ProCoat Experience in Telangana / Andhra Pradesh Power Sector

ProCoat Advanced Polymer Coating
Application Works Done &
Observed Performance
Over 132/33kV Substations Structures
&
132kV Transmission Towers
Exposed To Industrial Emissions,
Chemical Pollution / Saline Corrosion
In
AP Transco & TS Transco
(Andhra Pradesh & Telangana States)
2006-2016

ISO 9223 :
Classification
Atmospheric
Corrosivity
Corrosivity Typical Out Door
Conditions
Corrosion Of
Mild Steel
Corrosion Of
Galvanized Iron
C1 Very Low Dry, Very Low Pollution Around 1.3
microns/year
0.2-3 microns /
year
C2 Low Varying Temperatures, Low
Humidity, Low pollution
1.3 to 25 microns/
year
2-16 microns /
year
C3 Medium Moderate condensation,
Moderate pollution
25-50 microns /
year
16-25 microns /
year
C4 High High condensation, high
pollution
50-80 microns /
year
20-30 microns /
year
C5 - I
Very High
Industrial
Temperate & sub tropical
with very high sulphur
emissions, humidity
80-200 microns /
year
30-50 microns /
year
C5 - M Aggressive
Marine
Saline, Tidal, high humidity 80-200 microns /
year
20-30 microns /
year
CX Extreme -
Industrial cum
Marine
Very high saline, very high
industrial pollution,
Chemical pollution
200-700 microns
+ / year
30-80 microns /
year
Atmospheric Corrossivity & General
Deteriorations Of Mild Steel & Galvanized Iron
Corrosion Basics
Rate of corrosion depends upon the conductivity of electrolyte, i.e., metal corrosion increases when it
comes in contact with Moist Air, Moisture, Water, Seawater, Steam, Chemical Fumes, Alkalis, Acids, Mixed
Medium and if these mediums are at high temperatures then corrosion gets accelerated. Along with corro-
sion reaction, if the medium has abrasive particles, abrasive erosion of metal also takes place which is a
faster deterioration pattern of metal substrate.
 Ore which is in STABLE state when converted
to metal, becomes ACTIVE.
 In a piece of metal Anodic & Cathodic areas
form automatically due to potential difference
caused by impurities & surface irregularities.
Electron & Ionic conduction starts and circuit
is completed when it comes in contact with
moisture and oxygen, which acts as
electrolyte.
 Corrosion is an electrochemical reaction of
metal with electrolyte (i.e., with which metal is
coming in contact).
 In corrosion reaction, metal starts forming
oxide layers in the form of flakes, and
localized deterioration i.e., pitting, which
increases to form cavities. This ultimately
leads to loss of metal thickness and
mechanical strength.
 Negligence leads to replacement of structure
or equipment.
In all forms of corrosion of metal, fundamental
influencing parameter is Physical & Electrical
Contact of Electrolyte (environment / medium) with
Metal

Corrosion - Galvanized Iron (GI)
Hot Dip Galvanizing is a process of dipping mild steel member into molten zinc metal
by following stipulated duration of dip and angle of dip to get a metallurgical reaction of mild
steel and zinc. The deterioration phenomena of Zinc is explained as follows:
 Mild steel (Ferrous Metal) + Zinc coating = Galvanized Iron: Reactions taken place are..
 Zinc + Oxygen = Zinc Oxide ( a powdery substance)
 Zinc Oxide + Moisture = Zinc Hydroxide ( White rusting of Zinc)
 Zinc Hydroxide + Carbon Dioxide = Zinc Hydroxicarbonate (Also called a stable layer
i.e., ZINC PATINA. Time taken to form Zinc Platina is around 6 months time from the
moment GI comes in contact of free air flow.
 This so called “Zinc Patina” will never further react with oxygen, carbon dioxide and
moisture. But when this layer is exposed to industrial pollutants like chlorides, sulphates
and moisture, then it starts reaction (deterioration) as follows:
 Zinc Hydroxicarbonate + Sodium Chloride = Zinc Chloride + Sodium Hydroxide
(powdery substance, loose and soluble in water).
 Zinc Hydroxicarbonate + Sulphur dioxide = Zinc Sulphate (Powdery substance soluble in
water).
 Zinc Hydroxicarbonate + Oxides of Nitrogen = Zinc Nitrate ( Soluble in water).
 During rain this dissolves and fresh zinc is exposed to form new layer of Zinc Platina.
 Eventually all zinc from GI gets consumed and mild steel is exposed to corrosive
environment.
 Since mild steel is active, automatic formation of anodes and cathodes takes place due
to metallurgy, surface undulations, impurities in iron. This active surface undergoes,
 Cathodic reaction : 2Femetal= 2 Fe2+
+ 4e-
 Anodic Reaction : 2H2O + O2 + 4e-
= 4OH-
 Further Reaction : Fe++
oxidises to give Fe+++
(ferric ions) ; Fe+++
reacts with hydroxide
to form = Fe2O3 (rust)
 Ferrous will react with Sodium chloride and sulphur dioxide to form ferric chloride and
ferrous sulphate which are nothing but layers of metal salts resulting in loss of metal
thickness.
 Other reactions of ferrous with oxides of nitrogen produce ferric nitrate which is a
crystalline salts which tend to detach from the surface resulting in reduction of mild steel
thickness.
 When Galvanized Iron is exposed to CX-M environment i.e., saline + industrial +
chemical environment, deterioration of zinc takes place in extremely accelerated speed.
At these environments, DUPLEX coating systems i.e., Galvanized Iron + High End Epoxy
Coating System is the only solution to maintain the strength of GI structures.
ProCoat advanced, 100% solid, solvent & VOC free Novolac polymer coatings provide
protection to GI at CX-M, C5-M atmospheric categories.

