CGPISL PAGE ISSUE REVISION ISSUED BY

TRANSFORMER DIVISION (T2) NO. DATE NO DATE 1 OF 6

1 23/11/15 1 05/10/21 T2G/PPL/SS/DS

PROCESS SPECIFICATION:TSI - 136 (ADANI)

TITLE: PAINTING PROCEDURE FOR EPOXY & POLYURETHANE
PAINTS WITH EPOXY ZINC RICH PRIMER (DFT ≥ 320 m)

Revision : REVISED FOR PAINT DFT CHANGE Issued By Approved By Date Of

Initial Name Initial Name Issue
ARIF PPL
R0 – First Issue 23/11/15
A. Scope
1. This specification covers the procedures for surface preparation and application of high build epoxy (MIO)
and polyurethane paint system with epoxy zinc rich primer on structural steel, for surface protection against
environmental corrosion. This paint system is generally equivalent to ISO 12944-5 (paint system nos.:
S5.09, S6.06 and S7.07), recommended to protect steel surface against corrosivity categories, C5-I for high
durability (>15 years) and C5-M for medium durability (5 to 15 years).
2. The paint system specified in this procedure consists of the following paints
1) Priming coat: Epoxy zinc rich primer containing 85% zinc with 99.99% purity,
2) Intermediate coat: High build Epoxy MIO paint (pigmented with 80% micaceous iron oxide),
3) Top coat: Acrylic aliphatic polyurethane paint.
3. This specification is applicable for painting of transformer tanks and accessories, marshaling box and other
steel structures intended for out-door installation, in marine and industrial environments with high humidity
and aggressive atmospheric pollution levels.
4. The painting methods specified in this procedure are not applicable for radiators. However, the paint system
is suitable for radiators and applied by flow coating method.
5. The paint application parameters specified in this procedure are based on the approved manufacturers’
recommendations. Paints supplied by M/s.Akzo Nobel Coatings India Pvt. Ltd. have been approved for use.
Other makes shall not be used without prior approval from CG. The specified paints are suitable for
continuous service at temperatures, 100°C
B. Materials & equipments
1. The following materials and equipments are required for application of paints.
(1) Specified primer, intermediate and top coat paints for external application
(2) High density epoxy barrier coat paint, for painting of tank bottom (under base)
(3) Oil resistant paint, for internal painting on tank and other oil filled compartments.
(4) Thinner as specified for each paint
(5) Emery paper (No: 20), wire brush, fresh clean cotton cloth, etc. for cleaning.
(6) Spray painting equipments (airless spray or conventional spray with pressure pot attachment)
(7) Power agitator for blending and mixing of paints
2. Measuring apparatus: (1) Comparator for surface cleanliness
(2) Surface roughness gauge/meter
(3) Ford cup no: 4 for measuring application viscosity of paints
(4) Magnetic type paint thickness meter (Range, 0 – 450 m)
(5) Cutter and adhesive tape for carrying out adhesion test
(6) Gloss meter
 CGPISL PAGE ISSUE REVISION ISSUED BY
TRANSFORMER DIVISION (T2) NO. DATE NO DATE 2 OF 6
1 23/11/15 1 05/10/21 T2G/PPL/SS/DS

PROCESS SPECIFICATION:TSI - 136 (ADANI)

TITLE: PAINTING PROCEDURE FOR EPOXY & POLYURETHANE
PAINTS WITH EPOXY ZINC RICH PRIMER (DFT ≥ 320 m)

3. Shelf life of paints: 1 year @ 25°C (unless otherwise specified by the manufacturer)
4. Pressure feed type air spray guns, fitted with standard nozzles and filters shall be used for conventional
type of spray painting. The recommended models of spray guns are 620 and 630.
5. Pressure pot shall be compulsorily used with air spray guns for application of primer and intermediate
coats. Bullows type pressure feed container with fixed agitator is recommended.

