Two Component Spray Application System

TWO COMPONENTS SPRAY APPLICATION SYSTEMS

Two components application systems can be designed basically in various ways depending on the coating material to be sprayed or dispensed. VR Coatings offers customized / Standard systems for following applications: Fixed ratio hot/cold, low/high pressure systems for epoxy/polyurethane liquids/semisolids having set times from 15 seconds and above. Polyurea coatings and other having set time below 15 seconds. Variable ratio electronic / lever, hot/cold, low / high pressure systems.

TWO COMPONENT HOT AIRLESS SPRAYING EQUIPMENT

Two components high performance protective coatings are used in the fields where coating with extreme chemical resistance, mechanical influence and long term durable corrosion protection is required. These protective coatings are solvent free and fast curing Coatings. They have good chemical, abrasive, penetration and high temperature resistance properties. They are also used for corrosion protection and has excellent adhesion to steel. The combination of hardness and flexibility in these protective coatings provides a solution for an entire pipeline network including the areas like buried pipeline, bell hole and line pipe rehabilitation, field joints, distribution units, valves & fittings and containers / tanks. Specially because of its performance, outstanding life, anti corrosive properties, strong adhesion high film builds and fast application these high protective coatings are used for protecting storage tanks, oil and gas piping, water tanks, ships etc.These high protective coatings are used for protecting storage tanks, oil and gas piping, water tanks, ships etc.. Curing time of Two Component equipment is very fast ranging from few seconds to several minutes. Hot Airless Two Component Equipments are used to achieve high coating thickness. VR Coatings Two Component Equipments are very economical and eco-friendly. It has reduced operational cost. Reduction in Labour cost. Effective flushing and cleaning. Components having different viscosity can be handled easily because of inline heating facility. Downtime required for maintenance is very low. Their design feature ensures exact dosage of each component being dispensed into the mixing block. Integrated Monitoring System avoids mixing ratio error and further rework due to wrong mixing ratio. These equipments have flexibility for various mixing ratios just by changing few parts or position. Use of heating system allows applying uniform coating even at low ambient temperature. Principles of safety integration are followed while designing the machine. TWO COMPONENT HOT AIRLESS EQUIPMENT CHEETAH CONSIST OF: Plural Component High Pressure Pump Mixing Block Mixers -Static / Dynamic Flush Pump. Heating System Feed Pump and Supply System Monitoring and control System Spray Guns

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Plural Component High Pressure Pump

This is the core part of Two Component System. It is like a standard Airless Spray Equipment except three hydraulic cylinders driven by single common Air Motor. The Air Motor designed by VR Coatings ensures balanced tilt free operation of three material pumps resulting in reduced wear & tear. Mixing ratio is decided by capacity of the 3 cylinders. By simply exchanging any one of the cylinders, new mixing ratio can be accomplished effectively and quickly. Output per cycle up to 500 cc, pressure ratio up to 75:1 and mixing ratio ranging from 1:1 to 10:1 is consummated by this pump. Infact this pump is designed and constructed to achieve most mixing ratios with related parameters as required. These pumps can be equipped with Ø300mm or Ø350mm Air motor. Air Motor has pneumatic sensing and changeover with only two moving parts. It has compact and robust design and easy maintenance. Pneumatic Sensing & Direction Changeover with only two moving parts gives Quick stroke change over & pulsation free output. High durability and life. Less maintenance / Breakdown. Easy for troubleshooting and repair. Less down time in case of breakdown.

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Mixing Block / Manifold

Mixing Block is mainframe mounted. For the applications which have extremely short pot life it can be located directly where the coating is being applied. Both the components that are individually metered and delivered by Two Component Pump, are mixed in this Mixing Block incorporated with numbers of Non Return Valves. Return Line from the Mixing Block goes back to the tank in case of circulated system. VRC designed Mixing Block has following features: It is Equipped with four NRV''s and four pneumatic valves. Very compact and robust. Effective flushing of mixing block and mixed material by two separate solvent valves for base and activator. In case of diverse viscosities and single common solvent valve, solvent may channel by pushing through less viscosity component and keeping higher viscous component in mixing block as well as leaving coating of mixed fluid on the inner tube of hose. This is avoided by providing two individual solvent valves for base and activator Solvent (of previous flush cycle) gets wiped out by spray material in first pass. (Useful for solvent less 2K PU material) All valve seats & balls (including NRV) are in Tungsten Carbide. Easy for maintenance. Modular design of mixing block provides maintenance and cleaning frequency is very low and less downtimes. Manually operated Ball Valves can be provided instead of pneumatic valves with all above design features if desired.

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Mixers - Static / Dynamic

Mostly static mixers are used. These mixers consist of a series of left hand & right hand helical elements. When fluids are pumped through mixer they are progressively divided and recombined. The process is called inversion and results in a layering phenomenon. All contact parts are in Stainless Steel and are rigid, reliable and compatible with heated material. Diameter and length of the mixer depends upon material specifications.

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Flush pump

This is the standard Airless High Pressure Pump with pressure ratio ranging from 40:1 to 60:1 and output per cycle from 70 to 110cc used in Two Component Systems to rinse the whole system. Selection of flush pump depends on material to be flushed and hose lengths.

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Heating system

This may consist of inline fluid heaters, heated supply containers, heated hoses. VRC offers high-pressure inline fluid heaters to heat each individual component to the required temperature. Each heater is available with power 3 KW max, operating pressure 450 bar and temperature up to 100°C.These heaters are compact and rigid. Oil heated Jacketed Containers are offered by VRC to preheat the component individually as per material specification. They are available in different capacities upto 200ltr.These container has power ranging upto 12KW and temperature range up to 100°C. This is controlled and monitored by PID based Control Panel. VRC offers electrically heated hoses where material has to be sprayed at high temparature.In some cases insulated hose can be used instead of heated hose again depending on application, material specification and ambient temperature.

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Feed pump and supply system

Feeding pumps are used to feed the component from supply tank to Two Component pump. VRC offers various feed pumps from its standard pump range depending on the material specifications. Separate feed pumps can be used to transfer material from supplier''s drum to supply containers of Two Component System. Drumpress with Hoisting Unit can be used for transferring high viscous materials. Agitators may also be used depending upon the application and type of the material. VRC offers electrical driven high torque agitator for viscous material. Pneumatic agitator is also available where torque requirement is less.

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Monitoring and control system

The monitoring system is required to keep a check against off mixing ratio of the Two Component system. VRC offers pressure monitoring system; which helps in automatic shut down of the machine. This malfunction may be because of internal / external leakages, material deficiency, damaged seal etc. Automatic ''switching off'' of the system prevents reworks caused due to off mixing ratio. Sophisticated additional controls can be provided as per customer requirements.

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Spray guns

Trigger operated and insulated handle spray guns are used to apply coatings manually. For automatic spraying pneumatically operated automatic guns are used. High-pressure spray gun has working pressure up to 450 bars with carbide seat and needle. For semi solid spray higher seat bore size is recommended.

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