Processing Nu-Seal - Efficiency Vermont · · 2016-02-04This presentation and the related handout material is ... Introduction •Where does Processing fit in to an SPF project

2/3/2016

1

ABX 2015 Henri Fennell, CSI/CDT

Henri is an architect and building envelope specialist with over forty years of experience in the construction industry. He was a pioneer in the solar industry, introduced the installation technique for field-applied closed-cell closed-cavity-fill polyurethane foam and has designed and constructed a net-zero energy research structure in Antarctica. He has four energy-related U.S. patents.

1. First spray foam project was in 1971

2. Foam manufacturing from 1973 to 1979

3. Foam contracting and BE consulting from 1979 to 2009

– Developed the method for injecting closed-cell foam on site

– Installed ~ 5 million pounds of foam

4. Foam and BE commissioning from 2009 to present

5. Noteworthy foam projects include:

– 1977 net-zero solar project in Boston, The Big Dig, 4 American Ski Grande Hotels in the Northeast, Net-zero energy weather station in Antarctica, The Guggenheim Museum

6. Two US patents and numerous technical papers related to foam & foam QA

HCF foam experience

The challenges of creating the perfect conditions for proper machine processing polyurethane foam

By: Henri Fennell, CSI/CDT © H. C. Fennell 2016

16 Course Description

The challenges of creating the perfect conditions for properly machine processing polyurethane foam

This session will introduce the most common causes of problems in field-applied polyurethane foam plastic installations and present guidelines for ensuring proper chemical processing, the most common source of problems. It will start with an overview of the parameters that the foam’s chemistry requires for proper processing, then discuss the implications of these needs on how the equipment is set up and used, and how to verify that the processing parameters are being met. We will review industry-standard quality control procedures and then demonstrate additional methods that installers can use to ensure and verify proper processing.

Copyright Materials

This presentation and the related handout material is

protected by US and International Copyright laws.

Reproduction, distribution, display and use of the

presentation and the related handout material without

written permission of the speaker is prohibited.

© HC Fennell Consulting, LLC 2016

www.polyurethanefoamconsulting.com

The challenges of creating the perfect conditions for properly machine processing polyurethane

foam

Introduction

• Where does Processing fit in to an SPF project – Safety – Application Design/Building Science – Preparation – Equipment – Processing – Installation – Follow-up

• Note: Installation comes after processing!

http://www.hcfennellconsulting.com/

http://www.hcfennellconsulting.com/

2/3/2016

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Processing vs. Installation

The Installation

The processing system

The foam industry relies on this

equipment to provide processing

quality Common problems

and causes

Let’s start with a few train wrecks! Note, these are not

common, but I have to solve these problems all too often.

Causes of foam problems

1. Lack of national ANSI standards and certifications 2. Lack of installer training and/or experience

– The “Cleveland Museum experience”

3. Manufacturer issues (foam and equipment) – Documentation – Tolerances not defined – Critical parameter feedback and fault-protection engineering controls not provided

4. Design issues – Product selection (Purfil spray foam?) – Installer qualifications not specified – Material compatibility and substrate conditions – Building Science implications (hybrid systems, unvented slopes) – Documentation and guarantees not addressed – Design intent not clear (R-value vs. thickness?) – Not code compliant

5. Price-driven marketplace (price vs. quality) 6. Distributors (different standards than manufacturers) 7. GCs lack experience with subcontracting foam installations

– No standard work requirements in bid solicitations – No in-house quality assurance protocols

8. Lack of barrier inspections by building officials

Common problems and causes

Unrelated causes blamed

on foam installations

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Causes of problems

Design - HVAC

What’s wrong with these pictures?

Building Science cause – mixed insulation

Project #2

Moisture

Building Science cause – mixed insulation

Common problems

and causes

Installation issues

Foam Problem – Processing or installation?

Thermal Shock and

pass thickness

Causes of problems

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4

Preparation problem

Pass thickness failure

Deep rim joist design with a spray foam spec.

Design for a pass thickness failure

One 11” pass with an 1-1/2” lift spray foam product

Too hot - burnout

2012 Cape Cod attic fire

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Scorching or burn-out

Common problems

and causes

Processing issues

Infrared locates off-ratio material Off ratio - fluctuations

Off ratio - fluctuations Off ratio - fluctuations

Layers of A-rich, good quality, and B-rich foam

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Off ratio - fluctuations

Frozen pipes inside

$150,000 removal and replacement – house and garage apartment

The remediation process - removal

Flat bar and a

hammer worked the

best

Off ratio – B-rich

Low-tech froth equipment with no

monitoring capabilities

$8,500 removal and replacement

The cost of remediation Removal was required as this

was a Type II problem

$30,000 removal and permanent Owner injury

Short-term off-ratio event Short-term off-ratio event

$3,000 repair and lost reputation

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Intermittent processing problem Processing affects dimensional stability

Before

Elongated cells are weaker perpendicular to the grain, and hot box exposure causes the material to shrink laterally.

After

Processing affects dimensional stability

Before

After

Processing affects dimensional stability

Before

After

Processing – Step #1 Understanding the

processing parameters

What does the chemistry require?

SPF is a two-component chemical system that requires:

• Properly conditioned chemicals

• Precise proportioner performance

• Proper delivery of the chemicals from the proportioner to the gun

• A complete chemical reaction of all of the components

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What does the chemistry require?

Proper conditions at the gun to assure a fully mixed and reacted product:

• The proper ratio of the two chemicals

• Adequate pressures to assure a good mix

• Adequate temperature to assure a complete chemical reaction

Where do we get the processing information?

