Dos and Donts for Polymer insulator:

Design:

a) The 3-d electric field simulation has to be carried out to validate the size and location of corona
rings for various types and voltage ratings. The software may be standardized by POWERGRID.
b) The max. electric field strength at the triple point(junction of FRP rod, housing and fitting) must be
specified.ex 1.586KVmax/mm.
c) Sealing the interface between rod, fitting and housing is a vital process for the reliability of
composite insulator. Sealing also covers the triple point, the point of highest electrical stress. The
efficiency of sealing by overmoulding i.e. direct application of silicone housing over fitting ,
depends on the composition of the zinc layer on the steel fitting. Use of high pressures during
injection moulding assures better adhesion between zinc layer and housing.However, the
overmoulding technique gives lower electric field stress. Therefore, overmoulding has to be
insisted for voltages above 220KV.FEM analysis of electric field is to be done to validate sealing
methods.
d) Uni-directional corona ring design must be insisted to prevent misapplication of corona rings.
e) Both the end fittings must be of same type of manufacture, preferably hot forging with specified
heat treatment. Presently, some manufacturers produce ball fittings by forging and socket fittings
by SG iron casting.
f) The glass transition temperature of the rod to withstand the temperatures during production as
well as operation must be given in the specification.
Manufacture:
a) The production of rods by pultrusion process must be in a dust and contamination free
environment. Clean room of atleast 300,000 level may be insisted.
b) For proper pultrusion, the viscosity of resin mix should be less than 2000mPas.The viscosity
of the resin is to be checked periodically.For proper wetting of glass fibres with resin,the
temperature of the resin is to be controlled.In winter and rainy season,IR lamps have to be
used in the processing area.
c) Low/medium sandblasting or using a sanding machine to roughen the very smooth surface of
the rod to improve adhesion with housing. However, loose particles must be removed.
d) The rod must be cleaned with a non-polar solvent e.g. mineral spirit followed by polar
solvent e.g. acetone to remove surface contaminants before application of primer.
e) The efficacy of different methods of application of primer on the rod by dippng, spraying,
Blade coating or brushing is to compared to choose the best method.
f) Sufficient time must be allowed for evaporation of solvent at room temperature in humidity
controlled environment or higher temperature of 120 degrees for 60 minutes. Adhesion trials
are necessary because initial adhesion may be suffiecient for handling but final adhesion
strength may be achieved only after a few days.
g) The silicone moulding has to be done ideally within 5 hours after primer application but not
later than 2 days after the application of primer.
h) The end fittings shall be free from defects like cracks, seams, shrinks etc. and should have
smooth surfaces to avoid corona. The roughness of internal surfaces of the fittings is to be
within allowed limits.
i) The hardness of the fittings has to be maintained with closer tolerance than allowed in the
standard to achieve uniform crimping parameters. (say,180-200BHN,standards allow 170-
240)
j) Each batch of rods should be checked for density, Barcol hardness, glass content , glass
transition temperature and capillary dye penetration test.
 k) Fittings should be checked for dimensional control on sampling basis using GO and NO GO
gauges as per standards.
l) Ultrasonic cleaning of metal parts would be desirable to ensure freedom from oil,dust and
other impurities.
m) Security clip is to be checked for dimensions using suitable gage mentioned in the standard.
n) The hold time of radial compression used for crimping shall be linked to first and second level
alarms generated by acoustic emission signals for uniform crimping quality.
o) Suitable arrangement should be made to ensure concentricity of rod and fitting during
crimping.
p) Preferred mode of failure during mechanical tests with proper crimping is pullout of fitting
from the rod. The load at failure should be within a close range.
q) For HTV silicone, injection pressures of the order of 1500 bars and above are desirable.
r) Displacement of rod during moulding due to machine vibration is to be avoided by suitable
guide pins. Autoprogramming facility for reclamping during cure time at regular intervals is
required.
s) Oil leakage from nozzles onto the mould are to be eliminated.

INSTALLATION OF CORONA RINGS

1. It is important to install corona rings at the energized end of polymeric insulators used

on 400 kV overhead lines. This is true for both suspension and tension towers since corona can

reduce the effective service life of such insulators to less than 14 years. It is also important to

take into account whether the route of a line passes areas with agricultural, maritime or industrial

pollution as this will accelerate irreversible structural damage to such insulators. The outcomes

described here were not due to manufacturing defects but rather to the absence a corona ring.

This resulted in a high concentration of electric field, producing corona effects that permanently

destroyed the silicone rubber housing and left the core rod exposed to the environment.

2. Corona rings designed and supplied by their manufacturer must be installed on polymeric

insulators used at transmission voltages. Some manufacturers recommend grading rings at both

ends of the insulator at higher transmission line voltages.

3. It should be mandatory that corona rings be installed during construction of any line and, if such

accessories are missing, the line should not be energized.

4. Visual inspection with binoculars and evaluation of corona activity using high sensitivity UV

cameras can help detect problems affecting polymeric insulators. Both should therefore be part of
 routine annual or bi-annual inspections to prevent insulator failures on overhead transmission

lines.

5. Suitable inspection procedures should be developed by utility maintenance departments to

establish proper methodologies for visual inspection and detection of corona activity on polymeric

insulators at close distance. Work methods must address such inspection with the line energized

or de-energized and the main objective is to evaluate the physical operating condition of

polymeric insulators and identify any units with higher risk of failure. Depending on maintenance

resources, the inspection methodology should be performed tower by tower, climbing each

structure and avoiding stepping on insulators. It can also performed using trucks with aerial work

platforms or insulated ladders.

HANDLING INSTRUCTIONS
Despite the overall advantages, composite insulators are not indestructible. They pass through a
series of stages from manufacturer to final installation: receipt and storage, transport, handling
and in-line installation. All these stages require specific consideration and care. Damage or
laceration of the insulating part can affect the creepage distance or expose the core, thus
reducing the insulating effect and the life of the insulator. All this can happen if improper tools,
such as knives and cutters, are used with the insulators or if the package is unsuitable or poor
quality. The insulators must always be transported in their original packaging and when they are
removed they must never be mixed with other materials.
The composition of the fiberglass-reinforced core is a guarantee of excellent resistance to axial
pull-out force, but long insulators are not designed to withstand twisting or bending forces,
precisely why no twisting or bending loads must be applied. Aluminium ladders are often used for
carrying them. If cords are used to raise the insulator to the point of installation, they must
always be attached to the metal part of the end fittings never to the silicone rubber housing.