RPR INDUCTION-BASED RUST & PAINT REMOVAL
Contents
1. Technical data 50 kW 3 phase 360 480 V 50 60 Hz other voltages optionally available Power source must be 3 phase 125 A fused Power supply Fusine Enerey efficientcy Approximately 90 Protection class IP 69 Ex version optionally available Cooling system Water cooling closed loop cooling optionally available min 12 l min clean freshwater 3 US eall at min 4 bar pressure 220 ke 460 Ibs 800 x 600 x 800 mm 32 x 24 x 32 in Weight LxWxH GE RPR is supplied with CE marking and Manufacturer s CE Declaration of Conformity Warranty A 1 year warranty on defective parts and good workmanship is applicable subject to proper handling use and maintenance of the equipment by the user In compli ance with the relevant User Manual and Warranty Terms RPR versus Conventional surface preparation Abrasive blasting and water jetting are established and excellent surface preparation methods each with their specific characteristics and merits RPR will not always be suitable to replace these methods However abrasive blasting will increase the waste mass and its related high collection and disposal costs by a factor of many times while depending on local conditions and regulations water jetting often requires continuous pickup decontamination and recycling of water When and where the RPR system is suitable and appropriate it offers sienificanteconomic technical and environmental advantages In general thick and difficultto2. amp Paint Removal fast environmentally friendly and low cost RPR Testing In the lab and in the field RPR has been field tested extensively in Europe and SE Asia over a period of 18 months and has proven to be highly efficient as well as very reliable It has no moving parts and requires very little maintenance research and test program by the Norwegian National Institute of Technology has shown conclusively that electromagnetic emission from all parts of the RPR equipment are far below the established limits for operator and equipment safety The emissions of potentially irritant or hazardous fumes caused by heat transfer from the steel to the coating remain far below the applicable safety limits Paint residues and fumes can be collected with standard off the shelf equipment Testing has also shown that the temperature eradients remain far below the applicable safety limits for structural integrity of steel A temperature range of between 150 and 200 C is ample to cause disbonding of rust mill scale and most paints and coatings kt rv _ The graph shows the temperatures induced with RPR in 3 205 positions against time lapsed in a 5 mm thick low carbon r ae steel plate at 50 kW energy load A ied 1 upper curve RPR treated surface Li 2 middle curve at 2 5 mm depth an 3 lower curve at 5 mm backside 200 C upper curve is reached within 0 3 seconds At 2 5 mm penetration the te
3. RPR treatment depending on job and product specifications an afte treatment of the surface may be required for example a fast sweep blast to give a new surface profile or water washing to remove water soluble salts Many paint manufacturers however now offer good surface tolerant coatings that in many cases can be applied direct over RPR treated surfaces without problem If a sweep blast is done after RPR treatment it will be obvious that abrasive consumption and related costs are very significantlyreduced compared with a full dry blast from the start www norspray no 10 Induction based rust amp paintremoval NORSPRAY Removal rates per hour 20 to 200 m2 215 to 2150 ft2 At an energy output between 10 and 50 kW RPR generally achieves paint and rust removal rates of 20 200 m2 per hour 215 2150 ft2 Productivity depends on the type and condition of surface to be treated as well as the type condition and thickness of coating to be removed as well as other variables The following results were achieved in the field with fairly difficult to remove coatis thickness range 400 to 500 microns 16 20 mils and can be regarded as realistic Energy output Removal rate per hour 10 kW 20m2 215 ft2 17 kW 33m2 377 ft2 25kW 40m2 430 ft2 90 kW 0 m2 753 ft2 With coating thicknesses of 300 500 microns 12 20 mils RPR will usually show removal rates of between 50 and 200 m2 per hour 540 2150 ft2 at full energy output 50
4. blast coatings are handled best with the RPR induction method Conventional RPR System Productivity Low Hieh m per hr 5415 20 200 ft per hr 90 160 215 2150 Enerey consumprion Hieh Low kWh per m 3 00 0 75 kWh per ft 0 28 0 07 Waste contamination medium to high minimal to low Disposal cost medium to high minimal to low Dust emission dry medium to high zero n a Water mist Wj medium to high zero n a Containment structure expensive zero n a Noise level Safety operator Other factors Environment high 112 1155 dBA intrinsically unsafe intrinsically unsafe unfriendly high costs practically silent intrinsically safe intrinsically safe friendly minimal costs WWwWw norspray no 12 Induction based rust amp paintremoval NORSPRAY Advantages of using RPR m RPRremoves coatings and rust 5 20x faster than conventional methods m Production with 1 RPR unit approx 20 to 200 m per hour depending on conditions m Pracitically noiseless no nuisance to the surroundings E No abrasive media or significant reduction in case of sweep blast after treatment m Very little waste and disposal only the removed paint and rust minimal costs environmentally Friendly m Complete removal or with restrictions selective coat removal m RPR treated surfaces are suitable for application of most paint systems especially surface tolerant coatines m No abrasive particle bounce back m No dust
