FMDS0727

FM Global Property Loss Prevention Data Sheets
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January 2007 Page 1 of 42
SPRAY APPLICATION OF FLAMMABLE AND COMBUSTIBLE MATERIALS
Table of Contents
Page 1.0 SCOPE ................................................................................................................................................... 3 1.1 Changes ............................................................................................................................................ 3 2.0 LOSS PREVENTION RECOMMENDATIONS ....................................................................................... 3 2.1 Flammable Solvent Base Coatings ................................................................................................. 3 2.1.1 Introduction ............................................................................................................................ 3 2.1.2 Construction and Location .................................................................................................... 3 2.1.3 Protection .............................................................................................................................. 5 2.1.4 Equipment and Processes .................................................................................................... 7 2.1.5 Electrical ................................................................................................................................ 8 2.1.6 Ignition Source Control ........................................................................................................ 12 2.1.7 Operation and Maintenance ................................................................................................ 12 2.1.8 Occupancy ........................................................................................................................... 14 2.2 Water Base Coatings ..................................................................................................................... 19 2.2.1 Introduction .......................................................................................................................... 19 2.2.2 Construction and Location .................................................................................................. 19 2.2.3 Protection ............................................................................................................................ 19 2.2.4 Equipment and Processes .................................................................................................. 19 2.2.5 Electrical .............................................................................................................................. 19 2.2.6 Occupancy ........................................................................................................................... 19 2.2.7 Operation and Maintenance ................................................................................................ 20 2.3 Powder Coating ............................................................................................................................. 20 2.3.1 Introduction .......................................................................................................................... 20 2.3.2 Protection ............................................................................................................................ 21 2.3.3 Equipment and Processes .................................................................................................. 21 2.3.4 Ignition Source Control ........................................................................................................ 22 2.3.5 Electrical .............................................................................................................................. 22 2.3.6 Operation and Maintenance ................................................................................................ 23 3.0 SUPPORT FOR RECOMMENDATIONS ............................................................................................. 23 3.1 Loss History ................................................................................................................................... 23 3.1.1 Flammable Solvent Base Coatings ..................................................................................... 23 3.1.2 Water Base Coatings .......................................................................................................... 26 4.0 REFERENCES ..................................................................................................................................... 26 4.1 FM Global ...................................................................................................................................... 26 APPENDIX A GLOSSARY OF TERMS ..................................................................................................... 27 APPENDIX B DOCUMENT REVISION HISTORY ..................................................................................... 27 APPENDIX C SUPPLEMENTAL INFORMATION ...................................................................................... 27 C.1 General ......................................................................................................................................... 27 C.2 Flammable Solvent Base Coatings ............................................................................................... 28 C.2.1 Coatings .............................................................................................................................. 28 C.2.2 Spray Application Methods ................................................................................................. 28 C.2.3 Spray Booths ...................................................................................................................... 31 C.2.4 Applications ......................................................................................................................... 36 C.3 Water Base Coatings .................................................................................................................... 37 C.3.1 Coatings .............................................................................................................................. 37 C.3.2 Spray Application Methods ................................................................................................. 38 C.4 Powder Coating ............................................................................................................................ 38
2007 Factory Mutual Insurance Company. All rights reserved. No part of this document may be reproduced, stored in a retrieval system, or transmitted, in whole or in part, in any form or by any means, electronic, mechanical, photocopying, recording, or otherwise, without written permission of Factory Mutual Insurance Company.
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C.4.1 Coatings .............................................................................................................................. 38 C.4.2 Application Methods ........................................................................................................... 38 C.6 NFPA 33 ........................................................................................................................................ 41 C.6.1 Flammable Solvent Base Coatings .................................................................................... 41 C.6.2 Water Base Coatings .......................................................................................................... 42 C.6.3 Powder Coatings ................................................................................................................ 42
List of Figures
Fig. 1. Spray room showing recommended cutoffs and protection. .............................................................. 4 Fig. 2 Two spray booths and drying oven with exhaust to fume incinerator. Automatic sprinklers in ducts are shown. (Spray booth and oven protection is not shown.) ............................................................ 6 Fig. 3. Acceptable energy conservation methods for air exhausted from spray booths. (Sprinkler protection is not shown.) .................................................................................................... 9 Fig. 4. Class I and II Areas adjacent to an unenclosed spray operation. ................................................... 10 Fig. 5. Class I or II Division 2 area adjacent to a closed top, open faced or open front spray booth. A. When ventilation system is interlocked with spray equipment, X is 5 ft (1.5 m). B. When ventilation system is not interlocked with spray equipment, X is 10 ft (3 m). ................................. 11 Fig. 6. Class I or II Division 2 Area adjacent to an open-top spray booth. ................................................. 11 Fig. 7. Spray room with water wash spray booths, cut-off mixing room, and finishing material distribution system. Also shown is manually actuated remote shutoff for pumps in mixing room. (Sprinkler protection and automatically actuated remote shutoff for pumps not shown.) ................................ 13 Fig. 8. Dry filter spray booth equipped with filter pads. Also shown is gauge used to indicate minimum air velocity. ........................................................................................................................ 15 Fig. 9. Electrostatic spray system, rotating disk type. ................................................................................. 29 Fig. 10. Hot spraying system. This type heats both atomizing air and finishing material. .......................... 31 Fig. 11. Airless Electrostatic Spray System. ................................................................................................ 32 Fig. 12. Dry filter spray booth equipped with baffles. .................................................................................. 33 Fig. 13. Downdraft water wash spray booth (room sprinkler system not shown). ...................................... 34 Fig. 14. Oil wash spray booth with removable baffles in exhaust plenum. Interlock to shut off oil pump in event of sprinkler operation is also shown. ................................. 35 Fig. 15. Manual spray booth with partial recirculation of filtered air. ........................................................... 39 Fig. 16. Integrated booth design with cartridge filter system in upper part of booth hopper. ..................... 40 Fig. 17. Electrostatic fluidized bed with perimeter exhaust system. ............................................................ 41
List of Tables
Sprinkler Protection Citeris for Flammable Liquid Spraying ........................................................... 6 Cause of Loss in Nonelectrostatic Spray Operations Based on 5-year Loss Study .................... 23 Cause of Loss in Electrostatic Spray Operations Based on 5-year Loss Study .......................... 24 Factors Contributing to Extent of Loss for 13 Fires Exceeding $200,000 Property Damage over Recent 5-Year Period ............................................................... 25 Table 5. Cause of Loss in Furniture Finishing Rooms over Recent 7-year Period ................................... 25 Table 6. Comparison of Effectiveness of various Types of Spray Booths in Furniture Plant Finishing Operations ...................................................................................................................... 26 Table 7. Location of Fires in Dry Booths With and Without Filters ............................................................ 26 Table Table Table Table 1. 2. 3. 4.
2007 Factory Mutual Insurance Company. All rights reserved.
Spray Application
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1.0 SCOPE This data sheet covers the spray application of flammable and combustible solvent and water base coatings, and the spray and fluidized bed application of plastic polymers in dry powder form. Fire hazards of flammable and combustible solvent base coatings applied in spray form are similar. In this data sheet, the term flammable solvent base coating will be used for both types. Methods of application, types of spray booths, loss experience and recommendations are discussed. 1.1 Changes January 2007. Clarification was made to the recommendation 2.1.8.3.3.3. 2.0 LOSS PREVENTION RECOMMENDATIONS 2.1 Flammable Solvent Base Coatings 2.1.1 Introduction The spray application of flammable solvent base coatings may lead to a serious fire and explosion hazard because of the presence of easily ignitable flammable liquids, vapors and combustible overspray residues. The following general safeguards are recommended: 1. Automatic sprinkler protection. 2. Cutoffs (distance or construction) to separate it from other occupancies. 3. Ventilation to confine overspray to the spray area. 4. Elimination of ignition sources in the vicinity of spray operations. 5. Limitation of quantities of finishing material in the vicinity of spray operations. 6. Regular cleaning to prevent excessive accumulations of overspray residue. 2.1.2 Construction and Location 2.1.2.1 General The following general recommendations apply to all flammable solvent base spray operations. Recommendations under Dry Spray, Water Wash, Oil Wash, and Traveling Spray Booths apply to the specific enclosure. Recommendations under Electrostatic, Catalytic, Hot, Steam, and Airless Spray Systems apply to the specific method of application. Recommendations pertaining to aircraft, furniture, and automobile finishing operations also are provided. 2.1.2.2 Location 2.1.2.2.1 Locate spray booths at least 3 ft (1 m) from any other operation, storage or combustible construction. 2.1.2.2.2 Spray operations that seriously expose surrounding occupancies to fire, water or smoke should be located either in a detached one-story spray building or a cut-off spray room at an outside wall in the first story. Basement areas are difficult to ventilate, drain and access for manual fire fighting. Floors above the first floor may result in water damage to equipment and goods in process on floors below. 2.1.2.2.3 Cover automatic sprinklers that are subject to accumulation of overspray residue from solvent or water based paint operations, with polyethylene or cellophane bags having a maximum thickness of 0.003 in. (0.08 mm), or with thin paper bags. Clean sprinklers subject to overspray from powder coating operations. Replace covers or clean heads frequently so that heavy deposits of residue do not accumulate. 2.1.2.2.4 Spray rooms (Fig. 1) should have walls of at least one-hour fire resistance. Self-closing fire doors should be provided at all openings. The use of windows in interior walls is not desirable. However, if needed, they should be wired glass in steel frames. 2.1.2.2.5 If it is not possible to locate the operation in a spray room, noncombustible draft curtains should be installed around the entire spraying operation to prevent rapid spread of heat in the event of fire. Draft curtains should be at least 20 ft (6 m) beyond the spray area and extend a minimum of 5 ft (1.5 m) from the
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Fig. 1. Spray room showing recommended cutoffs and protection.
ceiling. Automatic heat and smoke vents at the roof are desirable within the curtained area. Vent ratio should be 1 ft2 of vent area per 30 ft2 of floor area (1 m2 of vent area per 30 m2 floor area). 2.1.2.3 Construction 2.1.2.3.1 Spray booths should be constructed of steel or a material of equivalent resistance to fire. Aluminum may be used for intermittent or low volume spraying. 2.1.2.3.2 Spray booths should be designed for uniform air movement toward the exhaust outlet to prevent pocketing of overspray residue.
