Electrical Condition Assessment of Polymer Insulators for Live Working

Development of an Improved Portable Tester

1010244

Electrical Condition Assessment of Polymer Insulators for Live Working

Development of an Improved Portable Tester 1010244 Technical Update, October 2005

EPRI Project Manager A. Phillips

ELECTRIC POWER RESEARCH INSTITUTE 3420 Hillview Avenue, Palo Alto, California 94304-1395 ! PO Box 10412, Palo Alto, California 94303-0813 ! USA 800.313.3774 ! 650.855.2121 ! askepri@epri.com ! www.epri.com

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CITATIONS
This document was prepared by Electric Power Research Institute (EPRI) 1300 W.T. Harris Blvd. Charlotte, NC 28262 Principal Investigators A. Phillips T. Shaw L. van der Zel This document describes research sponsored by EPRI. This publication is a corporate document that should be cited in the literature in the following manner: Electrical Condition Assessment of Polymer Insulators for Live Working: Development of an Improved Portable Tester. EPRI, Palo Alto, CA: 2005. 1010244

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ABSTRACT
A requirement for ensuring worker safety when performing live work with polymer insulators is to confirm the short-term electrical integrity of both the installed and the replacement polymer units. Currently there are no generally accepted and easily applied procedures to accomplish this. The focus of this research report is therefore on the development of a simple detector to assess the electrical integrity of a polymer insulator. A proposed concept for the detector is given as well as the results from a laboratory bench top prototype. Requirements for future developments to convert the bench top device to field ready unit are also presented.

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CONTENTS
1 INTRODUCTION ....................................................................................................................1-1 Background ..........................................................................................................................1-1 Definition of Defect...............................................................................................................1-1 Current Detection Method for Porcelain Disc Type Insulator Strings...................................1-2 Overview of Development ....................................................................................................1-2 2 PRINCPLE OF OPERATION .................................................................................................2-1 Introduction ..........................................................................................................................2-1 Basic Concept ......................................................................................................................2-2 3 IMPLEMENTATION OF TECHNIQUE ...................................................................................3-1 Application of Electric Field ..................................................................................................3-1 Voltage Source...............................................................................................................3-1 Electrodes ......................................................................................................................3-2 Voltage Difference Measurement...................................................................................3-3 Bench Top Laboratory Demonstrator...................................................................................3-4 4 TEST RESULTS FROM BENCH TOP LABORATOY DEMONSTRATOR............................4-1 Defect Description................................................................................................................4-1 Results of Testing ................................................................................................................4-4 With No Conductive Object ............................................................................................4-4 Steel Rod .......................................................................................................................4-4 Copper Stand and Graphite Conductive Objects ...........................................................4-5 5 CONCEPT FOR FIELD DETECTOR......................................................................................5-1 6 SUMMARY, CONCLUSIONS AND FUTURE INVESTIGATIONS .........................................6-1 Summary..............................................................................................................................6-1 Conclusions..........................................................................................................................6-1 Future Investigation and Development ................................................................................6-2 7 REFERENCES .......................................................................................................................7-1

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1
INTRODUCTION
Background A requirement for ensuring worker safety when performing live work (LW) with polymer insulators (also called composite or non-ceramic insulators (NCI)), is to confirm the short-term (i.e., for the duration of the work) electrical and mechanical integrity of both the installed and the replacement polymer units. Currently there are no generally accepted and easily applied procedures to accomplish this. Consequently some utilities have opted not to use polymer insulators. In addition, a number of utilities that do use polymer insulators avoid live work on structures on which these insulators have been installed. Although both the electrical and mechanical integrity of the insulator are a concern, often work practices can be implemented to address the mechanical concerns. The focus therefore of this research report is on the development of a simple detector to assess the electrical integrity of a polymer insulator. To address this issue, discussions were held among many utilities with the objective of defining the characteristics of a simple detector. As result of these discussions, it was determined that the detector should [1]: ! ! Detect major defects in energized polymer insulators, and essentially ignore minor defect Use technologies that are both currently available and familiar to the craft