C. General instructions
1. All fabrication activities such as welding, testing, grinding etc. should be completed before the surface
preparation for painting. Weld spatter, slag/flux deposits, surface irregularities etc. shall be removed by
scrapping, chipping, grinding and wire brushing. Sharp edges and corners shall be ground and made
smoothly rounded.
2. Gas-cut edges shall be ground evenly to smooth finish. Uneven surfaces shall be filled by welding. Excess
build-up of weld metal shall be ground off smoothly.
3. Surface contamination with oil or grease shall be cleaned using detergents or hydrocarbon solvents.
4. Stage inspection shall be carried out after (1) surface preparation and (2) before applying each coat of
paint. All defects and deviations shall be rectified before further processing.
5. Tapped holes and externally threaded parts should be suitably masked with inserts or sleeves during
surface preparation and painting. Contact surface on earthing pads should be should be covered with
blanking plates.
6. Paint and thinner should be stored in their original containers. Relevant details such as make and type of
paint, shade, mixing ratio, pot life, manufacturing date, specified thinner etc. should be displayed on paint
containers for identification.
7. Shelf life should be verified before mixing the paints for use. Obsolete paints should not be used and the
paint shall be discarded after expiry of shelf life.
8. Same make of paints (primer, sealer, intermediate and finish paints) and their specified thinners only shall
be used. Mixing-up of different makes shall not be permitted.
9. Compressed air used for abrasive blasting and spray painting should be dry and completely free from
moisture, traces of oil and other contaminations. Air drier and filters with adequate capacity shall be fitted
on compressed air lines.
10. Abrasive blasting and/or painting should not be carried out under the following conditions.
(1) Surface temperature of steel below 5°C
(2) Surface temperature of steel less than 3°C above the dew point of surrounding air
(3) Relative humidity of surrounding air greater than 85%
D. Surface preparation
1. The entire surface to be painted (internal and external) shall be blasted with abrasives to a cleanliness
level, SA 2½ or better as per ISO 8501/SIS 055900. Surface roughness profile after blasting shall be
approximately 40-60 m. Abrasives used for blasting shall be: (1) Quartz sand,
(2) Steel grits,
(3) Chilled iron grits or
(4) Mixture of grits and shots
 CGPISL PAGE ISSUE REVISION ISSUED BY
TRANSFORMER DIVISION (T2) NO. DATE NO DATE 3 OF 6
1 23/11/15 1 05/10/21 T2G/PPL/SS/DS

PROCESS SPECIFICATION:TSI - 136 (ADANI)

TITLE: PAINTING PROCEDURE FOR EPOXY & POLYURETHANE
PAINTS WITH EPOXY ZINC RICH PRIMER (DFT ≥ 320 m)

2. Abrasive particles and dust shall be completely removed from the blasted surface using a clean brush and
by carefully blowing dry compressed air after completion of blasting. The blasted surface shall be painted
as early as possible. First coat of primer should be applied within 4 hours of blasting. In case of brown rust
formation on the blasted surface before painting, the rusted area shall be locally sweep blasted and applied
the first coat of paint .

E. Mixing of paints for application

1. Base paint shall be agitated thoroughly before mixing with hardener. Base paint and hardener shall be
mixed homogeneously in the specified mixing ratio. Paint viscosity shall be adjusted as required for spray,
by adding thinner. However, addition of thinner should not exceed 5% by volume (10% for primers).
Power agitator shall be used for paint mixing and blending.
2. The quantity of paint required for immediate use only shall be mixed. Leftover paints shall not be used
after expiry of pot life.
3. Air pressure and paint volume shall be appropriately set in the spray gun, to achieve required level of
atomization while spraying. Paints shall be applied in parallel coats with 50% overlap. For full surface
coverage, paint shall be sprayed uniformly in horizontal and vertical strokes.
4. Paint application equipments and containers used for mixing of paints shall be all cleaned thoroughly and
rinsed with thinner before use. Spray guns shall be fitted with appropriate size of spray tip/nozzle.
5. Fresh clean cloth shall be used for cleaning and wiping on surface. Waste cotton should not be used as it
would leave cotton dust and loose fibers on cleaned surface.

