SV-40007 6/30/00 2:44 PM Page 1 Dave ArtDept:WIP:Spraying Systems (SP):SV-40007:

SV-40007 6/30/00 2:45 PM Page 2 Dave ArtDept:WIP:Spraying Systems (SP):SV-40007:

Spray Characteristics
TECHNICAL/ENGINEERING REFERENCE

Because spray nozzles are date spray nozzle must be evalu-

designed to perform under many ated in order to achieve the most
different spraying conditions, it efficient spray performance in
is likely that there is more than your individual application.
one spray nozzle that would meet More specific information may
your general requirements. be obtained by contacting
Following is a discussion of spray a sales engineer at your local
characteristics to help explain sales office.
the criteria by which each candi-

Hollow Cone Spray Pattern Full Cone Spray Pattern

The hollow cone spray pattern A full cone spray pattern is round,
is essentially a circular ring of square, or oval, and completely
liquid. This pattern is generally filled with spray drops. This pattern
formed by use of an inlet tangen- is formed by using an internal vane,
tial to a whirlchamber, or by an which imparts controlled turbu-
internal grooved vane immedi- lence to the liquid prior to the orifice.
ately upstream from the orifice. Full cone coverage can also be
The whirling liquid results in a achieved with smaller drop size by
hollow cone configuration as it arranging atomizing or fine spray
leaves the orifice. nozzles on a header.

Solid Stream Spray Pattern Flat Spray Pattern

A solid stream spray pattern is a A flat spray pattern distributes

uniform stream of liquid. By using the liquid as a flat- or sheet-type
proper inlet chamber proportions spray. In the elliptical orifice
and contours ahead of the orifice design, the axis of the spray pat-
and/or by addition of internal flow tern is a continuation of the axis
stabilizing vanes, these nozzles of the inlet pipe connection. In
provide prolonged solid stream the deflector design, the deflec-
integrity and delay breakup and tion surface diverts the spray
drop formation after leaving the pattern away from the axis of
nozzle orifice. the inlet pipe connection.

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Spray Characteristics

TECHNICAL/ENGINEERING REFERENCE
Flat Tapered Edge Spray Pattern Flat Non-Tapered Edge Spray Pattern

Straight-through elliptical orifice Flat spray nozzles with non-tapered

spray nozzles normally produce or “even” edges are usually used
flat spray patterns with tapering in cleaning applications that
edges. This characteristic is require uniform impact across the
useful in establishing overlapping entire pattern width without
patterns between adjacent sprays overlapping the sprays.
on a multiple nozzle header. The
resulting distribution across the
entire sprayed surface can there-
fore be uniform.

Fine Spray Pattern Air Atomizing Spray Patterns

These low capacity nozzles pro- Air atomizing nozzles, available

duce a hollow cone spray pattern. in four patterns (round, wide angle
The drops are very small and the round, 360° round, or flat), provide
spray pattern is affected by air the finest degree of atomization.
friction and currents. Several feet The spray pattern remains as long
from the nozzle, depending on as the velocity of the atomizing air
pressure and nozzle capacity, is maintained. The drops may
the fine spray pattern disappears evaporate completely, depend-
as the drops become suspended ing on size, exposure time, and
in air. other ambient conditions.

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Engineering Discussions: Key Performance Considerations

TECHNICAL/ENGINEERING REFERENCE

Capacity
All capacity tabulations in this
catalog are based on water.
Since the specific gravity of a liq-
uid affects its flow rate, tabulated
catalog capacities must be multi-
plied by the conversion factor
that applies to the specific gravity
of the liquid spray as shown in
the chart below.
Nozzle capacity varies with
spraying pressure. In general, the
relationship between gpm and
pressure is as follows:

gpm1 (psi1)n
______ = _______
________________
gpm2 (psi2)n

where “n” is the exponent apply-

ing to the specific nozzle type as
shown below:

Capacity Factors for Specific Nozzle Types Conversion Factors for Specific Gravity
Exponent Specific Conversion
Nozzle Type Gravity Factors
“n”
.84 1.09
Hollow Cone Nozzles (All)
.96 1.02
Full Cone Nozzles (Vaneless)
1.00 (WATER) 1.00
Full Cone Nozzles (15˚ and 30˚ series)
1.08 .96
Flat Spray Nozzles (All) .50
1.20 .91
Solid Stream Nozzles (All)
1.32 .87
SpiralJet® Nozzles (All)
1.44 .83
HollowJet Nozzles (All)
®

1.68 .77
Full Cone Nozzles (Standard)
Full Cone Nozzles (Square Spray)
.46
Full Cone Nozzles (Oval Spray)
DistriboJet Nozzles (All)
®

Full Cone Nozzles (Wide Spray)

.44
Full Cone Nozzles (Wide Square Spray)

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Engineering Discussions: Key Performance Considerations

TECHNICAL/ENGINEERING REFERENCE
Estimating Pressure Drops Through Fluidline Accessories
The rated capacities listed in EXAMPLE For pressure drop information
this catalog for valves, strainers, on a specific product, contact
and fittings typically correspond Accessory rated capacity = 5 gpm your local sales engineer or
to pressure drops of approxi- Maximum recommended operating pressure = 500 psi Spraying Systems Co. Data
mately 5% of their maximum sheets listing pressure drops at
Estimated pressure drop at 5 gpm = 5% X 500 psi = 25 psi
operating pressure. various flow rates are available
To estimate pressure drop (psi2) for selected products.
This can be used to estimate the
pressure drop of other flow gpm1 (psi1).5 3 (psi1).5
rates as shown in the following ______ = ______ R __ = ______ R psi1 = 9 psi
example: gpm2 (psi2).5 5 (25).5

