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Effective December 6, 2006, this report has been made publicly available in
accordance with Section 734.3(b)(3) and published in accordance with
Section 734.7 of the U.S. Export Administration Regulations. As a result of
this publication, this report is subject to only copyright protection and does
not require any license agreement from EPRI. This notice supersedes the
export control restrictions and any proprietary licensed material notices embedded
in the document prior to publication.
Field Guide:
Visual Inspection of
Polymer Insulators
1013283
Please note that this field guide is the public version of EPRI
product 1020289, which is available for download only and
contains updated content.
NOTE
For further information about EPRI, call the EPRI Customer Assistance Center at 800.313.3774 or e-mail askepri@epri.com.
Electric Power Research Institute and EPRI are registered service marks of the Electric Power Research Institute, Inc.
Copyright 2006 Electric Power Research Institute, Inc. All rights reserved.
CITATIONS
This report was prepared by
Electric Power Research Institute (EPRI)
1300 W.T. Harris Blvd.
Charlotte, NC 28262
Principal Investigators
A. Phillips
T. Shaw
This report describes research sponsored by EPRI.
The report is a corporate document that should be cited in the literature in the following manner:
Field Guide: Visual Inspection of Polymer Insulators. EPRI, Palo Alto, CA: 2006. 1013283.
iii
CONTENTS
1. Anatomy of a Polymer Insulator . . . . . . . . . . . . . . . .1
2. Definition of Dimensions . . . . . . . . . . . . . . . . . . . . . .5
3. Maintenance Priority Rating . . . . . . . . . . . . . . . . . . .9
Maintenance Priority Rating . . . . . . . . . . . . . . . . . . .10
4. Sheds . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13
Splits and Punctures . . . . . . . . . . . . . . . . . . . . . . . . .14
Torn or Damaged . . . . . . . . . . . . . . . . . . . . . . . . . . .16
Gunshot Damage . . . . . . . . . . . . . . . . . . . . . . . . . . .18
5. Sheath . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .21
Exposed Rod (Electrical Activity) . . . . . . . . . . . . . . .22
Exposed Rod (Mishandling) . . . . . . . . . . . . . . . . . . .24
Unclipped Sections . . . . . . . . . . . . . . . . . . . . . . . . . .26
Splits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .28
Gunshot Damage . . . . . . . . . . . . . . . . . . . . . . . . . . .30
1. POLYMER INSULATORS
ELECTRIC POWER
RESEARCH INSTITUTE
End Fitting
Fiberglass Rod
Sheath
Sheds
End Fitting
Sheds
1. POLYMER INSULATORS
Sheath
Corona Ring
(Installed Incorrectly)
ELECTRIC POWER
RESEARCH INSTITUTE
Corona Ring
2. Definition of Dimensions
2.DEFINITION
OF
DIMENSIONS
Definition of Dimensions
Dimension
Definition
Properties
Influenced
Connection
Length
Physical location
of conductors and
hardware in
configuration
Dry Arc
Distance
(with no
corona ring)
Power frequency,
lightning, and
switching surge
performance
ELECTRIC POWER
RESEARCH INSTITUTE
Dimension
Definition
Properties
Influenced
Dry Arc
Distance
(with corona
ring)
Power frequency,
lightning, and
switching surge
performance
Leakage
(Creepage
Distance)
Contamination
flashover
performance
2.DEFINITION
OF
DIMENSIONS
Each polymer insulator condition illustrated in this Guide has been assigned a Maintenance Priority Rating which
indicates the severity of the problem.
The Maintenance Priority Ranking below is only a recommendation provided by EPRI.
ELECTRIC POWER
RESEARCH INSTITUTE
Definition
11
4. Sheds
Sheds
4. SHEDS
13
Sheds
ELECTRIC POWER
RESEARCH INSTITUTE
Observation
Action
Split progressing
towards or close to
sheath
Puncture through shed
Remove polymer
insulator from service
at next opportunity
What You See: Splits or punctures in sheds (splits often along mold line).