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2.1.2.3.3 Provide a smooth interior surface in the spray booth to facilitate cleaning. Combustible floors should be covered with a smooth-surfaced, noncombustible material. 2.1.2.3.4 Baffle plates should be easily removable or accessible for cleaning on both sides. 2.1.2.3.5 Conveyors should be shielded from overspray. Rail and wheel surfaces should be cleaned periodically to reduce the possibility of the workpiece being isolated from ground and charged by the application of electrostatic coatings. The resultant charge can arc to ground and cause a fire. 2.1.2.3.6 Exhaust ducts should be constructed of steel or other noncombustible materials. Baffles should not be installed in exhaust ducts. Where it is necessary to shut off ducts to reduce heat loss during cold weather, dampers may be provided. The dampers should be interlocked with the fan by a limit switch arranged so that the damper must be wide open before the fan will operate. 2.1.2.3.7 Exhaust ducts from spray booths should not: a) Pass through floors or fire walls. b) Discharge less than 6 ft (2 m) from combustible construction (Fig. 1). c) Discharge less than 25 ft (7.5 m) in the direction of combustible construction or unprotected openings in noncombustible exterior walls (Fig. 1). 2.1.2.3.8 Insulate exterior surfaces of exhaust ducts or stacks that pass through combustible construction or near combustible material, with: a) 1 in. (25 mm) vermiculite or perlite plaster on metal lath, or b) 2 in. (50 mm) heat insulating block material lagged in place; or c) provide a minimum 6 in. (150 mm) clearance around the duct to reduce possibility of ignition of combustible materials outside the duct in event of delay in operation of automatic sprinklers in the duct due to buildup of overspray residue. 2.1.2.3.9 Provide cleanout openings so that all areas exposed to overspray residue (plenum chambers, exhaust ducts, etc.) are readily accessible for cleaning. Deposits are likely to be heavy at elbows or turns. As a minimum, openings of ample size should be provided at least every 12 ft (3.5 m) in ducts, coinciding with sprinkler head locations. 2.1.2.4 Drainage 2.1.2.4.1 Provide curbs or ramps, 4 in. (10 cm) high at the doorways to spray rooms and around areas bounded by draft curtains. An alternative is to provide drained grating-covered trenches across all doorways. Drainage should be kept free of obstructions. 2.1.2.4.2 Trapped floor drains should be provided for spray rooms to safely dispose of water discharged from one 2-12 in. (65 mm) hose stream and the sprinklers located within the enclosed or curtained area. Refer to Data Sheet 7-83, Drainage Systems for Flammable Liquids, for details on drain sizing and layout. 2.1.2.4.3 Floors for spray rooms located above the first floor should be watertight if spray operations are located above an occupancy susceptible to serious water damage. 2.1.3 Protection 2.1.3.1 Provide automatic sprinkler protection for the spray area, adjacent mixing and dispensing areas, and where objects are dried in the open. Sprinkler water demand should be in accordance with Table 1. Automatic sprinkler installation should be in accordance with Data Sheet 2-8N, Installation of Sprinkler Systems (NFPA). Sprinklers should be of a lower temperature rating in the booth than in the room to reduce number of heads opening in the room. Exception: Automatic sprinkler protection may be omitted in noncombustible buildings with noncombustible contents where it is necessary to spray intermittently or on a small scale, if the following conditions apply: a) No nitrocellulose base finishing materials are used. b) The total quantity of finishing material and thinners at the spraying operation does not exceed 10 gal (40 dm3).
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c) Overspray is removed whenever any surfaces have overspray deposited in excess of 132 in. (0.8 mm) thick other than in the form of a dry film.
Table 1. Sprinkler Protection Citeris for Flammable Liquid Spraying Type of Sprinkler System Sprinkler Temperature Rating High Wet Intermediate Ordinary Hose stream demand: 500 gpm (1900 l/min). Duration 60 min.
1. Spraying operations vary and judgement must be used when determining the area of demand for this density. For example: a. Where the spraying area is enclosed by spray booth and duct construction and where flammable liquids are piped into the booth or located within the booth, there is no need to apply this density to the ceiling sprinkler system. The density for this condition would be determined by the surrounding occupancy. This assumes that the duct work is completely sprinklered. b. Where the spraying area extends beyond the confines of the spray booth and the duct construction, this density should then be applied to the portion of the ceiling sprinkler system within the spraying area. c. Where there is air drying of the material beyond the spraying area, this density should be applied to that portion of the ceiling sprinkler system where there is likely to be continuity of combustion due to the flammable solvents. Beyond this portion, the density is determined by the surrounding occupancy. 2. The spray area is defined as the area where spray residues are present plus adjacent mixing, dispensing, or solvent areas.
Density1, gpm/ft2 (mm/min)
0.30 (12)
Area of Demand, ft2 (m2) Spraying area2 or air drying area and 3000 (280) Spraying area2 or air drying area and 3500 (325) Spraying area2 or air drying area and 4000 (370)
2.1.3.2 Provide automatic sprinkler protection for exhaust ducts from spray booths or spray rooms in accordance with Data Sheet 7-78, Industrial Exhaust Systems. If exhaust ducts are manifolded, provide a sprinkler at the junction of each booth exhaust duct with the manifold (Fig. 2).
Fig. 2 Two spray booths and drying oven with exhaust to fume incinerator. Automatic sprinklers in ducts are shown. (Spray booth and oven protection is not shown.)
The sprinklers should be on a wet system where possible. Ducts or stacks outside buildings subject to freezing should be protected with either a nonfreeze system, connection to a dry-pipe system or an open-head system
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actuated by fixed temperature heat detectors. A sprinkler system in a duct or stack may freeze if booth ventilation is shut down and exhaust fans from other nearby operations cause a downdraft through the duct or stack. Where ducts or stacks are subject to freezing, either a dry pendant head system may be provided or piping may be arranged so that only the sprinkler head is inside the duct or stack. 2.1.3.3 Cover automatic sprinklers that are subject to accumulation of overspray residue from solvent or water based paint operations, with polyethylene or cellophane bags having a maximum thickness of 0.003 in. (0.08 mm), or with thin paper bags. Clean sprinklers subject to overspray from powder coating operations. Replace covers or clean heads frequently so that heavy deposits of residue do not accumulate. 2.1.3.4 An accessible indicating control valve should be provided for sprinklers in spray booths or spray rooms. 2.1.3.5 Provide portable extinguishers suitable for flammable liquids in accordance with Data Sheet 4-5, Portable Extinguishers. Water-type extinguishers or small hose with adjustable spray nozzles also should be provided for fires in overspray residue. 2.1.4 Equipment and Processes 2.1.4.1 Ventilation Mechanical ventilation systems are necessary to safely remove flammable vapors and confine overspray residue to the spray area. Guidance has been provided in sizing of ventilation systems in terms of velocities across booth openings. Booth manufacturers would be expected to exceed these minimum values when designing new spray booths because a number of factors affect the ability of a booth ventilation system to contain overspray. These factors are: 1) air flow in the area; 2) number of spray guns; 3) atomizing air pressure; and 4) size of workpiece (the larger the workpiece, the more resistance to air movement within the spray area). Exhaust systems may be individually ducted outside. Depending on the type and quantity of solvent, local authorities may require treatment of the exhaust. This can lead to two conditions that result in an increased fire hazard. First, ducts from two or more booths may be manifolded so that only one fume incinerator or scrubber is necessary. This increases the possibility of a fire starting in one booth and spreading to other spray booths. Second, heat exchangers may be used in either inlet or exhaust ducts from the incinerator to recover heat. This may result in spontaneous ignition of residue accumulations on the heat exchanger surfaces. Preferably, outside air should be used as makeup air for a spray operation. If local authorities permit, energy may be conserved by recirculating air exhausted from a spray operation. Exhaust air from one spray operation is sometimes sufficiently low in combustible solids and flammable vapor concentration to be used as makeup air for another operation, such as an automatic spray booth. 2.1.4.1.1 Mechanical ventilation systems should be provided to safely remove flammable vapors and confine overspray residue to the spray area. 2.1.4.1.2 Use the following guidelines to size ventilation systems for spray booths. Increase these minimum flow rates if conditions near the booth (draft from windows or doors, etc.) warrant: a) For electrostatic spray operations, the average air velocity across booth openings should be at least 60 ft/min (20 m/min). b) For other spray operations, the average air velocity across booth openings should be at least 100 ft/min (30 m/min). c) For automatic booths, 10,000 ft3 of air per gallon (75 m3 per liter) of solvent evaporated, or (a) or (b) above should be used, whichever is greater. Note: Air velocities should be higher when a booth is new because gradual loading of the filter will decrease air flow. For spray booths coating large objects such as tank cars or trucks, air velocities can be calculated assuming object to be coated is in place. If objects range in size, the smallest object should be selected. 2.1.4.1.3 Provide sufficient ventilation when spraying is performed outside a booth, flammable liquids are exposed during transfer, or coated objects are air dried, so that flammable vapor concentrations do not exceed 25% of the lower explosion limit (LEL) in any part of the room. Natural draft ventilation may be adequate for large open areas, but mechanical draft ventilation is necessary for spray rooms. Higher ventilation rates may be required because of the toxicity of some solvents.
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2.1.4.1.4 Maintain mechanical ventilation in operation while spraying equipment is in operation. Ventilation should be maintained for a sufficient time thereafter to allow vapor from coated objects and overspray residue to be exhausted: a. Solvent base coatings ................................................................................................................. 15 min b. Solvent base coatings with extensive air drying of workpiece ................................................... 30 min c. Water base and powder coatings ................................................................................................ 3 min 2.1.4.1.5 Interlock the exhaust fan with spray equipment where spraying is automatically controlled (and when practical, where manually controlled). 2.1.4.1.6 Exhaust from separate spraying operations should be individually ducted outside by the most direct route, except as noted in Recommendation No. 2.1.4.1.7 below. 2.1.4.1.7 Exhaust ducts from separate spraying operations may be manifolded (preferably with manifold outside the building) if the finishing materials used are not likely to react and cause ignition of residue in the duct and if: a) No nitrocellulose base finishing materials are used. b) The total frontal area of the booths does not exceed 18 ft2 (1.6 m2) or air pollution equipment is used to process exhaust from the spray operations (Fig. 2). c) A filter system reduces the amount of overspray carried into the manifolded duct. A booth filter system is adequate. 2.1.4.1.8 Ducts from ovens should not exhaust into the spray booth duct system(s). 2.1.4.1.9 Follow applicable recommendations contained in Data Sheet 7-78, Industrial Exhaust Systems. 2.1.4.1.10 Locate air inlets in the spray room for uniform air movement. Size openings to accommodate all fans exhausting air from spray rooms and booths. 2.1.4.1.11 Outside air is preferred as makeup air for spray operations. If a fume incinerator is used, the makeup air may be preheated by passing through a heat exchanger in the exhaust duct of the incinerator [Fig. 3(a)]. Other applicable recommendations contained in Data Sheet 6-11, Fume Incinerators, should be followed. If air from main plant areas is used, air inlet openings to the spray room should be protected by automatic closing shutters with fire resistance equal to the walls of the enclosure (Fig. 1). Air from a spray room or booth may be used as makeup air for another spray operation if overspray residue has been removed and flammable vapor concentration is at a safe level. A filter should be provided in the recirculated air stream and the pressure drop across it monitored. A combustible-gas analyzer should be provided in the exhaust from the second operation, interlocked to shut down spray equipment and warn the operator [Fig. 3(b)] when concentrations reach 25% of the LEL. 2.1.5 Electrical 2.1.5.1 Avoid locating electrical equipment in spray areas where possible. Where necessary, such as for robotic equipment, use electrical components that are Factory Mutual Research Approved (see Appendix A, for definition) for use with flammable vapors and combustible deposits. Refer to Data Sheet 5-1, Electrical Equipment in Hazardous Locations. 2.1.5.2 Use Class I or II, Division 2 electrical equipment for areas adjacent to the spray area as follows: a) Unenclosed Spray Operations. Equipment within 20 ft (6 m) horizontally and 10 ft (3 m) vertically of any spray area and not separated from it by partitions (Fig. 4). b) Spray Booth (closed top, open faced or front). Equipment within 3 ft (1 m) in all directions from openings other than the open face or front of the booth, equipment located either: 1) 5 ft (1.5 m) from the open face or front of the booth if spray equipment is interlocked with the ventilation system, or 2) 10 ft (3 m) from the open face or front of the booth if spraying equipment is not interlocked (Fig. 5). c) Spray Booth (open top). Equipment within 5 ft (1.5 m) of the top of the booth (Fig. 6) in addition to that specified in Recommendation No. 2.1.5.2 b.
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A. Exhaust air is treated by fume incinerator and exhausted directly to outside. Makeup air is heated by passing through heat exchanger in the incinerator exhaust and discharges directly into building or a process within the building. B. Exhaust air from one spray booth used as makeup air for another booth. A filter is located in the duct between first and second booth. Pressure drop across the filter is monitored. A combustible gas detector monitors exhaust from second booth. Both devices are interlocked so that a reading in excess of the preset value in either device will shut down spray equipment in both booths.
Fig. 3. Acceptable energy conservation methods for air exhausted from spray booths. (Sprinkler protection is not shown.)
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Fig. 4. Class I and II Areas adjacent to an unenclosed spray operation.
d) Spray Booth or Room (enclosed). Spray operations confined to an enclosed booth or room, the space adjacent to the booth or room, and within 3 ft (1 m) in all directions from any openings. 2.1.5.3 Lighting for booths may be provided through vapor-tight panels of wired glass or impact resistant glass. Panels should be located so that they are not subject to accumulation of overspray residue. Surface temperature should not exceed 20F (11C) above ambient temperature in the booth. 2.1.5.4 Electric lamps within 20 ft (6 m) of the spraying area should be protected from mechanical damage. 2.1.5.5 Do not use portable electric lamps in a spray area during spray operations. If needed for maintenance operations, use only the type suitable for Class I locations.
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Fig. 5. Class I or II Division 2 area adjacent to a closed top, open faced or open front spray booth. A. When ventilation system is interlocked with spray equipment, X is 5 ft (1.5 m). B. When ventilation system is not interlocked with spray equipment, X is 10 ft (3 m).
Fig. 6. Class I or II Division 2 Area adjacent to an open-top spray booth.
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2.1.5.6 Do not locate space-heating appliances, unprotected steam pipes or any other equipment with surfaces heated above 200F (93C) within either the Class I or II, Division 2 area or within 10 ft (3 m) of an open spray area. 2.1.5.7 Ground all metal parts of spray booths, agitators, exhaust ducts and piping systems conveying flammable liquids. 2.1.6 Ignition Source Control 2.1.6.1 Locate equipment with open flames outside the Class I or II, Division 2 area or 10 ft (3 m) horizontally of a spray area. Locate spark producing equipment such as cutting or welding operations 35 ft (10 m) from the Division 2 area. A tight, noncombustible shield or partition extending to the limits of the Division 2 area may be used to reduce the above distances. 2.1.6.2 When cutting or welding equipment is used at or near a spray booth or within a spray room: a) remove flammable liquids from the area, b) clean paint residues from spray booths, exhaust ducts and floors and c) wet down surfaces before work is started. 2.1.6.3 Smoking should be prohibited within spray rooms and within 20 ft (6 m) of a spray area. No Smoking signs should be posted at all spray areas. 2.1.6.4 Do not use spray areas for drying in an arrangement that would materially increase the temperature of overspray residue unless done in accordance with Section 2.1.8.1.5. 2.1.7 Operation and Maintenance 2.1.7.1 General Spraying operations, regardless of gun or filter efficiency, result in overspray deposits on booth walls and in exhaust ducts. If deposits are allowed to accumulate, fire frequency may increase because of the increased possibilities of spontaneous heating and friction. A materials susceptibility to spontaneous heating increases as its temperature and coating thickness increases. The possibility of ignition due to friction increases since exhaust fan blades are more apt to contact deposits on duct walls. If deposits are allowed to accumulate on automatic sprinklers, their operation will be slowed or prevented. 2.1.7.1.1 Periodically inspect and, if necessary, replace plastic tubing or hose. Replacement tubing, particularly for electrostatic applications, should be of a type recommended by the equipment manufacturer. 2.1.7.1.2 Cover automatic sprinklers that are subject to accumulation of overspray residue from solvent or water based paint operations, with polyethylene or cellophane bags having a maximum thickness of 0.003 in. (0.08 mm), or with thin paper bags. Clean sprinklers subject to overspray from powder coating operations. Replace covers or clean heads frequently so that heavy deposits of residue do not accumulate. 2.1.7.1.3 Overspray residue on all surfaces, i.e., booth walls, exhaust ducts, filter plenums, and the roof in the area of the exhaust duct should be kept to a minimum by daily cleaning if necessary. Aids such as strippable coatings and plastic films can be applied to booth walls. Use nonferrous scraping tools to remove overspray residue. Keep residues wet with water while cleaning. If flammable solvent is used, its flashpoint should be in excess of 100F (40C). Booth ventilation systems should be kept in operation at all times when cleaning with flammable solvents. 2.1.7.1.4 Waste, rags, and residue should be disposed of in Approved waste cans. 2.1.7.2 Flammable Liquid Handling Finishing material for large operations is typically stored and mixed in an area remote from the spray area and pumped to the spray area. For small operations drums of finishing material may be kept near the spray area and supplied to the spray area by pressure pot, portable tank, gravity tank or drum pump. 2.1.7.2.1 Remote Storage and Mixing
