PUMP COATING

Improving Pumping efficiency by Coating

by

R. G. Padalkar

Kirloskar Corrocoat Pvt. Ltd., Pune

3L PROGRAM Organized by

Bureau of Energy Efficiency

at Pune

21st September 2011

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 between Kirloskar Brothers Ltd. & Corrocoat Ltd. U.K. from April 2006

ISO 9001:2008 Certified Company

KIRLOSKAR CORROCOAT PVT LTD.

KIRLOSKARWADI PLANT

The field of coatings has seen great technical strides in the recent

past.

The glass flake coating with proper mixing of different resins result in

coatings with properties meeting even the most complex application.

These coatings provide protection from corrosion, abrasion , erosion

USE OF COATING

When a fluid flow is taking place on the coated surface, the

frictional losses are reduced to a negligible value.

This provides opportunity to save energy .

In pumps, the idea of applying coating on hydraulic surfaces is

now well established.

USE OF COATING FOR PUMPING.

It was found that when this coating is applied to the hydraulic

passages of the impeller and casing of the pumps, efficiency

improvement was observed.

It was proved that the efficiency improvement in the pump was

achieved due to better surface finish of the hydraulic passages.

ENERGY CONSERVATION

Pump Efficiency = hh X hv X hm

Where hh= Hydraulic Efficiency

hv = Volumetric Efficiencyy

hm = Mechanical Efficiency

PUMP EFFICIENCY

Max. attainable efficiency (as per HIS)

1. New Pumps

When this coating is applied to a new pump,

improvement in efficiency to the extent of

2% - 3% is observed.

THIS IS A REVOLUTIONARY CONCEPT.

PUMP EFFICIENCY IMPROVEMENT

Advantage of New Pump Coating

Sr. No. No of Years Efficiency (*) Pumping Cost

Efficiency -

Corrocoate

d Pump (*)

Pumping Cost of

Corrocoated Pump

Reduction in

Pumping Cost

Due to

Corrocoating

Per Day Per Annum Per Day Per Annum

Per

Day

Per

Annum

1 1st Year 80% 2160 788400 82.00% 2084 760729 76 27671

2 2nd Year 79% 2187 798255 81.90% 2087 761667 100 36588

3 3rd Year 78% 2215 808475 81.80% 2089 762605 126 45870

4 4th Year 77% 2244 819060 81.70% 2092 763543 152 55517

5 5th Year 76% 2274 830010 81.60% 2094 764481 180 65529

6 6th Year 75% 2304 840960 81.50% 2097 765419 207 75541

7 7th Year 74% 2335 852275 81.40% 2100 766357 235 85918

8 8th Year 73% 2367 863955 81.30% 2102 767295 265 96660

9 9th Year 72% 2400 876000 81.20% 2105 768233 295 107767

10 10th Year 71% 2434 888410 81.10% 2107 769171 327 119239

Total Saving due to Corrocoating for the span of 10 years 716303

Efficiency Improvement Properties

SURFACE FINISH

Efficiency Improvement PropertiesDIFFERENCE IN DROPLET CONTACT ANGLE

Water droplet Water droplet

Coating

SUBSTRATE

HYDROPHOBIC MATERIAL SEMI-HYDROPHOBIC ATTRACTIVE WETABLE

POLYMER (EASTER RESIN) MATERIAL, SURFACE, CAST IRON

POLYPROPYLENE

HYDROPHOBIC NATURE

Glass Flake Technology - Tortuous Path

Tortuous path for corrosive ion Layers of glass flakes Coating

SUBSTRATE

Corrosion Protection

Coating of Pipe Lines


LININGS AND COATINGS (Ref : Pumping Manual, 9th Edition, Page 472 by Mr. T.C. Dickenson)

diffusers

against


Linings and Coatings

Ref : Pumping Manual Page 473

Improvement of New Pump efficiency

Typical test curves showing

improvements in efficiency

after overhaul and treatment

with the Fluiglide system.

LININGS AND COATINGS

(Ref : Pumping Manual Page 473)

This coating can be applied even in OLD pumps.

Refurbishment of old pumps, worn out parts, even impellers with broken vanes or with holes, or bowls

can be carried out.

There are many instances where new life was blown using refurbishment technique into old pumps

which were to be scrapped.

PUMP REFURBISHMENT

The savings that accrue on refurbishment give a pay back period of around 1 year.

Moreover the rate of fall in efficiency of the coated pump is much lower that uncoated pump.

Efficiency of the uncoated pump may fall by 5% in 5 years where as in the case of Coated pump

efficiency fall will be 0.5% in 5 years

PUMP REFURBISHMENT

PUMP REFURBISHMENT

Surface preparation by abrasive blasting & Applying

energy efficiency improvement coating system

COATING PROCESS

Quality tests by customer with KCPL

Holiday & DFT Testing.

QUALITY TESTING

VERTICAL TURBINE PUMP BOWL

COATED NEW PUMP

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

PUMPS (CORROSION PROTECTION)

After 4 years sea-water service

After coating with Corrocoat Corroglass

After 7 years service

After 7 years service

After coating with Corrocoat Corroglass

After 4 years sea-water service

PUMPS (CORROSION PROTECTION)

CASING BEFORE AND AFTER COATING

IMPELLER BEFORE & AFTER COATING

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 %

CASE STUDY

Kirloskar Brothers Limited

New efficiency -- 86.43 %.