Typical documentation:

• Product Data

• Application Guide

• Installation Instructions

– The data is usually scattered among these documents and there is no standard for how or where the data is to be presented to the users

– There may be conflicts! Make sure the documents listed above are not out of date, even the ones on their web site

– Some products change, but the documents don’t

• Safety Data Sheets

• Evaluation Service Report

• Marketing documents

What processing information do we need? What did the chemists really ask for?

How many processing parameters are usually specified by manufacturers in these documents? • There should be about 20 Processing parameters provided,

not counting the tolerances for each • Usually, only about half of these are available • The chemical manufacturers will not provide tolerances for

most of these parameters • Manufacturers require the installer to be responsible for

proper processing, but often do not provide adequate information (or training) about how to do this

You have to ask!

Critical processing parameters include:

1. The temperatures, flow rates, and pressures of the supply chemicals as they are being delivered to the proportioning pumps

2. The temperature, flow ratio, and pressures of the proportioned chemicals as they are being delivered to the gun

Processing parameters installers have to meet!

Source date

10/11/2015

Blank or yellow Yellow = NR (not reported) or formulation documented not provided PDS/TDS = Product Data Sheet/Technical Data Sheet

Orange = conflict between documents ESR/IRR = Evaluation Service Report

Green = Reported - include document citation AG = Application Guide / Installation instructions

N/A = not required or not reported N/R= Not reported SDS = Safety data sheet (MSDS)

Low

limit,

Min.

Alarm Target Alarm

High

limit,

Max.

A Temperature

(degrees F)1 A N/A N/A N/A

B Temperature

(degrees F)1 B N/A N/A N/A

A Temperature


B Temperature


A Recirculation/

mixing3 A N/A N/A N/A Operator

B Recirculation/

mixing3 B N/A N/A N/A Operator

A Temperature


B Temperature


A Pressures (PSI) 5 A

B Pressures (PSI) 5 B

Pressure

difference (PSI)

Helps maintain

on-ratio

operation

Indicator or good

equipment

maintenance

Compare pressure

gauges if not

monitored (Insite or P-

monitor)

A flow proportion

(by volume)6 A N/A N/A N/A

B flow proportion

(by volume)6 B N/A N/A N/A

A flow proportion

(by weight)7 A N/A N/A N/A

B flow proportion

(by weight)7 B N/A N/A N/A

A Temperature


B Temperature


A Temperature


B Temperature


A Temperature

(degrees F)N/A N/A N/A

B Temperature


Reactivity profile -

Rise (Seconds)N/A N/A N/A

Reactivity profile -

Tack free

(Seconds)

N/A N/A N/A

Proper

reaction temp.

at inlet of mix

chamber

All parameters

are correct

Temperature

control and

equipment

maintenance

determine this

Proper

reaction ratio

Required

pressure at

gun chamber

for adequate

mixing

Proper

reaction ratio

Mix and reaction

quality

All controls are

correct

Control panel -

Primary heater

settings

Control panel -

Hose settings

Calibration of pump or

use of flow ratio

monitor system -

assumes flows are

constant through the


use of flow ratio

monitor system -

assumes flows are

constant through the

Temperature at outlet

of primary heater /

gauge, probe

thermometer, or

sensor, but temp. at

Temp. within 5' of gun

after dispensing cold

material from

unheated portion of

hoses - gauge, probe

thermometer, or

sensor

Temperature within 5'

of gun / gauge, probe

thermometer, or

sensor

Proper

reaction

temperature at

inlet of mix

chamber - one

temperature

10

Gauge or sensor

anywhere in the

hydraulic system after

the pump - check high

stall for leakage

Control panel -

pressure

settings

Temperature

control and

equipment

maintenance

determine this

5

diff

Chemical

Processing

A to B :

high to

low

tolerance

Machine/

Gun/ Mix

Chamber

Machine/

Gun/ Mix

Chamber

Icynene

Processing & installation

Matrix

Product

Par

ame

ter

ID

Process

parameterControl location

Setting/thresholds

Manufacturer

ProSeal

Initial launch date

N/R

Seasonal formulation

None available

Verification

location/method

Specific gravity

for

proportioning

the chemicals

at the proper

Chemical

health before

conditioning

Specific gravity

for

proportioning

the chemicals

at the proper

Chemical

conditioning

space or

temperature

control

Control for

chemical

condition

equipment

Average of high and

low readings in center

mass of container -

Immersion

thermometer/sensor

Temperature at inlet

of pump's

proportioning piston

or flow controller -

gauge, probe

Chemical conditioning

space - gauge, probe

thermometer, or

sensor

Chemical

shipping and

storage

environments

Uniformity -

material and

temperature

Mixer or

recirculation

system

Proper

reactivity

profile

11

Proper

reaction temp.

at inlet of mix

chamber

To make the data useful, create an

"at-a-glance" tool

to use in the field

The “Process Matrix”

Of these, there are four critical pairs of parameters (sort of)

The four critical processing parameter pairs

Source date

10/11/2015





Low

limit,

Min.

Alarm Target Alarm

High

limit,

Max.

