R1-082:2007

CEB
STANDARD

33kV- COMPOSITE INSULATOR FOR COASTAL

AREAS

CEYLON ELECTRICITY BOARD

SRI LANKA

Specification
for

33kV- COMPOSITE INSULATOR FOR COASTAL AREAS

CEB Standard R1-082:2007

CEYLON ELECTRICITY BOARD

No. 50, Sir Chittampalam A. Gardener Mawatha, Colombo 2.

Sri Lanka

Telephone: 94-1-430471, 421720

Facsimile: 94-1-430473

E-mail : cebdp@mega.lk

CEB STANDARD R1-082:2007

CONTENTS

PAGE

1.

Scope

2.

System Parameters

3.

Service Conditions

4.

Applicable Standard

5.

Basic Features

6.

Quality Assurance

7.

Additional Requirements

8.

Information to be Supplied with the Offer

9.

Sample Study

10.

Inspection and Testing

CEB STANDARD R1-082:2007

SPECIFICATION FOR MEDIUM VOLTAGE

COMPOSITE INSULATORS

1.0

SCOPE
This specification covers the general requirements of the design, manufacture, testing
supply and delivery of medium voltage composite insulators complete with hardware for
33kV overhead distribution lines in the coastal area.
The composite insulators shall be of the following types
a)
b)

2.0

SYSTEM PARAMETERS
a)
b)
c)
d)
e)
f)

3.0

Nominal Voltage
System highest voltage
System frequency
Number of phases
Method of earthing
System fault level

33kV
36kV
50Hz
03
Non effectively earthed
13.1 kA

SERVICE CONDITIONS
(a)
(b)
(c)
d)
e)
f)

4.0

Long Rod Insulators for conductor tension and suspension application

Pin Insulators for intermediate point application

Annual average ambient temperature

30C
Maximum ambient temperature
40C
Maximum relative humidity
90%
Operational Altitude
From MSLto 900 m above MSL
Isokeraunic (Thunder day) level
90 days.
Environmental condition
i)
Humid and heavily polluted with deposits of sand, dust and salt from the
sea,
industrial and agricultural pollution
ii)
Maximum temperature difference form day to night 250C.
iii)
Prolonged periods without rain (up to 10 months)
iv)
Long summer periods with lots of sunshine.

APPLICABLE STANDARDS
The composite insulators shall be designed, manufactured and tested in accordance with
the requirements of the latest published edition of the standards specified below and
amendments thereof
a)

IEC

61109; 1992

Composite insulators for A.C. overhead lines with a

nominal voltage greater than 1000V.

b)

IEC

60383 : 1980

Insulators for overhead lines with a nominal voltage

above 1000V.

All aspects, tests, etc. not covered by the above IEC standards shall be executed
according to this standard to the fullest satisfaction of the purchaser.

CEB STANDARD R1-082:2007

5.0

BASIC FEATURES
5.1

Design and Construction

The composite insulator shall have a core and insulating housing & whether shed housing
both manufactured by the same manufacturer and steel / aluminium hardware components
for attaching it to the support and conductor.
5.1.1

Core

The insulator core shall be made of brittle fracture-resistant electrical grade epoxy / vinyl
ester / Isopolyester based fiberglass rod to achieve maximum failing load. The core shall be
mechanically and electrically sound, free from voids, foreign substances and manufacturing
flaws.
Also the design shall be such as to ensure that the core is totally encapsulated and fully
sealed, from the live to the earthed ends, by the insulating material from the environment, in
order to avoid ingress of moisture. If any tacky substances are used as sealers, they shall
not be exposed to environmental influence.
5.1.2

Housing and Weathersheds

The housing and Weathersheds shall be made of silicone rubber material in order to
maintain their hydrophobicity during long term service in critical environments.
A minimum thick sheath of 3.0 mm of Silicone Rubber shall be extruded or injection moulded
on the reinforced fiberglass rod. The polymer sleeve and weathershed insulating material
shall have a chemical structure of 100 percent silicone rubber before fillers are added.
The silicone rubber shall be firmly bonded to the rod, be seamless, smooth and free from
imperfections. The strength of the silicone rubber to rod interface shall be greater than the
tearing strength of the silicone rubber.
The weathersheds shall be firmly bonded to the sheath, vulcanized to the sheath or moulded
as part of the sheath and be seamless smooth and free from imperfections. The strength of
the silicone rubber weathershed to sheath interface shall be greater than the tearing
strength of the silicone rubber.
Weathersheds shall be at intervals to provide optimum electrical performance and the
weathershed designs should provide a protected bottom surface that tends to keep dry in
wet conditions.
The insulator shall be capable of withstanding high pressure power washing. A power wash
test shall be performed on polymer insulators to demonstrate that the units can be power
washed. This test shall be a water spray at a shed seam approximately 3 meter from the
insulators. The spray shall be a solid stream through a 6mm diameter nozzle at 3.79Mpa for
a period of ten minutes. There shall be no signs of water entering through or under the
outside weathershed into the core or at the polymer hardware interface into the core.
The gap between hardware base and housing shall be sealed by an elastomer with
permanent elasticity. The sealing shall stick permanently to the surface of the material as
well as to the housing.
The base should be attached to insure a uniform distribution of the mechanical load to the
rod.

