Coating Booklet - Pinellas County Government

Transcript

POLLUTION PREVENTION Surface Coating Operations In Indoor Spray Booths Provided by: Pinellas County Department of Environmental Management Air Quality Division Pollution Prevention Program 300 S. Garden Ave.Clearwater, FL 33756 (727) 464-4422 Publication Date: February 2003 Pinellas County Department of Environmental Management’s V I S I O N The Department of Environmental Management is dedicated to providing responsible leadership necessary to manage our natural and urban environment to meet the needs of our present and future Pinellas County citizens. About this Manual This manual is designed to assist facilities to reduce wastes in surface coating operations when utilizing spray booth systems. Excessive wastes indicate an inefficient use of raw materials and resources. Businesses can minimize the amount of liquid, solid and gaseous wastes they generate by incorporating pollution prevention practices into their operations. This manual is intended to assist the spray booth operator in the following ways: ❇ Identify hazardous wastes associated with spraying operations. ❇ Provide assistance to reduce volatile organic compounds (VOCs) and hazardous air pollutants (HAPs) emissions. ❇ Provide assistance to avoid objectionable odor complaints from nearby residents. ❇ Provide a list of opportunities for waste reduction and tips for efficient spray booth operation. ❇ Provide additional assistance and technical resources. Manuals are developed by the Pollution Prevention and Resource Recovery Section of the Pinellas County Department of Environmental Management, a non-regulatory program that provides waste reduction technical assistance. Program staff provide information on new technologies, process modifications, substitute products, and current industry-specific Best Management Practices (BMPs). Staff can assist businesses in their efforts to become more efficient, profitable, and competitive, while complying with regulatory requirements. As a Pinellas County business, no fees are charged for using the Pollution Prevention Program’s services. On-site waste reduction assistance is available by contacting program staff at (727) 464-4761. Information support for this document provided by New Hampshire Department of Environmental Science Small Business Technical Assistance Program (SBTAP) publication, The Spray Booth Design & Operations Manual. The printing and distribution of this document was funded with Air Pollution Recovery Funds.  Introduction Many solvents used in the coating industry contain volatile organic compounds (VOCs), chemicals that combine and interact with other pollutants to form harmful ground-level ozone known as smog. Many of these individual VOCs are also associated with harmful effects on human health. EPA identifies a list of 188 hazardous air pollutants (HAPs), some of which are VOCs. VOC emissions are regulated under the Federal Clean Air Act (CAA). HAP emissions are regulated under the Federal Clean Air Act Amendments (CAAA). Many safety and environmental regulations affect small business. In addition to environmental regulations, small businesses must adhere to worker protection rules, building codes and fire codes. To determine which of these codes apply to your business, contact your local building and fire departments to determine which codes apply to your business. Contact your local Occupational Safety and Health Administration (OSHA) office for assistance with worker safety and protection rules. Pinellas County’s Pollution Prevention and Resource Recovery Program provides technical assistance to your facility to address environmental concerns. Regulatory requirements have the potential to increase operating costs. Business competition and the costs to produce goods and services continue to rise on an annual basis. By practicing waste minimization you can improve your bottom line while increasing your business’ competitive ability. Best Management Practices (BMPs) and new technologies are available that can offer facilities an opportunity to comply with the regulations and reduce harmful air emissions while saving money and improving efficiency. Waste reduction practices can: ❇ Reduce the use of raw materials. ❇ Minimize the expense of waste disposal. ❇ Reduce the exposure of workers and the general public to hazardous and toxic materials.  ❇ Reduce the threat of product liability. ❇ Maximize compliance with environmental regulations and requirements. What is pollution prevention? Pollution Prevention is the reduction or elimination of pollutants or wastes at the source. The idea behind pollution prevention is to avoid producing the waste in the first place. Preventing waste is easier than incurring treatment and disposal costs. Having less waste means a better environment for all of us. Look at some of the benefits of pollution prevention: ❇ Save money! ❇ Protect workers, the public, and the environment! ❇ Improve your company image! ❇ Reduce the risk of liability! Many pollution prevention practices are low-cost and low-risk alternatives to help minimize waste, and the resulting disposal costs. Wastes Associated With Coating Operations Each step in the coating process produces wastes and emissions. The following table summarizes the wastes from each coating procedure. COATING PROCESS MATERIALS COMMONLY USED Product Materials All materials in this column Surface Preparation Abrasives Solvents Alkaline Solvents Water  WASTESTREAMS CREATED Spills VOC/HAP emissions Leftover Paint Out-of-Date Product Ground abrasives (e.g. sand) Metal fines Spent solvents Alkaline solutions Wastewaters Sludge and metals VOC/HAP emissions Containers COATING PROCESS MATERIALS COMMONLY USED Paint Applications Paints Thinners Brushes Rollers Equipment Cleaning Solvents Alkaline solutions WASTESTREAMS CREATED Paint scraps/dust particles Paint sludge Filters Scrubber water Rags Brushes Rollers Spent Solvents VOC/HAP emissions Lead, nickel, & chromium wastes (depending on paint formulation) Containers Wastewater Spent solvents Paint sludge Alkaline solution VOC/HAP emissions Containers Air Emissions As a spray booth facility operator, you are responsible for acquiring the necessary permits for any air pollutants you produce. Pinellas County Department of Environmental Management Air Quality Division’s Compliance and Enforcement section can provide you with guidance on operations that require permits for air emissions based on overall emissions, specific device or pollutant. Many wastes are released into the air through fugitive dusts, evaporation, combustion processes, or otherwise. Many of these chemicals are regulated and require air permits depending on the amount released into the air. This includes particulates, sulfur dioxide (SO2), carbon monoxide (CO), nitrogen oxides (NOx), chlorofluorocarbons (CFCs), volatile organic compounds (VOCs), and hazardous air pollutants (HAPs).  