1、Manufacturing Standards Ford Motor Company I. II. III. ELECTROCOATINC SYSTEM, CATHODIC INTRODUCTION 1.0 SCOPE ELECTROCOAT CONSTRUCTION AND DESIGN 2.0 DIP AND PUMP WELL TANKS 3.0 CIRCULATING SYSTEMS 4.0 ANODE PLATES 5.0 DIP TANK ENCLOSURE 6.0 LIGHTING 7.0 PAINT SUMPS 8.0 PAINT COOLING SYSTEM 9.0 DEIO
2、MZED WATER TANK FILL SYSTEM 10.0 FILTER - TRANSFER SYSTEM 11.0 PAINT FEED SYSTEM 12.0 ULTRAFILTER RINSING SYSTEM 13.0 RINSE PIPING 14.0 RINSE AND DRAIN HOUSING 15.0 SKID AND PART GUIDES/GUARDS 16.0 PAINTING 17.0 GENERAL PIPING GENERAL INSTRUCTIONS AND APPROVALS 18.0 GENERAL 19.0 APPROVALS 20.0 ACCEP
3、TANCE TEST 21.0 REFERENCES Manufacturing Staff hylLIu.sA July 1983 ELECTROCOATING SYSTEM, CATHODIC BFX-2 Page 1 B Manufacturing Standards Ford Motor Company BFX-l ELECTROCOATING SYSTEM, CATHODIC 1.0 SCOPE 1.1 This Standard is to outline the basic requirements for the construction of and/or revision
4、to electrocoating facilities. The Standard will be augmented with proposal drawings and detailed equipment description. 1.2 An electrocoating system, for the purpose of this Standard, shall consist of the dip tank, tank enclosure, circulating system, heat exchanger system, ultrafilter system, rinse
5、and drain section, feed system, filtration system, and related components and controls. 1.3 The basic standard shall be applicable to cathodic continuous flow body l lectrocoating systems in conformance to the Manufacturing Standard C-610. 2.0 DIP AND PUMP WELL TANKS 2.1 Construction 2.1.1 2.1.2 2.1
6、.3 The tanks shall be constructed of 3/S-inch minimum, mild steel plates, conforming to ASTM Type A238, Grade D quality. All plates shall be flat and free of appreciable buckling or warpage. Tanks shall be constructed from a minimum number of pieces with sides and bottom smooth, plumb and square. Th
7、e bottom comers of the dip tank shall be either mitered at a 30-degree angle in order to minimize sludge accumulation, or designed as square in order to accommodate the installation of a longer anqde cell. The tank shall be supported on structural iron channels and wide flange beams of length and sp
8、acing adequate to support the tank load without deflection. The top, bottom, and sides of the tank shall be reinforced with structural angles and channels as required to contain the hydrostatic pressure without deflection. All tank supporting members shall be on the outside, leaving the tank interio
9、r clear and free of obstructions. All joints shall be butt construction and continuous l Iec a compressed air connection shall be provided to blow- down the filter to remove paint. A small drain line terminating through rinse housing at exit of dip tank shall be provided for this procedure. Discharg
10、e of the filter shall be returned via the main tank and pump well drain connection as previously indicated in the DIP AND PUMP WELL TANKS section of this specification. 10.5.1 Specification of the pump are as follows: Self;priming pump, complete with 40 HP 460/3/60 motor, base plate, coupling and gu
11、ard. Pump equipped with tungsten titanium carbide mechanical seals which are lubricated with permeate A one-quart glass reservoir shall be provided for this lubricant. Pump shall be mounted on a concrete foundation per Manufacturing Standard BX3. 10.5.2 Specification for the bag filters are as follo
12、ws: Vessels shall be ASME tested, approved and stamped. A minimum of two bag filter units per pump shall be installed. The system shall be complete with isolation valves, air bleed fittings, air blow+jown connection, drain connection and pressure gages. The filter units shall be sized for 25 GPM per
13、 one square foot of bag area maximum flow rate. Contractor shall provide a spare set of “0” rings and filter bags. Bags are to be of polypropylene material of 50-micron size. Manufacturing Staff hry(rU3.A. July 1983 ELECTROCOATING SYSTEM, CATHODIC BI=X-2 Page 9 B Manufacturing Standards Ford Motor C
14、ompany BFX-2 - . 10.6 For transfer of the bath material to the storage facility, the contractor shall provide a valved connection at the discharge of the filter pump with piping to the flanged connection. 11.0 PAINT FEED SYSTEM 11.1 11.2 11.3 The method utilized for the addition of paint replenishme
15、nt material to an electrocoat system shall be dictated by the requirements of the individual supplier. In general, the requirements can be defined in terms of single-component or two- component feed systems; however, for the purposes of this specification, the feed systems shall be designated by mat
16、erial manufacturer. Cathodic Electrocoat Paint This material, approved by the appropriate materials department, Product Engineering Office, shall be supplied as a two-package feed of pigment and resin material. The pigmented material shall be shipped to the plant in 55-gallon drums. Resin material s
17、hall be received in bulk shipments and transferred to a storage tank. Resin material shall circulate from the storage tank to a lOOO-gallon day tank located in the paint makeup area. Schematically, filtered bath material will be pumped from the ultrafilter pump reservoir through the static mixer at