Possible Cause: Aging and/or poor design or manufacture, mishandling.
Resulting Failure Mode: Exposure of rod Brittle Fracture, Flashunder, Rod Destruction by Discharge Activity
4. SHEDS
15
Sheds
Torn or Damaged
ELECTRIC POWER
RESEARCH INSTITUTE
Torn or Damaged
Rating
Observation
Action
Remove polymer
insulator from service
at next opportunity
What You See: Torn/damaged sheds damage does not extend to sheath; rod not exposed.
Possible Cause: Mishandling during shipping, storage, or installation.
Resulting Failure Mode: Tear extends to sheath Exposure of rod Brittle fracture, Flashunder,
Destruction of rod by discharge activity
4. SHEDS
17
Sheds
Gunshot Damage
B
ELECTRIC POWER
RESEARCH INSTITUTE
Gunshot Damage
Rating
B or C
Observation
Action
19
5. Sheath
Sheath
5. SHEATH
21
Sheath
ELECTRIC POWER
RESEARCH INSTITUTE
Action
Remove polymer insulator
from service
What You See: Severe degradation of rubber and rod is exposed to elements.
Possible Cause: Excessive electrical activity, harsh environment, poor design and/or manufacturing.
Resulting Failure Mode: Exposed rod Brittle fracture, Flashunder, Destruction of rod by discharge activity
5. SHEATH
23
Sheath
ELECTRIC POWER
RESEARCH INSTITUTE
Action
Remove polymer insulator
from service
5. SHEATH
25
Sheath
Unclipped Sections
D
ELECTRIC POWER
RESEARCH INSTITUTE
Unclipped Sections
Rating
Observation
D
Exposed rod
- between end fitting and
sheath sections
- between sheath sections
Action
Remove polymer
insulator from service
What You See: Rubber sections unclipped from one another or end fitting; rod may be exposed.
Possible Cause: Mishandling during shipping, storage, and installation.
Resulting Failure Mode: Exposed rod Brittle fracture, Flashunder, Destruction of rod by discharge activity
5. SHEATH
27
Sheath
Splits
D
ELECTRIC POWER
RESEARCH INSTITUTE
Splits
Rating
Observation
Action
Exposure of rod
D
What You See: Splits along sheath sections.
Possible Cause: Excessive discharge activity and/or weathering of material.
Resulting Failure Mode: Splits extend to rod Exposure of rod Brittle fracture, Flashunder, Destruction
of rod by discharge activity
5. SHEATH
29
Sheath
Gunshot Damage
ELECTRIC POWER
RESEARCH INSTITUTE
Gunshot Damage
Rating
Observation
Action
Exposure of rod or
Remove polymer insulator
bullets lodged in sheath from service
What You See: Sheath punctured/damaged by shot. Bullet maybe lodged in rubber.
Possible Cause: Gunshot.
Resulting Failure Mode: Discharge activity Increased sheath damage Exposure of rod Brittle fracture,
Flashunder, Destruction of rod by discharge activity
5. SHEATH
31
Sheds
6. SHEDS
AND
SHEATH
33
Whitening
A
A
ELECTRIC POWER
RESEARCH INSTITUTE
Whitening
Rating
Observation
A
White powder or film
on surface
Action
No action
necessary
A
What You See: Whitening/white powder or film all along sheath surface. More prevalent closer to end
fittings and on surfaces facing the sun.
Possible Cause: Exposure of filler compound due to normal weathering.
Resulting Failure Mode: N/A
6. SHEDS
AND
SHEATH
35
Tracking
D
Severe Tracking*
ELECTRIC POWER
RESEARCH INSTITUTE
Severe Tracking
Tracking
Rating
Observation
Action
D
Conductive path along surface Remove polymer
insulator from service
What You See: Electrically conductive paths along the surface of sheds and/or sheath.
