Document 6wpjqGEo29obr2QrbG7m3qQyg

.Exhibit G~1' SECTXQI c Ss Xs .DO PONT J0E-SBMOURS AND.COMPANY, INC. 7tiBRlCS AND FINISHES DEPARTMENT FINISHES DIVISION PHILADELPHIA PLANT PROCESS AND METHODS 0RODP Jun 22, 1953 "48 PROCESS*' MEMORANDUM REPORT SHSTRHMEMATXOl AND CONTROL OF OPERAOTfl CONDITIONS STUDY P-X0` Prepared fey D:, Cl. BOSSE ABSTRACT Tlsis mmomMim covers installation .of aaaetsr and pyrometer recommended as standard instrumentation for "48 Process1* and co-ordinated specifications, for stan dard -operating'conditions. Exhibit C-2 "48 PROCESS" MEMORANDUM REPORT P-10 INSTRUMENTATION AND CONTROL Off OPERATING CONDITIONS PROBLEM UNDER INVESTIGATION: "48 Process" operation is controlled on the basis of power input, which is feasible as the agitator functions as a reliable indicator of the effective viscosity of heavy pastes* Esterline Wattmeter charts, which have been obtained on a large number of experimental batches and have proven extremely use ful for analysis of operating conditions, indicate that a properly installed and marked ammeter will be a satisfactory power Indicator for control of manufacturing operations. As "48 Process" manufacture is extended to include an in creasing range of products, close control of manufacturing operations becomes more essential, particularly in certain cases where very small pigment additions can result in a large increase in flow re sistance and power consumption. Location and marking of the ammeter to facilitate easy accurate observation of the power consumption by the operator while engaged in loading of pigments and liquids is essential for practical operation. Temperature markedly influences the flow resistance of "48 Process" dispersion mixtures and operating temperatures in the range of 120* to 150*P are desirable. Since the power requirements are higher at low operating temperatures, the power indicator and formulation serve indirectly to control minimum operating temperatures in a satisfactory manner* Maximum temperature control is necessary for plant scale operations, particularly with the products more difficult to manu facture* Ordinary thermometer types having liquid filled bulbs or tubes, or long shielded thermocouples which extend into the mixture are not satisfactory as they are subject to failure from repeated flexing. The special thermocouple unit mounted flush with the in side surface of the tank wall in the 150-gallon pilot plant "48 Process" mixer provided satisfactory readings with the stipulation that the thermocouple be located sufficiently distant from the cool ing jacket, in an active shear zone, and in the path of material moving outward from the center toward the jacketed portion of the wall* DUP030001809 -2- Exhibit C-3 RESULTS AMD RECQW-!IENPATIONS: The problems of power consumption and temperature control have been studied on the Philadelphia Plant; 1000-gallon "48 Process" Unit and recommendations are made on the basis of practical operating requirements. An ammeter mounted above the manhole at approximately operator eye level when loading pigment, and color coded for simple accurate reading is required for practical "48 Process" operation. Heavy concentration of solvent vapor, and dust in the vicinity of the manhole and vibration caused by ball mills operating In the same buildings require the specification of an explosion-proof instrument condulet suspended from