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2.1.7.2.1.1 Store and mix flammable liquids in detached buildings or cut-off rooms (Fig. 7). Recommendations for these areas are in Data Sheet 7-32, Flammable Liquid Operations, Data Sheet 7-88, Storage Tanks for Flammable and Combustible Liquids, and Data Sheet 7-29, Flammable Liquid Storage in Portable Containers.
Fig. 7. Spray room with water wash spray booths, cut-off mixing room, and finishing material distribution system. Also shown is manually actuated remote shutoff for pumps in mixing room. (Sprinkler protection and automatically actuated remote shutoff for pumps not shown.)
2.1.7.2.1.2 Piping from storage or mixing room to the spray area should be of steel or other material having comparable fire resistance. 2.1.7.2.1.3 An automatic means should be provided to shut off the supply of finishing material in the event of fire in the spray area. This may be accomplished by means of a sprinkler water flow alarm or heat detectors interlocked to shut down pumps. Additional recommendations are contained in Data Sheet 7-32, Flammable Liquid Operations. 2.1.7.2.2 Storage and Dispensing at the Spray Area 2.1.7.2.2.1 Flammable finishing material, solvents, and thinners should be transported in closed containers, portable tanks, Approved safety cans or properly arranged piping systems. 2.1.7.2.2.2 Limit the quantity of flammable finishing material, solvents and thinners in the vicinity of a spray booth or operation, not including material stored in Approved storage cabinets, to a one day or one shift supply, but not in excess of the following amounts: a) 120 gal (0.5 m3) combined of Class lB, lC, II or III liquids in drums or smaller containers; b) 660 gal (2.5 m3) of Class lB, lC, II or III liquids in Approved or DOT Specification 57 portable tanks located in spray rooms cut off from main plant areas by walls having 1-hr fire resistance and arranged in accordance with Data Sheet 7-88, Storage Tanks for Flammable and Combustible Liquids.
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2.1.7.2.2.3 Pressure vessels used to supply finishing materials should be designed in conformance with the ASME Code for Unfired Pressure Vessels. Provide a visible pressure gauge and a relief valve installed and sized in accordance with the Code. Do not pressurize original shipping containers. 2.1.7.2.2.4 If gravity flow containers are used to supply finishing material, they should not exceed 10 gal (38 dm3) capacity. 2.1.7.2.2.5 When flammable finishing materials are supplied from other than pressure containers, provide tight covers and fittings to reduce the escape of vapors. Approved flash arrestor vents also should be provided. 2.1.7.2.3 Flammable Liquid Handling in the Spray Area 2.1.7.2.3.1 Where finishing materials are piped to the spray area from remote locations, the steel piping should be extended into the spray area and a shutoff valve provided on the pipe. When pressure pots are used, a shutoff valve should be provided. Valves should be closed when not spraying. 2.1.7.2.3.2 Provide a fixed automatic protection system for areas where paint hoses carrying finishing material are shielded from the protection system in the spray area. 2.1.7.2.3.3 Do not use halogenated solvents to clean aluminum components or in a coating system where they will come in contact with aluminum components within an enclosed device such as paint pump, spray gun components, etc. If halogenated solvents are used, the gun and solvent transport systems should be of stainless steel. 2.1.8 Occupancy 2.1.8.1 Spray Booths 2.1.8.1.1 General 2.1.8.1.1.1 Incompatible finishing materials preferably should not be used in the same spray area. If used, the spray area should be thoroughly cleaned each time the finishing material is changed. Examples of hazardous combinations are: a) Nitrocellulose lacquers may spontaneously ignite in contact with finishes containing drying oils (e.g., varnishes, oil-based stains, enamels, etc.). b) Oxidizing or bleaching compounds (e.g., hydrogen peroxides, perchlorates, etc.) in contact with organic finishing material. 2.1.8.1.1.2 When bleaching compounds (hydrogen peroxide, hypochlorite, perchlorates) or other oxidizing compounds are applied, the spray booth should be used exclusively for this material. 2.1.8.1.2 Dry Spray Booths 2.1.8.1.2.1 Do not use incompatible finishing materials in a dry booth unless filters are replaced each time finishing material is changed. 2.1.8.1.2.2 Overspray collector filter pads or rolls should be of noncombustible or fire-retardant treated material. 2.1.8.1.2.3 A device should be installed to indicate the condition of the filter before loading becomes sufficient to reduce air velocities below the recommended minimum. This device may measure air velocity in the exhaust duct or across the open face of the booth, or pressure drop across the filter. A visible gauge or audible alarm may be used for manual spray operations (Fig. 8). An interlock to shut down the spray operation and sound an alarm should be used for automatic spray operations. 2.1.8.1.3 Water Wash Spray Booths 2.1.8.1.3.1 Water wash booths should be used where the operation results in a heavy overspray. 2.1.8.1.3.2 Booths using a water curtain should be a) properly maintained so that an effective water curtain is provided at all times; and
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Fig. 8. Dry filter spray booth equipped with filter pads. Also shown is gauge used to indicate minimum air velocity.
b) arranged so that the booth exhaust system cannot be operated unless the pump is in operation. 2.1.8.1.3.3 Water pan booths should be arranged so that the distance between the water level in the sump and the baffle is automatically maintained during spray operations. 2.1.8.1.3.4 Manufacturers recommendations should be followed regarding use of chemical additives. 2.1.8.1.4 Oil Wash Spray Booths 2.1.8.1.4.1 The oil used should be at least a Class IIIB liquid and should remain so over the period of use. 2.1.8.1.4.2 The oil pump should be interlocked with either a water flow detector in sprinkler supply piping or a heat detector to stop automatically in the event of a fire in the booth. 2.1.8.1.4.3 Overflow drains discharging to a secondary tank with a volume of at least 125% of the sump should be provided to prevent overflow of the sump due to sprinkler discharge in the booth. 2.1.8.1.5 Traveling Spray Booths 2.1.8.1.5.1 Automatic sprinkler protection should be provided where nitrocellulose base lacquers or dualcomponent coatings are used. Automatic sprinkler protection is preferred for other types of coatings. Protection should be provided for all areas of the booth containing combustible overspray residue, including areas where the object to be sprayed is shielded from ceiling sprinkler systems. Water supply may be by flexible metal hose connection from the building sprinkler system or from a tank and automatic starting pump
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on the booth. The tank and pump capacity should be sufficient to supply all sprinklers at 20 gpm (75 dm3/min) for at least 5 min Booth manufacturers should be informed during the design stage so that provisions can be made to carry the additional weight. If a special protection system is used instead of sprinklers, a connected reserve should be provided. 2.1.8.1.5.2 Provide 1-12 in. (40 mm) hose stations spaced to reach any spray booth position with at least one hose stream. 2.1.8.1.6 Combination Spray/Cure Booths 2.1.8.1.6.1 Do not use combination spray/cure booths for finishing materials subject to spontaneous heating. Examples are given in Recommendation No. 2.1.8.1.1 a. 2.1.8.1.6.2 Radiant drying equipment permanently located in the spray area should be Approved by Factory Mutual Research. 2.1.8.1.6.3 Fuel-fired equipment should be equipped with interlocks as recommended in Data Sheet 6-9, Industrial Ovens and Dryers. 2.1.8.1.6.4 Spraying equipment and drying apparatus should be interlocked such that: a) Drying apparatus will automatically shut off if air temperature exceeds 200F (93C). b) Drying apparatus cannot be energized with spray equipment in operation. 2.1.8.2 Methods of Application 2.1.8.2.1 Electrostatic Spray Systems 2.1.8.2.1.1 Electrostatic spray systems should be Approved by Factory Mutual Research. 2.1.8.2.1.2 Ground all conductive objects in the vicinity of spraying operations. 2.1.8.2.1.3 Contact points on workpiece hangers should be shielded from buildup of paint overspray and cleaned at regular intervals. Periodic checks should be made to ensure the workpiece is properly grounded. 2.1.8.2.1.4 Cleaning operations in the spray area should be carried out with the following safeguards: a) The power supply should be de-energized. b) The solvent container should be grounded. c) The ventilation system should be in operation. 2.1.8.2.1.5 Grids, disks, and charging electrodes should be grounded through the power supply so that residual charge is removed after the power supply has been shut off. 2.1.8.2.1.6 The workpiece should be supported on a conveyor or hanger so that: a) It is grounded. b) It is located at least twice the sparking distance from the grid, disk, or charging electrode. (This does not apply to Approved equipment of nonincendive design.) If not indicated in manufacturers data sheets, use a minimum of 12 in. (30 cm). c) It is prevented from movement that would reduce the clearance to less than specified above. 2.1.8.2.1.7 Automatic electrostatic apparatus should be provided with interlocks to de-energize the high voltage power supply in event of the following conditions: a) Loss of mechanical ventilating equipment. b) Stoppage of the conveyor, unless stoppage is required by the spraying operation. c) The occurrence of a ground or excessive current leakage at any point on the high voltage system. 2.1.8.2.1.8 The following applies to grid, disk and bell systems:
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a) Electric motors driving rotating disks or bells located in the spray area should be Approved for use in Class I, Division 1 locations. Residue accumulations should be kept to a minimum by cleaning after a maximum of eight hours operation. b) Grids should be installed in fixed locations, effectively insulated from ground. c) Fine wire elements used in grids should be under tension at all times and of unkinked, hardened steel or materials of comparable strength. 2.1.8.2.2 Catalytic Spray Systems 2.1.8.2.2.1 The storage and handling of organic peroxide catalysts should be in accordance with Data Sheet 7-80, Organic Peroxides, and Data Sheet 7-81, Organic Peroxides-Hazard Classification. 2.1.8.2.2.2 Quantities of organic peroxides in the spray area should be limited to that needed for one days operations. 2.1.8.2.2.3 Care should be used in preventing contamination of organic peroxides with dust or overspray residues. A spill of peroxide should be cleaned using a noncombustible absorbent. 2.1.8.2.2.4 Equipment in contact with organic peroxides should be constructed of stainless steel (300 Series), polyethylene, Teflon or other material specifically recommended for this application. 2.1.8.2.3 Hot Spraying Systems 2.1.8.2.3.1 Electric resistance heaters used to directly heat finishing material should be Approved for use in Class I, Division 1 locations. 2.1.8.2.3.2 Heaters should be located outside areas where they may accumulate overspray deposits. 2.1.8.2.3.3 Heater controls should be interlocked with the exhaust fan so that the finishing material can be heated only while the exhaust fan is in operation. 2.1.8.2.3.4 Heaters used for finishing materials susceptible to spontaneous heating should be drained and cleaned during idle periods. 2.1.8.2.3.5 Steam pipes within 10 ft (3 m) of a spray area should be covered with 1-12 in. (40 mm) thick standard molded magnesia insulation or its equivalent. Clearance of at least 1 in. (25 mm) should be provided between such insulation and any combustible material or construction. 2.1.8.2.4 Steam Spray Systems 2.1.8.2.4.1 Steam pipes within 10 ft (3 m) of any spray area should be covered as indicated under Recommendation No. 2.1.8.2.3.5 for hot spraying systems. 2.1.8.2.4.2 The steam spray operation should be located so that the boiler will not be subject to overspray residue. 2.1.8.2.5 Airless Spray Systems 2.1.8.2.5.1 Positive displacement pumps should be equipped with a relief valve discharging to a safe location (finishing material container). Provide compressed air-driven pumps with a relief valve on the air supply line, set so that the air supply cannot produce a pump discharge pressure in excess of 125% of the system working pressure. (Maximum pressure must not exceed design pressure.) 2.1.8.2.5.2 Inspect and test hose frequently and replace as necessary. 2.1.8.2.5.3 Existing low pressure systems, designed for less than 100 psi (790 kPa) (7.9 bars), should not be converted for use as high pressure systems. 2.1.8.2.5.4 The spray gun and the workpiece should be electrically grounded. 2.1.8.3 Applications 2.1.8.3.1 Aircraft Spray Finishing
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2.1.8.3.1.1 Complete the following precautions when electrostatic spray operations are carried out near tank vents: a) When fuel tanks contain JET A fuel, the tank vents should be sealed. b) When fuel tanks contain JET B fuel or aviation gasoline, they should be emptied and purged with an inert gas. 2.1.8.3.1.2 Electrical equipment within 10 ft (3 m) vertically and 20 ft (6 m) horizontally down to hangar floor level should be Class I, Division 2. 2.1.8.3.2 Furniture Plant Finishing Operations Using Nitrocellulose Base Lacquer Recommendations pertaining to applicable operations in other parts of this standard should be followed with the following additional precautions: 2.1.8.3.2.1 A smooth noncombustible surface should be used for ceiling construction to facilitate cleaning of overspray residue. 2.1.8.3.2.2 Finishing rooms should be located on the first floor for all new construction. Where located on floors above the first floor, the floor should be waterproofed and drained to a safe location. 2.1.8.3.2.3 Water wash, water pan, dry filter or baffle-type spray booths may be used. If water wash or water pan booths are used, the chemical additive used to control pH of water should be tested on wet overspray residue to ensure it will not result in spontaneous ignition. (See Section 3.1.1.2.3.) 2.1.8.3.2.4 Spraying in the open should not be permitted. Confinement of overspray deposits to spray booth interiors is critical. 2.1.8.3.2.5 If large quantities of overspray are found outside spray booths, or if during spray operations overspray can be seen escaping the booth, plant operating procedures and booth ventilation system should be evaluated. This may mean: a) limitation of lengths of hose to spray guns so operators cannot spray outside the booth, b) more frequent cleaning or replacement of booth filters to maintain capture velocities, c) sealing openings in ducts such as penetrations for fan drives and automatic sprinklers, d) measurements of air flow during normal spraying operations to determine whether fans are adequately sized. If fan(s) are not adequately sized to contain overspray, they should be replaced. 2.1.8.3.2.6 Cleaning frequencies should be established such that deposits do not exceed 18 in. (3 mm) in thickness. Frequency need not be greater than daily. This includes booth, plenum area, exhaust duct and the area on the roof around exhaust ducts. A cleaning schedule also should be established for the entire spray room, since there will be some escape of overspray even in efficient spray booths. 2.1.8.3.2.7 Air makeup units should be separate from booth exhaust outlets to prevent overspray from being drawn into air makeup units. 2.1.8.3.2.8 Washdown hoses should be provided on the roof near spray booth exhausts. These can be used both to clean roof and control fires that start in one booth and spread to the roof to prevent involvement of other booths. 2.1.8.3.3 Large Automobile Paint Spray Booths Using Rotary Atomizers Recommendations pertaining to applicable operations in other parts of this standard should be followed with the following additional precautions for large spray booths with multiple automatic electrostatic rotary atomizers. 2.1.8.3.3.1 A water deluge system should be provided at ceiling level in the booth arranged to provide 0.30 gpm/ft2 (12 mm/min) over the floor area of the booth. The system should be automatically actuated by optical detectors provided to cover the discharge from all spray guns and by thermal detectors at ceiling level. 2.1.8.3.3.2 Equipment such as housings containing paint hoses and color change equipment which would be shielded from ceiling protection systems should be protected with an automatically actuated fixed
