Resources Mechanical AESSEAL Guides AUTO
Resources Mechanical AESSEAL Guides AUTO
Resources Mechanical AESSEAL Guides AUTO
AUTOMOTIVE INDUSTRY,
PRE-TREATMENT & PAINT PLANTS
This information corresponds to our current knowledge on the subject. It is offered solely to provide
possible suggestions for your own experimentations. It is not intended, however, to substitute any testing
2 you may need to conduct to determine for yourself the suitability of our products for your particular
purposes. This information may be subject to revision as new knowledge and experience becomes
available. Since we cannot anticipate all variations in actual end-use conditions, AESSEAL plc makes
no warranties and assumes no liability in connection with any use of this information. Nothing in this
publication is to be considered as a licence to operate under or a recommendation to infringe any patent
right.
ACKNOWLEDGMENTS
We would like to thank Richard Smith, Sales Director, for his time
and commitment in producing this document.
We would also like to thank Jaguar Cars for the kind permission to
use various pictures from their Halewood Production Plant.
AUTOMOTIVE
INDUSTRY
L-UK/US-AUTO-02
Description Page
3
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3
Vehicle Paint Production Line . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4
Mechanical Seals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6
W2 Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12
Case Histories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13
Introduction
The global demand for automobiles is increasing year on year. This demand is fuelling manufacturers to
strive for higher quality in all aspects of automotive manufacture. As with most consumer driven
industries, the quality and commercial attractiveness of the product are of paramount importance to any
automotive manufacturer.
Customer demand for increased corrosion protection and variation in the vehicles color specification
dictate that the modern manufacturing line must be flexible and responsive to market changes.
The appearance of the vehicle; its shape, style and bodywork finish can go a long way to selling a
vehicle. Often, if these features are not aesthetically pleasing, the consumer will not even get inside to
test the technical features. The quality of the vehicle paintwork is, therefore, an essential part of the
automotive production processes and one which a manufacturer ignores at his peril.
In a typical car plant, more than 1000 cars are processed in any given day. This high volume and the
most exacting of standards mean that a manufacturer must invest in a modern and efficient production
line.
Automotive manufacturers have taken up the challenge and now provide vehicles and products with
many years of corrosion protection. Furthermore, they boast production lines which can accommodate
changes in color specification from car to car.
AUTOMOTIVE
The Vehicle Paint
Production Line
The vehicle body is generally pressed and welded and transported to a pre-clean area. Here, high
pressure water spray jets are directed at the body with the purpose of cleaning off dirt and debris from
previous processes. This detritus can take many forms ranging from parts of components used in the
production process, to operator refuse or items of clothing such as gloves.
INDUSTRY
The vehicle is then transferred to the alkali dip rinse. The bodies are circulated through a series of dip
tanks, which essentially degrease and clean the metal work. Each body is totally submerged in the
caustic rinse, ensuring that no section is left untreated. Afterwards, the alkali dip excess fluid is drained
from the vehicle body before the rinsing operation.
L-UK/US-AUTO-02 During the dip rinse the full body of the vehicle is submerged in de-ionized water. This, like so many
stages in the production process, is another cleaning operation. Next, the vehicle body goes onto the
conditional spray. Spray pumps direct de-ionized water onto the vehicle body, generally at ambient
temperatures before the phosphate operation.
IN 4379 - 01/2002 During the phosphate operation the body is completely submerged in a phosphate liquid which
chemically etches the metal work and provides a layer of crystal on the surface of the steel. This enables
the paint to bite into the metal work for good adhesion.
Occasionally, some plants opt for a partial phosphate dip, instead of a full phosphate dip, which is
4 complemented by spray jets directing phosphate solution onto the roof of the vehicle. It is not
uncommon to see many re-iterations of the same process, i.e. cleaning, etching, rinsing etc. This is a
safeguard against wasted efforts further along the production line.
The care and attention required in the pre-treatment makes this one of the most critical elements in the
plant in obtaining a good paint finish.
The phosphate system is sometimes referred to as "the bond". This is the part of the plant which bonds
the paint to the steel body frame.
Depending on the type of plant, a hot blower is sometimes employed. If the body is going into storage,
the hot blower is commonly encountered. If the plant is a continuous production line then this stage is
often omitted.
