POLYWATER® POWERPATCH®

LEAK REPAIR

DESCRIPTION
The PowerPatch® Sealant System provides a fast
and effective “in-field” leak repair for transformers,
PILC cables, and other oil and gas insulated
electrical equipment.
PowerPatch repairs active leaks with a two-part
putty followed by a strong, durable sealant.
PowerPatch provides permanent protection for
essential electrical grid assets.
PowerPatch is a field-ready system and includes
all the materials required to seal electrical
insulating oil and gas leaks. It bonds to
PowerPatch provides a fast and easy in-field repair system.
polyethylene, lead, aluminum, ceramic, and steel.

LEAK SEALING PERFORMANCE PRODUCT FEATURES

To test gas pressure sealing, a 1/16-inch hole was • Fast Repair: Stops active leaks without
patched. Sealant was applied to a prepared shutting down equipment.
surface and cured according to instructions. The • Convenient: Seals active leaks in minutes.
repair was then subjected to continuous air Also eliminates “bagging” of transformers during
pressure for 24 hours. transit.
MATERIAL PRESSURE RESULT • Resilient: Seal is UV and weather resistant for
Steel 200 psi (1.4 MPa) No leaks long-term durability.
HDPE 35 psi (0.24 MPa) No leaks
• High Adhesion: Adheres to numerous types of
Lead 50 psi (0.35 MPa) No leaks
metals, porcelain, and rubber materials.
To test oil sealing, a 1/16-inch hole in a Chemically Inert: Will not affect oils, solid
galvanized steel pipe filled with oil was patched. insulation, or other equipment.
The surface was prepared, and sealant was
applied and cured according to the instructions.
The oil-filled pipe was then subjected to
END USE
continuous air pressure. PowerPatch Sealant repairs oil and SF6 leaks and
restores electrical integrity to:
CONTINUOUS PRESSURE RESULT
Polybutene oil, 100 psi (0.69 MPa) No leaks • Transformers
one month
• Switchgear
PowerPatch Sealant shows good adhesion and no • Terminations
leakage under high pressure with both air and
polybutene oil. • PILC Cables
COMPONENT PHYSICAL PROPERTIES ELECTRICAL TESTING
PowerPatch Sealant is a 2-part thick gel, sold PowerPatch Sealant is non-conductive. Dielectric
ready to mix and use. strength was tested using a 2,000 volts/second rate
of rise and type 3 circular electrodes with a 0.25-
PROPERTY PART A PART B
inch diameter. All tests were performed in insulating
Color Black White
oil to prevent discharges and flashovers.
Form Thick gel Thick gel
SAMPLE BREAKDOWN DIELECTRIC
VOC content 0 g/L 0 g/L
THICKNESS VOLTAGE STRENGTH
Specific gravity 1.7 1.4 0.0916 Inch 43 kV 469 Volts/Mil
Tested using ASTM D149, Method A. Platen samples are cast and fully
CURED PROPERTIES cured. Results are the average of 10 trials.

PowerPatch Sealant cures to form a solid patch. MATERIALS COMPATIBILITY

Sealant has excellent strength and adhesion as
PowerPatch is compatible with electrical insulating
described below.
mineral oil.
PROPERTY RESULT
SAMPLE CONTROL
Color Dark grey TEST
OIL OIL
Peak exotherm @ 70°F/20°C <200°F (<95°C) Color, ASTM 1500 L 0.5 L 0.5
Hardness 7 days @ 70°F/20°C 79-89 Dielectric strength, 46 41
(Shore D Durometer) ASTM D877, kV
Flexural stress (ASTM D790) 6,925 lbf/in2 Interfacial tension, 40 43
(47.7 MPa) ASTM D971, mN/m
Flexural strain (ASTM D790) 1.43 x 10-2 in/in Neutralization number, <0.01 <0.01
(mm/mm) ASTM D974, mg KOH/g
Power factor @ 100°C, 0.236 0.480
TYPICAL T-PEEL STRENGTH ASTM D924, %
Tested using ASTM D3455 using Ergon Hyvolt II Mineral Oil. 14 grams
SUBSTRATE RESULT PowerPatch is immersed in the oil and aged for 164 hours at 100°C.
Oil is tested and compared to the control sample.
Galvanized steel 34.0 pli (6.0 N/mm)
Copper 21.4 pli (3.7 N/mm) This testing showed very little change in oil quality.
Lead 15 pli (2.6 N/mm) The IFT and dielectric of the sample oil are greater
Tested using ASTM D1876. Samples are sanded, cleaned, and than 35, the neutralization value is below 0.03, and
allowed to cure for 7 days. the power factor is below 0.8%. Results are
considered acceptable by industry experts.
TYPICAL SHEAR STRENGTH
SUBSTRATE RESULT CHEMICAL RESISTANCE
Steel 850 lb/in2 (5.9 N/mm2) PowerPatch resists dielectric fluids, SF6 gas,
Stainless steel 880 lb/in2 (6.0 N/mm2) ultraviolet light, water, and oil.
Aluminum 650 lb/in2 (4.5 N/mm2) PowerPatch was exposed to reagent and aged at
Polyethylene 120 lb/in2 (0.79 N/mm2) 50°C for 6 months. Adhesive strength to steel
PVC 150 lb/in2 (1.0 N/mm2) measured using ASTM D1002.
Copper 1,200 lb/in2 (8.3 N/mm2) APPEARANCE COMPARISON
FLUID*
Tested using ASTM D1002. Samples are sanded, cleaned, and (6 MONTHS) TO CONTROL
allowed to cure for 7 days.
Mineral oil No change 100% (Pass)
Polybutene fluid No change 100% (Pass)
TYPICAL IMPACT RESISTANCE
Hydrocarbon fluid No change 100% (Pass)
SUBSTRATE RESULT Silicone oil No change 100% (Pass)
HDPE 15 ft·lbf/in2 (31 kJ/m2) *Mineral Oil (Holland 70), Polybutene (Duddek PLIC), Hydrocarbon Fluid (Bio
Lead 36 ft·lbf/in2 (76 kJ/m2) Temp), Silicone Oil (GE Silicone SF 96-100)