Possible Cause: Leakage currents on highly contaminated polymer insulator surface.
Resulting Failure Mode: Tracking Exposure of rod Brittle fracture, Flashunder, Destruction of rod by
discharge activity
Tracking Flashover
6. SHEDS
AND
SHEATH
37
Animal Damage
C
D
Rodent Damage
ELECTRIC POWER
RESEARCH INSTITUTE
Bird Damage
Animal Damage
B
Rating
Observation
Action
A
B
No action necessary
Monitor and leave in service
What You See: Sheds and sheath have been eaten by birds or rodents.
Possible Cause: Birds or Rodents.
Resulting Failure Mode: Damage extends through sheath Exposure of rod Brittle fracture,
Flashunder, Destruction of rod by discharge activity
6. SHEDS
AND
SHEATH
39
Undermining
C
D
ELECTRIC POWER
RESEARCH INSTITUTE
Undermining
Rating
Observation
Action
Sheath damage,
rod not exposed
Rod exposed
What You See: A puncture hole through sheds, usually at the shed/sheath interface.
Possible Cause: Excessive discharge activity.
Resulting Failure Mode: Exposure of rod Brittle fracture, Flashunder, Destruction of rod by discharge activity
6. SHEDS
AND
SHEATH
41
Cracking
B-C
C
ELECTRIC POWER
RESEARCH INSTITUTE
Cracking
Rating
Observation
B
Only sheds cracked
C
Sheath and sheds cracked
Action
Monitor for future damage
Consider replacement
What You See: Surface Cracks on rubber sheds/sheath greater than 0.1 mm (0.004 in) in depth.
Possible Cause: Harsh environment or poor polymer insulator design/manufacture.
Resulting Failure Mode: Cracks extend through sheath Exposure of rod Brittle fracture, Flashunder,
Destruction of rod by discharge activity
6. SHEDS
AND
SHEATH
43
Alligatoring
C
Shed Top
ELECTRIC POWER
RESEARCH INSTITUTE
Alligatoring
Rating
Observation
A
Limited to surface,
material is not brittle
B
Significant depth
Shed Bottom
A
C
Severe embrittlement
Action
No action
Monitor for increased
degradation
Consider removal from service
Shed Bottom
What You See: A roughening of the surface resembling the texture of alligator skin. Material is brittle
to the touch. The condition is due to loss of filler material.
Possible Cause: Aging of material, harsh environment, or poor design.
Resulting Failure Mode: Excessive material loss Exposure of rod Brittle fracture, Flashunder, Destruction
of rod by discharge activity
6. SHEDS
AND
SHEATH
45
Erosions
ELECTRIC POWER
RESEARCH INSTITUTE
Erosions
Rating
Observation
Action
What You See: Loss (erosion) of material on either sheds or sheath, often close to end fittings.
Possible Cause: Excessive discharge activity, leakage currents, harsh environment, poor design
and/or manufacture, incorrect application of corona ring.
Resulting Failure Mode: Excessive material loss Exposure of rod Brittle fracture, Flashunder,
Destruction of rod by discharge activity
6. SHEDS
AND
SHEATH
47
Contamination
C
ELECTRIC POWER
RESEARCH INSTITUTE
Contamination
Rating
Observation
Action
A-C Varying levels of Depends on level and
contamination
type of contamination
AND
SHEATH
49
Crazing
ELECTRIC POWER
RESEARCH INSTITUTE
Crazing
Rating
Observation
A
Shallow surface fractures
Action
None
What You See: Shallow cracks on shed surface 0.1 mm (0.004 in) or less in depth.
Possible Cause: Weathering.
Resulting Failure Mode: N/A
6. SHEDS
AND
SHEATH
51
ELECTRIC POWER
RESEARCH INSTITUTE
Action
None
What You See: Fungus contamination on polymer insulator sheds and/or sheath.
Possible Cause: Fungal or mold growth.