The Environmental Protection Agency (EPA) estimates VOC emissions from spray booth operations to be: 8% from surface prep 17% from undercoats 20% from equipment cleaning and 55% from topcoats Your facility’s operations may be classified as a major source if your facility emits or has the potential to emit more than 10 tons per year of a single HAP or 100 tons per year of VOCs. Hazardous Wastes A waste is considered a hazardous waste if: 1) It has any one or more of the following characteristics: Ignitable (D001) Ignitable wastes are easily combustible or flammable. They have a flashpoint of less than 140°F or an alcohol content of 24% or more. (The flashpoint is the lowest temperature at which the vapor of a combustible liquid can be made to ignite in air.) Corrosive (D002) Corrosive wastes are liquids that dissolve metals and other materials, or burn the skin. They have a pH of 2 or lower, or 12.5 or higher. Reactive (D003) Reactive wastes are unstable and react rapidly or violently to shock, heat, or pressure, or when mixed with water or other materials. Toxic (D004) Toxic wastes generally have adverse health effects. They need only contain a small amount of a certain material such as heavy metals or toxic organics. OR 2) It is listed as a hazardous waste in the Code of Federal Regulations, 40 CFR Part 261. This list is very long and may include chemicals that you use daily. If you are unsure, it is suggested that you refer to the list cited and have your waste tested by an approved laboratory.  Handling and Disposal of Hazardous Wastes The proper handling of hazardous wastes is critical in assuring the health and safety of the public and protection of the environment. Some important things to remember are: ❇ Never pour waste fluids on open ground, in storm drains, or down shop drains. ❇ Never mix hazardous and nonhazardous wastes. Even a little hazardous waste can make the entire mixture hazardous and more expensive to dispose of properly. Containers ❇ Maintain containers in good condition. Prevent leaks, ruptures and the accumulation of rainwater on the top of drums. ❇ If a container leaks, transfer all of the waste to a new container. ❇ Keep lids on, and containers closed, when not in use. ❇ Use funnels when pouring liquids. ❇ Use containers that are compatible with the waste being stored. ❇ Do not mix different or incompatible wastes in the same container. Labels Proper labeling can reduce accidents and ensure proper disposal. The example of a label below shows some of the information that should be included. HAZARDOUS WASTE (or NON-HAZARDOUS WASTE) FEDERAL LAW PROHIBITS IMPROPER DISPOSAL If found, please contact the nearest police or public safety authority or the U.S. EPA (the date when waste was first put in the drum)  Waste Storage Areas ❇ Try to store all hazardous wastes in a single area, however do not store incompatible materials beside each other. Satellite collection points are allowed for work-in-progress, but should be moved to the main storage area once the container is filled or not in use. ❇ Wastes should be stored in a covered area to prevent stormwater runoff and protect the containers from weather exposure. ❇ Secondary containment should be provided that is able to contain at least 110% of the largest container’s capacity in case of leaks, spills, or punctures. It should have an impermeable (sealed) surface and should be under cover, preferably indoors. ❇ Ensure that there is sufficient aisle space between drums to allow complete inspection for leaks or damage. ❇ Check with the local Fire Department for their requirements. Transportation and Disposal ❇ Hazardous waste must be shipped out by a properly permitted hauler to an EPA-approved treatment, storage, and disposal facility. Check for all the proper local, state, and federal licenses. ❇ Use reputable permitted companies for transport and disposal. You are forever liable for any hazardous waste that you generate; a “cradle-tograve” liability. Even if you have proper documentation, you may still be a potentially responsible party to a clean-up if your waste contributes to the contamination of the environment. Inspections and Record Keeping ❇ Keep all records of hazardous waste handled for at least three (3) years on-site. This includes amounts purchased, stored, reused, and hauled away. ❇ Keep records of lab tests for at least three (3) years.  ❇ Keep land disposal restriction forms for at least five (5) years. ❇ Inspect storage containers and areas for leaks or damage at least once per week and maintain a written inspection log on-site for at least three (3) years. ❇ Keep any training records for at least three (3) years. ❇ An EPA identification number should be obtained by any facility generating a hazardous waste, unless officially classified as a “Conditionally Exempt Small Quantity Generator.” Contact the address below: Florida Department of Environmental Protection Southwest District Hazardous Waste Management 3804 Coconut Palm Dr. Tampa, FL 33619-8318 (813) 744-6100 Regulated Non-Hazardous Wastes Although not classified federally as a hazardous waste, there are many materials that are stringently regulated in Pinellas County. When in doubt, treat a material as a hazardous waste until you are able to verify that it is not, and then determine what are the correct handling and disposal measures. A common example of this type of non-hazardous waste is used motor oil. Hazardous Materials Although less stringently regulated