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A Detailed Investigation of Overhead Line Insulators

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University of New South Wales

School of Electrical Engineering and Telecommunications

3
INDIVIDUAL Assessment Task: ______________________________

Course Code ELEC 9214 Course Name Power System Equipment

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August 2005
1

A DETAILED INVESTIGATION ON OVERHEAD LINE INSULATORS

Author: Adam Junid

Course: ELEC9214 (Power System Equipment)

School: Electrical Engineering & Telecommunications

Date: 3 June 2006

Disclaimer:

Data and references sourced in this report are, as far as I know, without copyright. I
have avoided, as far as possible, using photos or figures from the web where the
webmaster or owner clearly indicated copyright presence.

Abstract:

This report is a relatively detailed investigation on overhead line insulators. Aspects


covered in this report include insulator type, design and material; environmental and
voltage stress effects, relevant standards, and condition monitoring techniques.

Name: Adam Junid


Elective: ELEC9214
Report Topic: “A Detailed Investigation on Overhead Line Insulators”
2

Acknowledgements:

I thank my course lecturer Dr Toan Phung for his efforts and explanations to my
questions on specific practice and design during ELEC9214 (Power System
Equipment) lectures.

I also thank Azmi Md Yusof of Tenaga Nasional Berhad (TNB) for his helpful feedback
on overhead line types, design, their condition monitoring and typical contractual
specifications.

Name: Adam Junid


Elective: ELEC9214
Report Topic: “A Detailed Investigation on Overhead Line Insulators”
3

Acronyms and Abbreviations:

ANSI: American National Standards Institute


(http://www.ansi.org/)

AS: Australian Standard


(http://www.standards.org.au)

ASTM: American Society for Testing and Materials


(http://en.wikipedia.org/wiki/ASTM_International)

BS: British Standards


(http://en.wikipedia.org/wiki/British_Standards)

IEC: International Electrotechnical Commission


(http://en.wikipedia.org/wiki/International_Electrotechnical_Commission)

JIS: Japanese Industrial Standard


(http://en.wikipedia.org/wiki/Japanese_Industrial_Standard)

MDWL: Maximum Design Withstand Load of the line insulator, also referred to
as an insulator’s designed “holding tension” (IEEE Std 987, 2001)

MAD: Minimum Approach Distance for live line work


(IEEE Std 516, 2003)

MAID: Minimum Air Insulation Distance for live line work


(IEEE Std 516, 2003)

SML: Specified Mechanical Load of the line insulator, also referred to as an


insulator’s “nominated conductor tension” (IEEE Std 987, 2001). An
insulator’s SML will be much less than its MDWL

Std: Standard

Name: Adam Junid


Elective: ELEC9214
Report Topic: “A Detailed Investigation on Overhead Line Insulators”
4

Glossary:

Capacitance
grading: A method of balancing the voltage stress more evenly over a string of
insulator units by adjusting each units’ capacitance towards the line
end (Yusof, 2006b).

Core: Fibre reinforced resin rod that forms the mechanical load-bearing
component of a synthetic composite line insulator.
(IEEE Std 987, 2001)

Creep: “Permanent deformation under stress, time and temperature” (IEEE


Std 987, 2001). Creep behaviour of synthetic composites are different
from metals.

Grading device: A device for controlling the potential gradient at insulator end fittings,
such as a metal ring or various semiconductive polymeric devices.
(IEEE Std 987, 2001)

Linemen: Service personnel for line construction or maintenance.

Overhead line
insulator: A structure designed specifically to electrically insulate live cables
from electricity pylons, towers or poles.

Pylon: A structure that may resemble a pole or tower frame, from which
overhead lines are suspended via overhead line insulators .

Hotstick: An electrically insulative rod or pole used by linemen to perform


measurements or tests on live lines while keeping a safe distance
from it.

Housing: A synthetic composite insulator’s polymeric covering over its core


material.

Hydrophobic: Water-repellent

Phase to
phase
insulator: An insulator coupling two phases together as a means of controlling
conductor spacing during line galloping. It is designed to be loaded in
tension, torsion, bending or compression.
(IEEE Std 987, 2001)

Post insulator: A type of line insulator designed to be loaded in torsion, bending, or


compression. The most common applications are a horizontal line
post where the post projects nearly horizontally from a pylon and is
loaded in flexure by the conductor, and a station post insulator used
Name: Adam Junid
Elective: ELEC9214
Report Topic: “A Detailed Investigation on Overhead Line Insulators”
5

as a bus support. When post insulators are used in disconnect switch


applications, they may also be loaded in torsion.
(IEEE Std 987, 2001)

Shed: The “fins” seen on many line insulators, also referred to as water-shed
structures. Shed geometries are designed to prevent conductive
rainwater paths and increase external surface flashover paths.

Static
shielding: A method of reducing high potential gradients (voltage stress
densities) and reducing capacitance coupling. For line insulators, this
is typically achieved by using Grading devices (Yusof, 2006b).

Strain
insulator: Any line insulator intended primarily to carry tension loads. It includes
dead-end, V-string applications. Strain insulators may also be applied
as suspension insulators, in which case they will carry less tension
than in the strain application.
(IEEE Std 987, 2001)

Support
Insulator: Line insulators such as post and pin types designed to support
cantilevered weight and come with a support (compression) rating.

Tracking: Irreversible deterioration of surface material due to formation of


conductive carbonized paths (IEEE Std 987, 2001).

Treeing: Irreversible internal deterioration by the formation of conductive or


nonconductive filamentary channels (IEEE Std 987, 2001).

Name: Adam Junid


Elective: ELEC9214
Report Topic: “A Detailed Investigation on Overhead Line Insulators”
6

Contents:

Title 1
Abstract 1
Acknowledgements 2
Acronyms and Abbreviations 3
Glossary 4
Contents 6
List of Figures 7

Chapter 1: What is an overhead line insulator? 9


1.1: Types
1.2: Design
1.3: Material
1.4 Testing
1.4.1 Porcelain and glass insulators
1.4.2 Composite synthetic insulators
1.4.3 Design tests
1.4.4 Type tests
1.4.5 Tests to simulate lifespan and wearing
1.5 Other relevant standards

Chapter 2: Customer requirements, selection, installation and wearing 25


2.1 Load bearing requirements
2.2 Electrical withstand requirements
2.3 Creepage distance requirements
2.4 Grading requirements and string efficiency
2.5 Handling requirements
2.6 Installation practice
2.7 Voltage stress effects
2.8 Mechanical stress effects
2.9 Environmental effects
2.10 Vandalism

Chapter 3: Condition monitoring and maintenance 34


3.1 Condition monitoring techniques
3.2 Maintenance
3.3 Replacement
3.4 Reducing bird risk

References and Citations 41

Appendices
A: Insulation Design for Overhead Lines (Narain, 2006) 45
B: Sample design and type test report (Hubbell, 1995)

Name: Adam Junid


Elective: ELEC9214
Report Topic: “A Detailed Investigation on Overhead Line Insulators”
7

List of Figures:

Figure 1: Electrical pylon with disc and pin type overhead line insulators 9

Figure 2: Disc-type insulators applied as a strain (tension) string. 9

Figure 3: Disc insulators. Note the mixture of ball-socket and clevis-tongue


interlocking mechanisms. 10

Figure 4: Longrod insulators with clevis and tongue interlocking mechanisms. 11

Figure 5: Post insulator unit in a suspension application (foreground) and three 11kV
disc insulator units insulating 33kV lines in a strain (tension) application
(background) 12

Figure 6: Pin type insulators. 13

Figure 7: Disc type (foreground) and Pin type (background) insulators. 13

Figure 8: Shackle type insulators. 14

Figure 9: Shackle type insulators in operation. 14

Figure 10: Post type insulators. 15

Figure 11: Hewlett type insulator. 16

Figure 12: Hewlett type insulator in operation with “corona rings” used as grading
devices to help distribute electrical stress at the line bend. 16

Figure 13: Pot type insulators. 17

Figure 14: Synthetic composite insulator end-fitting, silicone rubber housing and
FRP rod core. 19