the connecting conduit which is, in turn, attached to the mixer through rubber padded clips. This rubber padded mounting is sufficiently simple and inexpensive to warrant use even though the actual increase in instrument life may be. debatable, A temperature indicator with an accuracy of not less than + 5*F at 150P is required to control maximum operating temperature. The same protection against dust solvent vapor, and vibration, as re quired for the ammeter, must be provided for the indicator. In ad dition, magnetic insultion is required for operation of a low tempera ture direct driven thermocouple pyrometer in the vicinity of the electric motor, and cold junctions compensation is desirable to elimi nate the necessity for frequent adjustment. The indicating instrument specified has the required fea tures and is relatively inexpensive. The instrument construction also permits simple mounting at the desired location and the use of a quick acting dust-tight thermocouple lead connection which makes it possible to remove, check and replace the instrument without disturbing the wiring Installation. The thermocouple unit specified is an Improved design utili zing as many standard parts as practical. The teflon packed reducer tank fitting provides thermal isolation of the thermocouple tip and acts as a support to prevent failure of the protective tube by flexure. Tie flexible rubber-covered thermocouple lead section, compressiontype tank fitting, and cannon plug assembly s amplifies removal and replacement of the thermocouple in the event of failure. Specifications for standard operating conditions co ordinated with the recommended Instrumentation, are covered in the list of "48 Process" Precautions" included in this report and designed for mounting on or near the "48 Process" Units for guidance of the operators. It will he noted that these precautions specify that the cooling water for the gear reducer should be turned on. Although at present an automatic solenoid valve to control the cooling water to the gear reducer, recommended by South San Francisco Finishes Plant, is not specified as Standard Equipment, it is desirable and we recom mend adoption of this proposal by all plants using "48 Process Units equipped with water cooled gear reducers. DUP030001810 '*48 PROCESS" INSTRUMENT ARRANGEMENT SPECIPIC ATIONS inhibit C-4 AMMETER: Suitable ammeter with full scale reading not less than 1.5 or more than 2.5 rated full load motor amps, in Crouse and Minds Explosion Proof Instru ment Condulet Type EMH for GE, Westlnghouse, Hickok, or Weston Instruments* The unit is moun ted by suspension from conduit which is attached to mixer by clips over rubber gromets to provide vibration insulation. Meter scale is to be color-banded as follows: 0 to 3/4 rated full load motor amp - White 3/4 to 1.0 " " " " " - Green 1.0 to 1.2 " " " " " - yellow over 1.2 " 11 M " " Red (Scale marking not to be obscured by color band} Wiring diagrams are attached. PYROMETER ASSEMBLY: (Ref. attached schematic) 1. Special model 30 Surface Pyrometer Range 0-300P - 5* sub-divisions without handle, and calibrated for 16 feet lead wire*Manufactured by The Pyrometer Instrument Co., Inc.,.Bergenfield. New Jersey - Philadelphia Agent, John C, Whiddett Co., ,f9 Union Avenue, Bala-Cynwyd, Pa, - Quote of 6/16/53 - $91.00. 