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 blasting material to ensure thorough removal and dust clearance. This operation is carried out simultaneously from both ends of a single pipeline section. Once the protective coating is applied, the pipe section (pressure regulating chamber) is removed and re-coated. Due to safety constraints, it is 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 before the water distribution pipe is processed.
Only after the blasting work has been reviewed and approved by TIWAG’s quality assurance experts, and the welding joints have been sampled and verified, can the coating be applied to the relevant sections of the pipeline. Given the significant destructive potential of corrosion—especially at the bottom of the pipeline where structural load is highest—a 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 can be driven in to spray the first layer. A visual inspection is performed to check for pores. For any open holes, severe corrosion pits, or existing damage, a spatula is used to apply Humeide P material. Then, the second layer of spraying is applied. Unlike traditional coatings, this method does not require any drying time or extended maintenance between layers, significantly improving work efficiency and reducing the potential downtime of the power station. The first layer has a relatively thick application—ranging from 400–500 micrometers, and up to 700–1000 micrometers in high-corrosion areas such as the bottom and weld joints—which helps avoid the need for large-scale manual repairs. The average thickness at the bottom of the pipe is approximately 1200 micrometers, while the remaining surfaces are coated to about 900 micrometers.
To complete the work as quickly as possible, flexible yet rigorous quality assurance measures are essential. Experts from TIWAG, appointed by Aizhicheveco, were present throughout the entire process, overseeing the condition analysis of the pipeline and conducting the final testing of the new coating. Quality assurance covers multiple aspects and requires full cooperation and coordination among all involved parties. Strict technical conditions must be followed, and clear quality assurance periods and standards must be established to ensure the reliability and durability of the entire project.
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