5. emission no costly and time consuming containment of structures with dry sweep blast after treatment some dust emission will occur m Other disciplines welders fitters mechanics electricians etc can carry on workine nearby m Operator can use standard personal protection equipment as Is customary for mechanical work in confined spaces respiratory protection and proper ventilation m Safe for operator and surroundings no known health or safety hazards E Energy bonus kWh per surface unit only 1 4 of conventional methods E Can be used in wet environments and on wet surface working in rain is no problem m Inductor stripping heads in many shapes and sizes and for many applications m Easily adaptable for semi automation with remote controlled robot or manipulator equipment m No moving parts hardly any wear and tear practically mainenance free m No adverse effects on electric or electronic equipment such as audio video computers navigation equipment measuring instruments cathodic prot systems m CE makine and Manufacterer s CE Declaration of Conformity m Warranty I year m High production ensures fast turnaround resulting in shorter downtime lower costs per surface unit lower total project costs Summary With productivity often in excess of 5 10 times higher than conventional methods sometimes even better RPRis fast efficient and economic powerful and attractive alternative for the removal of coa
6. head position The system requires 12 I min 3 US gall of clean freshwater at 4 bar When working at a height of 20 m 66 ft or more above the location of the main unit the water pressure must be increased to 5 bar Optionally a closed loop cooling system can be supplied equipped with its own water tank and circulation pump no pressure regulation A choice of various designs and cooling media is available depending on the specific conditions at thejob location This option comes mounted as a box on the main unit with inlet and return connections If clean water is not available the cooling system A RPR cooling water system l i Now diagram must be equipped with a special water filter contact RPR Technologies for details Ceding vater niet HA cooing woer return www norspray no 7 Induction based rust amp paintremoval NORSPRAY Various equipment and accessories RPR Induction Generator The physical size of the machine is quite small 800x600x800 mm and the weight is approximately 220 ke 460 Ibs The machine is robustly built for site work E aboard ships or on offshore rigs mM inside tanks or on floating roofs E onor under bridges etc etc The unit can be wheeled around but it can also be handled by forklift or crane Standard RPR Inductor Body The standard hand held inductor unit anda flat 20 cm wide coil ead is supplied with all systems Multiple coil heads can be ordered see b
7. NORSPRAY Utstyr til overflateindustrien RPR INDUCTION BASED RUST amp PAINT REMOVAL te chnologies Gr WWWw norspray no Induction based rust amp paintremoval NORSPRAY The innovative RPR Rust amp Paint Removal System is a highly cost effective and extremely efficient method for removine paint and corrosion products from steel surfaces This patented system is based on induction heatine a proven reliable technology that has been further devel oped by RPR Technologies AS The RPR system delivers a cost saving and environmentally friendly method of surface preparation EXTREMELY FAST COATINGS REMOVAL NO NOISE NO ABRASIVES OR WATER REMOVES DIFFICULT COATINGS NO DUST CLEAN amp SAFE www norspray no 2 Induction based rust amp paintremoval NORSPRAY The RPR concept RPR removes coatings mill scale rust bacterial corrosion and oil amp grease residues from electrically conductive surfaces steel etc by breaking the interfacial bonding between the material to be removed and the substrate usine controlled localized induction heating with a minimum consumption of enerey The principle of induction heatine The RPR induction generator sends alternating current Magnetic field through an induction coil which generates an electro FEE EET maenetic field This magnetic field induces eddy JE a a PPR currents ina conductive material like steel i m mn DA mn Due to the resist
8. ance of the steel these currents are 1 M 1 M 1 M 1 M converted to heat induction heatine a Er a The heat is generated below the coating resulting in quick and clean disbonding The RPR system is ideal for the removing paint rust and other coatings vulcanized rubber fire protectant epoxies etc with control possibilities for the following functions Frequency of the electromaenetic field Enerey consumption Disbonding temperature range Heat penetration Removal speed With above setting possibilities RPR delivers unequalled performance and is the system of choice for cost effective safe and environmentally friendly surface coating removal from steel substrates RPR Is ideal for marine tanks offshore and land based pipelines www norspray no 3 Induction based rust amp paintremoval NORSPRAY How does it work SO Rust amp Paint Removal by controlled induction heating INDUCTION STRIPPING HEAD ee ae Perret errr rrr rrr rere rrr rrr rrr rrr rrr rrr rr rrr Induction heats only the steel substrate not the paint PAINT ON REVERSE SIDE OF TREATED SURFACE Localized induction heating mem means that the coating on NG reverse side of the steel is not affected The basic components needed for RPR surface preparation are Main Induction m AC power supply Unit 220 kg m The patented RPR system consisting of the RPR induction generator unit with Induction