2. Special Model 12 Extension Arm with 1-1/2" stub shaft and 16 feet braided I.C. Lead Wire.Manufacturer and Agent same as above,Quote of 6/19/53 - $14.00 3. Compression Sleeve of 1/2" conduit with side slot and lugs for 3/16" bolt with lock washer, finished inside for 5/8" O.D* stub shaft and welded at 90"angle to 6-1/2" length of 1/2" conduit, threaded one. end* 4. Rubber gr.omet approximately 1/4" thick 2 required, 5. Conduit mounting clip - 2 required. 6. Brace of 1" x 1/4" strap from mixer frame to stut base of instrument and attached by com pression loop around rubber grotaet of approximately 1/4" thickness. DUP030001811 Exhibit C-5 7. Condulet Crouse and Hinds Type LB-17 or equivalent. 8. Conduit 1/2" {standard rigid electrical). 9. Thermocouple lead wire. 16. Frame of mixer drive. 11. & 12. Iron Constantan Thermocouple - Brown In strument Div., Minneapolis-Honeywell Regulator Company. No. 3D14K - 6" -X-Rl-12" 6 inch pencil type thermocouple with 12" rubber covered lead wire extension and 1/8" S.P.T, Compression fitting. Quote 6/22/53 (Tel.) - $34.00 *(Revised Aug. 1954 D.6.B.) *13. Reducer 1/2" to 1-1/8" S.P.T. Mild steel installed in tapped, opening in tank bottom midway between tank center and wall, flush with inside tank bottom surface, and machined to provide a straight inside bore and a 45 angle on the end (high side adjacent to bore) for subsequent peenlng as noted on Item 14 below. *14. Heat insulator and thermocouple support con sisting of Teflon discs or solid plug pressed into the reducer and held in place by peenlng the beveled end of the reducer down flat to produce a retaining lip. The hold for the thermocouple (light push fit) is then drilled, and the 1/8" S.P.T. compression fitting (Item 12 above) Installed. 15. Cannon Plug - WK-M2 - 21C - 5/16" Manufactured by Cannon Electric Development Co., 3209 Humboldt Street, Los Angeles 31. 16. Cannon Plug Mating Receptacle - WK-M2-22C - with clamp removed for Installation - source same as plug. 17. Round head bolts 1/8" x 3/16" through sleeve into tapped holes in skirt,of Mating Receptacle -- 3 required. 18. Sleeve 1" long welded to conduit, bored 13/16" I.D. for Cannon Plug Mating Receptacle. 19. Conduit 1/2" Notes: 20. Thermocouple lead wire. Installation thermocouple unit in tank bottom to be made carefully to obtain tight reducer fit without projection through inside surface of tank bottom. All lead wire joints carefully soldered with non-corrosive flux, maintaining maximum possible cleanliness of surfaces. DUP030001812 pr .* j ** ry xr * ' V " `' * ' V EXHIBIT c-e a.vfcMMit*.WT* *:* ' DUP030001813 EXHIBIT C-7 A ;v f. SC ri ; /;. ; , C 7> h LO/ h t77r l) /- e t.:.; i .,,v, 7 It y.-ir txmtr c-8 I (3) r* A] ffsTOr >< ;> . * # SF7i >7fr i - f,?, tc Pir. 3> HU'; Fi -i/ % l p /i r. *' < '' 3 *-.- : T//Rf CAT, fa 41 . TYfT 71}} CAK *b. f4(. &. F. /A. MTl W3Tm M60- 7< //*# LV77F''> V 7JPF-7 covifCT Fid , 6A Li> <!. ! o# 7 Ra T/q 2o q - (D -0 T Tyr L 1 p t S') -fy pi ^8 FfiGCESF AmSTIR, IViRwCr D/A&RAM Sc H A'. A Tic XU fhk P*h Javr, 22, }$SP D. &, 8l a s s c DUP030001815 Exhibit C-9 "48 PROCESS" PRECAUTIONS (1) BEFORE STARTING BATCH: GEAR REDUCER COOLING WATER ON; t an k j ac k et c o o l in g w at er o f f . (2) FOLLOW FORMULA AND DIRECTIONS IN DETAIL* (3) CAUTION: DO NOT OVERLOAD. FULL LOAD LIMIT - END OF GREEN BAND. TEMPORARY OVERLOAD LIMIT - END OF YELLOW BAND. <*> PIGMENT ADDS MUST BE MADE BY POURING NOT DUMPING. DO NOT LOAD WITH. POWER IN YELLOW BAND. (5) CHECK TEMPERATURE PERIODICALLY. J START COOLING WHEN MAXIMUM OF 150F. IS REACHED, UNLESS OTHERWISE SPECIFIED. (6) DO NOT STOP MIXER FOR MORE THAN WO MINUTES WHEN POWER IS OVER THE WHITE BAND. AND NOT UNLESS NECESSARY. ALSO, DO NOT JOCKY AGITATOR. (7) LETDOWN PORTIONS MUST BE ADDED SLOWLY WITH MIXER RUNNING. MAXIMUM RATE 1 AMPERE POWER DROP EVERY 2 MINUTES. DUP030001816 BIBLIOGRAPHY ENGINEERING DEPARTMENT STUDIES 1. ED-709.