! Be rugged for field use, small in size for ease of handling and to minimize distortion of the voltage distribution on the insulator, and simple to operate ! The detector should also provide a go-no-go type of indication that could allow the crew supervisor in the field to make a clear-cut determination as to whether live work can be performed safely on the subject insulator. Definition of Defect A major defect from the live working viewpoint, is understood to be a defect that would be detrimental to the withstand of the worksite during live work and in turn would prevent live work from being performed using standard procedures. Hence only defects that reduce the withstand of the worksite by greater than a critical amount should be identified. A critical defect is the least severe defect that would prevent live work due to the reduction of the withstand of the worksite as a result of the defect. Previous EPRI research showed that for a specific steel lattice 230kV configuration that the length of a critical defect was approximately 18% the length of the insulator [1]. The cross sectional area and composition of such a defect has not been well defined to date.

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Current Detection Method for Porcelain Disc Type Insulator Strings Prior to live working ceramic disc insulator strings the electrical condition of individual units maybe evaluated, using a buzz test, a DC test or visual inspection. The units are usually evaluated from the energized end to the grounded end evaluation is halted if a specified number of units is exceeded. The sum of the number of electrically compromised units in the string determines whether the string maybe worked live. The critical number of units above which live work cannot be performed differs by utility and application. Factors such as the system voltage, switching surge conditions, string length and utility practices all influence the critical number of units. Because these methods are currently accepted by the industry, a detector that works on similar principles would be well received. Overview of Development This report will document the following: 1. Principle of operation of proposed detector 2. Results of electric field modeling 3. Description of bench top laboratory demonstrator developed 4. Results from demonstrator 5. Concept for a field implementation 6. Future developments and testing

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PRINCPLE OF OPERATION
Introduction An electrically conductive object when placed an electric field (E-field) ensures that all parts of that object are at the same voltage. This means that if a conductive object is placed in an E-field the voltage distribution is changed by the presence of the conductive object. An example of how a voltage distribution between two parallel plates is changed by the presence of a conductive object is shown in figure 1.
A

(a)Voltage distribution without conductive object

(b)Voltage distribution with conductive object

Figure 2.1 Voltage distribution between two parallel plates energized at different voltages. Voltage distribution is shown both with and with a floating conductive object.

As can be seen from Figure 2.1, the voltage distribution in the air surrounding the conductive object is modified as a result of the voltage on all parts of the conductive object being the same, e.g. compare the voltage difference between two points at location A - both with and without the conductive object present. It can also be seen from figure 2.1 (b) that close to the conductive object the change in the voltage distribution is significant while the further away it is far smaller, (compare points A and point C in figure 2.1(b)). In fact a short distance away from the conductive object the changes are hardly apparent. It can also be seen from figure 2.1 that in some locations the voltage difference is reduced from the field without a conductive object present i.e. location A. While in other locations the voltage difference is larger due to the presence of the conductive object i.e. location D.

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Basic Concept Two electrodes separated by a set spacing are slipped around the polymer insulator as shown in figure 2.2. The voltage difference between two points (blue) is then measured if this voltage difference changes significantly from the unperturbed case it will mean that a conductive object is nearby.

Electrode

Measure Change in Voltage Difference

Electrode

Figure 2.2 Sketch of concept showing two electrodes surrounding portion of insulator.

Consider the case where a conductive object is placed inside the insulator between the plates as shown in figure 2.3. The change in voltage between the two points in the diagram will be different to the unperturbed case.

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Conductive object

Electrode

Measure Change in Voltage Difference

Electrode

Figure 2.3 Sketch of concept showing two electrodes surrounding portion of insulator.

The further the measurement point is radialy from the conductive objective the less the changes in the voltage difference between the measurement points. Therefore it is important to measure the voltage difference between the two points as close as possible to the conductive defect, i.e. as close as possible to the surface of the insulator. Figure 2.4 shows the change in both the voltage distribution and E-field magnitude for different positions of a conductive object (defect) between the electrodes.

