RPR Induction-based rust & paint removal
Contents
1. RPR Induction based rust amp paint removal The innovative RPR Rust amp Paint Removal System is a highly cost effective and extremely efficient method for removing paint and corrosion products from steel surfaces This patented system is based on induction heating a proven reliable technology that has been further developed by RPR Technologies AS The RPR sys tem delivers a cost saving and environmentally friendly method of surface preparation e EXTREMELY FAST COATINGS REMOVAL e NO NOISE e NO ABRASIVES OR WATER e REMOVES DIFFICULT COATINGS e NO DUST e CLEAN amp SAFE RPR Technologies Induction based rust amp paint removal The RPR concept RPR removes paint coatings thick 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 using controlled localized induction heating with a mini mum consumption of energy The principle of induction heating The RPR induction generator sends alternating Magnetic field current through an induction coil which gener ates an electro magnetic field This magnetic aie ce ee Gen i field induces eddy currents in a conductive mate ws PN ZN AN i rial like steel Due to the resistance of the steel e fe 2 eB 2 these currents are converted to heat induction SS gt heating The heat is generated below the coat E ing resu2. 215 1076 ft2 at full energy output 50 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 productiv ity will decrease Figures are based on field results and will vary case by case depending on a number of variables and job conditions Working in confined spaces When working inside tanks or similar confined spaces proper ventilation as also customary for dry blasting should be used Paint disbonding by induction heating may cause irritating or hazardous fumes therefore the operator should always use respiratory protection when working in confined spaces Removal of fire retardant coatings such as Removal of hard and soft vulcanized rubber Chartek from 8000 to 13000 microns from 12000 to 15000 microns Induction based rust amp paint removal RPR Technologies Technical data Power supply 50 kW 3 phase 360 500 V 50 60 Hz Fusing Power source must be 3 phase 125 A fused Energy efficiency Approximately 90 Cooling system Water cooling closed loop cooling optionally available min 10 l min clean freshwater 2 5 US gall at min 4 bar pressure Weight 220 kg 460 lbs LxWxH 800 x 600 x 800 mm 32 x 24 x 32 in CE RPR is supplied with CE marking and Manufacturer s CE Declaration of Conformity Warranty A 3 year warranty on defective parts and good workmanship is applicable subject to proper handling use and maintenance
3. AREA 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 mov ing parts and requires very little maintenance A research and test program by the Norwegian National Institute of Technology has shown conclusively that electromagnetic emission from all parts of the RPR equip ment 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 resi dues and fumes can be collected with standard off the shelf equipment Testing has also shown that the temperature gradients 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 Mavens The graph shows the temperatures induced with RPR in 3 AEE T positions against time lapsed in a 5 mm thick low carbon steel plate at 50 kW energy load R bolir pan E 1 upper curve RPR treated surface wee BSE 2 middle curve at 2 5mm depth miner sie 3 lower curve at 5 mm backside emg d yan biep Suissa Cope beet E 200 C upper curve is reached within 0 3 seconds At 2 5 mm penetration the temperature is
4. No moving parts hardly any wear and tear practically maintenance free No adverse effects on electric or electronic equipment such as audio video computers navigation equipment measuring instruments cathodic prot systems CE marking and Manufacturer s CE Declaration of Conformity Warranty 3 years High production ensures fast turnaround resulting in shorter downtime lower costs per surface unit lower total project costs Bottom line economy for whom it really counts tomthe contractor as well as the facility owner technologies Summary With productivity often in excess of 5 10 times higher than conventional methods sometimes even better RPR is fast efficient and econom ic a powerful and attractive alternative for the removal of coatings linings and rust from steel surfaces mainte nance of ships the offshore industry land based struc tures bridges cranes pipe lines storage tanks power stations oil refineries petrochemical plants gas installations etc More information Please contact us for more information RRP Technologies A S Rolighetsvegen 7C 3933 Porsgrunn Norway Tel 47 3560 3538 Fax 47 6743 0057 www rprtech com
5. 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 nuts and 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 manipulator 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 fireproofing as well as thick types of 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 RPR Technologies Induction based rust amp paint removal The RPR system features temperature control settings an iron oxide based primer and a chlorinated rubber coating have different disbonding temper
