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Improving Pumping efficiency by Coating

by
R. G. Padalkar
Kirloskar Corrocoat Pvt. Ltd., Pune
3L PROGRAM
Organized by
Bureau of Energy Efficiency
at Pune
21
st
September 2011
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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.
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KIRLOSKARWADI PLANT
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KIRLOSKARWADI PLANT
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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
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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.
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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
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Pump Efficiency = h
h
X h
v
X h
m
Where h
h
= Hydraulic Efficiency
h
v
= Volumetric Efficiencyy
h
m
= Mechanical Efficiency
PUMP EFFICIENCY
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Max. attainable efficiency (as per HIS)
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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
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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
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Efficiency Improvement Properties
SURFACE FINISH
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Efficiency Improvement Properties
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

HYDROPHOBIC NATURE

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Glass Flake Technology - Tortuous Path

Tortuous path for corrosive ion


Layers of glass flakes


Coating















SUBSTRATE
Corrosion Protection
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Coating of Pipe Lines
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Advantage of New Pump Coating
LININGS AND COATINGS
(Ref : Pumping Manual, 9
th
Edition, Page 472 by Mr. T.C. Dickenson)
diffusers
against
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Advantage of New Pump Coating
Linings and Coatings
Ref : Pumping Manual Page 473
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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)
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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
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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
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PUMP REFURBISHMENT
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PUMP REFURBISHMENT
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Surface preparation by abrasive blasting & Applying
energy efficiency improvement coating system
COATING PROCESS
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Quality tests by customer with KCPL
Holiday & DFT Testing.
QUALITY TESTING
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VERTICAL TURBINE PUMP BOWL
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COATED NEW PUMP
Page 27 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
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PUMPS (CORROSION PROTECTION)
After 4 years sea-water service
After coating with
Corrocoat Corroglass
After 7 years service
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After 7 years service
After coating with Corrocoat
Corroglass
After 4 years sea-water service
PUMPS (CORROSION PROTECTION)
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CASING BEFORE AND AFTER COATING
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IMPELLER BEFORE & AFTER COATING
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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
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Losses in Pipes
Hazen-Williams Equation
V= 0.849 C R
0.63
S
0.54
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
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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
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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
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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 flake
compound, 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
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
COATING SPECIFICATION CLEAR WATER
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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
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WATER REGULATIONS
ADVISORY SCHEME, UK
EFFECT ON WATER
QUALITY TEST as per BS
6920
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POTABLE WATER CERTIFICATION
Central Food Technological Research
Institute, Mysore
Water Quality Tests as per BS 6920
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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
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Comparision of Water Vapour
Transmission Rate
0.85
0.75
0.6
0.24
3.80
7.00
9.00
11.00
0
5
10
1 2 3 4
Dur ation in Days
M
o
i
s
t
u
r
e

V
a
p
o
u
r

T
r
a
n
s
m
i
s
s
i
o
n

g
/
m
2
,

2
4

H
r
s
.
Tested accor ding to BS 2782 : Par t 5 : Par t 513 A
Film Thickness - 175 micr ons.

Figure 4
Gr anular Filled
Glass Flake Filled
TRANSMISSION RATE
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PHYSICAL TESTS
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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 PSIx10
6
MPa GPa PSIx10
3
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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
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THANK YOU