A Temperature

(degrees F)4 A 65 70 80 90 95 30 N/A N/A

B Temperature

(degrees F)4 B 70 75 80 85 90 20 N/A N/A

A Pressures (PSI) 5 A 850 950 1200 1250 1300 50 N/A N/A

B Pressures (PSI) 5 B 850 950 1200 1250 1300 50 N/A N/A

A flow proportion

(by volume)6 A 98% 99% 1.00 102% 105% 7% N/A N/A

B flow proportion

(by volume)6 B 90% 95% 1.00 101% 102% 12% N/A N/A

A Temperature


B Temperature


113 115



material from unheated

portion of hoses - gauge,

probe thermometer, or

sensor

10

Proper

reaction

temperature at

inlet of mix

chamber - one

temperature

All controls are

correct105 108 110

Verification

location/method


use of flow ratio monitor

system - assumes flows

are constant through the

hydraulic system

Proper

reaction ratio

Temperature

control and

equipment

maintenance

determine this

Specific gravity

and viscosity

for

proportioning

the chemicals

Controls for

chemical

conditioning

equipment

Temperature at inlet of

pump's proportioning

piston or flow controller -

gauge, probe

thermometer, or sensor

Required

pressure at

gun chamber

for adequate

mixing

Control panel -

pressure

settings

Gauge or sensor

anywhere in the hydraulic

system after the pump -

check high stall for

leakage

Chemical

Processing

Par

ame

ter

ID

Process


Initial launch date

Sample Brand foam Sample foam 2# None available N/R

Setting/thresholds A to B :

high to

low

tolerance

Machine/

Gun/ Mix

Chamber

Machine/

Gun/ Mix

Chamber


Matrix

Manufacturer Product Seasonal formulation

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Critical processing parameter data includes:

1. The parameter name (A-side supply temperature)

2. The type of data (temperatures, flow rates, pressures, time, specific gravity, viscosity, etc.)

3. Optional – what controls the parameter (pump’s pre-heater control)

4. The Low, ideal, high, and “alarm” tolerances or thresholds for the parameters (60, 65, 75, 80, 85)

5. Special circumstances that may affect the tolerances (Mixer shape and output)

6. Optional – means of verification (thermometer)

Processing parameters installers have to meet!

Processing – Step #2 Pre-conditioning the

chemicals

Source date

10/11/2015





Low

limit,

Min.

Alarm Target Alarm

High

limit,

Max.

A Temperature

(degrees F)1 A 50 90 N/A N/A N/A

B Temperature

(degrees F)1 B 50 80 N/A N/A N/A

A Temperature

(degrees F)2 A 50 90 N/A N/A N/A

B Temperature

(degrees F)2 B 50 80 N/A N/A N/A

A Recirculation/

mixing3 A N/A N/A N/A Operator

B Recirculation/

mixing3 B N/A N/A N/A Operator

Within these limits

Within these limits

Within these limits

Within these limits


Matrix

Product Initial launch date

N/R

Par

ame

ter

ID

Process


Setting/thresholds

Manufacturer

ProSeal

Seasonal formulation

None available

Chemical

Processing

A to B :

high to

low

tolerance

Icynene

Verification

location/method

Chemical

health before

conditioning

Specific gravity

and viscosity

for

proportioning

the chemicals

Chemical

conditioning

space or

temperature

control

Average of high and

low readings in center

mass of container -

Immersion

thermometer/sensor

Chemical conditioning

space - gauge, probe

thermometer, or

sensor

Chemical

shipping and

storage

environments

Uniformity -

material and

temperature

Mixer or

recirculation

system

Not required

Not recommended

Machine/

Gun/ Mix

Chamber

Machine/

Gun/ Mix

Chamber

Storage and shipping parameters

Difference comes from concerns over boiling out the blowing agent from the B side

Processing – the steps Material preparation/conditioning

How to protect the supply chemicals

• Always maintain the material within the recommended temperature range

• Head-space blankets

– aka "Inert gas blanketing" (See AY-137 for more information)

– Reasons for A & B-side blanketing (its “crystal” clear)

– Head-space methods (dry air venting, desiccant cartridges, or N2 blanket)

Air Dryers There are three basic types

of automatic air dryers that will work for foam processing

Desiccant filter air dryer

Refrigerated air dryer

Membrane dryer

Replaceable desiccant air dryers

Avoid crystalized Isocyanate in your system

Air dryer and dry nitrogen for head space blanket

PVs can be kept under dry air or N2 pressure (up to 75 PSI) without placarding

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Avoid crystalized Isocyanate in your system

Nitrogen components for head space blanket

“Keep drums tightly closed when not in use and under dry air or nitrogen pressure of 2-3 psi after they have been opened.”

Processing – Step #2

Material storage and handling

• Maintain chemicals within recommended temperatures

– Avoids damage to the chemicals

– Extends Shelf life

• IT TAKES TIME! PB engineers indicate that it takes about 30 hours to heat or cool drums 15 degrees using air with a delta T of 15F

Kit temperature control

Quality control #2 – Verify the supply chemical temperatures with

thermometers or with engineering controls

More on measuring chemical temperatures in Step #3

Processing – Step #2 - pre-conditioning

Shipping and receiving

Maintain chemicals within recommended temperatures

Require "Protect from freezing" or "Min./max. temperature" on P.O.s

Check the chemical temperatures before accepting delivery – reject materials if below freezing (?)

Processing – Step #3 Conditioning the

chemicals

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Processing – Step #3a Maintain the proper

temperatures

The four critical processing parameter pairs Source date

10/11/2015





Low

limit,

Min.

Alarm Target Alarm

High

limit,

Max.

