Asian Experience with RTV Silicone Coatings for Insulators

Case Histories

Paper Presented at INMR Hongkong 2005 by Project Sales Corp. mailto:satish@projectsalescorp.com

Abstract
Review RTV silicone coating experiences for high voltage porcelain insulators in Asian countries such as Korea, China, Taiwan, Thailand and India. Focus on case histories of field application of RTV Silicone Coatings in these countries.

Paper Presented at INMR Hongkong 2005 by Project Sales Corp. mailto:satish@projectsalescorp.com

The Flashover Process

Accumulation of Contaminants (Salt particles from coastal environment/ industrial pollution) + Water Filming (light rain, dew, heavy fog)

Leakage Currents

Dry-band Arcing & Flashover

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Cost of Flashovers
Loss of revenue Disruption of business Disruption of service Inconvenience to consumers Poor service provider image

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Flashover Protection Methods

Cleaning
Manual wiping or energized washing with high pressure systems. Repetitive short-term solution. Cleaning must be repeated at a rate that will stay ahead of the contamination in order to be effective

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Flashover Protection Methods

Design
Extended creepage distance insulators/ Units designed for a high voltage class. When pollution problem is known before equipment is specified. More often pollution levels are not known or pollution comes after the construction of the utility system.

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Flashover Protection Methods

Surface Modification
Modify the surface properties of the insulator with the use of silicone greases and coatings. Silicones imparts hydrophobicity to the insulator surface that prevents a conductive film to be formed, thereby limiting and managing surface leakage currents. Additives used in the formulation suppress arc and control surface temperatures.

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RTV Silicone Coating

Developed by Dow Corning between 1970-74 as a response to industrys need for a maintenance free solution. Extensively tested at various utilities across the United States between 1974-84. Commercially available since 1984 as Sylgard HVIC. Global Applications across United States, Europe, Middle East and Asia in voltage ranging from 11kV to 500 kV DC.

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How RTV Silicone Coating Works ?

Imparts hydrophobicity and prevents wetting of contaminants and formation of an ionisable solution that can lead to increased leakage, dry band arcing and eventual flashovers. Low molecular weight silicone molecules encapsulate contaminants and neutralize them. In extreme weather events, arc resistance fillers, ATH releases H2O and resists degradative effects of high temperatures.

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Review Of Silicone RTV Coating Installations Across Asia

Few Case Studies

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Sylgard HVIC at 400

Customer: State Power Utility Location: South India

kvSS in India

Pollution: Salt particles from cooling tower of a thermal power plant. Very frequent flashovers Solution: Sylgard HVIC applied in 2004 on all equipments in one bay at the 400 kvSS

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Sylgard HVIC at 400

kvSS in India

All equipments in one bay of the 400 kVSS, incl. CTs, CBs, Pilots, Suspension, Pantograph Isolators, Supports, etc coated with Sylgard HVIC

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Sylgard HVIC at 400

kvSS in India

Paper Presented at INMR Hongkong 2005 by Project Sales Corp. mailto:satish@projectsalescorp.com

Sylgard HVIC at 400

kvSS in India

Paper Presented at INMR Hongkong 2005 by Project Sales Corp. mailto:satish@projectsalescorp.com

Sylgard HVIC at 400

kvSS in India

Paper Presented at INMR Hongkong 2005 by Project Sales Corp. mailto:satish@projectsalescorp.com

Sylgard HVIC at 400

kvSS in India

Paper Presented at INMR Hongkong 2005 by Project Sales Corp. mailto:satish@projectsalescorp.com

Sylgard HVIC at 400

kvSS in India

Paper Presented at INMR Hongkong 2005 by Project Sales Corp. mailto:satish@projectsalescorp.com

Sylgard HVIC at 400

kvSS in India

Paper Presented at INMR Hongkong 2005 by Project Sales Corp. mailto:satish@projectsalescorp.com

Sylgard HVIC at 400 kvSS in India

Paper Presented at INMR Hongkong 2005 by Project Sales Corp. mailto:satish@projectsalescorp.com

Sylgard HVIC Applied to Transformer Bushings at Taiwan Power Company

Customer: Taiwan Power Company Din - Hu Substation Location: LinCo, Taipei County, North West Region of Taiwan Pollution: Saline, smog, industrial and chemical pollution Solution: Sylgard HVIC applied in 1993 continues to perform until 1999

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Sylgard HVIC Applied to Transformer Bushings at Taiwan Power Company

Substation started operation in 1988 Situated near the coast exposed to saline environments as well as industrial and chemical pollutants. Weekly washing in the first few years of operation. Applied Silicone Grease in 1992. Substation wanted a long-term maintenance free solution. Sylgard HVIC applied on 345 kV transformer bushings in 1993. Washed them in 1996 during third year inspection. Continued to perform until 1998. Recoated with Sylgard HVIC 0.25mm thick in 1999.