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extinguishing system. A line-type heat detection system, either fiber optic or pneumatic, should be used. If a gas extinguishing system is used, a connected reserve should be provided to minimize downtime. 2.1.8.3.3.3 Provide interlocks so that when either optical detection covering the discharge from the spray guns or the fire detection system in a color change cabinet operates, the following occurs: a) shutoff of paint and thinner pumps; b) stoppage of the conveyor; and c) shutoff of the high voltage power supply. 2.2 Water Base Coatings 2.2.1 Introduction The following recommendations are for water base coatings only, and are directed primarily to confinement and safe removal of overspray. Many recommendations are the same as for solvent base coatings since the overspray residue represents the same hazard. Common recommendations are indicated by number below and refer by number to recommendations in Section 2.1, Flammable Solvent Base Coatings. If intermittent use of flammable solvent base coatings is expected, all recommendations for flammable solvent base coatings apply. 2.2.2 Construction and Location 2.2.2.1 For location, apply Recommendation Nos. 2.1.2.2.1 and 2.1.2.2.2 in Section 2.1.2.2. 2.2.2.2 For construction, apply Recommendation Nos. 2.1.2.3.1 to 2.1.2.3.9 in Section 2.1.2.3. 2.2.3 Protection 2.2.3.1 Apply Recommendation No. 2.1.3.1 in Section 2.1.3, except that water demand should be in accordance with Data Sheet 3-26, Fire Protection Water Demand for Nonstorage Sprinklered Properties. 2.2.3.2 Apply Recommendation Nos. 2.1.3.2 and 2.1.3.3 in Section 2.1.3. 2.2.4 Equipment and Processes 2.2.4.1 Apply Recommendation Nos. 2.1.4.1.1, 2.1.4.1.2a & b, 2.1.4.1.3, 2.1.4.1.4, 2.1.4.1.6, 2.1.4.1.7, 2.1.4.1.8, 2.1.4.1.9 and 2.1.4.1.10 in Section 2.1.4.1. 2.2.5 Electrical 2.2.5.1 Apply Recommendation Nos. 2.1.5.1, 2.1.5.4 and 2.1.5.6 in Section 2.1.5 and Recommendation Nos. 2.1.6.1, 2.1.6.2, 2.1.6.3 and 2.1.6.4 in Section 2.1.6. 2.2.5.2 Electrical equipment including lighting for booths located in areas adjacent to the spray area (areas that would be Class I, Division 2 if flammable solvent base coatings were used) should be gasketed to prevent entry of overspray residue. 2.2.5.3 Portable electric lamps should not be used in a spray area during spray operations. If used during maintenance operations, they should be equipped with guards to protect against mechanical damage. 2.2.6 Occupancy 2.2.6.1 Spray Booths 2.2.6.1.1 Dry Spray Booths 2.2.6.1.1.1 Apply Recommendation Nos. 2.1.8.1.2.1, 2.1.8.1.2.2, 2.1.8.1.2.3 in Section 2.1.8.1.2. 2.2.6.1.2 Water Wash Spray Booths 2.2.6.1.2.1 Apply Recommendation Nos. 2.1.8.1.3.1, 2.1.8.1.3.2, 2.1.8.1.3.3, 2.1.8.1.3.4 in Section 2.1.8.1.3. 2.2.6.1.3 Oil Wash Spray Booths
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2.2.6.1.3.1 Apply Recommendation Nos. 2.1.8.1.4..1, 2.1.8.1.4..2, 2.1.8.1.4..3 in Section 2.1.8.1.4.. 2.2.6.1.4 Traveling Spray Booths 2.2.6.1.4.1 Apply Recommendation Nos. 2.1.8.1.5..1, 2.1.8.1.5..2 in Section 2.1.8.1.5.. 2.2.6.2 Methods of Application 2.2.6.2.1 Aircraft Spray Finishing 2.2.6.2.1.1 Apply Recommendation No. 2.1.8.3.1.1 in Section 2.1.8.3.1. 2.2.6.2.2 Furniture Plant Finishing Operations 2.2.6.2.2.1 Apply Recommendation Nos. 2.1.8.3.2.1, 2.1.8.3.2.2, 2.1.8.3.2.3, 2.1.8.3.2.4 in Section 2.1.8.3.2. 2.2.7 Operation and Maintenance 2.2.7.1 General 2.2.7.1.1 Apply Recommendation Nos. 2.1.7.1.1, 2.1.7.1.2, 2.1.7.1.3 in Section 2.1.7.1. 2.2.7.2 Flammable Liquid Handling 2.2.7.2.1 Remote Storage and Mixing 2.2.7.2.1.1 Apply Recommendation Nos. 2.1.7.2.1.1 and 2.1.7.2.1.2 in Section 2.1.7.2.1. 2.2.7.2.2 Storage and Dispensing at the Spray Area 2.2.7.2.2.1 A plastic liner is recommended to reduce corrosion for pressure vessels containing water base coatings. 2.2.7.2.3 Flammable Liquid Handling in the Spray Area 2.2.7.2.3.1 Apply Recommendation No. 2.1.7.2.3.1 in Section 2.1.7.2.3. 2.3 Powder Coating 2.3.1 Introduction Spray operations involving the use of cyclone and/or bag filter systems present an explosion hazard. Losses are most likely to occur with automatic spray equipment. The ignition source is usually arcing from the electrostatic spray gun igniting the powder spray from the gun. If powder flow is stopped quickly, the fire is generally extinguished without spreading to the powder collection equipment. If there is a delay of several seconds, deposits on the sides of the booth can be ignited. These deposits flake off and are drawn into the dust collection system, resulting in explosion or fire. There is little danger of this happening with manual spray equipment. The operators natural instinct is to drop the spray gun, which immediately interrupts flow of powder to the gun. Integrated systems, where collection equipment is part of the hopper of the booth, can potentially present a fire or explosion hazard. Approved integrated booths have been tested at various powder flow rates to verify that an explosion will not occur in the powder collection area. However, a severe shielded fire can be expected in this area if not adequately protected. Basic safeguards are intended to do the following: 1. Provide explosion protection for powder collection equipment such as cyclone or bag collectors. 2. Immediately shut off powder flow on flame detection for automatic spray booths. 3. Limit fire damage by installation of automatic sprinkler protection. 4. Confine and safely move overspray to collection equipment by adequately sized ventilation systems.
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5. Eliminate ignition sources. 6. Reduce accumulation of powder in the spray area by regular cleaning Spray and fluidized bed coatings of plastic powders involve both dust explosion and fire hazard. 2.3.2 Protection 2.3.2.1 a) Provide automatic sprinkler protection for ordinary hazard occupancies for spray booths constructed of metal and Approved plastic and for recovery systems. If the spray booth is constructed of plastic and is not Approved, sprinkler protection should be designed for extra hazard occupancies. Where the recovery system is part of the booth, arranged to be detached, the sprinkler system should be provided with a quick disconnect fitting for connection to a water supply. Automatic sprinkler protection can be omitted for metal and Approved plastic booths and for integrated powder recovery systems; if the following conditions exist: a) the room is provided with sprinkler protection, b) the booth and the recovery system are quickly accessible, c) small hose is provided, and d) personnel are trained in firefighting. Portable extinguishers are not a substitute for small hose. Cyclone collectors and ovens will not normally require sprinkler protection. b) Provide automatic sprinkler protection at ceiling level for metal, wood, or plastic processing as outlined in Table 1, depending on the object being coated and the construction of the booth or enclosure. If plastic powder in combustible containers is located in the coating area and/or if a plastic booth or enclosure is used, water demand is that for plastic processing regardless of the object coated. For the more common case of metal spray booths and use of plastic powder in combustible containers in the spraying area, water demand specified for processing areas where in-process plastic storage is scant will normally be adequate. 2.3.3 Equipment and Processes 2.3.3.1 Dust Collectors 2.3.3.1.1 Dust collection equipment should be designed according to Factory Mutual Research recommendations for location, construction, venting and protection of equipment handling combustible dusts. Collection equipment may be located in the building, adjacent to the coating operation. Explosion vents should be vented outside the building. Where location of the process is such that it is not practical to vent outside the building, an Approved explosion suppression system should be installed. Arrange the explosion vents so they do not discharge into the building or process areas. 2.3.3.2 Spray Application 2.3.3.2.1 a) Ventilation rates for all manual and most automatic booths should keep the interior of the booth below the explosive limit of the powder coating used. The following formula should be used: V= W 0.50L
Where V = Ventilation rate, ft3/min (m3/min) at standard conditions. W = Maximum powder discharge from spray gun(s), oz/min (kg/min). L = Lower explosive limit, oz/ft3 (kg/m3). Where the LEL is not known, use 0.030 oz/ft3 (0.030 kg/m3). b) Ventilation rates for automatic booths in which a large percentage of the volume is occupied by the spray patterns from the guns (such as pipe coating) should be designed for optimum transfer efficiency. The booth should use a combination of explosion venting and construction to withstand an internal dust explosion. 2.3.3.2.2 Air velocity through electrostatic spray booth openings should be a minimum of 60 ft/min (20 m/min). Air velocities through openings of all other types of spray booths should be at least 100 ft/min (30 m/min). Air velocities for both types may be higher if dictated by the ventilation rate calculated by Recommendation No. 2.3.3.2.1, or if conditions near the booth warrant (draft from windows or doors, etc.).
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2.3.3.2.3 Where air is recirculated to spray booths or discharged to the plant, it should pass through a filter and be monitored so that a failure in the collection system (bag tear or rupture) will be detected, automatic equipment shut down, and an alarm sounded to warn the operator. The filter should be at least 99% efficient on particles of one-micron size. 2.3.3.2.4 Spray booth design should, wherever possible, eliminate places on which powder will accumulate, i.e., ledges, pipes, etc. 2.3.3.2.5 The power supply and powder flow to electrostatic spray guns in manual and automatic booths should be interlocked with the ventilation so that power will be cut off and powder introduction stopped on failure of the ventilating fans. In addition, power supply and powder flow to guns for automatic booths should be cut off if the conveyor carrying objects through the booth stops. 2.3.3.2.6 An infrared or ultraviolet detector should be provided for all automatic spray booths in which the operator cannot be expected to respond immediately to a fire involving powder discharge from the gun(s). Detector response should be a maximum of 3 sec. The detectors should be interlocked to shut off power supply and powder flow to the gun(s). 2.3.3.3 Fluidized Bed 2.3.3.3.1 An exhaust system designed to prevent appreciable overspray should be provided for all fluidized beds. 2.3.3.3.2 Where filtered air is discharged to the plant, it should pass through a filter and be monitored so that a failure in the collection system (bag tear or rupture) will be detected and an alarm sounded to warn the operator. The filter should be at least 99% efficient on particles of one-micron size. 2.3.3.3.3 Fluidized beds should use a combination of explosion venting and construction to withstand an internal dust explosion. 2.3.3.3.4 The air supply for fluidized and electrostatic fluidized beds, and the power supply for electrostatic fluidized beds should be interlocked with the exhaust system fan, so that electrodes cannot be energized and fluidizing air cannot be introduced unless the fan is in operation. 2.3.3.3.5 Fluidized beds containing large quantities of powder, in which failure of the pressure regulator could cause the powder to be ejected, should be provided with either of the following: a) A pressure supervisory switch installed downstream of the regulator and interlocked to cut off the flow of fluidizing air to the bed when a preset pressure is exceeded. b) A pressure regulator with an overpressure shutoff feature. 2.3.4 Ignition Source Control 2.3.4.1 The surface temperature of a preheated part should be 50F (28C) below the autoignition temperature of the powder. 2.3.5 Electrical 2.3.5.1 a) Electrostatic spray equipment should be of Approved types. b) Other electrical equipment used within the spraying area (spray booth, recovery system, associated ductwork and any areas in which dangerous quantities of powder are likely to accumulate during normal operation) should be Approved for use in Class II, Division 1 areas. c) Electrical equipment used within 5 ft (1.5 m) of the open face or front of the booth and within 3 ft (1 m) of other openings should be Approved for use in Class II, Division 2 areas (Fig. 5). 2.3.5.2 Other electrical equipment used within the coating area (fluidized bed, recovery system, associated ductwork and any areas in which dangerous quantities of powder are likely to accumulate during normal operation) should be Approved for use in Class II, Division 1 areas. 2.3.5.3 Electrical equipment used for fluidized beds within the following areas should be Approved for use in Class II, Division 2 areas: the area extending 10 ft (3 m) horizontally in all directions from the bed and floor to 3 ft (1 m) above the highest part of the object coated for a fluidized bed with an open top; and the area extending 3 ft (1 m) from conveyor openings for an enclosed fluidized bed.
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2.3.6 Operation and Maintenance 2.3.6.1 Loose powder should be removed from surfaces in and around the spraying area. Cleaning should not scatter powder to other areas or produce clouds of powder. Care should be used in transfer operations to prevent the escape of powder. 3.0 SUPPORT FOR RECOMMENDATIONS 3.1 Loss History 3.1.1 Flammable Solvent Base Coatings 3.1.1.1 General Over a recent five-year period, 76 fires at spray operations were reported totaling $9,735,000 property damage and $2,900,000 business interruption. One shut valve fire was responsible for $2,400,000 property and $500,000 business interruption. Dollar values given for losses are gross values adjusted to 1988 dollars. 3.1.1.1.1 Causes Nonelectrostatic spray equipment was involved in 48 cases, and electrostatic equipment in 28. The leading causes of fire in nonelectrostatic systems were 1) use of spark-producing equipment such as cutting, welding and grinding near the spray area; 2) friction-caused in most cases by overheated bearings on the exhaust fan shaft or by rubbing of exhaust fan blades against overspray deposits on walls of the exhaust duct; 3) arcing electrical equipment; 4) spontaneous heating; and 5) static sparks. (See Table 2.)
Table 2. Cause of Loss in Nonelectrostatic Spray Operations Based on 5-year Loss Study Cause Cutting, welding, grinding Friction Arcing electrical equipment Spontaneous heating Static electricity Chemical reaction Misc. (not exceeding 2 each) Unknown Percent 27% 12% 8% 8% 8% 6% 11% 20%
The leading causes of fire in electrostatic spray systems were 1) ungrounded objects in the spray area, and 2) pin-hole leaks in the paint hose to the spray gun. Other causes are similar to those for nonelectrostatic systems such as smoking and cutting and welding. (See Table 3.)
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Table 3. Cause of Loss in Electrostatic Spray Operations Based on 5-year Loss Study Cause Static discharge Ungrounded object Pinhole leak in paint hose Equipment maintenance Arc between workpiece & ground Coating head not grounded prior to cleaning Other causes Smoking Cutting & welding Spontaneous heating Fault in electrical equipment Unknown Percent 61% (28%) (18%) ( 7%) ( 4%) ( 4%) 19% ( ( ( ( 20% 7%) 4%) 4%) 4%)
