This document summarizes a project where Sylgard HVIC coating was applied to electrical equipment at the Kalpaka 400 kvSS substation in Visakhapatnam, India over the course of 60 days in 2004-2005. Around 660 kg of Sylgard HVIC was applied to 49 pieces of equipment including current transformers, circuit breakers, insulators, and other equipment. Safety precautions were taken due to working at heights over 20 meters. The project was completed on time and within budget estimates.

1. Sylgard HVIC in Pictures
®
• Location: Kalpaka 400 kvSS,
Visakhapatnam
• Client: APTRANSCO
• Duration: 60 days (2004-05)
• Quantity: 660 kgs
• Section: Bus Coupler 2 Bay
• Number of Equipments: 49

2. A bird’s eye view of Bus Coupler 2
Bay at Kalpaka 400 kvSS
Note the
Sylgard
HVIC
coated
equipments
in white,
visible in
the evening
at 1700
hours from
the watch
tower

3. A sectional view of the equipments coated with
Sylgard HVIC at Kalpaka Bus Coupler 2 Bay
•Current
transformers (6)
•Circuit Breakers (3)
•Support Post
Insulators (13)
•Pantograph
isolators (6)
•Pilot Strings (9)
•Double Tension
Insulators (12)
The figures in the
brackets indicate
the number of
equipments of each
type that were
coated with Sylgard
HVIC.

4. A sectional view of the equipments coated with
Sylgard HVIC at Kalpaka Bus Coupler 2 Bay
Support Posts
Double Pilots
CTs in a row
CBs Double Tension
Pentagraphs

5. Breathtaking View of Kalpaka Bus Coupler 2 Bay
at 8.45 pm. Sylgard HVIC Application in progress
Sometimes, Sylgard HVIC application went on until 21.00 hours in the floodlights available at the site. In
all, close to 50 equipments were coated with Sylgard by skilled painters trained for the job. Normal
working hours for the application was 10.00 to 17.00 hours, but depending on line clear availability, the
work was carried out until 21.00 hours to meet the deadline for completion of the job.

6. Sylgard HVIC on a Support Post
A close-up

7. Sylgard HVIC on Double Pilots and Double
Tension Strings at Kalpaka 400 kvSS

8. Sylgard HVIC on a CT
A close-up

9. Safety at Work
As the Sylgard HVIC
application involved
coating suspension
and pilot insulators at
a height of over 20
meters, full attention
was paid to fall
protection and safety
training imparted by
PN Safetech, Mumbai.
A complete set of
lanyards, fall arresters,
organic Vapour masks,
and lifelines were used
to carry out the
application of over
400 kgs of Sylgard
HVIC on the pilot and
tension strings over a
period of one month.

10. Safety at Work
Muhammad Ali (L) and Dharma Rao (R), Painters underwent 24 hours of field training
on the use of safety equipments from the safety trainers of PN Safetch, Fall Protection
Specialists.

11. Pictures of Work-In-Progress
Application of Sylgard HVIC at APTRANSCO
Kalpaka 400 kvSS Bus Coupler 2 Bay
Compressors 5 HP (2 Nos), EPCOAT GUNS with 2.2 nozzles, Hose pipes extending 50 metres long,
ladders, safety equipments, etc alongwith painters, trained linemen, and coating supervisors were
regular at the site for over a month. Kalpaka became their second home, with work extending upto 21
hours on some days.

12. Empty Pails of Sylgard HVIC in the
Kalpaka Store
A total of 147 pails of 4.5 kg pails of Sylgard HVIC was used for the project. After the first few days, practical estimates of
consumption per type of equipment was finalized and were matched with the initial estimates, and they were pretty close.

13. Lady in Sylgard white

14. Special Thanks
• Our special thanks goes to
– Mr. Nitin Kamat, Industry Sales Manager, Dow
Corning India (P) Limited, Mumbai for his persistent
support, without which the project could not have
been started or completed.
– Mr. Venkatraman, Sales Manager, EEI, Dow Corning
India (P) Limited, Mumbai
The Pentasafe Team of Mr. Nair and Tejus, Painters
Dharma and Ali, Coating Supervisor Dilip Nair of Project
Sales Corp, and all Kalpaka 400 kvSS staff-members.