A Temperature

(degrees F)4 A 65 70 80 90 95 30 N/A N/A

B Temperature

(degrees F)4 B 70 75 80 85 90 20 N/A N/A



A flow proportion

(by volume)6 A 98% 99% 1.00 102% 105% 7% N/A N/A

B flow proportion

(by volume)6 B 90% 95% 1.00 101% 102% 12% N/A N/A

A Temperature


B Temperature


113 115






sensor

10

Proper

reaction

temperature at

inlet of mix

chamber - one

temperature

All controls are

correct105 108 110





hydraulic system

Proper

reaction ratio

Temperature

control and

equipment

maintenance

determine this

Specific gravity

for

proportioning

the chemicals

at the proper

Control for

chemical

condition

equipment




gauge, probe


Required

pressure at

gun chamber

for adequate

mixing

Control panel -

pressure

settings

Gauge or sensor




leakage


high to

low

tolerance

Machine/

Gun/ Mix

Chamber

Machine/

Gun/ Mix

Chamber

Verification

location/method

Chemical

Processing

Par

ame

ter

ID

Process


Initial launch date



Matrix



A B

Conditioning - Measure supply chemical temperatures at the inlets of the A & B transfer pumps

Processing – Step #3a

#3a Material preparation/conditioning

• Achieve and maintain the proper supply chemical temperatures

• This assures the right specific gravity and viscosity material will be provided to the positive-displacement pumps. This allows the proportioner to pump the correct volume of each chemical to the gun (1:1 "ratio" by volume)

Why do pressures and ratios change? Processing – Step #3a

How to maintain the supply chemical temperatures once they are in the rig • Always start with pre-conditioned chemicals

• Maintain temperatures inside the rig at the proper supply chemical temperature (Electric heaters, Espar heaters)

• Protect the chemicals from cold sources once placed in the rig

• Add heat to the chemicals as required to maintain the proper temperatures

• Distribute heating sources evenly – avoid local hot spots to avoid boiling the 245fa blowing agent

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Supply drums delivered to the site too cold

Torpedo heater in use to try to warm up chemicals so the work can begin

Always start with pre-conditioned chemicals

12-volt diesel heater

https://youtu.be/guN0ZtemeO4?list=PL3k1IfMx4RIXCuXwak05vRlrwOqY505vv

Maintain temperatures inside the rig

40,000 BTU heater runs off of circulating diesel engine coolant

– this system can run while traveling to and from the site

Maintain temperatures inside the rig

12-volt fan

1.2 KW - 120 volt radiant electric

panels (8 < $100, < 8 lb. each)

Processing – Step #3a

Heating system options – track how much time is required for each option?

• Radiant floor and wall heaters, band heaters, blanket heaters

• Immersion heaters?

• Arctic Pack in-line heaters. Are they a good idea?

• Don't forget about summer time cooling requirements

Maintain the supply chemical temperatures once they are in the rig

Various electric band, blanket, and floor base

heaters

Supply drums delivered to the site too cold

Overheating drums can create a serious

pressure hazard

High temperature localized heat sources can damage the chemicals and boil out the blowing agent – reduces yield.

Always start with pre-conditioned chemicals






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13

Add heat to the chemicals as required

Supplement supply container heaters, if necessary

In-line preheater with built-in temperature control

Add heat to the chemicals as required

• Heat from the top, side, or bottom? Multiple sides?

• What is the maximum localized temperature you can apply to the drum without damaging the chemicals?

• Heating the B side in closed-cell foam is more problematic due to boiling the blowing agent, over-pressurizing the drums

• Totes are more problematic when raising the core temperature. Why?

• Pressure vessels are the easiest to manage

Quality control #3a – Verify the supply

chemical temperatures are on spec.

Processing – Step #3a Material preparation/conditioning

How to verify supply chemical temperatures?

• How to measure the supply chemical temperatures

– Tools

– Where to measure

• Quote from the documentation…

– “Cold chemicals can cause poor mixing, pump cavitation, or other process problems due to higher viscosity at lower temperatures.”

#3 Material preparation/conditioning

Temperature readings during recirculation indicate chemical temperature once the readings stabilize

In-line thermometers

In-barrel thermometers

IR surface temperature thermometers

Supply inlet temperatures

Preheater settings do not impact the supply chemical temperatures unless you recirculate

Supply chemical temperatures

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14

Processing – Step #3a Conditioning

How to verify supply chemical temperatures?

55-gallon drums (Degrees F)

55-gallon drums

(Degrees F) Diff.

Ambient 21.0 25.0

Thermostat inside Rig

65/72 Rear door

open 1 hour

Top in liquid 72.0 72.0 0.0

Top on side 73.0 53.8 -19.2

Middle in liquid

N/M N/M

Middle on side

67.0 42.2 -24.8

Bottom in liquid

58.0 58.0 0.0

Bottom on side

60.0 43.0 -17.0

Processing – Step #3a Conditioning

Test for chemical temperature uniformity

5,000# Totes (Degrees F)

5,000# Totes (Degrees F)

Diff.

Ambient 21.0 25.0

Thermostat inside Rig

65/72 Rear door

open 1 hour

Top in liquid

Head space Head space

Top on side Not full Not full

Middle in liquid

65.0 66.0 1.0

Middle on side

65.0 53.4 -11.6

Bottom in liquid

60.5 60.5 0.0

Bottom on side

60.2 40.6 -19.6

Tests indicate about a .42 average degrees rise per hour in a hot room

maintained at 15 degrees above the 55-

gallon storage container starting point (about

two hours per degree)

How to verify supply that the proper chemical temperatures are being delivered to the pump?

Processing – Step #3a (Continued) Where to check supply temperature

Why should you measure at the drums and at the proportioner pump inlets?

Proportioner

Pro

po

rtio

ner

Verifying supply inlet temperatures

Supply chemical temperatures

Processing – Step #3b Mix the chemicals

when recommended by the manufacturer

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Processing – Step #3b

How to achieve uniformity within the supply containers

– Maintain chemical component distribution - reduce stratification and separation of the chemical compounds

– Mixing - Low pressure recirculation • Minimize splash – return below the surface

of the liquid

• Draw from the bottom

• Start slow when the material is coldest

– Stirring/agitation • Minimize splash, stir at all levels or from the

bottom to the top (blade angles)

Recirculation through the hoses and gun manifold

Recirculation through the pump manifold

Pressure balance ports converted to recirculation

return lines. Is this the high or low pressure side of the pump?

