Transcript
Page 1: Kirloskar Corrocoat GFC CaseStudy

IMPROVING LIFE AND

EFFICIENCY OF PUMPS &

SYSTEMS USING

COMPOSITE COATINGS

Page 2: Kirloskar Corrocoat GFC CaseStudy

Cost of energy for pumping water constitutes an important element of

utilities for industries. The authorities responsible for pumping water

are among the biggest consumer of electricity and in some locations

largest single consumer. Cost of electricity in pumping the water over

a period of its' life amounts to 90-95 % of the total cost, while 5-

10% relates to purchase of pump and maintenance cost.

In any pumping system, over the years, the hydraulic passages of

casings and impeller vane shape gets damaged due to wear, tear and

corrosion, also the clearance in wearing rings increases substantially.

All these damages lead to head & flow losses and ultimately

deteriorate hydraulic performance. Due to this deterioration of

performance the power consumption increases putting pressure on

energy demand due to inefficient operation of pump.

Page 3: Kirloskar Corrocoat GFC CaseStudy

In order to keep balance of energy demand, frequent shutdown of

plants are essential. These frequent shutdowns lead to production

loss and lower utilization of scarce energy resource. To overcome

these situations it is essential to have a longer period between

shutdowns and minimal cost for maintenance.

Page 4: Kirloskar Corrocoat GFC CaseStudy

To achieve these objectives high technology composite resin systems

along with glass fiber matting technology are available which can be

used to refurbish and restore the hydraulic passages of the pump.

These passages can be applied with specially formulated energy

improvement coating, “Fluiglide.” The Fluiglide system helps to

achieve very low coefficient of friction as compared to original metal

substrate. With this, not only performance is improved

over existing one but the life of equipment is also increased.

Over a period of last 8-10 years number of pumps have been applied

with Fluiglide systems. These systems have following attributes:

They limit the effect of mechanical damage.

They resist chemically aggressive constituents in the service

environment.

They provide a barrier to prevent permeation of corrosion ions to

the substrate.

They provide low coefficient of friction.

Page 5: Kirloskar Corrocoat GFC CaseStudy

Most of the pumps, medium and large size, can be effectively treated

with polymer resin systems, both old and new. Before deciding the

specific polymer system for the pump under consideration its

operating and service conditions are studied. Based on the operating

and service conditions a appropriate resin system is selected to give

protection to the substrate from corrosion and /or erosion. This resin

system is then over-coated with “Fluiglide.”

These coatings are known to be effective by two established

qualities:

1. The reduction in surface roughness. (Refer Illustration No. 1)

2. The hydrophobic nature of coating. (Refer Illustration No. 2)

Page 6: Kirloskar Corrocoat GFC CaseStudy

1. The reduction in surface roughness :

It is well known that surface roughness has substantial bearing on

flow characteristics. A rough surface introduces micro or even macro

turbulent eddies in the boundary layer causing an increase in velocity

gradient. This velocity gradient creates resistance in passage of flow.

With the application of coatings surface roughness is reduced by

manifolds, thereby allowing the flow to be comparatively less

turbulent. Due to this phenomenon overall performance i.e. head and

flow characteristics increases.

For example the surface roughness of a cast iron substrate is Ra 18.8

microns while surface roughness of Fluiglide coating is as low as Ra

0.4 to 0.08 microns (Refer illustration no. 1). Due to lower coefficient

of friction, between the fluid and the coating and hydrophobic nature

Page 7: Kirloskar Corrocoat GFC CaseStudy
Page 8: Kirloskar Corrocoat GFC CaseStudy

2. The hydrophobic nature of coating:

When the attractive forces between the substrate and the water

molecules exceed the cohesive forces in the fluids, then the water or

other media will spread across the surface until a state of equilibrium

is reached between the two.

Therefore, where the surface energy is high, low contact angles will

be achieved and where surface energy or attraction is low, the high

contact angles will result in large gradients in velocity between the

mainstream flow and the boundary layer. In case of aqueous media,

materials which have low surface attraction are hydrophobic and repel

water, will result in lower frictional losses than surfaces which are

highly attractive to water molecules.