6. of the equipment by the user in compliance 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 significant economic technical and environmental advantages In general thick and difficult to blast coatings are handled best with the RPR induction method Conventional RPR System Productivity low high m2 per hr 5 15 20 100 ft2 per hr 50 160 215 1076 Energy consumption high low kWh per m2 3 00 0 75 kWh per ft2 0 28 0 07 minimal to low mimimal to low Waste contamination Disposal cost medium to high medium to high 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 112 115 dBA intrinsically unsafe intrinsically unsafe unfriendly high costs practically silent intrinsically safe intrinsic
7. then only 50 60 C Bedek Mibo At 5 mm depth untreated backside hardly any temperature RPR Technologies Induction based rust amp paint removal RPR equipment set up The system consists of a compact Induction Generator featuring the unique pat ented RPR control system enabling control of frequency temperature and heat penetra tion 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 featuring water cooling Standard length of a cable pack is 20 m 66 ft plus a whip end for easy operator handling of another 5 m 16 ft It is possible to work with up to 5 cable packs plus the 5 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 length can be used APR MAG CONTROLLED INDUCTION HEATANG RUST S PAINT REMOVAL SYSTEM PARER Soy ee pal ep het PA oie eT TG OC 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 sensors with operator re set at the stripping head position The system requires 10 l min 2 US gallons min of clean fr
8. water cooling e An electrically conductive work piece i e the steel surface to be treated 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 disbonding of coatings and rust or mill scale beneath the inductor head posi tion 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 disbonding 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 auto matically to achieve the temperature range required for slower or faster heating and disbonding RPR Technologies Induction based rust amp paint removal RPR induces heat energy only where and when it is needed As induction heating by itself does not produce harmful emissions smoke loud noise or waste heat and th
9. ally safe friendly minimal costs Advantages of using RPR RRP removes coatings 5 20x faster than conventional methods Production with 1 RPR unit approx 5 to 100 m2 per hour depending on conditions Practically noiseless no nuisance to the surroundings No abrasive media or significant reduction in case of sweep blast after treatment Very little waste and disposal only the removed paint and rust minimal costs environmentally friendly Complete removal or with restrictions selective coat removal RPR treated surfaces are suitable for application of most paint systems especially surface tolerant coatings No abrasive particle bounce back Novdust emission no costly and time consuming containment of structures with dry sweep blast as after treatment some dust emission will occur Other disciplines welders fitters mechanics electricians etc can carry on working nearby Operator can use standard personal protection equipment as is customary for mechanical work in confined spaces respiratory protection and proper ventilation Safe for operator and surroundings no known health or safety hazards Energy bonus kWh per surface unit only 1 4 of conventional methods Can be used in wet environments and on wet surfaces working in rain is no problem Inductor stripping heads in many shapes and sizes and for many applications Easily adaptable for semi automation with remote controlled robot or manipulator equipment
10. ature 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 proc ess 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 S e Pigg oe i Chemical Tank France June 2007 elites tank bottom Aircraft Carrier US May 2007 E tg aeai lining Fiberglass reinforced epoxy 1500 2000 microns coating Epoxy with carborundum grit 2000 3000 microns Naval Shipyard US January 2008 Removing various Ohio Oil Platform North Sea June 2007 Removing coatings including rubber and anti skid Chartek fire retardant 8000 13000 microns Railroad Bridge UK June 2007 Removing epoxy paint Ship Hull Gothenberg Sweden February 2008 Removing 400 600 microns with iron oxide primer epoxy coating Epoxy tie coat epoxy mastic polyurethane topcoat Norsok system 1 dft 350 micron 14 mils ISO Sa 2 5 SSPC SP10 NACE 2 Inductio
11. e application of certain coatings following RPR treatment depending on job and product specifications an after 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 significantly reduced compared with a full dry blast from the start RPR Technologies Induction based rust amp paint removal Removal rates per hour 20 to 100 m2 215 to 1076 ft2 At an energy output between 10 and 50 kW RPR generally achieves paint and rust removal rates of 20 100 m2 per hour 215 1076 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 coatings thick ness range 400 to 500 microns 16 20 mils and can be regarded as realistic Energy output Removal rate per hour 10 kW 20 m2 215 ft2 17 kW 35 m2 377 ft2 25 kW 40 m2 430 ft2 50 kW 70 m2 753 ft2 With coating thicknesses of 300 500 microns 12 20 mils RPR will usually show removal rates of between 20 and 100 m2 per hour
