Design of external insulation

from the point of view of pollution

Dr.N.Vasudev
High Voltage Division
Central Power Research Institute,
Bangalore-560080
email - vasu@cpri.in
1/5/2010
 Central Power Research Institute
(CPRI)
Centre for applied research in electrical power engineering
assisting the electrical industry in product development and
quality assurance

Independent authority for testing and certification of power

equipment.

1/5/2010
31/5/2010
Million volts , 150 kJ Impulse Generator
 TESTING TRANSFORMER
1/5/2010 1200 kV
 Testing of ZnO Arrester Blocks As per IEC 60099-4

Impulse Current Generator 100 kV, 150 kJ

1/5/2010
 „

POLLUTION LABORATORY

1/5/2010
12x12x12 metre
5 Million volt Impulse Generator

1/5/2010
 1600 kV, 6A POWER FREQUENCY
1/5/2010 TRANSFORMER, UHVRL, HYDERABAD
 POLLUTION LABORATORY, UHVRL
1/5/2010 HYDERABAD
 Suspension Tower of the experimental line
Experimental line – 720 m length , with one
1/5/2010 360 m suspension span
 A corona cage of size 6.4 x 6.4 x 18 meter (length) was
built
Corona Cage
1/5/2010
 CONTENTS

„ Importance of pollution in transmission line

„ Mechanism of pollution flash over (pollution
phenomenon)
„ Testing methods
„ Different types of insulators
„ Pollution problem under DC
„ Importance of pollution mapping
„ Polymeric insulators

1/5/2010
 Importance of pollution problem
- Electrical Insulation is the backbone of all
modern power system networks.

- The rapidly growing demand for electrical

energy, necessitates its transmission at extra
high voltages.

- Line design up to EHV transmission lines is

based on the LI & SI performance of the air
gap
- The reliability of power system mainly depends
on the pollution performance of insulators
1/5/2010
 Specific creepage distance V/s system
voltage
Specific creepage distance

35
30
25
mm/kV

20
15
10
5
0
0 200 400 600 800
System voltage in kV

1/5/2010
 Requirement of creapage length for
pollution performance
Creepage requirement for Pollution performance

25000
Air gap length/Creepage length

20000

15000 Air gap

Creepage actual

10000 Creepage required

5000

0
0 100 200 300 400 500 600 700 800 900
System voltage

1/5/2010
 Classification of pollution

„ Marine pollution
„ Industrial pollution

1/5/2010
 Light

„ Areas with low density of houses equipped

with heating plants.
„ Areas with low density of industries or
houses, but subjected to frequent winds
and/or rainfall.
„ Agricultural areas
„ Mountain areas

1/5/2010
 Medium

„ Areas with high density of houses and/or industries, but

subjected to frequent winds and/or rainfall.
„ Areas exposed to wind from the sea, but not too close to
the coast
(at least several kilometers distant)

1/5/2010
 Heavy

„ Areas with high density of industries and

suburbs of large cities with high density of
heating plants producing pollution.
„ Areas close to the sea or in any case exposed to
relatively strong winds from the sea

1/5/2010
 Very heavy
„ Areas generally of moderate extent, subjected to
conductive dusts and to industrial smokes producing
particularly thick conductive deposits.

„ Areas generally of moderate extent, very close to the

coast and exposed to sea-spray or to very strong &
polluting winds from the sea.

„ Desert areas, characterized by no rain for long

periods, exposed to strong winds carrying sand and
salt, and subjected to regular condensation.

