12-E-HVS-747

Performance Investigation of HV Insulators Coated

by Silicon Rubber

Ali Naderian1,2, Majid Sanaye-Pasand1, Hosein Mohseni1,

Saleh Moonesan 1, Ayman H. El-Hag3 , Edward Cherney2,
Shesha Jayaram2, Gholamreza Jalali 4

1 Electrical and Computer Engineering , Faculty of Engineering, University of Tehran

2 High Voltage Lab, Faculty of Engineering, University of Waterloo, Ontario, Canada, anaderia@uwaterloo.ca
3 Electrical Department, American University of Sharjah, Sharjah, UAE
4 Alvand Pooya Niroo Co., Tehran, Tel: 66925272, 66595371

Keywords : Insulator, RTV coating, silicone rubber, filler, pollution

Abstract :
This paper discusses important parameters for
evaluating room temperature vulcanized
(RTV) silicone rubber coatings for high
voltage insulators of substations and overhead
lines. It presents the results of conducted tests
for 3 different commercial RTVs which are
used by utilities nowadays. Tracking and
erosion resistance, loss of hydrophobicity,
mechanical strength, thermo-gravimetric
analysis, and scanning electron microscopy,
have been employed to evaluate these
coatings in laboratory. As a final conclusion,
RTV-C, which has both ATH and silica fillers
with the filler size about 1 µm , shows the best
electrical, mechanical and chemical
performance among available insulators. It is
recommended for applying to ceramic
insulators in the field.
1. Introduction
Insulator contamination has been a problem
since the birth of electrical power distribution.
Natural pollution likes salt spray and desert
sand and industrial pollutants can lead to
costly power interruptions due to arcing and
flashover. Wet atmospheric conditions give
rise to water filming and, in the presence of
contaminants, an uncontrolled leakage current
develops and results in flashover. This type of
disruption can be very costly. Application of
Room temperature vulcanized (RTV) silicone
rubber coating has been investigated as an
effective solution to make a hydrophobic
surface spraying over the bushing of
transformers, stand of circuit breakers and
post insulators and even cap and pin
insulators of new overhead lines[1,2,3,4].
Application of RTV silicone rubber coating is
recommended for insulator of existing
substations in highly polluted areas [1,2,3].
Fig 1 shows different type of application of

