Transmission Insulator Specification

TRANSMISSION MATERIALS STANDARD SPECIFICATION
15-TMSS-02, Rev. 0
PAGE NO. 2 OF 15 15TMSS02R0/MAA

Date of Approval: April 9, 2006
TABLE OF CONTENTS

1.0 SCOPE

2.0 CROSS REFERENCES

3.0 APPLICABLE CODES AND STANDARDS

4.0 DESIGN AND CONSTRUCTION REQUIREMENTS

4.1 General
4.2 Design Criteria
4.3 Ratings
4.4 Materials
4.5 Fabrication
4.6 Dimensions
4.7 Markings

5.0 TESTS

6.0 DATA SCHEDULE

15-TMSS-02, Rev. 0

1.0 SCOPE

This Transmission Material Standard Specification (TMSS) specifies the minimum technical
requirements for design, engineering, manufacture, inspection, testing and performance of
porcelain and toughened glass suspension insulators intended to be used on the overhead
transmission line system of Saudi Electricity Company (SEC), Saudi Arabia.

2.0 CROSS REFERENCES

This Material Standard Specification shall always be read in conjunction with the latest
revision of SEC General Specification No. 01-TMSS-01, titled "General Requirements for
All Transmission Equipment/Materials", which shall be considered as an integral part of this
TMSS.

This TMSS shall also be read in conjunction with SEC Purchase Order or Contract
Schedules for project, as applicable.


The latest revision/amendments of the following Codes and Standards shall be applicable for
the equipment/material covered in this TMSS. In case of conflict, the vendor/manufacturer
may propose equipment/material conforming to one group of Industry Codes and Standards
quoted hereunder without jeopardizing the requirements of this TMSS.

3.1 IEC 60120 Dimensions of ball and socket couplings of string insulator units

3.2 IEC 60372 Locking Devices for ball and socket couplings of string insulator units
- Dimensions and tests.

3.3 IEC 60383-1 Insulators for overhead lines with a nominal voltage above 1000V,
Part 1: Ceramic or glass insulator units for a.c systems-Definitions,
test method and acceptance criteria

3.4 IEC 60383-2 Insulators for overhead lines with a nominal voltage above 1000V,
Part 2: Insulator strings and insulator sets for a.c systems -
Definitions, test methods and acceptance criteria

3.5 IEC 60507 Artificial pollution tests on high voltage insulators to be used on a.c.
systems

3.6 IEC 61467 Insulators for overhead lines with a nominal voltage above 1000V-
AC power arc tests on insulator sets

3.7 IEC 61211 Insulators of ceramic material or glass for overhead lines with a
nominal voltage greater than 1000V-Impulse puncture testing in air

3.8 ANSI C29.1 Test Methods for Electrical Power Insulators

15-TMSS-02, Rev. 0


3.9 ANSI C29.2 Insulator, Wet-Process Porcelain and Toughened Glass, Suspension
Type

3.10 ASTM C151 Test Method for Autoclave Expansion of Portland Cement


4.1 General

4.1.1 The wet-process aluminous porcelain or toughened glass suspension
insulators shall meet or exceed the requirements of this specification in all
respects.

4.1.2 The manufacturers design drawings, as required in 01-TMSS-01, shall
show the outline of the suspension insulators, together with all pertinent
dimensions. Any variations in these dimensions due to manufacturing
tolerances shall be indicated.

4.2 Design Criteria

4.2.1 Service conditions referenced in 01-TMSS-01 shall be the basis of design
criteria.

4.2.2 The wet-process aluminous porcelain or toughened glass insulator design
shall be antifog, superfog, or aero form (open profile) type with ball and
socket couplings. These shall be designed to withstand water jet pressure of
3800 kPa.

4.2.3 The ball and socket couplings of all insulators must be ANSI or IEC
compatible.

4.2.4 The metal parts and the porcelain or glass parts shall be movable in relation
to each other to avoid large mechanical stresses due to difference in
coefficient of thermal expansion of the metallic parts, cement and the
porcelain or glass materials. Thus, the metal cap shall move up and down,
in an elastic manner under the external tension load, on the sloping surface
of the adjacent cement. The metal pin shall act in the same manner.