Figure 15: Suspended glass insulator undergoing HV discharge during accelerated


aging test. 23

Figs. 16,17: Line insulator assemblies for strain (left) and suspension applications. 25

Figure 18: Line insulators taking strain (tension) at change of transmission line
direction. 26

Figure 19: Line insulators assembled prior to pole erection. 28

Figs. 20,21: Overhead lines strung and clipped to insulators after pole erection. 29

Figure 22: Surface tracking seen on a contaminated insulator surface. 30


Name: Adam Junid
Elective: ELEC9214
Report Topic: “A Detailed Investigation on Overhead Line Insulators”
8

Figure 23: Arcing horns used to protect a Hewlett-type insulator from surface
tracking. 31

Figure 24: Disc insulator pin corroded by airborne saltwater. 32

Figure 26: Line insulator polluted by bird droppings. 33

Figs. 26,27: Birds electrocuted at pin-type (upright) insulators. 34

Figure 28: A vandalised disc insulator suspension string. Note the cement
integrity and adhesion to remaining glass despite disc destruction.
Note also the grading device rings below the suspension string. 34

Figs. 29-31: Radio Direction Finding (RDF) methods used to pinpoint RFI sources. 35

Figs. 32,33: Infrared (IR) and Ultraviolet (UV) photography methods used to locate
and monitor insulator defects. 36

Figure 34: Line insulator washing via helicopter. 37

Figure 35: Live line insulator replacement. 38

Figure 36: Application of safe bird perches and bird guards to protect line
insulators. 39

Figs 37,38: Application of bird guards over line insulators. 39

Figure 39: A bird nesting over line insulators. 40

Figure 40: Preparing to hoist a bird nesting platform beneath line insulators. 40

Name: Adam Junid


Elective: ELEC9214
Report Topic: “A Detailed Investigation on Overhead Line Insulators”
9

1.0 What is an overhead line insulator?

Overhead line insulators, as the name suggests, are used to electrically insulate pylons
(see Figure 1) from live electrical cables (RTE, 2006).

Figure 1
Electrical pylon with disc and pin type overhead line insulators
(Source: Teleramics, 2006)

Overhead line insulators may consist of a string of insulator units (see Figure 2),
depending on insulator type and application. The higher the line voltage insulated, the
more insulator units used in the string (RTE, 2006).

Figure 2
Disc-type insulators applied as a strain (tension) string.
(Source: Yusof, 2006a)

Name: Adam Junid


Elective: ELEC9214
Report Topic: “A Detailed Investigation on Overhead Line Insulators”
10

1.1 Types

Different types of line insulators are used, depending on voltage and mechanical strain
(tension) requirements. The more widely used types are as follows (UNSW, 2006a):

1) Disc type (Figure 3 below), where insulation discs (also called insulation units) are
strung together depending on the insulation level desired.

Figure 3
Disc insulators. Note the mixture of ball-socket and clevis-tongue interlocking mechanisms.
(Source: Adapt Australia P/L, 2006)

Each disc is typically rated at 10-12kV, with a capacitance of 30-40pF (UNSW, 2006b).
Discs are strung together via their caps and pins. Locking mechanisms may be ball-
socket or clevis-tongue type. The cap is insulated form the pin via the porcelain (or glass)
disc which adheres to the cap and pin via adhesive cement.

Name: Adam Junid


Elective: ELEC9214
Report Topic: “A Detailed Investigation on Overhead Line Insulators”
11

2) Longrod type (Figure 4 below). These may also be strung together for higher
insulation and may have similar ball-socket and clevis-tongue locking mechanisms
used among the disc types (UNSW, 2006a). Their longer length makes them
applicable for phase-to-phase insulation to reduce line galloping during strong
winds (IEEE Std 987, 2001).

Figure 4
Longrod insulators with clevis and tongue interlocking mechanisms.
(Source: Adapt Australia P/L, 2006)

Name: Adam Junid


Elective: ELEC9214
Report Topic: “A Detailed Investigation on Overhead Line Insulators”
12

Both disc and longrod-type insulators are commonly used in suspension or strain
(tension) insulator applications (Figure 5 below).

Figure 5
Post insulator unit in a suspension application (foreground) and three 11kV disc insulator units insulating
33kV lines in a strain (tension) application (background)
(Source: Teleramics, 2006)

Name: Adam Junid


Elective: ELEC9214
Report Topic: “A Detailed Investigation on Overhead Line Insulators”
13

3) Pin type (Figure 6). Pin types are screwed onto a bolt shank secured on the cross-
arm of the transmission pole or pylon.

Figure 6
Pin type insulators.
(Source: Adapt Australia P/L, 2006)

As seen in the below Figure 7 background, the pin type does not take main
transmission line strain (tension) (Cotton, 1958), and functions as a jumper line
insulator.

Figure 7
Disc type (foreground) and Pin type (background) insulators.
(Source: Teleramics, 2006)

Name: Adam Junid


Elective: ELEC9214
Report Topic: “A Detailed Investigation on Overhead Line Insulators”
14

4) Shackle type insulators (Figures 8 and 9 below). These are mostly applied to
support line strain (tension), such as at changes of transmission line direction
(Cotton, 1958).

Figure 8
Shackle type insulators.
(Source: Utilex, 2006)

Figure 9
Shackle type insulators in operation.
(Source: Teleramics, 2006)

Name: Adam Junid


Elective: ELEC9214
Report Topic: “A Detailed Investigation on Overhead Line Insulators”
15

5) Post type (Figure 10 below). These may have thicker insulation and more discs
than pin types and can be mounted via clamp (Dulmison-Tyco, 2006) or pin
method. They may be applied as a pin or strain type insulator, but rarely as a
suspension type (IEEE Std 987, 2001).

Figure 10
Post type insulators.
(Source: Adapt Australia P/L, 2006)

Since post-type insulators may also also act as a cantilever to support line weight,
post-type insulators normally have a Maximum Design Cantilever Load (MDCL)
rating1 (IEEE Std 987, 2001).
Note: 1. IEEE Std 987 (2001) allows full utilisation of the MDCL rating for cantilever work loadings on post-type applications.

Name: Adam Junid


Elective: ELEC9214
Report Topic: “A Detailed Investigation on Overhead Line Insulators”
16

6) Hewlett type (Figures 11, 12). A variation of the disc type, but can take more
mechanical strain due to internally insulated steel bolt interlocks holding discs
together instead of cement. On the other hand, the Hewlett type has higher internal
electrical stress due to its internal steel bolts.

Figure 11
Hewlett type insulator.
(Source: Gish, 2006)

Figure 12
Hewlett type insulator in operation with “corona rings” used as grading devices to help distribute electrical
stress at the line bend.
(Source: Gish, 2006)

Name: Adam Junid


Elective: ELEC9214
Report Topic: “A Detailed Investigation on Overhead Line Insulators”
17

7) Pot type (see Figure 13), which are usually pin mounted and often used with
telephone lines.

Figure 13
Pot type insulators.
(Source: Teleramics, 2006)

Telephone utilities may use various types of insulators other than the above pot types
(Teleramics, 2006). However, most telephone line insulator design variations appear very
similar to the pot type.

Name: Adam Junid


Elective: ELEC9214
Report Topic: “A Detailed Investigation on Overhead Line Insulators”
18

1.2 Design

Overhead line insulators are designed to have both electrical insulation and mechanical
strength. Highly insulative material is used (see section 1.3) and a recurring design theme
are the “watershed” fins that discourage conductive water paths during rain and provides
the required electrical leakage insulation distance (IEEE Std 987, 2001).

The following design and manufacturing care is taken to ensure smooth electrical stress
loading and mechanical integrity of line insulators:

1) Insulation materials may only be drilled or cored parallel sided, and may only be
hot-punched at forging temperatures (AS1154.1, 2004).