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Sylgard HVIC at Hsinchu

Industrial Park 68 kV Substation

Customer: Taiwanese Power Utility Hsinchu Industrial Park Substation Location: Hsinchu Industrial Park, Taiwan Pollution: Dust, salt deposits and chemical pollution Solution: Sylgard HVIC applied in 1993 continues to perform.

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Sylgard HVIC at Hsinchu Industrial Park 68 kV Substation

Substation located 10 km from ocean. Serves Industrial customers including large manufacturing plants. Used Silicone Compound but found shutdown for repetitive application difficult. Started energized washing weekly but experienced flashovers during and between washing. Entire substation coated including support and suspension insulators, bushings, etc with Sylgard HVIC in 1993. Sylgard HVIC sprayed over a week in two stages 8 hours each. No flashovers since 1993. Sylgard HVIC continues to perform.

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Shanghai Extra High Voltage Power Transmission Company

500kV Nanqiao HVDC Converter station, wall bushings coated with Sylgard HVIC. This line links central and eastern network (Yangtze to Shanghai). HVDC creates special problem. Contaminated particles get polarized and attract to the insulators.
Converter stations are located at each end of the line. Light industrial and river pollution necessitated continual hand cleaning of the HV DC insulators until the application of Sylgard HVIC coating in 1991

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Bhutan Power Station 220/132 kVSS

Customer: Pashaka Substation 220/132 kVSS Location: Bhutan Pollution: Slurry from land slides, carbide dust from carbide plant, cement dust from cement plant Problem: Frequent tripping and repeated shutdowns to clean 220 kv support insulators and isolator switches. Solution: Sylgard HVIC applied in 2000

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Cement Plant, North India 132/33 kVSS

Customer: Gujarat Ambuja Cement 132/33 kV SS Location: North India Pollution: Captive Dust; Fly Ash from adjacent thermal plant Problem: Frequent tripping and shutdowns to clean insulators Solution: Sylgard HVIC applied in 2004

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Gujarat, West India, Petrochemicals Complex 220kv SS

Customer: Reliance Petrochemicals Location: Gujarat, West India Pollution: Iron Ore Dust from a neighboring steel plant, captive dust and saline environment Problem: Shutdowns to regularly clean insulators was difficult; CT Failure Solution: Sylgard HVIC applied in 2000 on CTs and other critical equipment

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What kind of approach would you use ?

Paper Presented at INMR Hongkong 2005 by Project Sales Corp. mailto:satish@projectsalescorp.com

What kind of approach would you use ?

Paper Presented at INMR Hongkong 2005 by Project Sales Corp. mailto:satish@projectsalescorp.com

What kind of approach would you use ?

Paper Presented at INMR Hongkong 2005 by Project Sales Corp. mailto:satish@projectsalescorp.com

What kind of approach would you use ?

Paper Presented at INMR Hongkong 2005 by Project Sales Corp. mailto:satish@projectsalescorp.com

Trend Towards RTV Coating in Power Utilities

Utilities gradually moving from water washing and greasing to one time application of Silicone RTV Coating for installed equipments. Silicone RTV coating has proven as a very cost-effective protection method. Internal study of 132 kv SSs in a state utility in India (i) The cumulative revenue losses from outages over a period 3 years is almost equal to the investment in Sylgard HVIC coating. (ii) It also works to approx. 1% of annual revenue of the sub-station. With better reliability vis--vis other methods.