Seventeen (17) of the 28 fires involving electrostatic spray operations were the direct or indirect result of the use of electrostatic spray finishing equipment. At least six fires could be attributed to operator error or inadequate operator training. An example is the use of an ungrounded can of solvent in the spray booth to clean the spray gun. Of the 11 remaining fires, one involved nonincendive equipment, and eight involved equipment with high enough energy to cause ignition (directly charged or stiff equipment). In two losses, equipment used was unknown. A fire can result from using nonincendive or stiff equipment near an ungrounded object. Either type of equipment can build up a charge on the ungrounded object, followed by an arc to a grounded object such as part of the spray gun. The energy of the spark is determined by the size of the ungrounded object (the larger the object the greater the charge). Six explosions were reported involving halogenated hydrocarbons. Three explosions occurred in paint pumps, two occurred in paint heaters and one in a cup-type spray gun. In one of the pump explosions, the pump had been in service for over three years. It was pumping a coating containing a halogenated hydrocarbon as one of the solvents in the paint system. The explosion occurred in the pump a few minutes after it was shut off at the end of the shift An explosion occurred in another pump that had been in service for one year. The explosion occurred shortly after the pump was flushed with 1,1,1-trichloroethane and run dry. Information regarding the other incidents is not available. Most paint handling equipment (pumps, heaters, spray guns) is aluminum. These explosions were apparently the result of the decomposition of the halogenated hydrocarbon in a Friedel-Craft type reaction similar to what can occur in a vapor degreaser (Data Sheet 7-97, Metal Cleaning). It is suspected that aluminum trichloride and hydrochloric acid are formed by the reaction of the hydrocarbon and an exposed aluminum surface. The exposed surface results from abrasion that has removed the protective oxide layer. The hydrochloric acid formed removes additional oxide coating, exposing more aluminum. The aluminum trichloride acts as a catalyst; the reaction is exothermic. The result can be either severely corroded equipment, reported in a number of cases, or an explosion. Stabilizers are added to the halogenated hydrocarbon to prevent this reaction, but they can be ineffective when water or other organic solvents are present. 3.1.1.1.2 Factors Contributing to Losses Thirteen fires over a recent five-year period exceeded $200,000 property damage. Most had at least two and some had four factors that contributed to the size of the loss. The most common factors are as follows: 1. Inadequate sprinkler protection. In nine fire losses, either no sprinkler protection was provided, sprinkler protection was not provided throughout the spray area, or heavy accumulations of overspray on sprinklers resulted in their failure to operate. In one loss, protection was out of service at the time of the fire. In one unsprinklered fire, sections of the building roof over the paint spray area collapsed. 2. Poor housekeeping. In six fire losses, overspray buildup was heavy inside the booth, and in five losses overspray deposits also extended outside the booth on the ceiling. Overspray deposits outside the booth result in fire spread over a much larger area than would normally be expected. 3. Lack of automatic shutoff of paint supply to spray area. In three fires, continued pumping of paint to the spray area was a factor in increasing the size of the loss. (See Table 4.)
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Table 4. Factors Contributing to Extent of Loss for 13 Fires Exceeding $200,000 Property Damage over Recent 5-Year Period Factor No sprinkler protection, protection out of service or incomplete protection Poor maintenance Lack of automatic shutoff of paint supply Inadequate water supply Combustible construction Others (improper storage of flammable liquids, use of nitrocellulose base lacquer, improper location of spray area, inadequate fire barrier) No. of Losses 9 6 3 3 2 1 each
Other factors that were present in a previous five-year loss study also showed up in this loss study as follows: 1) use of nitrocellulose base lacquers; 2) inadequate cutoff of spray area from other plant areas; and 3) excessive or improper storage of flammable liquids. 3.1.1.2 Furniture Plant Loss Experience Over a recent seven-year period, 32 fires were reported in furniture plant finishing operations. The following areas were examined: 1) cause of loss; 2) contributing factors that resulted in higher than expected losses; and 3) comparisons between fires in water pan and dry-type booths. The seven-year period was selected because the industry was operating under capacity due to economic conditions for approximately three to four years during the period referenced in 3.1.1.1. There were 15 fires during this 5 year period and 17 during the previous 2 year period. 3.1.1.2.1 Cause of Furniture Plant Finishing Room Fires The leading cause of fires was electrical equipment, both electrical equipment associated with spray finishing operations (arcing or overheating of exhaust fan motors) and electrical equipment outside but adjacent to spray booths (lighting system ballast failures). Other causes were similar to 3.1.1.1.1. (See Table 5.)
Table 5. Cause of Loss in Furniture Finishing Rooms over Recent 7-year Period Cause Electrical Equipment Related to spray operation Not related to spray operation Cutting, welding, grinding Spontaneous combustion Friction Other Percent 37% (23%) (14%) 23% 14% 9% 17%
3.1.1.2.2 Factors Contributing to Furniture Plant Finishing Room Loss Experience The major contributing factor determined by previous loss studies was lack of or incomplete automatic sprinkler protection. There were no fires during this period where incomplete protection was identified as a deficiency. Four (4) fires in this seven-year period ranged from $100,000 to $265,000 property damage. One contributing factor was the location of the finishing room above the first floor. Spray booth fires on multi-floor buildings will result in water damage to goods in process on floors below. Another contributing factor was housekeeping. Overspray deposits outside spray booths and heavy deposits inside spray booths result in high heat release rate fires, which quickly involve the finishing room or other spray booths. 3.1.1.2.3 Loss Experience with Water Pan and Dry Filter Booths Two losses were reported in water pan booths. The property damage values were $60,000 and $100,000, with an average loss of $80,000. The property damage values for booths with filters ranged from $5,000 to $75,000, with an average loss of $24,000. (See Table 6.) Both water pan booth losses involved heavy overspray deposits and occurred when the booths were shut down for cleaning. Fire quickly involved the entire booth and spread across deposits on the ceiling.
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These losses illustrate that good housekeeping is important in any booth. The design of these booths was such that there were hard-to-clean areas with the result that these areas were cleaned less frequently than a dry booth of similar size. Also of interest, one of the water pan booth fires occurred as the tank was being refilled with water, and potassium hydroxide was being added to control the pH. Tests indicated that potassium hydroxide reacted with wet overspray lacquer residue on the sides of the tank and resulted in ignition.
Table 6. Comparison of Effectiveness of various Types of Spray Booths in Furniture Plant Finishing Operations Type of Booth Water Wash Dry Filter No Filter No. of Losses 2 7 5 Range of Losses Property Damage $60,000-100,000 $ 5,000-75,000 $10,000-250,000 Avg. Value of Loss $80,000 $24,000 $78,000
3.1.1.2.4 Loss Experience with Dry Filter Booths and Booths Without Filters A comparison was made of seven losses involving booths with dry filters vs five losses involving booths without filters. The seven booth losses with filters ranged from $5,000 to $75,000, with an average loss of $24,000. The five booth losses without filters ranged from $10,000 to $250,000 property damage, with an average loss of $78,000. (See Table 6.)
Table 7. Location of Fires in Dry Booths With and Without Filters In Exhaust Ducts % 30 80 In Booths % 30 Outside Booths % 40 20
With Filters Without Filters
The major difference between booths with filters and booths without filters is the frequency and intensity of fire in the exhaust duct. Booths with filters had 30% of fires originate in exhaust ducts; booths without filters had 80% originate in exhaust ducts. (See Table 7.) The most common cause of ignition was a fan blade rubbing against overspray deposits on duct surfaces, or overloading of a motor due to deposits on fan blades. 3.1.2 Water Base Coatings Loss experience has been good with water based coatings. The good experience relative to solvent based coatings is probably due to the 1) limited use of water based coatings, probably no more than 15% of coatings used are water based; and 2) the reduction of the hazard during spray operations. Fires occur from ignition of overspray residue. Four losses were reported over a recent five-year period. The losses ranged from $35,000 to $60,000 property damage. Two losses were caused by friction (fan blade against residue deposits in duct), one by spontaneous heating, and one by hot metal from a drilling operation. In three cases, fire damage was confined to the booth and exhaust duct. One fire spread through the duct and involved combustible roof covering. 4.0 REFERENCES 4.1 FM Global Data Data Data Data Data Data Data Data Data Data Sheet Sheet Sheet Sheet Sheet Sheet Sheet Sheet Sheet Sheet 2-8N, Installation of Sprinkler Systems (NFPA). 3-26, Fire Protection Water Demand for Nonstorage Sprinklered Properties. 4-5, Portable Extinguishers. 5-1, Electrical Equipment in Hazardous Locations. 6-9, Industrial Ovens and Dryers. 6-11, Fume Incinerators. 7-29, Flammable Liquid Storage in Portable Containers. 7-32, Flammable Liquid Operations. 7-78, Industrial Exhaust Systems. 7-80, Organic Peroxides.
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Data Data Data Data
Sheet Sheet Sheet Sheet
7-81, 7-83, 7-88, 7-97,
Organic Peroxides-Hazard Classification. Drainage Systems for Flammable Liquids. Storage Tanks for Flammable and Combustible Liquids. Metal Cleaning.
APPENDIX A GLOSSARY OF TERMS Approved: references to Approved in this data sheet means the product and services have satisfied the criteria for Factory Mutual Research Approval. Refer to the Approval Guide for a complete listing of products and services that are Factory Mutual Research Approved. Spray Area: a spray area is any area in which flammable vapors and combustible residues are present as a result of spraying operations. This area will always include but not be limited to: The interior of the spray booth. The interior of ducts exhausting from spraying operations. Any area in the direct path of spray. APPENDIX B DOCUMENT REVISION HISTORY January 2007. Clarification was made to the recommendation 2.1.8.3.3.3. September 2004. Cross-reference to recommendation numbers in section 2.2.6.1.2.1 were corrected. January 2001. Table 1, Sprinkler Protection Criteria for Flammable Liquid Spraying, has been included. Previously the information was located in Data Sheet 3-26, Fire Protection Water Demand for Non-storage Sprinklered Properties. September 2000. This revision of the document has been reorganized to provide a consistent format. June 1989. The following changes have been made to Data Sheet 7-27. Section 2.1 Flammable Solvent Base Coatings 1. Added recommendations for combination spray/cure booths (Section 2.1.8.1.6). 2. Added recommendations for aircraft finishing in Section 2.1.8.3.1, furniture plant finishing in Section 2.1.8.3.2 and automobile plant finishing in Section 2.1.8.3.3. Section 2.2 Water Base Coatings 1. Recommendations regarding storage of finishing material in spray area revised (Section 2.2.7.2). Section 2.3 Powder Coating 1. Explosion protection recommendation for dust collector revised to allow venting only to outside, or use of explosion suppression systems for dust collectors (Section 2.3.2). APPENDIX C SUPPLEMENTAL INFORMATION C.1 General Coatings may be applied by hand-held or fixed equipment. Fixed equipment may be stationary, mounted on a reciprocator or mounted on a robot. Reciprocators are limited usually to one dimension of movement, up and down being most common. Robots may be programmed to duplicate any of the movements of a human operator. Robots consist of at least two major components: the operating arm and the electronic control. The operating arm holds the spray gun or applicator, and through a system of hydraulic or electric drives can move the applicator in a number of programmed directions. A robot is usually programmed by a paint spray operator. The robot is put on low power and the operator goes through the movements to apply one coat to the workpiece. Programs for a number of work pieces can be stored in memory. Robots may be arranged such that air pressure, coating supply (both quantity and color change), and electrostatic voltage levels may be controlled by the computer. Early robots were hydraulically powered. The trend is to electric drives since a greater degree of accuracy can be obtained.
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C.2 Flammable Solvent Base Coatings C.2.1 Coatings Coating means any factory applied finish. Coatings such as varnish, shellac, and some clear lacquers are not pigmented. However, most coatings include: 1. Pigment: an organic or inorganic powder(s) that provides color and hiding power. 2. Binder, resin or vehicle: a film-forming organic polymer or natural resin. 3. Special additive: a material that enhances a characteristic of the finished coating such as weathering, solvent resistance, flexibility, etc. This material may be solid or liquid, organic or inorganic. 4. Solvent, thinner, or volatile: a combination of flammable organic liquids used to control viscosity and drying rate. Most solvent evaporates during and shortly after application, and does not form a part of the dried film. EPA standards are aimed at reducing the amount of organic solvents emitted during spraying operations. This may be done by any of the following methods: 1. use of high solids or water-base coatings; 2. more efficient methods of application such as electrostatic spraying systems; and/or 3. treatment of air exhausted by use of incinerators or air cleaning devices. Halogenated hydrocarbons may be used as cleaning solvents or as solvents in the coating system. In the coating system they replace organic solvents to comply with EPA regulations limiting emissions of volatile organic compounds (VOC). Coatings containing these solvents are generally called compliance coatings; the solvents are generally called compliance solvents. Any halogenated hydrocarbon can be used. The two most common are 1,1,1-trichloroethane and methylene chloride. The use of these solvents is not peculiar to any industry. C.2.2 Spray Application Methods C.2.2.1 General Spray equipment is designed to atomize and direct finishing material onto the object to be coated. The most common and earliest method used compressed air. Other methods have since been developed to improve coating efficiency, reduce solvent usage, and improve the quality of the coating. C.2.2.2 Conventional Spray Systems Conventional spray systems use compressed air to atomize and carry finishing material to the object. C.2.2.3 Electrostatic Spray Systems Electrostatic spray systems apply electrically charged, atomized coating material to a grounded conductive workpiece or a nonconductive object prime coated with a conductive coating. The major advantage of this method is increased efficiency. Particles of finishing material that would otherwise miss the workpiece are attracted to the edges and back of the workpiece by their electrical charge. Types of Applicators. Three types of applicators are commonly used: 1. Spray guns using external grids or electrodes. This system was one of the first methods for electrostatic application of solvent base coatings. It is now most widely used for the application of conductive solvent base and water-base coatings. This method of application does not require isolation from ground of the paint supply system; the system is grounded at the applicator. A high voltage grid is located adjacent to the workpiece. The coating material, discharged between grid and workpiece, is charged by the grid. The grid is electrically isolated from the applicator. It is a fixed system with the spray gun(s) and grid(s) stationary. 2. Electrostatic Spray Gun. The gun atomizes particles of coating material by pneumatic or hydraulic pressure. These particles are charged by an electrode near the discharge nozzle. Power is supplied through a cable from a high voltage d.c. power supply. The gun may be hand held, fixed or mounted on a reciprocator or robot.
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3. Disk or bell system. Coating material is fed to a rotating disk or bell, and carried uniformly to the edge by centrifugal force. When the system is charged, particles of coating material are pulled from the edge and carried to the object (Fig. 9). The disk system is an automatic system. The bell system may be either automatic or hand held (manual). In the automatic system, the disk or bell is either fixed or mounted on a reciprocator or robot. Electrostatic bell and disk applicators are increasingly used to improve the efficiency of paint transfer, and thereby reduce volatile organic coating (VOC) emissions.
Fig. 9. Electrostatic spray system, rotating disk type.
Nonincendive/Stiff Electrostatic Spray Equipment. Both nonincendive and stiff electrostatic spray equipment are widely used in industry. Presently only nonincendive spray equipment is Approved by Factory Mutual Research. Electrical ignition may occur from an arc to a grounded object such as workpiece swinging on the conveyor, or to an ungrounded object such as a bucket of solvent brought into the booth for cleaning. For grounded objects, nonincendive devices do not have enough energy at the charging electrode to cause an arc of sufficient intensity to ignite the solvent-base coating material. Stiff systems do have enough energy, and rely on prevention of ignition by 1) maintaining the spray gun at twice the sparking distance from the workpiece, and 2) provision of current limiting and/or arc detection features to shut off the power supply and ground the charging electrode to prevent an arc. Sparking distance in dry air is well known. It is not clearly defined during the spray operation, and will depend on such things as 1) coating material (conductivity of solvent and solids content); 2) rate of spraying; and 3) shape and speed of approach of the workpiece. Studies are underway to determine the effect of these variables on sparking distance. The interlock used to shut off the gun depends on detection of rate of current increase or on current exceeding a preset value. These settings should be properly set by the manufacturers representative when the system is installed. If interlocks actuate, every attempt should be made by the operator to find out why, rather than pressing the reset button or adjusting to less sensitive settings.
