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Technical specification

STATNETT SF
NYDALEN ALL 33
0484 OSLO
NORWAY


Title
Composite insulator specification

Classification
Open
Document number
1527789
Number of pages + enclosures
22











Distribution




Rev Date Author/
Doc. owner
Controlled Recommended Approved

4

2013-10-31

Miroslav Radoji
Boris Adum / BLE

Kjell ge Halsan /
BLE

Faggruppe-L7

yvind Rue/D

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Revisions

Rev. 4 - 31.10.2013 TL: Data sheet with requirements for insulators added. Connection
length for long-rod insulators now specified. Corrected error in required SML in sect. 5.11.
Rev. 3 - 13.01.2012 SB/MR: Complete specification revision. All chapters have been slightly
modified.
03.03.2011 SB: Updated according to Statnetts specification template
01.11.2006. The insulators shall be delivered with protective covering. The composite
insulator colour shall be grey.

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Table of contents

1 SCOPE ..................................................................................................................................................... 5
2 NORMATIVE REFERENCES ....................................................................................................................... 5
3 DEFINITIONS ........................................................................................................................................... 5
4 GENERAL REQUIREMENTS ....................................................................................................................... 6
4.1 DRAWINGS ................................................................................................................................................... 6
4.2 HANDLING AND ASSEMBLY INSTRUCTIONS ........................................................................................................... 7
4.2.1 Handling and storage instructions .................................................................................................. 7
4.2.2 Assembly instructions ...................................................................................................................... 7
4.3 SERVICE EXPERIENCE ....................................................................................................................................... 7
5 DESIGN REQUIREMENTS ......................................................................................................................... 8
5.1 IDENTIFICATION ............................................................................................................................................. 8
5.2 END FITTINGS ................................................................................................................................................ 8
5.3 END FITTING SEAL .......................................................................................................................................... 8
5.4 HOUSING OF THE COMPOSITE INSULATOR ........................................................................................................... 8
5.5 COLOUR ....................................................................................................................................................... 8
5.6 SHED DESIGN ................................................................................................................................................ 8
5.7 GRADING RING REQUIREMENTS ........................................................................................................................ 9
5.8 ARC PROTECTION ........................................................................................................................................... 9
5.9 DIMENSIONAL REQUIREMENTS ......................................................................................................................... 9
5.10 ELECTRICAL REQUIREMENTS ........................................................................................................................ 9
5.11 MECHANICAL REQUIREMENTS .................................................................................................................... 10
6 TESTS .................................................................................................................................................... 10
6.1 GENERAL.................................................................................................................................................... 11
6.2 DESIGN TESTS.............................................................................................................................................. 11
6.3 TYPE TESTS ................................................................................................................................................. 11
6.4 SAMPLING TESTS .......................................................................................................................................... 12
6.4.1 Dry power frequency withstand test (E1) ...................................................................................... 12
6.4.2 Verification of minimum housing thickness (E1): .......................................................................... 12
6.4.3 Visual inspection (E1+E2) .............................................................................................................. 12
7 PACKING REQUIREMENTS ..................................................................................................................... 13
8 DETAILS OF THE INFORMATION REQUIRED ........................................................................................... 13
8.1 LANGUAGE AND UNITS ................................................................................................................................. 13
8.2 INFORMATION TO BE SUPPLIED WITH TENDER .................................................................................................... 13
8.3 INFORMATION TO BE SUPPLIED AT ORDER ......................................................................................................... 14
ANNEX A - PRINCIPLE DRAWINGS .................................................................................................................. 15
PRINCIPLE DRAWING OF LINE POST INSULATOR FOR JUMPER LOOP SUPPORT (OUTER PHASE .................................................. 15
PRINCIPLE DRAWING OF LONG-ROD INSULATOR FOR JUMPER LOOP SUPPORT (MID PHASE) ................................................... 16
PRINCIPLE DRAWING OF LINE POST INSULATOR FOR LOOP SUPPORT IN TOWERS FOR FJORD CROSSINGS .................................... 17
PRINCIPLE DRAWING OF SUSPENSION AND TENSION STRING COMPOSITE INSULATOR ........................................................... 18