ProCoat 100% solid, solvent & VOC free, high performance Novolac polymer
coating systems with optimum surface preparation method for (new or
weathered) GI is used to prevent zinc reactions, deterioration and to enhance
overall structural life.
Sweep blasted with either sand or copper slag to remove white rust from
surface and to achieve average profile of 35 microns (roughness) on GI
surface (care should be taken not to remove total zinc from the surface).
Roughness and cleanliness is MOST important in order to ensure
ADHESION of coating on GI surface. (Based on condition, water wash may
be required with blasting). After measuring surface roughness with
Elecometer gauge, application of ProCoat coating system is done with high
hand pressure to ensure complete wetting of surface to attain polar-polar
adhesion, chemical adhesion and mechanical interlocking with the substrate.
Further application to build average recommended film thickness by synthetic
roller is done taking utmost attention over edges of angles. when ProCoat
coating is tack free a top coat of aliphatic polyurethane is applied to ensure
UV protection. Quality checks like surface roughness, coating thickness and
coating integrity is carried out with appropriate testing instruments.
Fully cured ProCoat coating offers excellent resistance to chemical, salt,
moisture attack and prevents ingress of these molecules so that zinc gets
isolated physically and electrically from the contact of environment hence
protected.
Duplex Coating System Protecting GI
In highly corrosive environments such as C5-I, C5-M & CX where saline salts, industrial pollutants as well as
chemical constituents present, protection of Galvanized Iron (zinc coated mild steel) becomes mandatory due to
deterioration mechanism of zinc from galvanized iron by chemical reactions and zinc run-off.

Failures Of Conventional Paint Systems
In Highly Corrosive Environments
Many conventional paint systems has been used for protecting electricity substation / transmission towers of MS / GI located in
Industrial, Chemically Polluted & Saline Zones, but none of them yielded desired life and ended up with failure of paint as well as
deterioration of metal thickness. These practices also lead to replace structures on account of corrosion before designated life.
Red Oxide + Two Coats of Aluminium Paint: This system has shown deterioration within 3 months of application with
aggravated underneath corrosion leading to complete deterioration of paint and metal loss. Layers of rust was formed over metal
within 2 years of painting.
Primer + Epoxy Paint + Polyurethane Top Coat System: Severe deterioration and metal loss is observed within a span
of 18 months as shown above. This structure was eventually replaced with new ones. This happened due to severe chemical
reactions with MS in-spite of having paint over it.
Zinc Rich Primer + Chlorinated Rubber Paint System: Applied over GI structure located in Acid Rain Environment. The
paint system failed in less than 2 years exposing GI to chemically polluted environment, leading to consumption of total zinc with
aggressive metal loss. Above condition observed within 8 years of installation.
Zinc Chromate Primer + Anti-Corrosive Epoxy Paint System: This paint system was applied over GI structure located in
saline cum industrially polluted zone. Absorption of chemical molecules and moisture through paint due to developed micro
pores on surface caused by solvent evaporation leading to protection failure and metal loss.
Epoxy Primer + Polyurethane Top Coat: System performance can be seen in above pictures, paint de-laminated and
surface beneath paint has started corroding after zinc runoff from galvanized iron in a span of just 3 years.

As per APTransco’s advise, Demonstration of ProCoat
coating given on 06-02-2006 over three angles just by
cleaning with wire brush.
In September 2006, this tower was painted with one coat of
red oxide + two coats of aluminium paint. (By this time,
ProCoat demo had crossed 7 months).
After 3 months of aluminium painting i.e., December 2006, rust spots over aluminium painted
surface were observed while ProCoat applied surface was INTACT without any rust spots. By this
time, ProCoat demo had crossed 11 months without any problem and aluminium paint was just 3
months old with rust spots.
ProCoat Applied
Surface
Aluminium
Painted Surface
ProCoat Applied
Surface
Aluminium
Painted Surface
Year - 2008
Year - 2006
Performance Evaluation of
Aluminium Paint Vs ProCoat Coating System
ProCoat
Demo
Given on
06-02-2006