`Part 2, "Agitation Studies", Feb. 1934 2. ED-709?Part 3, "Agitation Studies", March 1935 3. ED Design Standards:DG-3E "Selection of Agitator" 4. ED Design Standards:D6-5E "Calculation of Power Input" 5. ED-1993:MX-1034, "Study of Fine Grinding and Dispersion", December 1948 6. ED-2135, "Agitator Blade Width", October 1950 7. IED-PFF-4:MX-676, "study of Medium intensity Liquid Shear Dispersion", Jah. 1947 "c a " p r o c e s s s t u d y r e f e r e n c e s 8. Finishes Division Grinding and Dispersion Conference Notes, Kidder, G.W.; November 12, 1946 9. CIL - Paint and Varnish Division Memorandum, "Alkyd Resin White Enamels by Mixer Dispersion", Booth, J,,, Dec. 19, 1946 10. MCP-1045, "Mixer for CA Process Development" 11. Philadelphia Finishes Plant Report, "CA Progress", Mar. 31,1948 12. Philadelphia Laboratory Release Letter No, 1046, "Manufacture of House Paint by CA Process *, August 6, 1947 13. Philadelphia Laboratory Supplementary Release Letter No. 114S-A, "Recommendation for Sale of 301-875 Lead Free No. 40 Outside White House Paint", Feb. 28, 1949. CHEMICAL DEPARTMENT PIGMENT DISPERSION STUDIES 14. CCD-LSX-IO28, "States of Pigment Dispersion as Related to Finishes Problems", April 1939 15. Philadelphia Laboratory Report No. 837, "Exploratory Research Report, "Flocculation in Organic Liquids", March 7i 1946. 16. Philadelphia Laboratory Report 848, "Exploratory Research Flocculation in Mill Base Systems", June 19, 1946, DUP030001817 CHEMICAL DEPARTMENT PIGMENT DISPERSION STUDIES (Coat'd.) IT. Philadelphia Laboratory Report No, 872, "Exploratory Research Report ~ '45 Process* Grinding of Dulux Bases", July 15, 194?. 18. Philadelphia Laboratory Report No. 887, "Exploratory Research Report *- Grinding Studies", November 3, W. PAINT AND VARNISH PRODUCTION CLUB ~ OFFICIAL DIGEST 19. Hoback, W.H., Off. Digest Fed, of Paint and Varnish Prod. Clubs No. 316 (1951), "Practical Aspects, of Pigment Dispersion", 20. Baker, C.P.; and Vozzella, J.F.j Ibid, No, 319 (1951), "The Roll Mill, Pebble,Mill, and Kneader as Pigment Dispersion Equipment"; 21. Foy, W.L., Ibid, No. 322 (1951),""A preliminary Study of Fine Pigment Dispersion in the Morehouse Mill". 22. Asbeck, W.E.; Ladderman, D.D.; and Vanloo, M., Ibid., No, 32o (1952), "Oil Absorption and Critical Pigment Vol ume Concentration", 23. Zimmerman, E.K., Ibid., No, 334 (1952), "A Study of Pigment Dispersion: IV Coating properties". 25. Long, J-.S., Ibid, No, 358 (1954), "The Mattiello Lecture", BOOKS 26. Green, H., "Industrial Rheology and Rheological Structures" N.Y.; J. Wiley & Sons, 1945, 27. Fischer, E.K., "Colloidal Dispersions" N.Y. J. Wiley & Sons, 1950. 28, Dallavalle, J.M., "Micromeritics - The Technology of Fine Particles", N.Y,, Pitman publishing Corp,, 2nd Ed. 1948. 29. Rouse, H., "Elementary Mechanics of Fluids", N.Y., J. Wiley St Sons, 1946. 30, Mattiello, J.J., "Protective and Decorative Coatings" , N.Y., J, Wiley & Sons, Vol. II, 1942; Vol. Ill, 1943; Vol. IV, 1944. 