From the phosphate operation, the body of the vehicle is transported to the preparation deck and then
onto the ELPO (Electro Coat Paint Operation), commonly referred to as the E-Coat, a water based
painting operation. During the ELPO process, the body is immersed or dipped into electro-coat paint.
The whole body is charged with electricity (similar to a plating process). The paint sticks to the body as
the body is charged, as it effectively becomes a cathode whilst the paint becomes an anode.
After this process the body is transported to an UF-dip (Ultra Filtrate) and then onto a UF-spray.
Lastly the vehicle body goes through a DI-spray and DI-dip which is effectively a cleaning spray
operation, then into an oven for approximately 20 minutes. Afterwards the body is transferred to the
finishing plant where it is masked, PVC (Uniseal) sprayed, de-masked and sent to the sealer-deck for
sealant to be applied between the seams and under the bonnet of the vehicle.
AUTOMOTIVE
INDUSTRY
L-UK/US-AUTO-02
IN 4379 - 07/2001
01/2002
The body is then stone chipped, which is the heavy black paint finish underneath the car, and then sent
to the primer booths for either manual or robotic spraying. It is here where the flexibility of the plant is
realized as atomizing bells provide the flexibility to rapidly change the color of a vehicle body in the
production line.
After the primer booths, the body is then transported to the ovens, then onto the color booths, where it
is once again manually or robotically sprayed using atomizing bells.
After a last oven operation the body is then sent to the trim/assembly area where the finished product
is realized.
AUTOMOTIVE
Mechanical Seals
Mechanical seals are found in many positions in the plant. This is due to the fact that the paint plant
uses massive volumes of liquid, mainly during the pre-treatment operations. Centrifugal pumps and
mechanical seals, therefore, play an important part in the efficient running of a modern automotive paint
plant. The following text indicates the seal standardization for the respective sections of the production
line.
IN 4379 - 01/2002
Mechanical seals may be found on the high-pressure centrifugal pumps, which feed the sprays. These
can be a multi-staged arrangement, or a bank of single stage pumps, which go from suction to INDUSTRY
discharge of the next pump in the line. Knock-off is generally set at (30 - 45 psi) 2-3 bar on single
centrifugal pumps, used to throttle back the spray pressure, so that it is not too high.
Knock-off is sometimes "soapy" and can contain heavy deposits of swarf. Depending on the pump
specification and duty, CDSA double seals TC/TC//Chrox/Car (Z895) with SSE10 W2 support
7
system, are sometimes preferred.
Mechanical seals may be found on the circulation centrifugal pumps, which re-circulate the dip tanks.
Note: Caustic is hazardous, therefore, double seals are preferred.
Seal Standardization
Mechanical seals may be found on the centrifugal pumps, which feed the sprays. Soilds can be present
depending on the conditioner additive used (Titanium).
Seal Standardization
AUTOMOTIVE
Sealing "Phosphate Dipping"
During the phosphate dip, the vehicle body is chemically etched, providing a layer of crystal on the
surface of the steel, which provides a "tooth" for the paint to adhere to. Mechanical seals may be found
on the phosphate circulation pumps, which circulate the liquid around the dip tank or on phosphate
sludge pumps, which take the sludge away to the filtering process.
Phosphate contains DI-water and it is undesirable to leak vast quantities, however, it is difficult to seal.
If one can seal the "phosphate" process, one can seal the whole paint plant. The key to successful
sealing is to keep the phosphate moving and avoid dead areas in the pipework where "growth" can
INDUSTRY occur.
L-UK/US-AUTO-02
IN 4379 - 01/2002
Seal Standardization
Mechanical seals will be found on the centrifugal recirculation pumps. Solids can be present depending
on the conditioner additive used (Zirconium).
Seal Standardization
IN 4379 - 01/2002
Seal Type: DMSF double cartridge seal with Z895 grease
Seal Faces: TC/TC//TC/Car
Seal Elastomers: Viton
Seal System: SSE10 W2
Barrier Fluid: Ultra filtrate/ Di water (consult AESSEAL on application). 9
Alternative
The Ultra Filtrate dip consists of DI mineralized water and generally is found with bits of paint in it.
Mechanical seals may be found on the centrifugal circulation and filter pumps.
Problems arise should the Ultra Filtrate vaporize between the seal faces and leave paint residue behind.
This sticks the seal faces together which can break Silicon Carbide seal faces on equipment startup.