ProCoat Applied
Surface
Aluminium
Painted Surface
Year - 2009
ProCoat Applied
Surface
Aluminium
Painted Surface
Year - 2012
Absolute METAL Protection By ProCoat Even After 6 1
/2 Years
Where as
Complete failure of Alumnium Paint with severe corrosion & heavy metal loss at
painted area in less than 6 years
By simple wire brush cleaning and ProCoat coating application, service life obtaining is 6+ years at the time
of inspection. Adopting superior methods like cleaning by Sand Blasting, application of ProCoat advanced
coating, measurement of wet film & dry film thickness, quality checking of entire coated surface by means of
Holiday spark testing to ensure complete integrity. With this upgraded method and product, service life
(protection life) expected is minimum 10+ years without any underneath corrosion of mild steel, by ensuring
“genuine and barrier corrosion protection to metal” thereby enhancing life of structures without arising need
for structure replacement.
In Continuation...
Performance Evaluation of
Aluminium Paint Vs ProCoat Coating System

Structures - ProCoat Work Execution Method
Heavily corroded mild steel structure
with complete conventional paint
deterioration leading to metal loss.
Initial round of sand blasting to
remove failed paint and corrosion
deposits from mild steel surface.
Checking of chemical contamination
over blast cleaned surface of mild
steel structure with pH, Litmus
methods.
Testing of salts over blast cleaned
surface with silver nitrate test
method.
Second round of blast cleaning of
contamination free surface to
achieve Swedish Sa2.5 “near white
metal finish”
Measuring of “surface roughness”
by Elcometer profile gauge to
ensure desired profile over blast
cleaned surface to ensure optimum
adhesion of ProCoat coating.

Structures - ProCoat Work Execution Method
Application of ProCoat coating
directly over “clean, rough and
contamination free surface” to
ensure polar-polar adhesion,
chemical bonding & mechanical
interlocking with metal.
Measuring of Wet film thickness
with Elcometer WFT gauge. Being
100% solids, both wet film & dry
film thickness after cure remains
same for ProCoat systems.
Measuring of Dry film thickness with
Elcometer DFT gauge to get average
thickness on surface for fixing
desired testing voltage for integrity
checking instrument.
Coating integrity checking with
Porosity / Holiday detector to
ensure flawlessness of applied
coating on surface.
Completely protected mild steel
structures with thorough
implementation of application
method to ensure long term
protection from corrosive
environment.
UV & Weather resistant top coat
over and above ProCoat coating to
meet “colour” coding of structures
based on requirement of users.

Important Point for Performance :
High End Chemistry & Characteristics of ProCoat Coating
ProCoat Coating Performance Characteristics
White Metal Surface
Finish (Sa 2.5 / 3),
Thoroughly cleaned
metal to make
“Contamination Free”
& Surface Profile
( Surface Roughness)
Curing by polymerisation reaction to
form a high density, highly complex,
three dimensional cross linking
polymer matrix lining with excellent
resistance to permeability, which
meets Physical Isolation of metal
from corrosive chemical & moisture
molecules.
Coating attains Polar-
Polar Bonding, Chemical
Bonding, Mechanical
Interlocking with
substrate and adheres
on surface to protect.
Exposure conditions: Coatings get exposed to saline salts,
steam, sea water, immersion, industrial pollutants such as
NOx, Cox, SOx, acidic, alkaline or mixed chemical effects
and even under variable temperatures, cyclic temperature
variations conditions based on equipment location in various
industries.
Important Point for Performance :
Strict adherence of surface cleaning, coating application, quality checks throughout the work execution ensures
optimum adhesion, curing of coating and protection to metal. ProCoat Specialities application team strives heard for
achieving this quality to provide optimum protection to substrate.
Single coat system
directly applied on
prepared surface
without primers.
Attains high Tg (Glass Transition) temperatures of 70 o
C
without any changes in coating chemistry.
ProCoat coating
effectively passed 5000
hours of “SALT FOG” &
“HUMIDITY CABINET”
exposure which makes
the coating resistant to
“undercut corrosion” &
“immersion protection”.
ProCoat Coating sustain without spreading
flame and limiting the damage to localized
even in the event of high temperature
exposure.
Absolute Metal Protection is possible when the applied coating has excellent chemistry, adheres properly with
substrate, resist ingress of chemical molecules, isolates metal surface from physical and electrical contact of medium
along with excellent engineered mechanical strengths, temperature and chemical resistance. ProCoat Coating are
capable for this kind of protection.
ProCoat coating posses exceptional mechanical
strengths such as “Tensile strength,” “Shear strength”,
“Compressive strength”, “Flexural strength” & Peel off
strength” which makes the coating tough, durable and
dependable.

