Appendix 5, Requirements For Protective Coating in Hydro Power Plants P 2012-0133

Utfärdare/Handläggare Sign Datum Vår beteckning
Roger Karlsson RK 2013-04-19 P-2012/0133

Granskad/tillstyrkt Sign Datum Utgåva Sida
Magnus Nilsson MN 2013-05-20 1 1 (14)
Godkänd/fastställd Sign Datum Giltigt från datum Arkiverad datum
Fredrik Engström 2013- 2013- 2013-
Reviderad av Sign Datum Hänvisning till
Requirements for Protective Coating in Hydro Power Plants

1. Qualification
The painting contractor shall possess a certificate of authorisation for anti-
corrosive painting, or equivalent. The Swedish Authorization for Protective
Coating, Auktorisation för Rostskyddsmålning, (AFR) approves painting
contractors. The certificate shall, upon request, be presented to the Purchaser.
Personnel who are involved in the work must have completed diploma training for
protective coating, or equivalent. This shall, upon request, be validated.
2. Health and safety and environmental protection

Statutory requirements and safety regulations must be followed, see SS-EN ISO
12944-1 Chapter 5.
When working with thermosetting plastics, the ordinance AFS 2005:18 by the
Swedish work environment authority applies. Work in the course of activities
coming under these provisions may only be directed and done by persons who
have sufficient knowledge concerning hazards and necessary precautions in
connection with the work.
The substitution principle should be applied when selecting the appropriate paint
system. That means substitution of hazardous substances by less hazardous
alternatives when it is technical possible.
Data sheets of the paint manufacturer on health and safety risks connected to the
product and its application shall be available at work site giving information on
composition, preventive measures, personal protective measures, etc.
3. Basic design criteria for corrosion protection proposes

The overall design of the structure has large impact of its corrosion resistance.
Structures to be corrosion protected by painting shall be designed in accordance
with the recommendations in SS-EN ISO 12944-3, SS-EN 1090–2, SS-EN ISO
5817 and SS-EN ISO 8501-3.
1 (14) Vattenfall Vattenkraft AB

4. Surface preparation
4.1. Removal of grease and soil
Oil, grease, dirt and other contaminants shall be removed as far as possible, prior
to further surface preparation, using appropriate method, see SS-EN ISO 12944-
4. This also complies for salts which shall be removed by high pressure water
jetting or steam. When selecting a surface preparation method, environmental
and safety requirements shall be considered. Test methods to determine if the
surface is clean are described in SS-EN ISO 8502-6 and SS-EN ISO 9502-9.
4.2. Hand and Power-tool cleaning
Cleaning with hand-tool or power-tool can be used on objects in environments
with low humidity. Wire brushes are not allowed.
4.3. Blast cleaning
Before blast cleaning and if required after, all imperfections as rolled errors,
shelling, welding splatter, welding slag, weld ripple, sharp edges etc. shall be
removed to comply with the requirements in SS-EN ISO 8501-3.
One of the methods specified in SS-EN ISO 12944-4 shall be used. Blast
cleaning abrasives shall be chosen to achieve specified preparation grade. It can
be sand, sponge or sodium bicarbonate.
Blast cleaning is normally performed to preparation grade Sa 2½ according to
SS-EN ISO 8501-1.
5. Corrosion protection by painting

5.1. Protection against dust
If no other agreement has been made, it is the painting constructor responsibility
to meet all the costs involved in the covering, dust suction, filtration as well as the
protection of the machine halls and surrounding equipment against blasting and
paint dust which can occur during the painting process.
5.2. Paint system
Each coating must be uniform without visible running’s (curtains), dripping, dry
spray, pores, blisters, pin holes, craters or other defects. Sandpaper structure,
orange peel surface or uncoated areas are not acceptable.
Care shall be taken to achieve the dry film thickness. The method and procedure
for checking the thickness of dry films on rough surfaces shall be in accordance
with SS-ISO 19840.
Selection of paint system is dependent on the corrosivity category of the
environment where the structure will be located, and the demands of health and
safety and environmental protection.
Zinc paints and galvanized coating should not be used in streaming freshwater.
Because the salts formed on the surface to protect the zinc is easily dissolved in
water with low salinity. Streaming water is preventing salt formation on the
surface and then the zinc can go into solution immediately.
Unless otherwise agreed, the durability of the paint systems is expected to be
more than 15 years.
The color shall be approved by the purchaser.
Table 1 and 2 gives information on which paint system to be used. The
requirements for each paint system are shown in appendix 4.