2) Sharp radii of curvature shall be avoided to reduce electrical stress (AS1154.1,


2004). In practice, this also means that porcelain insulators will be glazed and free
from rough particles and unevenness (TNB, 2006). Glass insulators will be free
from internal bubbles (TNB, 2006) that cause partial discharge and put the insulator
at risk of explosion and failure

3) Dimensions such as shed and creepage distances may be adjusted for service in
high pollution environments (with or without rainwashing), areas of airborne sea
salts, icing (IEEE Std 987, 2001) and bird risk areas (AS2947.2, 2002). Extra
creepage distances are used to avoid inadvertent flashover in such highly ionised
atmospheres or areas with large bird sizes (e.g. Sudan, North America).

4) Dimensions of insulator couplings are material strength dependent and guidelines


are specified in national standards such as AS2947.3 (2004) and IEC 120.

5) Voltage and waveform tests, including test control parameters such as water and
dampness are also specified in standards such as AS2947.4 ‘Insulators – Porcelain
and glass for overhead power lines (Voltages greater than 1000Vac) – Part 4: Test
methods – Insulator strings and insulator sets’ (2004).

6) For disc-type insulators, the cement adhesion strength should be strong enough to
hold the contacted disc insulator material to the cap and pin even when the
exposed disc perimeter is shattered or vandalised (Figure 28, section 2.9).

Name: Adam Junid


Elective: ELEC9214
Report Topic: “A Detailed Investigation on Overhead Line Insulators”
19

1.3 Materials

Overhead line insulators are mostly made of the following materials (UNSW, 2006a):

1) Porcelain, which is widely used for all the abovementioned overhead line insulator
types.

2) Glass, which may be used for disc and pin types (Figure 7). It’s thermal stability is
consistent up to 538 degrees C (UNSW, 2006a).

3) Composite synthetics, which may be a combination of fibreglass, plastic and resin.


These are sometimes used for the longrod and post type insulators and have been
in service for more than 25 years (IEEE Std 987, 2001). When modern composite
synthetics are used, often the insulative core consists of glass fibers in a resin-
based matrix to achieve maximum tensile strength (AS4435.1, 1996).

4) Plasticised wood, also referred to as Polymer Concrete (Gunasekaran, 1992) is


sometimes used for post type insulators. Polymer Concrete has demonstrated
thermal stability in excess of 300 degrees C. Since both these designs utlise
organic material, there have been concerns about material lifespan and lack of UV
resistance (Kobayashi et al, 1999).

Figure 14
Synthetic composite insulator end-fitting, silicone rubber housing and FRP rod core.
(Source: Kobayashi et al, 2000)

The housing (Figure 14) that encloses a composite synthetic or plasticized wood
also forms the water-sheds (Kobayashi et al, 1999) and may be hydrophobic (water
repellent), which helps reduce leakage current. Some housings are designed to
remain hydrophobic when polluted, giving composite synthetics a distinct advantage
over porcelain types (Trench, 2000). A rule of thumb operating temperature range
spec for housing is -50 to 50 degrees Celsius (IEEE Std 987, 2001).

5) Coupling fittings for overhead line insulators (i.e. the ball-socket and clevis-tongue
interlocks are normally galvanised cast iron and forged or mild steel. Clevis and
pins may be specified with a coating of hot-dipped galvanised zinc to protect the
base metal against severe corrosion (IEEE Std C135.20, 1998 and TNB, 2006).

6) For ease of load specification identification, each insulator is marked with its specified
Electromechanical Failing Load in conformance with IEC 60383(1993). Each insulator
is also marked with the name or trademark of the manufacturer in accordance with
IEC Publication 60383 (1993) (TNB, 2006).
Name: Adam Junid
Elective: ELEC9214
Report Topic: “A Detailed Investigation on Overhead Line Insulators”
20

1.4 Testing

1.4.1 Porcelain and glass insulators

In Australia, two types of tests are specified (AS1154.1, 2004) for porcelain and glass
insulators: type tests and batch tests. For type tests, AS1154.1 (2004) requires three
representative samples from each factory production specification run tested. A single
factory production specification run is a factory production run using a consistent set of
manufacturing specifications. Type tests for porcelain and glass insulators are mainly
voltage withstand tests (Seeing Corona, 2004).

For batch tests, AS1154.3 (2004) specifies both voltage and mechanical loading tests,
based on the amount of units per batch of customer orders (IEEE C135.61, 1997).

1.4.2 Composite synthetic insulators

Due to greater manufacturing variability in electrical and mechanical properties of


composite synthetic insulators and difficulty in predicting polymer insulation performance
(IEEE Std 987, 2001), two additional tests are required to ensure design viability and
quality consistency: (1) design tests and (2) routine tests (AS4435.1, 2006).

The complete family of design, type, batch and routine tests for composite synthetic
insulators specified in AS4435.1 (2006) appears more comprehensive and stringent than
the tests specified for porcelain and glass in AS1154.3 (2004). The tests detailed in
AS4435.1 (2006) are:

1) Design tests, which include sudden release loading, thermal-mechanical loading,


water immersion, mechanical loading and dye penetration tests to detect material
permeability.

2) Type tests, which include wet power testing and mechanical loading.

3) Batch (sample) tests, which include dimension, locking system and mechanical load
testing.

4) Routine tests, which include visual inspection and mechanical testing.

The mechanical loading test consistently recurs at each stage of testing, underlining the
importance of insulator mechanical integrity under both static and dynamic loading caused
by wind, ice sloughing and fault current (Wang et al, 2001).

Name: Adam Junid


Elective: ELEC9214
Report Topic: “A Detailed Investigation on Overhead Line Insulators”
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1.4.3 Design tests

Design test standards vary from manufacturer to manufacturer. In general, design tests
will indicate specifications for holding tension1, failing load2, and nominated conductor
tension3 for each insulator design. For composite synthetic insulators, holding tensions
(MDWL) are typically 80-90% of failing load (Ultimate Strength), while nominated
conductor tension (SML) are usually specified at 50% of holding tension (Polycast, 2006).
Notes: 1. Also referred to as Maximum Design Withstand Load (MDWL) (IEEE Std 987, 2001)
2. Also referred to as Ultimate Strength, which Is usually twice the MDWL (IEEE Std 987, 2001)
3. Also referred to as Specified Mechanical Load (SML) (IEEE Std 987, 2001)

Minimum design tests for composite synthetic insulators described in IEC 61109 clauses
5.1-5.4 (Hubbell, 1995) are as follows:

1) Tests on Interfaces and Connections of Metal Fittings, which include the following:
- Dry power frequency voltage test
- Sudden load release test
- Thermal-mechanical test
- Water immersion test
- Steep-front impulse voltage test
- Repeated dry power frequency test after the initial five tests.

2) Assembled Core Load-Time Test, which consist of:


- Determination of the average failing load of the core of the assembled
insulator
- Control of the slope of the strength-time curve of the insulator

3) Test of Housing: Tracking and Erosion Test

4) Tests for Core Material, which consists of a:


- Dye penetration test
- Water diffusion test

Depending on application requirements, a more rigourous set of composite synthetic


insulator design test standards may be specified (Kobayashi et al, 2000) as follows:

1) Overall performance:
- UV durability test (ASTM G53)
- Ozone durability test (JIS K 6301)
- Durability of end-fitting interfaces (IEC 61109)
- Core load-time test (IEC 61109)
- Housing tracking and erosion test (IEC 61109)
- Core material test (IEC 61109)
- Flammability test to (IEC 60707)

2) Electrical performance of insulator:


- Power-frequency wet withstand voltage (IEC 60383)
- Lightning impulse wet withstand voltage (IEC 60383)
- Switching impulse wet withstand voltage (IEC 60383)
- Maximum withstand voltage of pollution to (JEC 170)
Name: Adam Junid
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Report Topic: “A Detailed Investigation on Overhead Line Insulators”
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- Arc-withstand characteristics (IEC SC36B (Secretariat) 116)


- Corona characteristics (IEC 60437)
- TV interface test (for V string insulators only)

3) Mechanical performance of insulator:


- Tensile breakdown strength (IEC 61109, JIS C 3801)
- Tensile withstand load (IEC 61109)
- Bending characteristics (JIS C 3801)
- Bending breakdown strength (JIS C 3801)

The IEC 61109 durability of end-fittings test is particularly salient because end fittings are
particularly prone to water ingress due to electromechanical defects. The insulator must
endure 1000kV/microsecond steep-front voltage tests in positive and negative polarity, 25
times each without puncture of the end-fitting, housing or core material.