F. External painting
The painting procedure specified in this clause is applicable for steel surfaces that remain exposed to
external weather conditions during service life, except the under-base surface of transformer tanks.
1. Primer coat
Type of paint Surface tolerant High Solid Polyamide Cured Epoxy
Approved make M/s Akzo Nobel Coating India Pvt.Ltd.
Type & brand name INTERSEAL 670 HS
Applicable thinner GTA 220 or GTA 415
Mixing ratio (parts Base paint :
by volume) Hardener = 5.67:1
Working pot life 2 hrs. at 25°C & 1 hr. at 40°C
Drying time (touch dry) 5 hrs. at 25°C & 2 hrs. at 40°C
Overcoat interval 18 hours
Application method Conventional (air) spray with or without pressure pot
Number of coats 2 coats by conventional spray
Paint thickness(DFT) 75 µm (Min)
Note: the primer shall be over coated as soon as the min. overcoat interval is elapsed.
 CGPISL PAGE ISSUE REVISION ISSUED BY
TRANSFORMER DIVISION (T2) NO. DATE NO DATE 4 OF 6
1 23/11/15 1 05/10/21 T2G/PPL/SS/DS

PROCESS SPECIFICATION:TSI - 136 (ADANI)

TITLE: PAINTING PROCEDURE FOR EPOXY & POLYURETHANE
PAINTS WITH EPOXY ZINC RICH PRIMER (DFT ≥ 320 m)

2. Stripe coat: After application of each paint (primer, intermediate and top coat) by spray, the
following areas shall be stripe coated by brush painting with the same paint. Geometric shape,
surface conditions, restricted access etc. may result into insufficient coating in these areas during
spray painting..
(1) Welded area
(2) Edges and corners of plates (curb, tank walls, cover etc.), flanges, pads, lugs, supports, structural
sections, gussets etc.
(3) Inner surface of plain holes, slots, weld reliefs, cut-outs, gasket grooves etc.
(4) Hidden surface (back side) of mounting flanges, supports, lugs, pipe connections and all other
areas that are in-accessible to spray painting.
3. Intermediate coat
Approved make M/s Akzo Nobel Coating India Pvt.Ltd.
Type of paint Polyamide High build epoxy (MIO) paint
Brand name Intergard 475 HS
MIO content -
Volume solids 80%
Applicable thinner International GTA007
Mixing ratio (by volume) Base paint: Hardener = 3 : 1
Working pot life 1 hour at 25°C
Drying time (Touch dry) 1 hour at 25°C
Overcoat interval 5 hours (min.) at 25°C
Paint application method Airless spray (Tip range: 0.53 - 0.63mm and Output pressure:³190 g/cm² )
conventional spray (air spray) with pressure pot
Number of coats One or two coats
Coating thickness DFT = 150 m (min.)
4. Top coat
Approved make M/s Akzo Nobel Coating India Pvt.Ltd.
Type of paint Acrylic aliphatic polyurethane finish paint
Brand name Interthane 990
Volume solids 57 ± 3%
Applicable thinner International GTA733
Mixing ratio (by volume) Base paint : Hardener =6 : 1
Working pot life 2 hrs. at 25°C & ¾ hr. at 40°C
Drying time (Touch dry) 1½ hour at 25°C
Over coat interval 6 hrs. at 25°C & 3 hrs. at 40°C
Paint application method Airless spray(Tip range:0.38-0.53mm & output pressure: 106 kg/cm²)
Conventional (air) spray with or without pressure pot
 CGPISL PAGE ISSUE REVISION ISSUED BY
TRANSFORMER DIVISION (T2) NO. DATE NO DATE 5 OF 6
1 23/11/15 1 05/10/21 T2G/PPL/SS/DS

PROCESS SPECIFICATION:TSI - 136 (ADANI)

TITLE: PAINTING PROCEDURE FOR EPOXY & POLYURETHANE
PAINTS WITH EPOXY ZINC RICH PRIMER (DFT ≥ 320 m)

