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Dealing with Corrosion Problems in Electrical Substation Equipment

Electrical substations are critical components of the power grid, ensuring the efficient transmission and distribution of electricity. To maintain the reliability and safety of these substations, it's essential to address various maintenance challenges, like equipment corrosion.

Corrosion is a common problem in electrical substations, primarily due to their outdoor exposure and the presence of metal equipment. This can severely affect the performance, lifespan, and safety of substation equipment.

Effects of Corrosion to Equipment

Rust can interfere with the electrical conductivity of metal components, leading to poor grounding, increased resistance, and even electrical failure.

Corrosion degrades the structural integrity of metal equipment, potentially resulting in accidents and equipment failure.

Regular maintenance and repair are required to address rust-related issues, increasing operational costs for substations.

Causes of Corrosion in Electrical Substations

Environmental Conditions – Substations are often located in areas with high humidity, salt exposure, or chemical pollutants, which can accelerate rust formation.

Age of Equipment – Older equipment is more susceptible to rust due to wear and tear over time.

Poor Maintenance – Inadequate cleaning, painting, and maintenance practices can lead to rust formation and exacerbate the problem.

In order to mitigate corrosion on substation equipment, comprehensive maintenance program have been implemented which includes regular inspections, cleaning, and repainting of equipment to prevent rust formation and early detection of corrosion. For spare parts and equipment, it should be stored in a dry and controlled environment to prevent corrosion during storage.

When replacing or upgrading equipment, consider using corrosion-resistant materials and alloys that are less prone to rust. It is also important to train substation personnel on the importance of rust prevention and best practices for mitigating corrosion.

Corroded equipment before coating
Corroded equipment before coating
Equipment after silprocoat application
Equipment after silprocoat application

Lastly, anti-corrosive coatings are now available in the market which help protect equipment from severe environmental elements leading to corrosion. Silicone coatings are highly effective due to its elasticity and resistivity to harsh weather conditions. It can be easily applied by spray, roller or brush, there is no need to mix it, dries fast and no primer is necessary. Midsun IKM, based in Austria, specializes in producing ready-to-use one-part system coating, named Midsun Silprocoat to protect against corrosion and optimize the usage of equipment. Moreover, the product cures in less than 1 hour and will last more than 10 years in challenging environments. Midsun Silprocoat is a top-notch resistance to weathering, water and chemical substances – making it ideal to use in coastal, industrial and desert areas.

Corrosion problems in electrical substations can have serious consequences, including reduced equipment lifespan, increased maintenance costs, and potential safety hazards. By understanding the causes of corrosion, implementing effective prevention and mitigation strategies, and conducting regular maintenance, electrical utilities can ensure the reliability and longevity of their substation equipment.


Soares, C. G. (2005). Corrosion and metal artifacts—a dialogue between conservators and archaeologists. Journal of the Brazilian Chemical Society, 16(6), 1113-1123.

Roberge, P. R. (2008). Handbook of Corrosion Engineering. McGraw-Hill Education.

Strunz, J., & Boehm, M. (2010). Introduction to Materials Engineering and Technology. Wiley-VCH.


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