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ANNEX B TABLES OF REQUIREMENTS FOR INSULATORS .............................................................................. 19
TABLE OF REQUIREMENTS FOR LINE POST INSULATOR FOR JUMPER LOOP SUPPORT (OUTER PHASE) ........................................ 19
TABLE OF REQUIREMENTS FOR LONG-ROD INSULATOR FOR JUMPER LOOP SUPPORT (MID PHASE) ........................................... 20
TABLE OF REQUIREMENTS FOR LINE POST INSULATOR FOR FJORD CROSSING LOOP SUPPORT .................................................. 21
TABLE OF REQUIREMENTS FOR SUSPENSION AND TENSION INSULATORS ............................................................................ 22


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1 Scope
This specification covers the design, manufacture, testing and supply of composite line
insulators for use on Statnett's overhead power transmission system.
2 Normative references
Composite insulators shall be designed, manufactured and tested in accordance with the latest
versions and amendments of the following standards:
IEC 60071-1 Insulation co-ordination - Part 1: Definitions, principles and rules
IEC 60120 Dimensions of ball and socket couplings of string insulator units
IEC 60471 Dimensions of clevis and tongue couplings of string insulator units
IEC 60687 Electrical insulating materials used under severe ambient conditions - Test
methods for evaluating resistance to tracking and erosion
IEC 60815-1 Selection and dimensioning of high-voltage insulators intended for use in
polluted conditions - Part 1: Definitions, information and general principles
IEC 60815-3 Selection and dimensioning of high-voltage insulators intended for use in
polluted conditions - Part 3: Polymer insulators for a.c. systems
IEC 61109 Insulators for overhead lines Composite suspension and tension insulators for
a.c. systems with a nominal voltage greater than 1 000 V Definitions, test
methods and acceptance criteria
IEC 61284 Overhead lines - Requirements and tests for fittings
IEC 61466-1 Composite string insulator units for overhead lines with a nominal voltage
greater than 1000 V - Part 1: Standard strength classes and end fittings
IEC 61466-2 Composite string insulator units for overhead lines with a nominal voltage
greater than 1000 V - Part 2: Dimensional and electrical characteristics
IEC 61952 Insulators for overhead lines - Composite line post insulators for a.c. systems
with a nominal voltage greater than 1 000 V - Definitions, test methods and
acceptance criteria
IEC 62073 Guidance on the measurement of wettability of insulator surfaces
IEC 62217 Polymeric insulators for indoor and outdoor use with a nominal voltage greater
than 1 000 V - General definitions, test methods and acceptance criteria
IEC 61952 Insulators for overhead lines - Composite line post insulators for A.C. systems
with a nominal voltage greater than 1 000 V - Definitions, test methods and
acceptance criteria
CIGRE 184 Composite Insulator handling guide. Cigr WG 22.03, Brochure 184, April
2001
3 Definitions
The terms used in this specification are defined in the normative references. Additional
definitions are:

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Corona extinction voltage: the voltage at which corona extinction occurs during a test
voltage series.
Connecting length: refers to the shortest distance between fixing points of the live and
earthed metal ware, ignoring the presence of any stress control rings, but including
intermediate metal parts along the length of the insulator (see Figure 1).


Figure 1 - Definition of connection length
4 General requirements
The supplier shall be fully responsible for his designs and their satisfactory performance in
service. Approval by Statnett does not relieve the supplier of responsibility for the adequacy
of his design, dimensions and details. Only manufacturers approved by Statnett may offer
insulators.
The manufacturer is responsible for suppling bolts for clevis and flange end fittings.
4.1 Drawings
Each tender shall include one copy of all the detail and assembly drawings of the composite
insulator offered. The final versions of these drawing shall be submitted when the tender has
been awarded. The drawings shall contain the following information and dimensions in metric
units:
a) Identification Marking
b) Manufacturers Catalogue number
c) Maximum system voltage
d) Dry lightning impulse withstand voltage
e) Wet switching impulse withstand voltage
f) Wet power frequency withstand voltage
g) Specified mechanical load (SML)
h) Coupling method, dimensions and IEC designation
i) Housing material description
j) Colour of housing
k) Minimum arcing distance
l) Minimum creepage distance
m) Connecting length and tolerance

