Kirloskar Corrocoat Pvt.Ltd. - INDUSTECH || a leading Corrocoat Pvt.Ltd. ... Kirloskar Brothers...

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Transcript of Kirloskar Corrocoat Pvt.Ltd. - INDUSTECH || a leading Corrocoat Pvt.Ltd. ... Kirloskar Brothers...

  • Page 1

    Kirloskar Corrocoat Pvt.Ltd.

    Anti-corrosion and energy conservation products

  • Page 2

    Started in 1992-93 in India

    JV from April 2006 with M/s.Corrocoat Ltd.,

    U.K.

    Manufacture of Glassflake Coatings

    Application and Engineering Expertise

    Long Term Corrosion Protection & Energy

    conservation coatings

    Refurbishment Technology

    An ISO 9001:2008 & ISO 14001:2004

    Certified Company

    KBL - KCPL

  • Page 3

    Kirloskarwadi Plant

  • Page 4

    Kirloskarwadi Plant

  • Page 5

    Solutions to Corrosion

    COATINGS

    CHANGE IN POTENTIAL

    METALLURGICAL CHANGES

    DESIGN CHANGES

    ENVIRONMENTAL CHANGES

  • Page 6

    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 7

    GLASS FLAKE TECHNOLOGY

    TORTUOUS PATH

    Tortuous path for corrosive ion

    Layers of glass flakes

    Coating

    SUBSTRATE

  • Page 8

    Comparison of Water Vapour

    Transmission Rate

    0.850.750.60.24

    3.807.00

    9.0011.00

    0

    5

    10

    1 2 3 4

    Duration in Days

    Mois

    ture

    Vapour

    Tra

    nsm

    issio

    n g

    /m2,

    24 H

    rs.

    Tested according to BS 2782 : Part 5 : Part

    513 A

    Granular Filled

    Glass Flake Filled

  • Page 9

    Benefits of KCPL products

    Excellent temperature & chemical resistance

    Excellent dry and immersed adhesion

    Low permeation rate

    Applicable over a wide range of substrates

    High abrasion resistance

    Machinable, Dimensionally stable, Reparable,

    Impact resistant, High tensile strength

    High resistance to cathodic disbondment

    Cost effective with long service life

  • Page 10

    Polyglass-100 / Standard

    Polyglass VE / VEF / VEHA

    Plasmet ZF

    Plasmet ZE / ZX / HTE

    Zipcoat

    Fluiglide

    Corroglass 202 / 232 / 252 / 602

    Product Range

  • Page 11

    KCPL products for Pipeline

  • Page 12

    Pipeline Coatings (RIL)

    All arteries & veins at Reliance Jamnagar are coated with KCPL

    products

  • Page 13

    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 14

    Pipe coating Equipments

    Blasting equipment

  • Page 15

    Pipe coating-various steps

    Surface Cleaning remove loose scales

    Surface Preparation - Blast cleaning ( SA 2.5 )

    Environmental checks - Standard checks

    Surface Contamination chemical test.

    Humidity Control relative humidity

  • Page 16

    Abrasive Blasting

  • Page 17

    Pipe Coating & Inspection

    Holidat detection test

  • Page 18

    Internal Coated Pipes

    Flanged pipes

  • Page 19

    Internally Coated Pipes

  • Page 20

    Internal and External Coated Pipes

  • Page 21

    24 M Long Pipes

  • Page 22

    Large Pipe coating at site

    3.6 m. dia. Internally

    Coated pipe

    Internal view of 2.6 m. dia

    coated pipe

  • Page 23

    Pump Efficiency Improvement

    Coating on Hydraulic surfaces of the Pumps

  • Page 24

    Operating cost

    90 - 95%

    Initial cost

    5 - 10%

    Life Cycle Cost

  • Page 25

    Glass Flake Coatings

    We offer superior surface finish to Hydraulic

    Passages within less time and efforts.

    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 26

    Roughness amplitude of surfaces

  • Page 27

    DIFFERENCE IN DROPLET CONTACT ANGLE

    Water droplet Water droplet

    Coating

    SUBSTRATE

    HYDROPHOBIC MATERIAL SEMI-HYDROPHOBIC ATTRACTIVE WETABLE

    POLYMER (EASTER RESIN) MATERIAL, SURFACE, CAST IRON

    POLYPROPYLENE

    ILLUSTRATION NO 02

    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.