Page 9: Kirloskar Corrocoat GFC CaseStudy

As all common untreated metals have relatively high attraction

energies wetting out of the surface with aqueous media and the

consequent low contact angle is readily achieved. A substantial

reduction in boundary layer friction can therefore be achieved by

utilizing a coating, which is hydrophobic. The effects of these are

demonstrated below

Page 10: Kirloskar Corrocoat GFC CaseStudy

It has been observed that efficiency gains from coating are presented

in two different ways:

An increase in flow (water output) for the same input energy

(electrical consumption).

A reduction in input energy for the same water output.

It is possible to obtain the combination of these two extremes and

this is usually the case. The actual improvements achieved depend on

various factors including the specific speed of the pump.

Page 11: Kirloskar Corrocoat GFC CaseStudy

A lot of experimentation has been carried out by coating small as well

as medium and large size pumps and testing them. After the study it

has been established that low flow pumps having delivery sizes upto

100-mm size are not amenable to substantial efficiency enhancement

by coating. But pumps of delivery sizes larger than 100 mm and

impellers with outlet widths larger than 20 mm show a remarkable

improvement in efficiency, and discharge rates and head development.

The life of coating is generally more than 5 years. The coating can get

damaged only by external causes like foreign matter with sharp

corners and edges getting into the pump and passing through it or by

operation of the pump under cavitation due to inadequate available

NPSH or cavitation due to re-circulation during operation at part

capacities.

Page 12: Kirloskar Corrocoat GFC CaseStudy

GLASS FLAKE TECHNOLOGY

TORTUOUS PATH

Tortuous path for corrosive ion

Layers of glass flakes

Coating

SUBSTRATE

Page 13: Kirloskar Corrocoat GFC CaseStudy

• The development of in-house Glassflake technology has allowed for the production of the inner more uniform and consistent Glassflake

• Glassflake can now be made at sub micron thickness

ADVANCED GLASSFLAKE TECHNOLOGYADVANCED GLASSFLAKE TECHNOLOGY

Page 14: Kirloskar Corrocoat GFC CaseStudy

COMPARISONS OF PHYSICAL PROPERTIES

COMPARISONS OF PHYSICAL PROPERTIES

ALUMINIUM

BRONZE

CAST IRON

MILD STEEL

POLYESTER COMPOSITE

EPOXY COMPOSITE

DENSITY TENSILE STRENGTH

MODULUS OF ELASTICIY

SHEAR STRENGTH

lbs/cuft kg/m²

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

PSIx10³ MPa PSIx106 MPaGPa PSIx103

Page 15: Kirloskar Corrocoat GFC CaseStudy

• Excellent temperature resistance

• Excellent chemical resistance

• Excellent dry and immersed adhesion

• Low permeation rate

• Applicable over a wide range of substrates

• High abrasion resistance

• Machinability

BENEFITS/PROPERTIES OF

GLASSFLAKE COATINGS

BENEFITS/PROPERTIES OF

GLASSFLAKE COATINGS

• Dimensional stability

• Reparability

• Impact resistance

• High tensile strength

• High resistance to cathodic disbondment

• Durability, very long service lives

• Very low VOC

• Cost effective

Page 16: Kirloskar Corrocoat GFC CaseStudy

Sr. No. Liquid Type and

Name

Description 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 flake

compound, cured by the addition of organic

compound.

Adhesion layer to ensure

proper bonding with

respect to Base Metal

Intermediate Coat A heavy Built Glass Flake coatings based on

low reactivity , Bisphenol ‘A’ Polyester resin

pre accelerated, A two pack resin system

sing organic peroxide

Anticorrosion Layer

Top Coat A cold cured highly modified chemically

resistant, 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

2 Raw Water , ETP

and Sewage

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

Page 17: Kirloskar Corrocoat GFC CaseStudy
Page 18: Kirloskar Corrocoat GFC CaseStudy
Page 19: Kirloskar Corrocoat GFC CaseStudy
Page 20: Kirloskar Corrocoat GFC CaseStudy

PUMPS

After 4 years sea-water service

After refurbishment with Corrocoat Corroglass

After 7 years service

Page 21: Kirloskar Corrocoat GFC CaseStudy

PUMPS

After 7 years service

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

After 4 years sea-water service

Page 22: Kirloskar Corrocoat GFC CaseStudy

Case Study

Background:

20”X24” horizontal split casing pumps, 8 Nos. are working for supplying

cooling water. These pumps were designed for 70.4 meter head and

4500 M3 / Hr. flow at 90.5% efficiency. These pumps were installed in the

year 1985. During the course of operation it was observed that these pumps

were operating at lower head at 50.0 meter and higher flow consuming more

power and operating with the danger of cavitation.

