Insulators 101

Insulators 101
Section A Introduction
Presented by Andy Schwalm
IEEE Chairman, Lightning and Insulator Subcommittee
IEEE/PES 2010 Transmission and Distribution

Conference and Exposition
New Orleans, Louisiana
April 20, 2010
IEEE T&D Insulators 101
What Is an Insulator?
An insulator is a dam*** poor conductor!
And more, technically speaking!
An insulator is a mechanical support!
Primary function - support the line mechanically
Secondary function electrical
Air is the insulator
Outer shells/surfaces are designed to increase
leakage distance and strike distance
What Does an Insulator Do?

Maintains an Air Gap
Separates Line from Ground
length of air gap depends primarily on system voltage,
modified by desired safety margin, contamination, etc.
Resists Mechanical Stresses

everyday loads, extreme loads
Resists Electrical Stresses

system voltage/fields, overvoltages
Resists Environmental Stresses

heat, cold, UV, contamination, etc.
Where Did Insulators Come From?

Basically grew out of the needs of the telegraph
industry starting in the late 1700s, early 1800s
Early history centers around what today we would
consider very low DC voltages
Gradually technical needs increased as AC
voltages grew with the development of the electric
power industry
History
Glass plates used to insulate telegraph line DC to
Baltimore
Glass insulators became the norm soon
thereafter typical collectors items today
Many, many trials with different materials wood
cement porcelain - beeswax soaked rag wrapped
around the wire, etc.
Ultimately porcelain and glass prevailed
History
Wet process porcelain developed for high voltage

applications
Porcelain insulator industry started
Application voltages increased

Insulator designs became larger, more complex
Ceramics (porcelain, glass) still only choices at
high voltages
History
US trials of first NCIs cycloaliphatic based

Not successful, but others soon became interested
and a new industry started up
Europeans develop modern style NCI fiberglass

rod with various polymeric sheds
Now considered First generation
History
NCI
insulator industry really begins in US with field

trials of insulators
Since that time - new manufacturers, new designs,
new materials
NCIs at generation X there have been so many
improvements in materials, end fitting designs, etc.
Change in materials have meant changes in line
design practices, maintenance practices, etc.
Ceramic manufacturers have not been idle either
with development of higher strength porcelains, RG
glazes, etc.
History
Domestic manufacturing of insulators decreases,

shift to offshore (all types)
Engineers need to develop knowledge and skills
necessary to evaluate and compare suppliers and
products from many different countries
An understanding of the basics of insulator
manufacturing, design and application is more
essential than ever before
Insulator Types
For simplicity will discuss in terms of three broad

applications:
Distribution lines (thru 69 kV)
Transmission lines (69 kV and up)
Substations (all voltages)
Insulator Types
Distribution lines
Pin type insulators -mainly porcelain, growing use
of polymeric (HDPE high density polyethylene),
limited use of glass (in US at least)
Line post insulators porcelain, polymeric
Dead end insulators polymeric, porcelain, glass
Spool insulators porcelain, polymeric
Strain insulators, polymeric, porcelain
Types of Insulators Distribution
Insulator Types
Transmission lines
Suspension insulators - new installations mainly
NCIs, porcelain and glass now used less frequently
Line post insulators mainly NCIs for new lines
and installations, porcelain much less frequent now
Types of Insulators Transmission
Insulator Types
Substations
Post insulators porcelain primarily, NCIs growing
in use at lower voltages (~161 kV and below)
Suspension insulators NCIs (primarily), ceramic
Cap and Pin insulators legacy type
Types of Insulators Substation
Insulator Types - Comparisons
Ceramic
Porcelain or toughened
glass
Metal components fixed with
cement
ANSI Standards C29.1
through C29.10
Non Ceramic
Typically fiberglass rod with
rubber (EPDM or Silicone)
sheath and weather sheds
HDPE line insulator
applications
Cycloaliphatic (epoxies)
station applications, some
line applications
Metal components normally
crimped
ANSI Standards C29.11
C29.19
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
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
Ceramic
Generally designs are
mature
Limited flexibility of
dimensions
Process limitations on sizes
and shapes
Applications/handling
methods generally well
understood
Non Ceramic
Material properties have
been improved UV
resistance much improved
for example
Standardized product lines
now exist
Balancing act - leakage
distance/field stress take
advantage of hydrophobicity
Application parameters still
being developed
Line design implications
(lighter weight, improved
shock resistance)
Insulators
101
Section B - Design Criteria
Presented by Al Bernstorf
IEEE Chairman, Insulator Working Group
April 20, 2010
Design Criteria - Mechanical

An insulator is a mechanical support!
Its primary function is to support the line
mechanically
Electrical Characteristics are an afterthought.
Will the insulator support your line?
Determine The Maximum Load the Insulator Will
Ever See Including NESC Overload Factors.