Seal Standardization
AUTOMOTIVE
Sealing the Anolite
This is a conductive fluid (Citric Acid & Demin) that is circulated through the anodes in the E Coat tanks.
Seal Standardization
L-UK/US-AUTO-02
Coagulation/Sludge Plant
IN 4379 - 01/2002 Air is continuously blowing through the booths to the water curtain, residing either behind or underneath
the booth.
The water "river" takes all the overspray paint particles away, into the coagulation plant.
10 The paint particles may be removed from the water by one of several methods:
The chemical approach: Chemicals are injected into the water, which makes the paint molecules stick
together and sink. Conveyers or PCP pumps then mechanically move the paint sludge to a skip.
The aeration system: Air is added to the water causing the paint molecules to stick to the surface of
the bubbles, which then float to the top of the water. The paint sludge is then skimmed off the surface
of the water and transported to skips.
The mechanical approach: Water is pumped through filters, which screen the paint molecules,
separating them from the water. The filters are then opened and the paint sludge is taken to skips.
INDUSTRY
*Optional: CURC TC/TC-Viton with town water flush at 25 psi.
L-UK/US-AUTO-02
IN 4379 - 01/2002
11
Finished body shells ready for assembly at the Halewood Jaguar plant.
AUTOMOTIVE
W2 SYSTEMS
INDUSTRY
L-UK/US-AUTO-02
IN 4379 - 01/2002
12
Pressure
Water Supply Gauge
Regulator
Air Vent
Valve
Spring
Loaded Side
Non-Return View
Valve Flow
Indicator
Inline Filter
Option
Ball
Valve
STAINLESS STEEL VESSEL
MIN LIQUID
LEVEL
Vessel
MAX 2 METER
LEVEL SEAL
QU
EN
CH
MAX 1 METER
Peak
3-Way Valve Temperature
Current
Temperature
Drain Hose
12mm (1/2)
Hose Kit
CASE No. 843H directly onto the shaft and service life was
AUTOMOTIVE
more than 4 years. Stores now only need to
In a car plant in the U.K., a 65mm CDSA stock a single part number and not the 5
seal was fitted to a Euramo Salmson parts of a back to back assembly.
centrifugal pump, model number M4/C4. The
duty being pumped was phosphate 1 - Sleeve INDUSTRY
recirculation operating at a shaft speed of 2 - Inboard Seal
1440 rpm with inlet pressure being 5 psi (0.3 3 - Inboard Stationary
bar) and outlet pressure being 20 psi (1.4 4 - Outboard Seal
bar). The seal faces were TC/TC//CRO2/C 5 - Outboard Stationary
with Viton elastomers and 316L wetted parts. L-UK/US-AUTO-02
The mechanical seal operated with a CASE No. 847H
SSE10 W2 system pumping town water at
25 psi (1.7 bar). The CDSA and W2 system In a car plant in the U.K., a 48mm CDSA
lasted 3.5 years due to the seal having to be seal was fitted to a Tangie pump, model
removed because the pump failed. The number HB 125-250. The duty being pumped IN 4379 - 01/2002
customer was previously using a double was electro coat operating at a temperature
back to back and sleeve with quench to drain of 104F (40C) with a shaft speed of 1450
which lasted less than 12 months. rpm with an inlet pressure of 15 psi (1 bar)
and outlet pressure 37 psi (2.5 bar). The seal
13
CASE No. 845H faces were TC/TC//CRO2/C with Viton
elastomers and 316L wetted parts. The
In a car plant in the U.K., a 48mm CDSA mechanical seal operated with a SSE10
seal was fitted to a Tangie pump, model W2 system for 4 years.
number HB-125-250. The duty being
pumped was paint recirculation operating at The customer was previously using back to
a temperature of 104 - 122F (40 - 50C). The back PTFE wedge seals with a gland seal
seal faces were TC/TC//CRO2/C with Viton circulation system, with a stuffing box
elastomers and 316L wetted parts. The adapter ring and new impeller spacer being
mechanical seal operated with a SSE10 used.
W2 system and lasted for 5 years.
See Z895 for further information.