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Object Position (% of plate spacing) None (measurement location for figure 2.5 shown by blue circle)

Voltage Distribution

E-field Distribution (magnitude: red highest / yellow lowest)

20%

60%

80%

100%

Figure 2.4 Changes in the voltage and E-field distribution surrounding a fiberglass rod (yellow in voltage distribution images) between 2 electrodes as a function of conductive object position. The conductive object is located in the center of the rod.

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A measurement of the voltage difference between two points 1mm apart as a function of the conductive object position is shown in Figure 2.5. As can be see a change in the voltage difference compared to the unperturbed case occurs depending on the position of the conductive object. The location of the measurement is halfway between the plates and is on the edge of fiberglass rod as shown in the first voltage distribution image in figure 2.4.

Voltage Difference (V)

Unperturbed Voltage

Distance Of Conductive Object Into Plates

Figure 2.5 Change in the voltage difference between two points as a conductive object moved between the plates

Although the above analysis is for a single measurement location, it maybe preferable to measure at more than one location between the electrodes. This will allow a better understanding of the conductive object present and its extent. The basic principle of the tool under development is to set up a local electric field around a section of an insulator and determine whether there is a change from the unperturbed case in the voltage or E-field distribution.

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IMPLEMENTATION OF TECHNIQUE
The technique maybe split into two different sections: ! ! Application of E-field Measurement of voltage difference between two points (E-field)

How these are realized is discussed in this chapter. A bench top laboratory demonstrator is also presented. Application of Electric Field Voltage Source Three different high voltage sources were considered for this application: ! ! ! Power Frequency (60Hz) DC High Frequency Generator (4 to 5 MHz)

Extensive analysis and testing was done with all three voltage source types. Based on results the High Frequency Generator option was chosen for the following reasons: ! ! ! ! Safety: The human skins resistance at these frequencies is high reducing the risk. The impedance of the coupling capacitances between the electrodes and defects is lower improving the detection rate. The sensitivity of the sensing elements (discussed later) is better at these frequencies. High voltage high frequency generators are relatively small, light and compact.

A variable high frequency generator was used in testing. The range of the source was between 10 and 50kV. The generator used is shown in Figure 3.1 although smaller models without the attached box are available.

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Figure 3.1 Image of high frequency high voltage generator used.

Electrodes Both parallel plates and half-cylinder electrodes were tested. Sketches of both electrode types are shown in Figure 3.2.
Fiberglass Rod Top Electrode

Electrode

Bottom Electrode

Fiberglass Rod
Parallel plate electrodes
Figure 3.2 Sketches of the electrodes investigated.

Half-cylinder electrodes

Although further testing and modeling is necessary, success was achieved with the half cylinder approach. The parallel electrodes tested were large and future testing with intermediate parallel plate electrodes is underway.

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Voltage Difference Measurement A number of complex and expensive E-field measurement techniques were investigated and evaluated. Challenges when selecting technique included: ! ! ! ! Repeatable Did not disturb the electric field by a large amount Low cost Provide the operator a good understanding of the phenomena

A simple approach was finally selected: a glass encapsulated gas gap designed to spark at a predefined voltage as shown in figure 3.3.

Figure 3.3 Glass Encapsulated Gas Gap

The gas gap when placed in a high enough electric field the voltage difference between the electrodes will exceed the predefined value and the gap will spark. If a conductive object is in close proximity to the gas gap the voltage difference will not be large enough and the gap will not spark. It also is possible to obtain an indication of voltage difference across, and impedance path in series with, a sparking gas gap by measuring the luminescence. Figure 3.4 shows a gas gap sparking in a high frequency high electric field.

Figure 3.4 Gas Gap sparking in a high electric field.

One of the advantages of using a gas gap is that the conductive parts are small in dimension and hence the gaps distortion of the field is small. Another advantage is that the principle of operation is easily understood and is comparable to the buzz test method. It also provide a go/ no-answer.