CEB STANDARD R1-082:2007

5.1.3

Hardware

The hardware components for clamping conductors shall be of the following types
i)
ii)
iii)

Bolted type tension clamp

Crimp type tension clamp
Suspension clamp

The bolted type tension clamp shall be of the 3 bolt type, made of aluminium alloy, suitable
for accommodating raccoon conductor as shown in the drawing no. DS&S/2007/82A-R1
The compression type tension clamp for Elm conductor shall be of single part fitting made of
aluminium alloy and for Lynx conductor it shall be of two part fitting made of steel and
aluminium alloy with jumper socket as shown in the drawing no. DS&S/2007/82B-R1 and as
requested in the schedule of prices.
The suspension clamp shall be made of aluminium alloy suitable for accommodating Elm /
Lynx conductors as shown in the drawing no DS&S / 2007/ 82C-R1. as requested in the
schedule of prices.
The hardware component required for mounting the insulator to the cross arm shall be U
shackle for long rod insulator and stud for line post insulator as shown in the relevant
drawings. All the steel hardware component shall be galvanized to protect them against
corrosion.
5.2

Long Rod Insulators

The long rod insulator shall be of type A as per IEC 60383 and as shown in the drawing No.
DS&S/2007/82A,B,C-R1 with hardware for fixing the conductor tension (bolted type / crimp
type) /suspension clamps on one and U shackle shall be provided on other end (for
mounting the insulator to the cross arm) shall be provided..
The long rod insulators shall be supplied complete with necessary hardware such as
galvanized steel U shackle / tension clamp (bolted type / crimp type) / suspension clamp as
shown in the drawing and as requested in the schedule of prices.
5.3

Pin Insulator

The Pin insulator shall be of type A as per IEC 60383 and as shown in the drawing
No.DS&S / 2007 / 82D-R1. The conductor grove of 16 mm radius shall be provided on the
top (head) of the pin insulator for accommodating conductors as indicated in the Clause 5.5
- Technical requirements and as requested in the schedule of prices.
The pin insulators shall be supplied complete with necessary hardware such as galvanized
steel pin with nut spring washer and a lock nut for mounting the insulator to the channel iron
cross arms as shown in the drawing.
5.4

Galvanizing

All steel hardware components shall be galvanized after their machined bent or worked
operations of any manner. The zinc coating shall adhere tightly to the surface of the base
metal. The zinc coated parts shall not have any un-coated spots.

CEB STANDARD R1-082:2007

The coating shall be uniform and free from blisters, flux, black spots, dross, tear drop edges,
flaking zinc, rough appearance and in general shall be smooth, clean and unscarred when
received. The minimum thickness of the coating of the steel or iron base will be 80 micron.
5.5
Technical Requirements

6.0

a)

Rated Voltage

kV

36

b)

Minimum Creepage Distance

mm

1000

c)

Mechanical failing load (min.)

i)
Long rod Insulator (tensile load)
ii)
Line post Insulator (cantilever load)

KN
KN

70/80/100
12

d)

Dry lightning withstand voltage (peak)

kV

170

e)

Wet power frequency withstand voltage

Duration

kV/min -

70/1
1

f)

Radio Interference level at

22kV

30db

g)

Conductor applicable

Raccoon
Lynx
Elm

QUALITY ASSURANCE
Manufacturer shall possess ISO 9001 quality assurance certificate for manufacture of FRP
core rod and composite insulators of 36kV rating and above at the plant where the
manufacture is done. Certified copy of the ISO certificate as true copy of original by the
manufacturer shall be furnished.

7.0

ADDITIONAL REQUIREMENTS
7.1

MARKING

Each insulator shall be moulded with the name or trade marked of the manufacturer, the
year and week of manufacture and the specified mechanical load. The marking shall be
legible and indelible.
7.2

Routine Tests

The following routine test according to IEC 61109 and IEC 60383 shall be carried out on all
insulators and the routine test report shall be made available for the observation of the CEB
inspector at the time of inspection.
i)
Identification of the composite insulators
ii)
Visual examination
iii)
Mechanical routine test
7.3

Packing

All insulators shall be packaged in individual weatherproof containers to protect the

weathersheds against damage during shipping. The containers should be weatherproof and
designed to be removable by hand without cutting.
Each shipping container shall have a packing list and in addition, shall be marked with the
following information.