1.4.4 Type tests

Minimum type tests are covered in detail in IEC 61109 clauses 6.1-6.4 (Hubbell, 1995) are:

1) Dry Lightning Impulse Withstand Voltage Test

2) Wet Power Frequency Test

3) Wet Switching Impulse Test

4) Mechanical Load-Time Test

As in design testing, type testing may also be expanded and/or made more rigourous,
depending on customer requirements.

Name: Adam Junid


Elective: ELEC9214
Report Topic: “A Detailed Investigation on Overhead Line Insulators”
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1.4.5 Tests to simulate lifespan and wearing

For synthetic composite insulators, electrical aging simulation tests (Figure 15) may be
carried out according to IEC 61109 Annex C, which involves accelerated electrical
stressing under a natural environment and measuring cumulative insulator charge,
leakage current, hydrophobicity and surface conditions using scanning electron
microscopy (SEM) and photoelectron spectrometry (XPS) (Kobayashi et al, 1999).

Figure 15
Suspended glass insulator undergoing HV discharge during accelerated aging test.
(Source: Howson, 2006)

In Japan, it was found that overhead line insulator failures increased during typhoons.
Hence there have been studies on the links between increased leakage currents during
typhoons and electrical aging due to “accelerated pollution” during the typhoon (Kobayashi
et al, 1999).

IEEE Std 987 (2001) also provides helpful guidelines in designing tests that simulate
insulator aging, including load-time tests.

Name: Adam Junid


Elective: ELEC9214
Report Topic: “A Detailed Investigation on Overhead Line Insulators”
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1.5 Other relevant standards

Apart from the AS, JIS and IEC design, manufacturing and test standards referred to in
sections 1.2-1.5, relevant BS, IEC and IEEE standards for line insulators and associated
fittings commonly used in the UK, Singapore, Malaysia (TNB, 2006) and US are:

BS

BS 3288-1 :1997 - Insulator and conductor fittings for overhead power lines.

BS 3288-2 :1990 - Specification for a range of fittings

BS 3288-3 :1989 - Dimension of ball and socket coupling of string insulator unit

BS 3288-4 :1989 - Locking devices for Dimension of ball and socket coupling of
string insulator unit: dimensions and test

IEC

IEC 60060 – 1 (1989-11) - High Voltage Test Techniques: General definitions and test
requirements

IEC 60060 – 1 (1989-11) - High Voltage Test Techniques: Measuring system

IEC 60120 (1984-01) - Dimensions of ball and socket coupling string insulator units

IEC 60305 (1995-12) - Characteristics of string insulators of the cap and pin type

IEC 60372 (1984-01) - Locking devices for ball and socket couplings of string
insulator units: dimensions and tests

IEC 60383-1(1993-04) - Insulators for overhead lines with a nominal voltage above
1000V: Ceramic or Glass Insulator units for A.C system

IEC 60383-2(1993-04) - Insulators for overhead lines with a nominal voltage above
1000V: Insulator String and Insulator for A.C System

IEC CISPR 18-2 - Radio Interference characteristics of overhead power lines


and high voltage equipment

IEEE

IEEE 987 (2001) - IEEE Guide for Application of Composite Insulators


(includes sample and routine tests for tension loading)

IEEE C135.61 (1997) - IEE Standard for the Testing of Overhead Transmission and
Distribution Line Hardware
(includes batch testing guidelines)

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2.0 Customer requirements, selection, installation and wearing

Line insulator manufacturers supply their insulators to customers such as utilities or utility
contractors based on customer and application requirements, which in good practice
should exceed application requirements. Prior to placing an order for line insulators, the
customer, contractor or design consultant would specify line insulator designs based on
load bearing requirement calculations, electrical withstand requirements and creepage
distances (which are typically based on IEC 815 pollution indices).

Longrod and disc types insulators are widey applied as either strain (tension) type
insulators or suspension type insulators (Figures 16,17) (Cotton, 1958).

Figures 16 (left) and 17 (right)


Line insulator assemblies for strain (tension) (left) and suspension (right) applications.
(Source: Yusof, 2006a)

Strain type insulator assemblies are commonly applied at long river and road crossings
and changes of transmission line directions (Figure 18).

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Figure 18
Line insulators taking strain (tension) at change of transmission line direction
(Source: Yusof, 2006a)

2.1 Load bearing requirements

To meet mechanical service requirements, line insulator applications are normally ordered
and supplied based on specifications for holding tension1, failing load2 and nominated
conductor tension3 (AS 1154.3, 2004) based on load-bearing calculations. An example of
a line insulator load bearing calculation is given Appendix A. The transmission line
designer must be aware of such load specifications, dynamic tension and safety margins
to apply the insulator correctly. In practice, overhead line system designers will limit
working loads for insulators to 50% of the manufacturer’s nominated conductor tension
(SML) (IEEE Std 987, 2001).

Sometimes, porcelain post-type insulators tested to ANSI standards may only have a
single mechanical rating given as an average of failing load (Ultimate Strength) test
results. In such circumstances, IEEE Std 987 (2001) recommends taking the MDWL as
40% of failing load. It is important for the line designer or drafter to be aware of the
insulator rating systems being used.

To prevent galvanic corrosion, electrical contact (mating) surfaces of the insulator are
normally specified to be of similar material to the adjacent connections(TNB, 2006)
Notes: 1. Also referred to as Maximum Design Withstand Load (MDWL) (IEEE Std 987, 2001)
4. Also referred to as Ultimate Strength, which Is usually twice the MDWL (IEEE Std 987, 2001)
5. Also referred to as Specified Mechanical Load (SML) (IEEE Std 987, 2001)

2.2 Electrical withstand requirements

The transmission line designer must also specify the desired electrical withstand of the
insulators, including switching impulse voltage magnitudes (see Appendix A). For voltages
less then 220kV lightning impulses may have more effect on voltage transients than
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27

switching, so the designer may decide that insulator lightning withstand spec is the critical
spec for insulators applied at less then 220kV.

2.3 Creepage distance requirements

Creepage distance calculations are based on pollution indices at the area of installation.
An sample creepage distance calculation is given in Appendix A and is based on IEC 815
pollution level classifications. Minimum distances for porcelain and composite synthetic
insulators may also be specified (typically 20-25 mm/kV).

2.4 Grading requirements and string efficiency

The transmission line designer must be aware that voltage stress does fall off linearly from
the line end disc with number of insulator discs used. This is due to capacitance coupling
of each disc with the pylon and neighbouring structures. This has an effect on string
efficiency, defined as {total voltage insulated} divided by {number of discs x voltage on line
end unit} (UNSW, 2006b).

Grading devices (Figure 12, section 1.1, Figure 28, section 2.10) are often used to even
out voltage stress along the string by spreading the voltage stress densities away from
line-end units, increasing string efficiency, (UNSW, 2006b). Grading devices also channel
external flashovers away from insulator surfaces, preventing surface damage. They are
specified for insulators 230kV and above in IEEE Std 987 (2001).

Capacitance grading may also be used to increase string efficiency but is rarely
implemented because discs of different capacitance are tedious to stock and replace
(Yusof, 2006b).

Typically, 132kV lines have 10-14 11kV insulator discs and 275kV lines 20-25 11kV discs,
depending on grading ring design and pylon material (Yusof, 2006b).

2.5 Handling requirements

Synthetic composite insulators are light and can cut and scratch easily. The following
handling practice is recommended in IEEE Std 987 (2001):

1) Storage away from rodents.

2) Careful cutting and unpacking of the packaging they are delivered in.

3) Insulators should not be stepped on or stacked directly on one another because


their sheds can cut into each other.