Steel 33 ft·lbf/in2 (69 kJ/m2)

Tested using ASTM G14. Samples are sanded, cleaned, and allowed
to cure for 7 days.
APPLICATION PAINT ADHERENCE
PowerPatch Sealant is easy to use. For full PowerPatch Sealant can be painted 15 minutes
installation information, please see PowerPatch after application. In this test, the paste is applied,
Use Instructions. painted, and allowed to dry for 24 hours. Then, a
cross-cut tape test is run.
Each kit contains material to repair a standard
leak area or seam. Below is the coverage area. PAINT TYPE RESULT
COVERAGE Enamel paint 0% paint removed
PACKAGE
AT ¼-IN (6 MM) DEPTH Alkyd paint 0% paint removed
EPCT-50 cartridge 13 x 1-inch (33 x 2.5 cm) bead Tested using ASTM D3359, Test Method B.
EPCT-250 cartridge 65 x 1-inch (165 x 2.5 cm)
bead Both paints adhere well to the PowerPatch Sealant.
EP paste 18 x 1-inch (46 x 2.5 cm) bead
ENVIRONMENTAL RESISTANCE
In cold weather, PowerPatch should be kept as
warm as possible. Store in a warm vehicle and Temperature Range:
use chemical warming pad to increase the Application: 40°F to 120°F (4°C to 50°C)
temperature of the repair surface. In Use: -40°F to 300°F (-40°C to 150°C)

CURE RATE PowerPatch works in extreme temperatures. A seal

tested to 30 psi (207 kPa) at 300°F (150°C) and
Recommended application temperature is 40°F to then at -40°F (-40°C) held without failure.
120°F (4°C to 50°C). Cure rate is temperature
dependent. Temperature Cycle Testing:
Ten cycles at -5°F to 120°F (-20°C to 50°C) showed
WORKING FUNCTIONAL no significant change in adhesion. Lap shear
TEMPERATURE
TIME CURE strength was measured after aging and compared to
40°F (4°C) 40 minutes 7 hours a non-aged control as shown below.
52°F (11°C) 20 minutes 3½ hours
COMPARISON TO
60°F (16°C) 10 minutes 1½ hours MATERIAL RESULT
CONTROL
70°F (20°C) 6 minutes 60 minutes Galvanized steel 84% Pass
90°F (32°C) 4 minutes 40 minutes Aluminum 73% Pass
Copper 130% Pass
An oil pressure test was used to determine
effective seal time under ambient conditions. Stainless steel 131% Pass