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Most hand held (manual) spray equipment is nonincendive. This design feature is important for a hand held device subjected to random operator movement. Most hand held equipment is Approved. Automatic electrostatic spray equipment is either nonincendive or capable of ignition. Even with properly designed and maintained equipment, if a conductive object near the applicator is not properly grounded, a charge can build up on the surface of the object. The energy of the charge is dependent on the surface area and shape of the object. An electrical discharge may occur from the object to any other grounded object. The energy of the discharge may be sufficient to ignite solvent vapors regardless of the design features of the electrostatic system. The ungrounded or improperly grounded object may be a can of solvent brought into the spray area to clean the system. It also may be the workpiece that has been insulated from ground by overspray residue accumulating on the support hanger. In several cases, the ungrounded object was an operator on an electrically insulated floor or wearing rubber soled shoes. Loss prevention during cleaning operations is a matter of proper operator training. Improper grounding of the object being coated can be avoided by preventing overspray from accumulating on the contact point between 1) workpiece and hanger and 2) the hanger and conveyor. The point between the hanger and the conveyor may be kept free of overspray by shielding from overspray. The point where the workpiece is attached to the hanger may be shielded when not in use, or the hanger cleaned frequently. Hangers need to be cleaned or replaced at a frequency adequate to ensure good electrical contact. Examples of continuous cleaning methods are: 1. Wet systems. The conveyor line includes a tank of stripping compound which dissolves overspray residue from the hooks. 2. Burn off. An excess air burner is used to burn residue off the hooks without formation of char. 3. Mechanical systems. Rotary wire brushes are used on either side of the hook to brush off the residue. 4. High pressure water. A water spray at from 10,000 to 50,000 psi (70,000 to 340,000 kPa) (680 to 3400 bars) is directed at the hangers. 5. Cryogenic cleaning systems. Liquid nitrogen has been used to clean hangers. C.2.2.4 Catalytic Spray Systems Catalytic spraying, also called dual-component coating, involves discharging two components through the same spray gun. The second component may act as a catalyst to initiate a chemical reaction between compounds in the first component. Glass fiber-reinforced plastics are formed by the reaction (copolymerization) of an unsaturated polyester alkyd and styrene; both are contained in one of the components. This reaction is initiated by a second component, usually an organic peroxide. The most widely used is methyl ethyl ketone peroxide (MEKP). The fiber may be injected into the spray pattern as chopped strands or may be on a mold in front of the spray pattern in the form of a mat. As the reaction proceeds, heat is generated which further increases the reaction rate. The second component also may take part in the reaction. Polyurethane foam can be made by discharging an isocyanurate and a glycol through a spray gun into a mold. These components react to form the polyurethane foam. The components may be kept in separate pressure containers and conveyed to the spray gun through separate hoses. One component is expelled through the fluid tip in the conventional manner, while the second is admitted into the atomizing air through a metering venturi. The two components are mixed in the gun or most commonly in the spray pattern after discharge from the gun. These coatings are cured by a chemical reaction; in many cases this reaction can occur without the external application of heat. In some cases, however, low temperature curing ovens are used. Heat is usually generated during the curing reaction. Cleanup may be a problem with this type of coating unless strippable coatings or plastic films are used to cover exposed surfaces in the spray area.
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C.2.2.5 Hot Spray Systems Hot spray equipment is used to heat finishing material either before it reaches the spray gun or as it leaves. Steam, hot water, or electric resistance heaters may be used. This method uses little solvent and a heavier film may be deposited on the object. (Fig. 10)
Fig. 10. Hot spraying system. This type heats both atomizing air and finishing material.
C.2.2.6 Air Assisted-Airless Coating material is supplied to the atomizer by a pump with fluid pressures at 300 to 500 psi (2050 to 3430 kPa) (20 to 35 bars). The coating is discharged through an airless-type spray nozzle. Air pressure also is used as in a conventional system to provide pattern control. C.2.2.7 Airless Spray Systems Coating material is atomized by hydraulic pressure instead of air pressure. Equipment consists of a hydraulic paint pump and spray gun (Fig. 11). The pump supplies coating material to a spray nozzle at pressures from 300 psi to 3500 psi (2050 to 24,000 kPa) (20 to 250 bars). The coating material may be heated or at ambient temperatures. C.2.3 Spray Booths C.2.3.1 General Spray booths confine overspray, and filter as much of the overspray residue as possible before solvent vapors are exhausted. Booths have mechanical ventilation systems to maintain air velocity through all openings,
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Fig. 11. Airless Electrostatic Spray System.
and to keep flammable vapor air concentrations below the lower explosive limit. Various types of filters may be used to remove solid particulate. The booth designation is frequently based on the type of filter (dry spray booth, etc.) or direction of air flow (downdraft, etc.). C.2.3.2 Dry Spray Booths Dry spray booths are equipped with either baffles, filter pads, or filter rolls to prevent excessive quantities of residue from entering the exhaust system. Their efficiencies vary greatly. Baffle booths (Fig. 12) are least efficient. A properly maintained dry filter booth (Fig. 8) is one of the most efficient methods of collecting overspray residue. Some residue will pass through the filter and coat the plenum and exhaust duct downstream. A high filter efficiency does not eliminate the need for protection in the plenum and exhaust duct. A highly efficient, well maintained filter, however, will reduce cleaning frequency. Filter disposal is becoming an increasing problem. Due to changes in EPA requirements, methods of disposal that were previously acceptable may be costly. This may make it necessary to change the way filters are
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Fig. 12. Dry filter spray booth equipped with baffles.
disposed of, or other types of booths may be more widely used. One method of disposal of used filter media is to cure in an oven; this would then allow the filter to be treated as ordinary waste. Where high-solid coatings are used, baffles may be installed before the filter media to improve transfer efficiencies (by reusing paint overspray) and to extend the life of the filter media. Baffles may be designed to allow high solids overspray to flow down into a trough which in turn slopes to a container from which it may be reused. Overspray collector filters are tested and Approved by Factory Mutual Research. Test procedures involve exposure of a clean filter assembly to an ignition source for a predetermined period. The fire resistance indicated by these tests is valid for a short period after installation. After extensive use, however, the filter is coated with residue and its burning characteristics will be more nearly those of the residue. C.2.3.3 Water Wash Booths Water wash booths replace the dry filter with a water curtain or mist. In the water curtain booth, water is pumped from a sump at the bottom of the booth to perforated pipes, troughs, or nozzles in the top rear of the booth. Coating operations are directed so that overspray residue comes in direct contact with the curtain or is drawn by the booths exhaust system through the curtain (Fig. 13). Water pan booths use mist to collect overspray. The mist is formed by air at high velocity passing between the surface of the water in the sump and a baffle located a few inches above the surface, or by spray nozzles discharging water at 50 to 100 psi (345-690 kPa). The distance between the surface of the water in the sump and the baffle is critical. If the space is too large, the mist is not formed and residues are carried into the
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Fig. 13. Downdraft water wash spray booth (room sprinkler system not shown).
exhaust duct; if too small, the increased pressure drop across the opening reduces air flow. This is normally automatically controlled by measuring air velocities between the baffle and the sump, and either raising or lowering the water level. Chemical additives are used to precipitate the residues so that they may be skimmed off the top or removed from the bottom of the sump. In the curtain-type booth, it is important that the perforated pipes, troughs or nozzles are not plugged with residue. If these are plugged, open areas in the water curtain decrease collection efficiencies and result in residue accumulations in the exhaust duct. In the water mist booth, residue accumulations on the surface of the water in the sump may reduce formation of mist or block the spray nozzles, also decreasing collection efficiencies. Water wash booths are preferred when quantities of overspray residue are heavy. They reduce fuel loading since most residue is collected in the sump. The water curtain also helps to confine a fire occurring in the exhaust duct from spreading to the booth and vice versa. The use of a water wash booth does not eliminate the need for protection in the plenum area behind the water mist or curtain, or in the exhaust duct. Overspray residue will build up in these areas. When residues are wet, the chance of ignition is minimal. However, residues dry quickly when booths are shut down. C.2.3.4 Oil Wash Spray Booths Oil wash spray booths are arranged so that air and overspray are drawn through a continuously flowing oil curtain which removes overspray residue. The oil curtain may be formed by oil discharge from overflowing troughs at the top rear of the booth. The oil then flows down baffles into a sump at the base of the booth from which it is recirculated. Residues picked up by the oil curtain sink to the bottom of the sump (Fig. 14). Solvent absorbed by the oil curtain is released into the exhaust air stream. Oils with flash points of 350-400F (175-200C) are presently used. Reports indicate that the oil flash point decreases no more than 5F (3C) during normal operation.
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Fig. 14. Oil wash spray booth with removable baffles in exhaust plenum. Interlock to shut off oil pump in event of sprinkler operation is also shown.
Booths range from 5 to 20 ft (1.5 to 6.1 m) wide. Five ft (1.5 m) wide booths contain approximately 150 gal (600 dm3) of oil; 20 ft (6.1 m) wide booths contain 500 gal (2,000 dm3) of oil. Newer installations have been provided with a 180F (82C) rated heat detector in the work space which is interlocked to 1) transfer oil to a holding chamber, 2) shut off the oil pump, and 3) shut off booth ventilation. C.2.3.5 Traveling Spray Booths Traveling dry or water wash spray booths are used for coating large objects such as railroad cars, buses, and tanks. The object remains stationary and is straddled by the booth. The booth may be self-propelled and usually moves on tracks or fixed supports. In most cases, air exhausted from the booth cannot be discharged directly outside. A hood is usually provided at ceiling level, extending the length of the booths travel, with its own exhaust fan and duct discharging outside. As in any spray booth, combustible residues will build up on the filter and in the exhaust plenum behind the filter. The booth also may shield the coated object from ceiling sprinklers. Automatic sprinkler protection supplied from a flexible connection to the plant sprinkler system is sometimes not practical. However, automatic sprinklers can be supplied from a tank and pump assembly mounted on the booth. Sprinkler protection is preferable. However, a special protection system with a connected reserve is acceptable. C.2.3.6 Combination Spray/Cure Booths Combination spray booths are used largely for automotive refinishing operations. They are designed so that the coating can be applied and cured at elevated temperature in the same booth. The newer coatings in use in the automotive market require above-ambient cure temperatures. Heating systems on booths presently available may be direct-fired or indirect-fired gas or oil, with the burner systems located outside the booth, or infrared (IR) with the IR heating units mounted on the walls of the booth. Where oil-fired or gas-fired burner systems are used, the exhaust arrangement for paint spray operations is separate from the booth heating system, and is not in operation when spraying operations are carried out
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in the booth. The concern is prevention of overspray residue on surfaces that would be exposed to flame or flame temperature during the cure cycle. The IR units are generally mounted in the booth and would be exposed to overspray. One IR heating system has been Approved by meeting the requirements of not causing ignition of overspray residue or solvent vapor. C.2.4 Applications Aircraft, furniture plant, and automobile spray finishing operations were reviewed as follows: C.2.4.1 Aircraft Spray Finishing An operation was reviewed in which a large commercial aircraft was being painted with manual airless electrostatic spray guns. The coating used was a premixed two-component coating with a closed cup flashpoint of 46F (8C). The operation took about 1-12 hrs to complete using 10 gal (40 dm3) of paint. During the spray operation vapor concentrations were measured adjacent to the operators and at several points on the staging and wing areas. The highest concentration measured was 180 ppm under the wing of the aircraft It was concluded that the chance of a fire involving the paint supply was low due to 1) the distance between paint supply and spray operation, and 2) paint supply would be automatically cut off on release of the spray gun. The primary hazard is believed to be ignition of the paint spray and undried coating by an arc between the gun and the aircraft Aircraft fuel tanks are not always emptied of fuel and purged when brought into the hangar. Electrostatic spray finishing near a vent with tanks containing JET B (JP-4 fuel) would be particularly hazardous. Few airlines outside the United States and no U.S. airlines use this fuel. However, some airlines do contract work for foreign airlines. Vapors from JET A (Kerosene) would probably not be ignited since flashpoints of JET A range from 95 to 165F (35 to 74C). C.2.4.2 Furniture Plant Finishing Operations Using Nitrocellulose Base Lacquers Several chair finishing operations were reviewed in which water pan booths, baffle booths and dry filter booths were used. The operations involved application of base stain, wash coat, fillers, sealers, glazes and lacquer coatings with either air dry, oven dry and/or sanding operations in between. The percent solids range from 0.05% in an alcohol based stain to 13% in a nitrocellulose based lacquer. All coatings used were low flashpoint flammable liquids. In a high volume production operation, each coating is applied in a different spray booth. In low volume or custom operations one booth may be used for more than one coating. Inadequate control of overspray is the major contributing factor in large losses. If overspray is confined to the booth and exhaust system, a fire can be controlled by a well designed and well maintained automatic sprinkler system. If overspray residue accumulates outside spray booths, particularly on the ceiling, a fire can spread rapidly across the ceiling above and ahead of opening automatic sprinklers. Overspray may be outside the booth for the following reasons: 1. The operator sprays outside the booth. This could be either because the workpiece is larger than the booth or the operator is trying to stay ahead of the conveyor. 2. Low capture velocity. This could be due to plugged filters, high spray application rates, large workpiece, inadequately sized exhaust fan(s), etc. 3. Openings in the exhaust duct, i.e., fan mounts, sprinkler penetrations. 4. Inadequately sized exhaust system. There will always be some overspray outside the booth. Hence, it is important to establish a periodic cleaning program to minimize accumulations. C.2.4.3 Automobile Paint Spray Booths Using Rotary Atomizers The automobile chassis is painted in a series of long spray booths that are part of the assembly line. Or, the chassis may be shifted off the assembly line into a modular booth where the chassis stops until the painting operation is complete.
