TRAFOTECH 2014 - Ninth International Conference on Transformers

Vital consideration about painting system for EHV/UHV Transformer Tank

and Accessories
Amulya Deota S. G. Bokade
Manager Sr. DGM
BHEL, BHOPAL

ABSTRACT

Selection of type of paints and painting process
is vital on all transformers from the smallest
distribution transformer to the largest super grid
transformer. Due to the vulnerability of tank
surfaces to the corrosive effects of moisture
and the atmosphere, it is essential to take
different considerations into account when
specifying paints and painting process for the
tank and accessories like conservator, turrets,
cooling pipes, supports etc.

This paper focuses on those considerations,
ranging from the choice of primers and paints
to the importance of the top coat. The
information presented in this paper helps
explain which paint or paint system is best for
the particular combination of conditions present
or anticipated i.e. the condition of tank steel
plate, painting conditions, coating properties
desired and the environment to be withstood by
the applied finish, as well as the total cost for
material and application
INTRODUCTION
The power transformer is precious equipment
in the entire substation. Considering the total
life span & installation location, the painting of
transformer requires highest attention. The
painted surface needs to with stand the
adverse climatic conditions and also to retain
the properties of transformer oil inside tank.
The Industrial grade paint for above application
typically consists of pigment, resin, solvent and
additives:
Pigment - to provide colour, hiding and
control gloss.
Resin the binder to hold the pigment
particles together and provide adhesion to
the surface painted.
Solvent to act as a carrier for the
pigments and resin
Additives to enhance certain properties
such as ease of brushing, mould
resistance, scuff resistance, drying and sag
resistance
Mild Steel is generally used for fabrication of
tank and accessories for transformer because
of its exceptional physical and mechanical
characteristics. The primary quality of steel i.e.
its ability to retain its physical and mechanical
strength is generally long-lasting and is only
compromised when corrosion reduces its cross
section to such a degree that safety and
reliability is adversely affected.
Corrosion is the gradual destruction of material,
usually metals, by chemical reaction with its
environment. In the most common use of the
word, this means electrochemical oxidation of
metals in reaction with an oxidant such as
oxygen. Rusting, the formation of iron oxides is
a well-known example of electrochemical
corrosion. Figure 1 shows the process of
corrosion on steel surface.

Figure 1: Schematically exhibits of corrosion
process
The service life of a transformer tank and
accessories depends on the rate of reaction
TRAFOTECH 2014 - Ninth International Conference on Transformers

between the steel and its environment. These
reactions depend on the nature and
concentration of the corrosive agents present.
Rusting not only corrodes the surface, but also
weakens the metal. Fortunately, if there is an
interruption in any of the steps, the entire
process stops. A way to accomplish this is to
cover the metal surface with a protective
coating that will block moisture from reaching
the metal substrate. If suggested painting
system based on environmental condition
followed, life span of coating in the range of 12-
15 years may be expected. A number of
different coating technologies can be used to
attain this objective, including waterborne
acrylic coatings, alkyds, epoxies,
polyurethanes etc. Now days, water borne
paints are preferred as it is more environmental
friendly.
ENVIRONMENTAL CONDITION
Special care should be given to the
environment in which the coating must perform.
In addition to the generic descriptions of
environment as heavy, medium or light duty,
there have been attempts to better describe the
possible environments where metal structures
are found, such as the classifications given by
ISO, captured in the Table 1. Before selecting
the paints and painting system, this Table 1
should be referred.
SUGGESTED PAINTING SYSTEM FOR
TRANSFORMER AND ACCESSORIES
The selection of a painting system for
transformers depends on the performance
requirements from the proposed system. These
requirements are different for the exterior &
interior surfaces of the transformers, as they
are exposed to different environments. Painting
systems as per Table 2 are suggested for
Transformer and accessories for corrosion
prevention and other required conditions. Hot
dip galvanizing can be used prior to painting for
radiators to get more protection.
Where large areas of transformer tank are to
be painted, the specifications written for paints
should address the following main
consideration:
Protect the Transformer from corrosion
Reduce maintenance cost
Avoid unnecessary shut down's due to
corrosion problems
Extend the assets life time
Following are the desired properties of paints
for exterior surface of transformer
Perfect adhesion to substrate
Excellent corrosion resistance
Weather ability
Color and Gloss retention
Protection from environment pollutants like
water condensation, vapor and other
gases, salinity, heat, etc.
High abrasion resistance
Good impact resistance
Good flexibility and hardness
Resistant to chemicals
Fast drying
Following are the desired properties of paints
for interior surface of transformer
Should have good compatibility with hot
insulating oil.
Coating properties like color change,
electrical conductance change, etc should
be checked
Coatings should be tested for the below
parameters

Temp up to 140 Deg C
Time from 96 Hrs to 240 Hrs
Resistance to transformer oil
Salt spray -500 Hrs
Impact / Pencil hardness
Scratch hardness
Flexibility
Adhesion
Fast draying
Chemical and thermal resistant
Volume solid more than 60 %
Pigment more than 40 %

TRAFOTECH 2014 - Ninth International Conference on Transformers

SURFACE PREPARATION PRIOR TO
PAINTING
The initial condition of the transformer tank and
accessories before painting, and the method of
preparing the surface are also extremely
important considerations. A thorough
assessment of the structure, including the
existing protective coating system, needs to be
made. This includes any failures such as
cracking or peeling, dis-colourisation, the
adhesion of the remaining coating, and any
corrosion that may have occurred.