Table 1. Corrosivity classes and paint system for hydraulic gates.
Object Surfaces in water Surfaces in air
Corrosivity Paint Corrosivity Paint
category system category system
Intake gate and Spillway gate Im1 1A Alt. 1B C5M 1C, 1D Alt.
incl. guides 4A
Internal/external surfaces of Im1 1A Alt. 1B C3 – C4 2A, 2B Alt.
gates 4A
Internal surfaces of gates, if C2 – C3 2A Alt. 2C
encapsulated, dehumidified
and warm
Stop log Im1 – C3 1A-2D Alt.
4A
Guard rails, etc. C2 – C4 1C Alt. 2A-B
Alt. Hot dip
galvanized
Table 2. Corrosivity classes and paint system for turbines and waterways.
Object Surfaces in water Surfaces in air
Corrosivity Paint Corrosivity Paint
category system category system
Penstock exposed to air Im1 1A Alt. 1B C4 – C5 M 1C Alt. 1D
Penstock exposed to soil Im1 and Im3 1A Alt. 1B C5 M 1C Alt. 1D
Draft tube cone/liner Im1 1A Alt. 1B C5 M 1C Alt. 1D
Spiral Case Im1 1A Alt. 1B C5 M 1C Alt. 1D
Guide vane, stay vane Im1 1A Alt. 1B
Head cover, bottom ring, Im1 1A Alt. 1B C5 M 1C Alt. 1D
discharge ring
Runner hub, runner cone Im1 1A Alt. 1B
Regulating ring C3 – C4 1C-D Alt.
2A-B
Turbine shaft Im1 1A Alt. 1B C3 – C4 1C Alt. 2B
Sealing surfaces of guide 3B 3B
vanes as well as other sealing
surfaces where steel elements
will be joined together
Surfaces exposed to oil 3A
Additional objects to be Im1 1A Alt. 1B C3 – C5 M 1C-2D
specified
Screw joints e.g. in turbines C4 – C5 M 5A
and its design components

6. Supervision
The execution of the work shall be supervised at all stages, at least according to
SS-EN 1090-2 section 10 and SS-EN 12944-7. The contractor shall be
responsible for carrying out this supervision himself. Supervision shall be
undertaken by suitable qualified and experienced people.
The ambient conditions on site shall be checked in order to ensure that they meet
the requirements such as temperature and air humidity given in the technical data
sheets of the paint manufacturer.
’Report on basic inspection’, see Appendix 1, (or similar) shall be completed
during the work process and not at a later stage.
Painting is one of the processes where quality cannot be fully assessed merely
based on the acceptance inspection of the finished coating. Therefore,
supervision and control during paint work over all parameters that may affect the
coating outcome is imperative. Emphasis is also increasingly being placed on the
qualification of personnel.
The contractor shall call to inspections at occasions that have been agreed on.
Unless otherwise stated an inspection shall always take place after surface
preparation before painting. Purchaser inspections can in addition comprise
control of surface cleanliness, porosity (surfaces exposed to water), adhesion,
thickness and liquid sampling, see Appendix 2 ’Report on additional inspections’.
Deviations and other noteworthy matters shall be reported, see Appendix 3.
These reports are part of the final documentation. Photographs taken to verify
particular surface conditions shall also be attached to the final documentation.
Necessary control equipment, provided by the contractor, shall be available to
determine air temperature, temperature of substrate, relative humidity, wet film
thickness, dry film thickness, surface roughness and surface profile. The
instrument used shall be checked, calibrated and maintained at regular intervals
and the results shall be recorded.
At the final inspection of objects in Im classified environments, test of porosity
according to ASTM D 5162-01 shall be performed. Pore detection measurements
is intended for the entire painted surface including corners, sharp edges, rivet
and bolt heads and welds. Pores will not be tolerated.
7. Guarantee period
The guarantee period is five (5) years and the contractor shall guarantee that the
requirements set out in Table 3 will be fulfilled during the guarantee period:
Table 3. Requirements at the end of the guarantee period.
Degree of rusting Max Ri1 SS-EN ISO 4628-3
Blistering 0 SS-EN ISO 4628-2
Cracking Class 0 SS-EN ISO 4628-4
Flaking 0 SS-EN ISO 4628-5
Adhesion 6 MPa for epoxy system, 2,5 SS-EN ISO 16276-1
MPa for others

8. Revision history
Rev-nr Date Description of revision
0.1 05-11-12
0.2 28-12-12 New paint system 4A and 5A.
0.3 04-01-13 Changed corrosively class in paint system
0.4 01-03-13 Zinc colors and galvanized coating
0.5 06-03-13 Changes in Painting system
0.6 19-04-13 Text editing