4) They should be handled by their end fittings and inspected for cuts and abrasions
prior to mounting and secured to pre-erected pylons to prevent swinging and
compression.

5) Lift slings should never be placed over the sheds.

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An inspection of type test certificates and data sheets supplied with the insulators is
usually done by nominated utility inspectors prior to actual installation. On-site certificate
checking prior to installation may include checks of sample and routine test certificates.

2.6 Installation practice

A summary of insulator and line installation is as follows.

First, electrical pylons are designed and constructed according to function: suspension,
strain or dead-end. Line insulator specification selection is also made and is thus part of
the pylon’s design and function (IEEE Std 977, 1991). For construction efficiency, line
stringers (travelers) and line insulator assemblies are mounted while the pylon is
assembled on the ground (IEEE Std 1025, 1993) as per Figure 19.

Figure 19
Line insulators assembled prior to pole erection.
(Source: IEEE Std 1025, 1993)

However, if pylon assembly is done from the air via the “pole stack” method, line insulator
mounting is only done after the entire pole stack is completed to prevent “impact loading”
of the line insulators.

IEEE Std 1025 (1993) emphasises grounding of structures under erection when erecting in
the vicinity of energized lines.

After complete assembly and erection of pylons, all pylon bolts should be securely
tightened. Line insulator bolts and nuts must be torqued to design drawing specifications.

Overhead lines are then strung along travellers at 5-8 km/h, avoiding unnecessary torsion
(Figures 20 and 21 below). Cable static seating for more than 24 hours is avoided to
prevent cable creepage (IEEE Std 1025, 1993).

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Figures 20 and 21
Overhead lines strung and clipped to insulators after pole erection.
(Sources: Roosevelt, 1945 and Babock PLC, 2006)

After cables are tensioned and sagged to design drawings, suspension insulator
connection locations are then attached (“clipped”) to their appropriate locations on the
lines (IEEE Std 524, 2003). All lines are grounded during clipping.

After clipping, line conductors are lifted, stringers (travelers) removed, and suspension
clamps are placed on conductors for permanent line tension.

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2.7 Voltage stress effects

For line insulators in general, changes in surface resistance due to chemical changes and
variations on the surface or pollutive films covering the surface have an effect on surface
resistance, leakage currents and withstand voltage of the insulator (IEEE Std 987, 2001).

Hence voltage discharge external to the insulator may occur when the insulation material
is too polluted, wet, and has a reasonably low resistance path allowing for the discharge
during lightning, switching or transient overvoltages. Every time a discharge (external
flashover) occurs, the insulator is at risk of “tracking”, a phenomenon where a physical
indentation or scar appears as a semiconductive “track” caused by an electrical arc over
the insulator surface (Figure 22).

Figure 22
Surface tracking seen on a contaminated insulator surface..
(Source: Kobayashi et al, 2000)

Over time, with more and more discharges along the surface, the track may worsen and
weaken the insulator further. Arcing horns (Figure 23) installed on line insulators may
reduce the risk of surface tracking by providing a discharge path further away from the
insulator material.

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Figure 23
Arcing horns used to protect a Hewlett-type insulator from surface tracking.
(Source: Anderson, 2001)

For the specific case of synthetic composites, studies have shown that the surfaces
synthetic composite polymer housings are relatively mobile compared to porcelain and
glass, and “have much greater freedom for rearranging in the bulk or at the surface” (IEEE
Std 987, 2001). Polymer surfaces also have the interesting ability to interact with
pollutants to reduce the conductance of the pollution layer, thereby improving insulator
performance (IEEE Std 987, 2001).

2.8 Mechanical stress effects

Mechanical stresses are caused by tension, bending, compression or torsion loads, which
may be static or dynamic (IEEE Std 987, 2001). Repeated mechanical stresses can result
in a unique creep1 phenomenon for composite synthetic insulators, where the residual
strength of the composite material remains very high until the instant of failure (IEEE Std
987, 2001). Mechanical stress effects are minimised by stringent mechanical testing of
insulators.

Long term mechanical and insulative performance of composite synthetic insulators are
critically dependent on the continued protection provided by the housing (IEEE Std 987,
2001). Housing deterioration or aging must never result in exposure of the rod to the
environment because this will rapidly change the mechanical characteristics of the rod
(IEEE Std 987, 2001).

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2.9 Environmental effects

Environmental effects on line insulators such as end-fitting moisture ingress, surface area
contamination and extreme wind-loading (such as in typhoons) contribute to insulator
failure (Farquhar, 1998 and Kobayashi et al, 1999). Saltwater ingress can also corrode
disc insulator pin material and weaken its strain (tension) rating (Figure 24).

Figure 24
Disc insulator pin corroded by airborne saltwater.
(Source: Yusof, 2006a)

Periodic testing of insulators using the “Hi-test insulator tester” or “Buzzer” method (section
3.1) minimises risk of insulator failure due to moisture ingress (Farquhar, 1998 and TNB,
2006).

Insulators installed in areas with heavy airborne pollutants such as phosphate, cement,
pulp and lime processing plants have experienced external flashovers due severe insulator
pollution that sometimes engulfs the entire insulator. In South Africa, line insulator
reliability was found to suffer due to bird droppings (Figure 25) and bird electrocutions
(Figure 26, 27). In South Africa, birds perched above line insulators that do not bridge an
electrical circuit still get electrocuted when they excrete continuous “streamer” droppings
or urine that bridge a circuit across the below insulators (Endangered Wildlife Trust, 2006).

Periodic insulator washing (section 3.2 and Western Power, 2006) reduces the risk of
insulator failure due to surface area contamination. Maintenance techniques to prevent
bird perching are discussed in section 3.3.

Bird electrocution occurs when a bird’s wings or “other appendages” complete an electrical
circuit by bridging the gap between two live wires, or a live wire and a grounded wire or
structure (UCSC, 2002). In addition to insulator failure, line outages and endangered bird
deaths, hazardous bushfires and wildfires sometimes start when the electrocuted bird
catches fire and falls to the ground. During electrocution, the insulator is shorted out, the
bird is killed or severely burned, and power outages occur.
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Figure 25
Line insulator polluted by bird droppings.
(Source: Endangered Wildlife Trust, 2006)

Studies by The German Society for Nature Conservation (NABU, 2005b) have shown that:

1) Birds as small as 25 cm can short out pin-type or pot-type “upright” insulators


between the metallic cross-bar and the live line (Vosloo, 2003).

2) Insulator arcing horns with gaps 60 or less are particularly at risk of shorting due to
bird electrocution.

3) Insulators that most at risk to shorting via bird electrocution are those designed
between 1 - 60kV transmission.

A bird-safe arcing horn has been developed in Japan by IERE (2005). In effect, the device
utilises a subhorn and “mini-insulator” that prevents bird electrocution through the main
horns under normal operating conditions. Abnormal operating currents from lightning
strikes and voltage surges are passed through the mini-insulator to the main horns. The
subhorn picks up flashovers due to surface area contamination.

Although vultures in South Africa have been known to eat fibre-optic cable insulation
(Vosloo, 2003), incidents of synthetic composite line insulator housing being eaten by
vultures or other wildlife are rare.

Crows’ nests that contain abandoned wiring material have also been known to short out
insulators when they span a circuit bridge (Endangered Wildlife Trust, 2006). Maintenance
techniques to reduce such risks are discussed in section 3.3.

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Figures 26 and 27
Birds electrocuted at pin-type (upright) insulators.
(Sources: NABU, 2005a, and UCSC, 2002)

2.10 Vandalism

Glass and porcelain insulators are more susceptible to shattering by thrown or shot
projectiles (Figure 29). This is a major reason for recent trends in insulator replacements
to composite synthetics.