12. ere is no negative impact on the surrounding environment RPR uses only 25 of the energy 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 energy 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 o higher frequency less penetration o lower frequency more penetration o this function can be controlled with the RPR system RPR can be pre set by the operator to achieve repeatable optimum performance de pending 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 heating The inductor head generates the electromagnetic field and is moved by the RPR operator over the surface to be treated At the position of the inductor head the steel reaches the required pre set temperature range within milliseconds This causes instant disbond ing between paint rust mill scale etc Wi
13. eshwater 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 sup plied equipped with its own water tank and circula tion pump no pressure regulation A choice of various designs and cooling media is available depending on the specific conditions at the job location This option comes mounted as a box on the main unit with inlet and return connections RPR cooling water system flow diagram NOLATOH GENERATOR STPPP HEAD If clean water is not available the cooling system must be equipped with a special water filter E Coding woter iet ME Cooting water return contact RPR Technologies for details Induction based rust amp paint removal RPR Technologies Various equipment and accessories RPR Induction Generator The physical size of the machine is quite small 800x600x800 mm and the weight is approximately 220 kg 460 lbs The machine is robustly built for site work o aboard ships or on offshore rigs o inside tanks or on floating roofs o on or 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 and a flat 20 cm wide coil head is supplied with all systems Multiple coil heads can be ordered see below and an optional extention shaft will
14. lting in quick and clean disbonding i The RPR system is ideal for the removing paint rust and other coatings vulcanized rubber fire protectant epoxies etc with control possibili ties for the following functions e Energy consumption e Disbonding temperature range e Heat penetration e 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 m Induction unit amp head many sizes available Connector transformer box Induction based rust amp paint removal RPR Technologies How does it work INDUCTION STRIPPING HEAD See SII Rust amp Paint Removal by controlled induction heating Perret rrr rer rere teri Serres Induction heats only the steel substrate not the paint PAINT ON REVERSE SIDE OF TREATED SURFACE Orr rrr a x Localized induction heating means that the coating on ho reverse side of the steel is not affected The basic components needed for RPR sur Main Induction face preparation are Unit 220 kg AC power supply e The patented RPR system consisting of the RPR induction generator unit an intermediate transformer the RPR inductor hand held unit induction coil paint stripping head system cables with
15. n based rust amp paint removal RPR Technologies Surface cleanliness RPR gives a surface cleanliness which depends on the condition of the surface to be treated and the type and condition of the coating to be removed RPR will in most cases also clean the pores of the steel and even corrosion pittings A heavily cor roded 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 coating 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 and re 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 o ISO Sa 2 to Sa 2 5 o SSPC SP 6 to SP 10 o NACE 3 to 2 Surface profile Like UHP water jetting RPR does not produce a new surface profile but it will bring back the profile as present under the coating prior to its removal After treatment Befor
16. th the induction heat penetrating only 0 3 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 affected at 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 5 mm slightly less than 14 RPR has been tested on steel plates of 3 mm thickness just under 1 8 The coatings removal was a success but RPR recom mends that operators themselves run trial tests on all steel less than 5mm before full coatings removal jobs SO Rust amp Paint Removal fast environmentally friendly and low cost I maa h F moo A F u DREN a m wa i Mh zaz rise is detectable 2 Tej EE i Lent __ ea __ Induction based rust amp paint removal RPR Technologies The image below shows how the RPR system disbonds coatings o inductor head yellow at a distance of 3 5 mm 1 8 1 4 from the surface o disbonding white occurs between the paint blue and the steel grey o induction heating red area with penetration of approx 0 3 mm 1 2 mils INDUCTOR POPererrrr rrr rrr rrr rrr rrr rrr HEATED
Download Pdf Manuals
Related Search