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n) Position and dimensions of the corona ring(s) if present.
This shall include the tube diameter, ring diameter and its position with respect to the
end fitting.
o) Insulator mass
p) Minimum diameter over sheath
q) Shed diameter of both the large and small sheds
r) Shed spacing
s) Maximum diameter over insulating part
t) Core diameter
u) Core material description
v) Routine test load (RTL)
4.2 Handling and assembly instructions
The supplier shall provide handling, storage and assembly instructions together with the offer,
in one or more documents. Instruction shall be attached to each crate in a weather resistance
material.
4.2.1 Handling and storage instructions
Handling and storage of composite insulators shall be in accordance with Cigr composite
insulator handling guide (Cigre brochure 184). Instructions shall cover at least the following
aspects:
a) Required actions on receiving insulators,
b) Instructions for unpacking,
c) Instructions for storage,
d) Instructions for transportation,
e) Instructions for field handling.
4.2.2 Assembly instructions
Instructions for assembly and attachment of corona (or grading) rings to composite insulators
shall contain all necessary information for correct assembly of rings and include at least:
a) Assembly procedure
b) Tools required
c) Control operations that shall be performed to verify that the ring is located in the
correct position.
4.3 Service experience
Documented evidence shall be submitted of the achieved service experience with the insulator
design offered. This shall at least include details on numbers of insulators installed, life time
of the units and number of insulators removed from service.

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5 Design requirements
5.1 Identification
Each insulator shall be marked with the
a) Name or trademark of the manufacturer
b) Catalogue number
c) The year and month of manufacture
d) The SML
e) A unique serial number or batch identification.
These marks shall be legible and permanently readable for the duration of the service life of
the insulator.
5.2 End fittings
The end fittings of the insulators shall be connected to the core by crimping. All ferrous
material, except stainless steel, shall be hot-dip galvanized.
5.3 End fitting seal
The interface between the end fittings and housing, named the end fitting seal, shall from a
weather proof seal. The supplier shall submit information to prove that the end fitting seal
shall remain water tight for the useful life of the insulator. This shall include the following
information:
a) Details of the end fitting seal design
b) Years of service experience obtained with this particular design
5.4 Housing of the composite insulator
To prevent moisture ingress from the environment, the core shall be totally encapsulated and
fully sealed, from live to earth ends, by the insulator housing.
The housing shall have a minimum thickness of 3 mm over the core at any point along or
around the insulator.
The housing material is specified in the Schedule of requirements.
5.5 Colour
The colour of the composite insulators is in the Schedule of requirements
5.6 Shed design
The shed design shall be according to IEC 60815 Part 3 and the requirements as specified in
the Schedule of requirements.
The Minimum Ratio of Shed Spacing to Shed Projection shall be 0,8.
The shed spacing shall be more than 35 mm.

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5.7 Grading ring requirements
Grading rings shall be designed and supplied to control the E-field along the sheath of the
insulator housing to below 4.5 kV/cm under dry and clean conditions. The E-field shall not
exceed 3.5 kV/cm on the end fitting seal. The design of the ring shall be based on the
maximum system voltage and insulator assembly as shown in Annex A.
The grading ring and attachment design shall allow for the installation or removal of grading
rings while the insulator is installed on the transmission line.
The supplier shall provide proof, in the form of detailed E-field calculations, on the suitability
of the supplied grading ring.
The grading ring design may incorporate the arc protection features for the insulator. It shall
be able to withstand the power arc current and duration specified in the project specific
requirements.
Grading rings shall be designed so that there will not be partial discharges from the ring to the
insulating material even in the case of severe pollution.
Grading rings shall be designed with a smooth surface in order to avoid corona discharges on
the surface of the grading ring.
5.8 Arc protection
The insulator and all fittings in the configuration in which they shall be used shall be resistant
to the consequences of a power arc as described in lEC 61467. If, in the opinion of the
manufacturer, arc protection devices are required to guarantee enough durability, then this
shall be stated on the datasheet. The arc protection may be incorporated in the grading ring
design.
5.9 Dimensional requirements
The insulator shall be dimensioned according to the project specific requirements.
5.10 Electrical requirements
The electrical characteristics shall be as specified in the project specific requirements.