Saline Corrosion,
Chemical Corrosion Protection Of
Substation Structures / Transmission Towers
Works
Executed By
ProCoat Specialities Pvt Ltd,
Rajkot, Gujarat
In
Electricity Boards of
Telangana & Andhra Pradesh States

132/33kV - Kamalapur Substation
Work Completed May 2006
This substation is in the vicinity of AP Rayons chemical factory and their gaseous emissions comprising sulphur
dioxide, oxides of nitrogen, methane, hydrogen sulphide, moisture are coming in contact with these mild steel
structures on continuous basis. Conventional red oxide + two coats of aluminium paint is getting deteriorated within
very short periods and causing mild steel to corrode at a faster rate. As a trial case, APTransco given the opportunity to ProCoat
Specialities for the protection CPL structures in this substation. Tedious mechanical grinding of angles in the CPL structures to
remove corrosion deposits and deteriorated paint from the surface. Followed by fresh water cleaning to remove contamination.
ProCoat engineer spent around two months time in this substation for cleaning and application of coating system over CPL
structures. Over mechanically cleaned surface, ProCoat coating was applied with tynex bristle brush with a specific attention
over intricate areas of structures and edges of angles. Relevant checks related to film thickness and coating integrity were
carried out and completed given work in May 2006.
Exposure Conditions: Chemically Polluted Highly Corrosive Ambience of AP Rayon
P.O.No. : 26/2005-06 of CE/TL&SS/Wgl/Tech/AE1/D.No.2779/06 Dt.31-03-2006
Work Completed: May 2006 Inspected: December 2012
Type of Environment:: ISO-9223-C5 - I / Industrial & Moderate Condensation.
Corrosion Rate of Mild Steel At this Environment: @80-200 microns thickness loss / year.
Presently Protected By: ProCoat - 1521 & Aliphatic Polyurethane Top Coat.
Surface Preparation Standards: Blast Cleaning To Swedish Sa2.5 “ Near White Metal Finish”.
Quality Checks: Surface Roughness, Wet Film Thickness, Dry Film Thickness, Coating Integrity.

ProCoat coating is protecting these structures completely even after a period of 6 years & 6 months. Surrounding
environment is highly corrosive industrial chemical and gases. ProCoat coating is proven in offering “barrier
protection” to metal resulting in enhancement of life of these structures without any deterioration and metal loss.
132/33kV - Kamalapur Substation
Performance Inspection: December 2012 (After 61
/2 Years)

132/33kV - Naval Wharf Substation
Work Completed November 2007
Exposure Conditions: Saline & Aggressive Chemical Fumes from Adjacent Industries
P.O.Nos : CE/TL&SS/VSP/O&M/AE2/FLPO No.21/07-08/D.No.3085/07 Dt.21-09-2007 & CE/TL&SS/VSP/O&M/AE2/
FLPO No.08/07-08/D.No.1876/07 Dt.29-06-2007
Work Completed: November 2007 Inspected: November 2012
ENVIRONMENT: Naval Wharf Substation is surrounded by chemical factories like HPCL, CFL, APCL & Essar. It is
also only 100 meters from sea. Supporting mild steel structures are exposed to industrial emissions & pollutants
comprising of sulphur dioxide, oxides of nitrogen, hydrogen sulphide, moisture, sodium chlorides etc.
Type of Environment: ISO-9223-CX - Extreme Industrial Cum Marine.
Corrosion Rate of Galvanized Iron at this Environment: @30-80 microns zinc runoff / year.
Paint Applied Before ProCoat System: Epoxy / Zinc Rich etc.

132/33kV - Naval Wharf Substation
Performance Inspection: November 2012 (After 5 Years)
Every year, substation was repeatedly inspected to evaluate the performance of ProCoat coating in this aggressive
chemically polluted zone. Even after 5 years, ProCoat coating is offering best possible protection to these MS
structures with a nominal corrosion at edges and over mechanically damaged areas. ProCoat coating is offering best
underneath protection i.e., without allowing the corrosion to propagate beneath coating thereby remaining coated
surface is under absolute protection.

132kV Nawal Wharf GI Towers
Work Completed January 2009
Exposure Conditions: Saline & Aggressive Chemical Fumes from Adjacent Industries
P.O.Nos : CE/TL&SS/VSP/O&M/AE2/FLPO No.26/08-09/D.No.3753/08 Dt.04-10-2008
Loc.No. 28 In Naval Wharf-Gajuwaka DC Line, Visakhapatnam.
Work Completed: January 2009 Inspected: December 2013
ENVIRONMENT: Naval Wharf Substation is surrounded by chemical factories like HPCL, CFL, APCL & Essar. It is
also only 100 meters from sea. Supporting mild steel structures are exposed to industrial emissions & pollutants
comprising of sulphur dioxide, oxides of nitrogen, hydrogen sulphide, moisture, sodium chlorides etc.
Type of Environment: ISO-9223-CX - Extreme Industrial Cum Marine.
Corrosion Rate of Galvanized Iron at this Environment: @30-80 microns zinc runoff / year.
Paint Applied Before ProCoat System: Epoxy / Zinc Rich etc.

132kV Nawal Wharf GI Towers
Performance Inspection: November 2013 (After 5 Years)
Coating was inspected every year due to aggressive industrial, chemical and saline environment. No serious
deterioration or failure was observed after 5 years of life, except for minor mechanical damages and some edges.
ProCoat coating is offering best possible protection to these MS structures. ProCoat coating is offering best
underneath protection i.e., without allowing the corrosion to propagate beneath coating thereby remaining coated
surface is under absolute protection.

