RG-2400® IN DEPTH INSTALLATION

TRAINING CLASS

RG-2400® IN DEPTH INSTALLATION

TRAINING CLASS

PRESENTED BY: PATRICK J. DUNN Sr.

AUTHORIZED INSTRUCTOR

RG-2400® FAM ILY OF PRODUCTS

HOW IT WORKS

RG-2400® LT

A grayish light blue colored gel; the workhorse of corrodedpipe rehabilitat ion/ remediat ion projects. RG-2400 LT isused extensively (but not exclusively) in the refrigerat ion(Ammonia), oil and gas, and chemical industries. This gel canbe used on new pipes, but is primarily used on alreadycorroded pipes up to +240°F. All gels in the RG family donot have a lower temperature limit (except for installat iontemperatures)

RG-2400® NP

A purple colored gel; a recent addit ion to the RGline of products. RG-2400 NP is used extensively inthe refrigerat ion (Ammonia), oil and gas, and chemicalindustries. This gel can be used on new pipeinstallat ions, up to +240°F.

RG-2400® CHW

A mint green colored gel; an answer to thetemperature range applicat ion on chilled waterpiping. RG-2400 CHW is used extensively in thechilled water, HVAC industries. This gel can beused on new and rusted CHW pipe installat ions in+34°F to +130°F temperature ranges.

RG-2400® ET

A light blue colored gel; ET for ‘elevatedtemperature’ for applicat ion on industrial pipingup to +350°F. RG-2400 ET is used extensively inthe oil/ gas/ asphalt , refining, mining, pulp & paper,and low pressure steam industries. This gel can beused on new and rusted pipe installat ions.

RG-2400 AK

A light blue colored gel; AK for ‘Alaska’ is used when a gelM UST be applied to an in-service HOT pipe, we would notrecommend installat ion over +160°F without special safetyequipment , putt ing the gel on very hot pipes can createpopping and airborne gel (kind of like frying bacon). The uppertemperature limit of RG-2400 AK is 250°F. RG-2400 AK isused extensively in the oil/ gas, refining, and low pressuresteam industries. This gel can be used on new and rustedpipe installat ions.

RG-CSARG-CSA is a gray topcoat calcium sulfonate alkaloidpaint ; an answer to uninsulated rusted piping. RG-CSAis used to paint st ructural steel, exposed valve groups,and un-insulated piping which requires protect ionfrom the elements. It can be spray or brush applied.Surface preparat ion is minimal just like our gelproducts. For ext reme condit ions, a red primer isapplied, then top coated with the gray CSA. (Thisproduct will be discont inued soon.)

TYPES OF CORROSION

GENERAL CORROSION (widespread)

General corrosion is a widely distributed and

low level attack against the entire metal

surface with little or no localized penetration.

It is the least damaging form of corrosion.

TYPES OF CORROSIONC.U.I CORROSION (corrosion under insulation)

CUI is a major threat to any piping system which operates at

lower temperatures, Ineffective vapor retarders and pipe

coatings, allow moisture to penetrate into and through the

insulation and condense at the pipe surface. The moisture

being the electrolyte completing conductivity and causing the

anode portion of the metal to sacrifice itself. CUI is commonly

found on chilled water piping - being most severe at the colder

supply side piping, ammonia refrigeration, brine, glycol, liquid

natural gas; the moisture drive is to the pipe on below ambient

systems.

TYPES OF CORROSION

M IC CORROSION (M icrobiologically Influenced Corrosion)

M icrobiologically Induced or Influenced Corrosion (M IC) is probably the most severe threatening form of corrosion to HVAC and other piping systems; caused by the presence of various microbiological agents under specific environmental condit ions - in some cases result ing in advanced and widespread failure of ent ire piping systems within a few years, somet imes in as lit t le as months.

TYPES OF CORROSION

GALVANIC CORROSION (dissimilar metals)

This is an aggressive and localized form of corrosiondue to the elect rochemical react ion generally betweentwo or more dissimilar metals in a conduct iveenvironment . The more elect ronegat ive material (theAnode corrodes to protect the more elect roposit ivematerial (the Cathode).

