COASTAL INDIA. Supply & Application of: Epsilon Midsun 570 Gen-4 RTV HVIC (High Voltage Insulator Coating) and

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1 Supply & Application of: Epsilon Midsun 570 Gen-4 RTV HVIC (High Voltage Insulator Coating) and Epsilon Midsun 579 RTV Anti-Corrosion Coating In COASTAL INDIA Supply & Application of 8,000kg of Epsilon Midsun HVIC by Epsilon Asia Group: 2011

2 Epsilon: Key Partners in India Epsilon an engineering company and is exclusive national partners with: Dongfang India for Minimal-Oil Boiler Combustion Systems Dongfang-Hitachi VFDs, PV Inverters SYCG/Nexans XLPE Cable Epsilon Midsun HVIC & Silicones

3 Switchyard Overview Insulators prone to severe contamination due to: Coastal Location Cooling Tower Drift as Seawater is used for cooling No Drift Eliminator Installed at the Cooling Towers at the time Extreme Leakage Current & Corona observed Frequency of unplanned outages due to flashovers was increasing rapidly Extreme Corrosion on JBs and metal infrastructure observed epsilon

4 Contaminated Insulator Surfaces Despite Extremely frequent Washing Cycles, pollution deposits were unavoidable The salt deposit in this image is within 7 days of the previous wash

5 Extreme Corrosion to Ferrous Infrastructure Metal Infrastructure Corroding within 18 months Such Corrosion Results in degrading IP54/IPxx ratings which pose a safety risk Changing JBs requires recommissioning of equipment After coating with EM 579, Resistance to Corrosion Fortified epsilon

6 Corona Visible with the naked eye epsilon

7 Corona Visible through UV Corona-Cam Watch the Full Video at:

8 HVIC of Choice: Epsilon Midsun 570 Gen-4 RTV Ultra-Hydrophobic RTV High Voltage Insulator Coating (HVIC) Targets: Mitigate Risks of Leakage Current Reduce the need for Insulator Washing Mitigate Risks of Flashovers

9 Conductive Tracking Path Cannot be Formed (All drops of water are discrete)

10 IEEE Evaluation of RTV Coating in Coastal Conditions IEEE Evaluation of RTV Coating for Station Insulators subjected to Coastal Pollution H.M Schneider, Senior Member, EPRI High Voltage Research Centre) Performance of Breaker Support Insulators (BSIs) tested before and after application of RTV Coating Resistance to Flashovers tested in field tests to check for additional equivalent creepage imparted by the coating

11 The results Measurements are given in ESDD as: Quantity of NaCl per unit area (mg/cm 2 ) Test Reports showed ESDD as high as mg/cm 2 several months after wind storms, natural and manual washing Uncoated BSIs flashed over at 209kV RTV coated BSIs flashed over at 300kV Improvement of performance of: 43.5% withstand voltage

12 Hydrophobicity Recovery (CPRI labs Test) It is essential for the silicone material to recover its hydrophobicity for long-term effective performance Epsilon HVIC Test Results of Hydrophobicity recovery at CPRI Hydrophobicity Tested (CPRI Labs) Virgin Sample HC 1 After 100-hours continuous exposure to Corona Epsilon Midsun Hydrophobicity Recovery within 48 hours of Corona Destruction HC 6 HC2 Hydrophobicity Classification (HC level as per STRI) epsilon

13 Hydrophobicity (Water-Repellency) Classification Hydrophobicity Classification (HC) goes from HC1 to HC7 HC1: Completely Hydrophobic HC7: Completely Hydrophilic HC Description HC1 HC2 HC3 Only discrete droplets formed. θ r 80 (or larger) for majority of droplets Only discrete droplets formed. 50 <θ r < 80 for the majority of droplets. Only discrete droplets formed. 20 < θ r <50 for majority of droplets. Usually they are no longer circular HC6 Wetted areas cover > 90% small un-wetted areas still observed HC7 Continuous water film Typical Examples from HC1 to HC6 epsilon

14 Application Procedure

15 Surface Preparation epsilon

16 Gentle Scraping of Salt Deposits epsilon

17 Application of Epsilon HVIC Airless Spray Application epsilon

18 Application of Epsilon HVIC epsilon

19 Corona Eliminated on Coated Insulators

20 Epsilon HVIC Team Safety Training + Documentation SEP 2011 Scheduled Start: 01 OCT 2011 Actual Site Mobilization: 01 OCT 2011 Scheduled End: 31 OCT 2011 Actual End: 98.5% job completed by 31 OCT 2011 At least 9 working days were lost due to UPCL not being given shutdown permission by Karnataka Government epsilon

21 Thank you Epsilon Asia Group X29 Hauz Khas, New Delhi, India Level 29, Offices at CentralWorld, Bangkok, Thailand ;