Figure 28
A vandalised disc insulator suspension string.
Note the cement integrity and adhesion to remaining glass despite disc destruction.
Note also the grading device rings below the suspension string.
(Source: Yusof, 2006a)

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3.0 Condition monitoring and maintenance

Studies have shown that the highest incidence of insulator failure occurs at dead-end
applications, where the mechanical and electrical stresses are higher (Farquhar, 1998 and
Kobayashi et al, 1999). In addition, non-visible insulator failure is more common than
visible insulator failure (Farquhar, 1998). Symptoms of non-visible insulator failure include
(Farquhar, 1998):

1) Radio frequency interference (RFI)


2) Blinking lights
3) Nuisance overcurrent relay and ground fault tripping
4) Blown fuses
5) Pole top fires

Non-visible insulator failure includes non-visible moisture ingress inside an insulation


string. The moisture may get vapourised during a lightning strike or switching surge,
resulting in sudden internal volume expansion and the insulator blown apart (Farquhar,
1998).

Condition monitoring of line insulators allows operation and maintenance crews to detect
and pinpoint insulator failure. This may be done in real time via leakage current monitoring
(Metwally et al, 2006), during RFI troubleshooting (Martin, 2005), during periodic
inspections or as a safety procedure prior to live line work (Farquhar, 1998).

3.1 Condition monitoring techniques

A power utility that receives customer complaints about non-visible insulator failure
symptoms will usually investigate sources of RFI interference along nearby overhead line
insulators. Such investigations may utilise Radio Direction Finding (RDF) techniques
(Martin, 2005), and equipment for such techniques are shown in Figures 29-31 below.

Figures 29, 30, 31


Radio Direction Finding (RDF) methods used to pinpoint RFI sources.
(Source: Martin, 2005)

Alternatively, or in conjunction with RDF, infrared (SPI, 2006) or UV photography


(Consillia, 2006) may be applied to further pinpoint the insulator responsible for the RFI
noise (Figures 32, 33). An advantage of UV over IR photography is the UV camera’s
ability to capture electrical corona discharges on cracked or punctured insulators at up to
150m range (Ofil, 2005).

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Figures 32, 33
Infrared (IR) and Ultraviolet (UV) photography methods used to locate and monitor insulator defects.
(Sources: Thermal Wave, 2006, Consillia, 2006)

Since non-visible insulator failure may also pose a safety threat to line crews, standard
practice for condition monitoring prior to live-line work involves line testing using a the “Hi-
test insulator tester” (Farquhar, 1998) or “Buzzer” (TNB, 2006) method. This method has
also been used to detect non-visible defects on insulators within hotstick range.

The “Hi-test insulator tester” or “Buzzer” method involves fitting a 10kVDC self-contained
insulator tester at the end of a hotstick (Figure 31) and placing the tester’s two probes
such that the line insulator is in between them. The condition of the insulator is then
indicated via a LED display or audible warning buzzer (Farquhar, 1998).

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3.2 Maintenance

One way of reducing or eliminating radio frequency interference (RFI) caused by insulator
failure or defects is to de-energise the line and replace the insulator. A temporary method
for porcelain or glass insulators is to repair or patch the insulator’s arc voids using grease
(Boucher, 2005). Greasing is not recommended for synthetic composite (IEEE Std 987,
2001), because the grease may worsen tracking along the composite’s surface.

Preventive maintenance of line insulators involves ensuring they are debris, salt and
pollution-free. There have been studies and proposed techniques for assessing line
insulator pollution rates by monitoring insulator leakage currents (Elkateb and Khalifa,
1988) but such real-time pollution monitoring techniques are not yet widespread.

Scheduled washing of line insulators remains a more widespread and economical practice
for preventive maintenance. One method of washing is by helicopter (Figure 34),
however, washing via live line approaches are also possible (Silcock, 2006).

Figure 34
Line insulator washing via helicopter.
(Source: Heliservices, 2006)

IEEE Std 987 (2001) recommends consulting with insulator manufacturers prior to high
pressure washing (3-7 MPa), because not all composite synthetic insulator designs can
withstand such force.

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3.3 Replacement

Damaged and defective insulators usually require replacement. If a porcelain or glass


insulator is to be replaced with its synthetic composite equivalent, care must be taken in
selection of the new insulator because insulators with similar dry arc ratings may have
different electrical characteristics due to the difference in end-fitting lengths. However, if
grading rings are used, the dry arc distance is still the distance between rings (IEEE Std
987, 2001).

Insulator replacement (Figure 35) is typically done via live-line methods (KTPower, 2006
and Smith & Mailey, 2003) to prevent grid power interruption.

Figure 35
Live line insulator replacement.
(Source: Transgrid, 2006)

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3.4 Reducing bird risk

A guide to reducing risks of bird electrocutions by making electrical pylon and design and
insulator location more bird-friendly is provided in a copyrighted brochure by The German
Society for Nature Conservation (NABU, 2005b).

Current practice in South Africa and North America is to place safe perches and bird guard
structures on pylons (Figures 36-38).

Figure 36
Application of safe bird perches and bird guards to protect line insulators.
(Source: Hill Air Force Base, 2006)

Figures 37, 38
Application of bird guards over line insulators.
(Source: Endangered Wildlife Trust, 2006)

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To reduce the risk of birds nesting over power lines (Figure 39) and their urine or dropping
shorting out line insulators, bird nesting platforms (Figure 40) are sometimes constructed
in pylons safely below the level of the line insulators (Endangered Wildlife Trust, 2006).

Figure 39
A bird nesting over line insulators.
(Source: Endangered Wildlife Trust, 2006)

Figure 40
Preparing to hoist a bird nesting platform beneath line insulators.
(Source: Endangered Wildlife Trust, 2006)

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Elective: ELEC9214
Report Topic: “A Detailed Investigation on Overhead Line Insulators”
42

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Name: Adam Junid
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43

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m , viewed 29 May 2006. ml ,
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Roosevelt, F.D. 1945, ‘Stringing rural ml ,
TVA transmission line’ by Rural http://teleramics.com/inuse/inuse2006.ht
Electrification Administration (REA) – ml ,
Tennessee Valley Administration (TVA), http://teleramics.com/type/indextype.html
Franklin D. Roosevelt Library Public , viewed 21 May 2006.
Domain Photographs,
http://www.archives.gov/education/lesson Thermal Wave, 2006, ‘Insulator Oxidation
s/fdr-inaugural/ , viewed 27 May 2006. Effects’, Fittings High Tension,
http://www.thermalwave.it/eng/applic/high
RTE, 2006, Réseau de Transport _voltage.htm , viewed 30 May 2006.
d'Electricité website, http://www.rte-
Name: Adam Junid
Elective: ELEC9214
Report Topic: “A Detailed Investigation on Overhead Line Insulators”
44

TNB, 2006, Extract from sample contract


for insulator, conductor and earthwire Utilex, 2006, ‘Low tension insulators
fittings, Tenaga Nasional Berhad. hardware’,
http://www.utilex.com/lowtension.htm,
Transgrid, 2006, ;Liveline/Barehand viewed 21 May 2006.
Method Application and Development’,
Transgrid, Australia, Vosloo, H, 2003, ‘Birds and power lines’,
http://www.transgrid.com.au/trim/trim1750 ESI Africa, Issue 3, 2003, http://www.esi-
66.pdf , viewed 28 May 2006. africa.com/last/esi_3_2003/033_38.htm ,
viewed 28 May 2006.
Trench, 2000, ‘Composite Insulators’,
http://198.173.130.4/main/trench/trenchm Wang, L. and Yin et al, ‘Study on air
ain.nsf/AllDownLoadDocs/0CC190CFA02 insulator strength under conductor
32D3485256B6E000D13F2/$FILE/E205. galloping condition by phase to phase
pdf , viewed 28 May 2006. spacer’ by Tsinghua University, IEEE
2001 Annual Report Conference on
UCSC, 2002, ‘Bird deaths spur grant: Electrical Insulation and Dielectric
California Energy Commission enlists Phenomena.
UCSC research group in effort to prevent
bird deaths caused by power lines’, Western Power, 2006, ‘Overhead Line
University of California - Santa Cruz Insulator Washing’,
currents online, 27 May 2002, http://www.westernpower.com.au/mainCo
http://www.ucsc.edu/currents/01-02/05- ntent/ourServices/PowerTrainingServices
27/birds.html , viewed 28 May 2006. /coursesAvailable/OverheadPowerlineTra
iningCourses/Overhead_Line_Insulator_
UNSW, 2006a, ‘Overhead Lines: Washing.html , viewed 27 May 2006.
Insulators’, Power System Equipment
(ELEC9214) Lecture Notes, section 4.5, Yusof, A.M. 2006a, Photograph samples
slides 19-21. of line insulators in Malaysia, e-mail
received 30 May 2006.
UNSW, 2006b, ‘Power Equipment:
Insulation of High Voltage Equipment’, Yusof, A.M. 2006b, ‘Insulator String
Electrical Energy Systems (ELEC9213) Efficiency’, e-mail received 2 June 2006.
Lecture Notes, section 4.4.1, slides 33-
43.