Suspension Insulators
Porcelain
- M&E (Mechanical & Electrical) Rating
Represents a mechanical test of the unit while energized.
When the porcelain begins to crack, it electrically punctures.
Average ultimate strength will exceed the M&E Rating when new.
- Never Exceed 50% of the M&E Rating
NCIs (Polymer Insulators)

- S.M.L. Specified Mechanical Load
Guaranteed minimum ultimate strength when new.
R.T.L. Routine Test Load Proof test applied to each NCI.
- Never Load beyond the R.T.L.

Line Post insulators
Porcelain
- Cantilever Rating
Represents the Average Ultimate Strength in Cantilever when new.
Minimum Ultimate Cantilever of a single unit may be as low as 85%.
- Never Exceed 40% of the Cantilever Rating Proof Test Load
NCIs (Polymer Insulators)

- S.C.L. (Specified Cantilever Load)
Not based upon lot testing
Based upon manufacturer testing
- R.C.L. (Rated Cantilever Load) or MDC or MDCL (Maximum Design

Cantilever Load) or MCWL or WCL (Working Cantilever Load)
- Never Exceed RCL or MDC or MDCL or MCWL or WCL
- S.T.L. (Specified Tensile Load)
- Tensile Proof Test=(STL/2)

Other Considerations
Suspensions and Deadends Only apply tension loads
Line Posts
- Cantilever is only one load
- Transverse (tension or compression) on line post loading
transverse to the direction of the line.
- Longitudinal in the direction of travel of the line
- Combined Loading Curve
Contour curves representing various Longitudinal loads
Available Vertical load as a function of Transverse loading
Manufacturers have different safety factors!!!

69 kV Post - 2.5" Rod
V E R T IC A L L O A D , L B F
2500
0 Longitudinal
2000
500 Longitudinal
1500
1000 Longitudinal
1000
1500 Longitudinal
500
2000 Longitudinal
-3000
Compression
-2000
-1000
1000
2000
TRANSVERSE LOAD, LBF

3000 LINE POST APPLICATION

CURVES
9-12-05
Ten sion
Design Criteria - Electrical

An Insulator is a mechanical support!
Air imparts Electrical Characteristics
Strike Distance (Dry Arcing Distance) is the
principal constituent to electrical values.
Dry 60 Hz F/O and Impulse F/O based on strike distance.
Wet 60 Hz F/O
- Some would argue leakage distance as a principal factor.
- At the extremes that argument fails although it does play a role.
- Leakage distance helps to maintain the surface resistance of the
strike distance.
Leakage Requirements do play a role!!!

Dry Arcing Distance
(Strike Distance) The
shortest distance through
the surrounding medium
between terminal
electrodes. 1
IEEE Std 100 - 1992

PICKING A SUITABLE INSULATOR
ELECTRICAL PARAMETERS
A. NOMINAL SYSTEM LINE-TO-LINE VOLTAGE
B. MAXIMUM SYSTEM LINE-TO-GROUND VOLTAGE
(line A/1.732)*1.05
C. MAXIMUM PEAK LINE-TO-GROUND VOLTAGE (e)
e=(line B * 1.414)
Define peak l-g kV
69 kV (rms)
41.8 kV (rms)
59.1 kV (peak)
LEAKAGE DISTANCE REQUIREMENTS
Determine Leakage Distance

Required
CONTAMINATION LEVEL
(typical values)
D. ZERO
E. LIGHT
F. MODERATE
G. HEAVY
Enter inches/kV -
SUGGESTED LEAKAGE
(inches/(kV line-to-ground))
UP TO 1.00
1.00 - 1.25
1.50 - 1.75
2.00 - 2.50
1
H. INSULATOR LEAKAGE (MIN.)