Input power -- 740.98 kW

Annual power saving, kWh (24 hrs

operation)

-- 5,17,015.20 kWh

Annual saving with Rate per unit

Rs. 7.00

-- Rs. 36,19,106

Losses in Pipes

Hazen-Williams Equation

V= 0.849 C R0.63 S0.54

Where,

- V is velocity in m/s

- C is coefficient ranging from about 80 for very rough pipes to

150 of more for smooth pipes.

- R is the hydraulic radius in meters, For a pipe running full, it

is Pipe Cross Section Area / Wetted Perimeter = D/4

- S is the friction head loss per unit length or slope of the

energy gradient line in meters per meter.

C VALUE

Q, m3/h C Pipe Dia,

D m

Hyd Rad. R m Vel m/s

10000 120 1.5 0.375 1.5719

S, loss m/m 0.001387

Friction Loss in 1 km

pipe length 1.387 m

Q, m3/h C Pipe Dia,

D m

Hyd Rad. R m Vel m/s

10000 157 1.5 0.375 1.5719

S, loss m/m 0.000843

Friction Loss in 1 km

pipe length 0.843 m

C VALUE

Frictional Losses in a pipe will be reduced by

almost approx. 40% for the changes in C value

from 120 to 157 in Hazen - William formula

C VALUE

Sr. Liquid

Type

and Name

Descriptio

n

Specifications Attributing

Properties of

Coating

1 Clear

Water

Fluiglide

System

Dry Film

Thickness

DFT 1000 microns Avg.

Tolerance Minus 100 micron

Dry Film

Thickness

Base Coat A medium viscosity pre accelerated

Bisphenol A polyester glass flakecompound, cured by the addition of

organic compound.

Adhesion layer to

ensure proper

Bonding with

respect to Base

Metal

Intermedia

te

Coat

A heavy Built Glass Flake coatings

based on low reactivity , Bisphenol

APolyester resin pre accelerated, A

two pack resin system sing organic

peroxide

Anticorrosion

Layer

Top Coat A cold cured highly modified chemicallyresistant, two-pack resin system filled

with stabilizing enforcement to reduce

cold flow characteristics. The coating

should have good gloss with waxy

appearance when cured.

Efficiency

Improvement

Layer

COATING SPECIFICATION CLEAR WATER

Sr. Liquid

Type

and Name

Description Specifications Attributing

Properties of

Coating

2 Raw

Water ,

Fluiglide E

System

Dry Film

Thickness

DFT 1500 microns Avg.

Tolerance minus 100

micron

Dry Film

Thickness

Base Coat A solvent free, high build,

two or three Pack Epoxy

coating with excellent

erosion resistance,

toughness and outstanding

erosion properties.

Adhesion layer

to

ensure proper

bonding with

respect to Base

Metal

Intermediate

Coat

A solvent free, two or three pack

epoxy coating with excellent

erosion resistance, toughness and

outstanding erosion properties.

Anticorrosion

Layer

Top Coat A cold cured 100 % solid epoxide Specially modified to give

roughness amplitude of 0.08

microns.

Efficiency

Improvement

Layer

COATING SPECIFICATION RAW WATER

WATER REGULATIONS

ADVISORY SCHEME, UK

EFFECT ON WATER

QUALITY TEST as per BS

6920

POTABLE WATER CERTIFICATION

Central Food Technological Research

Institute, Mysore

Water Quality Tests as per BS 6920

NEW PUMPS AT PROCUREMENT STAGE

Supply of New Pump with Coating System

Use of coating system in place of higher metallurgy

Coating of Pipe Lines For Head Losses Reduction

Coating of Valves

Low life cycle cost sustenance of efficiency

Comparision of Water Vapour

Transmission Rate

0.850.750.60.24

3.80

7.009.00

11.00

0

5

10

1 2 3 4

Duration in Days

Mois

ture V

apour

Transm

issio

n g

/m2,

24 H

rs.

Tes ted according to BS 2782 : Part 5 : Part 513 A

Film Thickness - 175 m icrons .

Figure 4

Granular Filled

Glass Flake Filled

TRANSMISSION RATE

PHYSICAL TESTS

COMPARISONS - PHYSICAL PROPERTIES

ALUMINIUM

BRONZE

CAST IRON

MILD STEEL

POLYESTER COMPOSITE

EPOXY COMPOSITE

DENSITY TENSILE STRENGTH

MODULUS OF ELASTICIY

SHEAR STRENGTH

lbs/cuft kg/m

168

557

458

491

104

94

2698

8920

7300

7860

166

1550

22

33

32

47

117

90

155

230

220

325

807

621

10

15

17

30

18

17

3.0

4.5

26.1

5.0

12.0

9.0

1.9

31

180

35

83

62

70

103

120

210

123

120

PSIx10 MPa PSIx106 MPaGPa PSIx103

1. It can be said that by use of Coatings, Quantum leap in

Energy conservation is possible in Pumps alone as they

are the largest consumer of electricity.

2. Higher efficiency thus achieved remains constant over

a very long period

3. Coating is a good tool for Energy Auditors to save

energy.

4. It is possible to bring down frictional losses in the

pipeline thus reducing Total head against which pump

has to work. This saves energy from the start of the

Project itself

5. LOWEST Life Cycle Cost can be achieved

CONCLUSION

THANK YOU

PUMP COATING

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