Name: Adam Junid


Elective: ELEC9214
Report Topic: “A Detailed Investigation on Overhead Line Insulators”
45

Appendices:

A: Insulation Design for Overhead Lines (Narain, 2006)

B: Sample design and type test report based on IEC 1109 (Hubbell, 1995)

Name: Adam Junid


Elective: ELEC9214
Report Topic: “A Detailed Investigation on Overhead Line Insulators”
Insulation Design for Overhead Lines

By

S. NARAIN
Insulation Design

• Least cost line component


• great impact on line Reliability

DEVICE
• Mechanically support conductors
• Electrically isolate conductors
Types of Insulators
Insulator Pictures
Positives
Performance quantified Lighter weight
Long history of use Pollution performance
Spotting & replacing HYDROPHOBICITY
damaged units Lower installed cost
Inert to environment Impact strength
Negatives
Pin corrosion Reduced strike dist.
Hidden porcelain defects Aging
Real ‘fun’ to shoot Handling
Design Considerations

Assembly Types

Creepage/Leakage

Dry-arcing distance

Connecting length
Insulator Selection
ASSEMBLY TYPES

i.e. STRAIN, SUSPENSION, SLACKSPAN

• Different Orientations of Strings


e.g. I, V, Tension, Special
• Different Strength Requirements
of Components e.g 120kN, 210kN
Mechanical Ratings
As an example - 3xTERN:
SUSPENSION: Conductor unit mass (1.34kg/m)
x9.81/1000 (kg to kN)
Conductor unit weight (0.01315kN/m)
x3 x450m No. of & Weight Span
Conductor weight (17.75kN)
x2.5 Safety factor - adverse conditions
Conductor load (45kN)

STRAIN: Conductor Load = UTS of bundle


3x98.7kN = 296.1kN
End Fittings
Coupled to strength class of Insulator
For the Eskom system:
DESIGNATION IEC120 COUPLING

U120 16

U210 20

U300 24
CREEPAGE

Shortest distance along all contours of external


dielectric surface between those parts that normally
have the operating voltage between them.
G = σΛ
Value depends on Pollution severity -----
L
Creepage...
UNITS: mm/kV

- kV refers to Umax
e.g. 420kV for 400kV

- e.g. 31mm/kV-> 31x420 = 13020mm


Shed Profile
QUANTITY AND QUALITY

Glass - Aerodynamics
Composites - Shed space to Projection Ratio
Pollution Severity
• IEC 815 Classification
Heavy industry,
Domestic, inland,
coastal, irregular rain
agric., mountain

Light Medium Heavy Very Heavy

• Measurements DDDG & ESDD


Pollution Level Pollution Index ESDD
Light 0-75 0.03-0.06
Medium 76-200 0.10-0.20
Heavy 201-350 0.30-0.60
Very Heavy >350 >0.80

• Existing Lines
Pollution Severity

Pollution level Specific creepage


(mm/kV Um)
Light 16
Medium 20
Heavy 25
Very heavy 31
Eskom Requirements

ESKOM Minimum Requirements

Glass: 20mm/kV

Composites: 25mm/kV
Dry-Arcing Distance
SABS 0280: 1998 - Safety Clearances
- Phase-to-earth
- Phase-to-phase
Connecting Length

Dry-Arcing Distance

Creepage Requirements

Tower Geometry
Electrical Withstand

SABS 0280:1998
Up to 220kV
- Lightning impulse withstand
- 60 s power frequency r.m.s.
Above 220kV
- Lightning impulse withstand
- Switching Impulse withstand
Vandalism

GLASS
Fun to shoot
PORCELAIN
Not so funny

COMPOSITES
Not funny at all
IEC
Design and Type Test Report
Veri*Lite Distribution Dead-End Insulators
Insulator Type: PDI-15, PDI-25, PDI-28, PDI-35
Catalog No. 401015, 401025, 401028, 401035
Table of Contents
Section IEC Clause Page
Design Tests 3
I. Tests on Interfaces and Connections
of Metal Fittings 5.1 6
II. Assembled Core Load - Time Test 5.2 6
III. Test of Housing: Tracking and
Erosion Test 5.3 6
IV. Tests for the Core Material 5.4 6
Type Tests 7
I. Dry Lightning Impulse Withstand
Voltage Test 6.1 7
II. Wet Power - Frequency Test 6.2 8
III. Wet Switching Impulse Withstand
Voltage Test 6.3 8
IV. Mechanical Load - Time Test 6.4 8

This design test report records the results of laboratory


tests made on the Ohio Brass Veri*Lite Distribution Dead-
End Insulators.

Tests performed in accordance with IEC Standard 1109,


Clauses 5 and 6.

The Veri*Lite dead-end insulators meet all applicable


requirements of this standard.

John D. Sakich M.G. Comber


Senior Development Engineer Vice President - Engineering

®
®

POWER SYSTEMS, INC.

573-682-5521 Fax 573-682-8714 http://www.hubbellpowersystems.com


©Copyright 2000 Hubbell Power Systems • 210 North Allen Street • Centralia, MO 65240 bulletin EU1440-H
Manufacturer ID

Company Hubbell / The Ohio Brass Company


Contact Person: John Sakich
Mailing Address: 8711 Wadsworth Rd.
Wadsworth, OH 44281
Phone Number: (330) 335-2361
Fax Number: (330) 336-9252

Test Facility

Company Hubbell / The Ohio Brass Company


Test Location: Wadsworth, Ohio
Contact Person: John Sakich
Mailing Address: 8711 Wadsworth Rd.
Wadsworth, OH 44281
Phone Number: (330) 335-2361
Fax Number: (330) 336-9252

2
Design Test Report
Section I Tests on Interfaces and Connections of Metal Fittings
(IEC 1109, Clause 5.1)

I.1 Test specimens and preliminary tests

Insulator design:
Shed/Housing EP/ Silicone Alloy Rubber
Color Dark Gray

Core:
Material Fiberglass, Resin Vinylester
Young’s Modulus 41,300 MPa
Rod Diameter 15.9 mm

Metal Fittings:
Material Forged 1018 or 1020 Steel
Method of Attachment to Core Crimp

Dimensional Data, Electrical Ratings and Mechanical Ratings:

Insulator PDI-15 PDI-25 PDI-28 PDI-35


Section length (mm) 318 475 445 635
Leakage distance (mm) 406 787 660 838
Shed diameter (mm) 92 89 76 76
No. of weathersheds 4 8 8 8
Dry power frequency 110 150 130 200
flashover voltage (kV)
Wet power frequency 75 130 110 160
flashover voltage (kV)
Critical impulse 140 (pos.) 260 (pos.) 200 (pos.) 325 (pos.)
flashover voltage (kV) 160 (neg.) 280 (neg.) 225 (neg.) 360 (neg.)
Specified mechanical 70 70 70 70
load S.M.L. (kN)

The PDI-35 and PDI-28 use the same diameter fiberglass rod and end fittings as the PDI-25 and PDI-15. Tests in Sections
I and II of Design Test Report and Section IV of Type Test Report apply to the PDI-35. Tests in Sections III and IV of Design
Test Report apply to the PDI-28.