1/5/2010
 Methods for assessing the
pollution severity of the site
„ ESDD measurement
„ Measurement of layer conductance
„ Surge counting
„ Measurement of highest peak of leakage current
„ Measurement of insulator flashover stresses at
experimental stations
„ Deposit gauges
„ Atmospheric sampling
1/5/2010
 SITE SEVERITY MEASUREMENT TECHNIQUES

ELECTRICAL DEPOSIT GAUGES

&
AIR SAMPLING
OFF-LINE ON-LINE

1/5/2010
 OFF-LINE ELECTRICAL
METHODS

EQUIVALENT LAYER
SALT DEPOSIT CONDUCTANCE
DENSITY (ESDD)

1/5/2010
 ON-LINE
ELECTRICAL METHODS

SURGE HIGHEST PEAK FLASHOVER

COUNTING OF LEAKAGE VOLTAGE
CURRENT OBTAINED AT
EXPERIMENTAL
STATIONS

1/5/2010
 1. ESDD MEASUREMENT

ESDD is the quantity of NaCl in

water which would give the same
volume conductivity as that of the
actual deposit dissolved in the
same quantity of water

1/5/2010
 SQUEEZED POLLUTED INSULATOR
COTTON
AFTER
WASHING

BEAKER

COTTON IS DIPPED IN
DISTILLED WATER AND REPEAT THE
THE POLLUTANT IS PROCESS TILL
WASHED THOROUGHLY ALL POLLUTANT
IS WIPED OFF

POLLUTION WIPED OFF

WET COTTON WITH SQEEZED
WITH WET COTTON
WIPED POLLUTANT WET COTTON
AT THE END, WEIGH THE DISTILLED WATER WTH COTTON AND FIND THE WEIGHT OF POLLUTANT
AND ALSO VOLUME CONDUCTIVITY AND THERE BY ESDD

1/5/2010
 SURFACE AREA CALCULATIONS

1
2
3

4
5
D
6
d

1/5/2010
Calculations:
„ From axis to point 1 radius is 35 mm.
„ From axis to point 2 radius is 46 mm.
„ Length between points 1 and 2 is 12 mm.
„ Surface area between two points is Л (35+46)
X12 = 6107.3 mm2.
„ From axis to point 3 radius is 60 mm.
„ Surface area between two points is Л (60+46)
X20=13313.1 mm2.
„ Surface area between points 2 and 3 is Л
(92+46) X50 = 43354 mm2.
„ Surface area between points 2 and 3 is Л
(92+102) X15=9137.4 mm2.
„ The diameter of the circle is 10 mm.
„ The distance of the center of the circle from
the axis is 97 mm.
1/5/2010
 „ Surface area between two points 5 & 6 is
0.5x Л2x10x194=9563.8 mm2.
„ Total top surface area is A=50088.4 mm2.

„ Conductivity of water without pollution is

0.02mS/cm
„ Conductivity of water with pollution is
0.2mS/cm
„ Salinity of the solution is; Sa=(5.7 x 0.15)
1.03.=0.85
„ The salt deposit density in mg/cm2 is;

SDD= Sa X V/A=0.85x250/501=0.425
mg/cm2
V is the volume of water used.
1/5/2010
 Pollution level

Mean severity (Kg/m3) mg/cm2

„ I – Light 10 0.045
„ II- Medium 20 0.15
„ III-Heavy 80 0.45
„ IV- Very heavy 160 -

1/5/2010
 IEC 60815
Artificial pollution test severity withstand values at
Specific creepage the phase to earth voltage
distance Solid layer method
( mm/ kV) Salt-fog method SDD Layer
(kg/m3) (mg/cm )2
Conductivity
(µS)
16 5 to 14 0.03 to 0.06 15 to 20
20 14 to 40 0.1 to 0.2 24 to 35
25 40 to 112 0.3 to 0.6 36
31 > 160 > 0.6 -

1/5/2010
 Pollution map of Italy

1/5/2010
 Pollution map of India ?