15-TMSS-02, Rev. 0

4.3 Ratings

The wet-process aluminous porcelain or toughened glass suspension insulators shall
have the minimum ratings as indicated in Table 1:

Table 1: Minimum ratings for Insulators

Aero Form
Ratings
Fog/Super Fog
(Porcelain and
Toughened Glass)
Porcelain
Toughened
Glass
Combined Mechanical and
Electrical (M&E) Strength,
kN
111/160/210* 111/160/210* 111/160/210*
Tension Proof Load 50% of specified M&E Rating
Dry 95 80 65/75/75
Low Frequency
Flashover, kV
Wet 55 50 50
Positive 135 105 95/105/105
Critical Impulse
Flashover, kV
Negative 145 105 95/105/105
Low Frequency Puncture
Voltage, kV
110/110/125
RIV Low Frequency Test
Voltage (rms to ground), kV
10
Maximum RIV at 1000kHz,
V
50
Residual strength after
maximum loadings
70% of rated M&E
* Refer to Data Schedule

4.4 Materials

All insulator shells shall be sound and free from defects that might adversely affect
the insulator. Metal parts, except for cotter keys, shall be made of the best
commercial grade of malleable iron, ductile iron or steel, galvanized in accordance
with 01-TMSS-01. The thickness of zinc coating on the insulator caps and pins shall
not be less than 0.110 mm (770 g/m) and 0.053 mm (381 g/ m) respectively.

Insulators shall be furnished with a positive locking device of the split cotter key
type. The cotter keys shall be made of bronze, brass or austenitic stainless steel. In
addition, specific requirements as stated below shall be met.

15-TMSS-02, Rev. 0

4.4.1 Porcelain Insulators:

The insulator shells shall be made of the highest grade, dense,
homogeneous wet-process aluminous porcelain. The entire exposed wet-
process aluminous porcelain surface of the insulator shell shall be glazed,
relatively smooth and free from imperfections. The porcelain used shall be
non-porous with high dielectric strength, chemically inert and high fusion
point.
The color of the porcelain glaze shall be brown and of uniform coverage
and thickness.

Portland cement or Alumina cement shall be used as the bonding agent
between the wet-process porcelain and the metal parts. Sulfur based
cements shall not be used.

4.4.2 Toughened Glass Insulators

The entire glass surface of the insulator shell shall be toughened, smooth
and free from imperfections. The toughened glass used, shall have no
surface defects such as folds, blowholes, prejudicial to satisfactory
performance in service and there shall be no bubbles in the glass greater
than 5 mm in diameter.

Aluminous cement mortar shall be used as the bonding agent between the
toughened glass and the metal parts. Portland cement mortar may also be
used as the bonding agent but sulfur based Portland cements shall not be
used.

4.5 Fabrication

4.5.1 The hardware shall be cemented on the porcelain or glass with load
distribution evenly throughout the porcelain or glass. Before cementing,
the hardware surface in contact with the cement shall be coated with
bituminous compound.

4.5.2 The contours of the metal and porcelain or glass parts shall be such as to
eliminate areas of high electrical stress concentrations.

4.5.3 The axial, radial and angular displacements of the Insulator and their
verification shall be in accordance with IEC 60383-1

4.5.4 To inhibit the accelerated corrosion of insulator pin due to leakage currents,
a corrosion intercepting zinc sleeve fused to the pin shall be provided at the
point where the steel pin emerges from the cement.

4.5.5 Cotter keys shall be humped to maintain the key in the locked and unlocked
positions and shall have prongs spread to prevent complete withdrawal
from the socket. The design of the keys shall be such that their engagement

15-TMSS-02, Rev. 0

and disengagement can be achieved with the use of standard transmission
hot line tools without excessive force required.

4.5.6 For 111kN insulators, ball and socket couplings shall be Type J as per
ANSI C29.2 or Size 16A as per IEC 60120.

4.5.7 For 160kN and 210kN insulators, ball and socket couplings shall be Type K
as per ANSI C29.2 or Size 20 as per IEC 60120.

4.6 Dimensions

The dimensions of the suspension insulators shall be as specified in Data Schedule
and as shown in the Table 2:

Table 2

Minimum Leakage
Distance
(mm)
Maximum Shell
Diameter
(mm)
Nominal Spacing
Distance
(mm)
Minimum
M&E
Strength
(kN)
Fog
Super
Fog
Aero
Form
Fog
Super
Fog
Aero
Form
Fog
Super
Fog
Aero
Form
111 432 612 335 280 330 380 146 146 146
111 545 330 146
160 432 300 156
160 545 - 335 330 - 420 156 - 156
210 545 - 335 330 - 420 170 - 170
Note: While replacing insulators on existing transmission lines it must be ensured
that adequate clearances to tower/ground are maintained.

