Optimizing Your Spray System Spray nozzle maintenance and control for improved production efficiency Spray Nozzles Spray Control Spray Analysis Spray Fabrication

3 This handbook is a compilation of the knowledge we’ve acquired through more than 60 years of helping users solve spray application problems. Our experience reaches into more than 200 different industries and has led us to develop tens of thousands of spray nozzles and accessories, a turnkey systems division, spray research and analysis services and custom fabrication facilities. We have manufacturing locations around the world and we work with hundreds of thousands of customers. The intent of this handbook is educational. Our goal is to help you maximize the performance of your spray system...

4 What is Spray System Optimization? Spray systems are often perceived as pretty simple. After all, what’s so complicated about pumps, piping, liquid and spray nozzles? As long as the nozzles are spraying, the system is working properly, right? Wrong! Spray nozzles are precision components designed to yield very specific performance under very specific conditions. Just because a nozzle is spraying doesn’t mean that it is working properly. And it certainly doesn’t mean that your spray system performance is optimal. Many other factors can impact your spraying system. To achieve long-term, efficient,...

5 An I n t r o d u c t i o n What are the benefits? When your spray system is optimized, you should experience trouble-free operation including: • maximum system efficiency • low operating and maintenance costs • excellent quality control • consistent cost of consumables • predictable labor costs • normal maintenance schedules and no unexpected downtime • minimal environmental impact Sound good? It will require some effort but it’s well worth it. Your Spray System Optimization Program will go beyond checking system performance against published specifications and will include: • an evaluation...

8 Many spray systems today are manual systems. However, automated systems — with a controller that “manages” performance — are gaining popularity quickly. Whether you have a manual or an automated system, there are two main considerations when evaluating your spray system. 1. How is your system performing today? Could you improve performance by making some minor modifications or changing your maintenance procedures? 2. Could performance be further enhanced if you automated your system or upgraded your existing control device? A Spray System Optimization Program begins with an assessment of your...

9 Assessing the effectiveness of your spray system The Va l u e o f Spray O p t i m i z a t i o n In general, a good place to start is to review your costs for water, chemicals and electricity. If your present system isn’t performing properly, you could experience significant waste and increased costs. The charts on pages 10 and 11 will give you a feel for how much this waste could be costing. As you think about your application, keep the following factors in mind as well. They can have a significant impact on cost, too. • Labor: Are you spending a lot of time operating or monitoring your system?...

1 0 The costly consequences of a spray system that isn’t optimized The Va l u e o f Spray O p t i m i z a t i o n If you are spraying water: Based on a 5 day work week, 24 hours per day, assuming 15% waste rate. Water/sewage cost: $0.003 ( 0.0027) per gallon — $0.00079 ( 0.00071) per liter Note: The cost of wastewater disposal should also be considered. In addition, excessive wastewater may aggravate water shortage problems. All figures calculated with a conversion factor of 1USD = 0.90. $90,000 ( 81,000) $80,000 ( 72,000) $70,000 ( 63,000) $60,000 ( 54,000) $50,000 ( 45,000) $40,000 ( 36,000)...

1 2 Common spray applications and common problems The Va l u e o f Spray O p t i m i z a t i o n A i r C o n t r o l C l e a n i n g , Wa s h i n g a n d R i n s i n g C o a t i n g application: Cooling, cleaning, drying and moving of materials. potential problems: – Uneven cooling, cleaning or drying. – Quality control issues from product not being rejected or moved. – Increase in compressed air usage. application: Low and medium pressure using centrifugal-type pumps for cleaning of tanks, products, vehicles, plant processing equipment. High-pressure washers using positive displacement pumps...

1 3 Common spray applications and common problems The Va l u e o f Spray O p t i m i z a t i o n Spray D r y i n g application: Cooling of solid objects such as fabricated products and processing equipment. Cooling of air and gases. Cooling of pond water and cooling tower water. potential problems: – Poor product quality such as distortion and cracks and excessive downtime. – Less efficient cooling. – System performance degradation. – Emission problems or duct, chimney or equipment damage possible. – Water system efficiency reduction. application: Drying of feed stock to powder. potential problems:...

1 4 Calculating the potential cost in your application The Va l u e o f Spray O p t i m i z a t i o n The next step in the assessment of your present system is to obtain information specific to your application. One way to do this is to utilize our Spray System Savings Calculator. Available at www.spray.com/save, this tool will allow you to enter detailed information about your application and determine how much you may save by optimizing your spray system. The calculator prompts you for information about the cost of the liquid you are spraying, the number of nozzles you’re using, your flow rates,...

1 6 Setting specific performance standards is critical to any Spray System Optimization Program. After all, how can you optimize performance if you haven’t determined what optimal performance is? The first step is to identify the most critical requirements in your application. For instance, in some spray applications there is one primary purpose such as metering a specific amount of liquid into batches, tanks, etc. In these applications, it is critical to ensure that an accurate flow rate is delivered consistently. In precision coating applications, the spray pattern is as important as the flow...