telephone Nu*ber»s
Transportation Eaergcncy-Caapany s (409) 727-0831
CHENTIEC : (800) 424-9300
Health Eaergancy -Company : (9141 831-3400
General NSCS Aaaiatence : (713) Z3S-6432
Technical InforMtion : (512) 4S9-6S43
2. COMPOSITION/INFORMATION Oil IHGREDIEHTS
THE CRITERIA FOR LISTING COMPONENTS IN THE COMPOSITION SECTION IS AS FOLLOWS:
CARCINOGENS ARE LISTED WHEN PRESENT AT Q.I X OR GREATER; COMPONENTS WHICH ARE
OTHERWISE HAZARDOUS ACCORDING TO 0SKA ARE LISTS WHEN PRESENT AT t.O X OR
GREATER; HO*-HAZARDOUS COMPONENTS ARE USTEB AT 3.0 X OR GREATER. THIS IS NOT
INTENDED TO IE A COMPLETE COMPOSITIONAL DISCLOSURE. REFER TO SECTION 14 FOR
APPLICABLE STATES' RIBHT TO WOU AND OTHER REOUUTORT INFORMATION.
Product and/or Canponent(a) Carcinogenic According to:
OS HA I ARC NTP OTHER NONE
X
Composition: (Sequence Nunber and Chariest Naac)
Seq. Chearical Name CAS Nuaber Range in X
PAGEi
M,D. - HOT DETERMINED H.Jt.. - HOT APfX.ICABLl M.T. - MOT TESTED
< - LESS TEAM > - GREATER TEAM
3 - 119
-------
JBFFSOL PC
HUNTSMAN CHEMICAL CO.
PRODUCT CODS« 75436
DATS ISSOTDi 10*31*94
PRODUCT CODSi 7543C
NAME* JEFFSOL PC
Data lasuedi 10-31-94
Sup«rsadeai 07-01-94
2. COMPOSITION/INFORMATION OH INGREDIENTS (CONT)
01 » 1,J-dloxolan-2-ene, e»thyl- 108-12-7 100.00
PRODUCT IS KAZWUXXJS ACCCROING TO OS HA (191Q.1Z00).
• COMPONENT IS HAZARDOUS ACCOM)IMC TO OSMA.
Expoaure iiaits referenced by Sequence Nuifeer in th* Cwpotition Section
Seq. liait
Hon*
3. HAZARD IDENTIFICATION
EMERGENCY OVERVIEW
Appeiranee;
Colorless liquid
Odor:
Slight odor
WARNING STATEMENT
CAUTION I NAY CAUSE EYE IRRITATION
ASPIRATION HAZARD IF SUALlOUiD •
OW ENTER UlNGS AM) CAUSE DAMAGE
CONTAMINATION MAT RESULT IN DANGEROUS CQ2 PRESSURE WILD-UP
WIS
Health: 1 Reactivity: 0
Flanaabi lity: 1 Special : •
MFPA
Health: 1 Reactivity: 0
FlwMbilfty: 1 Special ; •
POTENTIAL HEALTH EFFECTS
ETE SKIN INHALATION INGESTION
Primary touta of Exposure: XX X
EFFECTS OF OVEREXPOSURE
Acuta:
Eyea:
My cauae irritation, experienced a* aild discoaifert and aeen aa alight
excess re6wM sf the aye.
PACT J 2
N.D. - NOT DETERMINED 8.A. - HOT APPLICABLE H.T. - MOT TESTED
< - LESS THAU > - GREATER THAN
3 - 120
-------
JEFPSOL PC
EUHTSMAH CBSMXCAL CO.
PRODUCT CODEt 75496
DATS ISSUEDi 10-31-94
D«t* Zsiu«di 10-31-9-
Superaede»i 07-01-9
3. HAZARD JDEHTZPICATIOIT (COMT)
PRODUCT CODXi 75436
MAMBi JEFFSOL PC
Skin:
Srief contact Is not Irritating. Prolonged contact, as tilth clothing
wetted n
-------
JEFPSOL PC
EUNTSKAK CHEMICAL CO.
PRODUCT CODIi ?S43«
DATS ISSUEDi 10-31-94
PRODUCT CODBt 7543«
MAXEt JEFPSOL PC
Data Issuedi
Supersedes
10-31-5^
07-01-9*
4. FIRST AID MEASURES
lyeas
¦mediately flush eye* with plenty of inter for at tcast IS ainutea, Hold
eyelids apart tfcile flushing to rinae entire aurfaca of eye and ltd* with
water, Cat aedieal attention.
Skin:
Hash akin m1th plenty of soap and Hater for several ainutes. Get aedieal
attention if skin irritation develops or persists.
Insestion:
If parson is conscious and csn suallon, give too glasses of Mater (16 ox.)
but do not induce voniting. tf vaulting occurs, five fluids again. Have
medical personnel deteraine if evacuation of stcaach or induction of
vomiting is necessary. Oe net give anything by aouth to an unconscious or
convulsing person.
Inhalation;
tf irritation, headache, nausea, or drowsiness occurs, raaove to fresh air.
Gat aedieal attention If breathing becomes difficult or respiratory
Irritation persists.
Other Instructions:
Aspiration of this product during induced eaesis aey result In severe ting
injury. If evacuation of stcaach is necessary. "*< aethod least likely to
causa aspiration, such as gastric lavage after endotracheal intubation.
Contact a Poison Center for additional freatamt Information.
5. PIRJB - FIGHTING KEASURSS
Ignition Tee^erature (degrees f):
Hot detenu!ned.
Flash Point (degrees f J:
275 (CO
flaneable Lla - CREATE* TEAS
3 - 122
-------
JBFFSOL PC
HUNTSMAN CHEMICAL CO.
PRODUCT CODSj 75436
DATS ISSUESt 10-11-94
PRODUCT CODEi 75434
NAME) JBFFSOL PC
Data Issuedi
Supersedes!
10-31-94
07-01-94
5. PZRE-FIGHTING MEASURES (CONT)
Unusual or explosive Hsiards:
Man*
Special Protect!** Cquipaent for firefightera:
Wear full protKtiv* clothing and positive pressure breathing apparatus.
6. ACCIDENTAL RELEASE MEASURES (Transportation Spillst CBEXTKBC (800)424-5300)
Precadures in Case ef Accidental Idtnt, |rHb|» or leakagei
Contain »pHl If possible, contain Kith aba or bant ¦¦terials audi at clay or
coil, and shovst fcf». Avoid akin and aye contact.
If sore than 10,000,000 pounds of product is spiI tad, than report spilt
according to SAM 104 md/or CEtCU 102(a) requirements, wless product
qualifies for the petroleu* exwption (CEHCLA Section
7. HANDLING AND STORAGE
precaution* to ba Taken in
Handling:
Nininj* feasible handling temperatures should be Maintained.
Storage:
Periods of exposure to high tesperetures should be alniatzed. water
contMinotion should ba avoided.
Alkyl carbonate* my decotpose In tha presence of Mater, acids, bases,
salts, or Betel oxide* such as cannon rust to causa • pressure build-in
processing or storags vessels. This My lead te ixpture of the container.
Pressure-relief device* ere recomnended an such containers.
8. EXPOSURE CONTROLS/PERSONAL PROTECTION
Protective Iquipacnt (Type}
Eye/Feet Protection:
Safety glasses, chealcal type toggles, or face shield recwinrtiri te
prevent eye contact.
— PAGEt 5 - -
H.D. - NOT DETERMINED H.A. - MOT APPLICABLE H.T. - HOT TESTED
< - LESS TEAK > - GREATER THA13
3 - 123
-------
JBFFSOL PC
HONTSHAN CHEMICAL CO.
PRODUCT CODBi 7S436
DATS ISSUEDt 10-31-94
PRODUCT CODSi 75436
NAMBt JEFPSOL PC
8. EXPOSURE CONTROLS/PERSONAL PROTECTION (COMTI
Cat* Xisu«dt 10-31*94
Sup«r»ed«t» 07-01-94
Skin Protection:
Workers should uash enposad skin several time dally tilth soap and Mttr,
foiled iwrk clothinf should be lawdered or dry-cleaned.
teiptratory Protection:
Airborne concerrtratio»» should In kept to loimt levels possible. If
vapor, alst or duet la generated and (ha occupational exposure Malt of the
product, or any component of tha product, I* exceeded, uae appropriate
KIOSK or MSHA approved air purifying or air netted respirator after
deteralnlng the airborne concentration of the contaarfnant. Air (implied
respirators should slimy* be Horn when airborne concentration of the
contaminant or oxygen content Is unknown.
ventitatlon:
local exhaust ventilation recenraended If generating vapor, dust, or «i«t.
If exhaust ventilation Is net available or Inadequate, use ttSiU or niosn
approved respirator at appropriate.
Exposure Lieit for Total Product:
Hone established for product.
9. PHYSICAL AND CHEMICAL PROPERTIES
Appearance:
Colorless liquid
Odor:
Slight odor
•oiling Point (degrees ri:
468
Melting/Freezing point (degrees f);
•to
Specific Gravity (wtter*1):
1.203
pM of tridi luted product:
7
N.D. • HOT DETERMINED N.A. -
< - LESS THAU >
n, j-
NOT APPLICABLE N.T. - MOT TESTED
GREATER TEAM
3 - 124
-------
•JBPPSOL FC
HUNTSMAN CHEMICAL CO.
PRODUCT CODKi 7543«
DXTE ISSUEDi 10-31-94
Data Issuedt 10-31-9
Supersedesi 07-01-9
9. PHYSICAL AND CHEMICAL PROPERTIES (COST)
PRODUCT C0D8j 75436
NAHEi JBPPSOL PC
Vtpor Pressure;
.02 «nH( at 68.0
Viscosity:
1.6 cit at 43.S C
VOC Content:
Mot detenu" nad.
V«por Density (sir»l):
3.5
Solubility In Utter (X):
1 - 10
Other; Hon*
10. STABILITY AND REACTIVITY
This Material Reacts Violently with:
(If others fa checked below, see consents for details)
Air Vater Heat Strang Oxidizers Others None of These
X
COMMTltS:
Hone
Products Evolved When fefcjected to Meat or Coifeustlon:
Toxic levels of carbon aonoxide, carbon dioxide, irritatir* aldehydes and
ketones my be foraed on burning. Matins in air nay produce irritating
aldehydes, acids, and ketones.
Hazardous Polymerizations: DO NOT oca*
11. TOXICOLOGICAL INFORMATION
TOXimOGIUL INFOWWTIONCMIINM. TOXICITY DAT*)
Median Lethal Dose
Oral:
to50 » 5.00 i/fci (rat) practically non-toxic
_____ pxGBt 7
M.D. - NOT DETERMINED N.A. - HOT APPLICABLE H.T. - NOT TESTED
< - LESS THAN > - GREATER THAN
3 - 125
-------
JEFFSOL PC
hoktskah CHEMICAL CO.
PRODUCT CODSi 75436
DATS ISSUED« 10-31-94
PRODUCT CODS: 75436
NAMEi JSFPSOL PC
Dab* Zaau«d<
Suparaadea t
10-31-94
07-01-94
11. TOXICOLOQICAL UtFORXATIOW (COHT)
Inhalation:
•aliavad ta be practically non-toxic
Derml:
IfiSO » 3.60 fl/kg (rabbi t) practically non-toxic
Irritation India, (stimtion of Irritation (Species)
Skin;
(Oralis) .20 /I.O (rabbit) no appraciabla affect
lyess
(Oraize) 12.SO /110 (rabbit) slightly irritating
Sanaitiietions
(luehler) Negative • skin (guinea pig)
Other:
This product my contain residual (less than 100 ppn) concentrations of
propyl me oxide. There it evidence that propylene oxide cause* tumors in
laboratory anioala.
12* DISPOSAL CONSIDERATIONS
Uaata Disposal Methods
This product has been evaluated for tCSA characteristics and does not Met
the criteria of a hazardous msta if discarded In (ts purchased fora.