18、the paint makeup area and returned to the circulating heat exchanger pump reservoir. Feed material and/or additives, single or in multiples, will be added to this line on the inlet side of the static mixer. I Transfer pumping of the feed material shall be as described herein. The feed system shall b
19、e designed for continuous duty. 11.3.1 The required major components of this system are: 11.3.1.1 11.3.1.2 11.3.1.3 11.3.1.4 Static Mixer Supply Pump - 16-stage vertical turbine rated 80 GPM at 230 feet head complete with 10 HP, 1750 rpm, 460/3/60 motor and Ford approved. Static Mixer - Standard des
20、ign, 2-inch diameter, No. 316 stainless steel threaded connection and Ford approved. Flow Meter, Bath Supply to Static Mixer - Rated for 120 CPM maximum flow, No. 316 stainless steel metering tube complete with alarm switch, 2-inch diameter, size No. 13, or equal, The alarm switch shall provide the
21、interlock for the various component pumping subsystems, preventing their operation unless flow is established. Pigment Feed Component Pumping System - A pumping system shall be provided to pump the pigment feed component material from 55-gallon drums. The system shall include the following: . Three
22、3:l air-operated pumps with elevator unit, 55-gallon drum cover with agitator. BFX-2 Page 10 - n U.S.A. ELECTROCOATING SYSTEM, CATHODIC Manufacturing Staff July 1983 m =l007LbCl cl053242 !ibil m Manufacturing Standards Ford Motor Company B BFX-2 11.3.1.5 Resin Component Pumping System - A lOOO-gallo
23、n circular day tank, complete with high/low level controls and a resin supply line with an automatic valve, shall be provided for intermediate storage. Resin material shall be pumped (5-10 CPM) into the circulated bath line on the inlet side of the static mixers from the day tank. The day tank shall
24、 also include the following: . Air set, regulator, fluid hoses and miscellaneous controls per Ford Motor Company requirements for E-Coat systems. . One Ford-approved 3:l air-operated pump. 11.3.1.6 Deionized Water Flushing System - Provide a 3/4-inch stainless steel D.I. waterline to the paint makeu
25、p area for flushing the pumps after each component is added and to insure that low volume additives are flushed into the main feed makeup loop. All material used for the deionized water flushing system shall be stainless steel. 11.4 It is the intent that this system be designed to provide a fail-saf
26、e condition in cases of power and/or air pressure loss. System air pressure interlocks shall be provided to prevent operation during low pressure conditions. 12.0 ULTRAFILTER RINSING SYSTEM 12.1 The l lectrocoating rinse system shall be designed for the utilization of ultrafiltration to provide the
27、rinsing media. As referenced in Ford Manufacturing Standard C610, this rinsing concept is as follows: 12.1 .l The ultrafilter system extracts permeate material from the. electrocoat bath. 12.1.2 The permeate material is collected in a storage tank and is used for: . Rinse material in the fourth rins
28、e-stage. Drain sheets return rinse media to recirculated rinse tank (third stage). . Makeup for the second and third stage recirculated rinses. . The second stage supplies, the rinsing media for the first stage rinse at the dip tank exit, drain sheets return rinse media from third stage to second st
29、age. 12.2 The ultrafilter system shall be comprised of three ultrafilter loops. Each lwp shall consist of a vertical turbine pump, supply and return piping, ultrafilter, associated valves, gages, and fittings. Schematically, paint will be pumped from the isolated pump well through the ultrafilter an
30、d returned to the pump well. Fresh material shall be supplied to this tank from the return side of the fine filter system and from the coarse filter system. The tank shall be provided with an overflow connection to the cooling system pump well. Manufacturing Staff -nU.SA July 1983 ELECTROCOATING SYS
31、TEM, CATHODIC BFX-2 Page 11 B Manufacturing Standards Ford Motor Company BFX-2 12.3 Fresh, filtered paint supply shall be a minimum of 15 times the ultrafiltration permeate rate. The pump well shall be equipped with high/low level controls. On low and high levels, this control will activate a visual
32、/audible alarm. 12.4 The ultrafilter supply pumps shall be vertical turbines, rated to suit ultrafiltration requirements. 12.5 The three ultrafilter units required shall be Abcor, Romicon or Ford-approved equal modules supplied with membranes manifolded as required to provide 6 CPM each (minimum) of
33、 permeate when supplied with paint under the following conditions: Type: Cathodic Electrocoat Solids: 20 percent NVM Temperature: 80 degrees F (26.7 degrees Cl If: 2 degrees F 12.6 The ultrafilter units shall include the following items: 12.6.1 12.6.2 12.6.3 12.6.4 12.6.5 Five copies of operating ma