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If one is close to the spark gap in a low light environment identifying whether the gap is firing can be done visually. For field operations this is not possible as the gap will be a significant distance away from the operator in bright sunlight. Therefore a fiberoptic light intensity measurement device was used as shown in Figure 3.5 to determine whether the gap is firing and to what degree. The advantage of using the fiber optic measurement device is that it has minimal impact on the localized E-field.
Gas Gap

Attached Fiber Fiber to Detector

Fiber attached to gas gap

Detector, fiber and gas gap.

Figure 3.5 Fiber optic light intensity measurement device.

Bench Top Laboratory Demonstrator Figure 3.6 shows the final laboratory demonstrator. Other embodiments including power frequency AC and DC sources as well as parallel plates were tested. The demonstrator shown and discussed uses cylindrical electrodes and a high voltage high frequency generator.

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Energized Electrode

Gas Gaps

Grounded Electrode

Variable HV HF Generator Figure 3.6 Photograph of bench top laboratory demonstrator.

The distance between the electrodes was 11.5 (292mm). This distance was arbitrary and in a final implementation would have to be adjustable as the shed spacing differs by application and manufacturer. Figure 3.7 is a sketch showing the critical dimensions of the demonstrator.

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11.5" (292mm) 5.75" (146mm)

1.5"
(38mm)

0.1" (2.5mm)

Energized Electrode

Gas Gaps

Grounded Electrode

Detector Body

Figure 3.7 Dimensions of demonstrator

A PVC tube was placed between the electrodes in experiments to simulate an insulator - with the advantage that defects could easily be inserted inside the tube. Figure 3.8 shows the demonstrator with the PVC insulator installed.

Figure 3.8 Photograph of bench top laboratory demonstrator with PVC Insulator Installed

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Figure 3.9 shows all three gap gaps firing with no conductive defect internal to the PVC Insulator.
Gas Gaps Firing

Figure 3.9 Gas gaps firing on bench top demonstrator.

Fiber optic detection of the light intensity of the gas gaps was not implemented on the demonstrator it was however demonstrated with a variable voltage source directly attached to the gas gaps at low current magnitudes.

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4
TEST RESULTS FROM BENCH TOP LABORATOY DEMONSTRATOR
Defects of different length were simulated and installed in the PVC Insulator. The firing of the gas gaps was then visually noted to determine the efficacy of the detector. Defect Description Three different types of cylindrical defects of different lengths were tested: ! ! ! Steel rod of 1/10 (3mm) in diameter and 20 (508mm) in length Individual copper stands of 9/1000 (0.25mm) in diameter these were attached to nonconductive fiberglass rods that were 0.25 (6mm) in diameter A graphite of 0.08 (2mm) in diameter and 4.7 (120mm) in length

Figure 4.1 shows examples of different lengths.

0.1 (3mm) 0.25 (6mm) 0.08 (2mm)

9/1000(0.25mm)

Steel Rod

Copper Stand

Graphite Rod

Figure 4.1 Images of defects used to evaluate detector (note not all images at the same magnification)

The steel rod was inserted into the PVC Insulator from the ground electrode side. The one end of the defect always passed over the grounded electrode and the location of the steel rod tip was varied as required. Shown in Figure 4.2.

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Hollow PVC Insulator Tube

Distance into Gap Steel Rod

Energized Electrode

Gas Gaps

Grounded Electrode

Detector Body

Figure 4.2 Sketch showing location of steel rod.

The location and length of the copper strand defects are shown in figure 4.3 (defects A through C) and 4.4 (defects D through E).
2.5"
(64mm)

2.75" C 6" (152mm) A B

(70mm)

2"
(51mm)

Energized Electrode

Grounded Electrode

Detector Body

Figure 4.3 Location and length of copper stand defects A through C.

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2.5"
(64mm)

5.75" (144mm) D E 2.75"

(70mm)

2.5"
(64mm)

3.75" (95mm)

Energized Electrode

Grounded Electrode

Detector Body

Figure 4.4 Location and length of copper stand defects D through F.