Mechanical routine test:


Insulator Type: PDI-35, Catalog No. 401035-0215
Test Date: August 3 to September 6, 1995

Insulator #1 #2 #3
Evaluation (Pass) Yes Yes Yes

3
I.2 Dry power frequency (60 Hz) voltage test

Insulator Type: PDI-35, Catalog No. 401035-0215


Test Date: August 8, 1995

Test atmospheric conditions:


Dry bulb temperature: 22.2°C
Wet bulb temperature: 28.3° C
Barometric pressure: 976.8 kPa

Insulator #1 #2 #3
Uncorrected average flashover voltage (kV rms.) 199 200 200
Corrected average flashover voltage (kV rms.) 200 200 201

I.3 Sudden load release test

Insulator Type: PDI-35, Catalog No. 401035-0215


Test Date: August 3 to September 6, 1995

Insulator #1 #2 #3
Evaluation (Pass) Yes Yes Yes

I.4 Thermal-mechanical test

Insulator Type: PDI-35, Catalog No. 401035-0215


Test Date: August 3 to September 6, 1995

Insulator #1 #2 #3
Pre-cycle reference length (mm) 493.15 492.87 492.94
Post-cycle reference length (mm) 493.28 493.30 493.10
Evaluation (Pass) Yes Yes Yes

I.5 Water immersion test

Insulator Type: PDI-35, Catalog No. 401035-0215


Test Date: September 11-14, 1995

Insulator #1 #2 #3
Visual evaluation (Pass) Yes Yes Yes

4
I.6 Steep-front impulse voltage test

Insulator Type: PDI-35, Catalog No. 401035-0215


Test Date: September 14-15, 1995

The voltage was applied to the first half (line end) and the second half (ground end) separately.

Insulator #1 #2 #1
Line end Ground end Line end Ground end Line end Ground end
Positive average 422 421 426 433 436 425
flashover (kV)
Negative average 443 460 444 469 452 462
flashover (kV)
Evaluation (Pass) Yes Yes Yes Yes Yes Yes

I.7 Post dry power frequency (60 Hz) voltage test

Insulator Type: PDI-35, Catalog No. 401035-0215


Test Date: September 15, 1995

Test atmospheric conditions:


Dry bulb temperature: 21.1°C
Wet bulb temperature: 15.0° C
Barometric pressure: 988.6 kPa

Insulator #1 #2 #3
Uncorrected average flashover voltage (kV rms.) 201 201 198
Corrected average flashover voltage (kV rms.) 202 202 199
Evaluation (Pass) Yes Yes Yes

Power frequency (60 Hz) withstand test (30 minutes):

Insulator #1 #2 #3
Pre-test temperature (°C) 21.2 21.2 21.6
Post-test temperature (°C) 22.9 23.1 23.2
Evaluation (Pass) Yes Yes Yes

5
Section II Assembled Core Load-Time Test (IEC 1109, Clause 5.2)

II.1 Determination of the average failing load of the core of the assembled insulator

Insulator Type: PDI-35, Catalog No. 401035-0215


Test Date: August 3 to September 6, 1995

Insulator #1 #2 #3 Average
Mechanical failing load (kN) 81.8 81.0 81.4 81.4

II.2 Control of the slope of the strength-time curve of the insulator

Insulator Type: PDI-35, Catalog No. 401035-0215


Test Date: August 3 to September 6, 1995

Insulator #4 #5 #6
Evaluation (Pass) Yes Yes Yes

Section III Test of Housing: Tracking and Erosion Test (IEC 1109, Clause 5.3)

Insulator Type: PDI-28, Catalog No. 401028-0215


Test Date: September 1 to October 16, 1995

Insulator #1 (horizontal) #2 (vertical)


Evaluation (Pass) Yes Yes

Section IV Tests for Core Material (IEC 1109, Clause 5.4)

IV.1 Dye penetration test

Insulator Type: PDI-28, Catalog No. 401028-0215


Test Date: May 10, 1995

Sample #1 #2 #3 #4 #5 #6 #7 #8 #9 #10
Evaluation (Pass) Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes

IV.2 Water diffusion test

Insulator Type: PDI-28, Catalog No. 401028-0215


Test Date: May 5-10, 1995

Sample #1 #2 #3 #4 #5 #6
Evaluation (Pass) Yes Yes Yes Yes Yes Yes

6
Type Test Report
Section I Dry Lightning Impulse Withstand Voltage Test (IEC 1109, Clause 6.1)

Insulator Type: PDI-15, Catalog No. 401015


Test Date: January 25-26, 1990

Insulator #1 #2 #3
Positive critical flashover voltage (kV) 150 161 158
Positive withstand voltage (kV) 132 138 137
Negative critical flashover voltage (kV) 184 182 190
Negative withstand voltage (kV) 169 163 166

Insulator Type: PDI-25, Catalog No. 401025


Test Date: January 26 and February 26, 1990

Insulator #1 #2 #3
Positive critical flashover voltage (kV) 271 265 267
Positive withstand voltage (kV) 261 241 256
Negative critical flashover voltage (kV) 288 290 286
Negative withstand voltage (kV) 273 270 269

Insulator Type: PDI-28, Catalog No. 401028


Test Date: March 31, 1995

Insulator #1 #2 #3
Positive critical flashover voltage (kV) 227 227 228
Positive withstand voltage (kV) 213 217 213
Negative critical flashover voltage (kV) 244 244 246
Negative withstand voltage (kV) 235 235 235

Insulator Type: PDI-35, Catalog No. 401035


Test Date: April 6 and 7, 1995

Insulator #1 #2 #3
Positive critical flashover voltage (kV) 391 384 372
Positive withstand voltage (kV) 366 340 341
Negative critical flashover voltage (kV) 397 387 388
Negative withstand voltage (kV) 371 372 372

Results were corrected to normal standard atmospheric conditions.

7
Section II Wet Power Frequency Test (IEC 1109, Clause 6.2)
Insulator Type: PDI-15, Catalog No. 401015
Test Date: January 24, 1990

Insulator #1 #2 #3
Wet flashover voltage (kV) 77 78 77
Wet withstand voltage (kV) 74 72 74

Insulator Type: PDI-25, Catalog No. 401025


Test Date: February 27, 1990

Insulator #1 #2 #3
Wet flashover voltage (kV) 136 134 137
Wet withstand voltage (kV) 133 132 134

Insulator Type: PDI-28, Catalog No. 401028


Test Date: March 10, 1995

Insulator #1 #2 #3
Wet flashover voltage (kV) 123 121 120
Wet withstand voltage (kV) 111 115 117

Insulator Type: PDI-35, Catalog No. 401035


Test Date: April 5, 1995

Insulator #1 #2 #3
Wet flashover voltage (kV) 184 184 187
Wet withstand voltage (kV) 175 174 177

Results were corrected to normal standard atmospheric conditions.

Section III Wet Switching Impulse Withstand Test (IEC 1109, Clause 6.3)
Not applicable.

Section IV Mechanical Load - Time Test (IEC 1109, Clause 6.4)


Insulator Type: PDI-35, Catalog No. 401035
Test Date: August 3 to September 6, 1995

Insulator #1 #2 #3
Evaluation (Pass) Yes Yes Yes

NOTE: Because Hubbell has a policy of continuous product improvement, we reserve the right to change design and specifications without notice.
®

POWER ® ® ® ®
ANDERSON
SYSTEMS, INC.
UNITED STATES • 210 N. Allen • Centralia, Mo 65240 • Phone: 573-682-5521 • Fax: 573-682-8714 • e-mail: hpscontact@hps.hubbell.com
CANADA • 870 Brock Road South • Pickering, Ontario L1W 1Z8 • Phone: 905-839-1138 • Fax: 905-831-6353 • e-mail: jpearl@hubbell-canada.com
MEXICO • Av. Coyoacan No. 1051 • Col. Del Valle • 03100 Mexico, D.F. • Phone: 525-575-2022 • Fax: 525-559-8626 • e-mail: vtasdf@hubbell.com.mx

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