Under it CM, it is the responsibility of the user of the product to deter-
mine at the tfm of disposal, nhether the product mets tCU criteria for
hazardous waste. This is because product uses, transformations, «i*tures,
processes, ate. say render the resulting mteriele hazardoua.
Reourks
None
13. TRANSPORT INFORMATION
Transportation
GOT:
Proper Shipping Nana:
Not regulated
1X16:
Proper Shipping lam;
Mot evaluated
PAGE I 8 — ——
H.D. - HOT DETERMINED H.A. • HOT APPLICABLE H.T. - HOT TESTED
< - LESS THAH > - GREATER TSAH
3 - 126
-------
JEPFSOL PC
HUNTSMAN CEEKICAL CO.
PRODUCT CODEi 75436
OATS ISSUEDi 10-31-94
PRODUCT CODEi 75436
NAME: JBFFSOL PC
13. TRANSPORT INFORMATION CCOHTI
D»t« Zaauadt 10*31-34
Sup«rsed« t 07-01-94
ICAO:
Proper Shipping Mat:
Not evaluated
TC6:
Proper Shipping Mm:
Not regulated
TWWfVBMfcTTflll
-------
JEFFSOL PC
HUNTSMAN CHEMICAL CO.
PRODUCT CODSt 75436
DATS ISSUEDi 10-31-94
PRODUCT CODBt 75436 Cat* Xasucdt 10-31-94
NAMEt JEFFSOL PC Suparaedeai 07-01-94
14, REGULATOR* INFORMATXOH (COOT)
TSCA Inventory Status:
This product it listed on the Toxic Siixtinci Control Act (TSCA) Cheateel
Substance Inventory.
Other;
Nona.
State Regulations;
California Proposition 6$:
The following detactable eeeponents of this product art s»fcstane«s,
or belong to classes of substances, known to tha State of California
to cause cancer and/or reproductive toxicity.
Chemical la«t CAS Kuitjer
Residual propyl*"* oxide (typical) ?5-56-»
Stata* *ight-te-kno* Regulations:
Chemical Hawe Stat# Right-to-know
Nona
Stata lift: CI (Connectfcut), R (Florida), II (Illinois), Ml (Michigan)
LA (Louisiana), *A (Massachusetts), IU (He* Jersey),
PA (Pennsylvania), II (Rhode Island),
International Regulations:
Export Notification (TSCA-12b):
This product My be subject to export notification tndar TSCA
section 12(b); contains:
Residual propylene oxide (typical)
MM1S Classification:
Hot regulated
Canada Inventory Status:
All cosponants are listed on tha Canadian Domestic Substance list (OSt).
PAGE: 10-
K.D. • HOT DETERMINED N.A. - HOT APPLICABLE N.T. - HOT TESTED
< - LESS THAN > - GREATER THAN
3 - 128
-------
JEFFSOL PC
HUNTSMAN CHEMICAL CO.
PRODUCT CODEi 75436
DATE ISSUEDt 10-11-94
PRODUCT CODSi 75436 Dat« Iasuedi 10-31-9
MAMS* JEFFSOL PC Supersedeas 07-01-9
14. REGULATORY INFORMATION (CONT)
CINECS Inventory SMtut:
All eeflfxmtnt* are listed on the European Inventory of Existing Cfceafcat
Substance* (EiNCCS).
Australia Inventory statu*:
All component* are listed an the Australian Inventory of Chemical
Substance* (ACIS).
Japan Inventory Statu*:
All component* are listed on the Japanese NITI inventory.
15. ENVIRONMENTAL INFORMATION
Aquatic Toxicity:
Not determined.
Nobility:
Not determined.
Persistence and Ifodegredabillty:
Not deterained.
Potential to lioacomulate;
Not deterained.
teaerka:
None
16. OTHER INFORMATION
Propoxylated products nay contain residual aaomts a1 free propylene oxide.
Residual propylene oxide can accuaulate in the container headtpaee and be
released into the aafeicnt environment. This process is enhanced ttftan the
product it agitated, aa during tank ear loading and unloading, and blending
operations. There ia evidence that propylene oxide cauM* tiaors In
laboratory aniaals. The OSHA and ACGltt eight-hour tiae mightad average
exposure Halts are both 20 ppa. The Kuitsasn internal standard is It ppa
for an eight-hour tiae weighted average expoeure.
FAGBi 11
N.D. - NOT DETERMINED N-A. - NOT APPLICABLE N.T. - MOT TESTED
< • LESS THAN > - GREATER THAN
3 - 129
-------
JBPFSOL PC
HUNTSMAN CHKMICAL CO.
PRODUCT CODSi 7I43S
DATS ISSUEDi 10-31-94
PRODUCT CODE« 75436 Data Xacuedt 10-31-94
NAMEi JBPFSOX. PC Superceded 07-01-94
1€. ftTHKa 1HPORK.1TIOU CCONT)
THE INFORMATION CONTAINED HEREIN IS iELIEVEO TO K ACCURATE. IT IS PROWOO
INOEPEHOENTLT OF ANT SALE Of THE PRODUCT FOR PURPOSE OF HAZARD COMMICAriOH
AS PART OF HUNTSMAN'S PRODUCT SAFETY PROGRAM. IT IS NOT INTENDED TO CONSTITUTE
PERFORMANCE INFORMATION CONCERNING THE PRODUCT. HO EXPRESS KMRANTY, OR
IMPLIED WARRANT* OF MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE IS
MADE WITH RESPECT TO THE PRODUCT OR THE INFORMATION CONTAINED HEREIN. DATA
SHEETS ARE AVAILABLE FOR ALL HUNT SNA* PROOUCTS. YOU ARE URGED TO OBTAIN DATA
SHEETS FOR ALL HUNTSMAN PROOUCTS TQU IUT, PROCESS, USE OR DISTRIIUTE AND TOU
ARE ENCOURAGED AND RiOUESTED TO ADVISE THOSE WHO MAT COME IN CONTACT VITN
SUCH PRODUCTS OF THE INFORMATION CONTAINED HEREIN.
TO DETERMINE APPLICABILITY OR EFFECT OF ANT LAW OR REGULATION WITH RESPECT TO
THE PRODUCT, USER SHOULD CONSULT HIS LESAL ADVISOR OR THE APPROPRIATE
GOVERNMENT AGENCY. HUNTSMAN DOES NOT UNDERTAKE TO FURNISH ADVICE ON SUCH
MATTERS.
Date: 10-31-94 MM X Rtvisad, Sip*rs*dM: 07-01-94
Inquiries regarding MSOS should b* dtrtctad to:
Xmtsaan
Coordinator, Product Safety
P.O. lex 27707
Houston, TX 77227-7707
PLEASE SEE NEXT PAGE FOR PRODUCT LABEL
PAGEi 12-
H.fi. - NOT DETERMINED H.A. - NOT APPLXCAB1A H.T, - HOT TESTED
< - LESS THAN > - GREATER T2AH
3 - 130
-------
JEPFSOL PC
HUNTSMAN CHZMICAL CO.
PRODUCT CODIj 7S436
DATS ISSUEDi 10-31-94
PRODUCT CODBi 75431
NAKEi JEFPSOL PC
S«t« Issued*
Supersedesi
10-31-f'
07-01-f<
17. PRODUCT LABEL
REM) MO UNDERSTAND MATERIAL SAFETY BAT* SHEET RE FORE ttAKOLINC M 01 SINKING
Of MOOUCT. THIS LA1EL COMPLIES WITH THE •EOlllHIlt Of THE OSHA KAZAJtO
CQtMMICATlON STANOARfi {29 CFR »10.1200> FOR USE ill TKI WORKPLACE. THIS
LA8EL IS NOT tNTENOlO TO K USED WITH PACKAGING INTEKOEO FOR SALE TO CONSIDERS
AND HAT HOT CONFORM WITH THE REOUIREMENTS OF THE CONSUMER PRODUCT SAFETY ACT
OR OTHER RELATED REGULATORY REQUIREMENTS.
754J6 JEFFSOl PC
WARNING STATEMENT
CAUTION I HAT CAUSE EYE IRRITATION
ASPIRATION HAZARD IF SWALLOWED •
CAN ENTER LUNGS AND CAUSE DAMAGE
CONTAMINATION MAY RESULT IN DANGEROUS C02 PRESSURE «UILO-UP
PRECAUTIONARY MEASURES
•Avoid prolonged breathing of vapor, aist, or s»«.
-Avoid contact with lyH.
-Keep container elated.
¦Wash thoroughly after handling.
FIRST AID
Eye Contact!
[•Mediately flush eyes tiith plenty of Mater for at least If ainutea. Hold
eyelid* apart tAile flushing to rinse entire surface of aye and ltd* Kith
water. Get aedical attention.
Skin Contact!
Wash skin with plenty of soap and Meter for several afnutes. Gat aedical
attention if skin Irritation develops or persists.
Ingestion:
If person fs conscious and can seallOM, five two gtasses of neter <14 ox.)
tut do not induce waiting. If vsaiting occur*, give fluids again. Have
aedical personnel detenalne if evacuation of stoaaeh or induction of
voaiting is necessary. lia not give anything by aouth to an ireonscioua or
convulsing person.
Inhalation:
If irritation, headache, nausea, or drowsiness occurs, raaove to fresh air.
Get aedical attention if breathing bacoaai difficult or respiratory
Irritation persists.
PiQIl 13 i i i ii i .mi .nil i
N.D. - HOT DETERMINED H.JU - HOT APPLICABLE H.T. - HOT TESTED
< - LESS THAN > • CREATE* THAN
3 - 131
-------
I"
JEFFSOL PC
HUNTSMAN CHEMICAL CO.
PRODUCT CODSt 7S436
DATS ISSUEDi 10-31-94
PRODUCT CODSi 7543S
NAKBt JEPPSOL PC
Dttt« Issuftds 10-31-94
Sup«rs«d*at 07-01-94
17. PRODUCT LABEL (CONT)
Not* to Physician:
Asplratlonof this product during induced mhIi aay result tn »#vtr* twg
Injury. If *v*cuat(on of ttomch I* mchury, use Mthod l«*st Hktty to
cause aspiration, audi •• gastric lavs#* after endotracheal intubation.
Contact a Potion Cantor for additional treataant Informal (on.
In case of fIra, uta tutor spray, dry chemical, foaa or carbon dioxide.
Watar nay cause frothing. Uta nater apray to cool fire-e*poted container*.
If mora than 10,000,000 pound* of product is spilled, than report spill
according to SAM 304 and/or CERCUk 102(a) requi resents, unless product
qualifies for the petroleu* exemption (CECCIA Section 101(H)).
Chemical Naaa CAS Nsntser tang* in X
• 1,3-dioxotan-2-ane, aathyt- 108-32-7 100.00
PRODUCT IS HAZARDOUS ACCORDING TO OS HA (1910.1200).
• COMPONENT IS HAZARDOUS ACCtKSlMC TO OS HA.
Pennsylvania Special Hazardous S<4»tance(s) CAS Niafaer Rang* In X
FIDE
MIS
Health: 1 Reactivity: 0
Ftaanabllity: I Special : -
nfpa
Healths 1 Reactivity: 0
flambillty: 1 facial : •
Transportation
DOTS
Proper Shipping Use:
Not regulated
H.D. - MOT DETERMINED
< - LESS TEAM
PASS* 14
N.A. - NOT APPLICABLE
> - GREATER TEAS
K.T. - HOT TESTED
3 - 132
-------
JBFFSOL PC
HUNTSMAN CHEMICAL CO.
PRODUCT CODSi 75436
DATE ISSUEDt 10-31-94
Date Isaueds 10-31-9'
Supersedes < 07-01-9'
17. PRODUCT LABEL (COOT)
PRODUCT CODSt 75436
NAMSt JBFFSOL PC
CttJTIOK: Misuse of eapty containers can ba hazardous. Eapty container* can
ba hazardous if used to store toxic, flammsbU, or reactive
Materials. Cutting or voiding of oRpty containers sight cause
fira, tip I oi ion or toxic fuses froa residues. Da not pressuriie
or expose to open Ume or heat. tHp container closed and dry*
bins* in place.