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The chassis can be coated manually or automatically using robots or reciprocators. There could be two atomizers on two robots in a modular booth. There could be from 10 to 20 atomizers on reciprocators in a large booth. There are usually from 10 to 15 different colors used in prime coat booths. Typically, paint and thinner is piped in welded steel piping from the paint kitchen to color changers at the booth. For manual spray operations, and in some automatic spray operations, the color changers are mounted on the wall of the booth. In other automatic installations, particularly where there are limitations on volatile organic solvent emissions, the color changer is inside the booth near the automatic spray gun. Location near the spray gun minimizes the amount of solvent discharged between color changes. This results in long runs of 10 to 14 plastic paint and thinner hoses to each atomizer. For at least part of the distance, the hose and the power supply for the atomizer will be within a housing to protect against overspray. These housings may shield the hose from overhead sprinklers. High solids paint and rotary electrostatic atomizers (bell or disk systems) are used to increase paint transfer efficiency. Voltages, in many cases, can be in excess of 100,000 volts. Fire frequencies have been high. A fire, if not quickly controlled, could spread to other atomizers across the wetted surface of the chassis or from a pinhole leak resulting in burn through of plastic hose. The major cause of loss has been pinhole leaks in the paint hose supplying finishing material. Some coatings are conductive. A charge on the paint in the hose may arc to a grounded object through a defect in the wall of the hose, resulting in a pinhole leak. The major contributing factor in all automotive spray booth fires has been the lack of interlocks for paint and thinner pumps. For rotary electrostatic atomizers, with color changers near the atomizer, lack of protection for shielded areas such as the housing containing numerous plastic paint and thinner hoses has also been a contributing factor. Three levels of protection for this type of booth have been provided. 1. Protection for housings containing paint and thinner hose. If enclosed on sides and bottom, halon or C02 has been used. If partially enclosed, water spray has been used. Fire detection has been provided by line-type pneumatic heat detection. A line-type fiber optic detection system has recently been designed for this application and is Approved. Detection of a fire in one housing results in discharge of protection systems for all housings in the booth. 2. Water spray at ceiling level in the booths. Design criteria have varied from 0.30 gpm/ft2 (12 mm/min) to 0.6 gpm/ft2 (24 mm/min). Deluge systems may be actuated by either: a) dual frequency IR, b) UV, or c) a combination of IR and UV. 3. Ceiling sprinkler system in the booth. C.3 Water Base Coatings Water base coatings have, in many cases, provided a satisfactory answer to restrictions by local authorities on emissions from organic solvent base coating systems. C.3.1 Coatings Water base coatings feature a combination of an organic resin and volatile solvent. The resin forms the coating when it dries. The solvent is a mixture of water and several organic solvents where water normally comprises 80% of the volatile solvent. There are three types of water base coatings: 1. Emulsion: The emulsion coating is composed of a volatile solvent and a resin. The resin is a high molecular weight polymer. Particle sizes range from 0.25 to 1.0 microns. 2. Water Reducible: Water reducibles, also called water soluble or water thinnable coatings, use a relatively low molecular weight resin dissolved in a water miscible organic solvent. 3. Colloidal Dispersion: A colloidal dispersion contains very fine resin particles, each having a water soluble polar group which allows uniform dispersal in water. The major differences between solvent base and water base coatings are 1) water base coatings have lower heats of combustion, and 2) they are soluble in water. In the event drums or containers of water base coatings are involved in a fire, less heat would be generated, resulting in few sprinklers opening. Water should also extinguish the fire regardless of the flash point of the coating.
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The major similarity between solvent base and water base coatings is in the overspray residue. Many recommendations for solvent base systems would apply to water base systems, even if the volatile solvent was 100% water. C.3.2 Spray Application Methods C.3.2.1 General The changeover from flammable solvent to water base systems may be slow since water base coatings are still under development. For example, if several different colors are used in one operation, water base coatings may give an acceptable coating for all but one or two colors. Until an acceptable water base coating is obtained, flammable solvent base coatings may be sprayed part of the time and water base part of the time. C.3.2.2 Conventional and Airless Spray Systems Water base coatings may be applied by either air or airless atomization principles. In many cases, flammable solvent base equipment may be used without modification. C.3.2.3 Electrostatic Spray Systems Water base coatings are electrically conductive. Some change in equipment may be necessary, depending on the method used to charge the coating. Some systems, though, such as the grid system, may require little change. For systems such as the disk, bell, and electrostatic spray gun in which the charging electrode comes in direct contact with the paint column, the paint supply must be isolated from ground. C.4 Powder Coating Plastic polymers can be applied in dry powder form by means of a spray gun or fluidized bed. The workpiece may be heated and/or the powder electrostatically charged. Powder coatings can be used for most applications when protective or finish coatings are applied. C.4.1 Coatings Both thermoplastic and thermosetting plastic polymers are used. Thermosetting powders include epoxy, hybrid epoxy, polyester and acrylic resin based materials. Epoxies are currently the most widely used. Polyester and acrylic polymers, in use to a limited extent, are available both as thermoplastic and thermosetting coatings. Thermoplastic powders include polypropylene, polyethylene, nylon, polyvinyl chloride, and cellulose acetate butyrate. Thermosetting coatings can be applied directly to the surface without a primer. Thermoplastic coatings usually require a primer for the coating to adhere properly. The primer coat may be either water, solvent base or powder. Both types of coatings contain, in addition to the thermoplastic or thermosetting resin, a curing agent or hardener, pigment and/or filler, and flow control additives. The particle sizes of the powder vary depending on the desired coating thickness and method of application. Coatings of from 1 mil (25 microns) to 10 mils (250 microns) in thickness normally involve particle sizes ranging from 1250 mesh (10 microns) to 125 mesh (120 microns). Coatings of from 10 mils (250 microns) to 40 mils (1000 microns) normally involve particle sizes ranging from 350 mesh (40 microns) to 60 mesh (250 microns).
C.4.2 Application Methods C.4.2.1 Spray Application Powder may be applied by spray gun onto a workpiece that has been preheated to a temperature above the melting point of the powder. This process is called fusion bonding. Pipe coating is the most typical example of this coating process. More commonly powder is applied by electrostatic spray gun using a combination of air pressure and electrostatic charging to direct the powder onto a workpiece at elevated or room temperature. Coatings of from less than 1 mil (25 microns) to 20 mils (500 microns) may be applied by spraying.
Spray Application
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Both operations may be done manually or automatically. In an automatic booth, the guns may either be stationary or mounted on a reciprocator or robot. The spray guns may be arranged to discharge continuously when the conveyor is in operation, or intermittently when the workpiece passes in front of them. Spraying is carried out in an enclosure similar in design to the downdraft spray booth used in flammable solvent base spray finishing. Air movement is usually designed to carry powder overspray to the bottom of the booth. There are two basic booth designs relating to location of powder recovery equipment. In one design powder recovery equipment is separate from the booth. In this design powder recovery may be by cyclone and bag collector in series or by a bag collector (Fig. 15). In the integrated design the powder collection equipment is part of the booth. Cartridge filters may be located in the upper part of the booth hopper to remove overspray (Fig. 16). In the integrated design, the filter system may be a permanent part of the booth.
Fig. 15. Manual spray booth with partial recirculation of filtered air.
If color changing capability is needed, it may be arranged to be detachable from the booth. When changing from one color to another, the filter and hopper section may be detached and replaced with the filter and hopper system of the new color. In the powder coating of pipe, fixed spray guns may be arranged around the circumference of the pipe. Spraying is conducted inside an enclosure resembling a collar, that completely surrounds and is only slightly larger than the diameter of the pipe. A combination of construction and venting may be provided so that the enclosure can withstand an internal dust explosion. In this case, air velocities that would give the highest transfer efficiencies may be used. The amount of powder collected on the surface in relation to the amount discharged by the spray guns expressed as a percentage is termed the transfer efficiency. It can range from 10 to 90 plus percent, depending on the shape of the object coated. A recovery system is used so that oversprayed powder can
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Fig. 16. Integrated booth design with cartridge filter system in upper part of booth hopper.
be collected and reused, substantially increasing the efficiency of the operation. The recovery system may be a filter system designed as part of the booth (integrated system), or a bag collector located near the booth. With an integrated system the recovery system may be a permanent part of the booth hopper. The hopper may be fixed to the booth or detachable. The former would be used for extended runs involving the same powder coating. The latter would be used in coating operations where color change capability is needed. Each filter system would be arranged for a different color. Factory Mutual Research has Approved powder coating booths with the filter system as part of the booth. There was a concern that an explosion could occur in the powder collection area. Tests were conducted at various powder discharge rates to determine whether an explosion would occur in the recovery system following ignition of powder at the gun. It was determined that an explosion did not occur probably due to the opening between the recovery system and the booth. However, a fire did occur in the filter system. Small hose was required to extinguish the fire; it could not be extinguished with portable extinguishing equipment. When a bag collector is used, it is generally located adjacent to the spraying area. The powder may be recovered and used again, as is normally done in automatic spray booths, or discarded. The filtered air may be partially recirculated to the plant or spray booth, as is frequently done in automatic operations, or discharged to the atmosphere. In applications in which filtered air is used in the plant, a second filter system is installed as a final filter in the duct discharging air to the booth or plant. The pressure drop across it can be monitored and an alarm installed to indicate when the filter needs to be serviced. This also acts as a safeguard to prevent the discharge of powder into the booth or plant from a leaking filter bag in the collection system.
Spray Application
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C.4.2.2 Fluidized Bed Application Powder may be applied by preheating the object and dipping it into an aerated bed of powder (fluidized bed). It may also be applied by grounding the object and electrostatically charging the powder so that when the object is dipped into or supported just above the aerated bed, the powder clings to it (electrostatic fluidized bed, Fig. 17). Perimeter exhaust systems (Fig. 17) or exhaust hoods are normally used to remove powder overspray. If thick coatings are desired in electrostatic bed systems, the object may be preheated. Coatings of from 6 mils (150 microns) to 40 mils (1000 microns) may be applied by these methods.
Fig. 17. Electrostatic fluidized bed with perimeter exhaust system.
Powder also may be applied using a cascading electrostatic fluidized bed. This is essentially two separate electrostatic beds with a space between wide enough to pass an object on a conveyor. Both beds are enclosed except for an opening at the top of the conveyor side of each bed. Charged powder passes through the openings and coats the grounded object. An exhaust system removes powder overspray. Coatings of from 1 to 7 mil (25 to 175 microns) may be applied by this method. Cyclone collectors and/or bag-type filters similar to those employed in powder spraying may be used to recover powder overspray. The filtered air may be discharged to the plant or recirculated to the bed. C.6 NFPA 33 Spray application of flammable and combustible material is covered in NFPA Standard No. 33 (1985). This NFPA standard differs from the Factory Mutual Research standard in the following areas: C.6.1 Flammable Solvent Base Coatings Flammable solvent base coatings are covered by the NFPA in Chapters 1 to 10 and Chapter 14. C.6.1.1 Location Factory Mutual Research allows use of draft curtains and smoke and heat vents to isolate the spray area from other occupancies, where one-hour fire resistant construction is not practical. NFPA recommends one-hour fire resistance rating for spray rooms. C.6.1.2 Location Factory Mutual Research specifies automatic sprinkler protection for spray areas. The NFPA allows use of an Approved fixed automatic fire extinguishing system for spray areas. Loss experience indicates that sprinklers are effective in controlling fires in spray areas. Dry chemical may not cover all surfaces coated
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with overspray residue. Gaseous extinguishing systems are less reliable than sprinklers due to 1) the need to shut down ventilation to maintain an extinguishing concentration, and 2) the ignition source may remain after dissipation of the extinguishing agent. An example would be where cause of ignition was reaction between dissimilar coatings or spontaneous ignition. C.6.1.3 Electrical and Other Sources of Ignition The NFPA does not allow open flame or spark producing equipment within 20 ft (6 m) of the spraying area unless separated by a partition. In addition, means must be provided to prevent sparks or hot metal from entering the spray area or the area designated as requiring Division 2 electrical equipment. FM Global does not allow open flame within 10 ft (3 m) and spark producing equipment within 50 ft (15 m), unless separated by a noncombustible partition. The 50 ft (15 m) distance is based on the 35 ft (11 m) distance that a spark may possibly travel, plus a 10 ft (3 m) distance from a booth that may be classified as a Division 2 area. C.6.1.4 Drainage The NFPA has no recommendations for drainage or waterproofing of floors in areas in which spray operations are carried out. C.6.1.5 Spray Booths Factory Mutual Research has a series of recommendations pertaining to dry booths, water wash booths, oil wash and traveling spray booths. These recommendations are not included in the NFPA standard. C.6.1.6 Applications Factory Mutual Research also has recommendations pertaining to aircraft spray finishing and furniture plant finishing operations not contained in the NFPA standard. C.6.2 Water Base Coatings The NFPA states that recommendations for solvent base coatings that apply to overspray residue apply for water base coatings without defining specific recommendations. C.6.3 Powder Coatings The NFPA covers powder coating in Chapter 13 of NFPA 33. C.6.3.1 Spray Booths Design The NFPA recommends that nondeposited, air-suspended powders be safely removed to a powder recovery system. The Factory Mutual Research standard specifies exhaust ventilation rates based on type and quantity of powder discharged. In a limited number of cases, as outlined in Recommendation No. 2.3.3.2.1 b, Factory Mutual Research allows the use of explosion venting and adequate booth construction in lieu of providing sufficient air to keep the booth volume below the explosive range. C.6.3.2 Fluidized Beds Factory Mutual Research recommendations are aimed at preventing release of powder from the bed and confining overspray. NFPA recommendations are intended to prevent ignition.