132kV Bollaram MS Towers
Exposure Conditions: Highly Polluted Chemical Corrosive Ambience of IDA-Bollaram
P.O.Nos : 52/2009-10CE/TL&SS/RZ/Hyd/ADE(O&M)/FPO09-10/D.No.453/09Dt.29-03-2010 & LOI Ref : SE/TL&SS/
SRDADE(T)/F.LOA/D.No.683/10 Dt.28-07-2010 Loc. No. 40/12, 40/14 & 40/15
Work Completed: January 2011 Inspected: March 2016
ENVIRONMENT: Towers are surrounded by chemical factories in IDA-Bollaram Industrial Estate Mild Steel
supporting structures are exposed to industrial emissions & pollutants comprising sulphur dioxide, oxides of nitrogen,
hydrogen sulphide, moisture etc.
Type of Environment: ISO-9223-C4 - High Industrial & Condensation.
Paint Applied Before ProCoat System: Red Oxide + Aluminium etc.

132kV Bollaram MS Towers
Performance Inspection: March 2016 (After 5 Years 3 Months)
ProCoat engineer inspected towers for evaluation of performance of applied ProCoat coating over tower structures
and found even top coat is in intact condition after 5+ years. Under this top coat, chemical resistant ProCoat coating
is in intact condition without allowing any corrosion ingress.

132kV Bapatla M Type & K+3 Type Multi Circuit Towers
Work Completed May 2011
Exposure Conditions: Sulphur Dioxide & Oxides of Nitrogen Emission from Brick Burning
P.O.Nos : CE/ZONE/VJA/Tech/LPO.No. 75 /2010-11/D.No.119 /11 Dt.25-01-2011
LS Agreement : 146 / 2011-12 of SE / TL&SS / Vijayawada Dated. 24-03-2011 Loc. No. 108/1, 2 & 3
Work Completed: May 2011 Inspected: March 2016
ENVIRONMENT: Towers are located in vicinity Brick manufacturing unit. Due to which chemical gases comprising
sulphur dioxide, oxides of nitrogen, hydrogen sulphide are getting produced and moisture from the adjacent pond is
causing chemical precipitation over MS tower parts, leading to extreme chemical corrosion.
Type of Environment: ISO-9223-C4 - High Industrial & Condensation.

132kV Bapatla M Type & K+3 Type Multi Circuit Towers
Performance Inspection: March 2016 (After 5 Years)
On inspection it is observed that till date there is no deterioration of coating or any significant corrosion on structure.
It is protected from sulphur dioxide, oxides of nitrogen, hydrogen sulphide, moisture etc. from the surrounding
atmosphere.

132kV Bapatla Towers (Loc.252/3 & Loc.2)
Work Completed June 2011
Exposure Conditions: Saline Breeze & Pesticides Chemical Effect
P.O.Nos : CE/ZONE/VJA/Tech/LPO No.76/2010-11/D.No.120/11 Dt.25-01-2011 &
LS Agreement No: 23/2011-2012 of SE/TL&SS/Vijayawada
Work Completed: June 2011 Inspected: March 2016
ENVIRONMENT : These towers fall under saline zone and exposed to pesticides fumes from surrounding farm
fields. Saline salts and chemical molecules precipitates on MS tower parts and inducing severe corrosion which
leads to gradual deterioration of metal thickness.
Type of Environment: ISO-9223-C4 - M / Marine & High Condensation.

132kV Bapatla Towers (Loc.252/3 & Loc.2)
ProCoat coating protecting towers from saline & chemical corrosion even after 21
/2 years.

132/33kV NTS Substation
Work Completed July 2011
Exposure Conditions: Saline Salts and Industrial Pollutants.
P.O.Nos : LPO No.CE/TL&SS/VJA/Tech/LPO.No.87/2009-10/D.No.536/10 Dt.30-03-2010 &
CE/Zone/VJA/Tech/LPO.No. 60/11-12/D.No.2335/11 Dt.31-12-2011 :
LS Agmt No. 11 / 2010-2011 of SE-TL&SS / Nellore
Work Completed: July 2011 Inspected: December 2013
ENVIRONMENT: This substation falls under saline zone category. MS structures are always under exposure to
saline salts and moisture condensation, which leads to gradual deterioration of metal.
Type of Environment: ISO-9223-C5 - M / Marine & High Condensation.

132/33kV NTS Substation
/2 Years)
ProCoat coating showing absolute saline corrosion protection to Mild Steel equipment supporting structures since 2
1/2 years without any sign of corrosion. ProCoat coating offering best barrier protection without any chloride
molecules ingress or chemical reaction.