TYPES OF CORROSION

PITTING CORROSION

This is localized corrosion, somet imes caused from underdeposit corrosion with deep penetrat ion of the surfacewith some general corrosion in the surrounding area. Dueto surface deposits, elect rical imbalance or othermechanisms, corrosion attacks individual sites.

TYPES OF M ETAL SURFACES

GOOD

• STEEL

• STAINLESS STEEL

• COPPER

• BLACK IRON (DUCTILE)

ADVERSE

• ANY M ETAL WHICH IS AFFECTED BY A HIGH ALKALINE ENVIRONM ENT

– ALUM INUM

– BRONZE

– ZINC

– M OST NOBLE M ETALS

INSULATION COM PATIBILITY

CALSIUM SILICATE – M ust use barrier like ZeroPerm

PERLITE– Absorpt ion issues

PHENOLIC – Absorpt ion issues

ELASTOM ERIC – Installat ion difficult ies only

POLYISOSYANURATE - Good

EXTRUDED POLYSTYRENE - Good

EXPANDED POLYSTYRENE - Good

FOAM GLAS - Good

M INERAL FIBER - Good

INSULATION COM PATIBILITY

CALSIL (CALSIUM SILICATE)

• M ust be installed with ZeroPerm over the RG

• Temperature cannot exceed Gel limits

PERLITE• M ust be installed with ZeroPerm

over the RG

• Temperature cannot exceed Gel limits

• Absorpt ion issues

• M ust be installed with ZeroPerm over the RG

INSULATION COM PATIBILITY

ELASTOM ERIC (RUBBER)

• Fully compat ible

• Split one side, 6’ lengths makes installat ion over RG very messy!

• M any contractors will apply the gel, then cover it with saran wrap from the grocery store; then apply the elastomeric insulat ion with no mess.

PHENOLIC

INSULATION COM PATIBILITY

PIR (URETHANE)

• Compat ible with RG-2400

• ALL VERSIONS LT, NP, CHW

XPS (Dow Styrofoam)

• Compat ible with RG-2400

• Used Extensively on Ammonia

• All versions LT, NP, CHW

INSULATION COM PATIBILITY

FOAM GLAS® (Cellular Glass)

• Excellent compat ibility

• Acts as an ant i-abrasive coat ing

• Temperature cannot exceed Gel limits

FIBERGLASSM INERAL WOOL• Some wicking can occur, not an issue

• Temperature cannot exceed Gel limits

SURFACE PREPARATION

New Pipe

• RG can be applied over bare pipe with no surface preparat ion.

• RG can be applied over primed pipe or that which has a mill scale varnish applied.

• Painted or epoxy coated pipes can be applied over, however it will be ineffect ive unt il the primary coat ing fails.

SURFACE PREPARATION

What to Know

• IT IS THE RESPONSIBILITY OF THE OWNER TO DETERM INE IF THE PIPE RETAINS ENOUGH INTEGRITY TO PERFORM AT SYSTEM PRESSURES AND STRESSES AFTER ITS REM EDIATION!

• Painted or epoxy coated pipes can be applied over, however it will be ineffect ive unt il the primary coat ing fails.

• Primed or pipe with M ill Scale Varnish can be applied over.

SURFACE PREPARATION

Corroded Pipe

• Perform a NACE standard SP-2 or better surface preparat ion.

• M ost pipes merely require wire brushing. Others may require power brushing.

• If the pipe had a failed coat ing, all loose (not adhered) coat ing must be machine brushed off.

• M ethods include; pot scrubber, wire brush, wire wheel, surface blaster.

• If leachable chlorides are present the pipe must be power washed or scrubbed using Hold Tite 102 Chloride Remover.

APPLICATION

How M uch is Enough?

• M inimum thickness on new piping is 25 M ILS.

• M inimum thickness on corroded piping is 30 M ILSP

• Thickness can be checked with a wet film thickness gauge if desired.

• Basically, if you install it and cannot see the pipe through it , you have installed an appropriate amount .