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21th International Power System Conference
this coatings on the insulators of substations
and overhead lines[1,2,5].
a) spraying RTV coating on a HV circuit breaker
b) spraying on a transformer bushing
c) pre-coating of cap and pin glass insulators
Fig.1 – Spraying RTV silicon rubber coatings[1,2,5]
It was observed that a layer of silicon rubber
coating on a porcelain insulator can suppress
the leakage current tremendously as it is
shown in Fig. 2[1].
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Fig.2. Suppression of leakage current on a coated
insulator during slat fog test, the first generation[1]
The anticipated life of present coatings is
estimated to be about 10 to 20 years [3].
IEEE guideline suggested using standard tests
like dielectric strength, dissipation factor, arc
resistance, insulation resistance and erosion
and tracking resistance for the evaluation of
RTV coatings [4]. Also, salt fog test and
tracking wheel test is recommended as non-
standard methods of evaluation. However
commercial RTVs usually have acceptable
specifications according to the recommended
standard tests, evaluation of aging of them
and prediction of lifetime is the most
important problem which is not clear in the
standard.
There are some literature on RTV coatings
[3,4,5,6], however, in all of this work the main
emphasis has been on the degree at which the
various fillers are capable of reducing the
degree of mass loss during dry band arcing. Of
course this assumes that the temporary loss of
hydrophobicity inevitably leads to the
development of leakage current and dry band
arcing on insulators in the field. After many
years of HVIC use, this observation has yet to
be reported. What has been observed by users
is a loss of hydrophobicity but only on the
unprotected parts of the leakage path., for
example on the upper surfaces of insulators as
evident in Fig. 3.
Flashover has also been reported without the
usual dry band activity that is normally
associated with uncoated insulators. This type
of flashover is somewhat analogous to a wet
flashover of an insulator but at normal line-to-
 Performance Investigation of HV Insulators Coated by Silicon Rubber
21th International Power System Conference
ground voltage and the mechanism has been
referred to as a “sudden flashover” which has
been previously discussed on non-ceramic
insulators by Gorur [7].
Fig.3. Photograph of the top end of a RTV coated
500 kV station post insulator, corona discharge.
2. Important Parameters
Basically the formula of the RTV determines
the electrical, mechanical and chemical
properties of the coating. RTV coatings
usually consist of a polymer like silicone, a
reinforcing filler, a catalyst, colorant pigment
and a cross linking agent.
The most important part of RTV which
determines its performance is the filler,
because other raw materials are mostly
common in commercial coatings. Filler, when
is added to the composition, has a two fold
effect. First, it will displace silicone and
therefore result in a reduction of available free
fluid. The hydrophobicity of a coating
depends on the amount of free fluid and the
amount and the size distribution of the filler.
Second, filler can be viewed as having the
same effect as imbedding a screen in the
coating, the presence of which will slow
down the diffusion of free fluid to the surface.
Three important factors related to fillers are:
type of filler, percent of filler and filler size
[1,2]. Two main type of fillers are alumina tri-
hydrate (ATH) and Silica. It was investigated
that there is no difference on erosion of ATH
or Silica filled RTV coating if the filler is
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added 50% by weight which is commonly
used in practice [5]. The basic parameters of
RTV which should be taken into account
before choosing and applying are described in
this part.
2.1. Loss of Hydrophobicity
The loss of hydrophobicity of a RTV coating
comes with time through natural washing and
this process takes a very long time before
coating performance is affected.
Contaminant, and in particular the removal of
contaminant speeds up the depletion of the
fluid responsible for hydrophobicity.
However, in coastal regions where wetting is
often constant, the loss of hydrophobicity
occurs very rapidly. Loss of hydrophobicity
is usually simulated by a salt fog test for non-
ceramic insulators as well as RTV coatings;
although a clear relationship between salt fog
test and field experiments has not been
conducted yet. Increasing of 3rd harmonic of
Fast Fourier Transform (FFT) of leakage
current has correlated to dry band arcing
which is a step after loss of hydrophobicity in
salt fog test [6]. Measuring of contact angle is
often used to evaluate the hydrophobicity and
IEEE has suggested this method to evaluate
RTVs as well.
2.2. Tracking and Erosion Resistance
Tracking is a partially conducting path in the
surface of rubber or in the core of a composite
insulator. IEC and ASTM recommend proper
tests to evaluate erosion and tracking of
polymers [5], named as inclined plane test
(IPT). A voltage between 2 to 6 kV is applied
to a layer of polymer. During voltage a
conductive path of liquid flows on the
surface. The failing criterion of the samples is
a current more than 60 mA (rms) or reaching
the tracking path to the half of total path (HV
to ground electrode).
3. Evaluation Methods
The two main tools for evaluation of RTV
silicone rubber has been introduced in part 2
named as salt fog test and inclined plane test
[1,2,3,4]. Accelerated aging test which is
 Performance Investigation of HV Insulators Coated by Silicon Rubber
21th International Power System Conference