9. chlorinated rubber coating have different disbonding temperature charac teristics but can both be removed by RPR with equal ease Vulcanized material or very thick glued on rubber linings can also quickly and easily be disbonded and removed The same applies to powder coatings always hard to remove now easy as pie with RPR Selective coating removal is sometimes possible depending on the material s temperature characteristics and only from the bottom and up the RPR process starting with induction heating of the steel substrate Possible is for example leave a zinc silicate primer intact and remove other coating on top or leave an iron oxide primer intact while removing a bituminous coating on top Images from typical RPR coating removal jobs Solventfree coaltar polyurethane pipe coating approx 2 5 3 Chlorinated rubber 25 year old pitted deck approx 1500 mm 100 120 mils micron 60 mils Epoxy mastic Norsok system 1 approx 250 micron 10 Many coats mix alkyds chlorinated rubber approx mils 1500 micron 60 mils Mix mainly alkyds on mill scale 60 year old crane approx Epoxy powder coating pipe coating approx 1500 micron 1000 1500 micron 40 60 mils 60 mils www norspray no Induction based rust amp paintremoval NORSPRAY Surface cleanliness RPR gives a surface cleanliness which depends on the condition of the surface to be treated and the type and conditi
10. control panel unit amp head many sizes an intermediate transformer the RPR inductor hand held unit with induction coil paint strippine head SD system cables with water cooling le WT D m An electrically conductive work piece pr s the steel surface to be treated Connector transformer box available Extention cable max 100 m While the system Is activated the power supply sends alternating current through the heating coil generating an electromagnetic field and inducing eddy currents within the work piece giving precisely controlled amounts of clean localized heat without any physical contact between the inductor head and the work piece no wear and tear This controlled localized heating causes instant disbondine of coatings and rust or mill scale beneath the inductor head position The heating pattern Is always the same for a given set up ensuring consistency and optimizing the resulting surface treatment quality When activated the process starts instantly inducing heat in the work piece immediately achieving control of the disbondine temperature level within milliseconds The RPR induction heating is highly directional a very small area of the work piece limited to the position of the inductor stripping head is induction heated without affecting surrounding areas Power input Is controlled automatically to achieve the temperature range required for slower or faster heating and disbondin
11. e www norspray no 4 Induction based rust amp paintremoval NORSPRAY RPR induces heat energy only where and when it is needed As induction heating by itself does not produce harmful emissions exhaust gases smoke loud noise or waste heat there is no negative impact on the surrounding environment RPR uses only 25 of the enerey per surface unit required for conventional methods Power consumption RPR abrasive blasting water jetting kWh per m2 0 75 3 00 kWh per ft2 0 07 0 28 The energy efficient RPR process converts over 90 of the enegy expended into useful heat This represents a much higher efficiency rating than is possible with conventional surface preparation methods The results are reduced costs and time savings Stand by heat loss is reduced to a minimum since the heat is only active while the system is actually working i e performing its task There is a correlation between the frequency of the electromagnetic field and the heat penetration in the work piece m higher frequency less penetration m lower frequency more penetration m this function can be controlled with the RPR system RPR can be pre set by the operator to achieve repeatable optimum performance depending on the condition of the surface to be treated the material to be removed and other applicable specifications RPR Rust amp Paint Removal by localized induction heatine The inductor head generates the electromagnetic field and i
12. elow and an optional extention shaft will allow the operator to stand upright while rolling the coil head over horizontal surfaces Many different inductor coil heads available RPR can provide an almost limitless range of special designs for the treatment of various diameter pipes flanges beams corners nutsand bolts rivets etc Changing the inductor heads takes only minutes Contact RPR for more information regarding different coil head types and designs Crawler system this image is only an example Inductor heads can easily be fitted to many standard robot and manipul tor systems similar to those used for dry abrasive blasting or UHP water jetting Remote controlled equipment for semi automatic applications Is available in many different types and brands Contact RPR for more information Which coatings can be removed RPR removes most types of coatings including thick fireproofi as well as rust An exception Is inorganic zinc zinc silicate which requires a high disbonding temperature As it is usually preferred to leave a good zinc silicate intact rather than remove it and since it requires a temperature closer than desired to the level that may adversely affect steel properties it is not recommended to use RPR for this application www norspray no RPR TECHNOLOGIES Induction based rust amp paintremoval D NORSPRAY The RPR system features temperature control settings an iron oxide based primer and a