Number of coats 1 coat by airless spray or 2 coats by conventional spray

Coating thickness DFT = 100 m (min.)
Shade As per D/L (Drawing list) of transformer tank/customer requirement
Total paint thickness DFT = 320 m (min.)
5. Painting of tank bottom
(1) Under base surface of the transformer tank bottom plate shall be painted with high density epoxy
barrier coat directly after blasting. This is a self priming paint and does not require separat primer
coat. The barrier coat paint provides better protection against condensation and abrasion. The first
coat of paint shall be applied within 4 hours of blasting.
(2) The entire surface shall be coated uniformly, without leaving any isolated locations unpainted.
(3) One coat of polyurethane finish paint as per Clause-6.4 shall be applied as top coat, as and when
required to meet customer specification or to achieve uniformity in shade.
(4) Approved paint for under base coating and application parameters are given in the following table.
Approved make M/s Akzo Nobel Coating India Pvt.Ltd.
Type of paint High density self priming epoxy paint
Brand name Interzone 954
Volume solids 83 ± 3%
Applicable thinner GTA220 or GTA415
Mixing ratio (by volume) Base paint : Hardener = 4 : 1
Working pot life 1½ hr. at 25°C & ¾ hr. at 40°C
Drying time (Touch dry) 4 hrs. at 25°C & 1½ hr. at 40°C
Over coat 6 hrs. at 25°C & 3 hrs. at 40°C
Paint application Airless spray (Tip range: 0.53 - 0.66 mm and Output pressure:
method ³176 kg/cm²) or conventional spray (air spray) with pressure pot
Number of coats One or two coats
Coating thickness DFT = 320 m (min

G. Internal painting
1. Inside surface of tank, conservator, pipe connections and other oil filled compartments shall be painted
with oil resistant white paint, directly after blast cleaning or pickling. The first coat shall be applied
within 4 hours of blasting.
2. The specified oil resistant paints and their application parameters are as given below.
Approved make M/s Akzo Nobel Coating India Pvt.Ltd.
Type of paint Single pack PVB based primer
Brand name Interprime 741
 CGPISL PAGE ISSUE REVISION ISSUED BY
TRANSFORMER DIVISION (T2) NO. DATE NO DATE 6 OF 6
1 23/11/15 1 05/10/21 T2G/PPL/SS/DS

PROCESS SPECIFICATION:TSI - 136 (ADANI)

TITLE: PAINTING PROCEDURE FOR EPOXY & POLYURETHANE
PAINTS WITH EPOXY ZINC RICH PRIMER (DFT ≥ 320 m)

Mixing ratio (by volume) Not Applicable

Pot life Not Applicable
Applicable thinner GTA 741
Application method Spray
Drying time (Touch dry) ¼ hour
Over coat interval (min.) 3 hours
Paint thickness (DFT) 40 – 80 m
Shade White

3. For the surface preparation of pipes, chemical pickling also can be used instead of abrasive blasting. To
ensure full coverage of surface , inside painting in pipes shall be carried out by flow coating method.
4. Unless otherwise specified in drawing, the following areas shall be painted with external paints.
(1) Inside surface of air filled compartments such as cable box, DC chamber, CT terminal box etc.
(2) Mounting faces of all types of flanges, inspection window pads and other mounting pads.
(3) Area between gasket locators and outer periphery in tank curb
(4) Area between mounting holes and outer periphery on inside tank cover and conservator covers.
H. Paint touch-up for rectification
1) Damages caused in paint coatings (due to abrasion or re-work) and areas that were left un-painted for
conducting dye penetration test (DP test) at later stages, shall be promptly touched-up before dispatch.
2) Touch-up on external paint coatings (including the under base paint) shall be carried out in accordance
with the procedure specified in TSI-140.
3) Alternatively, original paints also may be used for touch up as per the application parameters given in
this specification.
4) Damages in internal paint films shall be rectified by touch-up with the original oil resistant paint.
I. Testing
1) Visual inspection : Painted surfaces shall be visually inspected. Defects such as blisters, rundown,
bubbles, wrinkles, orange peel effect etc. shall not be present in the coating.
2) Dry film thickness (DFT) shall be measured as per ASTM D1186.
3) Adhesion test shall be carried out after the paint is hard dried, as per ASTM D 3359-83.
4) Gloss measurement on top coated surface shall be carried out after the paint film is hard dried as per
ASTM D-523. Measured values shall be reported for information.
J REFERENCES
(1) ISO 8501, (2) ISO 12944,
(3) SSPC Vol.-I & II, (4) ASTM D1186,
(5) ASTM D3359 and (6) ASTM D523