34、nuals including parts list and sources for all nonproprietary major components. Six diaphragm (two per ultrafilter) isolated pressure gages complete with . shutoff valves on paint side of diaphragm. I Three closed permeate options if Abcor. Three days operator training. Two days technical startup se
35、rvices. 12.7 The contractor shall provide flow meters for monitoring the permeate flow rate for each ultrafilter cabinet or module. The permeate from the ultrafilter system shall be collected and stored in a lOOO-gallon holding tank. Permeate will be pumped from this tank to supply the fourth stage
36、(18 GPM) rinse located after the third stage recirculating rinse tank. The tank shall be constructed of l/4-inch plate complete with hinged access covers, drain connections and removable pump suction screens. Interior of tank shall be coated with Ford-approved material applied per manufacturer% inst
37、ructions. Tank preparation shall be as specified under the DIP AND PUMP WELL TANKS SECTION. The fourth stage rinse pump shall be a vertical turbine, rated 25 CPM at 90 feet head completed with a 3 HP, 1800 rpm motor. Rinse piping shall be equipped with a l-1/2 inch diameter meter with midscale range
38、 of 15 CPM, all wetted parts to be stainless steel. 12.8 Provisions shall be included for an ultrafilter flushing system. This system SS or PVC shall consist of a pump, filters, supply and return piping, and miscellaneous valves, fittings and gages. The system shall be designed to permit the flushin
39、g of an ultrafilter unit during production periods without shutting down the remaining units. BFX-2 P?ama am USA. Manuf acturmg Staff Page 12 ELECTROCOATING SYSTEM, CATHODIC July 1983 y Manufacturing Standards Ford Motor Company B BFX-2 12.9 The second and third stage rinse shall be recirculated per
40、meate. The contractor shall provide a 2500-gallon tank for stage two with a 575 CPM at 80 feet head pump. The pumps may be a chair-mount or vertical turbine conforming to the specifications contained herein. Rinse tanks shall be constructed and coated as specified for the fourth stage (permeate) rin
41、se tank. The tanks shall be located directly below the rinse section drain pans and shall be elevated if required to minimize the distance between the bottom rinse nozzles and the recirculate tank liquid level. A baffle extending from the drain pan (i.e., housing wall) to within 15 inches of the tan
42、k bottom (full width of tank) shall be included to act as a foam barrier. Tank shall be complete with all necessary hinged access lids, drain connections and pump suction screens. 12.10 The makeup to these tanks shall be pumped overflow from the permeate storage No. 4 stage tank. In addition, drain
43、sheets return rinse media from stage No. 4 to stage No. 3 and from a single riser from stage No. 3 to stage No. 2. Each rinse stage tank shall be quipped with a high tank liquid, high operating liquid, low operating liquid and low tank liquid level controls. The high tank liquid and low tank liquid
44、level controls will cause a visible/audible alarm to be activated. The high operating liquid alarm, when activated, will automatically bleed materials from the tanks as follows: 12.10.1 The permeate storage (No. 4 stage) tank will have a solenoid-operated line which will transfer material (using dis
45、charge of rinse pump) to the main dip or recirculated rinse tanks. 12.10.2 The recirculated rinse tank (No. 2 stage) tank will have a solenoid-operated line which will transfer material (using pump discharge) to the main dip tank. The No. 3 stage shall have a solenoidoperated line which will transfe
46、r material to the No. 2 stage. 12.11 The duration of this material transfer shall be controlled by the low operating liquid level controls. Each system shall be complete with manual control to permit valve operation for tank pumpout. Return to normal liquid levels, between high and low operation poi
47、nts, shall automatically reset high/low liquid level alarm. 12.12 The fifth stage rinse shall be virgin deionized water at 40-45 CPM. The drain from this stage shall be arranged to discharge to the waste tank located under the rinse housing. 12.13 The deionized water rinse shall be rated at 45 CPM a
48、nd shall be complete with a conveyor-activated solenoid valve and a stainless steel flow meter, 1 -l/2 inch diameter. A timer and limit switch shall shut down the D.I. rinse during skips while the conveyor is running. Manufacturing Staff July 1983 -*USA ELECTROCOATING SYSTEM, CATHODIC BFX-2 Page 13
49、m 7llCl=lLbil 005ll2Y5 27T m B GEEa Manufacturing Standards Ford Motor Company 12.14 A recirculated D.I. water rinse shall be installed ahead of the clean D.I. water rinse. This stage will be similar in sizing to the second recirculating permeate rinse stage. The tank shall be constructed of stainle
50、ss steel or suitable lined mild steel. The pump shall be rated at 400 CPM at 80 feet head. Provide lined bag filter vessels, stainless steel piping and a lined enclosure shall be provided. The makeup to this system will k the fresh D.I. water rinse, and it will overflow to .drain or waste treatment.