132/33kV Kottur Substation
Exposure Conditions: Chemically Polluted Highly Corrosive Ambience of IDA-Kottur
P.O.No: CE/Tr/SE/Tr.(O&M)/E35/D.No.392/11 Dt.19-04-2011 & LOI Ref:No.24/2010-2011 of SE-TL&SS/Mahabubnagar
Work Completed: November 2011 Inspected: March 2016
ENVIRONMENT: This substation is located in industrial area and surrounded by chemical, rubber, polymer
manufacturing companies which are emitting highly corrosive pollutants. MS structures of this substation is coming
under contact with these corrosive gases, moisture etc. and undergoing aggressive chemical corrosion.
Type of Environment: ISO-9223-C5 - I / Industrial & Condensation.

132/33kV Kottur Substation
Performance Inspection: March 2016 (After 41
/2 Years)
ProCoat inspected substation in March 2016 for evaluation of performance of applied ProCoat coating over substation
structures. No signs of deterioration even under continuous exposure of corrosive emissions and industrial pollutants
in IDA Kottur.

132/33kV Bollaram Substation
Exposure Conditions: Highly Polluted Chemical Corrosive Ambience of IDA-Bollaram
P.O.No : No.3 / 2010 CE/RZ/HYD/ADE(O&M)/FPO.10-11/D.No.1907/10 Dt.30-12-2010
LS Agreement 19 / 2011-12 of SE / TL&SS / Sangareddy Dated. 16-12-2011
ENVIRONMENT: This substation is surrounded by pharmaceutical & bulk drug industries which are emitting
chemical pollutants like SO2, NOx, H2S, CH4 and moisture making environment highly corrosive to mild steel.
Photographs reveal high degree of corrosion.

132/33kV Bollaram Substation
No signs of deterioration even under continuous exposure of corrosive emissions and industrial pollutants.

132/33kV Pamarru Substation
Work Completed June 2012
Exposure Conditions: Saline Breeze & Pesticides Chemical Environment
P.O.No : CE/ZONE/VJA/Tech/LPO.No.9/11-12/D.No.897/11 Dt.02-06-2011
LS Agmt No. 75 / 2011-12 of SE / TL&SS / Vijayawada Dated. 19-12-2011
Work Completed: June 2012 Inspected: December 2013
ENVIRONMENT: High degree of corrosion and complete deterioration of applied aluminium paint can be seen over
mild steel structures here in this substation due to continuous exposure to saline salts and fumes of pesticides from
the vicinity.
Type of Environment: ISO-9223-C5 - M / Saline & Condensation.

132/33kV Pamarru Substation
/2 Years)
1/2 years without any sign of corrosion. ProCoat coating offering best barrier protection without any chloride
molecules ingress or chemical reaction.
As per feedback on March 2016 the coating is in good condition without deterioration. The coating
performance after 3 years and 8 months is very good.

132/33kV Bapatla Substation
Exposure Conditions: Saline Breeze & Pesticides Chemical Environment
P.O.No. : CE/ZONE/VJA/Tech/LPO.No.84/10-11/D.No.320/11 Dt.22-02-2011 &
Agreement No : 24 / 2011-12 of SE / TL&SS / Vijayawada Dated. 01-06-2011 &
P.O.No. : CE/ZONE/VJA/Tech/LPO.No.25/2011-12/D.No.1522/11 Dt.27-08-2011
Agreement No: 75/2011-12 of SE/TL&SS/Vijayawada
Work Completed: November 2011 (132kV Side) & October 2012 (33kV Side) Inspected: December 2013
ENVIRONMENT: High degree of corrosion and complete deterioration of applied aluminium paint can be seen over
mild steel structures here in this substation due to continuous exposure to saline salts and fumes of pesticides from
the vicinity.
Type of Environment: ISO-9223-C5 - M / Saline & Condensation.

132/33kV Bapatla Substation
Performance Inspection: December 2013 (After 2 Years)
years without any sign of corrosion. ProCoat coating offering best barrier protection without any chloride molecules
ingress or chemical reaction.
performance after 4+ years is very good.

132kV SKZ-SPM Feeder Towers
Work Completed February 2013
Exposure Conditions: Highly corrosive Ambience of Sirpur Paper Mills
P.O.No.: SE/TL&SS/NZB/Tech/F.No/D.No.31/13 Dt.02-01-2013 Loc.No.9
Agreement No: 86 / 2012-13 of SE / TL&SS / Nizamabad Dated. 04-01-2013
Work Completed: February 2013
ENVIRONMENT: High corrosion rate can be observed due to corrosive ambience of Sirpur Paper Mills. Severe
deterioration of applied aluminium paint can be seen over mild steel structures.
performance after 3+ years is very good.

132/33kV Pashamylaram Substation
Exposure Conditions: Chemical Corrosive Ambience of IDA-Pshamylaram
P.O.No.: 30/12-13 CE/RZ/HYD/ADE(O&M)/FPO/DNO.3840/12 Dt.17-01-2013
Agreement No: 86 / 2012-13 of SE / TL&SS / Sangareddy Dated. 03-03-2013
ENVIRONMENT: This substation is located in industrial area where many chemical industries are emitting pollutants
comprising sulphur dioxide, oxides of nitrogen, methane and other chemicals and moderate condensation is taking
place over MS structures leading to accelerated degree of corrosion.
Type of Environment: ISO-9223-C5 - I / Industrial & Moderate Condensation.