than hazardous wastes, the proper storage and handling of hazardous materials is equally important. Many of the storage and handling practices described above for hazardous wastes should, and in some cases must, be applied to hazardous materials as well. This includes certain labeling and spill prevention measures. ❇ Store on an impermeable (sealed) surface, i.e. resists infiltration or corrosion by the stored materials. ❇ Store under cover, whether indoors or outdoors, to keep out the rain. Be sure containers are properly sealed. ❇ Provide secondary containment that will hold up to 110% of the largest container stored in the area. This area should be able to contain any leaks or spills. ❇ Label containers properly, including contents and date of generation for any hazardous wastes. ❇ Make sure drums are easily accessible but not stored in high traffic areas where they can be easily knocked over. Regularly check for any signs of leakage, rust, etc. The ABCs of Spray Booths A properly designed spray booth is an important piece of equipment to any spraying/coating operation. A properly designed spray booth combined with good spray operator technique will not only protect the environment, but will also reduce operating costs. Savings can result from reduced overspray, decreased paint usage, reduced disposal fees resulting from the decrease in wastes generated, and compliance with environmental, health and safety regulations. Non-compliance can be costly. Objectionable Odors A poorly designed paint booth may result in objectionable odor complaints from nearby residents. Periodically assess your booth to avoid such complaints. Common assessment approaches include surveying and identifying stack odors, surveying nearby properties and air dispersion modeling. Factors such as ventilation, design, stack location in relation to nearby buildings, stack height, capture efficiency, stack obstructions (certain rain caps), final discharge velocity, and local weather conditions can all effect the dispersal of air contaminants. These factors are discussed in detail later in this booklet. Your booth design should consider local weather conditions. For example, humid air and strong winds help disperse odors. On a windless day, odors may linger in the area and be more noticeable. Odor complaints may occur more frequently during the summer months when more people are outdoors. Consider these factors into your spray booth design. Safety and Fire Codes Your surface coating operations must adhere to health and safety regulations and fire codes to minimize the physical and health hazards associated with the materials used. To determine which codes and building requirements apply to your business, contact your local building and fire departments for assistance. A list of local fire and building departments is available in the Resources section of this booklet. As required in OSHA Standard 29CFR 1910.94(c)(3)(i), “Spray booths shall be designed and constructed in accordance with 1910.107(b)(1) through (4) and (6) through (10) (see sections 301-304 and 306-310 of the Standard for Spray Finishing Using Flammable and Combustible Materials, NFPA No. 33-1969), for general construction specifications”. Pre-manufactured or Custom Built Spray Booth? Regardless of which type of paint booth you are using or plan on using, a properly designed spray booth should collect overspray and remove solvent fumes from the work place through a ventilation system and then exhaust vertically through a stack, away from employees and nearby buildings. As with any equipment choice, there are advantages and disadvantages to each type of booth. Both booths require extensive planning to determine which system and features best meet your operational needs. The cost of a custom-built booth could exceed the cost to purchase a pre-manufactured booth once you factor in materials, compliance issues, and the time of an engineer or design professional to help you design your booth. If the booth is improperly constructed, the resulting poor quality finish and environmental issues could cost you money in the competitive market of surface coating. Time spent researching your options is time well spent. With pre-manufactured booths, you have the option to buy or lease the booth. The booth design information in this manual is only a general guide with the intention of minimizing the impact of spray operations on the environment.  Keep in mind that the spray booth you use must meet the construction and operation requirements of the Occupational Safety and Health Administration (OSHA 29 CFR 1910.94, 1910.107, 437-02-081,437-02-102), the National Fire Protection Association (NFPA 33-1989), and Uniform Fire Code (UFC Art. 45 -1991). In addition, before acquiring a spray booth, you should consult your local building and fire departments to meet their codes. Ventilation The cost of a spray booth system is directly related to the efficiency of ventilation. Ventilation is a common problem in spray booths. Improper ventilation can result in some chemicals reaching their combustible thresholds, which can result in their ignition if a spark occurs, odor complaints from nearby neighbors, and increased worker and community pollutant exposures. The spray booth ventilation system should: ❇ Provide enough circulation to remove airborne particles and prevent them from settling on the finish. ❇ Maintain a concentration of explosive volatile chemicals below 25 percent of their lower flammable limit (LFL) to prevent explosion or combustion. ❇ Maintain airborne concentration of HAPs and VOCs below occupational exposure levels to protect the employee. ❇ Vent pollutant-containing exhausts above the roofline, away from building influences, your facility and nearby buildings. Air movement within the booth should be enough to remove overspray, but should not affect transfer efficiency. The placement of inlet and outlet vents should allow for maximum airflow efficiency. Determine the recommended flow rate and fan capacity of your booth design for adequate air movement (a ventilation consultant can determine if your design provides the proper airflow). Additional technical information on industrial ventilation is available in the latest edition of Industrial Ventilation: A Manual of Recommended Practices, published by the American Conference of Governmental Industrial Hygienists (ACGIH).  