introduced by IEEE and IEC for polymeric materials commonly used for coating of
insulators has been used for evaluation of insulators in substations and overhead
RTV silicone rubber insulators too [8]. transmission lines. Table 1 summarizes the
Effects of partial discharge and ozone as well coatings specifications according to
as ultra violate radiation and heat of the sun is manufacturers [9,10].
simulated in an accelerated aging chamber
which seems important for such a polymeric
4.1. Primary observation
insulator.
Flashover of insulator in a clean fog test can Considerable variation in viscosity, skin-over
also be considered as a comparative tool to and cure times, and specific gravity of the
evaluate the coatings. Tough it is hard to four commercial coatings was observed in the
prepare a setup to test insulators of as-received condition. Therefore, all samples
substations and it is limited to small post were made under the same conditions after
insulators. thorough mixing and left to air cure for 7 days
Thermo-gravimetric analysis (TGA) is a prior to characterization and acid-water
laboratory based test to analyze the polymer immersion.
based on decomposition by heat which is
employed to investigate the composition of
insulator or to compare new and aged samples Table 1- Physical specification of insulators
[3]. TGA is simply the weight vs. temperature Coating RTV-A RTV-B RTV-C
as a sample is heated in air. Suspected filler ATH Silica ATH+Silica
Thermal conductivity of coating is another Dark Bright
Color Gray
important factor because dry band arcing due white White
to any partial discharge on the surface of Dielectric
insulators will increase the speed of Strength 8.4 9.4 14.3
(kV/mm)
degradation [5]. So if the thermal conductivity Volume
is high, the heat comes up to the surface fast resistivity 3.7 × 10 15 9 × 10 14 7.8 × 10 14
and the degradation will be slow. (Ωcm)
Scanning electron microscopy (SEM) Dielectric
photographs and energy dispersive X-ray constant @100 3.93 4.5 4.26
Hz
attachment (EDAX) are usually helpful to
Dissipation
analyze the coating and track any changes due factor@100 Hz
0.01 0.059 0.024
to aging [1,2,3,5].
Water absorption by a RTV coating is an The specific gravity, primary filler type and
indication of porosity and in filled materials.
concentration, porosity, the amount of free
This is most often related to bonding between
fluid available, were the main properties used
the filler particles and the matrix. Soaking in
in the characterization of the coatings. Table
water can show this weakness.
In coastal regions where wetting is often 2 summarizes sample composition and the
constant, the loss of hydrophobicity occurs data obtained in the initial characterization
very rapidly. On the other hand, in other which obtained by authors in the lab.
regions the loss of hydrophobicity is
accelerated by acid rain which often causes
depolymerization of the RTV coating [3]. Table 2. Characteristics of cured coatings
RTV Primary Filler Specific Fluid
4. Comparison of Available RTVs Coating Filler Wt Gravity Wt
% %
Three different coatings, which are
A ATH 47 1.45 3.47
commercially available, are used in this B Silica 40 1.61 1.14
research. These are basically the available C ATH 54 1.48 2.26

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4.2. Inclined Plane Test 1.6

The loss of hydrophobicity is assessed by the
1.4 RTV-C
ease in which leakage current develops in an RTV-B

3rd harmonic of FFT of current, mA

incline plane test. Fig 4 shows the inclined 1.2 RTV-A

plane test setup employed. Figure 5 compares

1
the development of 3rd harmonic of FFT of
leakage current of 3 coatings and the 0.8

important parameters of this monitoring is 0.6

shown in Table3.
0.4

0.2

0
20 60 100 140 180 220 240
time, minute

Fig. 5 Comparison of leakage current pattern

Table 3- IPT result of different coatings

Coating RTV-A RTV-B RTV-C

Fundamental LC
3.63 4.12 2.28
(mA)
3rd harmonic LC
0.48 0.75 0.59
(mA)
Failed samples 0 3 0
Length of erosion
6.8 22.5 5.4
(mm)
Erosion area
65 150 53
(mm2)

4.3. Thermo-gravimetric Analysis

TGA was arranged by a TA Instruments
system model SDT 2860.

Fig. 4 Inclined plane test setup and a picture of thermal

distribution from a FLIR thermo camera

Three samples of five samples of RTV-B

failed in inclined plane test which proves
silica filled coatings without ATH has not
enough resistance to tracking and erosion
under severe ambient conditions. Erosion
area after IPT test confirms the above
conclusion. RTV-C which has both of fillers
shows the best performance in this test. Fig. 6 TGA of RTV coatings

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The temperature increased from 100 0C to 800 115

0
C by a slope of 20 0C/minute. The weight RTV-B

Contact Angle, Degree

loss versus temperature for RTVs is plotted in 105 RTV-A
Fig. 6 which confirms the presence of ATH in RTV-C