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FM Global Property Loss Prevention Data Sheets

SPRAY APPLICATION OF FLAMMABLE AND COMBUSTIBLE MATERIALS

2007 Factory Mutual Insurance Company. All rights reserved.

2007 Factory Mutual Insurance Company. All rights reserved.

Fig. 1. Spray room showing recommended cutoffs and protection.

2007 Factory Mutual Insurance Company. All rights reserved.

2007 Factory Mutual Insurance Company. All rights reserved.

Density1, gpm/ft2 (mm/min)

2007 Factory Mutual Insurance Company. All rights reserved.

2007 Factory Mutual Insurance Company. All rights reserved.

2007 Factory Mutual Insurance Company. All rights reserved.

2007 Factory Mutual Insurance Company. All rights reserved.

Fig. 4. Class I and II Areas adjacent to an unenclosed spray operation.

2007 Factory Mutual Insurance Company. All rights reserved.

Fig. 6. Class I or II Division 2 Area adjacent to an open-top spray booth.

2007 Factory Mutual Insurance Company. All rights reserved.

2007 Factory Mutual Insurance Company. All rights reserved.

2007 Factory Mutual Insurance Company. All rights reserved.

2007 Factory Mutual Insurance Company. All rights reserved.

2007 Factory Mutual Insurance Company. All rights reserved.

2007 Factory Mutual Insurance Company. All rights reserved.

2007 Factory Mutual Insurance Company. All rights reserved.

2007 Factory Mutual Insurance Company. All rights reserved.

2007 Factory Mutual Insurance Company. All rights reserved.

2007 Factory Mutual Insurance Company. All rights reserved.

2007 Factory Mutual Insurance Company. All rights reserved.

2007 Factory Mutual Insurance Company. All rights reserved.

2007 Factory Mutual Insurance Company. All rights reserved.

2007 Factory Mutual Insurance Company. All rights reserved.

2007 Factory Mutual Insurance Company. All rights reserved.

With Filters Without Filters

2007 Factory Mutual Insurance Company. All rights reserved.

Data Data Data Data

Sheet Sheet Sheet Sheet

7-81, 7-83, 7-88, 7-97,

2007 Factory Mutual Insurance Company. All rights reserved.

2007 Factory Mutual Insurance Company. All rights reserved.

Fig. 9. Electrostatic spray system, rotating disk type.

2007 Factory Mutual Insurance Company. All rights reserved.

2007 Factory Mutual Insurance Company. All rights reserved.

2007 Factory Mutual Insurance Company. All rights reserved.

Fig. 11. Airless Electrostatic Spray System.

2007 Factory Mutual Insurance Company. All rights reserved.

Fig. 12. Dry filter spray booth equipped with baffles.

2007 Factory Mutual Insurance Company. All rights reserved.

2007 Factory Mutual Insurance Company. All rights reserved.

2007 Factory Mutual Insurance Company. All rights reserved.

2007 Factory Mutual Insurance Company. All rights reserved.

2007 Factory Mutual Insurance Company. All rights reserved.

2007 Factory Mutual Insurance Company. All rights reserved.

2007 Factory Mutual Insurance Company. All rights reserved.

2007 Factory Mutual Insurance Company. All rights reserved.

Fig. 17. Electrostatic fluidized bed with perimeter exhaust system.

2007 Factory Mutual Insurance Company. All rights reserved.

2007 Factory Mutual Insurance Company. All rights reserved.

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