Manufacturer1x Nana and Address:
HUNTSMAN
P.O. Box 27707
Houston, TX 77227-7707
TRANSPORTATION EMERGENCY Company: (409) 727-0831
CHEMTREC: (800) (24-9100
HEALTH EMERGENCY Company: (914) S3!-3400
3 - 133
-------
SECTION 4:
EVALUATION OF INNOVATIVE PAINT APPLICATION TECHNOLOGY
By:
J. T. Hanley, J. B. Flanagan,
J. M. Elion, J. H. Turner, and E. A. Hill
4-i
-------
ABSTRACT
This section describes the procedures and findings of a pollution prevention demonstration
performed at the Marine Corps Logistics Base (MCLB) in Albany, GA. The research was
performed by U.S. EPA with the contractor services of Research Triangle Institute (RTI).
Funding was provided by the Strategic Environmental Research and Development Program
(SERDP). The test location was the paint booth located in Building #2222 at the MCLB. The
measurements were performed during December 1995.
The objective was to determine if the amount of paint required to coat a vehicle could be
reduced by providing the painters with a real time readout of how much paint they have used.
The study began with the design, specification, purchase, and installation of a paint monitoring
system in one of the MCLB's paint booths. The system monitored paint use gravimetrically by
continuously measuring the weight of the 5-gallon paint pot that held the paint pumped to the
spray guns. The system included programmable digital scales, a small printer, and large remote
displays visible from within the paint booth. The displays continuously showed the cumulative
amount of paint used, beginning at zero at the start of a painting job.
The initial portion of the test period was devoted to baseline or control measurements
taken "without feedback" of paint consumption information. During this period, the displays
were not visible to the painters while they were in the booth. After sufficient baseline information
had been gathered, the displays were installed in the booth and the painters were instructed in how
the displays could be used to control their usage rate. 'Target" levels for High Mobility
Multipurpose Wheeled Vehicles (HMMWYs) and 5-ton trucks were set based on the lowest
usage during the baseline period.
The system proved to work reliably, and paint usage measurements were obtained on a
total of nineteen vehicles; ten HMMWVs, five 5-ton cargo trucks, and four other vehicles. The
measurements show that, for one set of identical vehicles (the ten HMMWVs), paint consumption
differed by up to 30% between the highest and lowest vehicles. This indicates that a potential for
significant reductions may exist. However, during the brief study period, no statistically
significant decrease in paint usage was seen between the baseline (without feedback) and the
experimental (with feedback) portions of the demonstration. This may be due to the short
duration of the demonstration and to the presence of monitoring personnel at the paint booth
during the baseline period. However, the system could still provide reductions in paint usage and
other benefits when used in combination with other strategies such as mixing only the amount
needed for each vehicle rather than the current practice of mixing paint in multiples of five
gallons. The system could also be used to assist in training new employees, and to assess the
impact of equipment inspection and maintenance practices on paint consumption.
The recommendation is that the MCLB continue to collect paint usage data for a period of
several months to determine if measurable reductions in paint usage are realized after the staff
become accustomed to the equipment.
4-ii
-------
TABLE OF CONTENTS
ABSTRACT 4-ii
FIGURES 4-v
TABLES 4-v
ACRONYMS 4-vi
METRIC UNITS 4-vii
ACKNOWLEDGMENTS 4-viii
NOTICES 4-ix
4.1.0 INTRODUCTION 4-1
4.1.1 Background 4-1
4.1.2 Objectives 4-2
4.2.0 TECHNICAL EVALUATION 4-3
4.2.1 Introduction 4-3
4.2.2 Equipment Evaluation and Selection 4-4
4.2.3 Measurement Procedure 4-5
4.2.4 Evaluation of Paint Use Reduction 4-7
4.2.5 Test Variables 4-7
4.2.6 Data Reduction, Validation, and Reporting 4-9
4.3.0 DEMONSTRATION OF INNOVATIVE PAINT APPLICATION TECHNOLOGY
4-9
4.3.1 Baseline Data 4-9
4.3.2 Demonstration Data With Feedback 4-21
4.3.3 Data Evaluation and Discussion 4-23
4.4.0
QUALITY ASSURANCE
4-25
-------
TABLE OF CONTENTS (continued)
4.5.0 IMPLEMENTATION PLAN .. 4-27
4.5.1 Equipment 4-27
4.5.2 Installation of the Monitoring System at the MCLB 4-27
4.5.3 Safety 4-28
4.5.4 Economic Analysis 4-29
4.5.4.1 OAQPS Control Cost Manual 4-30
4.5.4.2 Obtaining Cost Elements 4-32
4.5.4.3 Unit Costs, Rates, and Assumptions 4-33
4.5.4.4 Paint Application Monitoring 4-36
4.5.4.5 Return on Investment and Payback Period for Paint Application-40
4.6.0 CONCLUSIONS 4-41
4.7.0 RECOMMENDATIONS 4-42
4.8.0 REFERENCES 4-44
APPENDICES
4-1: Evaluation of ULV Paint Delivery System 4-45
4-2: Painting Procedure Instruction Sheet 4-48
4-3: Summary Data For Paint Demonstration 4-49
4-iv
-------
FIGURES
dumber Page
4-1. Schematic of Paint Monitoring System 4-6
4-2. Paint Consumption for Test 1 4-13
4-3. Paint Consumption for Test 2 4-14
4-4. Paint Consumption for Test 3 4-15
4-5. Cumulative Paint Consumption, Test 3 4-16
4-6. Cumulative Paint Consumption, Test 4 4-17
4-7. Cumulative Paint Consumption, Test 5 4-18
4-8. Cumulative Paint Consumption, Test 6 4-19
4-9. Cumulative Paint Consumption, Test 7 4-20
4-10. Random Noise in Paint Consumption Data 4-26
TABLES
Number Pace
4-1. Project Variables 4-8
4-2. Paint Consumption Data "Without Feedback" 4-21
4-3. Paint Consumption Data "With Feedback" 4-22
4-4. Statistical Data Summary 4-24
4-5. On Site Calibration Check Data for Paint Scale 4-25
4-6. Equipment for the Paint Monitoring System 4-28
4-7. Capital Costs for Paint Application with Flow Monitoring 4-37
4-8. Annualized Cost Analysis for Paint Application with Flow Monitoring 4-38
4-9. Annualized Cost Analysis for Paint Application without Flow Monitoring 4-39
4-10. Summary Comparison of Painting With and Without Flow Monitoring 4-39
4-v
-------
ACRONYMS
APPCD
Air Pollution Prevention and Control Division
CAA
Clean Air Act
CARC
Chemical agent resistant coating
CERCLA
Comprehensive Environmental Response, Compensation, and Liability Act
DMA
Depot Maintenance Activity
EPA
Environmental Protection Agency
EPCRA
Emergency Planning and Community Right-to-Know Act
LED
Light emitting diode
HMMWV
High mobility multipurpose wheeled vehicle
HAP
Hazardous air pollutant
MCLB
Marine Corps Logistics Base
MEK
Methyl ethyl ketone
MSDS
Material Safety Data Sheet
P2
Pollution prevention
PP
Payback period
QA/QC
Quality Assurance/Quality Control
RCRA
Resource Conservation and Recovery Act
ROI
Return on investment
RTI
Research Triangle Institute
SARA
Superfund Amendments and Reauthorization Act
SERDP
Strategic Environmental Research and Development Program
ULV
Ultra low volume (spray gun)
VOC
Volatile organic compound
4-vi
-------
METRIC UNITS
English units have been included in the report to simplify communication with most of the
intended readership and because they are the primary units used by the Marine Corps Logistics
Base. The multiplying factors for converting from the English units to their metric equivalents are
given in the table below.
METRIC CONVERSION FACTORS (Approximate)
Symbol i When You Know
the Number of
Multiply By
To Find the
Number of
Symbol
LENGTH
in
inches
2.54
cm
centimeters
VOLUME
gal
gallons 1 3.79
liters 1
MASS
lb
pounds I 0.454
kilograms | kg
PRESSURE
psi
pounds per square
inch
6.89
kilopascals
kPa
TEMPERATURE
op
degrees
Fahrenheit
519
(after subtracting 32)
degrees
Centigrade
°C
DENSITY
lb/ft3
pounds per cubic
foot
16.0
kilograms per
cubic meter
kg/m3
FLOW
efm
cubic feet per
minute
0.472
liters per second
1/sec
4-vii
-------
ACKNOWLEDGMENTS
The authors gratefully wish to acknowledge the following people at the MCLB, without whose
cooperation and assistance this demonstration would not have been possible:
Steve Allan
Dave Baxter
Wayne Chauncey
Scott Clements
Clarence Clyde
Larry Fountain
John Gates
George Hagan
Duke Hellinger
Dave Hudson
Mark Joyner
Willie Walker
The authors would especially like to recognize the contribution of EPA and MCLB5 s Project
Engineers J. Kaye Whitfield and Dan Gilium to this report. Their project oversight, guidance,
direction, and technical assistance greatly contributed to this research demonstration.
4-viii
-------
NOTICES
QA/QC requirements apply to this project. Data are supported by QA/QC documentation as
required by USEPA's policy.
The use of trade names and company names in this section does not signify recommendation for
use or endorsement by either the EPA or Research Triangle Institute.
4-ix
-------
4.1.0 INTRODUCTION
This section reports on the demonstration of an innovative paint application technology
performed at the Marine Corps Logistics Base (MCLB) in Albany, GA. It contains detailed
descriptions of the technical evaluation, including baseline and operational tests conducted at the
MCLB. Information regarding potential cost savings and estimated reductions in hazardous air
emissions is contained in the Implementation Plan (Section 4.5.0).
4.1.1 Background
This document describes the procedures and findings of a pollution prevention
demonstration performed at the MCLB. The test location was the paint booth located in Building
#2222 at the MCLB. The measurements were performed during December 1995.
The pollution prevention technology demonstration research was performed by:
1) U. S. Environmental Protection Agency (EPA), Air Pollution Prevention and Control
Division (APPCD), Research Triangle Park, NC
2) Research Triangle Institute (RTI), Research Triangle Park, NC
3) MCLB, Albany, GA
The EPA/APPCD initiated this project with funding from the Strategic Environmental
Research and Development Program (SERDP) and provided guidance throughout its duration.
The on-site demonstration was conducted in which the alternative paint application process was
demonstrated in a production environment. RTI provided contractor services (e.g.coordinated
the project, provided technical expertise for the design and implementation of the demonstration),
and reported to the EPA Project Officer. The primary responsibility of the MCLB was to support
the demonstration by providing the facilities and staff for carrying out the demonstration. The
MCLB technical representative supervised the project at the site and served as a contact person
with EPA and RTI.
The MCLB carries out maintenance activities on a wide variety of equipment from small
arms to tanks, trucks, and other vehicles. Much of the maintenance on the vehicles requires
4-1
-------
removal of existing paint prior to the repair procedures and application of new paint once the
maintenance has been performed. The processes for paint stripping, repainting, and cleaning of
paint application equipment release significant amounts of hazardous air pollutants (HAPs). By
executive Order 12856, the MCLB is required to reduce these air emissions by 50% from 1992
levels. The MCLB desires to accomplish this goal by implementing pollution prevention (P2)
technologies.
The demonstration performed at the MCLB was based on previous scoping studies carried
out in collaboration with the EPA and the MCLB. The scoping study for the spray paint
application was performed under a cooperative agreement with the EPA/APPCD.