(line B)*(inches/kV) =
Switching Over-voltage
Requirements
Impulse Over-voltage
41.8 inches
SWITCHING OVERVOLTAGE REQUIREMENTS

I. SSV = (line B) * 3.0
125 kV (peak)
IMPULSE OVERVOLTAGE REQUIREMENTS

J. PEAK IMPULSE WITHSTAND = (I(t) * R(f))+e
I(t) =
20 kA (typical value = 50 kA)
R(f) =
15 ohm (typical value = 10 - 20 ohm)
e=
59.1 (line C)
K. IMPULSE WITHSTAND =
359 kV
SELECT INSULATOR BASED ON REQUIREMENTS:
Chart Courtesy of Ohio Brass/HPS EU1429-H
SYSTEM
REQUIREMENT
H. LEAKAGE
DISTANCE
I. SWITCHING
SURGE VOLTAGE
K. IMPULSE
WITHSTAND
T. SELECT
INSULATOR
VALUE FROM
PAGE 1
41.8
125
359
NUMBER OF
POLYMER VALUES PORCELAIN BELLS
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
1 IEEE Std 100 - 1992

Whats an appropriate Leakage Distance?
Empirical Determination
- Whats 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 Distance

Application Guide for Insulators in a Contaminated Environment
by K. C. Holte et al F77 639-8
ESDD (mg/cm2)
Site Severity
Leakage Distance
I-string/V-string
(/kV l-g)
0 0.03
Very Light
0.94/0.8
0.03 0.06
Light
1.18/0.97
0.06 0.1
Moderate
1.34/1.05
>0.1
Heavy
1.59/1.19

IEC 60815 Standards
ESDD (mg/cm2)
Site Severity
Leakage Distance
(/kV l-g)
<0.01
Very Light
0.87
0.01 0.04
Light
1.09
0.04 0.15
Medium
1.37
0.15 0.40
Heavy
1.70
>0.40
Very Heavy
2.11

Leakage Distance Recommendations
2.5
2
Leak ("/kV l-g)
IEEE V
IEEE I
1.5
IEC
Poly. (IEC)
Poly. (IEEE V)
Poly. (IEEE I)
0.5
0
0
0.1
0.2
0.3
0.4
ESDD (mg/cm^2)
0.5
Improved Contamination Performance

Flashover Vs ESDD
300
250
Flashover Voltage
200
Porcelain
New EPDM
Aged EPDM
150
New SR
Aged SR
100
CEA 280 T 621
SR units - leakage equal to porcelain
EPDM Units - leakage 1.3 X Porcelain
50
0
0.01
0.1
ESDD (mg/cm^2)

Polymer insulators offer better contamination
flashover performance than porcelain?
Smaller core and weathershed diameter increase
leakage current density.
Higher leakage current density means more
Ohmic Heating.
Ohmic Heating helps to dry the contaminant layer
and reduce leakage currents.
In addition, hydrophobicity helps to minimize
filming

the contamination performance of composite
insulators exceeds that of their porcelain counterparts
the contamination flashover performance of silicone
insulators exceeds that of EPDM units
the V50 of polymer insulators increases in proportion
to the leakage distance
CEA 280 T 621, Leakage Distance Requirements for Composite Insulators Designed for Transmission Lines
Insulator Selection
Where do I get these values?
Leakage Distance or Creepage Distance
Manufacturers Catalog
Switching Surge
Wet W/S
((Wet Switching Surge W/S)/2) 60 Hz Wet Flashover (r.m.s.)
Peak Wet 60 Hz value will be lower than Switching Surge Wet W/S
Impulse Withstand
Take Positive or Negative Polarity, whichever is lower
If only Critical Impulse Flashover is available assume 90%
(safe estimate for withstand)
Insulator Selection
PICKING A SUITABLE INSULATOR
Select the 69 kV Insulator

shown at right.
ELECTRICAL PARAMETERS
A. NOMINAL SYSTEM LINE-TO-LINE VOLTAGE
B. MAXIMUM SYSTEM LINE-TO-GROUND VOLTAGE
(line A/1.732)*1.05
C. MAXIMUM PEAK LINE-TO-GROUND VOLTAGE (e)
e=(line B * 1.414)
69 kV (rms)
41.8 kV (rms)
59.1 kV (peak)
LEAKAGE DISTANCE REQUIREMENTS
I-string Mechanical
CONTAMINATION LEVEL
(typical values)
D. ZERO
E. LIGHT
F. MODERATE
G. HEAVY
Enter inches/kV -
Worst Case 6,000 lbs

Suspension: 12k min
ultimate
SUGGESTED LEAKAGE
(inches/(kV line-to-ground))
UP TO 1.00
1.00 - 1.25
1.50 - 1.75
2.00 - 2.50
1
H. INSULATOR LEAKAGE (MIN.)