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RTV Silicone Coating in Taiwan and China

Year 1989 1989 1990 1990 1990 1990 1991 1991 1991 1991 1991 1991 1992 1993 1993 1993 1994 Ge Zhou Ba Power Plant Nan-Pu Power Plant Hsin- Tao Substation Mai-Laio Transmission line Ta-Lin Power Plant Sang-Min Power Plant Sang-Yang Motor Company Taiwan Styrene-Petrochemical Plant Taiwan Glass Fang-Liau Substation Fang-San Substation Taichung Transmission Lines Chung-Mei-Ho Power Plant (petrochemical) Hseih-ho Power Plant Lin-Co Substation Taichung Power Plant Shen-au Power Plant Customer Voltage 500 kV DC 161 kV 69 kV 69 kV 161 kV 161 kV 69 kV 69 kV 69 kV 69 kV 69 kV 345 kV 69 kV 69 kV 345 kV 345 kV 161 kV Contaminant Industrial pollution Salt, dust Salt, dust Salt Salt, Industrial Salt, Industrial Industrial, dust Industrial, dust Salt, industrial Salt Salt Salt Salt, Industrial Salt Salt Salt Salt

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RTV Silicone Coating in Thailand

Year 1993 1993 1994 1994 1994 1994 1994 1995 1995 1995 1995 1995 1995 1996 1996 1996 1996 1996 1996 1996 Customer TPI Petrochemical Public co. Ltd MEA Transmission Line Thai Asahe Thai Central Chemical Nagyang Factory Co Ltd Charernsawat CoLtd Nakornluang Cement Phadaeng Industry Public Co Egat ( Switchyard Bay 1 - 6 ) Egat ( Switchyard Bay 11 - 12 ) Magtric Co Ltd Siam Tire cord Co Ltd Egat ( Switchyard Bay 7 - 10 ) KR Precision Public Co Ltd Thai Caprolactam Public Co Ltd Egat Substation Egat Substation Egat Substation Egat Substation Egat CC&CC Block 1 & 2 Voltage 11 kV 69 kV 69 kV 69 kV 22 kV 22 kV 115 kv 230 kV 230 kV 230 kV 22 kV 22 kV 230 kV 22 kV 115 kV 115 kV 115 kV 115 kV 115 kV 230 kV Contaminant Industrial pollution Pollution Sodium hydroxide/others Phosphate/others Industrial pollution Industrial pollution Pollution Salt, industrial Salt, industrial Salt, industrial Industrial pollution Industrial pollution Salt, industrial Industrial pollution Lignite, Chemical Salt, industrial Salt, industrial Salt, industrial Salt, industrial Salt, industrial

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RTV Silicone Coating in Korea

Year 1995 1997 1998 2000 2001 2001 2002 2002 2002 2003 2003 2003 2003 2003 2004 2004 2004 2005 Customer KEPCO (Suncheon Power Station) Namdong Power plant (Samcheonpo) Dongseo Power plant (Ulsan petro) Hyundai Mipo (Ship building Co.) KERI KEPCP (Jinju Power Station) Nambu Power Plant (Hadong petro) Youngkwang Nuclear Plant Kumho Power Plant KEPCO (Sin-Ulsan) KEPCO (Sin-Goyang) Nambu Power Plant (Youngnam petro) Seobu Power Plant (Pyungtaeck) Uljin Nuclear Power Plant KEPCO (Suwon Power Station) Gori Nuclear Power Plant Wolsung Nuclear Power Plant Dongseo Power plant (Dangjin petro) Voltage 154 kV 345 kV 345 kV 154 kV 154 kV 345 kV 345 kV 345 kV 154 kV 345 kV 345 kV 154 kV 154 kV 345 kV 345 kV 345 kV 345 kV 345 kV Contaminant Industrial Salt, dust Salt, dust Salt, dust Industrial Salt, Industrial Dust Salt, dust Salt, industrial Salt Salt Salt Salt, Industrial Salt Salt Salt Salt Salt

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To Conclude
After its commercial introduction in 1984, hundreds of installations have been successfully coated in Asia and worldwide with Sylgard HVIC, the brand from Dow Corning. In particular, Asian installations now have a proven alternative to mitigating contamination related flashovers. Sylgard HVIC has successfully avoided flashovers in most kinds of pollution and weather environments. Sylgard HVIC is a cost-effective method to prevent contamination induced flashovers..

Paper Presented at INMR Hongkong 2005 by Project Sales Corp. mailto:satish@projectsalescorp.com

Special Thanks
Mr. Venkatraman Sundaramoorthy, Sales Manager, EEI, Dow Corning India (P) Limited, India Mr. Nitin Kamat, Industry Sales Manager, HVIC, Dow Corning India (P) Limited, India

Paper Presented at INMR Hongkong 2005 by Project Sales Corp. mailto:satish@projectsalescorp.com

Thank you

Paper Presented at INMR Hongkong 2005 by Project Sales Corp. mailto:satish@projectsalescorp.com