132k/33V Pashamylaram Substation
ProCoat coating was inspected and observed in intact condition after 2+ years. Under this top coat, chemical
resistant ProCoat coating is in intact condition without allowing any corrosion ingress.

132kV Pashamylaram Towers
Exposure Conditions: Chemical Corrosive Ambience of Pshamylaram
P.O.No. : 24/13-14 CE/RZ/HYD/ADE(O&M)/FPO/DNO.2724/13 Dt.11-11-2013
Agreement No : 28 / 2013-14 of SE / OMC / Sangareddy
ENVIRONMENT: These towers are located in industrial area where many chemical industries are emitting pollutants
comprising sulphur dioxide, oxides of nitrogen, methane and other chemicals and moderate condensation is taking
place over MS structures leading to accelerated degree of corrosion.
Type of Environment: ISO-9223-C5 - I / Industrial & Moderate Condensation.

132kV Pashamylaram Towers
As the photographs shows there is no deterioration of coating after 2 years and 3 months of application.

33/11 kV Durganagar Substation
Exposure Conditions: Sewer Fumes & Chemical Environment
P.O.No. : Ref: 4810000289 Dt.11-09-2012 &
Agreement No : CGM/MZ/Hyd/S&P/D.No. 432/2012-13, Dt. 11.09.2012
P.O.No. : SE/SCADA/Tech/L.S.Agt No. 5500018783/12-13 F.No /D.No 3421/ Dt. 10.01.2013
Agreement No: 5500018783
Work Completed: January 2013 Inspected: January 2016
ENVIRONMENT: Amberpet sewer fumes, highly corrosive pollutants from adjacent MUSI river consisting of
ammonia, methane, hydrogen sulfide, chlorides, oxides of nitrogen, domestic and hospital waste making the
environment extremely corrosive for mild steel.
Type of Environment: ISO-9223-C4/ High Condensation., High Pollution
Corrosion Rate of Mild Steel At this Environment: @50-80 microns thickness loss / year

33/11 kV Durganagar Substation
Performance Inspection: January 2016 (After 3 Years)
years without any sign of corrosion. ProCoat coating offering best barrier protection without any chloride molecules
ingress or chemical reaction.
After continuous exposure of adjacent sewerage
fumes and highly corrosive gases from flowing
MUSI river, applied ProCoat coating is in intact
condition even after 3 years and effectively resisting
the chemical attack and offering barrier protection
to mild steel substation structures. Based on the
condition of coating after 3 years, it is expected that
ProCoat coating will sustain and offers similar kind
of protection for another 3-4 years before it comes
for first maintenance coating. In that condition also,
no replacement of entire coating will not arise
except localized repairs. With this high
performance coating, structural dimensional
stability is maintenance without any deterioration of
metal.

33/11 kV Durganagar Towers
Work Completed October 2013
Exposure Conditions: Chemical Corrosive Ambience
P.O.No. : Ref: 4810000336 Dt.21-05-2013 &
Agreement No : CGM/MZ/Hyd/S&P/F./D.No. 922/2013-14, Dt. 21.05.2013
P.O.No. : SE/SCADA/Tech/L.S.Agt No. 5500018783/12-13 F.No /D.No 3421/ Dt. 10.01.2013
Agreement No: 5500018783
Work Completed: October 2013 Inspected: January 2016
ENVIRONMENT: Amberpet sewer fumes, highly corrosive pollutants from adjacent MUSI river consisting of
ammonia, methane, hydrogen sulfide, chlorides, oxides of nitrogen, domestic and hospital waste making the
Type of Environment: ISO-9223-C4 - M / High Condensation., High Pollution

33/11 kV Durganagar Towers
Performance Inspection: January 2016 (After 2 Years)
ProCoat coating was inspected and observed in intact condition after 2+ years. Under this top coat, chemical
resistant ProCoat coating is in intact condition without allowing any corrosion ingress.
Same towers are inspected after 2 years and found applied ProCoat coating is in excellent condition without any sign
of surface deterioration or rust spots. Under given harsh Musi River & sewerage fumes exposure conditions,
ProCoat coating’s chemical resistance and barrier properties facilitating to ensure absolute metal protection and
expected to perform for another 3-5 years before coming for the first maintenance of applied ProCoat coating. Even
in that instance, complete removal and re-application of coating will not arise, only maintenance and localized repairs
will solve protection requirement.

33/11 kV Jeedimetla Substation
Work Completed December 2015
Exposure Conditions: Industrial & Chemical Environment
P.O.No. : CGM/OP/RR Zone/ DE(T)/ADE-II/Agmt No.167/14-15, D.No.5694/14 Dt.30-03-2015
Agreement No: 167/14-15
Work Completed: December 2015
ENVIRONMENT: Mild Steel substation structures are exposed to highly corrosive pollutants from nearby chemical
and process industries in IDA Jeedimetla comprising corrosive substances such as, hydrogen sulfide, chlorides,
oxides of nitrogen, sulphur dioxide, ammonia and moisture making environment extremely corrosive to mild steel.
Existing paint system was unable to resist the corrosive attack.
Type of Environment: ISO-9223-CX / Very high industrial Pollution, chemical pollution.