There are three main types of spray booth ventilation systems. AIR FLOW Down draft Most expensive to build and maintain due to ducts in the ceiling and in the floor; however, provides the best decrease in curing time and increase in productivity. AIR FLOW Semi down draft Second best for efficiency of ventilation. Cross draft AIR FLOW Least expensive and least effective in ventilation control. OSHA Standard 29 CFR 1910.94(c)(6)(i), addresses air velocities and ventilation: “Except where a spray booth has an adequate air replacement system, the velocity of air into all openings of a spray booth shall be not less than that specified in Table G-10 for the operating conditions specified. An adequate air replacement system is one which introduces replacement air upstream or above the object being sprayed and is so designed that the velocity of air in the booth cross section is not less than that specified in Table G-10 when measured upstream or above the object being sprayed.”  TABLE G-10 - MINIMUM MAINTAINED VELOCITIES INTO SPRAY BOOTHS Operating conditions for objects completely inside booth Electrostatic and automatic air-less operation contained in booth without operator. Air-operated guns, manual or automatic Air-operated guns, manual or automatic Crossdraft, f.p.m. Negligible Up to 50 Up to 100 Airflow velocities, f.p.m. Design Range 50 Large booth 100 small booth 100 large booth 150 small booth 150 large booth 200 small booth 50-75 75-125 75-125 125-175 125-175 150-250 Note: Crossdrafts can be eliminated through proper booth design. OSHA Standard 29 CFR 1910.107(b)(5)(i) requires that “spraying operations except electrostatic spraying operations shall be so designed, installed and maintained that the average air velocity over the open face of the booth (or booth cross section during spraying operations) shall be not less than 100 linear feet per minute. Electrostatic spraying operations may be conducted with an air velocity over the open face of the booth of not less than 60 linear feet per minute, or more, depending on the volume of the finishing material being applied and its flammability and explosion characteristics.” Spray Equipment P2 Options Spray equipment options have come a long way since the days of conventional spray guns with a typical transfer efficiency of 35%. Transfer efficiency is a measurement of how well the spray equipment applies the coating to the substrate. A 35% transfer efficiency meant 65% of your spray product was lost in overspray. A higher transfer efficiency equals less overspray, less mist exposure to painters, less emissions to the community and increased economic savings in product. The transfer efficiency of paint spraying equipment varies. The following technologies are just a few examples of coating technologies with higher transfer efficiencies than conventional equipment:  Electrostatic: ❇ ~ 65-80% transfer efficiency. ❇ Electrostatic charge is applied to the coating or applicator tip by air or centrifuge, through bells or spinning discs. ❇ Centrifugally, transfer efficiency can be as much as 85-95%. ❇ Commonly used for metals, but can be used for other non-conductive materials with the application of a special charge-conducting primer. High Volume Low Pressure (HVLP): ❇ ~ 70% transfer efficiency. ❇ Uses high volume, low pressure to apply the coating. ❇ Can be equipped with pressure assist cups. ❇ May be gravity fed or siphon fed. ❇ Runs usually around 10 psi, depending on manufacturer’s recommendations. Roller/Curtain Coating: ❇ ~ 90-98% transfer efficiency. ❇ Products on a conveyor pass under a 90° vertical curtain. ❇ Works best for flat or flexible surfaces. Tumbling, Barreling & Centrifuging: ❇ Substrate parts are rotated in a coating. ❇ Commonly used for painting large number of small items. ❇ Experience and training are critical to the success of this application technology. Powder-coating: ❇ ~ 90-99% transfer efficiency. ❇ Two methods of application electrostatic charge or fluidized bed. ❇ Powder-coating can be given a positive electrostatic charge, then applied to grounded work pieces with a compressed air gun. ❇ Heat curing required. ❇ Powder that does not adhere can be collected and re-used.  ❇ Provides uniform thickness to even complex surfaces. ❇ In fluidized bed powder-coating, the part to be coated is heated, placed in a powder reservoir, air is passed through the reservoir to fuse the powder to the product and curing occurs in a conventional oven. ❇ Powder-coating produces almost no VOC emissions. Training, maintenance and good application technique are the keys to achieving higher transfer efficiency with all of these technologies. Before you decide on a spray system: ❇ Determine your spray equipment budget. ❇ Determine the types of coating you will be applying and the atomization requirements for their proper application. ❇ Choose the spray equipment within your budget that meets your coating atomization requirements. ❇ Before buying any paint guns, consult your coating representative to determine what type will work best with your product. ❇ Contact your coating representative or the spray gun manufacturer to determine the proper fluid tip/air combination and gun settings that should be used with your coatings. ❇ Complete proper spray technique training and maintenance for the purchased equipment. Filter Exhaust Systems Improper use of filters can contribute to the accumulation of residues within ventilation system components, creating a fire hazard. Spray booths should pass extracted air through an efficient filtering system to remove paint particulates. Exhaust systems may use either a dry-filter or water wash filter system. Dry-filter A dry-filter exhaust system passes contaminated air through dry-filters to remove particulates. The filters should be changed on a regular basis or when the air pressure falls below an acceptable level for efficient operation. If the filters are not changed when saturated or the in-flowing air is not adjusted, the  contaminated air particles may