RTV-A and RTV-C, because water of ATH 95

evaporated at a temperature between 300 and
400 0C. Percent of ATH filler weight can be 85
extracted from TGA. It is 47% and 54% for
RTV-A and RTV-C respectively. 75

65
0 5 10 15
4.4. Soaking in Water, Porosity and
Number of Days
Hydrophobicity
Porosity and hydrophobicity was evaluated Fig. 8 Static contact angle of insulators versus soaking
using two samples of each insulator. They days in water
were immersed in 800C tap water for 15 days.
At 5 day intervals, the samples were removed, 4.5. Mechanical Test
air dried and the weight gain was recorded. In order to investigate mechanical
Contact angle was also measured along with characteristics of these insulators, stress
porosity and the results are illustrated in Fig. versus strain, tensile and elongation of cured
7 and 8 respectively. RTV-B shows the best
materials measured with results shown in
performance in porosity test. So, bonding of
Table 4. The test objects were prepared
silica to the polymer matrix is more uniform
according to ASTM D3039. A tensile tester
and with less bubbles or pores. Contact angle
of RTV-A reached bellow 70 after 15 days for model composite samples, named
which is a hydrophilic surface. The other two MINIMAT 2000 was used to measure these
coatings rivaled during aging. Besides of the parameters. The speed of tension was tuned 2
filler, the bulk of polymer (PDMS) was mm/min for all samples. Tensile strength at
suspected different for RTV-A, because of break of RTV-B and C is almost double
such a poor performance in this test. So, gas compared with RTV-A. The main reason is
chromatography will be done for that later. having silica which causes a strong molecule
bonding in the polymer matrix. On the other
hand silica reduces the flexibility of silicone
25 rubber as the Young’s modulus of RTV-B is
21
RTV-B twice but it is not important for this
Increament of Weight %

RTV-A
application. Using a nano-silica filler was
17 RTV-C
suspected in RTV-C which justifies the
13 significant elongation at break of RTV-C.
9

5 Table 4- mechanical parameters of RTV coatings

1
Coating RTV-A RTV-B RTV-C
-3 Tensile strength at break
1.2 2.5 2.4
3 4 5 6 7 8 9 10 11 12 13 14 15 16 (Mpa)
Number of Days Young’s Modulus 20.5 37.7 20.8
(kpa)
Fig. 7 Porosity test of coatings, soaking in hot water Elongation at break 88.4 86.0 155.8
(%)

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4.6. Thermal Conductivity

Thermal conductivity measurement was
performed using a thermal contact resistance
rig. The test apparatus is enclosed in a Pyrex
bell jar connected to a 10-7 torr vacuum
system. The thermal conductivities of RTV-
A, B and C were measured to be 0.46, 0.46
and 0.60 W/m.oK respectively, which agree
with the IPT results. Material with higher
thermal conductivity has lower erosion. The
degradation of RTV-A was visible even
without microscope (Fig. 8). Such deep
cracks resembling mud crack was not
observed in the other coatings.