The customer considered trimming of impeller to suit the actual site duties of

4500 M3 / Hr at 50.0 meter head. They approached the manufacturer and

informed that with such a severe trimming of impeller there would be loss of

efficiency. The trimming was carried out and this resulted in deterioration

of efficiency.

Page 23: Kirloskar Corrocoat GFC CaseStudy

At this point customer approached us. A proposal was

put forward by us to restore the new duty point efficiency to

original level by modification to the casing and application of energy

efficient Fluiglide system. Customer placed an order for refurbishment

and coating of one pump.

Following activities were involved in the process:

1. Test the pump at factory with trimmed impeller and establish the

existing performance.

2. Design and carry out modification in the casing to suit new trimmed

impeller.

3. Application of energy efficient coating.

4. Test the pump after modification and coating with Fluiglide system to

establish the restoration of efficiency.

5. We decided to carry out CFD analysis of as built design and also with

modification (before carrying out actual modification on pump) to

give confidence to the client about the proposed modification in

design.

Page 24: Kirloskar Corrocoat GFC CaseStudy

Performance parameters: Performance

Parameters

Original

Performance

Performance

after

trimming of

impeller

After

refurbishment

& application

of coating

Flow in m3/Hr 4500 4500 4523.4

Head in m 70.4 50 50

Speed in RPM 990 990 990

Pump input in kW 953.31 729.45 671.64

Best efficiency 90.5% 84% 91.23%

• Due to restored dimensions inside casing and improved efficiency of

91.23% the modified pump consumes pump-input power of 671.64 kW only.

• Power saving 57.81 kW.

• This saving converted on yearly basis is 506415.6 kwH and is for one pump.

• For 8 pumps working it would be 40,51,324.8 kWH per year. This meant

saving of Rs.22,78,867 annually.

• Pay back period for re-furbishment worked out to be only 2-3 months.

Page 25: Kirloskar Corrocoat GFC CaseStudy

GU

NA

PU

MP

IN

PU

T (

)

ACHIEVED

DT-

DISCHARGE ( )

HEAVY WATER BOARD, MANUGURU

O/A NO./ITEM NO.:-

IMP. DIA./MAT.:-

CLIENT

CONSULTANTS/

SERVICE

INDENTOR

PROJECT

0

10

10J0V0050/01.00

-- mm --

COOLING WATER

--

--

1000 2000 3000

70

PU

MP

EF

FIC

IEN

CY

(

% )

30

20

40

50

60

80

90

400

2000

600

GUARANTEED DUTY POINT

990

--

--

729.5

84

4500

50

MIN. SUBMERGENCE13/11/1999

RECOMMENDED PRIME MOVER

FULL LOAD SPEED

REQUIRED NPSH

DISCHARGE Q

PUMP EFFICIENCY

PUMP INPUT

PUMP HEAD

4000 5000

m3/hr

H

6000 7000

mm

rpm

kW

%

m

kW

m3/hr

m

0

2

SPECIFIED

TE

ST

WIT

NE

SS

ED

BY

:

NP

SH

R I

N (

)

6

4

8 m

10

DA

TE

:--

--D

RA

WN

BY

:

17

/11

/00

DA

TE

:

ACHIEVED

THIS CURVE RELATES TO THE LIQUID OF SP. GRAVITY

KIRLOSKAR BROTHERS LIMITED, PUNE (INDIA)

20/24 CME (DV)

50PU

MP

HE

AD

(

)kW

30

40

60

m 70

80

85

*PERFORMANCE CURVE OF

PUMP AS DELIVERED TO KBL*

CORPORATE RESEARCH & ENGG.

DIVISION

mm

RKP/20173/0

SPECIFIED

SPECIFIED

1

SUC.

CURVE NO.

