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Kirloskar Corrocoat Pvt.Ltd.

Anti-corrosion and energy conservation products

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

Kirloskarwadi Plant

Solutions to Corrosion

COATINGS

CHANGE IN POTENTIAL

METALLURGICAL CHANGES

DESIGN CHANGES

ENVIRONMENTAL CHANGES

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.

GLASS FLAKE TECHNOLOGY

TORTUOUS PATH

Tortuous path for corrosive ion

Layers of glass flakes

Coating

SUBSTRATE

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

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

Polyglass-100 / Standard

Polyglass VE / VEF / VEHA

Plasmet ZF

Plasmet ZE / ZX / HTE

Zipcoat

Fluiglide

Corroglass 202 / 232 / 252 / 602

Product Range

KCPL products for Pipeline

Pipeline Coatings (RIL)

All arteries & veins at Reliance Jamnagar are coated with KCPL

products

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

Pipe coating Equipments

Blasting equipment

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 <85 %

Over coating – good flexibility

Abrasive Blasting

Pipe Coating & Inspection

Holidat detection test

Internal Coated Pipes

Flanged pipes

Internally Coated Pipes

Internal and External Coated Pipes

24 M Long Pipes

Large Pipe coating at site

3.6 m. dia. Internally

Coated pipe

Internal view of 2.6 m. dia

coated pipe

Pump Efficiency Improvement

Coating on Hydraulic surfaces of the Pumps

Operating cost

90 - 95%

Initial cost

5 - 10%

Life Cycle Cost

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.

Roughness amplitude of surfaces

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

LININGS AND COATINGS

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

Dickenson)

diffusers

against

Benefits for New Pump

Linings and Coatings

Ref : Pumping Manual Page 473

Advantage in New Pump

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

Concrete Volute Pump

CVP Casing & Draft Tube

Casing Draft tube

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

After 7 years service

After 4 years sea-water service

After refurbishment with Corrocoat Corroglass

Pump refurbishment

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

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

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


Divergent pipe

Bar screens

KCPL Products

for other equipments

Forebay area in CW pump House. CW Pump House Intake

CW Pump House

LancoUdupi site

GMR Tanirbavi site

Velocity cap Fender frame

KCPL for ETP Equipments


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

Reliance Energy

Scrubber Internal before coating

Reliance Energy

Scrubber internal after coating

Reliance Energy

Duct internal coating

FG Duct Internal Coating

Dampner Used in FGD

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

YEARS AFTER LINING WITH POLYGLASS 100.

KCPL products for tanks

Inside of Heater treater

Marine atmosphere structures

Valve refurbishment

Reliable & Proven Solutions to Combat Corrosion…..

Potable Water Certification

Central Food Technological

Research Institute, Mysore

Water Quality Tests as per BS

6920

KCPL product on Clarifier


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

JSW Steel Hospet

Stove Dome internals

Corrosion protection

Energy Conservation

Efficiency Improvement

Productivity & Profitability

Durability & Longevity of Assets

KCPL is committed towards

THANK YOU