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5.11 Mechanical requirements
The mechanical requirements shall be as specified in the project specific requirements.
For composite suspension and tension insulators a curve showing the load - time strength and
damage limit of the insulators shall be submitted with the offer.
The composite line post insulator shall withstand a mechanical load of 3.0 kN vertically and
1.5 kN horizontally at the far end of the insulator (see Figure 2).
6
3.0 kN
1.5 kN
Figure 2 - Illustration of Mechanical load
requirements

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Tests
6.1 General
The composite insulators shall be tested in accordance with IEC 61109 and IEC 61952 and
the provisions of this specification.
The supplier shall supply test certificates that verify that the insulator meets all required
characteristics.
Statnett reserves the right to randomly select insulators for exit tests to verify that the
insulators conform to all the requirements of this specification and that the traceability of the
insulators is in order. In case of deficiencies the inspector is entitled to demand that a number
of insulators in the batch are retested.
A test report shall be presented to the Client at the final day of testing.
6.2 Design tests
Test specimens and preliminary tests: The test specimens for all the design tests shall be as
described in the IEC 61109 and IEC 61952 with the following amendment:
The tested samples shall also include all the design features present on the insulator being
offered. These may be items such as spacers to fix the core rod in a concentric position in the
housing, joint sealant rings or other housing joints perpendicular to the core that may not be
present on the shorter insulators of the same product line.
Sudden load release test: The sudden load release test is performed as described in the IEC
61109 with the following amendment:
The temperature at which the test is performed shall be -30
o
C to -35
o
C.
Thermal-mechanical test: The thermal mechanical test shall be performed as described in
the IEC 61109 with the thermal cycle amended as follows:
Each 24 h thermal cycle has two temperature levels with a duration of at least 8 h, one at
+45
o
C 5 K, the other at -45
o
C 5 K.
Test of housing: tracking and erosion test: The insulator shall be tested according to IEC
62217 Annex B: Test at multiple stresses
The housing material shall successfully withstand the tracking and erosion test of IEC 60587
at 4.5 kV for 6 hours (incline plane test).
6.3 Type tests
Corona and radio interference voltage: Corona and radio interference voltage (RIV) tests
shall be performed on the composite insulator, with its grading ring and/or arcing protection
device according to Paragraph 14 of IEC 61284. The Test shall be performed according to the
Voltage Method on the Tension Test arrangement.
The specified minimum corona extinction voltage is stated in the project specific
requirements.
At a voltage stress equivalent to the maximum operating voltage the RIV noise limit shall be
60dB (1V/300) at a 500 kHz measurement frequency and reference atmospheric
conditions.

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6.4 Sampling tests
For the sampling tests the rules of IEC 61109 and IEC 61952 shall be followed with the
following amendments:
The sizes of these samples are indicated in the table below.
Table 1 - Sample sizes







If not otherwise agreed with Statnett the tests listed below have to be performed in addition to
the tests specified in IEC 61109 or IEC 61952. Please quote the additional costs involved, if
any, for following sample tests.
6.4.1 Dry power frequency withstand test (E1)
A dry power frequency test shall be performed on sample E1 before the verification of the
specified mechanical load, according to clause 9.2.3 of IEC 62217:2005.
6.4.2 Verification of minimum housing thickness (E1):
The minimum thickness of the housing shall be verified on sample E1 after the verification of
the SML. The verification is performed by cutting the insulator in sections at a maximum
interval of 400 mm. The cuts shall be performed perpendicular to the core rod, midway
between two sheds. A cut shall also be made on the two sheath portions closest to the end
fittings. The housing thickness is then measured at the thinnest point for each cut.
6.4.3 Visual inspection (E1+E2)
A visual inspection shall be made on each insulator with the following additional rejection
criteria: An insulator is rejected when:
a) The mould line or flashing is higher than 1 mm above the shed surface.
b) The depth of cavities is over 1 mm.
c) There are cracks at the root of the sheds next to the fittings
d) There are cracks in the metal fitting
e) There is a separation or lack of sealant at the shed/metal fitting interface
f) The axial misalignment of the metal fitting to the core rod is greater than 2 degrees
g) The rotational misalignment of one metal fitting with respect to the other greater than
10 degrees.
Lot size (N)
Sample size
E1 E2
N 50 2 1
50 < N 100 3 2
100 < N 300 4 3
300 < N IEC 61109 IEC 61109