Depending on the state of the existing paint
system and the degree of damage to the
substrate, a surface preparation should be
specified. Paint manufacturers are generally
provide the minimum surface preparation that
is needed for a particular paint to insure good
adhesion and final performance.

In general, on the transformer tank and
accessories, Shot or Grit blast the surface to
Sa 2.5 in accordance with ISO 8501 Part 1 or
Swedish standard SIS 055900. The flanges,
angles, concealed areas shall be blast cleaned
prior to fabrication & paint with one coat of
primer prior to fabrication.

After adequate blast cleaning of each large
surface where blasting time is more than 3
hours, an overall blast cleaning is to be done
on the entire surface once more so that entire
surface areas is exposed as fresh for 1
st
coat of
primer paint. Remove dust abrasive carefully
by clean brush, by hosing with dry air. The first
coat of primer or paint should be applied not
later than 3-4 hours after surface preparation to
avoid oxidation. Machined areas, Threaded
components studs etc should be suitably
protected during blast cleaning.
PROCEDURE FOR PAINTING
When it comes to application, paints should
always be applied to transformer surfaces as
per Table- 2 depending upon corrosion
category and atmospheric classification for
optimum durability and corrosion resistance.
Thats because the thicker the coat, the less
chance of moisture penetrating the paint
through pinholes in the film. Similarly, two
coats of a top coat are generally recommended
rather than a single coat for two reasons:
increased overall thickness of the coating, and
elimination of the possibility of pinholes
extending through the coating. Brushes may be
used for smaller applications, while rollers or
airless sprayers are better for covering large
areas. Before starting painting on surface of
transformer, following points should be ensured

Paint used for primer, under coat and
top or finish coat should be from the
same manufacturer and compatible to
each other.
Do not use paints after the shelf life has
expired.
Open the containers just before
application.
Thoroughly examine steel surface to be
coated prior to commencement of work.
Correct any condition that will adversely
affect cleaning and coating application.
Inspect and test at each step of the
painting operation before proceeding
with the next step.
Verify that all painted surfaces are free
from defects. If any defective area is
found, repair and re-inspect before next
operation.
Strictly follow the painting process
specification.
Use the paint shade as per IS / RAL
standard to meet customer
requirement.
TESTING
Painted surfaces shall be visually checked for
defects like rundown, bubbles, blisters wrinkles
etc. and for any area not covered by the coat.
Dry film thickness (DFT) shall be checked after
every coat as per ASTM D1186 and adhesion
test should be as per ASTM D 3359-83.
TRAFOTECH 2014 - Ninth International Conference on Transformers

CONCLUSION
Specifying paint for transformer tank and
accessories is not difficult as long as it is
known the environment, corrosion category
and the coating system. Paints for interior and
exterior surface of transformer should meet all
physical and performance parameter as
specified. Good paint performance depends on
good adhesion, and paint adheres best to
surfaces that are clean and sound. Taking
shortcuts on surface preparation can cause
even the highest quality paints to fail
prematurely. Corrosion category and
atmospheric classification should also be
selected for optimum durability and corrosion
resistance of the Transformer tank and
accessories.
BIBLIOGRAPHY
1. Transformer by BHEL Bhopal, Tata Mc
Grow Hill
2. ISO : 12944
ACKNOWLEDGEMENT
The authors wish to express their
acknowledgement and thanks to the
management of BHEL for their permission to
publish this paper


Table 1
ISO Corrosion Standards (from ISO 12944-2)
Corrosion Category C1 C2 C3 C4 C5-I C5-M
Atmospheric
Classification
Very low Low Medium High Very high
(Industrial)
Very high
(Marine)
T
y
p
i
c
a
l

E
n
v
i
r
o
n
m
e
n
t
s

Interior Heated buildings
with clean
atmosphere,
e.g. offices ,
shop schools,
hotels
Unheated
buildings
where
condensation
may occur
Production rooms
with high humidity
and some air
pollution, e.g. food
processing plants,
breweries, dairies
Chemical
plants,
swimming
pools, coastal
ship and
boatyards
Buildings or
areas with
almost
permanent
condensation
and with high
pollution
Buildings or
areas with
almost
permanent
condensation
and with high
pollution
Exterior ----------- Atmosphere
with low level
of pollution.
Mostly rural
areas
Urban and industrial
atmospheres,
moderate sulfur
dioxide pollution.
Coastal areas with
low salinity
Industrial
areas and
coastal areas
with moderate
alkalinity
Industrial areas
with high
humidity and
aggressive
atmosphere
Marine,
estuaries,
coastal areas
with high
salinity


Table 2
Corrosion Category C1/C2/C3 /C4
Medium/ High
C5-I / C5-M
Very high (Industrial / Marine)
Atmospheric
Classification
Painting System Two coat type Three coat type
S
u
r
f
a
c
e

Interior Chemical And Thermal Resistant Epoxy
Enamel White Paint
50 Chemical And Thermal Resistant Epoxy
Enamel White Paint
50
Exterior Chemical Resistant Epoxide Red Oxide
Zinc Phosphate Priming Paint
Full Gloss Polyurethane Finishing Paint

50

50
Chemical Resistant Epoxide Red Oxide
Zinc Phosphate Priming Paint
High Build Mica-ceous Iron Oxide Paint
Full Gloss Polyurethane Finishing Paint
50

75
50