Flow of Water Through Schedule 40 Steel Pipe Approximate Friction Loss in Pipe Fittings
In equivalent feet of straight pipe
Pressure Drop in psi for Various Pipe Sizes
Flow
(in 10 ft. length) Std.
in Gate Globe Std.
gpm 1⁄8" 1⁄4" 3⁄8" 1⁄2" 3⁄4" 1" 1-1⁄4" 1-1⁄2" 2" 2-1⁄2" 3" 3-1⁄2" 4" Pipe Actual Elbow
5" 6" 8" Inside Valve Valve Run of or Tee
Size 45° Run
Diam. Std. through
Std. FULL FULL Elbow of Tee
.3 .42 In. Tee Side
Wt. OPEN OPEN Reduced Outlet
.4 .70 .16 1/2
.5 1.1 .24
.6 1.5 .33 1⁄8" .269 .15 8.0 .35 .40 .75 1.4
.8 2.5 .54 .13 1⁄4" .364 .20 11.0 .50 .65 1.1 2.2
1.0 3.7 .83 .19 .06 1⁄2" .622 .35 18.6 .78 1.1 1.7 3.3
1.5 8.0 1.8 .40 .12 3⁄4" .824 .44 23.1 .97 1.4 2.1 4.2
2.0 13.4 3.0 .66 .21 .05 1" 1.049 .56 29.4 1.2 1.8 2.6 5.3
2.5 4.5 1.0 .32 .08
1-1⁄4" 1.380 .74 38.6 1.6 2.3 3.5 7.0
3.0 6.4 1.4 .43 .11
1-1⁄2" 1.610 .86 45.2 1.9 2.7 4.1 8.1
4.0 11.1 2.4 .74 .18 .06 2" 2.067 1.1 58 2.4 3.5 5.2 10.4
5.0 3.7 1.1 .28 .08
6.0 5.2 1.6 .38 .12 2-1⁄2" 2.469 1.3 69 2.9 4.2 6.2 12.4
8.0 9.1 2.8 .66 .20 .05 3" 3.068 1.6 86 3.6 5.2 7.7 15.5
10 4.2 1.0 .30 .08 4" 4.026 2.1 113 4.7 6.8 10.2 20.3
15 2.2 .64 .16 .08 5" 5.047 2.7 142 5.9 8.5 12.7 25.4
20 3.8 1.1 .28 .13 .04 6" 6.065 3.2 170 7.1 10.2 15.3 31
25 1.7 .42 .19 .06
30 2.4 .59 .27 .08
35 3.2 .79 .36 .11 .04 Air Flow (scfm) Through Schedule 40 Steel Pipe
40 1.0 .47 .14 .06
45 1.3 .59 .17 .07
50 1.6 .72 .20 .08
Nominal Standard Pipe Size
60 2.2 1.0 .29 .12 .04 Applied
70 1.4 .38 .16 .05 Pressure
80 1.8 .50 .20 .07 PSIG 1/8" 1/4" 3/8" 1/2" 3/4" 1" 1-1/4" 1-1/2" 2" 2-1/2" 3"
90 2.2 .62 .25 .09 .04
100 2.7 .76 .31 .11 .05
125 1.2 .47 .16 .08 .04 5 .5 1.2 2.7 4.9 6.6 13 27 40 80 135 240
150 1.7 .67 .22 .11 .06 10 .8 1.7 3.9 7.7 11.0 21 44 64 125 200 370
200 2.9 1.2 .39 .19 .10 20 1.3 3.0 6.6 13.0 18.5 35 75 110 215 350 600
250 .59 .28 .15 .05 40 2.5 5.5 12.0 23.0 34.0 62 135 200 385 640 1100
300 .84 .40 .21 .07 60 3.5 8.0 18.0 34.0 50.0 93 195 290 560 900 1600
400 .70 .37 .12 .05 80 4.7 10.5 23.0 44.0 65.0 120 255 380 720 1200 2100
500 .57 .18 .07 100 5.8 13.0 29.0 54.0 80.0 150 315 470 900 1450 2600
750 .39 .16 .04
1000 .68 .27 .07
2000 1.0 .26
Recommended capacity range for each size is shown in shaded areas.

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Engineering Discussions: Key Performance Considerations