Return (dip) tubes should extend to the bottom of the drum to avoid splashing the material - Why?

Note the strain relief coils on these hoses

Recirculation – through the gun manifold

Do not set the hose heat higher than the maximum chemical

storage temperature

These return (dip) tubes should also extend to the bottom of the drums

Use Jog mode or low pressure settings to recirculate material

Similar to using Jog mode during pump setup or bleeding the hoses

Caution – set heat “low” in either method to avoid boiling the blowing agent

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16

Caution – When using Jog mode or feed pumps – avoid over-pressuring the supply drums!

Jog mode is for bleeding the hoses, recirculation, or checking for leaks, but it is also useful for

calibrating a proportioner

Jog mode maximum pressure is 700 psi @ J10 See “J___5” on the pump

control

Processing – Step #3b

Mechanical mixing methods and equipment

Quality control #3b – Verify

supply chemical uniformity • Recirculate or stir for the period of time and at the

rate recommended by the manufacturer for the conditions at hand

• Ask the manufacturer for further instructions if the information is not provided in the installation manual (ideally in writing)

Processing – Step #4

Deliver the supply chemicals to the pump

Flow rates for supply/transfer pumps

Source date

10/11/2015





Low

limit,

Min.

Alarm Target Alarm

High

limit,

Max.

A Temperature

(degrees F)4 A 65 70 80 90 95 30 N/A N/A

B Temperature

(degrees F)4 B 70 75 80 85 90 20 N/A N/A

Transfer pump

flow rate (GPM)5 A

2X pump

flow rateN/A N/A N/A

Transfer pump

flow rate (GPM)5 B

2X pump

flow rateN/A N/A N/A



Pressure

difference (PSI)

Helps maintain

on-ratio

operation

Indicator or good

equipment

maintenance

N/A N/A N/A

Compare pressure

gauges if not

monitored (Insite or P-

monitor)

Required

pressure at

gun chamber

for adequate

mixing

Control panel -

pressure

settings

Gauge or sensor

anywhere in the

hydraulic system after

the pump - check high

stall for leakage

6 diff 50 or less

Specific gravity

for

proportioning

the chemicals

at the proper

Control for

chemical

condition

equipment

Temperature at inlet

of pump's

proportioning piston

or flow controller -

gauge, probe

Adequate

supply of

chemicals to

the

proportioner

Transfer pump

selection

N/A Manufactuer's

published flow rate

from the product

specificationsN/A


high to

low

tolerance

Machine/

Gun/ Mix

Chamber

Machine/

Gun/ Mix

Chamber

Verification

location/method

Chemical

Processing

Par

ame

ter

ID

Process


Initial launch date

Icynene ProSeal None available N/R


Matrix


A


B

Transfer pumps supply chemicals to the proportioner - transfer pumps must be sized properly

Pumps, filters, hoses, and valves must be clean and operational to prevent restrictions on the supply side of the proportioner

B A

2/3/2016

17

The material feed system -Transfer the supply chemicals from drums, totes, or pressure vessels to the proportioner

• Must supply adequate material to the proportioner

– What is the minimum supply/transfer rate/value?

– Typical stick pumps provide 100 or 200 feed PSI (one or two stage). 200 PSI systems are less prone to cavitation.

– “Caution: If the material feed system cannot feed “A” and “B” components as required by the proportioner, cavitation will occur causing intermittent off-ratio foam and/or plugged equipment.” AY-137

Transferring material to the proportioner

• Manifold systems - never use one pump to supply multiple primary pumps unless: – Adequate flow and pressure can be provided

– You can verify that adequate flow and pressure are being provided to both proportioners

– The auto shut-down feature (some newer proportioners) can calculate stroke count for two-pumps

– The transfer pump pressures are less than 25% of the primary pump pressures

– Note: Supply/transfer pump failure will reduce supply to both Proportioners

The material feed system -Transfer the supply chemicals from pressure vessels to the proportioner

Pressure vessels (fleet tanks, day tanks, etc.)

• Verify that the pressure and hose sizes are adequate to deliver the minimum supply volume for the output of the proportioner. How?

The material feed system -Transfer the supply chemicals from drums, totes, or pressure vessels to the proportioner

Transfer methods

• Stick pumps

• Diaphragm pumps

• Pressure vessels (fleet tanks, day tanks, etc.)


Potential problems

• Filtration

• Temperature drop (impact on chemical viscosity)

• Pressure drop (low flow if plumbing is too small)

• Cavitation (hose restriction, broken foot valve, closed make-up air inlet, empty drum)


• Kinked hoses, broken transfer/feed pump, clogged ”Y” strainer, filters, etc. can restrict the supply side of the system

2/3/2016

18

Even great rigs can have problems

• Upstream restrictions

Calibration can identify restrictions

Should be 1:1

One type of restriction

Supply-side restrictions

This system was off ratio about 14%

Avoid supply-side restrictions

Prevent kinks in hoses – processing

and safety

Quality control for Step #4 – Verify the supply chemical volume and pressure to the pump

• Dispense A & B chemicals into separate large containers through their respective transfer hoses. Time the dispense period, weigh the material dispensed, then calculate the flow rate from the hose. It should be at least twice the output of the pump with the mix chamber you are using in the gun and four times the pressure of the proportioner at the settings you will be using.

• Install pressure gauges in the two supply lines if they are not included in the original equipment.

Quality control for Step #4

In-line pressure gauge and thermometer kits are available for older machines without supply-side gauges

2/3/2016

19

Processing – Step #5 Pressurize the

chemicals


10/11/2015





Low

limit,

Min.

Alarm Target Alarm

High

limit,

Max.