settle out onto the painted product. Decreasing the in-flowing air may cause inadequate air circulation and additional problems. Dry-filters are available in several designs (e.g. baffle to increase surface area capture). Washable and reusable metal or styrofoam filters are available. When using a dry-filter system: ❇ Choose the correct dry-filter designed for the sprayed materials you are collecting (suppliers of both the spray material and the filters can provide information on different materials’ effects on filters). ❇ Do not use filters made of combustible materials. ❇ Check that the each filter fits snugly in the support frame spaces. ❇ Monitor static pressure drops across the filter with a dial gauge or manometer to determine when filters need changing. ❇ Follow the filter manufacturer’s recommendation for the amount of air movement necessary to maintain maximum filtration efficiency. ❇ Keep extra filters on hand. ❇ Test disposable “dry” paint booth filters periodically to determine if they are hazardous waste. Water Wash or Wet Scrubber A water wash booth uses water jets or curtains instead of dry filters to act as a filter. The used water is treated and reused again. The water wash booth requires frequent maintenance and can result results in high disposal costs. If a wet scrubber or water wash system is used to remove paint particles and solvent vapors. ❇ Check the spray nozzles regularly for proper operation. ❇ Maintain the correct water level to adequately filter exhaust air. ❇ Check water curtains regularly to verify that the water is re-circulating. ❇ Check the make-up water float level periodically. ❇ Check that the water curtain remains continuous all the way across the wall of the booth with no flow inconsistencies.  ❇ Install a manometer to monitor negative pressure between the entrainment and distribution plates. ❇ Follow the supplier’s recommendations for maintenance (e.g. water, alkali, oil amounts). A common misconception among booth operators is that typical paint booth filters will remove the VOCs from the air wastestream. These filters only remove the particulates, not the VOCs, which are most often the basis for objectionable odor complaints from neighbors. Adding an activated carbon adsorber cartridge to your filter system will capture solvents. The cartridge can be regenerated, used again and the collected solvent can be recycled. Your booth may also be equipped with removable baffle plates. These plates should be constructed of non-combustible materials. They should not be located in the exhaust ducts, but rather installed before the ducts to capture overspray before exit. Such baffle plates are easily removed for cleaning and allow for even distribution of air flow. Evaluating Your Paint Booth Spray booth operators can use the following checklist to assist them in evaluating booth construction, maintenance and proper operation. Spray Area ❒ Are the walls and ceilings in the enclosed spray area constructed of non-combustible or limited-combustible materials? ___Yes ___No ___NA ❒ Is the spray area free of hot surfaces? ___Yes ___No ___NA ❒ Do you periodically test for air leaks? (latex-based or similar sealants can be used to minimize leakage) ___Yes ___No ___NA ❒ Is the interior spray area surface smooth and designed to prevent air pockets? (air pockets can trap residues and result in poor ventilation) ___Yes ___No ___NA ❒ Is the spray booth separated from other operations by not less than 3 feet? ___Yes ___No ___NA ❒ Are booth doors closed during spraying operations? ___Yes ___No ___NA  Windows ❒ Are windows airtight? (windows should not be used for ventilation) ___Yes ___No ___NA ❒ Do windows prevent the uncontrolled release of vapors, mists and residues? ___Yes ___No ___NA ❒ Are windows fire-rated? ___Yes ___No ___NA Ventilation ❒ Does the mixing room or mixing area have a small vent fan installed to prevent the build-up of fumes? ___Yes ___No ___NA ❒ Is a filter part of the air intake to prevent dust and other particles from affecting the finish? ___Yes ___No ___NA ❒ Do exhaust filters fit snugly with no gaps between the filter and the housing? ___Yes ___No ___NA ❒ Are filters replaced often? ___Yes ___No ___NA ❒ Are filters disposed of properly? (if considered hazardous wastes, the filter cannot be thrown away in the regular dumpster) ___Yes ___No ___NA ❒ Is fresh make-up air supplied to the booth to compensate for air exhausted from spraying operations? (air should not be re-circulated in a booth) ___Yes ___No ___NA ❒ Is mechanical ventilation operating at all times during spraying operations and for a sufficient amount of time after to allow flammable vapors and residue to be exhausted? ___Yes ___No ___NA ❒ If you have an automated spray application system, is the system set up so that spray cannot be applied unless exhaust fans are operating? ___Yes ___No ___NA ❒ Does the total air volume exhausted dilute solvent vapor to at least 25 percent of the lower explosive limit of the solvent being sprayed as required in OSHA 29 CFR 1910.94(c)(6)(ii)? ___Yes ___No ___NA ❒ Is the average air velocity over the open face of the booth not less than 100 linear feet per minute? ___Yes ___No ___NA  Exhaust Stack ❒ Is the exhaust stack vented from the top? ___Yes ___No ___NA ❒ Are visible emissions not observed from the stack exhaust? ___Yes ___No ___NA ❒ Does the exhaust stack size and shape match the fan capacity of the spray booth in order to ensure efficient operation? (capacity is measured in cubic feet per minute - cfm) ___Yes ___No ___NA ❒ Is final discharge from the stack vertical with no obstructions? (standard rain caps, china caps, etc. can obstruct airflow which can limit proper dispersal of emissions, increase worker and community exposures and may result in odor complaints from nearby neighbors) ___Yes ___No ___NA ❒ Is stack height sufficient to adequately disperse contaminants so as not to create a pollutant hazard or odor problem for surrounding properties? (sufficient stack height can be determined using air pollution dispersion modeling) ___Yes ___No ___NA ❒ Is stack height sufficiently higher than the roof ridge to disperse the stack emissions rather than draw contaminants down to the ground?