33/11 kV Jeedimetla Substation
Work Completed December 2015 (Contd…)
International standards in surface preparation by means of blast
cleaning of mild steel structures, achieving permissible limits of
surface contamination after blast cleaning. Measuring of surface
roughness to an average 50 microns, application of ProCoat coating
with high hand pressure to accelerate wetting and then polar-polar
adhesion, chemical bonding and mechanical interlocking of coating
with substrate, measuring of average coating film thickness by
Elcometer WFT gauge, further cross checking of DFT to arrive
testing voltage and implementation of holiday spark testing of
applied coating and finally application of colour coding cum UV &
weather resistant polyurethane top coating over and above ProCoat
to achieve dual and long term corrosion and chemical protection to
these MS structures of Jeedimetla SS-4 from industrial pollutants.

33/11 kV Nagole Substation
Work Completed December 2015
Exposure Conditions: Chemical Environment
ENVIRONMENT: Mild Steel structures are exposed to highly corrosive pollutants from adjacent MUSI river consisting
of ammonia, methane, hydrogen sulfide, chlorides, oxides of nitrogen, domestic and hospital waste making the
Type of Environment: ISO-9223-C3 / Moderate condensation, Moderate Pollution

33/11 kV Nagole Substation
Work Completed December 2015 (Contd…)
International standards in surface preparation by means of blast cleaning of mild steel structures, achieving permissible limits of
surface contamination after blast cleaning. Measuring of surface roughness to an average 50 microns, application of ProCoat
coating with high hand pressure to accelerate wetting and then polar-polar adhesion, chemical bonding and mechanical
interlocking of coating with substrate, measuring of average coating film thickness by Elcometer WFT gauge, further cross
checking of DFT to arrive testing voltage and implementation of holiday spark testing of applied coating and finally application of
colour coding cum UV & weather resistant polyurethane top coating over and above ProCoat to achieve dual and long term
corrosion and chemical protection to these MS structures of Nagole SS from highly corrosive Musi River fumes and gases.

33/11 kV Katedan Substation
Work Completed February 2016
ENVIRONMENT: Mild Steel structures are exposed to highly corrosive pollutants from adjacent MUSI river consisting
of ammonia, methane, hydrogen sulfide, chlorides, oxides of nitrogen, domestic and hospital waste making the

33/11 kV Katedan Substation
Work Completed February 2016 (Contd…)

33/11 kV NPA Substation
Work In Progress
ENVIRONMENT:Mild Steel structures are exposed to highly corrosive pollutants from surrounding Katedan Industrial
Area’s factories which are emitting corrosive pollutants comprising ammonia, methane, sulphur dioxide, oxides of
nitrogen, chlorides, moisture thus causing severe chemical corrosion over mild steel structures of 33/11kV NPA SS.

On-Line Oil Leak Arresting Solution With
ProCoat Specialized Repair Products
For Oil Filled Equipment In Electricity Boards
ProCoat Experience

132 / 33 kV Electricity Substation Structures
Saline & Chemically Polluted Ambience
Due to continuous exposure of chemical gaseous pollutants, saline breeze and humidity, conventional red oxide and aluminium
paint is unable to sustain on surface of substation supporting structures. ProCoat adopted very thorough sand blasting to get
Sa2.5 near white metal finish and applied ProCoat advanced polymer coating along with a UV resistant topcoat which is
expected to offer protection for 10+ years in this harsh environment.

For Further Information Contact
Registered Office
202, Kruti Commercial Complex,
Opp. Jai Ganesh Auto Centre,
Near Balaji Temple,
150 Feet Ring Road,
Rajkot - 360 005 (Gujarat) India.
Phone: +91 - 281 - 2589355, 6540162
Fax: +91 - 281 - 2589155
E-mail: info@procoat-india.com Website: www.procoat-india.com
Marketing Office
601-A, Al-Karim Trade Centre,
Opp. Ranigunj Bus Stop,
M. G. Road,
Secunderabad - 500 003. A.P.
Phone: +91 - 40 - 66317998
Fax : +91 - 40 - 66316998
Establishing Corrosion Protection Performance Through High End Engineered
Coating Systems & Turn-Key Services
ProCoat Industrial Corrosion Protection Experience

ProCoat Experience in Telangana / Andhra Pradesh Power Sector

Recommended

Recommended

More Related Content

What's hot

What's hot (20)

Similar to ProCoat Experience in Telangana / Andhra Pradesh Power Sector

Similar to ProCoat Experience in Telangana / Andhra Pradesh Power Sector (20)

Recently uploaded

Recently uploaded (20)

ProCoat Experience in Telangana / Andhra Pradesh Power Sector