Materials Dispensing System Design Guide

Americas: One Lincoln Way St. Louis, MO 63120-1578 USA Phone +1.314.679.4200 Fax +1.800.424.5359

Form 440492 Copyright 2002 Printed in USA Web site: www.lincolnindustrial.com

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MATERIALS DISPENSING SYSTEM DESIGN GUIDE

Introduction
The purpose of this System Design Guide is to take the reader through the logical steps in selecting a Lincoln pump or pumps suitable for a particular application. The Materials Dispensing System Worksheet, which follows this page, is the most critical step in the system design process. By filling out the worksheet you will have, in most cases, enough information to proceed with the system design for relatively simple systems. More complex systems will require the assistance of Lincoln but they will need the worksheet filled out as completely as possible to be able to determine if further testing of the material in a simulated system is required before a final bill of materials can be developed for the application. The guide is divided into sections each containing information to which you will need to refer. Section A Pages 1 A-4A illustrate the four basic materials dispensing systems with typical accessories. Page 5A is a worksheet used with the charts and graphs which follow it to determine pipe size and system delivery pressure required.

Section B Pump performance charts. Section C Viscosity conversion charts and various methods of measuring viscosity. Section D Corrosion resistance and hose and packing compatibility charts. Section E Useful information.

MATERIALS DISPENSING SYSTEM DESIGN GUIDE

System Worksheet
Send to: LINCOLN One Lincoln Way St. Louis, MO 63120 Date District Manager

A. Customer: Address: B. Describe application: Material to be pumped and product number (Attach material data sheet if available) Manufacturer: Address: Telephone: 1. Is material toxic or otherwise hazardous to operators?

Phone:

If yes, explain

2. Is material flammable or combustible? If yes, what is National Fire Protection Assn. class? 3. Viscosity @ F, temperature @ F 4. Compatibility information: If known to require a specific seal material, please state material. a. Base material: b. Solvent: c. Clean-up solvent: d. Corrosive? PH e. Abrasive? If yes, explain 5. Specific weight (gravity): 6. Is material shear or pressure sensitive? If yes, explain. 7. Agitation required? 8. Pumping temperature: F. 9. Is material available for Engineering Test, should testing be deemed necessary? 10. How much material could be supplied? 11. Unused material to be sent to: C. System Parameters 1. System type: Transfer Flow Spray Measure (state volume per shot) Material required per outlet GPM @ PSI Number of outlets

MATERIALS DISPENSING SYSTEM DESIGN GUIDE

2. a. Suction line distance from material reservoir to pump (non-pressire primer applications): b. Suction supply line size (diameter): c. Number and type of fittings from material reservoir to pump (e.g. dry lock connector, cam lock connector, ball valve, globe valve, etc.

3. Total pumping distance: (If existing pipe, state size and pressure rating.) Main Supply Line: ft pipe, sch ft pipe, sch Branch or Drop Lines: ft pipe, sch Hose, type , ft. inside dia Net change in elevation ft. 4. Power available Air PSI SCFM Hydraulic PSI Electric: Volts Hz. 5. Size container to be pumped from Drum Open Topped? Pail Tapered? Tank Height , Width Tank manufacturer: How is pump mounted? D. E. System recommendation required by (date) If proposed system is successful in satisfying customers needs, describe potential for future sales.

GPM

, Depth Telephone:

Model

F.

Sketch of (proposed) system:

G.

Bill of Material: (Proposed by Lincoln District Manager, include foreign items where applicable.)

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Typical Materials Dispensing Systems Transfer System

In a transfer system, material is transferred from its original container to another point. Typically, low pressure, high volume pumps are used for simple transfer of low viscosity fluids through relatively short supply lines. If higher viscosity fluids are to be transferred, or longer supply lines are required, a pump capable of higher pressures would become necessary. This is necessary to overcome the additional resistance to flow caused by the higher viscosity fluid or the internal pressure losses encountered with longer supply lines. Systems can be used to: Transfer printing inks to press fountains. Transfer adhesives to reservoirs on packaging machinery. Transfer lubricants to smaller containers in remote locations. Transfer chemicals to mixing tanks. Transfer materials intermediately from bulk containers to high pressure pumps for spray or flow applications.

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Typical Materials Dispensing Systems Spray System
In a spray system, material is transferred from an original container through a supply line to spray guns or nozzles, either airless (atomized by materials pressure only) or air assisted (mixed with air at the gun or nozzle for atomization). Spray systems are used for Airless paint spray contractors, in plant.
-

Die lubricant spray. Trough grease spray in bakeries. Protective coatings. Cold roof coatings and resaturant spray systems. Sound deadener. Rust proofing. Adhesives and sealants.

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Typical Materials Dispensing Systems Flow System
In a flow system, material is pumped from the original container through the supply line to a flow gun which applies the material to a work piece. Typical flow systems include: Adhesives applied to substrates for bonding, such as construction. Adhesives used in the manufacture of modular or mobile homes. Sealants applied to various parts of vehicles, such as windshield, tail lights, weld lines and hem flanges during manufacture.