1/5/2010
1/5/2010
 Mechanism of pollution
flashover
• Surface current flows
when polluted insulator
is wet.
• This causes dry band
on the surface of
insulator.
• Most of the voltage
drop will be across the
dry band.
• Spark-over
(scintillation)across the
1/5/2010
dry band occurs.
 MECHANISM OF POLLUTION
FLASHOVER
„ Surface current
increases during
scintillation.
„ This causes formation
of more dry bands on
the surface of
insulator.
„ Many scintillation may
occur simultaneously.
„ If scintillation current
crosses a particular
1/5/2010
value then flash-over
 Choice of insulators under polluted
condition
Statistical approach
- determination of the pollution type for the site
under examination and choice of artificial laboratory
test method suitable for simulating this type of
pollution
- a statistical base the surface conductance
of sample insulators
- the corresponding pollution severity level
of the site in terms of severity parameters
characterizing the chosen laboratory test
method
- the withstand severity value of an insulator set
which assures pre fixed risk of failure of the overall
line or station to be designed
1/5/2010
Semi statistical approach

- Equivalent site severity (ESS) is defined based on few

measurements of degree of pollution on site.

1/5/2010
Deterministic approach
- A lower degree of approximation consists in determining
the ESS (Equivalent site severity)
- The artificial pollution test severity is determined
assuming a certain safety margin between ESS and
withstand severity required during pollution test.

1/5/2010
Qualitative, service- based approach

- Design can be as per IEC 60815

- This method is based on knowledge acquired
during long service experience in different
countries

1/5/2010
 Methods of combating pollution
problems
„ Proper design of insulators
- Creapage extension
- Aero dynamic design
- Booster sheds
- Increase no of insulators
- Resistive glazed insulators

1/5/2010
 Methods to combat pollution
problems
„ Hot line washing
„ Greasing
„ RTV coatings
– Polyurethane coatings
- Silicone rubber coatings
Performance - Coating thickness
- Coating life
- End of life
1/5/2010
 Proper selection of insulators

1/5/2010
 What does an insulator do?
Maintains an Air Gap
ƒ Separates Line from Ground
Length of air gap depends primarily on system
voltage, modified by desired safety margin,
contamination, etc.
ƒ Resists Mechanical Stresses

ƒ Resists Electrical Stresses

ƒ system voltage/fields, over voltages
ƒ Resists Environmental Stresses heat, cold, UV,
contamination, etc.

1/5/2010
 Types of Insulators –
Distribution

1/5/2010
 Insulator Types
Distribution lines
ƒ Pin type insulators -mainly porcelain,
growing use of polymeric (HDPE –
high density polyethylene), limited
use of glass
ƒ Line post insulators – porcelain,
polymeric
ƒ Dead end insulators – polymeric,
porcelain, glass
ƒ Spool insulators – porcelain,
polymeric
1/5/2010
ƒ Strain insulators, polymeric, porcelain
 Types of Insulators –
Distribution

1/5/2010
 Insulator Types
Transmission lines
„ Suspension insulators - new installations
mainly polymeric insulators, porcelain and
glass now used less frequently

ƒ Line post insulators – mainly polymeric for

new lines and installations, porcelain much
less frequent now

1/5/2010
Types of Insulators – Transmission

1/5/2010
 Insulator Types
Substations

ƒ Post insulators – porcelain

primarily, NCIs growing in use at
lower voltages (~145 kV and below)

ƒ Suspension insulators –polymeric

& ceramic
Cap and Pin insulators – Standard,
1/5/2010 semi fog & anti fog
 Types of Insulators –
Substation

1/5/2010
 Insulator Types - Comparisons
Ceramic Non Ceramic
• Porcelain or toughened • Typically fiberglass rod
glass with rubber (EPDM or
• Metal components fixed
Silicone) sheath and
with cement weather sheds
• HDPE line insulator
applications
• Cycloaliphatic (epoxies)
station applications,
some line applications
• Metal components
normally crimped

