Contracting

High Voltage Insulator Coating – HVIC

High Voltage Insulator Coating (HVIC)

RTV Silicone Coating for High Voltage System Reliability

S3C is proud to be a market leader in delivering innovative products and solutions to the energy sector, with a distinguished reputation as a pioneer of RTV silicone coating technology for high-voltage insulators. Through decades of technical expertise and successful project execution, S3C has established itself as one of the leading High Voltage Insulator Coating (HVIC) service providers in the Middle East.

High Voltage Insulator Coating (HVIC) is a single-component RTV silicone coating designed to enhance the performance and reliability of high-voltage transmission and distribution systems. The coating protects insulators against leakage current and flashovers caused by environmental contaminants such as salt fog in coastal regions, industrial emissions, desert dust, road salts, and other airborne pollutants. By maintaining a durable hydrophobic surface, HVIC significantly improves insulation performance while reducing maintenance requirements and unplanned outages.

Since completing its first HVIC project in 2000 at SEC Shoaiba Power Plant, S3C has accumulated over two decades of specialized experience in RTV silicone coating applications, becoming a recognized industry leader across the region. A landmark achievement was reached

in 2008 when S3C executed the world's largest HVIC project on the GCCIA 400 kV transmission network interconnecting Kuwait, Saudi Arabia, Bahrain, Qatar, and the UAE. To meet the project's challenging schedule, S3C established and simultaneously operated four coating facilities across three countries, demonstrating its capability to manage complex, large-scale international projects.

Today, S3C's HVIC services are performed in full compliance with applicable international and utility standards, including IEC, IEEE, CIGRÉ, and Saudi Energy (SE) requirements. Backed by a strategically maintained RTV coating inventory, dedicated workshop facilities, specialized equipment, and highly trained application teams, S3C provides responsive material supply, reliable project execution, and year-round support to customers throughout the GCC and neighboring regions. This combination of technical excellence, operational flexibility, and proven field experience continues to position S3C as a trusted partner for utilities seeking to improve system reliability and asset longevity.

High voltage substation infrastructure
HVIC substation coating application

HVIC Substation Services

We have completed RTV Coating services over 500 substation projects, including:

  • Locations in Saudi Arabia, Qatar, Kuwait, UAE, Oman, Pakistan, Egypt and Turkey

  • BSPs, power plant switchyards, Refineries, GOSPs

  • Over 400 completely new distribution substations, Power Plants and BSPs

  • Hundreds of existing substations of SE, Saudi Aramco, SABIC, SWCC, Marafiq, Steel and Aluminum plants

  • Coating services for harmonic filters, reactor drums, and capacitor banks other than porcelain bushings

  • Voltage ranges of 13.8 kV to 500 kV including DC Converter stations of 500 kV HVDC systems

  • On-shore oil field substation protection
  • Over 400 completely new distribution substations and BSPs
  • Coating services for harmonic filters, reactor drums, and capacitor banks
  • Varying voltage ratings of 13.8 kV to 380 kV

HVIC Transmission Line Services

S3C has successfully completed RTV coating services for more than 100 high-voltage transmission line projects, utilizing both dedicated on-site facilities and its fully controlled workshop. Designed to accommodate insulators of all sizes, the workshop provides a dust-free coating environment that meets the latest requirements and quality standards of the power utility industry.

To ensure consistent coating quality, S3C has developed proprietary in-house machinery capable of applying RTV coatings with uniform Dry Film Thickness (DFT) and superior surface finish. The coating process is conducted in an environmentally responsible manner using extraction and filtration systems that effectively capture and filter overspray.

S3C also maintains highly trained and experienced field crews capable of executing coating activities safely and efficiently at project sites. The majority of these transmission line projects have been carried out in Saudi Arabia, supporting both new 380 kV AC and 500 kV HVDC transmission line developments, as well as refurbishment programs involving the replacement and recoating of insulators on existing transmission networks. In addition, S3C has successfully completed numerous transmission line coating projects for utilities such as Kahramaa in Qatar and the Ministry of Electricity & Water (MEW) in Kuwait, further demonstrating its regional expertise and capability in delivering large-scale HVIC solutions. S3C HVIC transmission projects have included:

  • More than 200,000 long-rod ceramic insulators

  • More than 2,000,000 hardened glass and porcelain disc insulators, including both fog-type and aerodynamic designs, ranging from 120 kN to 420 kN

  • Voltage range of 66kV to 400 kV AC and 500 kV DC.

  • Capacity to coat around 400 long-rod insulators and 2,800-disc insulators per day

S3Cs controlled workshop facility is capable of handling high-voltage equipment and insulators of any size.The high-voltage equipment and insulators are coated in a dust-proof environment to meet the latest requirements of power utility industries. Moreover, S3C has a crew specially trained to execute the job on-site.

  • +100,000 long rod insulators
  • +2,000,000 disc insulators
  • Varying voltage ratings of 66 kV to 400 kV AC and 500 kV DC
  • Capacity to handle 1000 LR and 6000 Disc insulators per day
HVIC Transmission Line Services