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Typical Materials Dispensing Systems Measure System
In a measure system, material is pumped from original containers through the supply lines to measuring valves or ejectors, which in turn meter precise amounts of material to workpiece. Typical measure systems include: -Cartridge filling lines Small appliance manufacturing where measured amounts of lubricant are applied to small electric motors. Single shot applications of adhesives or sealants used in manufacturing. Multiple shots in patterns of adhesives used to bond substrates, such as automobile hoods and doors.456

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System Design Guide Steps for designing a Materials Dispensing System Step 1: Assume material velocity in feet per second (if unknown). Material/Viscosity A. Materials less than 19,999 cps* B. Materials greater than 20,000 cps but less than 34,999 cps C. Materials greater than 35,000 cps but less than 49,999 cps D. Materials greater than 50,000 cps but less than 99,999 cps E. Materials greater than 100,000 cpa

Velocity Feet/Second * Note: For paints and other materials containing suspended particles assume velocity of 1 foot per second. For fuels and light viscosity volatile materials assume velocity of 2 feet per second. Step 2. Determine pipe size and system losses from material supply to pump inlet. This is known as suction side. (For application where pressure primers are not used) A. B. C. Establish a flow rate in gallons per minute for the applictations needs. Multiply this by 2 and use this new flow rate for calculations on suction side only. * Using chart on page 6A, draw a line from flow in gallons per minute through velocity in feet per second. Read pipe size required. Determine equivalent lengths including pipe, fittings, shut-off valves, disconnects, etc. Use page 7A to determine equivalent lengths. (Note: Ball Valve has no equivalent losses.) Determine and quantify any additional supply head such as elevation or head added by using pressurized tank in psig. For elevation head use .5 psig per foot. e.g. If reservoir is 6 feet full of fluid, then elevation supply head is (6) (.5) = 3 psi. Determine pressure drop per foot using chart on Page 9A in psig/foot. Perform cavatation check. 12 LB-f + E in2 GPM GPM Inch

Velocity 3 2.5 2 1 .5

D.

Ft.

E.

psig

F. G.

psig/foot

>

FxD

Pump produces 12 PSI vacuum head. If right hand side of equation is greater than left hand side of equation, the pump will cavitate. That means the pump will not be able to draw in fluid sufficiently. If cavitation exists, you must reduce resistance to flow or add addtional supply head. Ways to reduce resistance to flow: - Reduce suction line length. - Go to larger diameter suction supply pipe or hose. - Reduce or eliminate valves or elbows, fittings. - Add additional pressure to tank. - Heat up fluid. - Reduce viscosity. Contact your local distributor or Lincoln Customer Service as required. * Intake flow rate is twice flow rate on pump outlet. This is because the pump draws in enough material on up stroke to allow pump to output material on both up and down stroke.

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System Design Guide Steps for designing a Materials Dispensing System (cont)
Step 3. Determine Pipe Size. A. Required system flow rate supply side in gallons per minute________. B. Using chart on page 6A, draw a line from flow in gallons per minute through Velocity in feet per second. Read pipe size required. Step 4. Determine Delivery Pressure Required. A. Determine total pipe length B. Determine equivalent length of pipe for fittings, valves, etc. (reference page 7A) C. Add A + B D. Determine pressure loss through pipe and fittings (reference pages 8A & 9A) E. Multiply C X D F. Determine pressure loss for vertical lift (use .5 psi/ft) Pipe Size

________feet ________feet ________feet ________psi. Pressure drop through pipe and fittings (psi) PSI PSI

G.

Determine pressure loss for Lincoln items (reference pages 1 0A-1 1 A)

H.

For spray systems only, add: 200 psi for air spray system, 2000 psi for airless system.

PSI

I.

Total System Delivery Pressure Required (E. + F. + G. + H.)

PSI

Step 5. Pump Selection - Select pump or pumps that will give the required output against total system delivery pressure required. Refer to pump performance charts in Section B.

Step 6. Determine Best Pump on Economics of System Application.

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Equivalent Length of Pipe in Feet for Various Valves and Fittings
In extensive supply line configurations, a quantity of valves and fittings may be used to route the pipe conveniently. Consideration should be given to pressure loss through these valves and fittings The chart below should be used to determine the equivalent length in feet for various pipe sizes For example, if the supply line is determined to be 150 feet of 1 pipe and will have four 45 elbows, two 90 elbows and a globe valve then total pipe length to be considered for pressure loss calculations would be: 1 pipe 150 ft. +4 45 elbows 5.2 ft. (1.3 X 4) +2 90 elbows 5.4 ft. (2.7 X 2) +1 globe valve 28 ft. TOTAL 188.6 ft.

