Adoption of Polymer Insulator in GETCO Field Experiences and Improvements

A A Joshi DE (Engg); D H Kalsaria JE (Transmission)

Gujarat Energy Transmission Corporation Limited (GETCO)

PREAMBLE: Though the use of Polymer Insulators in Transmission lines is not new in USA and many western countries, its acceptance and adoption has been limited and cautious in Indian context. It is amply proved that the polymer insulators have inherent superior quality of Hydrophobicity & better performance in polluted environment compared to porcelain insulators, however Indian utilities have been debating on material integrity and its longevity because manufacturers were not sharing composition of material. Negative feedbacks like birds and animals eating them, fast deterioration of fiber rods due to moisture and high cost around 2000-01 did not encourage Indian utilities, even though they were well aware of polymer insulators superiority. Gujarat and GETCO are bestowed with 1600 km. of coastal line and its saline weather conditions make severe impact (pollution particles sticking on surface) on insulator performance for its dielectric characteristic resulting in to leakage current and flash over of a string. GETCO introduced Polymer Insulators (Silicon Rubber Insulator) in transmission lines in 2005-06. This paper captures the genesis of decision taken by GETCO to adopt polymer insulators and analyze field experience for improvement in specification, testing and installation. GETCO Transmission System: The population of various class of SRIs in GETCO system as on date is as under,

GETCO was compelled to adopt on pilot basis the use of polymer insulator because of frequent trippings of lines in coastal areas of kutchh. The good result from this pilot project and other market conditions like scarcity of antifog insulators and cost competitiveness in 2006-07 made a platform to go for polymer insulator in existing lines close to coastal as replacement to increase system availability and maintain uninterrupted power supply to distribution companies and their consumers.
GETCO is State Transmission Utility having wide spread transmission network operating with 66 kV to 400 kV transmission lines effected by saline weather in coastal areas, chemical and ceramic industrial units in various parts of state. To improve network availability and customer satisfaction, minimization of interruption is a need of time. Looking to the same, use of Silicon Rubber Insulators in coastal and polluted areas was decided by GETCO. EHV Transmission Lines Voltage Class 400 kV 220 kV 132 kV 66 kV Total Length of line in cktkM (as on 31.03.12) 3187 14852 4807 22099 44945

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Voltage Class

Ckt-km with SRI

788 (25%) 6737 (45%) 132 kV 1391 12230 6890 (29%) 66 kV 3672 47696 34058 (17%) Total *** 124146 75602 S Suspension type; T Tension type

400 kV 220 kV

Number of S.R.I.s (as on 31.10.2012) S T 8210 6144 56010 28510

(fig. 1)

Installation of polymer insulator in large number as replacement in old line having badly deteriorated porcelain insulators for last five years is on account of higher

system availability recorded in the operation of grid in Gujarat. Now, GETCO is going for polymer insulators in all new lines inside the coastal belt.

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Performance assessment of polymer insulators was carried out for year 200809 and 2009-10 based on trippings of lines. The major root cause for tripping of lines is insulator failure as shown in fig.1

(fig. 2)

We also found that more than 30% of such insulator failures were in coastal and chemically polluted areas. Among voltage class, 220 kV lines were affected in large numbers (more than 50%). We had replaced insulators in 86 nos. of lines in various parts of states as shown in fig. 2 Our analysis (figure 3 below) shows that trippings in transmission lines dropped from 565 to 419 between 2008-09 and

2009-10 on account of insulator failure, but important point to note here is that trippings in coastal / chemical pollution affected areas out of 565 and 419 dropped from 172 to 4. this was noticeable improvement enhancing system availability and GETCO decided to adopt polymer insulators.

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(fig. 3)

We also carried out simultaneously the analysis of polymer insulator failure in our grid to improve upon specification and testing requirement. Some cases are as follows, Case Study 1:Silicon Rubber Insulators were installed on 132 kV Sikka Jamnagar line located in Saurashtra region in year 2007 by replacing existing porcelain insulators. Within short service span, interruptions were observed on said line.

Observations are 1) Flash over observed Suspension insulators. on

2) White marks observed on flashed insulator sheds. 3) Decolouring of sheds observed. Following tests performed as a part of failure analysis & results are as

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Type of test

Observed values on flashed insulator 0.5922 mA @ 132 kV rms 438 kV rms

Type of test Dye penetration Water diffusion test Brittle fracture resistance

Observed values No dye rise within 15 minutes 12 kV withstood for 1 minute No crack or deformation

Leakage current Dry power frequency voltage flashover test Wet power frequency voltage flashover test Salt Fog pollution withstand test

300 kV rms

Root cause of failure could be improper handling during transit or erection Case Study 3:After providing SRI on 220 kV Vapi Tarapore line of southern Gujarat, decapping of socket end fitting was observed in 2011.

Withstood

Flash over of suspension SRIs were attributed to 1) large bird droppings on insulators 2) insufficient creepage of 25 mm/kV Case Study 2:During replacement of porcelain insulator in 220 kV Tappar - Nanikhakhar line and Dhokadwa - Timbdi line of Kutchh and Saurashtra region in 2009, Mechanical Failure took place & SRI found broken in two pieces. Following tests carried out on FRP rod of broken SRI as a part of failure analysis, 1) Dye penetration test, Water diffusion test, Brittle fracture resistance test Tests results are as

Probable cause of failure was improper crimping of end fittings.

Changes made in specifications: Following changes are made in GETCO specifications since 2007 1) To increase creepage distance requirement from 25 mm/kV to 31 mm/kV. 2) Introduction of Electric Field Modeling test for analyzing optimum position of corona control ring. 3) Introduction of 5000 Hrs. multi stress test to ascertain housing material life.

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4) Introduction of power arc test to ensure insulator strength subjected to heavy fault current arc. 5) To use plain profile only & avoidance of under ribs. 6) End fitting crimping with acoustic method prior to injection moulding of weather sheds. 7) Use of housing material overlapping end fittings in place of end sealing. 8) Use of injection moulding of weather sheds in place of insertion of premoulded weather sheds.

Acknowledgement: The authors are grateful to the GETCO management for granting permission to publish this paper.

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