4.1,2 Objectives
The specific objectives of this task were to:
• select, procure, install, and demonstrate a paint flow monitoring system in one paint booth
at the MCLB;
• determine whether the paint flow monitoring system couid provide reliable, continuous
operation when used with the MCLB's paint coatings and solvents, and when used in the
MCLB's physical environment (heat, electronic noise, handling by painters, etc.);
• measure the amount of paint used as a function of vehicle type, painter, and coating; and
• acquire and analyze data to determine whether providing the painters and their managers
with real-time monitoring information would lead to reduced paint use during the
demonstration.
In defining the specific task objectives, it was important to note that MCLB is a high
production repair facility for military vehicles and operated on a tight schedule. Although the
MCLB provided valuable assistance and cooperation with the study, the demonstration activities
could not significantly interfere with or slow their work schedule. As a result, several important
test parameters could not be controlled and regulated to produce the most statistically efficient
experimental design. These parameters included the number and types of vehicles painted,
assignment of painters to the test booth, and the type of coating applied. The objectives of this
task were formed with these limitations in mind.
4-2
-------
(Note: an initial project objective, to evaluate an innovative paint pumping device, the ultra low
volume (ULV) system, proved inappropriate for the MCLB Chemical Agent Resistant Coatings
(CARC) coatings during preliminary trials by the manufacturer and was not evaluated further. A
summary of these findings is presented in Appendix 4-1.)
The MCLB is planning to implement another P2 technology for paint application, a paint
dispensing system. This system will allow quantities of less than the standard 5-gallon "kit" to be
mixed. This should have the beneficial environmental effects of reducing air pollution and
solid/hazardous waste disposal, as well as reducing the cost of paint consumed. This planned P2
technology will work well in combination with the weighing system, which can provide
quantitative data about the amount of paint that needs to be dispensed to cover each type of
vehicle. The weighing system could also be used to document the reduction in paint usage.
4.2.0 TECHNICAL EVALUATION
4.2.1 Introduction
Reducing the amount of paint sprayed is the primary method available to the MCLB to
reduce HAP air emissions from its paint booths. The MCLB has no VOC control devices on the
paint booth exhaust; only particulate paint arresters. Consequently, 100% of the VOC originally
in the paint (including added thinner) is emitted to the atmosphere. Paint that is discarded
without being sprayed is sent to a disposal contractor. The solvent content of the discarded waste
paint is not included in air emissions from the MCLB paint booths.
Prior to this study, the MCLB painters and managers had only crude estimates of how
much paint was being sprayed to coat a given type of vehicle. For example, the amount of paint
needed to paint a 1IMMWV (High Mobility Multipurpose wheeled Vehicle) was estimated to
range from 3 to 5 gallons. This estimate was based on the observation that the painters usually
use less than a 5-gallon kit to paint one HMMWV. (At the MCLB, paint is dispensed in 5-gallon
quantities or, for two-component paints, in 5-gallon "kits.") Similarly, it was estimated that about
5 to 8 gallons were needed for a 5-ton truck, based on the painters needing two 5 gallon kits to
4-3
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complete the job. This crude level of measure was insufficient to accurately quantify how much
paint was being used prior to making the measurements described in this report.
The MCLB already knew from prior short-term training sessions that painters would be
more careful not to waste paint when they were being observed by a supervisor. For example,
wasteful practices such as spraying at too great a working distance, spraying at too high a
pressure, and applying excessively thick coatings were reduced while painters were under close
supervision. It was anticipated that feedback provided by the paint flow monitor would provide
the same effects as "supervision and training" of the painters so that these benefits could be
extended over the long term. Acquiring an accurate means for measuring the amount of paint
sprayed was the first step towards quant ifying, controlling, and reducing it.
4,2.2 Equipment Evaluation and Selection
This task began with selection and installation of a suitable paint monitoring device. After
a period of investigation, project engineers found that measuring devices based on direct in-line
flow measurement would not be practical. This conclusion was based on the highly abrasive
qualities of the CARC and because of the probability of caking and fouling within any in-line
devices contacting catalyzed resins. As a consequence, a continuous readout scale was used as
the primary measurement device. This scale, the Weigh-Tronix Model BSA02020-200 with
associated readout, printer, and control units, was capable of displaying and recording both the
total weight of a paint container and the rate of paint usage. Since the measuring device never
contacted the CARC, there was no possibility of abrasion as with the in-line flow rate measuring
devices first considered. The presence of dried paint on the weighing surface is also not a concern
because the weighing pan is tared at the beginning of each painting session.
The Weigh-Tronix device was configured with two large light-emitting diode (LED)
readout panels so that the painters could continuously see both the amount of paint used and a
preselected "goal" or target for the vehicle. One of the key questions to be answered during the
demonstration was whether access to this information would enable the painters to reduce the
amount used to paint a particular type of vehicle. This was done by comparing the amount of
4-4
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paint used for vehicles of the same type with and without the displays. Other potential
applications for controlling and reducing paint use with the displays will be discussed below.
The availability of quantitative usage information may also enable the painters to complete
vehicles of the same type with a high degree of consistency in total paint usage. If so, it should be
possible to mix only the predetermined amount of paint needed for each type of vehicle. Paint
usage, corresponding VOC emissions, and wasted paint would thus be reduced to the absolute
minimum achievable without additional controls.
4.2.3 Measurement Procedure
A schematic diagram of the spray painting and measurement equipment setup is provided
in Figure 4-1. Immediately prior to beginning paint spraying of the vehicle, the scale was reset to
zero by pressing the "tare" and "print" buttons. After painting was completed, the amount of
paint used was directly read off the paint monitor and was printed on the tape. If additional paint
was needed during a job, the print button was pressed before adding paint.' After the addition of
paint, the tare and print buttons were again pressed. Finally, after each vehicle was completed,
the print button was pressed a final time. This procedure was used throughout the demonstration
period. The full procedure for using the scale is provided in Appendix 4-2, which is a replica of
the instructions posted at the spray booth.
As part of this procedure, data specific to each painting job were entered by the painter
and recorded on the printer. These data included vehicle identification number, vehicle type,
painter ID numbers, and coating type. There was also an option to print at a user specified
interval to provide a continuous record of paint usage. The printer was used in this way during
the baseline period to record 1-minute weight data. Operation of the printer was independent of
the LED displays.
4-5
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PAINT BOOTH
REMOTE DISPLAY
mnru
mum
REMOTE DISPLAY
SCALE
CONTROLLER
FAINT
PRINTER
PUMP
Figure 4-1. Schematic of Paint Monitoring System (not to scale)
The remote displays were located on the side walls of the paint booth.
-------
4.2.4 Evaluation of Paint Use Reduction
Due to changes in the schedule while the project was under way, on-site testing was
limited to two weeks. It was nevertheless possible to obtain limited statistics for paint
consumption with and without access to the paint use monitor.
It is important to note that even without feedback, the painters knew that paint
consumption was being measured. Knowing this, they may have been more careful in their
painting even during the baseline portion of the study conducted "without feedback." Thus, the
consumption measurements "without feedback" should not be considered as completely
representative of paint consumption prior to this project. While it would have been interesting to
measure paint consumption without the painters knowledge, such an approach was deemed
inappropriate and impractical for this study.
4.2.5 Test Variables
This study involved three independent variables: painter(s), type of vehicle, and whether
feedback of paint use information was given to the painters. Only one type of coating, green 2-
component CARC, was used for the demonstration. The independent and dependent variables are
discussed below and are summarized in Table 4-1.
• Painters: Two painters work simultaneously in the booth using the same paint source.
One or both may be spraying at any given time. The MCLB has approximately 30 painters
on staff; five different painters participated in this study. Painters were scheduled
randomly throughout the test period.
• Type of Vehicles: The study focused on the most frequently painted types of vehicles at
the MCLB which were HMMWVs and 5-ton trucks. For each of these, however, there
were several different body configurations. To the extent possible, the exact tody
configuration was noted for each vehicle painted. For each type, vehicles were considered
"identical" so long as there was no discernible difference that would affect the surface area
to be painted.
• Coatings: While the MCLB uses several different coatings, only 2-component green
CARC was used during the demonstration. After the two components were mixed, the
4.7
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• CARC was thinned with methyl ethyl ketone (MEK) in the ratio of 1 part MEK to 5 parts
CARC.
• Feedback: The study involves two levels of information feedback to the painters defined
as:
• "Without feedback": For the first half of the study, the flow monitor readings were
known only to the attending project technician. This information was not given to
the painter. It is important to note that even without feedback, the painters knew
that their paint usage was being monitored. Because of this, they may have been
more careful in their painting, which might result in a slight low bias in the results
taken without feedback. MCLB supervisors have stated that painters tended to
use less paint when they were under direct supervision.
• "With feedback": During the second half of the testing, a real-time readout of
cumulative paint use was readily visible to the painter. The painters could also see
the target level for the vehicles on the display. Painters were trained in the use of
the flow monitor and were informed of the importance to the MCLB that the
amount of paint sprayed be reduced.
Table 4-1. Project Variables.
VARIABLES
LEVELS
Painter
5 total painters during demonstration period,
randomly assigned from a pool of 20-30 painters
Independent
Variables
Type of Vehicle
1) HMMWV
2) 5-Ton Truck
3} all other*
Type of Coating
2-Component green CARC only
Feedback
1) Painter receives no feedback.
2) Painter receives real time data on paint
consumption and a target level for the vehicle
Dependent
Variables
Volume of Paint Sprayed
Data obtained as a function of painter, vehicle type,
coating, and feedback.
~Other vehicle types included a tractor-trailer cab, a mobile power unit, and small utility equipment.
4-8
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4.2.6 Data Reduction, Validation, and Reporting
It was planned that paint use data with and without feedback would be compiled based on
several independent variables including: painter, type of vehicle, and type of coating. Due to the
compression of the demonstration schedule and the consequent paucity of data, it was necessary
to limit the test to just two types of vehicles and one type of coating. The identity of the painters
was not used as a variable in the evaluation because there was insufficient data to draw a reliable
correlation between painter ID and paint usage. In addition, painters worked in pairs which
varied from day to day.
Percent reduction in paint use for a particular vehicle type is calculated using the following
equation:
V. - V
% Reduction = 100 • —5 !
where: Vb = the average volume of paint used without feedback, and
Va = the average volume of paint used with feedback.
To compute the statistical significance of the differences between means, Student's t-test
was used.
4.3.0 DEMONSTRATION OF INNOVATIVE PAINT APPLICATION TECHNOLOGY
4.3.1 Baseline Data
Between December 4 and December 13,1995, the paint monitoring equipment was
installed and functioning, but the displays were not installed. This period was used to acquire data
"without feedback". During the baseline period several complete vehicles were painted while the
printer recorded at 1-minute intervals. Several graphs of paint consumption vs. time for these
vehicles are shown in Figures 4-2 through 4-9. These graphs document the performance of the
monitoring equipment and show events and interruptions that occur during typical painting
4-9
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sessions. Appendix 4-3 provides the net paint consumption data for all vehicles painted during
the demonstration period, both with and without feedback.
Figure 4-2 shows data for the first vehicle painted after the scale was installed. This figure
illustrates features of a typical painting session:
• The initial slope of paint volume vs. time ("2 painters") was higher than near the end of
the job, when only one painter was spraying paint.
• The areas indicated as "Noise" were the result of opening and closing the door to the paint
booth and moving the plastic sheet covering the paint reservoir and scale. These
movements caused vibrations and changes in pressure that affected the scale's readout.
This type of noise was not seen in any subsequent vehicles because the plastic tarp
covering the equipment was moved away from the scale. A linear regression was used to
estimate the amount of paint used up to the first point noted "Paint Added." It was not
necessary to use linear regression for any subsequent vehicles because the source of this
noise had been eliminated.
• After the first paint addition there appeared to be about 1-2 minutes of additional noise,
followed by about five minutes of painting. The balance was not tared after this paint
addition.
• More paint was added, which caused the indicated weight to go below the original
baseline. This was because the paint reservoir was heavier than it was when the original
tare was done.
• A second tare was then done, which restored the baseline to 0.00 gallons.