Resulting Failure Mode: N/A
6. SHEDS
AND
SHEATH
53
Insect Activity
A
ELECTRIC POWER
RESEARCH INSTITUTE
Insect Activity
Rating
Observation
Action
A
Webs, nests, or cocoons present None
B
Excessive webs, nests, or cocoons Consider removal or washing
AND
SHEATH
55
AND
SHEATH
57
ELECTRIC POWER
RESEARCH INSTITUTE
What You See: Silicone grease on polymer insulator sheds and/or sheath. Mainly at shed/sheath interface.
Possible Cause: Natural aging of polymer insulator. Happens with certain polymer insulator designs.
Resulting Failure Mode: N/A
6. SHEDS
AND
SHEATH
59
7. Corona Rings
Corona Ring
(Installed Incorrectly)
Corona Ring
7. CORONA RINGS
61
Corona Rings
Flashover Damage
Leave in Service
Remove from Service
ELECTRIC POWER
RESEARCH INSTITUTE
Flashover Damage
Rating
Observation
Action
Serious damage
Leave in Service
What You See: Corona ring broken/punctured by flashover.
Possible Cause: Flashover due to lightning and/or power arc follow-on currents.
Resulting Failure Mode: Damage to corona ring Corona activity Audio noise, Radio Interference
7. CORONA RINGS
63
Corona Rings
Incorrect Position
C
Correct Position
ELECTRIC POWER
RESEARCH INSTITUTE
Backwards Installation
Correct Position
Incorrect Position
Rating
Observation
C
Corona ring backwards or in
incorrect position
Action
Reinstall corona ring correctly;
check for degradation of
rubber material
Note: Refer to EPRI Guide 1008741, Field Guide: Corona Rings for
Polymer Insulators.
Incorrect Position
What You See: Corona ring installed backwards or in incorrect position.
Possible Cause: Incorrect installation. Check manufacturers recommendations.
Resulting Failure Mode: Damaged sheds/sheath Exposure of rod Brittle fracture, Flashunder, Destruction
of rod by discharge activity
7. CORONA RINGS
65
Corona Rings
Loose Ring
C
ELECTRIC POWER
RESEARCH INSTITUTE
Loose Ring
C
Rating
Observation
C
Corona ring is loose
Action
Reinstall corona ring correctly
and check for damage to
insulator
What You See: Grading ring is loose or not perpendicular to polymer insulator.
Possible Cause: Poor installation or falling ice.
Resulting Failure Mode: Damaged sheds/sheath Exposure of rod Brittle fracture, Flashunder, Destruction
of rod by discharge activity
7. CORONA RINGS
67
Corona Rings
Gunshot Damage
B
ELECTRIC POWER
RESEARCH INSTITUTE
Gunshot Damage
Rating
B
C
Observation
Action
B
What You See: Bullet hole(s) in ring.
Possible Cause: Gunshot.
Resulting Failure Mode: Corona activity AN/RI
7. CORONA RINGS
69
8. End Fittings
End Fitting
End Fitting
8. END FITTINGS
71
End Fittings
Flashover Damage
D
ELECTRIC POWER
RESEARCH INSTITUTE
Flashover Damage
D
Rating
Observation
Action
73
End Fittings
Degraded Seal
C
ELECTRIC POWER
RESEARCH INSTITUTE
Degraded Seal
C
Rating
Observation
Action
Degraded end
fitting seal
Degraded end
fitting seal
What You See: Degraded sealant and rust surrounding end fitting seal.
Possible Cause: Aging, harsh environment, poor design or manufacture, and/or mishandling
during installation.
Resulting Failure Mode: End fitting seal failure Moisture penetration Brittle fracture, Flashunder,
Destruction of rod by discharge activity
8. END FITTINGS
75
End Fittings
Corrosion
B
ELECTRIC POWER
RESEARCH INSTITUTE
Corrosion
Rating
Observation
Action
B
Corrosion and rust
Monitor for further damage
accumulation of end fitting
B
What You See: Corrosion (rust) on polymer insulator metal end fittings.