31. Lewis, W.K.; Squires, L.; and Broughton, 0., "industrial Chemistry of Colloidal and Amorphous Materials", N.Y., Macmillan, 1942. 32. Suthelm, G.M., "Introduction to Emulsions", N.Y. Chemical Pub. Co., 194p. DUP030001818 INDUSTRIAL AND ENGINEERING CHEMISTRY 33o Asbeck, W.K., and VanLoo, M., Ind. and Eng. Chera. Vol. 4l No. 7, PP 1470-1475 (1949) "Critical Pigment Volume Relationships". 34. Rushton, J.H.j Costich, E.W.j and Everett, H.J.; Chemical Eng. Progress Vol. 46, No. 8, pp. 395-404 and Vol. 46, No,9 pp, 467-476 (1950)/ "Power Characteristics of Mixing Impellers". "48 PROCESS" DEVELOPMENT REFERENCES 35. Philadelphia Plant Process and Methods Group Report, "Experimental Manufacture - Cement and Stucco Emulsion Finish by 48 Process", Aug. 15, 1951. 36. FFD-1541, "48 Process Pigment Dispersion Patentability", Jan. 21, 1952. 37* Philadelphia Plant Laboratory Release Letter No. 44, "Manufacture by 48 Process", June 22, 1953. 38. Philadelphia Plant Laboratory Release Letter No,56* "Diatomaceous Earth Extender Modification in 601-911, White Cement and Stucco Finish", Dec. 29* 1954* DUP030001819 EXHIBIT H 1000 GALLON *48 PROCESS" OPERATING INSTRUCTIONS (1) BEFORE STARTING BATCH s SEAR REDUCER COOLING WATER OH} TAHK JACKET TANK JACKET COOLING WATER OFF, (2) FOLLOW FORMULA s DIRECTIONS IN DETAIL, (3) CAUTION: DO NOT OVERLOAD. 40 HP TOLL LOAD LIMIT - END OF SKEEN BAND 48 HP TEMPORARY OVERLOAD XlMtT ~ END OF YELLOW BAND. (4} PIGMENT ADDS MUST BE MADE BY POURING NOT DUMPING. DO NOT LOAD WITH POWER XI YELLOW BAND {ABOVE 40 HP. ) (5) CHECK TEMPERATURE PERIODICALLY, START COOLING WHEN MAXIMUM Of 150*F IS REACHED, UNLESS OTHERWISE SPECIFIED (6) DO NOT STOP MIXER UNLESS NECESSARY, AND NOT FOR MORE THAN TWO MINUTES WHEN POWER IS OVER THE WHITE BA (ABOVE 20 HP) ALSO, DO NOT JOCKEY AGITATOR. (7) .LETDOWN PORTIONS MUST BE ADDED SLOWLY WITH MIXER RUNNING.MAXIMUM RATE 1 AMP,- POWER DROP EVERY 2 MINUTES FOR 40 AMP. INDICATED FULL LOAD. (1*25$ OF FULL LOAD AMPERAGE DECREASE PER MINUTE) NOTE* POWER INPUT IS MEASURED BY AMMETER READINGS, COLOR CODING OF METER IS REG0S#1BED TO SUPPLEMENT NUMBERS WRITE -0 feo 20 HP EQUIVALENT II AMPS* GREEN -.20 feo.40 HP 85 15 8 TOLLON- 40 to 48 H? 51 18 RED - ABOVE 48 HP 8 55 8 DUP030001820 DISTRIBUTION LIST COPY NO. 1 2 3 4 5 6 7 S 9 10 11 12 13 14 15 16 17 18 19 20 & 21 'ga. M-- 1S <27 57 L. H. PRIDAY) IN S, E. FURST ) TURN WILMIINI GTON . J. S. ALLEN WILMINGTON R, A. DE WALL P. C. OLIN R. M. SHEPHERD H. R. AYRES F. E. WALTER R, J. KNAKE WILMINGTON WILMINGTON WILMINGTON CHICAGO FORT MADISON TOLEDO K. E. ACKLEY EVERETT H, E. JOHNSON FLINT N, I, DRESS H. F. ETHER ) IN C. B. SHERIDAN) TURN PHILADELPHIA PHILAD ELPHIA M. L, BYRON B. L. PRIDDY C. F. KALB R. B. DAVIS W. D, LAWSON R. W. LALLY J, D. PICKENS ) IN T. R. THOMPSON) TURN SO. SAN FRANCISCO PARLIN PARLIN MARSHALL LAB. ma r s h a l l LAB, NEWBURGH FLIiiNT LAit B. PROCESS & METHODS FILES (J & . c/tectA PHILADELPHIA ) Pt%1 PyM ?U 7*Jl- C, 3 c-e-n* J ^ erf d c jfn^ Vtyn^ DUP030001821 3d - -n/cke?*.' #*, piSjur (c a. 3! c.pkiU ' fi.: 33 3 *f *r { Avt*s & A/ >5^ 4r-4r$$,, {a *>~J*4m\-Aj O 3C %7 j*) ,, 0J m^ zb -zir ^r: W ^v- */ /^> / /* $/' ;fe^. Vz. yy yr v7 yr / A. U-> l\t. l 60^. - Fhy,i O ^ /y * '^vs s ' ' ~: /- s ^ / V3 t 'Prmt c~ ii. s-- / ^ i? ^ ^ ^ * C rfC-VS - * ^------ ,JS \ <. ,' v? &Q <J /) (3obJf<e^ Qjt - * PkJa pcfrf PLkr 'P*wt 76/i /^j^r DUP030001822