600

DA

TE

:

AP

PR

OV

ED

BY

:C

HE

CK

ED

BY

:

17

/11

/00

DA

TE

:

RG

PJT

K

17

/11

/00

500DEL. mm

GU

NA

PU

MP

IN

PU

T (

)

DT-

DISCHARGE ( )

HEAVY WATER BOARD, MANUGURU

O/A NO./ITEM NO.:-

IMP. DIA./MAT.:-

CLIENT

CONSULTANTS/

SERVICE

INDENTOR

PROJECT

0

10

10J0V0050/01.00

-- mm --

COOLING WATER

--

--

1000 2000 3000

70

PU

MP

EF

FIC

IEN

CY

(

% )

30

20

40

50

60

80

90

400

2000

600

GUARANTEED DUTY POINT

990

1080

--

673.76

91

4500

50

MIN. SUBMERGENCE13/11/1999

RECOMMENDED PRIME MOVER

FULL LOAD SPEED

REQUIRED NPSH

DISCHARGE Q

PUMP EFFICIENCY

PUMP INPUT

PUMP HEAD

4000 5000

m3/hr

H

6000 7000

mm

rpm

kW

%

m

kW

m3/hr

m

0

2

TE

ST

WIT

NE

SS

ED

BY

:

NP

SH

R IN

( )

6

4

8 m

10

DA

TE

:--

--D

RA

WN

BY

:

17

/11

/00

DA

TE

:

THIS CURVE RELATES TO THE LIQUID OF SP. GRAVITY

KIRLOSKAR BROTHERS LIMITED, PUNE (INDIA)

AFTER REFURBISHING OF CASING AND COATING OF PUMPS

20/24 CME (DV)

40PU

MP

HE

AD

(

)

kW

30

20

60

m 80

100

85

*PERFORMANCE CURVE OF

*

CORPORATE RESEARCH & ENGG.

DIVISION

mm

RKP/20172/0

1

SUC.

CURVE NO.

600

DA

TE

:

AP

PR

OV

ED

BY

:C

HE

CK

ED

BY

:

17

/11

/00

DA

TE

:

RG

PJT

K

17

/11

/00

500DEL. mm

Page 26: Kirloskar Corrocoat GFC CaseStudy

View of Bottom & Top Casing prior to blasting…………..

Page 27: Kirloskar Corrocoat GFC CaseStudy

View of coated components, top casing……

Page 28: Kirloskar Corrocoat GFC CaseStudy

View of coated components, bottom casing…….

Page 29: Kirloskar Corrocoat GFC CaseStudy

View of coated Impeller after coating & balancing…..

Page 30: Kirloskar Corrocoat GFC CaseStudy

Conclusion:

During last 5-6 years our company has used

Fluiglide coating systems on hundreds of

medium and large size pumps resulting in

efficiency gain of 1-3 points depending on

type of pump & the specific speed, in case of

new pumps. This gain in efficiency was over

and above designed one.

Page 31: Kirloskar Corrocoat GFC CaseStudy

Also hundreds of old pumps have been

refurbished to restore the shapes of hydraulic

passages near to its original one and

application of Fluiglide systems have resulted

into gain in efficiency of 4-6 points and

improvement in head – flow characteristics

over its existing one during the operation in

the plant.

Page 32: Kirloskar Corrocoat GFC CaseStudy

As the efficiency enhancement achieved with

Fluiglide treatment is expected to be retained

for a period of at least 3 years, the benefits

achieved is expected to continue for a

minimum period of 3 years. This has been

established by inspecting the pumps after

opening them during shutdown after a period

of 4-5 years.

Page 33: Kirloskar Corrocoat GFC CaseStudy

The concept of composite resin systems could

be advantageously used for internal lining of

pipelines to combat corrosion on internal

surface of pipes, which takes place mainly

due to depositions of chlorides and sulphates.

The depositions over a period of time increase

frictional head by reducing area of pipes.

Page 34: Kirloskar Corrocoat GFC CaseStudy

Composite coatings combined with appropriate

refurbishing techniques have potential to provide

pumping solutions which were so far not available.

This is a concept and not a product, which should

be propagated across the length and breadth of our

country to arrest huge national loss taking place

due to corrosion and wear of pumping and other

equipments.

Page 35: Kirloskar Corrocoat GFC CaseStudy

THANK YOU


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