A Temperature

(degrees F)4 A 65 70 80 90 95 30 N/A N/A

B Temperature

(degrees F)4 B 70 75 80 85 90 20 N/A N/A



A flow proportion

(by volume)6 A 98% 99% 1.00 102% 105% 7% N/A N/A

B flow proportion

(by volume)6 B 90% 95% 1.00 101% 102% 12% N/A N/A

A Temperature


B Temperature


113 115






sensor

10

Proper

reaction

temperature at

inlet of mix

chamber - one

temperature

All controls are

correct105 108 110





hydraulic system

Proper

reaction ratio

Temperature

control and

equipment

maintenance

determine this

Specific gravity

for

proportioning

the chemicals

at the proper

Control for

chemical

condition

equipment




gauge, probe


Required

pressure at

gun chamber

for adequate

mixing

Control panel -

pressure

settings

Gauge or sensor




leakage


high to

low

tolerance

Machine/

Gun/ Mix

Chamber

Machine/

Gun/ Mix

Chamber

Verification

location/method

Chemical

Processing

Par

ame

ter

ID

Process


Initial launch date



Matrix



B A

The pressure at the pumps and the gun should be the same given that this is a hydraulic system Verify the pressure with the gauges located at the primary pumps

B

A

Quality control #5 – Verify the

pressure of the chemicals provided to the gun by

manually reading the gauges or with engineering controls

The proportioner pumping system Supplying the chemicals to the gun

The Pressures of A and B are supposed to be close to the same and high enough to assure that the chemicals will be equally and fully mixed.

Therefore, our machines have to provide adequate pressure to:

• Overcome the pressure drop in the hoses and the gun

• Mix the chemicals properly

• Maintain adequate pattern control at the gun

• Dispense material with specialty adapters and delivery systems

Verify and adjust initial pressures

A 100 psi differential is best practice. A 200 psi differential approaches where you could have a cross over in the gun.

2/3/2016

20

Why do pressures go off?

… “could be a clog in the Y Strainer, an obstruction in the fluid hose or gun, or you’re out of material.

Double-acting hydraulic piston pump

Why do pressures go off? Why do pressures go off?

This is why you can’t rely on pressures to be sure of the material ratio, but the pressures can provide an indication of when the system’s

performance has changed.

Only positive-displacement flow meters can provide accurate feedback about ratio. The

possibility of having unbalanced pressures also indicates that virtually no equipment always

operates at a 1:1 ratio

Processing – Step #6 Proportion the

chemicals


A

Primary pumps “proportion” the chemicals and supply them to the gun at the prescribed ratio (theoretically 1:1)

B

http://www.animatedsoftware.com/pics/pumps/animdblf.gif

2/3/2016

21


10/11/2015





Low

limit,

Min.

Alarm Target Alarm

High

limit,

Max.

A Temperature

(degrees F)4 A 65 70 80 90 95 30 N/A N/A

B Temperature

(degrees F)4 B 70 75 80 85 90 20 N/A N/A



A flow proportion

(by volume)6 A 98% 99% 1.00 102% 105% 7% N/A N/A

B flow proportion

(by volume)6 B 90% 95% 1.00 101% 102% 12% N/A N/A

A Temperature


B Temperature


113 115






sensor

10

Proper

reaction

temperature at

inlet of mix

chamber - one

temperature

All controls are

correct105 108 110





hydraulic system

Proper

reaction ratio

Temperature

control and

equipment

maintenance

determine this

Specific gravity

for

proportioning

the chemicals

at the proper

Control for

chemical

condition

equipment




gauge, probe


Required

pressure at

gun chamber

for adequate

mixing

Control panel -

pressure

settings

Gauge or sensor




leakage


high to

low

tolerance

Machine/

Gun/ Mix

Chamber

Machine/

Gun/ Mix

Chamber

Verification

location/method

Chemical

Processing

Par

ame

ter

ID

Process


Initial launch date



Matrix


Quality control #6 – Verify the ratio of the chemicals

provided to the gun by manual calibration or with

engineering controls

Verify ratio (A to B)

Methods for manually verifying proportioner performance.

• Weigh drums before and after use

• Do volume tests at the gun manifold

• Do weight tests at the gun manifold

• Have the proportioners calibrated periodically by a third-party agency (or in house)

Manual calibration – by volume

These Installers removed the gun manifold to perform their ratio tests

Manual calibration through a recirculation system Calibration adapters

2/3/2016

22

Calibration adapters

This low-pressure adapter can only be used for open dispensing

Disposable adapter bolted to the gun manifold

These two tests are very close – a follow-up test by weight confirmed this is within .4%


E30 pressure set at 750 psi


This is a snap shot in time, but a worthwhile QA check for equipment performance

This one was off by more than the manufacturer’s tolerance – chemical temperature was too low

After heating the chemicals, the test result was within 1%

Manual calibration - by weight

This one is off by about 17% - High-stall test verifies that primary pump check valve is not closing

This calibration test is within 3% (recirculation block adapter)

Manual calibration - by weight

Weights S. G. Volume

A 1634.00 1.20 1960.80

B 1594.00 1.24 1976.56

Ratio (% = 2B/A+B) 100.400%

Difference (Ratio-1) 0.400%

Processing – Step #7 Pre-heat the chemicals

2/3/2016

23

Source date

10/11/2015





Low

limit,

Min.

Alarm Target Alarm

High

limit,

Max.