APPLICATION

Hand Application

• Hand applicat ion using a heavy PVC glove is the most common method for installing RG-2400

• Paint M itts do not work!

• Cut off chip brushes are good for smoothing out the gel after gloving.

• AccuTrowels are gauged at 25 and 30 M IL to get an exact thickness. Trails left by the t rowel have to be smoothed out . Trowels do not work well with corroded pipe.

APPLICATION

Spray Application

• RG-2400 LT, CHW, NP can all be sprayed with specialized equipment .

• Polyguard can supply criteria for the pumping system (cost around $20k)

• Polyguard can LEND the spray rig to you if you pay to ship it to you and back to us.

• Any damage to the unit will be charged to you.

SPECIAL SITUATIONS

WET PIPE

• CHW pipe systems ‘in service’ can be sweat ing

• IF the gel will apply, you can apply it , but if condensat ion forms on the RG, it is best to install ZeroPerm over the gel prior to insulat ing. Towels can be used to dry light ly condensing pipe, apply the RG quickly and immediately apply your insulat ion.

• IF the gel simply slides across the wet pipe, the areas must be tented and the space air condit ioned unt il the pipe does not sweat .

• If condit ioning the space is not possible, wait unt il NOV-JAN to do the job when temperatures are low and humidity less; normally a CHW system is not running in the winter months, if it is, the condensat ion may not be on the pipe during this t imes of year.

• IF a system cannot be dried enough to install the gel, it can be done by pre-applying it to ZeroPerm and applying the membrane to the pipe.

SPECIAL SITUATIONS

FROSTED/ ICED PIPE

• Light ly frosted pipes will usually accept RG without a ton of muscle. If there is too much frost , RG will not st ick.

• Use glycol to remove the frost

• Use alcohol to remove the frost

• Icy pipes must have the ice removed, as you de-ice, use glycol or alcohol to completely clean the pipe.

• The only other opt ion is to allow the system to defrost and apply RG after drying the pipe. A heat gun can help this process.

SPECIAL SITUATIONS

COLD WEATHER

• The colder it is, the thicker RG will become.

• Use small size (gal) containers.

• Keep RG as warm as possible (in the t ruck, in a warm room, employ blanket heaters to pails).

• Install as fast as you can, when it gets too thick to spread, change to a warmer pail.

• Worst case scenario, tent the work and heat the tent .

SPECIAL SITUATIONS

UN-INSULATED PIPE

• Un-insulated pipe can be approached in many different ways, the most common is to jacket over the RG.

• Polyguard offers many flexible jackets to apply over RG; AlumaWrap, ZeroPerm, UV Stretch Film, GeoWrap. You could also use PVC or M etal.

• Another Opt ion is RG-CSA paint .

TANK CHIM E INSTALLATIONS

RG-2400 is a non-curing solution to tank base corrosion issues where the tank ‘chime’ is accessible and subject to wet/dry, chloridecrevice environments where corrosion is a problem. The system is highly customizable to any specific tank built on a solid foundation

such as concrete or a Foamglas®. Installation is simple and surface preparation is minimal.

The concept is a simple one; stop corrosion in the crevice environment where a metal vessel or tank comes into contact with a solid

substrate or base. he process is very basic; clean the area to be treated as best as is possible (power wash, hand or power tools), dry the

area (via time or temperature), inject the gel into all crevice areas, prime the metal and concrete surface and install a weather barrier

membrane for protection. The gel product is a constant; RG-2400® injected via pump gun or caulk gun.

The protection system will vary dependent on substrates and desire to open the system for inspection over the years. The best system in

a rubberized asphalt compound with an aluminum foil facing or UV resistant polyethylene or polyester. This system is not the easiest to

open for re-inspection, but can be removed with a heat gun.

FLANGE/ NUT COVERS

Protect ing uninsulated flanges and nuts from corrosion is easy using specially designed covers.

OTHER USES

• STRUCTURAL STEEL

• FIRE SPRINKLERS

• BELOW GRADE PIPING

• ANTI-SIEZE

• BRIDGES

• NAVAL APPLICATIONS