Kirloskar Presentation - KCPL Products For Pumps, Pipes, Structures

Kirloskar Corrocoat Pvt.Ltd.
Anti-corrosion and energy conservation products

Page 1
KBL - KCPL
 Started in 1992-93 in India

 Technical Collaboration With M/s.Corrocoat Ltd., U.K.
 Manufacture of Glassflake Coatings
 Application and Engineering Expertise
 Long Term Corrosion Protection
 Refurbishment Technology
 Energy Saving Coatings
 JV from April 2006
 ISO 9001:2008 Certified Company
Page 2
Kirloskarwadi Plant
Page 3
Kirloskarwadi Plant
Page 4
Solutions to Corrosion
COATINGS
CHANGE IN POTENTIAL
METALLURGICAL CHANGES
DESIGN CHANGES
ENVIRONMENTAL CHANGES
Page 5
Galvanic Series of Metals
Page 6
Influence on Corrosion
COMPONENT ENVIRONMENT
ANODE/CATHODE ELECTROLYTE
• Concentration
• Metallurgy
• Temperature
• Inherent Reactivity
• Oxygen
• Ability to form insoluble
• Conductivity
Corrosion Products
• Velocity
• Solids
Page 7
Why Glass Flakes ?
 Glass is the most inert material.
 Except HF, no other chemicals can attack glass.
 Selective high performance glass is converted to
microscopic flakes.
 It leaves 80 – 90 layers of glass with in a DFT of
1 mm.
 It acts like a brick work cemented by resin.
 As corrosive agents are reflected by glass
layers, it can not reach substrate.
 As a result corrosion process is extremely
delayed.
Page 8
GLAS S FLAKE TECHNOLOGY
TORTUOUS PATH
To rtuo us path fo r c o rro s ive io n
Laye rs o f g las s flake s
Coating
S UBS TRATE
Page 9
Comparis on of Water Vapour
Trans mis s ion Rate
Trans mis s ion g/m2 ,
1 1.0 0
Mois ture Vapour
10 9 .0 0
Granular Filled
2 4 Hrs .
7 .0 0
5 3 .8 0
Glas s Flake Fille d
0 .2 4 0.6 0 .7 5 0 .8 5
0
1 2 3 4
Duration in Days
Tes ted acc ording to BS 2 7 8 2 : Part 5 : Part
513 A
Page 10
Physical Tests
Pull off Adhesion test Abrasion test Flexural strength
Page 11
Comparison-Physical Properties
DENSITY TENSILE MODULUS SHEAR

STRENGTH OF ELASTICIY STRENGTH
lbs/cuft kg/m² PSIx10³ MPa PSIx106 GPa PSIx103 MPa
ALUMINIUM 168 2698 22 155 10 70 3.0 1.9

BRONZE 557 8920 33 230 15 103 4.5 31
CAST IRON 458 7300 32 220 17 120 26.1 180
MILD STEEL 491 7860 47 325 30 210 5.0 35
POLYESTER COMPOSITE 104 166 117 807 18 123 12.0 83
EPOXY COMPOSITE 94 1550 90 621 17 120 9.0 62
Page 12
Benefits of Glass-flake Coatings
• Dimensional stability
• Excellent temperature resistance
• Reparability
• Excellent chemical resistance
• Impact resistance
• Excellent dry and immersed
adhesion • High tensile strength
• Low permeation rate • High resistance to
• Applicable over a wide range of cathodic disbondment
substrates • Durability, very long
• High abrasion resistance service lives
• Very low VOC
• Machinability
• Cost effective
Page 13
Product Range
• Polyglass-100 / Standard
• Polyglass VE / VEF / VEHA
• Plasmet ZF
• Plasmet ZE / ZX / HTE
• Zipcoat
• Fluiglide
• Corroglass 202 / 232 / 252 / 602
Page 14
Pipeline coating-Energy conservation
Page 15
Pipeline Coatings
Page 16
Pipeline Coating Methods
 Internal Application
• Flood & Drain Method
• Spinning Method
• Pipe Spraying Method
• Airless Spray
• Hand Brush / Trowel
 External Application
• Airless Spray
• Hand Brush / Trowel
Page 17
Equipments for Pipe coatings
Blasting equipment
Page 18
Various Steps during Coating
a. Surface Cleaning
b. Surface Preparation
c. Environmental checks
d. Surface Contamination
e. Humidity Control
f. Over coating Time
Page 19
Abrasive Blasting
Page 20
Pipe Coating & Inspection
Page 21
Internal Coated Pipes
Page 22
Internally Coated Pipes
Page 23
Internal and External Coated Pipes
Page 24
24 M Long Pipes
Page 25
ESSAR site – 3.6 M Dia. Pipes
Page 26
View of 2.6m Dia.Coated Pipe
Page 27
Pipes under erection
Page 28
Friction Loss in Pipeline
Hazen-Williams Equation
V= 0.849 C * R^0.63 * S^0.54
Where,
v is velocity in m/s
C is coefficient ranging from about 80 for very rough pipes
to
140 of more for smooth pipes.
R is the hydraulic radius in meters,
S is the friction head loss per unit length
or slope of the energy gradient line in meters
Page 29
Page 30
Q, m3/h C Pipe Dia, D Hyd Rad. R m Vel m/s
m
10000 120 1.5 0.375 1.5719
S, loss m/m 0.001387
Friction Loss in 1 km 1.387 m

pipe length
Q, m3/h C Pipe Dia, Hyd Rad. R m Vel m/s

Dm
10000 157 1.5 0.375 1.5719
S, loss m/m 0.000843
Friction Loss in 1 km 0.843 m

pipe length
Reliable & Proven Solutions to Combat Corrosion…..