Nominal Tee Pipe Globe Angle Gate 45 90 Thru Size Valve Valve Valve Elbow Elbow Run 1/2 17 9 0.35 0.8 1.5 1.1 3/4 22 11 0.5 1 2.2 1.4 1 28 14 0.6 1.3 2.7 1.8 1-1/4 38 18 0.8 1.7 3.7 2.4 1-1/2 45 22 1 2 4.5 2.8 2 55 30 1.2 2.5 5.5 3.5 2-1/2 70 35 1.4 3 6.5 4.3

Tee Thru Branch 3.5 4.5 6 8 9.5 12 14

Sudden Sudden Contraction Enlargement d/D=1/4 d/D=1/4 0.8 1.5 1 2.2 1.3 2.7 1.7 3.7 2 4.5 2.5 5.5 3 6.5

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Pressure Drop Through Pipe, Hose and Tubing

The nomograph on page 9A should be used to figure pressure drop through all pipe, hose and tubing (if applicable) in the system being designed. To use the nomograph you must know the required flow rate in gallons per minute, the viscosity in centipoise of the material and the size of the supply line. Determine pressure drop as follows: Step 1 -Locate point 1 on the scale marked Q (flow rate in gallons per minute). Step 2 -Locate point 2 on the scale marked M (viscosity in centipoise). Step 3 -Draw a line connecting points 1 and 2. Step 4 -Locate point 3 on the index line where it is intersected by the line drawn in Step 3. Step 5-Locate point 4 on the scale marked D (pipe size in inches/l.D. of pipe tube or hose in inches). Step 6-Draw a line from point 3 through point 4 and continue the line to where it intersects scale marked P (pressure drop per foot, in psi). You now have your pressure drop in psi per foot Try this simple example: Required flow rate - 1 GPM Viscosity of material - 10,000 cps Supply line: 10 100 3/4 l.D. hose 1 l.D. pipe

Using the six step process you should determine the following pressure drop: 8.5 psi per ft. 3/4 l.D. hose X 10 = 2.8 psi per ft. 1 l.D. pipe X 100 = Total pressure drop through supply line 85 psi 280 psi 365 psi

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Pump Performance
The following pages contain pump performance charts that should be used to determine if a particular model pump will deliver the required flow rate against the pressure drop calculated using this Design Guide. In order to explain how to use these charts lets look at several facts about air operated reciprocating pumps. Air operated reciprocating pumps are variable output pumps. The output, expressed usually in gallons per minute, is inversely proportional to the delivery pressure, expressed in psig. As the delivery pressure increases the output (or flow rate) decreases. Conversely, higher outputs can be achieved at lower delivery pressures. We know that delivery pressure is directly dependent upon the input air pressure to the pump and the ratio of the pump. Quite simply, a 12:1 ratio pump with 100 psi input air pressure, will theoretically yield 1200 psig output pressure at zero flow rate. We also know that depending on the configuration of the system you are designing, you will need to develop a certain pressure to overcome the resistance to flow through the supply line and other system components. This we figured as our system pressure drop. Another consideration is the speed, or cycles per minute, of the pump. Our pumps are designed to operate at 75 cycles per minute (CPM) maximum for continuous service. A cycle consists of an up-stroke and a down-stroke of the pump piston. Therefore, the pump performance charts are plotted with this 75 CPM limitation in mind. Now, lets look at the pump performance chart for model 2001 pump on page 8B which is typical for the rest of the charts presented. You will note that the horizontal axis plots the pump output in GPM. The left hand vertical axis plots the delivery pressure in psig. Lets say your system calculations call for a pump to deliver 1 GPM against 800 psig pressure drop and you want to see if model 2001 can be used. First, locate the 1 GPM required on the horizontal axis. Follow the vertical line up to the 800 psig delivery pressure. You will see the point you locate on the graph falls on the 70 psi air input pressure line on the chart. You now know that model 2001 will deliver 1 GPM against an 800 psig delivery pressure if your air input pressure is somewhere around 70 psi. The charts can also be used to determine air consumption for the pump. The air consumption in standard cubic feet per minute (SCFM) is located on the right hand vertical axis. Using the same example, locate the 1 GPM on the horizontal axis and follow the vertical line up to the broken input pressure lines. You see that 70 psi, air consumption is approximately 17 SCFM. At 100 psi input pressure, air consumption is approximately 25 SCFM. Since we are going to use about 70 psi input pressure, our air consumption will be approximately 17 SCFM. You have to extrapolate data based on air input pressure other that the 40, 70, and 100 psi lines plotted on the chart. Lets look at one more example. We have a customer who needs 2.5 GPM of product dispensed through his system. Through the pressure drop calculations, you determined the pressure drop through, the system is 1400 psi. Since the customer is pumping from a bulk tank you have tentatively identified model 2325, standpipe mounted, as a supply pump. Lets check the performance chart for 2325 on page 1 B and see if it will indeed do the job. Locate 2.5 GPM on the horizontal axis and follow the vertical line up to 1400 psig delivery pressure. The point located on the graph is just below 100 psi input pressure line, so that pump will work in your system. How much air will the pump consume? Locate 2.5 GPM on the horizontal axis and follow it up the vertical line to where it intersects the broken line for 100 psi. The point located is right at 80 SCFM.

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