Cases
Not only used on photovoltaic panels
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SystemEnergy and Power System
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Place220kV Substation in an Industrial Park, Chifeng, Inner Mongolia, China
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Date2025-11-15
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ApplicationAnti-icing, anti-corrosion and anti-fouling protection for outdoor electrical equipment
Project background
Project Type: Integrated anti-icing, anti-corrosion and anti-fouling protection project for outdoor electrical equipment in an energy and power system.
Project Location: A 220kV substation in an industrial park in Chifeng, Inner Mongolia. The site is located in a northern cold region, where the lowest winter temperature can reach -30°C. The area experiences frequent wind and snow, and nearby industrial enterprises generate dust and industrial pollutants.
Application Scenario: Full-scenario protection for outdoor core equipment in the substation, including suspension insulators, post insulators, disconnecting switches, busbar supports, equipment housings, grounding terminals and other outdoor exposed equipment.
Project Scale: The 220kV substation has a main capacity of 2×180MVA. The outdoor equipment protection area is approximately 8,000m², covering 320 groups of insulators, 46 disconnecting switches, 120 sets of busbar supports, as well as various outdoor equipment housings and connecting components.
As a core power supply hub for the local industrial park, the substation provides electricity to 12 surrounding industrial enterprises and nearby towns. Power supply stability is directly related to regional production and daily life. However, affected by the local natural environment and industrial layout, the outdoor equipment had long faced three major operational challenges.
First, icing was a major problem. In winter, temperatures often range from -10°C to -30°C. After snow and rain, thick ice layers easily formed on insulators and disconnecting switches, causing ice flashover and creepage faults. The substation experienced about 8 to 10 equipment failures every winter due to icing, and each repair usually required 4 to 6 hours, seriously affecting power supply continuity.
Second, corrosion was another serious issue. Outdoor equipment was exposed to wind, sand, rain and snow for long periods. Metal components such as equipment housings, brackets and grounding terminals were prone to rust and oxidation, while insulator surfaces were also subject to corrosion damage. Equipment service life was shortened to about 8 to 10 years, and annual equipment replacement and maintenance costs exceeded RMB 500,000.
Third, fouling also created operational risks. Due to surrounding industrial enterprises, dust, industrial powder and oil stains easily accumulated on equipment surfaces, especially on insulators. This contamination layer reduced insulation performance and increased the risk of pollution flashover. It also increased manual cleaning frequency, with annual labor maintenance costs exceeding RMB 300,000. High-altitude cleaning also created safety hazards.
Previously, the substation mainly used traditional protection methods, including ordinary anti-fouling coating on insulators, anti-rust paint on metal equipment and manual de-icing in winter. However, these methods had limited protection performance, short service life and complicated maintenance procedures. A long-lasting, integrated and convenient protection solution was urgently needed.
Project introduction
Based on the substation’s core pain points and equipment protection requirements, Yingcai New Materials formed a professional technical team to conduct an on-site survey, inspect the operating condition of the equipment and develop a customized integrated anti-icing, anti-corrosion and anti-fouling solution.
The solution adopted Yingcai’s special protective coating for electrical equipment, featuring a three-in-one formula for anti-icing, anti-corrosion and anti-fouling performance. Combined with a standardized construction process, it provided full-scenario and all-round protection for outdoor equipment without modifying the original power equipment, balancing protection performance and economic efficiency.
Core Product Selection:
Yingcai integrated anti-icing, anti-corrosion and anti-fouling coating for electrical equipment was selected for this project. Based on nano-modification technology, the coating provides three major functions.
For anti-icing, the coating creates a hydrophobic and ice-repellent surface, lowering the freezing point to -35°C. Snow and rain are less likely to adhere to the surface, and ice can fall off more easily after formation.
For anti-corrosion, the coating forms a dense protective film that resists wind, sand, rain and snow corrosion. It is suitable for multiple materials such as metal and ceramic surfaces.
For anti-fouling, the smooth surface resists dust and oil stains. Contaminants can be naturally washed away by rainwater, reducing the need for frequent manual cleaning.
The coating also has strong resistance to high and low temperatures and ultraviolet exposure, with a service life of more than 10 years.
Construction Deployment:
According to the operating characteristics of the substation equipment, the project adopted a zoned and time-scheduled construction model to avoid affecting normal power supply.
Before construction, the equipment surfaces were derusted, cleaned and dried to ensure strong coating adhesion. Professional high-pressure spraying equipment was then used to evenly coat insulators, equipment housings, brackets and other components. The coating thickness was controlled at 30–50μm to ensure consistent protection performance.
After construction, strict inspection was carried out to ensure that there was no missed spraying, peeling or delamination.
Adaptability Advantages:
The solution required no modification to the original electrical equipment and could be directly applied to various outdoor equipment materials, including metal, ceramic and composite materials. The construction efficiency was high, and the whole project was completed within only 15 days, greatly reducing the impact on power supply.
The product contains no toxic or harmful substances, complies with environmental requirements in the power industry, and ensures a safe and pollution-free construction process.
Customer value
After 12 months of operation, continuous monitoring by the substation maintenance team showed that Yingcai’s anti-icing, anti-corrosion and anti-fouling solution fully met the expected performance. It effectively solved the three major problems of equipment icing, corrosion and contamination, delivering significant benefits in safety, economy, operation and maintenance, and environmental protection.
Safety Benefits:
The solution thoroughly solved winter equipment icing flashover and pollution flashover problems. Equipment failures were reduced from 8–10 times per year to less than once per year, with the failure rate reduced by more than 90%.
It also effectively prevented equipment corrosion and damage, avoiding power supply failures caused by equipment aging. The reliability of regional power supply increased to 99.98%.
Economic Benefits:
The solution significantly reduced equipment maintenance and replacement costs. Annual manual cleaning costs decreased from RMB 300,000 to RMB 50,000, while equipment repair and replacement costs decreased from RMB 500,000 to RMB 150,000. Annual operation and maintenance savings reached approximately RMB 600,000.
The coating extended equipment service life from 8–10 years to an estimated 18–20 years, saving more than RMB 3 million in long-term equipment replacement investment.
In addition, the reduction in power outage losses brought further economic value. Each outage previously caused an estimated loss of about RMB 200,000, and annual outage losses were reduced by more than RMB 1.6 million.
Operation and Maintenance Benefits:
The solution simplified the maintenance process. Manual cleaning frequency was reduced from twice per month to once per quarter, greatly reducing the workload of maintenance personnel and safety risks associated with high-altitude operations.
With a coating service life of more than 10 years, frequent recoating is not required. Maintenance efficiency increased by more than 80%, significantly reducing the maintenance pressure of the substation.
Environmental Benefits:
The core product uses a degradable and environmentally friendly formula without toxic or harmful substances. It causes no environmental pollution during construction or use, meeting China’s dual-carbon goals and the green development requirements of the power industry.
The solution also reduces dust pollution caused by manual cleaning and lowers environmental pressure during maintenance, achieving green protection and green operation.
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1.Project background
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2.Project introduction
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3.Customer value
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