• The final, relatively uninterrupted section of the curve was a period during which one
painter did touch up and detail work, while the other painter assisted with taping and
masking. This accounts for the lower slope for this section of the curve compared to the
first section.
The total paint used, 5.49 gallons, was calculated as the total of the segments indicated. Because
of noise in the signal, this total has an estimated uncertainty of about 0.3 gallons.
Figure 4-3 shows the raw data for the second vehicle painted, the tractor unit from a large
truck. The high level of noise observed in the previous job (Figure 4-1) was not seen in this or
4-10
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any subsequent paint jobs. The time axis is shown as elapsed time from the beginning of the job.
The segment below the baseline is probably due to either adding paint without taring, or taring the
scale before it had stabilized. In either case, the calculation of the total is not compromised; the
0.14 gallons is included in the total of 5.74 gallons.
Figures 4-4 and 4-5 show the cumulative consumption, 6.45 gal., for an MK-48 power
unit (a large truck-like vehicle). Figure 4-4 is the raw data as recorded on the printout, and
Figure 4-5 shows cumulative paint usage calculated by joining the individual segments end-to-end.
The time axes for these figures show elapsed time from the beginning of the job. During the long
segment marked "Meeting," the painters were away from the booth. The printer tape continued
to run, which allowed data on random variability (low level "noise") in the signal to be captured.
This low-level noise is thought to be due to the vibration of the stirring motor, electronic noise,
etc., and is likely to be present in all the data. This noise is much smaller in magnitude than the
areas marked "Noise" in Figure 4-2, because it has a different source (see discussion above).
There also appeared to be a slight slope, which may be due to evaporation of the high-volatility
solvent. This segment is analyzed further in Section 4.4.0 of this report.
Figures 4-6 through 4-9 illustrate the variation in time, application rate, and total paint
used for four HMMWVs. The amount of paint used "without feedback" varied from 1.66 to 2.70
gallons. The time required to paint these identical vehicles ranged from about 20 to about 40
minutes. To facilitate comparison, Figures 4-6 through 4-9 are plotted on the same time scale.
Reasons for the differences in painting times were not recorded, but are most likely related to the
number of painters working at a given time, the paint flow rate, the amount of detail work needed
by a particular vehicle, etc. Note that the slope of paint usage changes on all four graphs at
around minutes 17-21. The rate of paint use slows significantly; perhaps only touch-up occurs
after this point. It is noteworthy that on Test 6, the HMMWV with highest paint usage, the
painters continued using paint at the lower rate for another twenty minutes, using approximately
an additional half-gallon paint. It would be well worth the effort to find out what activities take
place during these two distinct rates of paint usage.
Table 4-2 provides the total paint consumption figures for vehicles painted "without
feedback." Trials 1 and 13, both 5-ton trucks, had to be rejected for data analysis because their
4-11
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undercarriages had already been painted before they entered the booth. Consequently, their
results were not representative of other 5-ton trucks which received full paint jobs. The data tape
for Trial 11 indicated that the balance was not tared properly when paint was added. This error is
thought to be relatively small compared to the total variability of the measurements; consequently,
the data for Trial 11 were not rejected from the data analysis.
4-12
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TEST 1 - TYPE: 923 TRUCK
12/5/95
PAINT ADDED
Total = 5.49 gal
- • 2.95 gal used
3.00
NOISE'
2.50
PAINT ADDED
2.00
2 PAINTERS
$ 0.27 gal used
1 PAINTER
1.50
'NOISE'
1.93
1.00
REGRESSION
LINE
0.50
0.34 gal
0.00
10:00
10:30
11:00
9:00
9:30
-0.50
TARE
-1.00
Time of Day (hr:min)
Figure 4-2. Paint Consumption for Tf.st l.
-------
TEST 2 - Vehicle Type 818
12/5/95
6
TOTAL = 5.74 gal
5
4
3
Lunch Break
2
1
0
0:00
0:28
0:57
1:26
1:55
2:24
2:52
Elapsed Time (hr:min)
Figure 4-3. Paint Consumption for Test 2.
-------
TEST 3 - MK-48 POWER UNIT
12/6/95
2.5
TOTAL = 6.45 gal
s
co
c
o
75
0
Lunch Break
0.5
Meeting
0:57
0:28
1:26
1:55
2:24
2:52
3:21
-0.5
Elapsed Time (hrmin)
Figure 4-4. Paint Consumption for Test 3.
-------
TEST 3 - MK-48 POWER UNIT
12/6/95
TOTAL = 6.45 gal
Lunch Break
4 --
c
o
75
O
o
J-
Meeting
oo
CM
O
CN
I/)
CN
in
CM
CN
CO
Elapsed Time (hr:min)
Figure 4-5. Cumulative Paint Consumption, Test 3.
-------
TEST 4 - HMMWV
12/6/95
2.5
Total = 2.08 gal
CO
c
o
To
O
CO
o
h-
0.5
0:00
0:07
0:14
0:21
0:28
0:36
0:43
Elapsed Time (hr:min)
Figure 4-6. Cumulative Paint Consumption, Test 4.
-------
TEST 5 - HWWMV
12/6/95
TOTAL = 1.66 gal
(/>
I 09
(0
-
^ 0.7
o
h-
0.5
0.3
-0.1
0:00
0:07
0:14
0:21
0:28
0:36
0:43
Elapsed Time (hr:min)
Figure 4-7. Cumulative Paint Consumption, Test 5.
-------
TEST 6 - HWWMV
12/7/95
TOTAL = 2.7 gallons
2.5
0.5
0:00
0:07
0:14
0:21
0:28
0:36
0:43
Elapsed Time (hr:min)
Figure 4-8. Cumulative Paint Consumption, Test 6.
-------
TEST 7 - HMMWV
12/7/95
8
TOTAL = 1.68 gal
1.6
1.4
1.2
1
0.8
0.6
0.4
0.2
0
0:07
0:14
0:00
0:21
0:28
0:36
0:43
Elapsed Time (hr:min)
Figure 4-9. Cumulative Paint Consumption, Test 7.
-------
Table 4-2. Paint Consumption Data "Without Feedback"
DATE
TEST NUMBER
VEHICLE TYPE
TOTAL (gal)
12/5
1
5-ton Truck
5.49* !
12/5
2
818-Cab
5.74 !
12/6
3
Power Unit
6.45 !
12/6
4
HMMWV
2.08 i
12/6
5
HMMWV
1.66 1
12/7
6
HMMWV
2.7 !
12/7
7
HMMWV
_
12/7
8
HMMWV
2.04
12/7
9
5-ton Truck
7.16
12/11
10
HMMWV
_
12/12
11
HMMWV
1.92f
12/13
12
5-ton Track
5.84
12/13
13
5-ton Truck
4.1* 1
~Undercarriage not done.
tTare not recorded (estimated).
4.3.2 Demonstration Data With Feedback
The second part of the demonstration period began on December 14, the first full day of
activities after the remote displays had been installed in the booth. These displays were mounted
on the walls parallel to the long axis of the paint booth at a height of about seven feet. This
mounting allowed adequate visibility for the painters to refer to them frequently. The research
technician, Mr. K. David Carter, Jr. who was on-site at the time, instructed the painters to try and
minimize paint usage without sacrificing the quality of the paint job. He also alerted the inspector
to the change in process and asked to be notified of any increases in problems with the paint
quality. No increase in problems was reported. Target values for total paint usage were chosen
for two vehicle types for which multiple data sets had been acquired, the HMMWVs and the 5-
ton Trucks.
With prior information on paint requirements by vehicle type, low, but achievable, target
levels were set for how much paint should be used to paint a given vehicle. The exact value of the
initial target levels was not critical; their purpose was to raise awareness of paint usage and to
give the painters a goal. They were, however, intended to be relatively low values that would
require minimal waste to achieve. The target amount for the HMMWVs was set at 1.7 gallons,
and the target for the trucks was 6,2 gallons. (These target values may be adjusted when more
4-21
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consumption data have been collected.) During the demonstration, there was no penalty for
painters exceeding the target level. It was hoped that self-motivation, knowledge that the
supervisor would also see the results, and an atmosphere of friendly competition among the
painters would motivate them to do their best to meet the target levels.
The need to add paint to the reservoir bucket during a painting session for a single vehicle
had not been anticipated when the weight display program was developed. Adding paint during a
job causes the displayed "total" to be offset by the amount of paint added and, upon re-taring, to
return to zero. To account for this during the demonstration, after a refilling and taring step, the
project's attending technician quickly computed a new target level (by subtracting the displayed
"total'Value before adding paint and re-taring from the "target") and told the painters verbally
what the new target level was.
Because of the difficulty of tracking the target value under the current setup, it is
recommended that a software change be made within the WI-130 controller to allow for a "refill"
operation without loss of the currently displayed "total", or to change the painting procedure to
allow filling the paint pot with enough paint to complete the entire job. The recommended
programming change can be performed by the vendor.
Paint consumption data during this phase were recorded only when the painter pressed the
"print" button, as instructed in the procedure sheet shown in Appendix 4-2. As a result, one-
minute data were not printed out after the displays were installed. Consequently, no graphs of
paint consumption are provided for paint consumption "with feedback," Summarized paint
consumption data for the feedback period are provided in Table 4-3.
Table 4-3. Paint Consumption Data "With Feedback"
DATE
TEST NUMBER
VEHICLE TYPE
TOTAL (ml)
12/14/95
14
5-ton Truck
5.76
12/14/95
15
5-ton Truck
6.56
12/15/95
16
5-ton Truck
7.53
12/15/95
17
HMMWV
2.04
12/15/95
18
HMMWV
2.04
12/15/95
19
HMMWV
4-22
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4.3.3 Data Evaluation and Discussion
Table 4-4 summarizes the measurement results. The raw data from which Table 4-4 was
derived are presented in Appendix 4-3. Paint use for a total of ten HMMWVs (seven without
feedback, three with feedback) and five 5-ton tracks (two without feedback, three with feedback)
was obtained. Overall, paint use with and without feedback (i.e., use of the displays to show paint
use) were not significantly different between the two data sets. Reduced variability was seen for
the HMMWVs with feedback, however with such a small number of trials (n=3), this could be an
artifact.
The data show that paint use ranged widely, even for similar vehicles. For the HMMWVs,
paint use ranged from 1.66 to 2.70 gallons; for the 5-ton trucks the range was from 5.76 to 7.53
gallons. The presence or absence of user feedback did not significantly reduce the amount of
paint used during the testing period. The minimum value observed for the HMMWVs was 17%
below the HMMWV mean. The minimum value observed for 5-ton trucks was 27% below the
corresponding mean.
The large ranges in the amount of paint required to coat similar vehicles are difficult to
explain. Potential causes include the skill and experience of the painters, and the preparation and
detail work required by each vehicle. Significant variability was seen even for identical vehicles
painted by the same team of painters. Thus, the skill and experience of the painters is not the
whole explanation for the variability.
Target values shown in Table 4-4 were chosen based on the consumption values achieved
during the tests without feedback. For the HMMWVs, the target value was chosen to equal the
lowest value observed in seven trials without feedback. This was rounded to the nearest 0.1 gal.
for a target of 1.7 gal. For the 5-ton trucks, only two preliminary observations were available on
which to base the target value. After some discussion, a target value of 6.2 gallons was chosen,
which is slightly below the average for the two trials without feedback. Selecting the target value
for the 5-ton trucks was complicated by the following factors: the small number of previous
measurements (2); the relative complexity of this type of vehicle; and a concern that the smaller of
the two previous measurements might have been an anomaly. One subsequent trial with feedback
(5.76 gal.) was lower than both the target (6.2 gal.) rnd the minimum value observed without
4-23
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feedback (5.84 gal.). This indicates that the target for the 5-ton trucks could have been set lower.
There was some concern that reduced paint usage might result in thin, inadequate
coatings. However, all vehicles are inspected after painting as a normal part of the MCLB's
procedures, and no problems of this nature were found during the demonstration period.