Page 31
Friction loss in 1 km pipeline is
1.38 m with C = 120
&
0.84 m with C = 157
In a Total Head of 20 m, friction loss reduction of 0.5 m
is 2.5%. This energy saving will be for a period of at least 10
to 15 years.

Page 32
Pump Efficiency Improvement
Coating on Hydraulic surfaces of the Pumps
Page 33
Life Cycle Cost
Initial cost
5 - 10%
Operating cost
90 - 95%
Page 34
Glass Flake Coatings
• Superior Surface Finish to Hydraulic Passages in less time and
efforts can be achieved.
• Due to this superior surface finish, boundary layer is suppressed

and we get higher effective hydraulic passage
• The coating is hydrophobic in nature.
• The property of Superior surface finish combined with

hydrophobic nature of the coating, brings down the friction losses
drastically.
Page 35
Roughness amplitude of surfaces
Page 36
Industrial Pumps
 The hydrophobic nature of coating : In case of aqueous media, materials
which have low surface attraction are hydrophobic & repel water, will
result in lower frictional losses than surface which are highly attractive
to water molecules.
DIFFERENCE IN DROPLET CONTACT ANGLE
Wate r drople t Wate r drople t
Co ating
S UBS TRATE
HYDROPHOBIC MATERIAL S EMI-HYDROPHOBIC ATTRACTIVE WETABLE

POLYMER (EAS TER RESIN) MATERIAL, S URFACE, CAS T IRON
POLYPROPYLENE
ILLUS TRATION NO 0 2
Page 37
Advantage of New Pump Coating
Linings and Coatings

Ref : Pumping Manual Page 473
Page 38
Coated new Pump
Page 39
14” split case pump
Page 40
Concrete Volute Pump (Casing)
Page 41
Draft Tube of Concrete Volute
Page 42
Concrete Volute Pump Casing
Page 43
Pumps
After 4 years sea-water service
After 7 years service
After refurbishment with Corrocoat Corroglass, note the

wear ring areas using specialist casting techniques
Page 44
Pumps
After 4 years sea-water service
After 7 years service

After refurbishment with
Corrocoat Corroglass
Page 45
KCPL for Valves and Structures
Bar screens
Divergent pipe
This is a proprietary document of Kirloskar Corrocoat Private Limited Page 46

LANCO–UDUPI Power Plant
Forebay area in CW pump House.
CW Pump House Intake
CW Pump House
Page 47
Velocity Cap & Fender Frame
Page 48
ETP Coated Equipments
Page 49
FGD Units Coated in India
Customer Equipment Material Used Year of work
Tata Power C0., FGD Duct near quencher Corrothane XT 2000-01
Trombay
Reliance Energy •FGD duct •Corroglass HN4 2006-2007
Ltd., Dahanu T.P.S. •GGH •Polyglass VEF
•Chimney Internal
• Scrubber
•Dampener
Fouress Engineering •FGD Dampener •Corroglass HN4 2008-2009
Ltd. A/c- Udupi
Power Corporation
Tata Power •GGH •Corroglass HN4 2008-2009
Trombay •Dampener •Polyglass VEF
Ducon Technologies •Concrete scrubber •Corroglass HN4 2009-2010
Pvt. Ltd. A/c structure •Plasmet EP1 (unit # 2 in
LANCO Infratech •.FGD duct progress)
Ltd. •Dampener
Page 50
Reliance Energy
Scrubber Internal before coating
Page 51
Reliance Energy
Scrubber internal after coating
Page 52
Reliance Energy
Duct internal coating
Page 53
FG Duct Internal Coating
Page 54
Dampner Used in FGD
Page 55
Valve refurbishment
Page 56
Potable Water Certification
Central Food Technological

Research Institute, Mysore
Water Quality Tests as per BS 6920

Page 57
KCPL product on Clarifier surface

JSW Steel Hospet- Stove Domes

KCPL is committed towards
• Corrosion protection
• Energy Conservation
• Efficiency Improvement
• Productivity
• Profitability
• Durability & Longevity of Assets
Page 60
THANK YOU
Page 61

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Kirloskar Corrocoat Pvt.Ltd.

Anti-corrosion and energy conservation products

 Started in 1992-93 in India

DENSITY TENSILE MODULUS SHEAR

ALUMINIUM 168 2698 22 155 10 70 3.0 1.9

f. Over coating Time

S, loss m/m 0.001387

Friction Loss in 1 km 1.387 m

Q, m3/h C Pipe Dia, Hyd Rad. R m Vel m/s

S, loss m/m 0.000843

Friction Loss in 1 km 0.843 m

Reliable & Proven Solutions to Combat Corrosion…..

1.38 m with C = 120

0.84 m with C = 157

In a Total Head of 20 m, friction loss reduction of 0.5 m

is 2.5%. This energy saving will be for a period of at least 10

Reliable & Proven Solutions to Combat Corrosion…..

• Due to this superior surface finish, boundary layer is suppressed

• The coating is hydrophobic in nature.

• The property of Superior surface finish combined with

Wate r drople t Wate r drople t

HYDROPHOBIC MATERIAL S EMI-HYDROPHOBIC ATTRACTIVE WETABLE

Linings and Coatings

After 4 years sea-water service

After 7 years service

After refurbishment with Corrocoat Corroglass, note the

After 4 years sea-water service

After 7 years service

This is a proprietary document of Kirloskar Corrocoat Private Limited Page 46

Scrubber Internal before coating

Scrubber internal after coating

Duct internal coating

Central Food Technological

Water Quality Tests as per BS 6920

Reliable & Proven Solutions to Combat Corrosion…..

This is a proprietary document of Kirloskar Corrocoat Private Limited Page 58

This is a proprietary document of Kirloskar Corrocoat Private Limited Page 59

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