A graphite rod 0.08 (2mm) in diameter and 4.7 (120mm) in length was located between the electrodes as shown in figure 4.5.

3.4"
(86mm)

4.7" (120mm) Graphite Rod

3.4"
(86mm)

Energized Electrode

Grounded Electrode

Detector Body

Figure 4.4 Location and length of 2mm diameter graphite rod.

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All of the defects were located approximately 0.25 (6mm) above the gas gap detectors for the testing. Results of Testing With No Conductive Object The detector was energized so that each of the gaps was sparking and was plainly visible under low ambient light conditions. The gas gaps are named G1, G2 and G3 as shown in figure 4.4.

Energized Electrode

G1

G2 Gas Gaps

G3

Grounded Electrode

Detector Body

Figure 4.4 Naming of Gas Gaps and indication of relative spark strength: Red- high, Yellow-Medium.

As shown in Figure 4.4 the gas gap closer to the energized electrode, G1, had a stronger spark than G2 and G3 due to the non-uniform nature of the field. Similarly G2 sparked marginally stronger than G3. Similarly when increasing the voltage in a stepwise fashion G1 sparked at a lower voltage than G2, and G2 at a lower voltage than G3. If this poses a problem in future testing, revision to the electrode design or selection of different flashover gas gaps are future possible approaches. Steel Rod The steel rod was inserted in short increments into to the PVC Insulator as shown in figure 4.2. The response of the detecting gas gaps was observed as a function of the position of the rod. The following maybe summarized: ! ! As the tip of rod approached each of the gas gaps the sparking luminescence increases in intensity as the E-field at the rod tip is larger As the tip of the rod passes over each of the gas gaps the luminescence quickly become dimmer and the gaps then extinguish.

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If the rods pass directly over the gas gaps they extinguish completely. This is similar to a porcelain disc not resulting in an arc in a buzz test as it is shorted out.

Copper Stand and Graphite Conductive Objects Whether the gaps were firing was visually identified. Low light ambient conditions were utilized for ease of identification. Table 4.1 shows the results.
Table 4.1 Results of conductive object detection, Copper strand objects are indicated by Cu A, Cu B, Cu C, Cu D and Cu E as per the dimensions in figures 4.3 and 4.4. (Legend for gas gaps sparking strengths and defects shown at bottom of table)
Object

Energized Electrode
G1

Gas Gaps
G2 G3

Grounded Electrode

# of Gaps Sparking

None Cu A Cu B Cu C D Cu E Cu F Graphite Rod

3 0 2 1 2 1 3 2
Legend for Table 4.1 Gas gap sparking Gas gap NOT sparking Copper Stand Defect Graphite Rod Defect

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As can be seen from table 4 the presence of all of the conductive objects was detected, both Copper and Graphite. The extent of the objects can be determined by identifying which gaps are sparking. More information can be obtained by assessing the strength of sparking in each gap but this is not important for field evaluation of an insulator. A brief summary of the results is as follows: ! ! ! If all three gas gaps do not spark, it is an indication that an internal conductive object exists that is equal to or greater than the distance between the electrodes. If two of the gas gaps do not spark, it is an indication that an internal conductive object exists that is equal to or greater than half the distance between the electrodes. If one of the gas gaps does not spark, it is an indication that an internal conductive object exists that is equal to or greater than approximately quarter the distance between the electrodes.

The sensitivity of the final two statements can be adjusted by varying the applied voltage and / or selecting different firing voltage levels for the gas gaps. More information may also be gained by evaluating the magnitude of the spark by measuring its luminescence.

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5
CONCEPT FOR FIELD DETECTOR
The laboratory bench top detector presented in the previous chapter illustrates the concept on which the proposed detector would operate. This chapter provides a vision on how this detector would be implemented in a field ready unit. Figure 5.1 provides a conceptual sketch of the field unit.
Upper Electrode

RF Receiver with Go/No Output

RF Link

- HF HV Supply - Fiber Receiver - RF Transmitter - Battery

Lower Electrode
Fiber
Gas Gap Detector

Figure 5.1 Conceptual sketch of field unit.