TECHNICAL/ENGINEERING REFERENCE

Spray Angle and Coverage Included

Theoretical Coverage at Various Distances
From Nozzle Orifice
This table lists the theoretical is critical, write for specific spray Spray
Angle 2" 4" 6" 8" 10" 12" 15" 18" 24" 30" 36" 48"
coverage of spray patterns as coverage data. Liquids more vis-
calculated from the included cous than water form relatively 5° .2" .4" .5" .7" .9" 1.1" 1.3" 1.6" 2.1" 2.6" 3.1" 4.2"
spray angle of the spray and the smaller spray angles (or even 10° .4" .7" 1.1" 1.4" 1.8" 2.1" 2.6" 3.1" 4.2" 5.2" 6.3" 8.4"
15° .5" 1.1" 1.6" 2.1" 2.6" 3.2" 3.9" 4.7" 6.3" 7.9" 9.5" 12.6"
distance from the nozzle orifice. a solid stream), depending upon 20° .7" 1.4" 2.1" 2.8" 3.5" 4.2" 5.3" 6.4" 8.5" 10.6" 12.7" 16.9"
These values are based on the viscosity, nozzle capacity, and 25° .9" 1.8" 2.7" 3.5" 4.4" 5.3" 6.6" 8.0" 10.6" 13.3" 15.9" 21.2"
spraying pressure. Liquids with 30° 1.1" 2.1" 3.2" 4.3" 5.4" 6.4" 8.1" 9.7" 12.8" 16.1" 19.3" 25.7"
assumption that the spray angle 35° 1.3" 2.5" 3.8" 5.0" 6.3" 7.6" 9.5" 11.3" 15.5" 18.9" 22.7" 30.3"
remains the same throughout the surface tensions lower than 40° 1.5" 2.9" 4.4" 5.8" 7.3" 8.7" 10.9" 13.1" 17.5" 21.8" 26.2" 34.9"
entire spray distance. In actual water will produce relatively 45° 1.7" 3.3" 5.0" 6.6" 8.3" 9.9" 12.4" 14.9" 19.9" 24.8" 29.8" 39.7"
50° 1.9" 3.7" 5.6" 7.5" 9.3" 11.2" 14.0" 16.8" 22.4" 28.0" 33.6" 44.8"
practice, the tabulated spray wider spray angles than those 55° 2.1" 4.2" 6.3" 8.3" 10.3" 12.5" 15.6" 18.7" 25.0" 31.2" 37.5" 50.0"
angle does not hold for long listed for water. 60° 2.3" 4.6" 6.9" 9.2" 11.5" 13.8" 17.3" 20.6" 27.7" 34.6" 41.6" 55.4"
spray distances. Write for data 65° 2.5" 5.1" 7.6" 10.2" 12.7" 15.3" 19.2" 22.9" 30.5" 38.2" 45.8" 61.2"
70° 2.8" 5.6" 8.4" 11.2" 14.0" 16.8" 21.0" 25.2" 33.6" 42.0" 50.4" 67.2"
sheets on actual spray coverage. 75° 3.1" 6.1" 9.2" 12.3" 15.3" 18.4" 23.0" 27.6" 36.8" 46.0" 55.2" 73.6"
80° 3.4" 6.7" 10.1" 13.4" 16.8" 20.2" 25.2" 30.3" 40.3" 50.4" 60.4" 80.6"
Tabulated spray angles indicate 85° 3.7" 7.3" 11.0" 14.7" 18.3" 22.0" 27.5" 33.0" 44.0" 55.0" 66.0" 88.0"
Spray Spray
approximate spray coverages Angle Distance 90° 4.0" 8.0" 12.0" 16.0" 20.0" 24.0" 30.0" 36.0" 48.0" 60.0" 72.0" 96.0"
based on water. In actual spray- 95° 4.4" 8.7" 13.1" 17.5" 21.8" 26.2" 32.8" 39.3" 52.4" 65.5" 78.6" 105"
100° 4.8" 9.5" 14.3" 19.1" 23.8" 28.6" 35.8" 43.0" 57.2" 71.6" 85.9" 114"
ing, the effective spray angle 110° 5.7" 11.4" 17.1" 22.8" 28.5" 34.3" 42.8" 51.4" 68.5" 85.6" 103"
Theoretical
varies with spray distance. If Coverage
120° 6.9" 13.9" 20.8" 27.7" 34.6" 41.6" 52.0" 62.4" 83.2" 104"
130° 8.6" 17.2" 25.7" 34.3" 42.9" 51.5" 64.4" 77.3" 103"
the spray coverage requirement 140° 10.9" 21.9" 32.9" 43.8" 54.8" 65.7" 82.2" 98.6"
150° 14.9" 29.8" 44.7" 59.6" 74.5" 89.5" 112"
160° 22.7" 45.4" 68.0" 90.6" 113"
170° 45.8" 91.6"

Spray Drop Size (Atomization)

Drop size refers to the size of Number Median Diameter (NMD) 10 psi 40 psi 100 psi
the individual spray drops which expressed as NMD and DN0.5: A Spray Pattern
Type CAPACITY VMD CAPACITY VMD CAPACITY VMD
comprise a nozzle’s spray pat- means of expressing drop size in gpm microns gpm microns gpm microns
tern. All of the spray drops within terms of the number of drops in Air Atomizing .005 20 .008 15
a given spray are not the same .02 100 8 200 12 400
the spray. This means that 50% of
.03 110 .05 110
size. Some of the different ways the drops by count or number are Fine Spray .22 375 .43 330 .69 290
to describe drop sizes within smaller than the median diameter .05 360 .10 300 .16 200
a spray are defined below: Hollow Cone 12 3400 24 1900 38 1260
and 50% of the drops are larger
than the median diameter. .05 260 .10 220 .16 190
Volume Median Diameter Flat Fan 5 4300 10 2500 15.8 1400
(VMD) Dv0.5 and Mass Median One Inch = 25,400 Microns .10 1140 .19 850 .30 500
Full Cone
Diameter (MMD): A means of 12 4300 23 2800 35 1720
expressing drop size in terms of 500 Microns Based on a sampling of nozzles selected to show the wide range of possible
the volume of liquid sprayed. The drop sizes available.
1,200 Microns
Volume Median Diameter drop sizes. The smallest drop sizes sprayed, it is a widely accepted
size when measured in terms 5,500 Microns
are achieved by air atomizing reference and is used in the
of volume (or mass) is a value nozzles. Generally speaking, the chart above.
Actual Drop Sizes
where 50% of the total volume largest spray drops are produced
of liquid sprayed is made up of More complete drop size data
These drop sizes are usually by full cone hydraulic spray noz- is available on all types of spray
drops with diameters larger than expressed in microns (microme- zles. In the hydraulic spray nozzle
the median value and 50% with nozzles. Contact your local
ters). One micron equals 1/25,400 series the smallest drop sizes are Spraying Systems Co. sales
smaller diameters. inch – or 0.001 mm. 3,175 microns produced by hollow cone spray engineer for more information.
Sauter Mean Diameter (SMD) equals 1/8 inch. nozzles, including the hydraulic
also expressed as D32: A means Other than the effects of the atomizing type or fine spray.
of expressing the fineness of specific material being sprayed, Within each type of spray pattern
a spray in terms of the surface the three major factors affecting the smallest capacities produce
area produced by the spray. drop size are nozzle type and the smallest spray drops, and the
The Sauter Mean Diameter is capacity, spraying pressure, and largest capacities produce the
the diameter of a drop having spray pattern type. Lower spray- largest spray drops. Because the
the same volume-to-surface area ing pressures provide larger drop Volume Median Diameter (VMD)
ratio as the total volume of all sizes, while higher spraying is based on the volume of liquid
the drops to the total surface pressures yield smaller drop
area of all the drops.