Report on basic inspection Appendix 1
Final report Interim report No
Painting contractor Order No Description
Object Drawing
Has authorization certificate or similar
Purchaser Paint system
Total dry film µm

Painting carried out on
Hot rolled steel Cold rolled steel Casting _________________

Working operations inspected
Preparation Priming Finishing painting _________________
Deviations :
___________________________________________________________________________
Washing / degreasing with:
Rust grade according to SS-EN ISO 8501-1 A B C D

Surface preparation acc to SS-EN ISO 8501-1 Sa 2 Sa 2½ Sa 3 _______
Preparation grade acc to SS-EN ISO 8501-3 P1 P2 P3 _______
Surface roughness acc to SS-EN ISO 8503-2 Fine Medium Coarse _______
Time/Environmental/ Application of paint
Preparation
Material Film 1 Film 2 Film 3 Film 4 Film 5
Date
o
Air temperature C
Relative humidity %
o
Dew point C
o
Temp of steel substrate C
Blast cleaning abrasive
Paint supplier
Paint designation
Paint batch No
Hardener designation
Hardener batch No
Mean film thickness µm µm µm µm µm
Thickness of paint film
1) 1)
Acc to SS ISO 19840 Primer min ______µm max _______µm mean _______µm
1)
refers to min and max local Complete paint
1) 1)
film thickness System min ______µm max _______µm mean _______µm
Other observations
I certify that the above is correct:
______________ ________________________________________
Date Signature
Sweco Energuide AB 6 (14) Vattenfall Vattenkraft AB

Report on additional inspections Appendix 2
Object Drawing
Purchaser Paint system Color
Total dry film µm

Liquid sampling according to SS-EN ISO 15528
Paint supplier
__________________________________________________________________
Paint designation
__________________________________________________________________
Hardener designation
__________________________________________________________________
Adhesion according to SS-EN ISO 16276-1
Mean, MPa
__________________________________________________________________
Max, MPa
__________________________________________________________________
Min, MPa
__________________________________________________________________
Location of tests
__________________________________________________________________
Temp and relative
humidity at the test __________________________________________________________________
Test instrument (make,
model) __________________________________________________________________
Dolly (size, material)
__________________________________________________________________
Adhesive (make, type)
__________________________________________________________________
Porosity test according to ASTM D5162
Number of
discontinuities per area __________________________________________________________________
unit:
Test voltage, kV:
__________________________________________________________________
Test instrument (make,
model) __________________________________________________________________
Other observations
__________________________________________________________________
I certify that the above is correct:
______________ ________________________________________
Date Signature

Report on deviations Appendix 3
Reception Execution
Object Drawing
Purchaser Contact person
Deviations of requirements, time schedule etc. have been notified regarding:
Design Intermittent weld Edges made by drilling
Hollow components Lamination Welding spatter
Narrow gaps Rust grade Welds
Drain holes Sharp edges
Ambient condition Handling damage
Time interval Transportation damage
Preparation Top coat Packaging/transportation
Priming coat Curing/drying Other observations

Description of deviation
Proposed measures
Observed by
Measure
Decided
______________ ________________________________________
Date Signature

Appendix 4
Paint system 1A. Epoxy.
Environment: Surfaces exposed to water. Corrosivity Im1 and Im3.
Use: New steel structures and steel with a rust grade A or B.
Preparation: High pressure water cleaning is carried out to remove
contaminations.
Blasting is performed to preparation grade Sa 2 ½ according to
SS-EN ISO 8501-1:2007.
Preparation of steel according to SS ISO 8501-3:2006 Grade P3.
Medium roughness of blast cleaned substrates according to
SS-EN ISO 8503-2 (G).
The stated grades refer to the state at the time of application, if
they are not met, a new blasting shall be done.
Primer: One coat of micaceous iron oxide pigmented epoxy primer, to
min 80 µm.
Finish: One coat of two component epoxy paint, high solids ≥80%, to
400 µm.
Total paint system: Min 480 µm DFT.
Application: Brush Painting shall be performed on sharp edges, corners,
notches and weld beads before each paint application.
Paint system 1B. Epoxy.

Environment: Surfaces exposed to water. Corrosivity Im1 and Im3.
Use: Old steel with pitting corrosion according to rust grade C or D.
contaminations.
SS-EN ISO 8501-1:2007.
SS-EN ISO 8503-2 (G).
Primer: One coat of micaceous iron oxide pigmented epoxy primer, to
min 80 µm.
Finish: Min two coats of two component epoxy paint, high solids ≥80%,
to min 700 µm.
notches and weld beads before each paint application. Surfaces
with excessive pitting corrosion and reduced material thickness,
corrosion grade C to D, shall be treated by carefully and
accurately applying the primer with a brush into the pits and
craters.