4.7 Markings

4.7.1 Each wet-process porcelain or toughened glass insulator shall bear a
durable marking in accordance with IEC or ANSI Standards, identifying
the following:

a. Manufacturer's Name
b. Year of Manufacture
c. Combined Mechanical and Electrical Strength, "M & E"
d. Tension Proof Test Load, "TEST"
e. Country of Origin

4.7.2 Crate or Pallet Marking (whichever is applicable)

a. Insulator Shell (Porcelain/Toughened Glass)
b. Insulator Type (Fog/Super Fog/Aerodynamic)

15-TMSS-02, Rev. 0

c. SEC Purchase Order Number/Contract Number
d. 15-TMSS-02, Rev.0
e. Manufacturers Catalog No.
f. Number of insulators in the Crate and the Pallet

The markings shall be legible and durable.

5.0 TESTS

All test results shall be provided for review and acceptance by SEC.

5.1 Type (Design) Tests

All type (design) tests prescribed in the relevant IEC or equivalent ANSI standards
shall be performed on the representative unit or on the first unit of every new design
or rating to be supplied to SEC.

In lieu of the actual design (type) tests, certified test reports of design (type) tests
performed on a unit of identical design and rating may be submitted to SEC for
review and approval during bidding stage.

In addition to the above IEC or ANSI type test requirements, the following type tests
shall be carried out on the insulators to be supplied under these specifications. The
tests shall be performed at manufacturers own laboratory in the presence of SEC
representative or at an accredited Independent Testing Laboratory. The test results
shall be considered valid for a period of five years only, after which these tests shall
be repeated in case of any further supply from the same manufacturer and from the
same manufacturing plant. These tests may also be repeated at any time within a five
years period, if SEC considers it necessary for a particular project as specified in
Data Schedule.

5.1.1 Thermal Mechanical Performance Test on string insulator units in
accordance with IEC 60383-1 except that the temperature variation shall
be minus five degrees centigrade (-5
o
C) to plus sixty five degrees
centigrade (+65
o
C).

5.1.2 Steep Front-of-Wave Flashover Test: Ten (10) insulator units selected at
random from the first production lot shall be subjected to five successive
positive and negative impulse flashover with a wave front having a
minimum effective rate of rise of 2500 kV per microsecond. Each of the
ten (10) insulators shall be individually tested.

Each unit shall then be subjected to the rated low-frequency dry flashover
test (five successive flashovers). No electrical puncture shall occur, and the
flashover arc must be external.

The failure of any one unit either in the front-of-wave or subsequent low
frequency withstand voltage test shall require testing an additional 20

15-TMSS-02, Rev. 0

units. Failure of more than one unit from the total so tested shall constitute
failure to meet the requirements of this specification.

5.1.3 Power Arc Follow Through Test: Ten (10) insulators shall be selected at
random from the first production lot. Each unit from the ten insulators
shall be attached to the lower end of a vertical string of five other units.
Each string of six insulators shall be subjected to two flashovers of 6,000
A for 12 cycles. The 60 Hz voltage shall be applied to the bottom of the
string with ground at the top of the string. The insulators shall be stressed
to 40 % of rated strength of the insulator. The flashover shall be initiated
by a fuse wire connected from the cap of the top insulator to the pin of the
bottom insulator. The insulators shall be operationally safe after the
conclusion of the test and shall meet the following criteria:

i. There shall be no separation of metal components from
porcelain/glass body.

ii. The insulators shall not have an electrical puncture and the flashover
shall be external when subjected to dry flashover test.

iii. The mechanical strength of insulators shall not be reduced below 80
% of their rated M & E strength.

Failure of any one unit in the test shall be the cause for testing another
ten (10) insulators.

Failure of more than one unit from the total so tested shall constitute
failure of the insulator design to meet the requirements of the
specification.

5.1.4 Autoclave Expansion Test for Portland Cement- The soundness of
Portland Cement to be used as the bonding agent for wet-process
aluminous porcelain or toughened glass insulators shall be tested in
accordance with the ASTM C151.

Ten (10) samples of cement for the test specimen shall be selected at
random from the batch to be used for insulators. The bars prepared from
neat cement when subjected to high-pressure steam at 2 0.07 MPa for
three hours at 216C shall not show expansion of more than 0.12 percent.

The expansion of cement more than 0.12 percent in the test shall be the
cause for rejection of the whole batch of cement.

15-TMSS-02, Rev. 0

5.2 Routine (Production) Tests

All routine (production) tests prescribed in the relevant IEC or equivalent ANSI
standards shall be performed on all units prior to delivery to SEC.

5.3 Sample (Quality Conformance) Tests

All sample (quality conformance) tests prescribed in the relevant IEC and ANSI
standards shall be performed on each lot of insulator prior to delivery to SEC.

In addition to the above IEC or ANSI sample test requirements, the following sample
tests shall be carried out:

5.3.1 A dimension test shall be performed on three strings of six insulators each
selected at random and the connecting length of each string shall be 6
times the nominal spacing of the insulators with a tolerance of 19 mm.