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Engineering Discussions: Key Performance Considerations

TECHNICAL/ENGINEERING REFERENCE
Impact Operating Pressure
Impact, or the impingement of a Inch as a percent of the theoreti- Unit Impact The values given in the tabulation
Spray Per Sq. Inch
spray onto the target surface, cal total impact and multiply Pattern Spray
as a Percent sections of the Spraying Systems Co.
by the theoretical total. The result Angle catalog indicate the most com-
can be expressed in several dif- Type of Theoretical
Total Impact*
ferent ways. The most useful is the unit impact in lbs.-f/sq. inch monly used pressure ranges for
15° 30%
impact value with regard to spray at 12" (30 cm) distance from 25° 18% the associated spray nozzle or
nozzle performance is the Impact the nozzle. 35° 13% accessory. Some spray nozzles
per Square Inch. Basically, this Flat Fan 40° 12% and accessories can perform
The highest unit impact in 50° 10%
value depends on the spray pat- lbs.-f/sq. inch is provided by 65° 7% below or above the pressures
tern distribution and the spray solid stream nozzles and can
80° 5% shown, while others can be modi-
angle. To obtain the Impact per be closely approximated by the
15° 11% fied at our factory or redesigned
30° 2.5%
Square Inch (pounds-force per formula: 1.9 x (spraying pressure, 50° 1%
to accommodate the requirements
square inch) of a given nozzle Full Cone of specific new applications.
psi). As with all spray patterns, 65° .4%
first determine the theoretical 80° .2%
the unit impact decreases as 100° .1% You should contact your local
total impact using the formula the distance from the nozzle Spraying Systems Co. sales
Hollow Cone 60° 80° 1 to 2%
shown below. increases, thereby increasing engineer when information on
* At 12" (30 cm) distance from the nozzle.
Then, from the chart on the right, the impact area size. the performance of spray nozzles
obtain the Impact per Square or accessories outside of the
pressure range given in this
FORMULA: catalog is required.

Theoretical Total Impact Spraying Water (pound - force) = .0526 x (gpm at spraying pressure) x √spraying pressure, psi

Specific Gravity
Specific gravity is the ratio of the A formula that can be 1
mass of a given volume of liquid used instead of the Capacity of liquid being sprayed = Capacity of water x √ specific gravity
to the mass of the same volume chart below is:
of water. In spraying, the main
effect of the specific gravity of a
liquid (other than water) is on the 1.5
capacity of the spray nozzle.
Since the values are based on 1.4
spraying water, a conversion
1.3
factor can be applied to determine
Conversion Factor

the nozzle capacity when using a 1.2

liquid other than water.
1.1
Specific Gravity versus Conversion Factor
1.0
Water
.9

.8
Key:
Conversion factor multiplied by the .7
capacity of the nozzle when spraying
water gives the capacity of the nozzle .6
when spraying a liquid with a specific
gravity corresponding to the conversion
factor. This conversion factor accounts .5 .6 .7 .8 .9 1.0 1.1 1.2 1.3 1.4 1.5 1.6 1.7 1.8 1.9 2.0
only for the effect of specific gravity on
capacity and does not account for other Specific Gravity of Liquid
factors affecting capacity.

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Engineering Discussions: Key Performance Considerations

TECHNICAL/ENGINEERING REFERENCE

Viscosity Temperature Surface Tension

Absolute (dynamic) viscosity is Although liquid temperature The surface of a liquid tends The property of surface tension
the property of a liquid which changes do not affect the spray to assume the smallest possible is more apparent at low operat-
resists change in the shape or performance of a nozzle, they size; acting, in this respect, ing pressures. A higher surface
arrangement of its elements often affect viscosity, surface like a membrane under tension. tension reduces the spray angle,
during flow. Liquid viscosity is tension, and specific gravity Any portion of the liquid surface particularly on hollow cone and
a primary factor affecting spray which do influence spray nozzle exerts a tension upon adjacent flat fan spray nozzles. Low sur-
pattern formation and, to a lesser performance. For the effects of portions or upon other objects face tensions can allow a nozzle
degree, capacity. High viscosity temperature changes on spray with which it is in contact. This to be operated at a lower pres-
liquids require a higher minimum nozzle performance see the force is in the plane of the sure. See the summary chart
pressure to begin formation summary chart below. surface and its amount per unit below for the general effects of
of a spray pattern and provide of length is surface tension. Its surface tension on spray nozzle
narrower spray angles as value for water is about 73 dynes performance.
compared to those of water. per cm at 70°F (21°C). The main
The general effects of a viscosity effects of surface tension are on
other than that of water are minimum operating pressure,
shown in the summary chart spray angle, and drop size.
below.