___Yes ___No ___NA ❒ Is the final discharge velocity sufficient to adequately disperse air contaminants from spray operations? ___Yes ___No ___NA Heating and Curing ❒ Does the booth maintain the correct heat and ventilation balance to achieve optimum curing conditions? ___Yes ___No ___NA ❒ Is the heating system for makeup air located outside of the spray booth? ___Yes ___No ___NA ❒ Is the spray booth completely ventilated before using the drying apparatus? ___Yes ___No ___NA ❒ Is infrared drying apparatus kept out of the spray area during spraying operations? ___Yes ___No ___NA ❒ Is the drying apparatus properly grounded? ___Yes ___No ___NA  ❒ Do all drying spaces have mechanical ventilation? ___Yes ___No ___NA ❒ Do all drying spaces have adequate ventilation? ___Yes ___No ___NA Fire Extinguishing System/Safety ❒ Does both the spray booth area and the mixing room/area have an approved automated fire extinguishing system? ___Yes ___No ___NA ❒ Does the automated system activate a local alarm in the spray operation area? ___Yes ___No ___NA ❒ Does the automated system activate the overall facility alarm? ___Yes ___No ___NA ❒ Does the system stop all automated processes in the spray booth area and mixing area? (conveyors, coating delivery system, application equipment, ventilation system) ___Yes ___No ___NA ❒ Is the spray area at least twenty feet from flames, sparks, operating electrical motors and other ignition sources? ___Yes ___No ___NA ❒ Are portable lamps used to illuminate spray areas suitable for use in a hazardous location? ___Yes ___No ___NA ❒ Is approved respiratory equipment provided and used when appropriate during spraying operations? ___Yes ___No ___NA ❒ Do solvents used for cleaning have a flash point to 100°F or more? ___Yes ___No ___NA ❒ Do you avoid spraying materials that may be incompatible with each other? ___Yes ___No ___NA ❒ Are fire control sprinkler heads kept clean? ___Yes ___No ___NA ❒ Are “NO SMOKING” signs posted in spray areas, paint rooms, paint booths, and paint storage areas? ___Yes ___No ___NA ❒ Is the spray area kept clean of combustible residue? ___Yes ___No ___NA ❒ Are lighting fixtures for spray booths located outside the booth and the interior lighted through sealed clear panels? ___Yes ___No ___NA  ❒ Are the electric motors for exhaust fans placed outside booths or ducts? ___Yes ___No ___NA ❒ Are belts and pulleys inside the booth fully enclosed? ___Yes ___No ___NA Operation/Maintenance ❒ Do you check that your pressure drop gauge is zeroed each time before operating your booth? ___Yes ___No ___NA ❒ Do you check your entire ventilation/exhaust system for proper operation before spraying? ___Yes ___No ___NA ❒ Is there a visible gauge, audible alarm, or pressure-activated device installed to monitor that the required air velocity is maintained? ___Yes ___No ___NA ❒ Do ducts have access doors to allow cleaning? ___Yes ___No ___NA ❒ Are at least three sides of the booth kept free from storage or combustible material? ___Yes ___No ___NA ❒ Are you performing pressure drop readings, filter changes, visual observations of filter media condition, and other manufacturer recommended booth maintenance? ___Yes ___No ___NA ❒ Do you record all maintenance activities on a maintenance log? ___Yes ___No ___NA P2 Opportunities in Surface Coating Operations There are many opportunities to reduce wastes generated from coating operations. Surface Preparation ❇ Paint in dedicated, separate, and secure areas with no floor drains. ❇ Consider mechanical paint stripping methods such as sand, glass, garnet, CO2 or plastic bead blasting instead of conventional chemical stripping methods. ❇ Use a sander with a dust collector to remove paint instead of stripping. This removes paint and metal dust from the air and reduces use of hazardous chemicals. Consider using a vacuum sander instead of a  pneumatic sander. Vacuum sanders reduce worker exposure to dust, time spent cleaning dust off the floor, and cars. There is also less chance that dust will settle on newly painted cars. ❇ Sweep up filler dust separately, collect in disposable bags and dispose of it in the dumpster. Don’t mix filler dust with paint waste or sludge because this can increase the weight of your hazardous waste. ❇ Inspect parts before painting to be sure they are clean, dry and rust-free. ❇ Use the least amount of masking tape and paper as possible. Reduce prep wastes and labor by using spray on, peel off booth compounds. Product Materials ❇ Use waste paint as a rough coat for undercoating or other applications. ❇ Use neutral color primers and sealers to allow easy topcoat coverage. ❇ Rotate paint stocks, using the oldest first. Computerize inventory control to prevent materials from expiring. Consider having a computerized paint mixing system. ❇ Mix only the amount of paint needed. Keep records of the amount of paint needed for specific jobs for future reference. Spray paint in large batches of the same color and type to reduce the number of times a gun must be cleaned. ❇ Consider use of water-based paints over organic-based paints to reduce the amount of hazardous waste generated. When possible, use paints that do not include heavy metals. ❇ Use non-phenol strippers to reduce toxicity due to phenols and acid additives. Use enamel-based paints rather than lacquer-based paints because enamels have less solvent, reducing air pollution emissions. ❇ Enamels are less likely to react with fiberglass filler. ❇ Use paints with low volatility, lower metal concentrations, and higher solid content when possible. ❇ Warming paint mixtures may reduce the amount of thinner required. ❇ Purchase paints in recyclable or returnable containers to reduce disposal costs.  ❇ Review Material Safety Data Sheets (MSDS) of each product to assist in selecting least hazardous products. Paint Applications ❇ Use more efficient painting processes (e.g. electrostatic painting or powder-coating) when possible to reduce the amount of paint overspray and paint waste generated. ❇ Use high volume, low pressure (HVLP) or low volume, low pressure (LVLP) spray guns to increase transfer efficiencies and reduce worker exposure to overspray. ❇ Regularly calibrate paint transfer equipment to maintain proper application rates and reduce waste. Properly regulate the air supply to spray guns. ❇ Reduce the paint cup size on spray guns to reduce the amount of wasted paint. Scrape out dried paint in the paint cup instead of using paint thinner. Purchase several sizes of paint cups for different size jobs. ❇ Use refillable, air-powered spray paint containers to replace aerosol spray cans. These work especially well for small touch-up jobs. Equipment Cleaning and Clean-up ❇ Clean spray guns and nozzles immediately after painting before waste builds up and hardens. ❇ Use recycling spray gun washers to reuse solvent and reduce the amount of waste generated. ❇ Reuse cleaning solvents until they are too dirty for cleaning. Clean spray guns and equipment frequently for efficient paint transfer. ❇ Pour any unusable paints into a special closed container marked “Waste Paint”. ❇ Do not intentionally evaporate paint wastes as a means of disposal. ❇ Do a hazardous waste determination on paint overspray paper and paint filters and dispose of them accordingly. ❇ Totally enclose your spray gun during cleaning or flush solvent through the gun into a container that is immediately sealed to reduce air emissions.  ❇ Do not spray paint gun cleaner solvent onto the paint filters. Spray it into a container, and then add to the “Waste Paint” container for disposal, or reuse the solvent as thinner or as an ingredient in a followup paint job. A Final Consideration... One of the easiest and least expensive ways to reduce your wastes is keeping your shop clean. Poor housekeeping results in spills and overflows. This may double your expense by making you pay to replace lost material and also for its treatment and disposal. It can also lead to accidents and worker injury. Here are some tips: ❇ Keep your shop clean and your floors dry. Sweep floors and use dry or damp clean-up techniques. For example, use absorbent material for spills and if necessary, use a very small volume of water for final cleanup. This material should then be disposed of properly. ❇ Clean up all spills immediately. ❇ Practice good inventory control. Mark the purchase date on containers and adopt a “first in, first out” policy, so that older materials are used up before new ones are bought. ❇ Buy only the amount of materials needed. Buy materials in small quantities if only small amounts are required. ❇ Tightly seal all coating and solvent containers when not in use. ❇ Store all solvent-containing wastes in tightly sealed containers until disposal. ❇ Store solvent rags in approved tightly sealed containers when not in use. ❇ Keep the most current MSDS for materials used in an area for easy employee access.  For additional assistance on waste reduction in your coating operations, refer to the following Resources Section of this manual. Resources Fire Departments Belleair Bluffs:..........(727) 584-8392 Pinellas Park: ............(727) 541-0712 Clearwater:................(727) 462-4334 Pinellas Suncoast: .....(727) 595-1117 Dunedin:....................(727) 298-3102 Safety Harbor:...........(727) 724-1520 East Lake:..................(727) 784-8668 St. Pete Beach: ..........(727) 363-9207 Gulfport:....................(727) 893-1062 St. Petersburg: ...........(727) 893-7694 Largo:........................(727) 587-6714 Seminole: ..................(727) 393-8711 Lealman: ...................(727) 526-5650 S. Pasadena: ..............(727) 344-1666 Madeira Beach: .........(727) 391-3400 Tarpon Springs: .........(727) 938-3737 Oldsmar:....................(813) 855-1059 Treasure Island:.........(727) 547-4590 Palm Harbor: .............(727) 784-0454 Florida Forestry:........(941) 648-3168 Building Departments Belleair Beach:..........(727) 464-3168 Madeira Beach: .........(727) 391-9951 Belleair Bluffs:..........(727) 584-2151 N. Redington Bch: ....(727) 391-4848 Belleair Shore: ..........(727) 593-9296 Pinellas Park: ............(727) 541-0752 Belleair Town:...........(727) 588-3769 Redington Beach:......(727) 391-3875 Clearwater:................(727) 562-4567 Redington Shores:.....(727) 397-5538 Dunedin: ...................(727) 298-3202 Safety Harbor:...........(727) 724-1515 Gulfport: ...................(727) 893-1000 St. Pete Beach: ..........(727) 363-9240 Indian Rocks Bch:.....(727) 596-4759 St. Petersburg: ...........(727) 893-7231 Indian Shores: ...........(727) 595-4020 Seminole: ..................(727) 393-8711 Kenneth City:............(727) 544-2564 S. Pasadena: ..............(727) 343-4192 Largo:........................(727) 587-6711 Tarpon Springs:.........(727) 942-5617 Oldsmar: ...................(813) 855-2730 Treasure Island:.........(727) 547-4575  Assistance Centers and Information Sources Pinellas County Department of Environmental Management, Air Quality Division:..............................................................(727) 464-4422 Household Electronics and Chemical Collection Center 24 hour Hotline: .....................................................................(727) 464-4623 Utilities/Solid Waste:.................................................................(727) 464-7500 State of Florida Department of Environmental Protection Main Switchboard: ..............................................................(813) 744-6100 Hazardous Waste Compliance Assistance Program: .................(800) 741-4337 Emergency State Warning Point:...............................................(800) 320-0519 Florida Small Business Assistance Program: ............................(800) 722-7457 Pollution Prevention Information Clearinghouse: .....................(202) 260-1023 Earth’s 911 for Community Assistance: ....................................(800) 947-3873 Southern Waste Information Exchange (SWIX): ......................(800) 441-7949 United States Environmental Protection Agency Region IV, Atlanta:.................................................................(404) 562-9900 Small Business Assistance Ombudsman: ..................................(800) 368-5888 Waste Reduction Resource Center: ...........................................(800) 476-8686 Education and Outreach: ...........................................................