5.3.2 Verification of axial, radial, and angular displacement.

5.4 Special Tests

The pollution test, as an option shall be performed in accordance with IEC 60507, if
requested by SEC in Data Schedule.

5.5 Acceptance Criteria

5.5.1 The acceptance criteria of the specified number of insulators tested shall be
in accordance with ANSI C29.2 or IEC 60383, except for Thermal
Mechanical Performance Test and Mechanical & Electrical Failing Load
Tests.

5.5.2 The acceptance criteria for Thermal-Mechanical Performance Test and
Mechanical & Electrical Failing Load Tests shall be as specified below:

a. The result of the Thermal-Mechanical Performance test shall match
the result of the ordinary M&E failing load tests.

b. Each measured value shall not be less than the specified M&E
Strength +3.

c. Electrical puncture shall not occur before the ultimate fracture.

d. The acceptance constant, k shall be equal to or greater than 3;

3 k =X - Xs

15-TMSS-02, Rev. 0

where X = Mean value
Xs = M&E rated value
= Standard deviation

15-TMSS-02, Rev. 0

6.0 DATA SCHEDULE

SUSPENSION TYPE INSULATORS

SEC Enquiry No. Date:

SEC Purchase Order
No.

Date:

or Contract No.

SEC PTS No./Project Title with J .O. No.

REFERENCE
SECTION NO. DESCRIPTION 'A' 'B' 'C'


Applicable Industry Standards *


4.1 Insulator Material and Type
Porcelain/Toughened Glass

Fog/Super Fog/Aero Form

4.3 Ratings

Combined Mechanical and Electrical
Strength (kN) (111kN/160kN/210kN)

Tension proof load (kN)
(55.5kN/80kN/105kN)

Electrical Values (Porcelain Insulators)

Low frequency dry flashover (kV)
(95kV/80kV) *

'A'- SEC SPECIFIED DATA/PARAMETERS
'B'- BIDDER/SUPPLIER/VENDOR/CONTRACTOR PROPOSED DATA/PARAMETERS
'C'- REMARKS SUPPORTING THE PROPOSED DEVIATION IN COLUMN 'B'.
(*)- DATA/PARAMETERS TO BE PROVIDED/PROPOSED BY THE BIDDER/SUPPLIER/
VENDOR/CONTRACTOR IN COLUMN 'B'

15-TMSS-02, Rev. 0


6.0 DATA SCHEDULE


REFERENCE

Low frequency wet flashover (kV)
(55kV/50kV) *

Critical impulse flashover, Positive (kV)
(135kV/105kV) *

Critical impulse flashover, negative (kV)
(145kV/105kV) *

Electrical Values (Glass Insulators)

Low frequency dry flashover (kV)
(95kV/75kV/65kV) *

Low frequency wet flashover (kV)
(55kV/50kV) *

Critical impulse flashover, Positive (kV)
(135kV/105kV/95kV) *

Critical impulse flashover, negative (kV)
(145kV/105kV/95kV) *

Low frequency puncture Voltage (kV) 110/110/125

RIV low frequency test voltage (rms to
ground) (kV) 10

Maximum RIV at 1000 KHz (V) 50V

Weight per unit (kg) *

15-TMSS-02, Rev. 0

6.0 DATA SCHEDULE


REFERENCE

4.4 Color for Aluminous porcelain Brown Glaze

4.6 Dimension:

Coupling type (ANSI size J /K) (IEC size
16A/20)

Leakage distance per unit (mm) *

Shell diameter (mm) *

Spacing distance (mm) *

5.0 TYPE TESTS

5.1 Are additional type tests required? Yes/No

Are additional type tests performed? * Yes/No

5.4 SPECIAL TESTS

Is Pollution test required? Yes/No

Is Pollution test performed? * Yes/No

15-TMSS-02, Rev. 0

6.0 DATA SCHEDULE


ADDITIONAL TECHNICAL INFORMATION OR FEATURES TO BE FURNISHED BY
SEC:
A.

ADDITIONAL SUPPLEMENTARY DATA OR FEATURES PROPOSED BY
BIDDER/VENDOR/SUPPLIER/CONTRACTOR:
B.

OTHER PARTICULARS TO BE FILLED UP BY BIDDER/VENDOR/SUPPLIER/
CONTRACTOR:
B.

Actual Manufacturer
of Equipment/Material
Vendor/Supplier/
Contractor

Name of the Company
Location and address

Name and Signature of
authorized
representative

and date

Official Seal/Stamp
of the Company &
Date

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