A flow proportion

(by weight)8 A 98% 99% 1.00 101% 102% N/A N/A N/A

B flow proportion

(by weight)8 B 98% 99% 1.00 101% 102% N/A N/A N/A

A Temperature

(degrees F)9 A 120 122 125 128 130 N/A N/A N/A

B Temperature

(degrees F)9 B 120 122 125 128 130 N/A N/A N/A

A Temperature


B Temperature


A Temperature


B Temperature


128 130



material from

unheated portion of


thermometer, or

sensor

11

Proper

reaction

temperature at

inlet of mix

chamber - one

temperature

All controls are

correct120 122 125


of primary heater /

gauge, probe

thermometer, or


gun is the target

Proper

reaction temp.

at inlet of mix

chamber

Control panel -

Hose settings120 122 125 128 130



thermometer, or

sensor

Proper

reaction ratio

Temperature

control

calibration and

equipment

maintenance


use of flow ratio

monitor system

Proper

reaction temp.

at inlet of mix

chamber

Control panel -

Primary heater

settings


high to

low

tolerance

Machine/

Gun/ Mix

Chamber

Machine/

Gun/ Mix

Chamber

Verification

location/method

Chemical

Processing

Par

ame

ter

ID

Process


Initial launch date



Matrix




Manually verify process chemical temperatures at the outlets of the pump manifold where the hoses begin.

A B

Preheating – The primary heaters are right after the pumps in the fluid stream (behind the pumps). Read the temperatures at the proportioner control panel.

B A

Quality control #7 –

Verify the temperatures provided by the

proportioner heaters

Verify the temperatures provided by the proportioner heaters

Manually verify process chemical temperatures at the outlets of the pump manifold where the hoses begin.

Preheating – The primary heaters are right after the pumps in the fluid stream (behind the pumps). Read the temperatures at the proportioner control panel.

Processing – Step #8 Deliver the chemicals

to the gun

Source date

10/11/2015





Low

limit,

Min.

Alarm Target Alarm

High

limit,

Max.

A flow proportion

(by weight)8 A 98% 99% 1.00 101% 102% N/A N/A N/A

B flow proportion

(by weight)8 B 98% 99% 1.00 101% 102% N/A N/A N/A

A Temperature

(degrees F)9 A 120 122 125 128 130 N/A N/A N/A

B Temperature

(degrees F)9 B 120 122 125 128 130 N/A N/A N/A

A Temperature


B Temperature


A Temperature


B Temperature


128 130



material from

unheated portion of


thermometer, or

sensor

11

Proper

reaction

temperature at

inlet of mix

chamber - one

temperature

All controls are

correct120 122 125


of primary heater /

gauge, probe

thermometer, or


gun is the target

Proper

reaction temp.

at inlet of mix

chamber

Control panel -

Hose settings120 122 125 128 130



thermometer, or

sensor

Proper

reaction ratio

Temperature

control

calibration and

equipment

maintenance


use of flow ratio

monitor system

Proper

reaction temp.

at inlet of mix

chamber

Control panel -

Primary heater

settings


high to

low

tolerance

Machine/

Gun/ Mix

Chamber

Machine/

Gun/ Mix

Chamber

Verification

location/method

Chemical

Processing

Par

ame

ter

ID

Process


Initial launch date



Matrix



2/3/2016

24


Manually verify process chemical temperatures at the gun with a probe thermometer in the end of the hose wrap – adjust for the external measurement.

A B

Preheating – The hose heaters are controlled by a sensor in the hose assembly. Best practice is to install the FTS just before the whip. Read the temperatures at the proportioner control panel, but verify at the gun.

B

A

Quality control #8 – Verify the temperatures of the chemicals provided to the gun, at the gun

(Assume pressure and flow same as

at the pump as this is a hydraulic system)

The location of the FTS can impact the chemical temperature at the gun

Locate the FTS just before the whip for the best performance.

Heated hose with and without the wrap

Heat loss and gain in hoses

Heat retention hose sleeve

There are after-market wraps for heated (and unheated) hoses to aid in extreme hot and cold conditions

Processing – Step #9 Combine and mix the

chemicals


We made it. The gun is where it all happens now. The chemicals are combined and mixed in the gun. If all of the previous steps are complete, and nothing has changed in the last few feet of hose, we should be dispensing good quality material.

2/3/2016

25

Quality control #9 Industry-standard QA

Quality control (Testing) SFC "Guidance on Best Practices for the Installation of Spray Polyurethane Foam"

The PCP

The Spray Polyurethane Foam Alliance Professional Certification Program (“SPFA PCP”) was launched last year to aid in assuring that qualified installers are available to the construction industry. Hundreds of installers have participated in this program and some states are adopting it as a standards requirement.

See the SPF INSULATION CERTIFICATION HANDBOOK for more information (www.Sprayfoam.org)

Quality Control for the product

Manual methods for determining if parameters are being met at the gun

• Confirm the material temperature at the gun

• Verify that the chemicals are completely reacted

– Verify the chemical clock by checking the reactivity times

– Use strip tests sprayed within the maximum pass thickness

• Do not spray side to side or overlap the pass – one straight spray line

• Check the “surf board,” color uniformity, texture uniformity, odor, “snap,” etc.

– Verify the material density

“Surfboard” strip tests

Remember not to spray in the normal back-and-forth pattern when doing a strip test.

Label these if records are required. Take photos of the strip tests as proof of quality records.


Variations in color, cell size, and texture show inadequate temperature or mix. The textured area in this photo was friable and easily broken.

2/3/2016

26

“Surfboard” strip tests Always do test shots before starting the installation, if for no other reason than to clear the cold material from the whip. This type of

material could put the entire project’s quality in question.

Strip tests can show lead and lag, poor mix, and cold material.