Possible Cause: Harsh environment and/or poor galvanization.
Resulting Failure Mode: End fitting seal failure Moisture penetration Brittle fracture, Flashunder,
Destruction of rod by discharge activity
End fitting failure Mechanical failure
8. END FITTINGS
77
79
ELECTRIC POWER
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55%
51.1%
45%
35%
24.9%
25%
15%
10.4%
5%
Brittle
Fracture
8.1%
0.5%
Flashunder Mechanical Destruction
End
Failure:
of Rod by Fitting Pullout
Rod Failure Discharge
Activity
Failure Mode
81
Brittle Fracture
Axial Delamination
Broomstick
Fracture Planes
ELECTRIC POWER
RESEARCH INSTITUTE
Brittle Fracture
Type: Mechanical.
Identifying Features: Flat Fracture Plane (single or multiple), Multiple fracture planes maybe separated by axial
delamination. Broomstick.
Possible Cause: Moisture coming in contact with fiberglass rod. Moisture penetration occurs either through
end fitting seal or through rubber weathershed system.
51% of 221 Failures Collected
9. FAILURE MODE GUIDE
83
Flashunder
Tracking Through Rod
ELECTRIC POWER
RESEARCH INSTITUTE
Flashunder
Splits and Puncture Holes
Type: Electrical.
Identifying Features: Tracking through the rod or along the rod/rubber interface. Extends significant length of
insulator. Puncture holes and splits along length of polymer insulator due to power arc and
internal discharge activity bursting out.
Possible Cause: Moisture coming in contact with fiberglass rod. Moisture penetration occurs either through
end fitting seal or through rubber weathershed system.
25% of 221 Failures Collected
9. FAILURE MODE GUIDE
85
ELECTRIC POWER
RESEARCH INSTITUTE
Type: Mechanical.
Identifying Features: Charred / carbonized fiberglass rod. Often frayed ends of fibers exposed.
Possible Cause: Moisture coming in contact with fiberglass rod. Moisture penetration occurs either through
end fitting seal or through rubber weathershed system.
8% of 221 Failures Collected
9. FAILURE MODE GUIDE
87
ELECTRIC POWER
RESEARCH INSTITUTE
Type: Mechanical.
Identifying Features: Rod Failure - Broken rod and / or frayed fibers.
Possible Cause: Manufacturing issues (QC) or mishandling during storing, transporting and installing.
Usually occurs due to mishandling (See image marked 2).
Three cases have been observed due to overheating of the rod during manufacturing and
severe overload (See images marked 1).
10% of 221 Failures Collected
89
ELECTRIC POWER
RESEARCH INSTITUTE
Type: Mechanical.
Identifying Features: Pullout rod separated from end fitting. Occurs on both crimped and epoxy cone end fittings.
Possible Cause: Manufacturing issues (QC) or mechanical overstress or degradation of epoxy compound
(See images marked 3).
1% of 221 Failures Collected
91
If you experience, or have experienced, any failures of polymer insulators, it would be appreciated if you could inform
EPRI of these failures. By recording failures in a central repository, industrywide issues and concerns can be identified.
By making the industry aware of these concerns, unexpected failures may be avoided in the future. Your assistance in
this regard is appreciated.
If you have any questions about the information provided in this Guide, if you want to communicate findings or
actions taken in the field, or if you have suggestions for making the Guide more useful to you, please contact
Dr. Andrew J. Phillips at EPRI (see contact information below).
ELECTRIC POWER
RESEARCH INSTITUTE
Contact Information
93
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Alto, California, and Charlotte, North Carolina, was established in 1973 as an
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Together...Shaping the Future of Electricity
2006 Electric Power Research Institute (EPRI), Inc. All rights reserved. Electric
Power Research Institute ande registered service marks of the Electric Power
Research Institute
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1013283