AGING CONDITION RESULT PowerPatch Sealant is resistant to ultraviolet

Ambient (70°F/20°C) Holds 20 psi oil pressure exposure and withstands direct sunlight with no
after 15 minutes decrease in functionality.
The seal sets in less than 10 minutes at this PowerPatch has been environmentally aged in
temperature. extreme conditions including rain, snow, sleet,
VERTICAL SAG direct exposure to sunlight, and a temperature
range from -25°F to 110°F (-30°C to 45°C).
PowerPatch Sealant clings to vertical surfaces
and other non-horizontal angles common in field PowerPatch shows no deterioration and cannot be
repairs. Once applied, it stays in place. physically pried from the surface. It shows only
slight discoloration (1/16 inch/1.6 mm thickness).
To test, PowerPatch is applied to a vertical metal
surface. Displacement during cure is measured.
SAFETY
DISPLACEMENT FROM
TEMPERATURE PowerPatch Sealant has a low level of toxicity.
CENTER
60°F (16°C) 0 inches (0 mm) Follow good industrial hygiene practice during use.
75°F (24°C) 1/16 inch (1.6 mm)
Wear gloves and safety goggles to protect skin and
eyes. Use ventilation or respiratory protection
95°F (35°C) 3/32 inch (2.4 mm)
against decomposition products during
110°F (43°C) 3/16 inch (4.8 mm) welding/flame operations on or near cured product
PowerPatch Paste shows minimal sag within large (e.g., torches used to install heat shrink products).
temperature range. See SDS for specific details.
STORAGE AND HANDLING ORDER INFORMATION
Keep containers cool, dry, and away from CAT # PACKAGE DESCRIPTION
sunlight. Keep containers tightly closed. EPCT-KIT1 2 – PowerPatch Sealant
multi-use 2-part 50-ml cartridges
Product shelf life is 15 months. cartridge kit 4 – Mixing Nozzles
2 – 1¾-in/4 cm Putty Stick
MODEL SPECIFICATION 8 – Type RP™ Cleaning Wipes
1 – 24-in/61 cm Sanding Cloth
The statement below may be inserted into a 4 – Application Sticks
customer specification to help maintain engineering 1 – Instruction Sheet
standards and ensure work integrity. EPCT-KITB6 A box with 6 EPCT-KIT1

EPCT-KIT1G EPCT-KIT1 with

Approved electrical repair compound is dispensing tool
PowerPatch® Sealant. The electrical repair EPCT-KITB6G Case of 6 EPCT-KIT1 with dispensing
compound shall come in a system that contains tool
everything needed for the repairs. The system TOOL-50-11 Dispensing Tool
shall repair active oil leaks. The sealant shall not
sag during cure so that it may be applied to the EP-KIT11 1 – 2-part PowerPatch Sealant Paste
bottom side of leaking surfaces without running or (parts A and B)
1 – 1¾-in/4 cm Putty Stick
dripping. 2 – Type RP Cleaning Wipes
The adhesive repair patch shall have excellent 1 – 12-in/61 cm Sanding Cloth
2 – Mixing Sticks
adhesion to a variety of substrates with minimum 1 – Pair Disposable Gloves
T-peel strength of 20 pli (2.3 N-m) on stainless 1 – Instruction Sheet
steel, copper, and ceramic when measured by EP-KITB6 Case of 6 Single-use Kits,
ASTM D1876. The adhesive repair patch will EP-KIT11
retain 70% of its shear strength adhesion after 5 EP-KITB12 Case of 12 Single-use Kits,
freeze/thaw cycles and shall withstand in-use EP-KIT11
temperatures from -40°F to 300°F (-40°C to EP-KIT51 6 – 2-part Sealant Sets (part A & B)
PowerPatch Sealant
150°C). 1 – 7-in/18 cm Putty Stick
The adhesive repair patch shall seal mineral oil 12 – Type RP Cleaning Wipes
6 – 24-in/61 cm Sanding Strips
and polybutene dielectric fluid at up to 200 psi 12 – Mixing Sticks
(1380 kPa) oil pressure without leakage. It shall 6 – Pairs Disposable Gloves
be compatible with insulating oil. The cured repair 1 – Instruction Sheet
patch shall be impervious to water, salt water, oils, EPCT-250KIT1 1 – PowerPatch Sealant
2-part 250-ml Cartridge
and dilute acids and bases.
3 – Mixing Nozzles
The adhesive patch shall not contain any metals 2 – 1¾-in/4 cm Putty Stick
6 – Type RP Cleaning Wipes
and shall not corrode. It shall be non-conductive
1 – 24-in/61 cm Sanding Strip
with a minimum dielectric breakdown voltage of 3 – Application Sticks
40 kV as measured by ASTM D149. 1 – Instruction Sheet

CONTACT US
+1-651-430-2270 Main | Europe, Middle East, North Africa +31 10 233 0578 | email: support@polywater.com
IMPORTANT NOTICE: The statements here are made in good faith based on tests and observations we believe to be reliable. However, the completeness and accuracy of the information is not
guaranteed. Before using, the end- user should conduct whatever evaluations are necessary to determine that the product is suitable for the intended use.
American Polywater expressly disclaims any implied warranties and conditions of merchantability and fitness for a particular purpose. American Polywater’s only obligation shall be to
replace such quantity of the product proven to be defective. Except for the replacement remedy, American Polywater shall not be liable for any loss, injury, or direct, indirect,
or consequential damages resulting from product’s use, regardless of the legal theory asserted.

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