Appendix 4
Paint system 1C. Epoxy.
Environment: Surfaces in high humidity. Corrosivity C4 to C5-M.
Use: New steel structures and steel with a rust grade A or B.
contaminations.
SS-EN ISO 8501-1:2007.
SS-EN ISO 8503-2 (G).
Primer: One coat of micaceous iron oxide pigmented epoxy primer with
zinc phosphate as active anti corrosive pigment, to min 100 µm.
Intermediate: One coat of micaceous iron oxide pigmented epoxy primer, to
min 100 µm.
Finish: One coat of two component polyurethane paint, to min 80 µm.
Paint system 1D. Epoxy.

Use: Old steel with pitting corrosion according to rust grade C or D.
contaminations.
SS-EN ISO 8501-1:2007.
SS-EN ISO 8503-2 (G).
Primer: One coat of micaceous iron oxide pigmented epoxy primer with
zinc phosphate as active anti corrosive pigment, to min 100 µm.
Intermediate: Two coats of micaceous iron oxide pigmented epoxy primer to
min 200 µm.
Finish: One coat of two component polyurethane paint, to min 80 µm.
craters.
10 (14) Vattenfall AB Vattenkraft

Appendix 4
Paint system 2A. Alkyd.
Environment: Surfaces in moderate humidity. Corrosivity C3 to C4.
Use: New steel structures and steel with a rust grade A or B. For
example: internal surfaces of gates.
contaminations.
SS-EN ISO 8501-1:2007.
SS-EN ISO 8503-2 (G).
Primer: One coat of fast drying alkyd primer, to min 60 µm.
Finish: Two coats of fast dying alkyd paint, to min 140 µm.
Paint system 2B. Alkyd.

Use: Old steel with pitting corrosion according to rust grade B or C.
For example: internal surfaces of gates.
contaminations.
SS-EN ISO 8501-1:2007.
SS-EN ISO 8503-2 (G).
Primer: Two coats of fast drying alkyd primer, to min 100 µm.
Finish: Two coats of fast dying alkyd paint, to min 160 µm.
corrosion grade C, shall be treated by carefully and accurately
applying the primer with a brush into the pits and craters.

Appendix 4
Paint system 2C. Alkyd.
Environment: Surfaces in low level of humidity. Corrosivity C2.
Use: Steel with a rust grade A or B. For example: internal surfaces of
gates, if encapsulated, dehumidified and warm.
contaminations.
Partial blasting is performed to preparation grade P Sa 2.
Alternatively hand-/power-tool cleaning to grade P St 2-3 or P Ma
according to SS-EN ISO 8501-1:2007.
SS-EN ISO 8503-2 (G).
Primer: One coat of fast drying alkyd primer, to min 60 µm.
Finish: One coat of fast dying alkyd paint, to min 80 µm.
Paint system 2D. Alkyd Special.

Use: Maintenance of surfaces with degraded coatings to degree of
rusting Ri2 to Ri4. And old steel with pitting corrosion according
to rust grade A to D. For example: internal surfaces of gates with
remaining paint with alkyd or red lead.
contaminations.
Partial blasting is performed to preparation grade P Sa 2.
Alternatively hand-/power-tool cleaning to grade P St 2-3 or P Ma
according to SS-EN ISO 8501-1:2007.
SS-EN ISO 8503-2 (G).
Primer: One coat of highly penetrating, low viscosity, linseed oil alkyd-
based clear coat primer, to approximately 15 µm (e.g. Isotrol
Primer).
Intermediate: One coat of oil alkyd-based paint with micaceous iron oxide, to
min 80 µm (e.g. Isotrol Pansar).
Finish: One coat of alkyd paint, to min 80 µm (e.g. Isotrol Finish).
craters.

Appendix 4
Paint system 3A. Epoxy Special.
Environment: Steel surfaces in oil.
Use: Surfaces exposed to e.g. hydraulic oils.
For example: oil tanks, oil accumulators, oil lubricated bearings,
runner hub.
Preparation: High pressure water cleaning and solvent cleaning is carried out
to remove contaminations.
SS-EN ISO 8501-1:2007.
SS-EN ISO 8503-2 (G).
Primer: One coat two-pack epoxy phenolic, to min 120 µm.
Finish: One coat two-pack epoxy phenolic, to min 120 µm.
Note: Hydraulic oils may contain components that are
aggressive to the paint. At uncertainties, consult the oil
manufacturer/technical data sheet of the oil.
Paint system 3B. Epoxy Special.