Longer term use of the paint monitoring system (several months versus the 2 weeks of this
demonstration), with continued encouragement to the painters to strive for lower paint use values,
may show that a reduction in the mean paint use and/or reduction in variability can be achieved.
It is recommended, therefore, that the MCLB continue to operate the paint monitoring system to
determine if long term reductions can be achieved.
Table 4-4, Statistical Data Summary
Vehicle Type
N'
Average
(gal.)
Std.
Deviation
(gal.)
Eel. Std.
Deviation*
(percent)
Min.
(gal.)
Max.
(gal.)
Target
(gal.)
Without Feedback
HMMWV
7
1.99
0.35
17.84%
1.66
2.7
5-ton Truck
2C
6.5
0.93
14.36%
5.84
7.16
..
With Feedback
HMMWV
3
2.05
0.02
1.12%
2.04
2.08
1.7
5-ton Truck
3
6.62
0.89
13.40%
5.76
7.53
6.2
Notes;
a - Number of vehicles painted for each condition.
b - Relative standard deviation is the standard deviation divided by the average, expressed as a percent,
c - Two additional 5-ton trucks were painted but are not included in the statistics because they were "partial" jobs - i.e.,
the undercarriage had already been painted. Only 5-ton trucks receiving a complete paint job are included in the
statistics.
4-24
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4.4.0 QUALITY ASSURANCE
The primary Quality Assurance (QA) goal for the on-site portion of this project was to
estimate and control errors in paint consumption measurements. These measurements were done
with the Weigh-Tronix Flow Monitoring System that was installed at one paint booth. The chief
sources of error, uncertainty, and variability include the following:
* errors in the balance - zero offset, nonlinearity, and instrument noise
• ambient vibration and noise
The balance was set up at the site according to the manufacturer's specifications. This
included assuring that the feet had solid support (concrete floor) and that the balance transducer
was level. The accuracy and linearity of the electronic balance were assessed using a 25-pound
weight supplied by the manufacturer. The weight had been independently checked in a laboratory
before the on-site portion of this task. Calibration check data are shown in Table 4-5.
These data show that the balance, as installed, was accurate within the resolution of the scale and
that linearity was also acceptable.
Internal Quality Assurance (QA) was provided by Dr. James Flanagan of RTI's Center for
Environmental Measurements and Quality Assurance. Dr. Flanagan helped prepare the QA
Project Plan and visited the MCLB site twice to review the project.
As was discussed in Section 4.3.1, random noise experienced by the balance was recorded
while the system was not being used and the area was quiet. These data are shown in
Table 4-5. On Site Calibration Check Data for Paint Scale.
Location:
Operator:
Date:
MCLB Paint Booth
David Carter (RTI)
December 15, 1995
Empty Pan (after TARE1
With 25 lb. Weight
With paint can
Paint can + 25 lb. Weight
0.00 lbs.
24,99 lbs.
23.86 lbs.
48,86 lbs.
4-25
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Figure 4-10, plotted on a greatly expanded scale. Approximately one hour's worth of data was
acquired at one minute intervals. This provides an estimate of the data scatter that can be
attributed to the combined sources of noise affecting the balance. These include electrical and
instrumental noise, vibrations from the stirring motor, and the effects of wind and ambient
vibrations. The background noise level was found to be approximately 0.02 gallons. This amount
of noise is very small compared with the variability between the amount of paint used to paint
identical vehicles. The slope of 0.43 gal/day indicates that some weight loss may be occurring due
to solvent evaporation. This rate of weight loss is insignificant in the period of time over which
most vehicles are painted. For example, during a relatively long 3-hour job, the weight loss would
be only about 0.05 gallons.
Balance Noise - Test 3
During Morning Break 12/6/95
0.08
0.07 ¦¦
y = 0.4305X + 0.0208
R2 = 0.349
0.06 -¦
0.05 --
<0
c
o
= 0,04 --
«
CD
0.03 --
\
0.02 -•
0.01 --
0
0:00
0:14
0:28
0:43 0:5? 1:12
Elapsed Time (hr:min)
1:26
1:40
Figure 4-10. Random Noise in Paint Consumption Data.
4-26
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4.5.0
IMPLEMENTATION PLAN
4.5.1 Equipment
Table 4-6 lists the equipment comprising the paint monitoring system. The system
consists of two scales (one for inside the booth and one for outside the booth to match the
MCLB's painting practices), a control unit with keyboard, two remote displays mounted in
opposite side walls of the paint booth, a local tape printer, a remote tape printer for installation in
the supervisors office, a print and tare push-button station outside the booth, and a print and tare
push-button station inside the booth. Note that all of the equipment that is within the booth must
be rated for the hazardous environment use and be installed by qualified electricians.
The entire paint monitoring system was purchased through a single commercial vendor (J,
A, King & Company, Inc., Garner, NC). Using one vendor to help design and provide the system
had the important advantage that the vendor was responsible for ensuring that all components
worked together as intended. Prior to delivery, the vendor set up and tested the system at his
facility. The system was also set up and tested prior to delivery to the MCLB.
4.5.2 Installation of the Monitoring System at the MCLB
Installation of the system involved the following activities:
1. Cutting and installing two windows in the paint booth; one on each side wall. The
opening needed to be at least 29"W x 8"H to allow foil viewing of the remote displays.
The height of the displays is approximately 6-8 ft above the floor so as to be readily visible
to the painters and to avoid excessive overspray accumulation on the window.
2. Providing explosion-proof hook ups for the remote print and tare switch located in the
paint booth. (These are low voltage signal lines.)
3. Locating a small table near the paint booth door for the WI-130 controller, keyboard and
tape printer.
4. Running interconnecting low voltage cables from the WI-130 to the printers and displays.
5. Installing the scale immediately outside the paint booth door.
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6.
Running extensions cords to operate the scale, printers, and displays. The system operates
on 110V at roughly 1000W.
Table 4-6. Equipment for the Paint Monitoring System
ITEM
MODEL NO.
QTY.
Base scale
Weigh-Tronix BSA02020-200
2
Programmable controller
Weigh-Tronix Model WI-I30 with:
Extended memory
2-base interface
Opto-22 Modules (2)
Special Software
Interface cable
Multi-port controller
1
Explosion proof barrier box
NA
1
Cable between barrier box and base
NA
25 ft
Tape printer
Weigh-Tronix Model WF-233
2
Remote displays
Model Ml 000
2
Remote tare and print push-button station
NA
1
Explosion proof tare and print station
NA
1
Keyboard
Weigh-Tronix keyboard for WI-130
1
Interface cable to remote printer
NA
150ft
Interface cable to remote display
NA
25 ft
Interface cable to remote display
NA
100ft
25 lb. calibration weight
NA
2
4.5.3 Safety
Because paint booths contain potentially explosive vapors (paint solvents), all of the
electronic equipment within the booth must be rated for hazardous environment use and be
installed by qualified electricians. All electrical wiring for the demonstration was installed by
qualified MCLB electricians.
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4,5.4 Economic Analysis
One aspect of changing process operations for pollution prevention purposes is the effect
on capital and annual costs. Pollution prevention changes are more likely to be embraced if these
costs stay the same or decrease. The following sections provide measures of capital and annual
costs for installing weighing systems to allow painters to monitor their paint usage.
The methodology for estimating costs is taken from the EPA methods described in the
OAQPS Control Cost Manual2, which allows a convenient means of comparing different
processes based on their annualized costs. Where actual costs are not known, factors applied to
base equipment costs are used to estimate the remaining costs. These factors have been
developed from a wide variety of sources associated with pollution control systems.
The method for estimating costs used here provides a "study" estimate, which is intended
to give a cost estimate within an accuracy range of ±30% of the actual cost when all the
information affecting the costs is reasonably well known. This accuracy range is typical for EPA's
estimates of pollution control systems when assessing cost impacts on existing or model facilities.
Greater accuracy can be obtained with "budget authorization" estimates (±20%), "definitive"
estimates (± 10%), or "contractors'" estimates (± 5%). Improved accuracy of the estimate is
obtained only by improving the detailed knowledge of items that make up the estimate (and by
spending more time and money in preparing it). In the present case, the firm costs obtained for
most of the capital items could lead to a contractors' estimate if no assumptions were required for
the remaining costs. For the present work there are relatively few elements that must be
considered for paint application costing; however, several of these cost elements are not known
with sufficient accuracy to go beyond a "study" estimate.
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4.5.4.1 OAQPS Control Cost Manual
Analysis of the costs associated with this pollution prevention project is performed such
that comparisons can readily be made between competing processes. A consistent format for
costing is used so that comparisons are valid. To be compatible with EPA usage, the format in
this report is taken from the OAQPS Control Cost Manual cited above. This methodology
divides costs into two major categories, capital costs and annual costs. For the cost analysis to be
meaningful, it must include all elements associated with implementation of new technologies. An
exception is the case in which no new capital costs are incurred. Capital and annual costs can be
further subdivided into the categories shown below:
• Site preparation and buildings
• Equipment
• Emission controls
• Materials
• Energy and utility requirements
• Labor requirements, including training
• Waste disposal
• Special transportation costs (hazardous materials)
• Recovery credits
• Overheads and capital recovery
• Accommodation costs (for changes to use or behavior forced by the new
technology).
Treatment of each of the cost elements is briefly described below. As used in the OAQPS
Control Cost Manual, the first three items are capital costs, while the remainder are annual costs.
After all the cost elements are collected, they are presented as tables of capital and annual costs.
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Capital Costs
Capital cost items are those requiring relatively large expenditures for land, buildings, and
equipment expected to have a lifetime longer than a year (usually many years). Specific items are
collected in the following paragraphs. For those cases in which explicit costs are not available,
the factor method is used to estimate reasonable costs. Factors (as multipliers of the purchased
equipment cost) are available in costing manuals or can be based on engineering judgement.
Site Preparation and Buildings: No site preparation (land clearing and leveling) or new
buildings were required for this pollution prevention project.
Equipment and Emission Controls: Equipment costs include either new purchases
(including add-ons) or modifications for existing items. Costs include installation. These costs
are taken from invoices, vendor quotes, or other records where available, or are estimated from
cost manual data.
Indirect Costs: Associated with purchase and installation of equipment are the indirect
costs that include engineering, construction and field expense, contractor fees, start-up,
performance tests, and contingencies. Not all of these items are required.
Annual Costs
Annual costs include expenditures for operating and maintenance, labor and materials,
utilities, and waste disposal. Indirect costs include overheads, administrative charges, property
taxes (where applicable), insurance, and capital recovery. With the exception of overheads, the
indirect annual costs are related to capital costs. The annual cost elements are described in the
following paragraphs. The sum of the annual costs provides a total annual cost that is useful for
comparison with other systems or technologies.
Materials: Materials include raw materials for operation, and maintenance materials for
repairs and preventive maintenance. Costs and usage rates for materials are obtained from MCLB
records, vendors, or estimates from MCLB or RTI project personnel.
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Energy and Utility Requirements: Energy and utility usage rates are taken from MCLB
records, project data, or estimates for the equipment or process being analyzed. Considered for
this project are electric power, steam, water, and compressed air.
Labor Requirements: As with materials, labor is divided into operating and maintenance
categories. Operator labor hours are estimated from project records or from observation by
project personnel. Maintenance labor hours are projected based on estimates of project
personnel. Labor hours are also required for supervision and for training.
Waste Transportation and Disposal: Waste disposal costs include wastewater treatment,
solid waste disposal, and hazardous waste treatment or disposal. Transportation costs are
included in the waste disposal costs. Quantities are taken from MCLB records or are projected
from project data.
Recovery Credits: Recycling of spent solvents may provide money to offset costs of
operation.
Overheads and Capital Recovery: General and administrative overheads, property tax,
and insurance are taken from information provided by the MCLB or from estimates by project
personnel. Capital recovery charges are estimated from current EPA usage for interest rates;
equipment lifetimes are based on engineering judgement.
Accommodation Costs: Identifiable costs are included here that are associated with a
changeover to new technology.
4.5.4.2 Obtaining Cost Elements
Capital Costs
Because the factor method is dependent on base equipment costs for its capital cost
accuracy, special care must be taken to record all of the individual items purchased. For the
present work, each required item is purchased through RTFs purchasing department. All RTI
purchases are posted on a computer operated accounting system that allows identification of each
item associated with the project.
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Annual Costs
Annual cost items are largely dependent on the labor, utility, and materials costs
associated with operating a process and on recovery of capital. As with capital costs, accuracy of
the annualized cost estimate depends on the accuracy of the information collected for these cost
elements and also for the usage rates associated with the operating costs. Capital costs remain
important in estimating annualized costs because most of the costs and the capital recovery cost
depend on purchased equipment costs. For the present project, unavailability of some unit costs
and usage rates may affect the accuracy (and the conclusions) of the cost analysis.
4.5.4.3 Unit Costs, Rates, and Assumptions
The following cost analysis is based on an assumed reduction of 20% in paint spray usage
due to implementation of the paint monitoring system. While the data collected during the short
demonstration period showed no significant change between average paint use with and without
the monitoring system, the measurements do show that paint usage has considerable variability,
even among identical vehicles. Thus, the 20% reduction value appears to be a reasonable goal for
long term reductions, since it is well within the range of normal variability. It is recommended
that the MCLB continue to use the monitoring system to collect long-term data to determine if
actual reductions are realized. For example, a 20% reduction in paint for a HMMWV would
amount to about 0.4 gal. This would be a reduction from the current average of around 2.0 gal.
to 1.6 gal, which was nearly met in several tests. An overall 20% reduction would only require
that this level be achieved consistently, rather than as a consequence of random variation. A
further justification for a projected reduction of at least 20% is the MCLB's planned introduction
of a paint dispensing system. This system would allow only the needed amount of paint to be
mixed. This would minimize the air emissions attributable to unused paint, as well as the
procurement and disposal costs for the unused paint. As discussed elsewhere in this report, data
generated by the weighing system will be valuable in setting the amount of paint to be dispensed
by the new system, as well as for documenting the reduction in paint consumption.
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Unit Costs and Rates Used Throughout Economic Analysis
The following unit costs and rates were used throughout the economic analysis.
• Operating labor costs were $16.52/hr, taken from the OAQPS Control Cost
Manual, pp. 7-43, April 1991.
• Maintenance labor costs were $ 18.17/hr, taken from the OAQPS Control Cost
Manual, pp. 7-43, April 1991.
• Supervisory labor costs were 115% of operating labor costs, taken from the
OAQPS Control Cost Manual, pp. 7-43, April 1991.
• Training costs were $33.04/hr based on twice the operating labor rate,
• Waste disposal costs for low-end wastes included $0.35/lb for transportation and
$.80/lb for disposal, based on interpolation from the MCLB estimate.
• Waste disposal costs for high-end wastes included 0.35/lb fpr transportation and
S1.80/lb for disposal, based on interpolation from the MCLB estimate.
• Electricity costs were $0.0709/kWh, cited in Chemical Engineering, January
1995.
• Compressed air costs were SO. 19/1,000 scfnr from example problem in OAQPS
Control Cost Manual, pp. 5-49 (April 1991). Updated with Chemical Engineering
(CE) cost index.
• Wastewater disposal or treatment costs were $4.75/1,000 gal updated from
OAQPS Control Cost Manual, pp. 9-51, July 1992.
• Paint cost was an average of $4.76/lb based on the MCLB estimate.
• State air emission fee of $25/ton was required for hazardous air emissions, based
on MCLB information.
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The following assumptions were used for paint application without scales.
• No new capital equipment was required for painting without scales.
• Actual painting times was estimated at 3 hrs/day for each painter, 2
painters/booth, 4 booths in operation.
• Paint usage was estimated at an average of 3,1 5-gaI kits/day for each of 4 booths,
5 shifts/week, 52 weeks/yr. Paint specific gravity is 1.26.
« Power usage was estimated at 1 kW for miscellaneous electrical loads.
• Air consumption was based on 2 guns x 22 scfm/gun x 26.4 minutes usage/hr,
• Waste disposal was based on a total of 11 gal/day waste paint plus replacement of
ventilation system filters at the rate of 4/wk, 52 wks/yr, 3 lb/filter. Low-end
disposal charge applies.
Assumptions Used for Paint Application with Scales
The following assumptions were used for paint application with scales.
• Capital costs were included for the paint weighing system and associated
instrumentation. All direct installation costs were lumped under handling,
erection, and electrical. Construction and field expense were included under
installation costs. Engineering costs were estimated for 40 hours at $25/hr x 1.6
for overhead.
• Actual painting time was the same as for application without scales, but 0.4
hrs/day was added for tending to the weighing system. The effect of the scales on
actual time spent spraying is unknown. Although less paint would be sprayed,
any time savings might be offset by observing the readout unit and by increased
attention to detail that would be required. Therefore, no reduction was assumed in
actual time spent spraying paint.
• For paint consumption it was assumed that 20 % less paint is sprayed compared to
the previous method and that 10 % fewer kits are used. Charges for printer paper
and pens were included with paint consumption costs.
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• Maintenance costs were included for the paint weighing system.
• Power usage was estimated at 1 kW for miscellaneous electrical loads plus I kW
for instrumentation.
• Air consumption was based on 2 guns, 22 scfm, and 22 min/hr usage (vs 26.4
min/hr for the previous method).
• Waste disposal was based on 12 gal/day waste paint plus replacement of
ventilation system filters at the rate of 2/wk, 52 wks/yr, 3 lb/filter. Less paint was
assumed to be sprayed, but more paint went to waste because the paint is mixed in
discrete batches of 5 gallons. At the same time, the overspray load on the
ventilation system was reduced. Low-end disposal charge applies.
4.5.4.4 Paint Application Monitoring
Results of Costing for Paint Application Monitoring
Tables 4-7 and 4-8 show capital and annual costs for purchasing, installing, and using the
weighing equipment and instrumentations intended to reduce paint usage. Capital costs are
primarily for the scales and displays used to show the painters their rate of application. Direct
and indirect installation costs are largely for handling and erection and for engineering.
Estimated total capital investment is $22,161.
Estimated annualized costs are about $1.03 million, three fourths of which is for the
paint. Labor and waste disposal are about 14 % of the costs.
Discussion of Paint Application Results
The pollution prevention aspects of this task are aimed at equipment to reduce paint usage
(and improve coating quality). The purchased equipment and its annualization are a minor
portion of the total costs used in the analysis. However, with savings expected in both paint
usage and painting labor, these large costs are also included in the analysis. Greater accuracy
would be obtained with more operating time and examination of data.
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Table 4-7. Capital Costs for Paint Application with Flow Monitoring
Direct Costs
Purchased Equipment Costs
System with controls
$17,150
Instrumentation (if not included in controls)
$858
Sales Taxes
$0
Freight
$200
Purchased Equipment Cost, PEC
518,208
Direct Installation Costs
Foundations and supports
$0
Handling and erection
$1,057
Electrical
$750
Piping
$0
Insulation for ductwork
$0
Painting
$0
Direct Installation Costs
$1,807
Site Preparation as required,
Buildings as required.
Total Direct Cost
$20,015
Indirect Costs (installation)
Engineering
$1,600
Construction and Field Expense
$0
Contractor Fees
$0
Start-up
$0
Performance Test
$0
Contingencies
$546
Total Indirect Costs, IC
$2,146
TOTAL CAPITAL INVESTMENT, TCI
$22,161
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Table 4-8, Annualized Cost Analysis for Paint Application with Flow Monitoring
Direct annual Costs, DC
Operating Labor
Operator ([244 hours/day]*[260 days/year]* [SI 6.5 2/hottr]) SI04,803
Supervisor (15% of operator) $15,720
Training ([8 hours/year/employee]*[$33 04/hourJ*[32 employees]) $8,458
Operating Materials
Paint ([$4.76/pound]*[l63.734pounds/year]) $779,374
Maintenance
Labor (fO.4 hours/day]"[260days/year}*[SIS. I'hour]) Si,890
Material (Equalto $/50/year) SI50
Utilities
Electricity ([2.0 kW]*[$0,07l/kWhaur]*(2080 hours/year]) $295
Compressed air ([3870 scfm/hour]*[$0.19/1000 scfm]*[2080 hours/year]) $ 1529
Waste Disposal ([16.S3 tons/year]*[$2,300/ton]) S38,019
Total Direct Cost, DC S950,238
Indirect annual Costs, IC
Overhead (60% of sum of labor + maintenance materials) $78,613
Administrative charges TCI *0.02 $443
Property taxes TCI * 0.01 $222
Insurance TCI«0.0I $222
Capital recovery CRF*TCI (CRF=0.2439i $5,405
Total Indirect Costs, IC S84,905
Total Annual Cost, TAC (TAC = DC + IC) SI,035,143
Comparison with Current Application Method
Table 4-9 shows the estimated annualized costs for the current paint application method,
i.e., without an objective system for measuring and indicating paint usage during application.
Because the current system requires no change, no capital costs are charged. The annualized
costs are $1.097 million or about 6% more than for the new system. Table 4-10 compares the
costs for the two application methods. As with the new system, the major costs are in paint
usage and labor.
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Table 4-9. Annualized Cost Analysis for Paint Application without Flow Monitoring
Direct annual Costs, DC
Operating Labor
Operator ([24 hours/day]*[260 days/year)*[$ 16.52/hourJ) 5103,085
Supervisor (15% of operator) $15,463
Training ([8 hours/year/emplayee]*[$33.04fhour]*[32 employees]) $8,458
Operating Materials
Paints ([$4.76/pound]*[180,108pounds/year]) $857,314
Maintenance
Labor ([0 hours/day]*[260 days/year] *[$ 18.17/hourJ) $0
Material (Equal to Maintenance Labor) $0
Utilities
Electricity ([1.0kW]*[$0.071/kWhour]*[2080hours/year]) $148
Compressed air ([4260 sc/m/hour]*[S0.19/1000 scfm]*[2080 hours/year]) $ 1,684
Waste Disposal ([15.16 tons/year]*[S2,300/ton]) $34,868
Total Direct Cost, DC
$1,021,020
Indirect annual Costs, ic
Overhead (60% of sum of labor + maintenance materials)
Administrative charges TCI * 0.02
Property taxes TCI * 0.01
Insurance TCI * 0.01
Capital recovery CRF*TCI (CRF=0.2439)
$76,204
$0
$0
$0
$0
Total Indirect Costs, IC
$76,204
Total Annual Cost, TAC (TAC = DC + IC)
$1,097,224
Table 4-10. Summary Comparison of Painting With and Without Flow Monitoring
PAINTING METHOD
CAPITAL COSTS
ANNUALIZED COSTS
Without Flow Monitoring | $0
$1,097,224
With Flow Monitoring j $22,161
$1,035,143
The major long-term saving with the new system is due to the reduction in paint required.
The assumed reduction in paint sprayed is about 20%. Because mixed paint is prepared in
discrete quantities (5-gal kits) rather than being used as needed, the 20% reduction in sprayed
paint is assumed to result in a 10% reduction in the number of kits required. Waste disposal
increases a small amount because of the shift to less paint sprayed and resultant increased
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wastage from some of the 5-gallon kits. Labor hours are also reduced because of the more
efficient usage of paint; fewer passes are required to coat a given surface. A further benefit of
the scales might be better and more uniform coverage, resulting in less rework due to overly
thick coatings. However, this benefit remains to be verified. A reduction in labor hours is used
for this analysis, but in practice, the savings would more likely result in higher productivity.
4.5.4.5 Return on Investment and Payback Period for Paint Application
Return on investment (ROI) and payback period (PP) are two common measures for
estimating the profitability of a venture. Return on investment as used for this project is the
average yearly profit divided by total capital investment, expressed as a percentage. The average
yearly profit is taken as the difference in annualized cost between the existing process and its
intended pollution prevention replacement.
Payback period is the total capital investment divided by the sum of profit (as used
above) and depreciation of the pollution prevention equipment. For this project, the straight line
depreciation method is used with a 5% salvage value. Depreciation is total capital investment
minus salvage value, all divided by equipment life. For paint application with a weighing
system, ROI is found from:
TAC , - TAC ,
ROI = ,caU' ^ * 100
TCI ,
seals*
61»081
= —:— * too
22,161
= 280%
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and PP is found from:
PP =
TCI
teals*
TAC — TAC +
1A^*0 SC*Um MC&tiM
TCI,eaU, - 0.0S *TCItettUi
20
22,161
^ 61,181 +
= 0,4 years
22,161 - 1,108
20
These values, which require verification from further measurements of paint usage with
the weighing system, are highly encouraging. There is apparently a large economic incentive to
convert to the pollution prevention method of paint application.
4.6.0 CONCLUSIONS
The program has successfully demonstrated that very accurate and precise measurements
of paint usage by vehicle can be made using this system. As a result, the MCLB now has reliable
information about the amount of paint needed for two common vehicle types and the means for
developing additional data about other vehicle types.
There was no demonstrated decrease in mean paint usage immediately after the displays
were installed. However, results of the paint use measurements must be viewed in light of the
limited time available for the demonstration. The demonstration period included six days of data
acquisition without feedback and two days with feedback. Within this period, only five of the
approximate twenty-five MCLB painters were included in the measurements. Thus, the data
base both in terms of the number of vehicles painted and the number of painters monitored is
very limited. Within these limitations, the specific conclusions drawn from this study are:
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1) The gravimetrically-based paint monitoring system proved to be a reliable and accurate
means of monitoring paint use.
2) The amount of paint (two-component green CARC) sprayed to cover ten HMMWVs, five
5-ton trucks, and several other vehicles was recorded. HMMWVs required from 1.66 to
2.70 gallons. The 5-ton trucks required from 5.76 to 7.53 gallons.
3) During the demonstration period, no reduction in mean paint usage was observed after
use of display units to provide feedback to the painters.
4) Relative to the mean values for the combined (with and without feedback) data sets, the
minimum observed values were 17% below the mean for the HMMWVs and 27% below
the mean for the 5-ton trucks. These figures indicate that a reduction in emissions of
approximately 20% should be achievable if average paint usage could routinely be kept
near the observed minimums. Also, the MCLB's planned use of a paint dispensing
system to allow dispensing only the amount of paint needed, as opposed to the current
practice of dispensing in discrete 5-gallon kits, is expected to further reduce air emissions
through reduced paint usage.
5) Based on an economic analysis, a cost savings of approximately $62,081 per year would
be realized if a 20% reduction in paint usage could be achieved. Given the estimated
$22,161 capital cost to purchase and install the system, this yields a relatively short
payback period of approximately 0.4 years.
4.7.0 RECOMMENDATIONS
Although a reduction in mean paint usage was not measured, significant variations were
measured in the amount of paint sprayed to coat identical vehicles. This indicates the potential
for significant reductions in paint use with continued use of the paint monitoring system.
Therefore, the following recommendations are presented:
1) Continued use of the paint monitoring system and continued collection of the paint use
data by vehicle type is the first recommendation. After a period of several months, an
evaluation of these data would determine if measurable reductions in mean paint usage
were realized. During this several month period, it is recommended that relatively low
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target values be used and that the painters be encouraged to try to stay at or below the
target levels.
2) A modification of the paint monitoring system and/or painting practices would allow the
system to display the accumulated total per job regardless of refilling of the paint bucket.
(The need to add paint during a single job was not anticipated when the display unit was
programmed.) This could be accomplished by a software change within the WI-130
controller (performed by the vendor) to allow for a "refill" operation without loss of the
currently displayed "total," or through the use of a larger paint pot that could hold the
entire amount needed to paint the vehicle.
3) Continued investigation of complementary technologies for pollution reduction including
a paint dispensing system that is capable of mixing quantities of paint in less than 5
gallon increments is recommended. The combination of the two technologies (weighing
and dispensing) should provide better reduction than either technology alone.
During the demonstration, it appeared that in addition to reducing the amount of paint
sprayed through operator awareness of application rate and target value, there are other ways in
which the paint monitoring system could be used to reduce emissions. Some of these are as
follows:
F Training - With the weighing system, new painters can learn to apply uniform coatings
without using too much or too little paint by comparing their usage with the historical
data for the vehicle type.
F Equipment Maintenance and Setup - The ability to measure paint consumption can be
used to assess whether equipment maintenance and setup have any effect on paint
consumption. To do this, the MCLB personnel would have to record information such as
the condition of the nozzle, air pressure, etc., and make correlations with the amount of
paint used. Optimizing the equipment configuration may provide an opportunity for
significant emission reductions.
F Verification of other pollution reduction strategies including the paint dispensing system.
The weighing system demonstrated on this project can provide data that can be used for
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determining the amount of paint to be mixed for each vehicle type. Used in conjunction
with such a technology, the weighing system can provide documentation of pollution
reduction.
The MCLB may wish to consider these areas for further investigation and
implementation.
4,8.0 REFERENCES
1. OAQPS Control Cost Manual, EPA-450/3-90-006 (NTIS PB90-169954). January 1990.
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APPENDIX 4-1
EVALUATION OF ULV PAINT DELIVERY SYSTEM
An initial project objective to evaluate an innovative paint pumping device (the ULV
system) proved inappropriate for the MCLB's CARC coatings during preliminary trials by the
manufacturer and was not evaluated further. A summary of these findings are presented in this
appendix.
Introduction
The ultra low volume (ULV) system, manufactured by Air Compliance Technology,
Greensboro, GA, is a paint delivery system designed to improve the performance of airless spray
guns. It is different from conventional high-pressure paint systems in that rather than using a
piston pump to pump the paint to high pressure, it uses a nitrogen-pressurized floating piston to
pressurize paint in a high-pressure-capacity container.
Improved performance is obtained primarily because the ULV system allows airless
spraying at a lower paint pressure than airless (500-800 psi for ULV versus 1500 - 2000 psi for
conventional airless). For all types of spray painting, a significant amount of room air is
entrained into the paint plume due to the aerodynamic drag of the particles. Due to the high fluid
pressures associated with conventional airless spraying (1500 to 2000 psi), the spray particles
have a relatively velocity that results in a very turbulent, violent entrainment of air that reduces
transfer efficiency. By reducing the pressure to the 500 - 800 psi range, the velocity of the
particles is reduced and the entrained air is not nearly as turbulent or violent and thus, transfer
efficiency is increased.
Also, according to the ULV manufacturer, at the higher pressures of conventional airless
systems, the speed of the paint spray droplets through the air promotes evaporation of the solvent
carriers creating an undesirable dry film. The ULV system, by using lower paint pressures,
reduces this effect.
A secondary benefit of the ULV system is a smoother delivery of paint (i.e.. no pulsations
in flow) which can result in a more uniform coating thickness.
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Utility of ULV for Spraying MCLB's Coatings
Preliminary trials by the ULV manufacturer (Table 4-1-1) showed that, without thinning,
a ULV airless system could not spray the MCLB's CARC or primer coatings acceptably.
Discussion
The MCLB uses air-assisted airless for the majority of painting, and some conventional
guns for touch up work. The MCLB does not use airless systems. The benefits of air-assisted
airless relative to conventional airless are very similar to those provided by using ULV on airless
systems, reduced paint pressure, softer spray, higher transfer efficiency. Air-assisted airless
allows the paint pressure to be reduced to the 500 - 800 psi range because the air-assist helps in
the atomization of the paint and distribution of the particles within the plume. At these lower
pressures, if air-assist were not used the spray pattern would have unacceptable "heavy edges".
The MCLB has already obtained most of the benefit that the ULV system would provide
because the MCLB uses air-assisted airless. The ULV system could be used with the air-assisted
airless guns to provide a smoother paint delivery but this is not likely to be lead to significant
reductions in the amount of paint sprayed for vehicle painting. It is estimated that at least 75% of
the benefit of ULV comes from the reduced pressure and no more than 25% from smoother paint
delivery. Thus, while some benefit may be achieved from the smooth delivery, it is not likely to
be significant.
4-46
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Table 4-1-1. Summary of ULV Trials with Military Coatings
Coating
Was an Attempt Made
To Spray This Coating
With The ULV
System?
(Indicate Yes or No)
Was The Coating
Successfully Sprayed
With The ULV
System?
(Indicate Yes or No)
Comments
2-component CARC
YES
NO
I-component CARC
Primer
YES
YES
NO
(Better)
NO
(Close)
Undercoating
NO
* During testing, the ULV manufacturer noted that higher pressures (700 to 800 psi) caused compaction of the
material in the lines and on strainer and filter screens. 500 psi or less eliminates this clogging effect. All above
materials were sprayed with the ULV System. The spray pattern was unacceptable, having heavy "crows feet"
or heavy edges.
4-47
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APPENDIX 4-2
PAINTING PROCEDURE INSTRUCTION SHEET
"Use keyboardfor data entry.
*Make sure printer is on! (Red light will glow.)
1) Press (Start)
2) Enter data when prompted by display:
Display Prompt
Vehicle ID
Vehicle Code
Coating Code
Your ID
Partner ID
Target Amount
Pounds per gallon
Scale
Operator Entry
enter 6-digit ID number, press
enter 3-digit code (like 923), press
enter P (primer) or C (CARC), press
enter your badge number, press
enter partner's badge number, press
enter gallons of paint needed, press
enter 11.1 for CARC, press
enter 1 (outside) or 2 (inside), press
3) Screen will prompt "Start Flow Monitor?" Press (Yes).
4) Place solvent catch bucket on scale. Place the stirring motor and paint tube in the bucket as usual.
5) Press (yellow button on remote box).
6) Press (blue button on remote box).
7) If more paint is needed:
A) press
B) pour paint into bucket on scale
C) press
D) press again
8) When equipment is finished, press .
9) To stop, press (Stop); then (Yes).
10) When all data has printed, give data strip to Leaderman.
IMPORTANT: DO NOT HIT EXCEPT AFTER PAINT IS ADDED TO BUCKET!
To Correct Errors During Data Entry (Step 2):
Use for current entry.
Use after has been pressed. This will return you to Step 1.
4-48
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APPENDIX 4-3
SUMMARY DATA FOR PAINT DEMONSTRATION
TEST#
PAINTERS
DATE
DISPLAY
VEHICLE TYPE
AMOUNT
(g«l)
{ NOTES
I
6261,8938
12/5
No
923 - Track
5.49
'Underside not done
2
6261,8938
12/5
No
818-Cab
5.74
¦
3
6261,8209
12/6
No
MK-48 - Power
6.45
;
4
6261, 8209
12/6
No
HMMWV
2.08
5
6261, 8209
12/7
No
HMMWV
1.66
6
8938, 7478
12/7
No
HMMWV
2.7
•
7
8938, 7478
12/7
No
HMMWV
1.68
8
8938,7478
12/7
No
HMMWV
2.04
9
8938, 7478
12/8
No
5-ton Truck
7.16
12/8
No
misc.
..
Touch up only
10
8938,6261
12/11
No
HMMWV
1.82
i
11
8938,6261
12/12
No
HMMWV
1.92
iTARE not recorded ¦
12
8938,9791
12/13
No
! 927 - Truck
5.84
) :
13
8938,9791
12/13
No
813-Truck
4.1
! Underside not done
14
8938,6261
12/14
Yes
813-Truck
5.76
j
15
8938,7478
12/14
Yes
923 - Track
6.56
16
8938,7478
12/14-15
Yes
j 813 - Truck
7.53
(Across days
17
8938,7478
12/15
Yes
| HMMWV
*2.04
18
8938,7478
12/15
Yes
| HMMWV
2.04
|
19
8938,7478
12/15
Yes
HMMWV
2.08
'
! j
4-49
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