Until 2022, the utility develops an electricity transmission system composed of a 500 kV single-circuit transmission lines between different substations along Brazil.
During the previous years, the utility had experienced flashovers outages due to high humidity and salt concentration at substations located close to the sea. The engineers had to wash the insulators 6 times per year to ensure the reliability. For this major construction, they were seeking for a long-term solution to flashovers due to pollution on insulators.
Factory coated insulators are increasingly being applied in harsh service environments since they offer an excellent alternative which guarantees optimum quality and performance for overhead lines areas with heavy pollution. They minimise leaking currents and thereby reduce operation and maintenance cost.
The application process was performed by Midsun Group certified applicators at the facilities of Global Insulator Group (glass insulators manufacturer) located in Estonia, Europe.
The coated insulators were properly packed and shipped from the facilities to the end-user for its successful installation. Midsun HVIC will provide maintenance-free protection for an expected minimum of 10 years.
One of the major utilities in Chile was leading the interconnection project which connects the Norte Grande (SING) and Central (SIC) electrical systems of the country.
In these new lines construction, the challenge was to ensure the uninterrupted electrical supply due to arduous maintenance tasks and flashovers outages. They should wash the insulators for a minimum of 6-8 times per year to ensure the lines reliability. This required high maintenance cost and profit losses due to station shut downs and interruptions in electricity supply; and safety risks.
Midsun Group provided with immediate displacement for the application of Midsun High Voltage Insulator Coating (HVIC) on-site throughout their global applicators network.
Midsun HVIC works on the principle of providing a hydrophobic surface limiting the leakage current in the presence of moisture, extreme pollution and harsh environments.
Midsun HVIC has provided the reliable maintenance-free solution expected by the utility and the insulators have remained in continued service for this period with no flashovers.
The utility suffered from long-term weather and environmental related corrosion.
External and internal switch-gear cabinets damages were a big challenge, which were exposed to a very humid environment with high concentration of salty air blowing across their coastal stations.
Two-coat systems were tried with no positive results within 36 months.
Midsun Silprocoat is a proprietary formula silicone corrosion coating with excellent chemical resistance and adhesion characteristics. The applicators sprayed 2 coats of Silprocoat over the entire switchgear cabinets for complete protection.
Midsun Silprocoat was the best solution to create a protective seal for the cabinets. That cohesive Midsun Silprocoat seal prevented any further leakage to the internal bays. Midsun Silprocoat also prevented of any other chance for external corrosion.
Two years after the date of application, no indications of Midsun Silprocoat polymer degradation have been shown as it was common with epoxy coatings that exhibited chalking. Corrosion is unobserved on Midsun Silprocoat in field applications extending beyond fifteen years service, which allows Midsun to give this warranty to our customers.
Power Transmission Towers often rust and corrode over time, and without proper maintenance, utilities have to invest in untimely and costly replacement. Failures in this major utility's transmission line components amounted to thousands of dollars only in maintenance costs apart from other related expenditures.
Many of these failures were corrosion related due to the exposure of the system materials to aggressive atmospheric and soil environments. The engineers confirmed that in this case, the galvanizing on their structures have corroded over time, weakening the structures.
Midsun Silprocoat is a proprietary formula silicone corrosion coating with excellent chemical resistance and adhesion characteristics. After removing the rust, Midsun applicators sprayed 2 coats of Silprocoat over the towers for complete protection.
Midsun Silprocoat was the best solution to create a protective seal for the towers and prevent of any other chance for external corrosion.
Three years after the date of application, no indications of Midsun Silprocoat coating degradation have been shown as it was common with galvanized steel. Corrosion is unobserved on Midsun Silprocoat in field applications extending beyond fifteen years service, which allows Midsun to give this warranty to our customers.
Back in 2017, numerous neigbourhoods lost the electricity during 3 days after a civet cat roamed into a substation and disrupted the system. Besides, the damaged substation translated into costs of over $5 millions in repairs.
As part of the effort to improve reliability, the Spanish oil plant owner contacted Midsun to solve the long history of occasional animal related outages at their high voltage substations.
The optimal solution to ensure the protection of the equipment and lines, as well as the wildlife, is to insulate the bare metalwork and create an environment for wildlife to interact within the substations without damaging themselves or the equipment.
Midsun E/Products are manufactured from silicone rubber, providing a proven, cost-effective and easy to install solution to bird, animal and extreme weather-related outages. The natural hydrophobicity of silicone along with its superior UV and chemical resistant properties expected life beyond 20 years.
The application was supervised by one of Midsun Group personnel to fully conform with the power plant's high standards. The power plant has remained in continued service for this period with no wildlife induced flashovers up-to-date.
Massive bird settlement on distribution poles in desert environment
With high temperatures, sandstorms, fog and salty ocean winds, the arid desert climate is less than ideal for MV and HV equipment coexisting with numerous resident/migratory birds. One of the major oil producers experienced an average of four outages per month.
Due to the location, the birds had no tree to pose on, being the distribution poles their most common place to rest. The cost of each outage was a minimum of 15 million USD. They contacted Midsun Group to research a resistant material, other than plastic covers and epoxy coatings.
Midsun E/Products are manufactured from silicone rubber, providing a proven, cost-effective and easy to install solution to bird, animal and extreme weather related outages. The natural hydrophobicity of silicone along with its superior UV and chemical resistant properties expected life beyond 20 years.
The material was confirmed to function perfectly and there has been no outages recorded up-to-date. Due to the customer's satisfaction on the first project, Midsun Group has been consulting Overhead Lines regarding the installation on all other areas of the network since 2015.