1/5/2010
 Insulator Types - Comparisons
Ceramic
• Materials very resistant
to UV, contaminant
degradation, electric field
degradation
• Materials strong in
compression, weaker in
tension
• High modulus of
elasticity - stiff
• Brittle, require more
careful handling
• Heavier than NCIs
1/5/2010
Non Ceramic
• Hydrophobic materials
improve contamination
performance
• Strong in tension, weaker
in compression
• Deflection under load can
be an issue
• Lighter – easier to handle
• Electric field stresses
must be considered
 Insulator Types - Comparisons
Ceramic Non Ceramic
• Generally designs are • “Material properties
“mature” have been improved –
UV resistance much
• Limited flexibility of improved for example
dimensions • Standardized product
• Process limitations on lines now exist
sizes and shapes • Balancing act - leakage
• Applications/handling distance/field stress –
methods generally well take advantage of
understood hydrophobicity
• Application parameters
still being developed
• Line design implications

1/5/2010
(lighter weight, improved
shock resistance)
 Design Criteria - Electrical
„ Dry Arcing
Distance – (Strike
Distance) – “The
shortest distance
through the
surrounding
medium between
terminal
electrodes….”

1/5/2010
 Design Criteria - Electrical
„ Define system voltage kV

„ DetermineLeakage
Distance Required

„ Switching
Over-voltage
Requirements

„ Impulse Over-voltage

„ Pollution zones

1/5/2010
 Design Criteria – Leakage Distance

„ What is Leakage
Distance?
„ “The sum of the
shortest distances
measured along the
insulating surfaces
between the
conductive parts, as
arranged for dry
flashover test.”
1/5/2010
 Design Criteria - Electrical
„What’s an appropriate Leakage
Distance?
Empirical Determination
„ What’s been used successfully?
„ If Flashovers occur – add more leak?

„ ESDD (Equivalent Salt Deposit Density)

Determination
„ Measure ESDD
„ Pollution Monitors
„ Dummy Insulators
„ Remove in-service insulators
„ Evaluate ESDD and select appropriate Leakage
1/5/2010 Distance
 Questions?

1/5/2010
 TEST METHODS

„ Representability
„ Reproducibility

„ Repeatability

1/5/2010
 3R
„ Representability is the ability of an
artificial test procedure to simulate service
conditions that can give similar absolute
and relative results.
„ Reproducibility is the extent to which a
specified test gives the same results when
performed in different laboratories.
„ Repeatability is the degree to which a test
gives the same results when performed on
different occasions in the same laboratory
1/5/2010
 TESTING METHODS
- Salt fog method

- Solid layer method

* Procedure-A
* Procedure-B

1/5/2010
 SALT-FOG METHOD

- If insulator withstands, salinity can be

increased in order to find out at what
salinity it fails.
- The previous salinity is the maximum
withstand salinity.
- The site severity should be much less
than the maximum withstand value for the
good performance of the insulator.
1/5/2010
 TEST ARRANGEMENT

1/5/2010
 Solid Layer Method

„ Procedure A Wetting before & during energization

„ Procedure B Wetting after energization

1/5/2010
 TEST SET-UP FOR SOLID LAYER METHOD
CONDUCTANCE (G) MEASUREMENT
A

220 V V TO SUPPORT

HIGH DUMMY INSULATOR

VOLTAGE
SOURCE
TEST INSULATOR

H.V. STEAM

G = (I / V) ∪ POLYTHENE
ENCLOSURE
Where, I = Max. Leakage Current, A
V= Test Voltage, Volts

STEAM GENERATION SYSTEM 220 V

SUPPLY
1/5/2010
 Solid layer method

1/5/2010
 Solid layer method

1/5/2010
 Solid layer method

1/5/2010
System Highest Number of Creapage Specific
Voltage system insulators distance creapage
(kV) Voltage (mm) distance
(kV) (mm/kV)
11 12 1 350 29.17
33 36 3 1050 29.17
66 72 5 1750 24.3
132 145 9 3150 21.7
220 245 14 4900 20
400 420 23 8050 19.16
750 800 36 12600 15.75

Specific creepage distance

35
30
25

mm/kV
20
15
10
5
0
0 200 400 600 800
1/5/2010 System voltage in kV
 IEC 60815
Artificial pollution test severity withstand values at
Specific creepage the phase to earth voltage
distance Solid layer method
( mm/ kV) Salt-fog method SDD Layer
(kg/m3) (mg/cm2) Conductivity
(µS)
16 5 to 14 0.03 to 0.06 15 to 20
20 14 to 40 0.1 to 0.2 24 to 35
25 40 to 112 0.3 to 0.6 36
31 > 160 > 0.6 -

1/5/2010
 Questions?