    Hydrophobic nature

  • Page 28

    LININGS AND COATINGS

    (Ref : Pumping Manual, 9th Edition, Page 472 by Mr. T.C.

    Dickenson)

    diffusers

    against

    Benefits for New Pump

  • Page 29

    Linings and Coatings

    Ref : Pumping Manual Page 473

    Advantage in New Pump

  • Page 30

    Coated new Pump

  • Page 31 This is a proprietary document of Kirloskar Corrocoat Private Limited

    Coated new Pump

    UPH 1200 / 160, the largest HSC Pump coated by KCPL

    for corrosion protection and Energy conservation

  • Page 32

    Concrete Volute Pump

  • Page 33

    CVP Casing & Draft Tube

    Casing Draft tube

  • Page 34

    After 4 years sea-water service

    After 7 years service

    After refurbishment with Corrocoat Corroglass, note the wear ring areas using specialist casting techniques

    Pump refurbishment

  • Page 35

    After 7 years service

    After 4 years sea-water service

    After refurbishment with Corrocoat Corroglass

    Pump refurbishment

  • Page 36

    Performance parameters:

    Performance

    Parameters

    Original

    Specs

    Prior to application

    of Coating system

    After application

    of Coating

    system.

    Flow in L/S 1041.67 1030.36 1030.36

    Head in Meter 66.40 63.40 63.40

    RPM 990.00 990.00 990.00

    Pump input in

    kW

    810.00 800.00 740.98

    Best efficiency 83.34 % 80.00 % 86.43 %

    Kirloskar Brothers Limited

    Case study

  • Page 37 Kirloskar Brothers Limited

    Due to application composite coatings there was

    substantial saving in energy.

    Refer to the comparison of performance:

    New efficiency : 86.43 %.

    Power required to Pump : 740.98 Kw

    Flow : 1030.36 L/S

    Annual power saving :517015.20 kWh.

    (24 hrs operation for one year)

    Rate of electricity : Rs. 3.00 per kWh

    Annual saving : Rs. 15,51,045.60

    Refurbishment benefits

  • Page 38

    Energy saving

    M3/H M RPM EFF

    Imp

    Eff

    kW

    Before kW After

    Saving,

    kwh/ year

    Savings

    Rs/year

    Coating Coating

    UP

    150/38B 350 45 1450 85 87 50.46 49.30 10161.87 45728.43

    SCT

    250/51 1000 80 1450 88 90 247.57 242.07 48194.36 216874.60

    16 UPH

    2 2500 35 980 86 88 277.08 270.78 55164.33 248239.50

    BHR 70

    M 3500 60 980 88 89.5 649.88 638.99 95412.72 429347.20

    CVP 20000 21 296 90 91 1270.88 1256.91 122339.53 550527.90

  • Page 39 This is a proprietary document of Kirloskar Corrocoat Private Limited

    Divergent pipe

    Bar screens

    KCPL Products

    for other equipments

  • Page 40

    Forebay area in CW pump House. CW Pump House Intake

    CW Pump House

    LancoUdupi site

  • Page 41

    GMR Tanirbavi site

    Velocity cap Fender frame

  • Page 42

    KCPL for ETP Equipments

  • Page 43 This is a proprietary document of Kirloskar Corrocoat Private Limited

    45m diameter sour crude surge tank coated with Polyglass Vinyl Ester

    Glassflake in 1989. Tank had previously been lined with a coal tar

    epoxy which has failed within 5 years.

    Internally & externally coated tank DFT check

    KCPL for Tanks & vessels

  • Page 44

    Reliance Energy

    Scrubber Internal before coating

  • Page 45

    Reliance Energy

    Scrubber internal after coating

  • Page 46

    Reliance Energy

    Duct internal coating

  • Page 47

    FG Duct Internal Coating

  • Page 48

    Dampner Used in FGD

  • Page 49

    SEAWATER PRE-LOAD TANK, NOW BEEN IN SERVICE FOR 9

    YEARS AFTER LINING WITH POLYGLASS 100.

    KCPL products for tanks

  • Page 50

    Inside of Heater treater

  • Page 51

    Marine atmosphere structures

  • Page 52

    Valve refurbishment

  • Page 53

    Reliable & P