Environment: Corrosivity C3 to Im1.
Use: Sealing surfaces of guide vanes, bottom ring and head cover as
well as other sealing surfaces where steel elements will be joined
together.
contaminations.
SS-EN ISO 8501-1:2007.
SS-EN ISO 8503-2 (G).
Primer: One coat two-pack epoxy primer pigmented with micaceous iron
oxide to min 80 µm and max 100 µm.
Total paint system: Max 100 µm DFT.
Application: Brush painting or spray application.

Appendix 4
Paint system 4A. Modified Vinyl Anticorrosive (Replaces Silverprimocon)
Environment: Surfaces exposed to water Corrosivity C4 to Im1.
Use: Old steel structures with pitting corrosion according to rust grade
B or C. For example Stop logs, and other surfaces exposed to
water. Painting system 4A is primarily intended as a touch-up
paint option for previously painted surfaces with remaining
asphalt/ bitumen paints
Preparation: High pressure water cleaning and solvent cleaning is carried out
to remove contaminations.
SS-EN ISO 8501-1:2007.
SS-EN ISO 8503-2 (G).
Primer: One pack, tar free vinyl anticorrosive paint, to min 80 µm DFT
Finish: One pack, tar free vinyl anticorrosive paint, to min two coats a 80
µm DFT
corrosion grade C, shall be treated by carefully and accurately
applying the primer with a brush into the pits and craters.
Note: Can be applied down to 0 degrees C.
This paint system is a replacement for the previously common
asphalt/bitumen paints (so called Silverprimocon). These
products can be used for steel structures in a humid environment
or water. It’s meant as a simpler alternative for epoxy products.
Paint system 5A. Surface treatment of screw joints.

Use: Surface treatment of all types of screw connections used in
turbines and related plant components.
Preparation: Degreasing and wire brushing of screw connections.
Primer: Two layers with a wax based, high-penetrating, water-displacing,
rust preventive oil. Shall be treated by carefully and accurately
applying with a brush to about 60-80 µm.
Total paint system: Max 100 µm DFT.
Application: Brush painting or spray application.
Suitable products Tectyl 506 WD, Dinitrol Pasta or comparable

Appendix 5, Requirements For Protective Coating in Hydro Power Plants P 2012-0133

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Utfärdare/Handläggare Sign Datum Vår beteckning

Roger Karlsson RK 2013-04-19 P-2012/0133

Requirements for Protective Coating in Hydro Power Plants

2. Health and safety and environmental protection

3. Basic design criteria for corrosion protection proposes

1 (14) Vattenfall Vattenkraft AB

5. Corrosion protection by painting

2 (14) Vattenfall Vattenkraft AB

3 (14) Vattenfall Vattenkraft AB

4 (14) Vattenfall Vattenkraft AB

5 (14) Vattenfall Vattenkraft AB

Painting contractor Order No Description

Total dry film µm

Hot rolled steel Cold rolled steel Casting _________________

Preparation Priming Finishing painting _________________

Rust grade according to SS-EN ISO 8501-1 A B C D

I certify that the above is correct:

Sweco Energuide AB 6 (14) Vattenfall Vattenkraft AB

Painting contractor Order No Description

Purchaser Paint system Color

Total dry film µm

7 (14) Vattenfall Vattenkraft AB

Painting contractor Order No Description

Purchaser Contact person

Deviations of requirements, time schedule etc. have been notified regarding:

Design Intermittent weld Edges made by drilling

Hollow components Lamination Welding spatter

Narrow gaps Rust grade Welds

Drain holes Sharp edges

Ambient condition Handling damage

Time interval Transportation damage

Preparation Top coat Packaging/transportation

Priming coat Curing/drying Other observations

8 (14) Vattenfall Vattenkraft AB

Paint system 1B. Epoxy.

9 (14) Vattenfall Vattenkraft AB

Paint system 1D. Epoxy.

10 (14) Vattenfall AB Vattenkraft

Paint system 2B. Alkyd.

11 (14) Vattenfall AB Vattenkraft

Paint system 2D. Alkyd Special.

12 (14) Vattenfall AB Vattenkraft

Paint system 3B. Epoxy Special.

13 (14) Vattenfall AB Vattenkraft

Paint system 5A. Surface treatment of screw joints.

Suitable products Tectyl 506 WD, Dinitrol Pasta or comparable

14 (14) Vattenfall AB Vattenkraft

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