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7 Packing requirements
Each crate shall contain a maximum of 12 insulators. The packing of the composite insulator
shall be adequate for the handling and transport to the delivery destination. The walls of the
crate shall be sufficiently solid to prevent the entry of rodents. Separate items or accessories,
if packed with the insulators, must be properly secured within the crate.
Please describe your protection method, installation of protection and type of material and
quote addition cost for the covering pr insulator.
The requirements for wood packaging material and dunnage are based on the 2002 FAO
International Standard for Phytosanitary Measures (ISPM) n 15. The following measures are
required (Directive 2004/102/EC) for wood packaging material and dunnage entering Norway
from all non EU countries (except Switzerland):
the wood must be either heat treated or fumigated with methyl bromide, in line with
ISPM15 procedures;
the wood must be officially marked with the ISPM15 stamp;
all wood packaging material has to be debarked.
8 Details of the information required
8.1 Language and Units
All correspondence, literature, drawings and markings shall be submitted in the form of
uniquely identified documents, in the English language.
Dimensions and tolerances shall be in conformance to those specified in the relevant
standards. All dimensions shall be given in SI (metric) units.
8.2 Information to be supplied with tender
The following information shall be submitted with the tender:
a) Preliminary drawing of the complete insulator inclusive corona ring,
b) Material of the end fitting,
c) Fixing materials (bolts, nuts, ),
d) Details of grading rings:
Ring diameter,
Pipe diameter,
Attachment details,
Position relative to the end fittings,
e) Garantueed values as per schedule of requirements,
f) An overview of the relevant design and type test reports containing report references
and test dates,
g) Design test reports,

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h) Type test reports,
i) Preliminary inspection and test plan, according to the quality assurance system of the
manufacturer and the requirements of this specification,
j) Instructions for handling and storage of the composite insulators
k) Instructions for assembly and attachment of corona (grading) rings
l) Representative (correct tower configuration) results of E-field calculations
m) Documentation regarding treatment of wooden crate (chemical, thermal, gas etc.).
n) Power arc test results
o) Completed schedule of requirements
8.3 Information to be supplied at order
The following information shall be submitted within two weeks after contract award:
a) Final drawings, including all definite data
b) Final quality inspection and test plan, according to the quality assurance system of
the manufacturer and the requirements of this specification
The following information shall be included in each packed crate with insulators:
a) Final instructions for handling and storage of the composite insulators
b) Final installation instructions for the assembly and installation of the corona rings

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Annex A - Principle drawings
Principle drawing of line post insulator for jumper loop support (outer phase)
Note that the flange holes shall be in line with tongoue holes, as shown in the drawing.






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Principle drawing of long-rod insulator for jumper loop support (mid phase)






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Principle drawing of line post insulator for loop support in fjord crossing towers
The phase conductor clamp is to be supplied together with insulators.

CONDUCTOR CLAMP

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Principle drawing of suspension and tension string composite insulator


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Annex B Tables of requirements for insulators
Table of requirements for line post insulator for jumper loop support (outer phase)
Technical
Requirements
Guaranteed
values to be
filled in by
manufacturer
1 Manufacturer Please specify
2 Manufacturer's type reference Please specify
3 Classification
(a) Application Suspension
(b) Housing material Silicone Based
(c) Color of housing Grey
4 Operating conditions
(a) System Maximum Voltage U
m
420 kV
(b) Power Arc Rating 30 kA; 1 s
(c) Type of environment Marine
(d) Height above sea level < 1000 m
(e) Operating Temperature
Minimum Temperature -50 C
Maximum Temperature 40 C
Maximum Diurnal Variation 20 C
5 Mechanical Strength Requirements
(a) Specified Cantilever Load SCL 1,5 kN
(b) Specified Minimum Mechanical Failing Load SML 3,0 kN
6 Electrical Strength Requirements
(a) Dry Lightning Impulse Withstand (at Sea Level) 1425 kV
(b) Wet Switching Impulse Withstand (at Sea Level) 1050 kV
(c) Wet Power Frequency Withstand (at Sea Level) 630 kV
(d) Minimum Corona Extinction Voltage (phase to earth) 290 kV (RMS)
7 Dimensions and Clearances
(a) Connecting Length and tolerance Please specify
(b) Minimum Creepage Length 7200 mm
(c) Minimum flash over length 3000 mm
(d) End Fittings Flange-Tongue
8 Quantity