CEB STANDARD R1-082:2007

a)
c)
e)
g)

Descriptive name
Quantity packed in container
Gross weight of container
Applicable standard

7.4

Guarantee

b)
d)
f)

Rated voltage
Contract and lot number
Volume of container

The insulator manufacturer shall have a minimum of 15 years experience in the field of
manufacturing FRP core rod and composite insulators.
The supplier shall submit to the purchase a letter of guarantee that all materials used in the
manufacturing of the insulators will be durable and able to withstand under specified service
and Climatic conditions for at least 20 years.
8.0

INFORMATION TO BE SUPPLIED WITH THE OFFER

The bidder shall submit the following together with the offer.
a)
The catalogues indicating the model No. and technical literature
b)
General outline and cross-section drawing of the insulator (All data and
descriptive material shall be in English and all dimensions shall be in
metric units.)
c)
Quality assurance certificate conforming to ISO 9001
d)
Completed and filled-in schedule of guaranteed technical particulars
e)
Reference list including quantity of the supplied insulators.
f)
Test Certificates as per Clause 8.1 and 8.2
8.1

Design Tests

The following Design Test Certificates conforming to IEC 1109 shall be furnished as
applicable
i)
Tests on interface and connection of metal fittings.
ii)
Assembled core load-time tests
iii)
Tests of housing: tracking and erosion Test
iv)
Tests for core material
8.2

Type Tests

The following Type Test Certificates conforming to IEC 61109 shall be furnished as
applicable
i)
Dry lightning impulse withstand voltage tests.
ii)
Wet power frequency withstand voltage test
iii)
Mechanical load - time tests
All electrical tests for the insulators supplied under this specification - design, type, sample
and routine, shall be performed and evaluated in accordance with IEC Standard 1109,
unless stipulated otherwise in this specification.
The test of housing (design test) will include min 5000 hours aging test under operating
voltage, acc to Annexure C of the above standard.
The mechanical tests shall be performed and evaluated in accordance with IEC 60383.
8.3

Supply Record

CEB STANDARD R1-082:2007

Supply Record indicating the sales of composite insulators for last 15 years shall be
furnished indicating quantities and year of sale. The manufacturer shall have supplied
composite insulators to a minimum of ten utilities outside the country of manufacture
Test Certificates furnished shall be based on the Type Tests conforming to the relevant
standard.
The Test Certificates shall clearly identify the equipment showing the
manufacturer's identity, Type No. and basic technical parameters, and shall be from a
recognized Independent Testing Authority acceptable to the Purchaser.
Offers of Bidders who fail to furnish the above particulars and sample as requested in
clause 9.0 will be rejected.

9.0

SAMPLE STUDY
One sample of the make and model of the item quoted shall accompany the tender to
facilitate analysis and evaluation of the Bid. While analysing samples, the Purchaser
reserves the right to check dimensions, inspect workmanship and perform essential tests as
prescribed in relevant standards.

10.0

INSPECTION AND TESTING

10.1

Inspection

The selected Bidder shall make necessary arrangements for Engineers of the CEB to inspect
manufacturing processes and testing facilities available with the manufacturer and also to
witness acceptance /sample tests on the composite insulator offered.
10.2

Acceptance/Sample Tests

Following acceptance shall be witnessed by the CEB Inspector.

i)
ii)
iii)
iv)

11.1

Mechanical failing load test

Dielectric test
Electro mechanical load test
Power Wash Test Certifying that there shall be no signs of water penetration
through the housing or Weathersheds to the insulator core as per clause 5.12- para
6

Annex
Annex A 1 Dr. No DS&S / 2007/ 82A- R1-Composite tension insulator set 70kN
Annex A 2 Dr. No DS&S / 2007/ 82B- R1-Composite tension insulator set 100kN
Annex A 3 Dr. No DS&S / 2007/ 82C- R1-Composite suspension insulator set 70kN
Annex A 4 Dr. No DS&S / 2007/ 82D- R1-Composite post insulator
Annex B Schedule of particulars to be filled by the manufacturer

CEB STANDARD R1-082:2007

ANNEX

SCHEDULE OF GUARANTEED TECHNICAL PARTICULARS FOR

MEDIUM VOLTAGE COMPOSITE INSULATORS
(To be filled by the Bidder)
Pin Tension Suspecsion

1)

2)
3)
4)
5)
6)
7)

8)
9)
10)
11)
12)
13)
14)

15)
16)
17)

Name of Manufacturer & country of origin of

a)
Core Rod
b)
Housing/Whethershed
c)
Composite insulator
Model/Reference/Catalogue number
Applicable Standards
Specified mechanical load(Tensile/cantilever)
Dry lightning impulse withstand voltage (peak)
Wet 1 min. power frequency withstand voltage
Material
a)
Core material
b)
Housing and weathersheds material
c)
Sealing material
d)
End fittings material
i)
Bolted type Conductor Tension clamp
ii)
Compression type conductor tension clamp
iii)
Conductor suspension clamp
iv)
Anchor Shackle
v)
Cotter, Split Pin
e)
Average coating thickness of fittings
Nominal length
Creepage distance
Net weight
Whether the Dimensional Drawings furnished
Whether the quality assurance certificates furnished
Whether the type & design test certificates issued by
recognized Independent testing authority furnished
Whether the supply record for last 15 years
indicating utilities outside the country of
manufacture is furnished
Whether the Acceptance Test will be carried
If Yes, then place of testing of Accepting tests
Standard package
a)
Weight of crate
b)
Package volume
------------------------------------------------------------------------------------------------

SEAL AND SIGNATURE OF THE MANUFACTURER /

DATE-------------------

ibm/thaya/emcompo

kN
kV
kV

mm
mm
kg
Yes/NoYes/NoYes/No-

Yes/No Yes/No -

kg
m3