1/5/2010
 Problems faced by by Glass & porcelain
Insulators

• Decapping
• Puncture
• Flashover
• Shattering
• Cement Growth Cracking
• Pin erosion

1/5/2010
 Polymer/composite Insulators
„ Lightweight polymeric insulators considered
necessary for 1,000 kV lines
„ 1959: GE develops first polymeric insulator,
but experiences problems with tracking &
erosion of epoxy sheds
„ 1960s: Europeans introduce first generation
of modern Polymers fiber glass rod covered
with various types of polymer sheds &
hardware
1/5/2010
 Elements of Modern Polymers

„ Fiberglass Rod
„ Shed
„ Sheath
„ Metal end fittings

1/5/2010
 Composite insulators in Indian
Power system
„ POWERGRID 400 kV Lines
„ NTPC – Dadri Switch yard 220 kV & 400
kV
„ APTRANSCO - 132 kV & 220 kV
„ GETCO - 66 kV, 132 kV & 220 kV
„ TNEB- 110 kV & 220 kV
„ MSEB- 132 kV & 220 KV
1/5/2010
 Advantage of polymers over
ceramics
„ 90% weight reduction
„ Reduced breakage
„ Lower installation costs
„ Aesthetically more pleasing
„ Improved resistance to vandalism
„ Improved handling of shock loads
„ Improved power frequency insulation
„ Improved contamination performance
1/5/2010
 Problems encountered by first
generation NCI
„ Shed material tracking
„ shed puncture
„ insulator surface chalking and crazing
„ reduction in contamination flashover
strength
„ mechanical strength deterioration
„ end fitting loosening
„ brittle fracture

1/5/2010
 Brittle Fracture on Composite
Insulator

1/5/2010
 Tracking and erosion on composite
insulator

1/5/2010
 Biological Growth on Composite
Insulators

1/5/2010
 Failure of first generation NCI:
Related to
known weakness, worsens gradually and
are visible

1/5/2010
 18 years of field service with out
failure
Corona Cutting, hardware/shed
interface

1/5/2010
 Failure of first generation NCI:
Related to
known weakness, worsens gradually and
are visible

1/5/2010
 Storing

1/5/2010
 Failure of first generation NCI:
Related to
known weakness, worsens gradually and
are visible

1/5/2010
 Failure of first generation NCI

1/5/2010
 Problems seen in Today’s NCI.
Interface bonding issue

1/5/2010
 Storing

1/5/2010
 Failure of Rod Due to Discharges

Water ingress into rod

Discharge activity
degrades rod
Chemically
Ionic wind
UV
Temperature
Rod fails under load

1/5/2010
1/5/2010
1/5/2010
1/5/2010
Results after 10000 hours of ageing

1/5/2010
 Insulator performance is
dependant on many factors
Performance -
Material
-
Design
-
Manufacturing

Processing
-
Application
-
Environment
1/5/2010
 Selection of Housing Material
Choice of housing material, formulation
depends on
„ Insulator design

„ Manufacturing process

„ Cost

„ And properties deemed important by

supplier and user

1/5/2010
 DESIGNS

Modular design
Regular sheds
Alternate sheds

Moulded design

1/5/2010
 Advantage of modular designs

1/5/2010
 Manufacturing process

•Compression moulding

• Transfer moulding

• Injection moulding

1/5/2010
 Injection moulding

1/5/2010
 Multi step moulding

1/5/2010
1/5/2010
1/5/2010
 Injection moulding

1/5/2010
Extruder OVEN

Weather sheds
1/5/2010
1/5/2010
1/5/2010
 Materials for Housing

„ Silicone Rubber HTV, RTV, LSR

„ Ethylene Propylene Rubbers: EPDM, EP
silicone alloys
„ Epoxies: Cycloaliphatic epoxies
„ Polyolefins : Ethylele Vinyl Acetate
(heat shrinkable material)