Nozzle Wear
Nozzle wear is typically charac- pressure, particularly when using Approximate Abrasion
terized by an increase in nozzle positive displacement pumps. Resistance Ratio of Typical
capacity, followed by a general Spray Nozzle Materials
Plastics are not shown in the
deterioration of the spray pattern. table due to the extremely wide Aluminum 1
Flat fan spray nozzles with ellip- Brass 1
variation in abrasion resistance Steel 1.5 to 2
tical orifices experience a nar- of various plastics depending MONEL 2 to 3
rowing of the spray pattern. In on the application environment, Stainless Steel 4 to 6
other spray pattern types the dis- type of nozzle, and operating HASTELLOY 4 to 6
tribution within the spray pattern Hardened Stainless
parameters. Spraying Systems Steel 10 to 15
deteriorates – without substan- Co. offers many nozzles in plastic STELLITE 10 to 15
tially changing the coverage area. materials. In selecting a plastic Ceramics 90 to 200
The increase in nozzle capacity material, please refer your spe-
Silicon Carbide
can sometimes be recognized by (Nitride Bonded) 90 to 130
cific requirements to your local Carbides 180 to 250
a decrease in system operating sales engineer.

Factors Affecting Spray Nozzle Performance: Summary

The information in the chart at liquid decreases the specific
Increase in Increase Increase Increase in Increase
right applies to most spray appli- gravity, thereby producing a Operating in Specific in Fluid in Surface
cations. However, because there greater flow rate while at the Pressure Gravity Viscosity Temperature Tension
are so many different types and same time decreasing the
Pattern Improves Negligible Deteriorates Improves Negligible
sizes of spray nozzles, the effects viscosity which reduces the flow. Quality
may vary in each specific appli- Spraying Systems Co. welcomes Capacity Increases Decreases • •• No Effect
cation. In some applications, the opportunity to assist you with Spray Increases Negligible Decreases Increases Decreases
there are inter-related factors specific application questions. Angle Then Decreases
which may balance-out certain Please contact your local sales Drop Decreases Negligible Increases Decreases Increases
effects. For instance, in the case engineer with your individual Size
of a hollow cone spray nozzle, requirements. Velocity Increases Decreases Decreases Increases Negligible
increasing the temperature of the Impact Increases Negligible Decreases Increases Negligible
Wear Increases Negligible Decreases •• No Effect

• Full cone and hollow cone increase; flat spray decreases

•• Depends on fluid being sprayed and spray nozzle used

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Engineering Discussions: Key Performance Considerations

TECHNICAL/ENGINEERING REFERENCE
Materials
Spraying Systems Co. manufac- experience dealing with special
Aluminum Hard Stainless Steel Sapphire
tures spray nozzles and acces- requirements involving corrosive, Aluminum Bronze HASTELLOY Silicon Carbide
sories in a wide range of hot, and abrasive liquids; suspen- Aluminum Oxide HAVEG (Nitride Bonded)
materials to meet the needs sions; and corrosive environ- Beryllium Copper ILLIUM Silicon Carbide
of all spraying applications. For ments. We would be pleased to Boron Carbide INCOLOY (Reaction Bonded)
Brass INCONEL Silicon Carbide
each “standard” nozzle there discuss your special application Bronze KEL-F (Sintered)
is a selection of “standard” requirements, including choices Cast Iron KYNAR Stainless Steels
materials which have been of suitable nozzle materials. The Ceramic
LUCITE (all grades)
Chrome Carbide
determined to meet the usual list at right tabulates some of the MONEL Steel
Copper
requirements of the applications materials from which we have CPVC
Naval Brass STELLITE
most commonly associated with fabricated spray nozzles and Nickel Tantalum
Cupro Nickel
DELRIN Nylon TEFLON
that type of nozzle. accessories. Plated or coated Platinum 317 LMN Stainless Steel
Ductile Iron
Throughout our 60-plus years nozzles can also be supplied Polycarbonate Titanium
DURANICKEL
as the leading manufacturer of on request. DURONZE Polyethylene Tungsten Carbide
EVERDUR polypropylene ULTIMET
spray nozzles and accessories, Polyurethane VITON
FRP
Spraying Systems Co. has Graphite PVC ZIRCALLOY
accumulated much application Hard Rubber Reinforced Polyester Zirconium

See page 15 for trademark credits.

Dimensions
Spray performance data and
nozzle dimensions are also
available in Metric Units. Write
for information.

Table of Equivalents
Volumetric Units — Equivalents Liquid Pressure — Equivalents
Volumetric Cubic Pound Liquid
Unit Fluid US Cubic Cubic Pressure Lb/In2 Ft Atmo- Inch kPa
Centi- of Liter Kg/Cm2 Bar
Ounce Gallon Foot Meter (psi) Water sphere Mercury (kilopascal)
meter Water
Cubic Lb/In2 (psi) • 2.31 .070 .068 .069 2.04 6.895
Centimeter • .034 2.2 x10–3 .001 2.64x10–4 3.53x10–5 1.0x10–6 Ft Water .433 • .030 .029 .030 .882 2.99
Fluid Ounce 29.4 • .065 .030 7.81x10–3 1.04x10–3 2.96x10–5 Kg/Cm2 14.2 32.8 • .968 .981 29.0 98
Pound of Atmosphere 14.7 33.9 1.03 • 1.01 29.9 101
Water 454 15.4 • .454 .12 .016 4.54x10–4
Bar 14.5 33.5 1.02 .987 • 29.5 100
Liter 1000 33.8 2.2 • .264 .035 .001
Inch
US Gallon 3785 128 8.34 3.785 • .134 3.78x10–3 Mercury .491 1.13 .035 .033 .034 • 3.4
Cubic Foot 28320 958 62.4 28.3 7.48 • .028 kPa
Cubic Meter 1.0 x106 3.38x104 2202 1000 264 35.3 • (kilopascal) .145 .335 .01 .009 .01 .296 •