Always do test shots before starting the installation


Color, texture, and cell shape variations indicate unreacted, un-mixed, or off-ratio chemicals

“Surfboard” strip tests “Surfboard” strip tests

Do cross-sections and confirm cell size and shape, and color uniformity

Quality Control for the product

Manual methods for determining if parameters are being met at the gun • Confirm the material temperature at the gun

• Verify that the chemicals are completely reacted

– Verify the chemical clock by checking the reactivity times

– Use strip tests sprayed within the maximum pass thickness

– Do not spray side to side or overlap the pass – one straight spray line

– Check the “surf board,” color uniformity, texture uniformity, odor, “snap,” etc.

– Verify the material density

Verify the material density Density checks are on the edge between processing and installation QA. We are discussing density as a verification of processing quality, not pass thickness or environmental conditions that can affect physical properties.

2/3/2016

27

Foam inspections – Installation quality

Graduated beaker

displacement

density test

Courtesy: Air Barrier Association of America

Quality control

Engineering controls

The Manual Quality Control Option

• Everyone wants to “do it right” and avoid expensive

call backs

• But do you or your crews actually perform manual quality control protocols? (Do you weigh your drums before and after each project to check your pumps?)

• How often do your crews check the critical processing parameters during the work?

• Are standards and methods even available for performing all of these QA protocols? Is training by suppliers or the industry adequate to prevent problem projects?


• How much can a foam failure cost?

• One local-area failure -$1,000

• Large-scale failures - $25,000 to $250,000

• Does your insurance cover these types of losses?


Economics - Productivity(+) and cost implications(-)

• Manual QA will slow down your crews, adding costs and you won’t be competitive

• So, how can you actually do enough QA to prevent a problem project?

o Hire an extra technician to provide continuous verification during the work – too expensive

o Hire a foam commissioning agent – too expensive

The Automatic Quality Control Option

• Verifies all process parameters are being met

automatically

– Eliminates manual verification

– No wait time for manual calibrations

– WBF case in point

• Provides a warning to the installer before material quality is compromised

• Provides automatic fault protection

• Provides proof-of-QA reporting and records

After-market monitoring systems are readily available

2/3/2016

28

The Automatic Quality Control Option

Economics - Productivity(+) and cost implications(-)

– How much time do your crews spend on:

• Performing manual quality control protocols

• Making adjustments as environmental conditions change

• Making minor repairs when things go off spec.

• Repairing call backs

Engineering Controls - Automatic Quality Control

Automatic system capabilities • Parameter sensing

– Ratio - Flow meters – Temperatures - Temperature sensors at all local and remote parameter

locations – Pressures – Pressure sensor capability available

• System feedback – All of the data from these sensors is collected continuously and

permanently recorded – Once you have a record of your operations, you can see changes in

performance and trends – Now you have formal reporting capabilities and proof-of-quality

documentation – This gives you an advantage over the competition

• Fault protection (automatic shutdown) capabilities – Combine sensor output data with logic and you have auto shut-off

capabilities – Impact on productivity – less time spent "tweaking the system" – Eliminate catastrophic failures and local problem call backs and claims


Source date

10/11/2015





Low

limit,

Min.

Alarm Target Alarm

High

limit,

Max.

A Temperature

(degrees F)4 A 65 70 80 90 95 30 N/A N/A

B Temperature

(degrees F)4 B 70 75 80 85 90 20 N/A N/A



A flow proportion

(by volume)6 A 98% 99% 1.00 102% 105% 7% N/A N/A

B flow proportion

(by volume)6 B 90% 95% 1.00 101% 102% 12% N/A N/A

A Temperature


B Temperature


113 115






sensor

10

Proper

reaction

temperature at

inlet of mix

chamber - one

temperature

All controls are

correct105 108 110





hydraulic system

Proper

reaction ratio

Temperature

control and

equipment

maintenance

determine this

Specific gravity

for

proportioning

the chemicals

at the proper

Control for

chemical

condition

equipment




gauge, probe


Required

pressure at

gun chamber

for adequate

mixing

Control panel -

pressure

settings

Gauge or sensor




leakage


high to

low

tolerance

Machine/

Gun/ Mix

Chamber

Machine/

Gun/ Mix

Chamber

Verification

location/method

Chemical

Processing

Par

ame

ter

ID

Process


Initial launch date



Matrix


Program in the product parameters once – pick from a menu of products later


Additional engineering controls integrate with your machine controls

QA equipment is standard for OEM applications

OEM monitoring systems

OEM PU Foam processing

QA monitors with fault protection capabilities have been in use since 1954

2/3/2016

29

OEM monitoring systems

OEM/FR

Ratio-only monitor for OEM applications

Proportioner

Automatic calibration – by volume

Monitor

Graco

Pressure imbalance and low-chemical shutdown

Remote reporting and control system

Dashboard Features

Remote recording system

Up-to-the -minute information

2/3/2016

30

Processing quality control

Ratio, usage, and temperature monitor with auto shut-off

This is industry-standard off-the-shelf quality control equipment that can eliminate most foam processing failures – specify this type of processing QA for your projects!

Ratio Monitor

Engineering controls are continuous, provide fault protection shut down, and record your critical processing parameters

Automatic calibration – by volume

Timer and ratio monitor

Engineering controls and timer

Flow Monitor

Flow meters

2/3/2016

31

Flow meter styles P-Monitor connections

Flow meters in line

FTS connection

Type E thermocouple at supply inlet of A-side pump

P-Monitor in use

Access panel open to connect sensors

Alarm and shutdown light array

Wifi-capable laptop interface booting up

This concludes this Continuing

Education Systems Program

By: Henri Fennell, CSI/CDT © H C Fennell Consulting, LLC 2016

www.polyurethanefoamconsulting.com Cell: 802-222-7740

P-Monitor

http://www.polyurethanefoamconsulting.com/

Documents

Processing Nu-Seal - Efficiency Vermont · · 2016-02-04This presentation and the related handout material is ... Introduction •Where does Processing fit in to an SPF project