1/5/2010
1/5/2010
1/5/2010
 Hydrophobicity

„ Ability of surface to prevent water filming – water

drops beading
„ Often misunderstood property
- Hydrophobicity loss does not mean failure

1/5/2010
 Wettability

More hydrophobic Less

Hydrophobic

Critical surface tension (dynes/cm)

0 10 20 30 40 50
Flourines
Silicone
EPS
Epoxy

1/5/2010
 Hydrophobicity
„ All polymers are initially hydrophobic
„ Hydrophobicity is reduced during service
- Dirt, UV, Corona, discharges
„ For EPs , Epoxy, the above will eliminate
hydrophobicity
„ For silicones, only excessive corona and strong
discharges can destroy hydrophobicity locally.

1/5/2010
 Hydrophobicity recovery

„ Desirable as high surface resistance restored

„ Mainly due to diffusion of LMW polymer chains from bulk
to surface
„ Recovery ability different for polymers, Silicones-
highest – high surface resistance obtained even before
visible recovery occurs
„ Recovery ability lost for EP, epoxy when dirty

1/5/2010
 Hydrophobicity recovery
„ Silicones exhibit recovery even when contaminated
„ Is dependent on
- formulation
- temperature
- contamination ( thickness and type)
- ageing

1/5/2010
 Hydrophobicity recovery

Hydrophobicity before energization Hydrophobicity after energization

1/5/2010
 Hydrophobicity transfer

1/5/2010
 Methods for evaluating
Hydrophobicity
„ Contact angle – Advantages-
simple, inexpensive, quick,
field employable
Limitations- un reliable, affected by
weather

1/5/2010
 STRI Classification of
Hydrophobicity

1/5/2010
 Questions?

1/5/2010
 Grading rings

Energized End Grading Ring Grounded End Grading Rin

1/5/2010
 Why Grading Rings?
Prevent corona under dry conditions
Radio interference, audio noise
Prevent internal discharge
Voids & defects in rubber
Reduce wetting
corona activity
Ages rubber &
end fitting seal

1/5/2010
 Wetting Corona Aging Mechanism

Corona generates
„ UV light

„ Heat

„ Gaseous by-products

O3 (Ozone), NO2
NO2 + H2O = HNO3 (Nitric Acid)
1/5/2010
 Failure Modes
• Brittle fracture
• Failure of rod due to discharges
• End fitting attachment
• Contamination flashover
• Mechanical failure of rod

1/5/2010
 Failure of Rod Due to Discharges

Water ingress into rod

Discharge activity
degrades rod
Chemically
Ionic wind
UV
Temperature
Rod fails under load

1/5/2010
 End-fitting Attachment
„ Under crimping - pull out
„ Over Crimping
Cracked rod may break with
time

1/5/2010
 Mechanical Failure of Rod

Rod may fail mechanically in service due to:

• Poor rod manufacture
• Mishandling during shipping or installation
• Severe torsion
• Severe bending
• Mistreatment during manufacture
• Overloading

1/5/2010
 Issues with Polymers
• Aging of Polymer Materials
• Limited Experience
• Large Variation in designs, materials and
manufacturing techniques
• Handling concerns
Storing, transporting and installing

1/5/2010
 AGEING PHENOMENON
HYDROPHOPIC SURFACE

DRYBAND ARCING, CORONA

HYDROPHILLIC SURFACE

MORE DRY BAND ARCING CORONA

LOSS OF POLYMER FILLER EXPOSED

POLYMER BECOMES LESS AMORPHOUS

EROSION

TRACKING
LOSS OF MATERIAL
EXPOSED
FLASHOVER
1/5/2010
Flashover
 STATUS OF INTERNATIONAL
STANDARDS FOR POLYMERIC
INSULATORS
„ Standards for materials (ASTM)
- UV tests
„ Standards for insulators
- Tests for contamination
performance