Miscellaneous — Equivalents and Formulas

Linear Units — Equivalents Unit Equivalent Unit Equivalent
Linear
Milli- Centi- Ounce 28.35 Gr. Fahrenheit (F°) = 9/5 (C° + 32)
Unit Micron Mil Inch Foot Meter
meter meter Pound .4536 Kg. Celsius (C°) = 5/9 (F° – 32)
Micron • .039 .001 1.0x10–4 3.94x10–5 Horse-Power .746 Kw.
Circumference
Mil 25.4 • 2.54x10–2 2.54x10–3 .001 8.33x10–5 British Thermal Unit .2520 Kg. Cal. of a Circle = 3.1416 x
Millimeter 1000 39.4 • .10 .0394 3.28x10–3 .001 Square Inch 6.452 Sq. Cm. Diameter
Centimeter 10000 394 10 • .394 .033 .01 Square Foot .09290 Sq. M. Area of a Circle = .7854 x Square
Inch 2.54x104 1000 25.4 2.54 • .083 .0254 Acre .4047 Hectare of the Diameter
Foot 3.05x105 1.2x104 305 30.5 12 • .305 Acre 43.560 Sq. Ft. Volume of a Sphere = .5236 x Cube
Meter 1.0x106 3.94x104 1000 100 39.4 3.28 • of the Diameter
Area of a Sphere = 3.1416 x Square
of the Diameter

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SV-40007 6/30/00 2:46 PM Page 10 Dave ArtDept:WIP:Spraying Systems (SP):SV-40007:

Nozzle Maintenance
TECHNICAL/ENGINEERING REFERENCE

How nozzle maintenance can eliminate

quality problems, spray liquid waste, and
high operating costs
As the preceding pages indicate, maintenance schedule depends
there’s a multitude of factors on your particular application.
involved in selecting the best In some operations, nozzles are
nozzle for your application. still spraying usefully after thou-
And, just like other production sands of hours of operation; in
equipment, nozzles require others, however, nozzles require
maintenance: regular inspection, daily attention. Most nozzle
cleaning, and even replacement applications fall between these
in order to preserve final pro- extremes.
duction quality and to maintain At the very least, you should
production processes on a visually check for damage during
cost-efficient basis. every preventive maintenance
How often should you shutdown. Additional mainte-
nance scheduling depends on
inspect spray nozzles? application specifications, the
The type and frequency of your liquid used, and nozzle material.

Common causes of spray Erosion and wear. The gradual of the orifice can restrict the nozzle materials not intended for
removal of material from the flow and disturb spray pattern high-temperature applications.
nozzle problems surfaces of the nozzle orifice and uniformity.
What should you look for during internal flow passages causes Improper reassembly. Misaligned
inspection? The answer depends them to become larger and/or Caking. Overspraying, misting, gaskets, overtightening, or other
on your particular spraying or chemical buildup of material repositioning problems can result
distorted which can affect flow, on the inside or outer edges of in leakage as well as poor spray
applications. Sometimes it’s wear pressure, and spray pattern.
from a high-pressure process. the orifice from evaporation of performance.
Or caking from spraying a highly Corrosion. The chemical action liquid can leave a layer of dried Accidental damage. Inadvertent
viscous liquid. The seven most of sprayed material or the envi- solids and obstruct the orifice harm to an orifice can be caused
common causes include: ronment causes corrosion break- or internal flow passages. by scratching through the use of
down of the nozzle material. Temperature damage. Heat improper tools during installation
Clogging. Unwanted dirt or other may have an adverse effect on or cleaning.
contaminants blocking the inside

Erosion and wear Caked Corroded Heat damaged Damaged

Spray from clean nozzle Distorted spray from damaged

or clogged nozzle

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SV-40007 6/30/00 2:47 PM Page 11 Dave ArtDept:WIP:Spraying Systems (SP):SV-40007:

Nozzle Maintenance

TECHNICAL/ENGINEERING REFERENCE
How to check spray check the relative humidity for
humidity control.
nozzle performance
Depending on their importance Flow rate. The eye cannot
for your particular application, detect increased flow, so
you should check these five the flow rate of each nozzle
factors on a regular basis: should be checked periodically
by reading the flow meter or
collecting spray in a container
and the results compared to
specifications or to the
performance of new nozzles.
Spray pressure. Pressure in the
nozzle manifold can be checked
using a properly calibrated
pressure gauge.
Spray pattern. In many instances
you can visually check for
pattern uniformity. Changes
caused by orifice damage,
Product quality/application clogging, or caking are usually
results. Quality control inspection noticeable. However, to detect
could reveal product defects gradual orifice wear you may
caused by poor spraying need special measuring
performance such as uneven equipment.
coating, streaking, or structural Nozzle alignment. To provide
imperfections from improper uniform coverage, nozzles
product cooling. Application- should be oriented correctly in
specific measurements can relation to one another so that
also help you evaluate spraying all patterns are parallel.
performance; for example,
check the dust content of the
air for dust suppression and