The customer was previously using PTFE
wedge back to back seals with Car/Cer seal CASE No. 848H
faces, with a stuffing box adapter ring and
new impeller spacer being used. The average In a car plant in the U.K., a 55mm CURC
life was less than 12 months. seal (with API Plan 11) was fitted to an IDP
centrifugal pump, bearing frame 3. The duty
See Z895 for further information. being pumped was Ultra Filtrate operating at
ambient temperature with a shaft speed of
CASE No. 846H 1550 rpm with an inlet pressure of 10 psi (0.7
bar) and outlet pressure 30 psi (2 bar). The
In a car plant in the U.K., a 50mm CDSA seal faces were TC/TC with Viton elastomers
seal was fitted to a Euramo Salmson and 316L wetted parts. The mechanical seal
centrifugal pump model number 125/100/315 operated with a SSE10 W2 system
M3. The duty being pumped was electro coat pumping de-min water barrier at 22 psi (1.5
operating at a temperature of 86F (30C) bar).
with a shaft speed of 1440 rpm with an inlet The CURC seal (which lasted 3 years) was
pressure of 25 psi (1.7 bar) and outlet fitted to a new pump, replacing a non-
pressure of 90 psi (6.2 bar). The seal faces cartridge, TC/TC face seal, which only lasted
were TC/TC//CRO2/C with Vitonelastomers. 6 months.
The customer was previously using a back to
back with a sleeve. This was difficult to install
and service life was poor. They also required
a new sleeve. The CDSA was installed
AUTOMOTIVE
CASE No. 849H
The customer's previous seals life was less CASE No. 1316J
L-UK/US-AUTO-02 than 12 months. The CDSA life was more
In an automotive paint plant in the North West
than 3 years.
of England, AESSEAL supplied 10 off 50mm
DMSF and bespoke SSE10 W2 Systems
See Z895 for further details.
via an OEM. The pump units were End
Suction Isoglide Pumps model Ref HL-150-
IN 4379 - 01/2002 CASE No. 850H
125-315 and are used to circulate
In a car plant in the U.K., a 50mm CURC Electrocoat paint around dip tanks. The seal
seal was fitted to a pump. The duty being face combination was TC/TC/TC/C/V Z895.
pumped was effluent operating at an ambient
14 temperature with a shaft speed of 1450 rpm The barrier fluid media was UltraFiltrate and
with an inlet pressure of 15 psi (1 bar) and the application details are as follows:
outlet pressure 44 psi (3 bar). The seal faces Pump Suction Pressure - 1 Bar (g)
were TC/TC with Viton elastomers and 316L Pump Delivery Pressure - 3 Bar (g)
wetted parts. Pump Speed - 1450 rpm
Bulk Temperature - 30 to 40 Deg C
The customer has converted from packing.
Barrier fluid pressure is 4 Bar (g) and the
See Z895 for further information. SSE10 systems are energized from a
manifold pressurized by a small Air Operated
CASE No. 851H Piston Pump.
The pumps and seal were installed in July
In a car plant in the U.K., a 48mm CDSA 2000 and have been running trouble free ever
seal was fitted to a Jeumont Schneider, since.
model number MEN/100/300. The duty being
pumped was coagulant operating at a Important: Silicone grease can
temperature of 86F (30C) with a shaft speed
of 1440 rpm. Inlet pressure was 10 psi (0.7 contaminate the whole painting
bar) and outlet pressure 75 psi (5.2 bar), system, if used during the seal
quench being pressurized at 73 psi (5 bar).
assembly. The presence of
The customer was previously using a hard silicone grease can prevent
faced single spring seal with a life of 10 paint adhesion to the vehicle
minutes. The CDSA seal lasted more than
5 years. body. It is, therefore, essential
that it should never be used.
CASE No. 852H
See Z895 grease for a suitable
In a car plant in the U.K., a 2.125" CDSA replacement.
seal was fitted to a Tangie pump, model
number HB 150-315. The duty being pumped
was paint operating at a temperature of
122F (50C) with an inlet pressure of 15 psi
(1 bar) and outlet pressure 37 psi (2.5 bar).
The seal faces were TC/TC//CRO2/C with
Due to AESSEALs policy of continuous improvement the following seal types have been
upgraded:
Any prospective user of our product should verify the information stated to their own
satisfaction.
15
Further information is available on all the case histories contained in this booklet upon
request.
Issue A on a case history refers to information which was current on the 31st. January,
1989.
Where the statement 'The seals are still working' is made, this means that the customer is
or was still using AESSEAL mechanical seals at the time the case history was updated; as
denoted by either: