Area Source NESHAP Certified Painter Training

Introductions

Introductions
Nomenclature: paints, coatings, primers, topcoats, enamels, lacquers, basecoats, clearcoats, liquid paints, powder coatings

General Source NESHAPs

What is a VOC?
What is a HAP (organic and inorganic)?
What is a NESHAP?
Who needs to comply?
Review specific requirements for painting operations
Importance of recordkeeping
Painter training requirements
What comprises certification?

Basic Spray Booth Designs

Cross draft
Down draft
Side down draft
Regulatory velocity requirements – OSHA and NFPA-33
When to operate under positive pressure
When to operate under negative pressure
How to measure the spray booth pressure balance

Spray Booth Exhaust Filters

Purpose:  Removal of paint overspray vs. VOC
What do EPA regulations require?
Types of spray booth dry filters
– Single-, two- and three-stage filters
– Roll, panel, pocket, bag
Why single-stage filters should never be used
Determining filter efficiency to meet EPA requirements
Measuring pressure differentials
How to dispose of spent dry filters

Break

Measuring Filter Pressure Differentials

Manometers v magnehelic gauges
Proper gauge installation
Zeroing and calibrating the gauges
When to change filters
Do you need to change all filters at the same time?
Examples of filter installations that are EPA violations
Record keeping of pressure differentials

Spray Booth Air Intake Filters

Differences between air exhaust and intake filters
Examples of poor installation of intake filters

Water Wash Spray Booths (optional if relevant to facilities)

How they function
Water-wash v dry filter spray booths, pro’s and con’s
Chemicals to remove overspray, prevent corrosion, minimize foaming, kill bacteria
EPA requirements for water flow rate
How to control spray booth for optimum filtration of overspray
Processes for removing paint sludge
Prevent “painting of cars in parking lot”

Lunch

Spray Guns

Principles of atomization
The role of compressed air
Air atomizing spray guns - basics
Siphon, gravity-fed and pressure fed spray guns
Comparing conventional and HVLP air atomizing spray guns
Definition of HVLP
How to measure EPA compliance of HVLP spray gun
Causes of EPA violations
Possible size of fine

Other Spray Guns (optional if relevant to facilities)

Electrostatic spray guns - the principles
Electrostatic bells and discs
What constitutes compliance with EPA regulations
Airless and air- assisted airless spray guns
What type of air-assisted airless gun complies with EPAs definition of HVLP

Viscosity of Paint

What is viscosity?
Different types of viscometers for paints
How to use a Zahn cup
Effect of temperature on viscosity
Viscosity of two-component paints
Does the EPA allow you to add solvents to the paint?
Legal strategies for lowering viscosity

Break

Setting up a Spray Gun

Functions of:  fluid needle
– fluid control knob
– air regulator on spray gun
– fan control knob
Step-by-step approach
Testing for atomization
Measuring fluid flow rate
Preventing runs and sags

Getting Sufficient Air to the Spray Gun

Why HVLP guns are often starved of atomizing air
Role of compressor
Pressure drop from compressor to spray booth
Pressure drop from regulator to spray gun
Eliminating unnecessary pressure losses

Equipment Cleaning – Minimizing VOC/HAP Emissions and Hazardous Waste

Low VOC solvents for equipment cleaning
Flushing fluid hoses and fluid tubes
Pressure pots
Spray gun cleaning using gun washers and distillation units

Wrap-up

Transfer Efficiency (TE)

Principles of Transfer TE
Why TE is so effective in lowering emissions, hazardous waste and costs
Painting techniques that improve TE
– Gun-target distance
– Angle of spray gun (arcing of wrist and arm)
– First and last stroke
– Overlaps (banding)
– Efficient hanging of parts
– Efficient placing of parts on tables
– Fluid flow rate
– Atomization pressure
– Fan width
Equipment considerations that improve TE
– Spray booth design
– Air velocity in spray booth
– Air turbulence
– Lighting
– House keeping
– Viscosity
– Temperature in spray booth
– Coating composition
– Spray gun ergonomics
– Management/Painter Attitude

Break

Environmental

What are Volatile Organic Compounds (VOCs)?
How solvent-based paints are regulated by the EPA and state agencies
Waterborne paints
How waterborne paints are regulated
Hazardous Air Pollutants (HAPs)
NESHAP and MACT standards

Lunch

Hands-on Training

Measure air velocity in spray booth
Determine if filtration is single, two or three stage
Inspect intake filters - check for proper installation
Inspect manometer  - properly connected to booth, zeroed, calibrated, pressure differential
Inspect Magnehelic gauge - properly connected to booth, zeroed, calibrated, pressure differential
Determine if spray booth is operating under positive or negative pressure
Evaluate if there is turbulence in booth
Inspect walls, floor, ceiling and exhaust chamber for overspray
Evaluate lighting conditions

Break

Hands-on Training & Exam

Inspect regulators and pressure gauges
Evaluate compressed air hoses, quick disconnects and other connectors
Determine if air hose diameter is appropriate for HVLP - 1/4 or 3/8” diameter
Check for moisture and oil in compressed air
Does compressor have a drier
Measure viscosity – Zahn #2 and #3 cups, using paint, solvent, water
Review paint mixing procedures
Measure pressure drop at handle of spray gun
Demonstrate EPA compliance for HVLP guns

Hands-on Training (Continued)

Is spray gun appropriate for type of product?
Is spray gun properly maintained?
Determine if nozzle size is appropriate
Each painter to set up spray gun from scratch
– atomizing air pressure, needle adjustment, fan pattern
– prevent runs and sags
– measure fluid flow rate after gun has been set up

Appropriate painting practices to increase TE
– Painters will apply paint to aluminum panels and will be evaluated for the following: gun target distance, angle of gun to target (arcing), overlapping of strokes (banding), lead and lag triggering at beginning and end of each stroke, fan width, fluid flow rate, and quality of finish. 

Break

Exam (required 70% for passing

Aircraft Spray Booth Design

How aircraft booths differ from vehicle and parts booths
Calculating air velocity in the spraying zone
Maximizing velocity while minimizing energy usage
Allowances for wing tips, tails and overhead requirements

Spray Booth Lighting

OSHA lighting requirements for spray booths
What is the optimum lighting level for a paint booth?
What instruments measure lighting?
How does one measure brightness in a spray booth?
Electrical codes for placing lamps inside or outside a spray booth
How to light the bottom side of an aircraft
State-of-the-art lighting fixtures
Pro’s and con’s of T5, T8 and T12 fluorescent tubes
How brightness of fluorescent tubes decreases with age
How to keep overspray from ruining your booth brightness
Where to position lamps for maximum effect

Break

Pressure Pots

Single-regulated pressure pots
Double-regulated pressure pots
Pressure cups
Siphon cups

Why Spray Guns are often Starved of Air

Plumbing of compressed air lines
Purchasing the correct air hose
Quick disconnects
Other fittings
Preserving air pressure at the spray gun

Quality Control and Commonly used Instruments

Dry film thickness (different instruments)
Wet film thickness
Adhesion – tape pull-off
Adhesion – dolly pull-off
Hardness
Flexibility
Impact resistance
Gloss
Distinctness of Image (DOI)
Drying
Full cure
Color control

Quiz – Lighting, Pressure Pots, QC Testing

Lunch

Environmental

What are Volatile Organic Compounds (VOCs)?
How solvent-based paints are regulated by the EPA and state agencies
Waterborne paints
How waterborne paints are regulated
Hazardous Air Pollutants (HAPs)
NESHAP and MACT standards

Break

Environmental Nomenclature

RACT, BACT, LAER, MACT, NESHAP
Title III
Title V – Operating Permits

Quiz – Environmental

How to use MSDS and Technical Data Sheets for Calculations

Percent by weight vs percent by volume
Vapor pressure
CAS numbers
Chemical names of compounds
Examples of poorly written material safety data sheets (MSDS)
Analytical methods to determine VOC, HAP, water and exempt solvents

Break

Calculations

Calculating VOC/HAP of a single component coating
Calculating VOC/HAP of a plural component coating
Calculating VOC/HAP when thinners are added
Calculating VOC/HAP of waterborne coatings
Calculating emissions from spray booths

What to Expect from a Paint Facility Inspection

Record keeping
Permits
Covered containers
Empty cans
Spray booth filters
Spray guns

End of Class