For the original protective layer on the pipeline of the hydropower station, the process begins with sandblasting to remove the top layer. A second round of sandblasting is then conducted using a new, pure abrasive material to ensure thorough cleaning and dust removal. This operation is carried out simultaneously from both ends of a single pipeline section. After applying the protective coating, the pipe section (pressure regulating chamber) is removed for further treatment. Due to safety constraints, it's not possible to work on part of the inclined pipe (pipe section 3) and the water distribution pipe at the same time. Therefore, pipe section 3 must be completed first, followed by the processing of the water distribution pipe.
Only after the blasting work has been reviewed and approved by TIWAG’s quality assurance experts, and the welding joints have been sampled and inspected, can the relevant sections of the pipeline be coated. Given the severe corrosion risk—especially at the bottom of the pipeline, where structural integrity is critical—the vacuum spray equipment is used to apply two layers of Humeide ML material in different colors (gray and white). The total thickness after drying must be at least 800 micrometers at the bottom of the pipeline and at least 600 micrometers in other areas.
After 48 hours of drying, the work car is used to apply the first layer of coating, followed by a visual inspection for any pores or defects. For areas with open holes, deep corrosion pits, or damage, a trowel is used to manually apply Humeide P material. Then, the second layer of spraying is performed. Unlike traditional coatings, this method does not require drying between layers or long maintenance periods, significantly improving work efficiency and reducing potential downtime for the power station. The first layer has a relatively thick application—ranging from 400–500 micrometers, with higher thickness (700–1000 micrometers) in high-risk areas like the bottom and weld joints. This approach minimizes the need for large-scale troweling. The average thickness at the bottom of the pipe reaches about 1200 micrometers, while the rest of the surface maintains a thickness of around 900 micrometers.
To complete the project as quickly as possible, a flexible and effective quality assurance process is essential. Experts from TIWAG, appointed by Aizhicheveco, were involved throughout the entire process, from initial pipeline condition analysis to the final testing of the new coating. Quality assurance covers multiple aspects and requires full cooperation among all stakeholders. Strict technical standards must be maintained, and clear quality assurance periods and performance benchmarks should be established to ensure long-term reliability and compliance with industry regulations.
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