Fig. 10 SEM picture of RTV-C

5. Field aged coatings

Fig. 9 Surface deterioration of RTV-A observed after
aging
4.7. SEM
Several samples of RTV coatings were
examined using a LEO 1530 scanning
electron microscope. A recorded photograph
of RTV-C is shown in Fig. 10. The electric
field of microscope was tuned at 10 kV and
the magnification was 10,000. The size of
ATH fillers of RTV-C in this figure is about
1 to 2 µm which is significantly smaller than
ATH fillers of RTV-A. Filler size of RTV-A
was about 10 µm . It causes a uniform and
stronger bonding between molecules of filler
and polymer.
Considering employed tests and observations,
it is recommended to select a coating filled
with combination of ATH and silica with a
size in order of magnitude of 1 µm .
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Field aged coatings of RTV-A, removed from
insulators having 10 years of field exposure
were examined in the laboratory.
The return of hydrophobicity, after a
temporary loss, was investigated by
measuring the static contact angle as a
function of time. This was done on new and
field aged specimens of RTV-A. Before the
test, the samples were washed in water, which
simulates a heavy rain condition, to
temporarily destroy the hydrophobicity.
Then, the contact angle was measured at
intervals over a 36 hour period by averaging
the contact angle of 10 drops, each about
20 µL volume, of distilled water and these
results are shown plotted in Fig. 11. The
initial contact angle of the new and field aged
coatings was 124 and 110 degrees,
respectively. From Fig. 11, it is evident that
recovery on the new sample occurred within
24 hours, however the recovery on the field
aged specimen did not occur even after 36
hours, a result that can be expected due to the
 Performance Investigation of HV Insulators Coated by Silicon Rubber
21th International Power System Conference
depletion of LMW fluid and in particular, the
low- weight cyclic species of the fluid which
tend to diffuse more quickly than the mid-
and heavy-weight cyclic species from the
bulk to the surface layer.
Fig. 11. Return of hydrophobicity, static contact angle
of new and field-aged samples of RTV-A
6. Conclusions
Comparison of 3 different RTV silicone
rubber coatings which are currently used in
substations and overhead lines was
investigated in this research. Inclined plane
test showed RTV-C, the coating which is
filled by both of fillers, has the minimum
leakage current and erosion area. On the
other hand, RTV-B, silica filled coating,
absorbs water an order of magnitude less than
other 2 competitors. Mechanical test has
proved the tensile strength at break enhanced
by silica compared with ATH. RTV-A loses
hydrophobicity during 15 days aging in water
which is different from other two coating.
ATH filler with the size around 1 µm used in
RTV-C shows an acceptable performance in
hydrophobicity, resistance to tracking and
erosion, and mechanical strength and thermal
conductivity. On the other hand, GC proves
that these insulators have different PDMS
construction. RTV-A has a larger amount of
LMW which is another reason for speeding
the aging and degradation in the field. As a
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final conclusion, RTV-C has the best
performance considering all electrical,
mechanical and chemical parameters to use in
high voltage substations and transmission
overhead lines.
7. References
[1] E.A. Cherney, “RTV silicone-a high tech solution
for a dirty insulator problem”, IEEE Electrical
Insulation Magazine, Volume 11, Issue 6, pp. 8 –
14, Nov.-Dec. 1995
[2] E. A. Cherney, R. S. Gorur, “RTV Silicone Rubber
Coating for Outdoor Insulators”, IEEE Transaction
on Dielectric and Electrical Insulation, Vol. 6, No.
5, pp. 605-611, October 1999
[3] K. Eldridge, J. Xu, W. Yin, A. Jeffery, J.
Ronzello, S. A. Boggs, “Degradation of a Silicone-
Based Coating in a Substation Application”, IEEE
Transactions on Power Delivery, Vol. 14, No. 1,
pp. 188- 193, January 1999
[4] IEEE Std 1523-2002, “IEEE guide for the
application, maintenance, and evaluation of room
temperature vulcanizing (RTV) silicone rubber
coatings for outdoor ceramic insulators”
[6] Luiz H. Meyer, “A Study on the Role of Fillers in
Silicone Rubber Compounds for Outdoor
Insulation ”, PhD thesis, Electrical and Computer
Engineering, University of Waterloo, 2003
[7] R.S. Gorur, A. De La, H. El-Kishky, M.
Chowdhary, H. Mukherjee, and R. Sundarjan,
“Sudden flashover of non-ceramic insulators in
artificial contamination tests,” IEEE Trans. on
DEI, vol. 4, no.1, pp. 79-87, 1997.
[8] IEC1109 ,"Composite Insulators for A.C.
Overhead Lines with a Nominal voltage Greater
than 1000 V Definitions, Test Methods and
Acceptance Criteria" , 1992
[9] Technical report, Midsun Group Inc., 570 HVIC
High Voltage Insulator Coating,
[10] Daw Corning Inc., High Voltage Insulator
Coatings, case histories
[11] S. J. Clarkson, J. J. Fitzgerald, M. J. Owen, S. D.
Smith, M. Van Dyke, Synthesis and properties of
silicones and silicone-modified materials,
Published by American Chemical Society,
Washington, DC, 2003