We’ll help you set up and sustain a quality spray Spray Nozzle Maintenance Business. This 15-minute pro-
program. Handbook. This valuable, 56- gram provides an excellent
a nozzle maintenance page, illustrated booklet provides overview of “hidden” nozzle
The first step is an on-site evalu-
program a wealth of information about problems – how to detect
ation of your spraying operation.
Spraying Systems Co. will offer Our sales engineer can help you spray nozzle performance prob- them and how to avoid them.
assistance in developing a good identify hidden spray problems lems, causes, and solutions. It The program is available from
spray nozzle maintenance pro- that could be wasting your also includes a handy worksheet your local sales engineer.
gram for your spray installation. money, materials, time, and to help you calculate energy and Why put off proper nozzle
Simply contact your local sales contributing to defects in your materials costs of poor spray maintenance? The benefits
engineer. Their years of applica- finished product. nozzle performance. A copy of more cost-effective spraying
tions experience in many indus- is yours for the asking. could be yours immediately.
tries, along with the technologi- We’ve also developed educa-
tional materials and programs Spray Nozzle Maintenance Call your Spraying Systems Co.
cal back-up available from Video. Spraying Systems Co. sales engineer today to get
Spraying Systems Co.’s Technical to help you set up your nozzle
maintenance program: has produced a video program, started.
Services, can help you develop Making your Success our

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11
SV-40007 6/30/00 2:47 PM Page 12 Dave ArtDept:WIP:Spraying Systems (SP):SV-40007:

Drop Size Sampling, Terms, and Data Use

TECHNICAL/ENGINEERING REFERENCE

Drop Size Sampling Techniques

There are two different types of other is called flux (also known
drop size sampling techniques: as temporal).
one is known as spatial and the

Spatial Technique: The spatial the aid of holographic means,

technique (i.e., spatial distribu- high-speed photography, or light Measurement Volume
tion) is implied when a collection scattering instruments. This type
of droplets occupying a given of measurement is sensitive to
volume is sampled instanta- the number density in each
neously. Generally, spatial mea- class size and the number of
• Averaged over finite volume
surements are collected with particles per unit volume. • Instantaneous sample
• Sensitive to number density

Time
Flux Technique: The flux tech- generally collected by optical
nique (i.e., flux distribution) is measurements that are capable
implied when individual droplets of sensing individual drops. This
that pass through the cross- type of measurement is sensitive Measurement Cross-section
section of a sampling region are to the particle flux.
examined during an interval of
time. Flux measurements are

• Time averaged
• Sensitive to particle flux

Sampling Technique Summary

The sampling technique is critical The flux distribution may be In addition, these differences deposition, such as painting
for understanding drop size data. transformed to a spatial distri- depend on the type of nozzle, and agriculture, a flux sampling
Typically, nozzles measured using bution by dividing the number capacity, and spraying pressure. technique would be more
the spatial technique will report of samples in each class size by The sampling technique used appropriate.
drops smaller on average than the average velocity of the drops can also be application driven.
nozzles measured using the flux in that size class. If all drops in Applications, such as gas con-
technique. Sampling technique a spray are moving at the same ditioning, cooling, or similar
plays an important role when velocity, the flux and spatial dis- processes, would be better
comparing data from different tribution are identical. However, served with a spatial sampling
sources, and understanding the spray will generally exhibit technique. In applications
this issue would help resolve differences in drop velocities that requiring accurate spray
many data discrepancies. vary from class size to class size.

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SV-40007 6/30/00 2:47 PM Page 13 Dave ArtDept:WIP:Spraying Systems (SP):SV-40007:

Drop Size Sampling, Terms, and Data Use

TECHNICAL/ENGINEERING REFERENCE
Drop Size Analyzers
There are many drop size ana- holography. Non-imaging meth- analyzers are typically non- use proper testing procedures
lyzers available on the market ods can be subdivided into two intrusive, and thus they do not and take into account all test-
nowadays, most of which use classes: those that measure influence the spray behavior ing variables, including the
optical methods to characterize a large number of drops simul- during testing. analyzer’s limitations.
sprays. Optical methods fall taneously (ensemble) and Since repeatable test results
into two main categories: imag- those that count and size indi- are essential in comparing drop
ing and non-imaging. Imaging vidual drops one at a time (sin- size data, it is also essential to
includes photography and gle particle counters). These

Light Source Transmitter Spray Nozzle Receiver

Optics Spray Nozzle
(strobe)
Lens
Video Camera

Laser Detector

Scanning
Monitor
Receiver

Amplifier
A/D Converter

Console Printer
Computer

Reprinted by permission of Spraying Systems Co. Reprinted by permission of Malvern Instruments, Inc.
Wheaton, Illinois Southborough, Massachusetts

Typical Optical Imaging Analyzer Malvern Analyzer

Spray Nozzle Spray Nozzle

45° Mirror 45° Mirror Probe Volume
Laser

Beam Beam Splitter DET 1

Path Objective and DET 2
F = 60mm Frequency Shift DET 3
Module
Signal
Processing
Secondary
Zoom Lens
Scattered Light Computer
2.0 µm He-Ne 62
Laser Interference Pattern
Photodiodes

DET 1 Printer
Signal 45° Mirror
Processing DET 2

Printer Computer Photodiode DET 3

Array
Reprinted by permission of Particle Measuring Systems, Inc. Reprinted by permission of Aerometrics Inc.
Boulder, Colorado Sunnyvale, California

PMS-Optical Array Probe (OAP) Phase Doppler Particle Analyzers (PDPA)

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SV-40007 6/30/00 2:47 PM Page 14 Dave ArtDept:WIP:Spraying Systems (SP):SV-40007:

Drop Size Sampling, Terms, and Data Use

TECHNICAL/ENGINEERING REFERENCE

Terms Related to Drop Population

Drop size distribution: The size pling zone during a given interval indicative of the uniformity of the Spatial resolution: The size and
distribution of drop present in a of time, wherein individual drops drop size distribution. RSF is physical separation of drop sam-
spray sample. This distribution is are counted and sized. defined as: ples relative to the total region of
typically expressed by the size Global: Indicates measurements interest, taking into account the
versus the cumulative volume or observations of a total disper-
D VO.9 D VO.1 magnitude of drop size variations
percent. within the region.
sion of drops (e.g., a sample rep- D VO.5
Flux: The number of drops flow- resentative of an entire liquid
ing through a given plane area spray). Representative sample: A sample
per unit time. Local: Indicates measurements containing enough measured ele-
Flux-sensitive: A sampling or observations of a small part of ments that the effect of random
process where the magnitude a larger region of interest. fluctuations is acceptably small.
measured responds to the traffic Number density: The number of Spatial averaging: The combina-
of drops through the sampling drops contained in a specified tion of drop size distributions for
region. volume of space at a given regions or locations within a liq-
Flux/temporal size distribution: instant. uid dispersion into a distribution
The size distribution of drops representative of a larger
Relative Span Factor (RSF): sampling region.
passing through a planar sam- A dimensionless parameter

Drop Size Data Form

Drop size data is published or will often list the VMD or SMD of or flow rate range. This type of count for each size class, and the
reported in many forms. The most specific nozzles at specific pres- data is best used to illustrate the characteristic diameters. The
common forms are characteristic sure or flow rate conditions. This effect of increased pressure or graphical data form will typically
diameter (VMD/SMD) reports and data is best used to compare the flow rate on drop size. include all the information includ-
graphs, and drop size distribu- drop size from one nozzle to Drop size distributions: A tabular ed on the tabular form; however,
tions (graphical and tabular). another at specific operating or graphical representation of the cumulative volume percent
Depending on the intended use, conditions. the drop size distribution of a versus drop size is represented
some data forms could be more VMD/SMD graphs: A graphical particular nozzle at a specific with a graph. This type of data is
useful than others. The following representation of the requested operating condition. The tabular best used to study the complete
is a guide for the suggested use drop size information. This will data form will typically list the drop size distribution of a spray.
of each data form. often contain several nozzles analyzer used, sampling method,
VMD/SMD report: A tabular rep- on the same graph. The rep- and data processing criteria.
resentation of the requested drop resentation is VMD or SMD plot- Also included are the cumulative
size information. These reports ted against requested pressure volume distribution, the percent

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SV-40007 6/30/00 2:47 PM Page 15 Dave ArtDept:WIP:Spraying Systems (SP):SV-40007:

Drop Size Sampling, Terms, and Data Use

TECHNICAL/ENGINEERING REFERENCE
Practical Considerations for Drop Size Data Use
As shown on these pages, drop other words, if a test result indi- particularly from different uniform the spray will be (i.e.,
size data does not only depend cates a VMD of 100 µm, another sources, it is extremely important tightest distribution, smallest
on many variables, but is subject test with results ranging from to know the type of instrument variance from Dmax to Dmin).
to interpretation as well. The 94 to 106 µm can be considered and range used, the sampling RSF provides a practical means
following are some suggested identical. technique, and the percent vol- for comparing various drop size
guidelines to facilitate under- Instrumentation and reporting ume for each size class in order distributions and should be used
standing the drop size data and bias: While instrumentation to make valid data comparisons. when possible.
to help one use it effectively. and reporting bias have been dis- Relative Span Factor: Comparing
Data collection repeatability and cussed in great detail, it is impor- drop size distributions from alter-
accuracy: A drop size test is said tant to realize this bias will nate nozzles can be confusing.
to be repeatable if the data from directly affect those responsible The Relative Span Factor (RSF)
individual tests does not deviate for evaluating nozzle perfor- reduces the distribution to a sin-
by more than ±6 percent. This fig- mance and making recommen- gle number. This parameter is
ure could be larger for nozzles dations. There are a number of indicative of the uniformity of the
with a non-uniform surface finish formats used for reporting drop drop size distribution. The closer
(silicon carbide, ceramics). In size data. When evaluating data, this number is to one, the more

Trademark Registrations and Ownership

Trademark Property of:

Celcon® Hoechst Celanese Corporation

Delrin® E.I. DuPont de Nemours and Company
Duranickel® Inco Alloys International, Inc.
Everdur® BancBoston Financial Company
Fairprene® E.I. DuPont de Nemours and Company
Hastelloy® Haynes International, Inc.
Haveg® Ametek, Inc.
Illium® Stainless Foundry & Engineering, Inc.
Incoloy® The International Nickel Company, Inc.
Inconel® Inco Nickel Sales, Inc.
Kynar® Elf Atochem North America, Inc.
Lucite® E.I. DuPont de Nemours and Company
Monel® The International Nickel Company, Inc.
Refrax® Stemcor Corporation
Ryton® Phillips Petroleum Company
Stellite® Stoody Deloro Stellite, Inc.
Teflon® E.I. DuPont de Nemours and Company
Ultimet® Haynes International, Inc.
Viton® DuPont Dow Elastomers
Zircalloy® E.I. DuPont de Nemours and Company

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SV-40007 6/30/00 2:47 PM Page 16 Dave ArtDept:WIP:Spraying Systems (SP):SV-40007:

Represented by:

P.O. Box 7900 • Wheaton, Illinois 60189-7900 USA

Phone 1-800-95-SPRAY • Fax 1-888-95-SPRAY
Outside the U.S., Phone 1(630) 665-5000 • Fax 1(630) 260-0842
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Bulletin No. 498

Printed in U.S.A. ©Spraying Systems Co. 2000