The detector head will consist of: 1. Two electrodes which can be slipped around the sheath of a polymer insulator, either parallel or cylindrical. The spacing between the electrodes should be variable to account for different insulator designs. 2. A high frequency high voltage generator (HF HV generator) encompassed in a central housing between the electrodes.

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3. One or more gas gaps mounted as close as possible to the sheath of the insulator the housing of the gas gap should touch the sheath surface. The position of the gas gap should be variable to account for different designs of insulators. The gas gap should be mounted on a spring loaded mechanism so that it would be as close to the surface as possible. 4. Fiber optic light detectors. The end of the fiber cables will be attached to the gas gaps (one or more). The light detector electronics will be housed together with the HF HV generator. 5. Diagnostics and control electronics housed together with the HF HV generator housing 6. An RF link providing the results from the light detectors to the operator as well as the units diagnostics information. The RF link may also exchange control information, e.g. on/off. The RF electronics will be housed together with the HF HV generator. 7. A battery to power the HF HV supply, light detector electronics and RF link housed together with the HF HV generator. 8. The head will be mounted on the end of a hot stick. The receiver unit will consist of: 1. An RF receiver to obtain the RF signal from the head. 2. Electronics to process the signal from the gaps and provide a Go/No Go answer in a simple format for the user, e.g. red / green light. 3. Electronics to provide diagnostics of the condition of the detector 4. Control panel to control the functions of the detector head. It should be kept in mind that these ideas are conceptual and will continue to be developed as more information and feedback from members is received.

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SUMMARY, CONCLUSIONS AND FUTURE INVESTIGATIONS
Summary A detector having the following characteristics was developed and demonstrated: ! ! ! ! ! Able to detect conductive objects below the surface of an insulator Is independent of insulator voltage, configuration and design Utilizes a high voltage non-lethal voltage source Utilizes a detection method that provides an intuitive understanding of the presence of a conductive objectthat is, whether a gap is sparking The component cost of the demonstrator utilizing the off the shelf components is less than $1000

With development the detector has the following potential: ! ! ! ! To be lightweight Battery powered Provide a go/no (green/red light) results if the output of the gas gaps is inputted to a simple electronic circuit. To be implemented at the end of a hotstick if a RF link is developed

Conclusions It maybe concluded that a safe detector that is able to identify both the presence and the extent of a conductive object bellow the surface of an insulator has been developed and demonstrated. The detector uses relatively simple robust technology that provides an intuitive indication of the presence of a conductive object. The device also has the potential to provide indication of the insulator surface condition, although this has not been investigated. Before the detector can be verified as effective, further studies and development is needed. These are presented in the following section.

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Future Investigation and Development The fundamental understanding of the types of electrical conditions on/in polymer insulators, that will reduce the withstand of the worksite, needs to be expanded. Detection and testing to date has all been on artificially made conditions, e.g. copper strands, graphite, steel rods, copper rods, tin foil on sheds, etc. This set of defects needs to be expanded to include more representative conditions, e.g. semi-conductive tracking, etc. The following needs to be investigated prior to ratification of the applicability of the device: ! ! ! ! The distance from which defects can be assessed. The extent and type of conductive, high permittivity and semi-conductive internal objects that can be assessed The influence of surface moisture. Testing on real insulators.

Further development is also needed to improve the performance and readiness of the unit for full scale tests (both energized and de-energized): ! ! ! ! ! ! Refinement of the E-field distribution between the electrodes by adjusting electrode design Development of a battery powered high voltage high frequency power supply with a repeatable voltage source Refinement of the gap sparking voltages and location. Development of a robust and more sensitive gas gap fiber optic intensity measurement device. A RF link with associated go/no-go circuitry. Physical layout and practical issues.

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REFERENCES
[1] Electrical Condition Assessment of Polymer Insulators for Live Working: Development of a Simple Portable Tester, 1002030, EPRI Palo Alto, 10/2004

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