1/5/2010
 Laboratory Tests

Desirable features of any laboratory tests

CQA
„ Cheap
„ Quick
„ Accurate

1/5/2010
 ASTM TESTS COVER

„ Electrical properties ( Bulk and surface)

„ Mechanical Properties
„ Physical properties
„ Chemical properties
„ Environmental properties
OF THE MATERIALS

1/5/2010
 UV Tests For Materials
„ ASTM G 26 (Xenon arc)
„ ASTM G 53 (Flourescent)
„ ASTM G 23 (Corbon arc)
„ Some of these tests include humidity, run for
1000-5000 hours
„ All UV sources do not duplicate sun light
These tests are adequate to screen bad
formulations

1/5/2010
 Material tracking and Erosion
tests
„ ASTM D 2303 –
Inclined plane test
„ ASTM D 2132 - Dust
& fog test
„ ASTM D 3638 - Drop
test

All the above tests

should be viewed
as minimum
1/5/2010
requirement for
material
 Limitation of ASTM -IEC
Tracking and erosion tests
„ Surface condition and discharge activity
not benchmarked with service
„ Ignores hydophobic properties . Results are
largely controlled by filler magnitudes

1/5/2010
STANDARDS FOR INSULATORS

„ ASNI C 29.11
„ IEC 61109, IEC 62217
„ CEA LWIWG (Line post, dead end)
„ IEEE 1024 (Distribution insulators)
„ ANSI C 62.11 (Surge arresters)

1/5/2010
 What do insulator standards
evaluate
„ Mechanical, Electrical and Ageing
characteristics
„ Some tests are on sectional length but not on
full insulators
„ Field failures modes can not be duplicated by
the standards
Therefore knowledge of benefits and
limitations of standards is useful for
application of polymeric insulators

1/5/2010
 ANSI/IEC Tests
„ Design tests- Verify suitability of proto type
design, material and method
of manufacture

„ Type tests - Verify those characteristics of

insulators which depend on
the size and shape
„ Routine tests - Eliminate insulators with
manufacturing defects.

1/5/2010
 Ageing tests
Why ageing tests?
„ For users - Comparison of existing
products
- Service life estimation
- End of life mode

„ For manufacturers
- Design optimization
- New Product development
Tests developed should reflect on current
knowledge from field experience
Tests should be accelerated for practical reasons
(time, money)

1/5/2010
 Deficiencies in ageing tests in
standards
„ Testing of short sections is not adequate to
predict performance of full scale insulators
- Electric field distribution
„ Extreme condition of salinity, inadequate time for
resting can result in unrealistic discharge
intensity
- Material type and its response is a function of
discharge intensity
„ Therefore , Actual field experience is of great
help to the users.

1/5/2010
 Accelerated ageing test on
polymeric insulators
Salt fog

Humidification

Heating, 50°C

Solar radiation

De-ionized rain

Voltage

0 2 4 6 8 10 12 14 16 18 20 22 24

Not in operation In operation-

1/5/2010
 CPRI Ageing chamber as per
IEC 1109

1/5/2010
 TEST ARRANGEMENTS

1/5/2010
 Results of ageing test

Results after 100 hours of ageing

Results of SR insulators
1/5/2010
 CONCLUSIONS
„ ASTM tests provide minimum requirement for
polymeric insulators
„ Standard covers only some but not all aspects
adequately
„ Tests for contamination performance, Device
ageing, brittle fracture are not standardized yet
„ With proper diagnostics, computational tools, it is
possible to have laboratory tests that are:
QUICK, CHEAP and ACCURATE

1/5/2010
 CONCLUSIONS

) Polymeric insulators is now

preferred for all new power
projects

) The good news is that there

are technology and products
available today which will
ensure increased reliability of
the system
1/5/2010
 Questions?

1/5/2010
 Thank you
Wish you all
HAPPY NEW YEAR 2010

1/5/2010