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Table of requirements for long-rod insulator for jumper loop support (mid phase)
Technical
Requirements
Guaranteed
values to be
filled in by
manufacturer
1 Manufacturer Please specify
2 Manufacturer's type reference Please specify
3 Classification
(a) Application Suspension
(b) Housing material Silicone Based
(c) Color of housing Grey
4 Operating conditions
(a) System Maximum Voltage U
m
420 kV
(b) Power Arc Rating 30 kA; 1 s
(c) Type of environment Marine
(d) Height above sea level < 1000 m
(e) Operating Temperature
Minimum Temperature -50 C
Maximum Temperature 40 C
Maximum Diurnal Variation 20 C
5 Mechanical Strength Requirements
(a) Specified Minimum Mechanical Failing Load SML Please specify
6 Electrical Strength Requirements
(a) Dry Lightning Impulse Withstand (at Sea Level) 1425 kV
(b) Wet Switching Impulse Withstand (at Sea Level) 1050 kV
(c) Wet Power Frequency Withstand (at Sea Level) 630 kV
(d) Minimum Corona Extinction Voltage (phase to earth) 290 kV (RMS)
7 Dimensions and Clearances
(a) Connecting Length and tolerance 4750 100 mm
(b) Minimum Creepage Length 7200 mm
(c) Minimum flash over length 3000 mm
(d) End Fittings Clevis-Clevis
8 Quantity


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Table of requirements for line post insulator for loop support in fjord crossing towers
Technical
Requirements
Guaranteed
values to be
filled in by
manufacturer
1 Manufacturer Please specify
2 Manufacturer's type reference Please specify
3 Classification
(a) Application Suspension
(b) Housing material Silicone Based
(c) Color of housing Grey
4 Operating conditions
(a) System Maximum Voltage U
m
420 kV
(b) Power Arc Rating 30 kA; 1 s
(c) Type of environment Marine
(d) Height above sea level < 1000 m
(e) Operating Temperature
Minimum Temperature -50 C
Maximum Temperature 40 C
Maximum Diurnal Variation 20 C
5 Mechanical Strength Requirements
(a) Specified Cantilever Load SCL 1,5 kN
(b) Specified Minimum Mechanical Failing Load SML 3,0 kN
6 Electrical Strength Requirements
(a) Dry Lightning Impulse Withstand (at Sea Level) 1425 kV
(b) Wet Switching Impulse Withstand (at Sea Level) 1050 kV
(c) Wet Power Frequency Withstand (at Sea Level) 630 kV
(d) Minimum Corona Extinction Voltage (phase to earth) 290 kV (RMS)
7 Dimensions and Clearances
(a) Connecting Length and tolerance Please specify
(b) Minimum Creepage Length 7200 mm
(c) Minimum flash over length 3000 mm
(d) End Fittings
(Conductor clamp to be supplied with insulator)
Flange-Flange
(see specification)

8 Quantity


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Table of requirements for suspension and tension string insulators
Technical
Requirements
Guaranteed
values to be
filled in by
manufacturer
1 Manufacturer Please specify
2 Manufacturer's type reference Please specify
3 Classification
(a) Application Suspension
Tension

(b) Housing material Silicone Based
(c) Color of housing Grey
4 Operating conditions
(a) System Maximum Voltage U
m
420 kV
(b) Power Arc Rating 30 kA; 1 s
(c) Type of environment Marine
(d) Height above sea level < 1000 m
(e) Operating Temperature
Minimum Temperature -50 C
Maximum Temperature 40 C
Maximum Diurnal Variation 20 C
5 Mechanical Strength Requirements
(a) Specified Minimum Mechanical Failing Load SML (see tender
either 160, 210, or
300 kN))

6 Electrical Strength Requirements
(a) Dry Lightning Impulse Withstand (at Sea Level) 1425 kV
(b) Wet Switching Impulse Withstand (at Sea Level) 1050 kV
(c) Wet Power Frequency Withstand (at Sea Level) 630 kV
(d) Minimum Corona Extinction Voltage (phase to earth) 290 kV (RMS)
7 Dimensions and Clearances
(a) Connecting Length and tolerance Please specify
(b) Minimum Creepage Length 7200 mm
(c) Minimum flash over length 3000 mm
(d) End Fittings
IEC 60120 Designation Ball & Socket to comply with
specified mechanical requirements

Ball (at live end) -
Socket

8 Quantity

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