Dry Ice Blasting The Insulators At Constellium's Substation

Substations are the backbone of any industrial power system, and Constellium’s substation is no exception. Over time, the ceramic and composite insulators in these environments are exposed to:

• Dust and industrial residue
• Pollution and airborne contaminants
• Bird droppings and organic buildup
• Moisture, grime, and surface tracking

All of this contamination can reduce the effectiveness of insulators, increasing the risk of:

• Partial discharges
• Tracking and flashovers
• Unplanned outages
• Equipment damage

Constellium brought in Haztech Surface Solutions to carry out a thorough, efficient cleaning of the substation insulators using dry ice blasting — a method that minimizes risk to sensitive equipment while delivering powerful results.

Why Insulator Cleaning Is So Critical

Insulators are designed to separate energized components and keep electricity where it belongs. When they’re clean and in good condition, they do their job quietly in the background. But when contamination builds up, the risk to the whole system goes up.

Dirty insulators can lead to:

• Leakage currents along contaminated surfaces
• Arcing or flashover, especially during wet or humid conditions
• Decreased reliability, causing nuisance trips or major failures

For a facility like Constellium, which relies on stable, uninterrupted power for production, the stakes are high. Proactive insulator cleaning is a key part of preventive maintenance, helping avoid costly interruptions, repairs, and safety incidents.

Why Haztech Chose Dry Ice Blasting for This Substation

In a high-voltage environment, not just any cleaning method will do. Traditional approaches like water washing, abrasive blasting, or harsh chemicals can introduce new hazards or damage equipment.

Dry ice blasting offered several crucial advantages for this project:

1. Non-Conductive and Non-Abrasive

Dry ice blasting uses solid CO₂ pellets accelerated at high speed. On impact, the pellets fracture the contamination and then sublimate (turn directly into gas), lifting off grime without grinding down the surface.

For Constellium’s insulators, that meant:

• No conductive water or liquid around energized equipment
• No abrasion that could damage ceramic or composite materials
• Clean, restored surfaces without pitting, scratching, or erosion

2. No Secondary Waste or Slurry

Unlike sandblasting or water washing, dry ice blasting leaves behind no blasting media to sweep or shovel. The CO₂ simply turns into gas and dissipates.

The only cleanup required is the removed contamination itself, greatly reducing:

• Cleanup time
• Waste disposal needs
• Environmental impact

That’s a big benefit in tight, complex substation layouts where access is limited and every additional step adds risk.

3. Minimal Downtime and Smart Scheduling

Because the process is dry, contained, and targeted, Haztech could work around Constellium’s operating schedule and substation loading conditions.

This helped:

• Limit outages or switching requirements
• Avoid extended shutdowns
• Keep regular plant operations running smoothly

How the Project Was Planned and Executed

Working in and around high-voltage equipment requires strict procedures, clear communication, and trained personnel. For this project, Haztech followed a carefully planned process from start to finish.

Site Assessment and Planning

The project began with a detailed assessment of:

• The insulator types and locations
• Levels and patterns of contamination
• Clearance distances and access points
• Safety requirements and switching plans

Haztech collaborated closely with Constellium’s electrical maintenance and safety teams to:

• Identify which sections could be cleaned under specific conditions
• Plan safe working distances and barriers
• Determine the ideal sequence of work to minimize disruptions

Safety First: Lockout, Tagout, and Controls

Before any blasting started, Haztech implemented strict safety protocols, including:

• Lockout/tagout and switching procedures as needed
• Grounding and isolation where required
• Clearly marked work zones and barricades
• Use of PPE designed for both blasting and electrical environments

Safety wasn’t treated as a box to check — it was built into every step of the project.

Targeted Dry Ice Blasting on Insulators

With the plan in place, Haztech technicians went to work on:

• Line post insulators
• Station posts
• Bushings and support insulators
• Associated hardware and mounting points where contamination had accumulated

Using specialized nozzles and adjustable pressure, the team tailored the cleaning force to each surface, ensuring:

• Contaminants were removed without damaging the insulator body
• Metal fittings and hardware were cleaned effectively
• Nearby components were shielded as needed

This careful, controlled approach allowed for thorough cleaning without disturbing critical equipment.

Results: Cleaner Insulators, Reduced Risk, and Better Reliability

By the end of the project, the insulators at the Constellium Substation saw a dramatic improvement in cleanliness and visibility.

Visual and Functional Improvements

After dry ice blasting, surfaces that were previously dull, stained, or heavily coated with contamination were restored to a clean, uniform appearance. This:

• Reduced the risk of tracking and surface discharge
• Made it easier for technicians to inspect insulators for chips, cracks, or other damage
• Improved overall confidence in the insulation system during varying weather conditions

Support for Reliability and Uptime

Cleaner insulators help:

• Stabilize system performance
• Lower the likelihood of flashovers during storms, fog, or high humidity
• Reduce nuisance faults and trips that can interrupt production

For Constellium, that means greater operational reliability and fewer unexpected power-related issues.

Long-Term Maintenance Benefits

By removing years of layered contamination, Haztech helped reset the baseline for future inspections and cleaning. Now, Constellium’s team can:

• More easily monitor how quickly new contamination builds up
• Schedule future cleanings based on actual conditions, not guesswork
• Integrate insulator cleaning into a structured preventive maintenance program

What This Project Says About Haztech Surface Solutions

This substation project highlights several strengths Haztech brings to industrial and utility clients:

• Specialized expertise in dry ice blasting for electrical environments
• Safety-focused planning, especially around energized equipment
• Minimal downtime through smart scheduling and efficient work practices
• High-quality cleaning results that directly support system reliability

From substations and switchyards to industrial electrical rooms and control centers, Haztech understands how to balance cleanliness, safety, and uptime.

Considering Dry Ice Blasting for Your Electrical Assets?

If your substation insulators, switchgear enclosures, or electrical components are coated in grime, dust, or pollution, you don’t have to choose between “living with it” and risking damage with aggressive cleaning.

Dry ice blasting offers a powerful, dry, and non-abrasive option — especially when performed by a team that understands high-voltage environments.

Haztech Surface Solutions can help you:

• Assess the condition of your insulators and electrical assets
• Determine whether dry ice blasting is the right solution
• Plan a project that fits your safety standards and operating schedule

This recent work at the Constellium Substation demonstrates what’s possible: cleaner insulators, reduced risk, and stronger reliability without introducing water, chemicals, or unnecessary downtime.

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