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Huge Cost Savings Realized by the Southern California Edison Company thanks to Si-COAT 570 High Voltage Insulator Coating

Natural salt fog contamination from the Pacific Ocean and industrial pollution were major nuisances at a 2000 MW thermal generating station operated by the Southern California Edison Company.

The main source of irritation was the leakage current leading to flashovers on insulators in the 230 kV switchyard that was servicing the generating station.

The switchyard consisted of 144 insulators, of which, the Southern California Edison Company decided to coat 72 with Si-COAT 570 HVIC while leaving the other 72 uncoated as a control for the experiment.

The basis for the trial was a 10 year case study to observe the cost savings associated with using Si-COAT 570 HVIC.

BEFORE COATING:

Prior to coating the insulators, the insulators required a monthly water washing in order to keep them free of contaminants that would cause leakage current and flashover. Each water washing exercise cost US$5,010 for the 72 insulators in question. This cost was based on 3 people each working an 8 hour day for 3 days at a rate of US$55 per hour. As well, equipment rental costs of US$350 per day were included.

Thus, the annual cost of maintaining the 72 insulators, prior to coating with Si-COAT 570 HVIC was US$60,120.

COST OF COATING:

The actual coating of the 72 insulators required 72 gallons of Si-COAT 570 HVIC (based on the specific size and geometry of the insulators in question).

Before coating could take place, the insulators required a water wash to ensure that the surface was free of contaminant particles. Again, this cost US$5,010.

Material cost for the 72 gallons of coating was US$15,840 (at an approximate rate of US$220 per gallon).

Applying the coating required 3 people working for 8 hours per day for 5 days at a rate of US$55 per hour. Thus, the total application cost was US$6,600.

In total, the cost of coating the 72 insulators with Si-COAT 570 HVIC was US$27, 450.

AFTER COATING:

Once the 72 insulators were coated with Si-COAT 570 HVIC, a dramatic improvement in performance was noticed. The insulators that were previously being washed 12 times per year required only 1 annual water wash!

This reduced annual maintenance cost of the 72 insulators from US$60,120 per year to US$5,010.

Thus, in the first year, the Southern California Edison Company realized a saving of:
US$60,120 Annual water washing cost BEFORE coating
- US$27,450 Material and application cost
US$32,670 Total cost saving in first year

In subsequent years, savings totalled:
US$60,120 Annual water washing cost BEFORE coating
- US$5,010 Annual water washing cost AFTER coating
US$55,110 Annual savings after first year

Because the study was based on only a minimum 10 year product life, the 10 year cost savings for coating the 72 insulators was US$529,000!

This does not even take into account the revenue that was not lost in that 10 year time due to leakage current and flashover related power outages.

Now, imagine how many hundreds of millions of dollars can be saved if all insulators experiencing leakage current are coated, and if the true Si-COAT 570 HVIC life span of well over 10 years is taken into account.