(800) 241-1754 RCRA/Superfund Hotline: ........................................................(800) 424-9346 Occupational Safety and Health Administration (OSHA):........(813) 626-1177 Recycling Hotline:.....................................................................(800) 947-3873 Internet Sites Coating Alternatives Guide (CAGE): http://www.cage.rti.org/ Assists in selecting alternative coatings and coatings equipment. Chemical Coaters Association International: http://www.finishing.com Surface finishing industry’s educational and networking association. Corrosion Coatings and Lining Information Server: http://www.corrosion.com/index.html Information on products and services. EPA’s Enviro$en$e: http://es.epa.gov/index.html Site provides pollution prevention, compliance assurance, and enforcement information and data bases.  National Paint and Coating Association (NPCA): http://www.paint.org Voluntary, non-profit trade association Occupation Safety and Health Administration (OSHA) Home Page: http://www.osha.gov Site provides useful information and regulations pertaining to health and safety issues related to the spray booth industry Products/Vendors This list of resources does not constitute endorsement of any of the companies or products by Pinellas County Department of Environmental Management. Additional listing of products/vendors may be available in your local phone book or yellow pages or through your professional associations. The information is provided to you as a resource and is not intended to promote any one product or vendor. As the facility, you have the expertise to evaluate which product or alternative will best meet your production needs. Spray Equipment American Icon Auto Paint & Supplies: ..................................(727) 521-2478 4641 Lown Street North St. Petersburg, FL 33714 Chuck Chandler’s Tarpon Paint Equipment:..........................(727) 938-7511 315 Pinellas Avenue South Tarpon Springs, FL 34689 Collins Meyer & Company Inc: ............................................(727) 530-9426 6200 147th Avenue South Clearwater, FL 33760 E N G Manufacturing Inc: ....................................................(727) 942-3868 716 Wesley Avenue Tarpon Springs, FL 34689 Howard Industrial Machine: ..................................................(727) 538-2215 1255 Starkey Road Largo, FL 33777  Phoenix Equipment Company: ..............................................(727) 536-0868 8080 Ulmerton Road Largo, FL 33777 Scargill’s Equipment Service Inc: ..........................................(727) 577-5508 3899 Ulmerton Road Clearwater, FL 33762 Sherwin-Williams Co:............................................................(727) 942-1868 39920 US Hwy 19 North Tarpon Springs, FL 34689 Scott Paint: ............................................................................(727) 461-0511 532 South Missouri Avenue Clearwater, FL 33765 U-Spray Systems Inc: ............................................................(727) 547-1162 10461 75th Street North Largo, FL 33777 Universal Coatings & Supplies: ............................................(727) 561-0440 12003 49th Street North Clearwater, FL 33762 Paint Booth Filters ITW Industrial Finishing: ....................................................(800) 99-BINKS 195 Internationale Boulevard ....................................http://www.binks.com Glendale Heights, IL 60139 Fabtech: ..................................................................................(866) 244-2468 170 Wilbur Place, Suite 12 ........................http://www.trktech.com/fabtech Bohemia, New York 11716 Finishmaster:..........................................................................(727) 531-7701 6460 126th Avenue North Largo, FL 33771  American Icon Auto Paint & Supply: ....................................(727) 521-2478 4641 Lown Street North St. Petersburg, FL 33714 Paint Spray Gun Cleaners Bonny Marlin, Inc: ................................................................(301) 869-9830 17700 Muncaster Road ....................................http://www.bonnymarlin.com Rockville, MD 20855 (Self-contained spray gun cleaner and solution recycler: Manufacturer claims system is non-flammable, free of solvents, generates zero hazardous wastes, free of hazardous air pollutants, non-toxic, recyclable and biodegradable) Qt CrystaLac Spray Gun Cleaner: ........................................(800) 443-7937 McFeely’s Square Drive Screws ............................http://www.mcfeelys.com 1620 Wythe Rd / PO Box 11169 Lynchburg, VA 24506-1169 Automatic Spray Gun Cleaner: ............................................(727) 535-4051 RM Andress & Associates ..........................................or cell (727) 698-0774 12500 84th Way N. Largo, Fl 33773 Double Spray Gun Cleaner: ................................................ (866) 943-7524 HandsOnTools ................................................http://www.handsontools.com 3705 New Macland Rd. Suite: 200-212 Powder Springs, GA 30127   NOTES  The P2 rogram can provide additional resources regarding project funding, energy efficiency, product/equipment technology, and technical assistance. For information, contact our program at (727) 464-4422. The program was developed to minimize the amount of liquid, solid, and gaseous pollution as well as energy & water consumption within Pinellas County. If you are interested in the economic & environmental benefits of reducing wastes in your business, please contact the P2R2 Section at (727) 464-4422.  The P2 Program's mission is to minimize the amount of liquid, solid and gaseous pollution as well as energy & water consumption within Pinellas County. For any additional information, please contact the Pinellas County Department of Environmental Management Pollution Prevention and Resource Recovery Program at (727) 464-4422. Pinellas County Department of Environmental Management 512 S. Ft. Harrison Avenue Clearwater, FL 33756 www.pinellascounty.org Printed on Recycled Paper Pinellas County complies with the Americans with Disabilities Act. To obtain accessible formats of the document, please contact the Department of Environmental Management at: (727) 464-4761/TDD (727) 464-4106