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TRANSCRIPT
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 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 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 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 <85 %
Over coating – good flexibility
Page 22
Large Pipe coating at site
3.6 m. dia. Internally
Coated pipe
Internal view of 2.6 m. dia
coated pipe
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 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 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 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 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 49
SEAWATER PRE-LOAD TANK, NOW BEEN IN SERVICE FOR 9
YEARS AFTER LINING WITH POLYGLASS 100.
KCPL products for tanks
Page 53
Reliable & Proven Solutions to Combat Corrosion…..
Potable Water Certification
Central Food Technological
Research Institute, Mysore
Water Quality Tests as per BS
6920
Page 54
KCPL product on Clarifier
This is a proprietary document of Kirloskar Corrocoat Private Limited
Page 55 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
Page 56
Corrosion protection
Energy Conservation
Efficiency Improvement
Productivity & Profitability
Durability & Longevity of Assets
KCPL is committed towards