13. kW Maximum coating thickness that RPR will remove is in range of 20 30 mm 800 1200 mils At very high thicknesses removal speed and productivity will decrease Figures are based on field results and will varycase by case depending on a number of variables and job conditions Workine in confined spaces When working inside tanks or similar confined spaces proper ventilation as also customary for dry blastine should be used Paint disbonding by induction heating may cause irritating or hazardous fumes therefore the operator should always use respiratory protection when workine In confined spaces Workine in explosion hazardous environments Depending on various conditions such as the type of abrasive media being used abrasive blasting carries an inherent risk of sparking from particles impacting on the steel surface Such sparks are of very low intensity and need not necessarily be hazardous However this risk factor is not at all present when using RPR an additional safety feature which can be important when working In or around hazardous environments like oil tankers oil amp eas installations offshore rigs oil refine les and petrochemical plants storage tank farms etc The small area between the inductor stripping head and the surface is regarded as hot work zone in that respect RPR is comparable to abrasive blasting and similar methods www norspray no 11 NORSPRAY Induction based rust amp paintremoval
14. mperature is then only 50 60 C At 5 mm depth untreated backside hardly any temperature rise is detectable www norspray no 6 Induction based rust amp paintremoval NORSPRAY RPR equipment set up The system consists of a compact Induction Generator featuring the unique patented RPR control system enabling control of frequency temperature and heat penetration In addition there is the special RPR handheld Inductor Head equipped with 2 sensors regulating the temperature in relation to the speed of operator movement The Inductor Head is connected to the Induction Generator with special cable packs featurine water cooline Standard length of a cable pack is 20 m 66 ft plus a whip end for easy operator handling of another 15 m 50 ft It is possible to work with up to 4 cable packs plus the 15 m whip end allowing a work radius of up to 100 m well over 300 ft away from the Generator unit In addition power Input cables of any preferred leneth can be used IP PG TU SULLY PELA a VET MEAN ENER mer AEE PARMI Pe 272 EM Fa isksrsinsine ial mesen r Tai FG Fu z zint en is ba na sig EF EE amp a saM kl T Diagram of typical RPR Rust amp Paint Removal system Cooling system The RPR system features water cooling for the power cable packs and the inductor stripping head The circuit is protected against low water flow by tripping sensrs with operator re set at the stripping
15. on of the coating to be removed RPR will in most cases also clean the pores of the steel and even corrosion pittings A heavily corroded surface with a lot of rust will usually give a lesser grade of cleanliness than a surface with little rust and still mostly covered with coatine When removing materials with thermoplastic properties like chlorinated rubber or bituminous coatings heat transfer from the steel will soften and even melt the underside of the coating During the removal process this slight melt back will often cause tiny paint particles to flow back into the pores andre cure These particles can subsequently not be removed by scraping and will show up as a very thin visible residue almost like a form of discolouration If necessary this residue can easily and quickly be removed by a dry or wet sweep blast both with very low abrasive consumption or by water jetting Generally RPR will give a visual grade of cleanliness in the range of commercial to near white blast Mm ISOSa2toSa2 5 m SSPC SP6toSP 10 a lt gt gt __ gt Epoxy tie coat epoxy mastic polyurethane topcoat Norsok system 1 dft 350 micron 14 mils ISO Sa 2 5 SSPC SP10 NACE 2 Surface profile Like UHP water jetting RPR does not produce a new surface profile but it willbring back the profile as present under the coating prior to its removal After treatment Before application of certain coatings following
16. s movd by the RPR operator over the surface to be treated At the position of the inductor head the steel reaches the required preset temperature range within milliseconds This causes instant disbonding between paint rust mill scale etc With the induction heat penetrating only 0 3 0 5 mm into the substrate paint and rust will be disbonded on the treated side of the object while any coating on the reverse side will not be damaged or affectedat all Paint rust mill scale etc come loose and can easily be peeled off or removed otherwise with scraper tools or similar equipment Oil and grease residues present on the surface will also be removed by RPR induction heating A general recommendation is that steel objects to be RPR induction treated should have a minimum thickness of 9mm slightly less than 74 RPR has been tested on steel plates of 3 mm thickness just under The coatings removal was a success but RPR recommends that operators themselves run trial tests on all steel less than 9mm before full coatings removal jobs www norspray no 9 Induction based rust amp paintremoval NORSPRAY The image below shows how the RPR system disbonds coatings MH inductor head yellow at a distance of 3 5 mm 1 4 from the surface M disbondine white occurs between the paint blue and the steel grey MH induction heating red area with penetration of approx 0 3 0 5 mm 1 2 mils INDUCTOR ou HEATED AREA SI Rust
17. tings linings and rust from steel surfaces maintenance of ships the offshore industry land based structures bridees cranes pipelines storage tanks power stations oil refineries petrochemical plants gas installations etc Bottom line economy for whom It really counts for the contractor as well as the facility owner www norspray no 13
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