(line B)*(inches/kV) =
41.8 inches
SWITCHING OVERVOLTAGE REQUIREMENTS

I. SSV = (line B) * 3.0
Leakage Distance 42
125 kV (peak)
IMPULSE OVERVOLTAGE REQUIREMENTS

J. PEAK IMPULSE WITHSTAND = (I(t) * R(f))+e
I(t) =
20 kA (typical value = 50 kA)
R(f) =
15 ohm (typical value = 10 - 20 ohm)
e=
59.1 (line C)
K. IMPULSE WITHSTAND =
Switching Surge 125 kV

Impulse Withstand 359
kV
359 kV
SELECT INSULATOR BASED ON REQUIREMENTS:

SYSTEM
REQUIREMENT
H. LEAKAGE
DISTANCE
I. SWITCHING
SURGE VOLTAGE
K. IMPULSE
WITHSTAND
T. SELECT
INSULATOR
VALUE FROM
PAGE 1
41.8
125
359
NUMBER OF
POLYMER VALUES PORCELAIN BELLS
Insulator Selection
Porcelain 5-3/4 X 10 bells X 4 units
Characteristic
Required
Available
Leakage
Distance
42
46
Wet Switching
Surge W/S
125 kV
240 kV
Impulse W/S
359 kV
374 kV
M&E
12,000 lbs
15,000 lbs
Grading Rings
Simulate a larger, more spherical object
Reduce the gradients associated with the shielded object
Reduction in gradients helps to minimize RIV & TVI
Porcelain or Glass
Inorganic breaks down very slowly
NCIs
Polymers are more susceptible to scissioning due to corona
UV short wavelength range attacks polymer bonds.
Most short wavelength UV is filtered by the environment
UV due to corona is not filtered
NCIs and Rings

Grading (Corona) Rings
Due to corona cutting and water droplet corona NCIs may
require the application of rings to grade the field on the
polymer material of the weathershed housing.
Rings must be:
- Properly positioned relative to the end fitting on which they are
mounted.
- Oriented to provide grading to the polymer material.
Consult the manufacturer for appropriate instructions.

As a general rule rings should be over the polymer
brackets should be on the hardware.
Questions?
Insulators 101
Section C - Standards
Presented by Tony Baker
IEEE Task Force Chairman, Insulator Loading
April 20, 2010
American National Standards

Consensus standards
Standards writing bodies must include representatives from
materially affected and interested parties.
Public review
Anybody may comment.
Comments must be evaluated, responded to, and if found to be
appropriate, included in the standard .
Right to appeal
By anyone believing due process lacking.
Objective is to ensure that ANS Standards are developed in an

environment that is equitable, accessible, and responsive to the
requirements of various stakeholders*.
* The American National Standards Process, ANSI March 24, 2005
American Standards Committee

on Insulators for Electric Power Lines
ASC C-29
EL&P Group
IEEE
NEMA
Independents
C29
ANSI C29 Insulator Standards (available on-line at nema.org)
.1
Insulator Test Methods
.2
Wet-process Porcelain & Toughened Glass - Suspensions
.3
Wet-process Porcelain Insulators - Spool Type
.4
- Strain Type
.5
- Low & Medium Voltage Pin Type
.6
- High Voltage Pin Type
.7
- High Voltage Line Post Type
.8
- Apparatus, Cap & Pin Type
.9
- Apparatus, Post Type
.10
- Indoor Apparatus Type
.11
Composite Insulators Test Methods
.12
- Suspension Type
.13
- Distribution Deadend Type
.17
- Line Post Type
.18
- Distribution
Line Post Type
.19
- Station Post Type (under development)
ANSI C29 Insulator Standards

Applies to new insulators
Definitions
Materials
Dimensions & Marking (interchangeability)
Tests
1.
Prototype & Design, usually performed once for a given design.

(design, materials, manufacturing process, and technology).
2.
3.
Sample, performed on random samples from lot offered for

acceptance.
Routine, performed on each insulator to eliminate defects from lot.
ANSI C 29 Insulator Standard Ratings
Electrical & Mechanical Ratings

How are they assigned?
How is conformance demonstrated?
What are application limits?
Electrical Ratings
Average flashover values
Low-frequency Dry & Wet
Critical impulse, positive & negative
Impulse withstand
Radio-influence voltage
Applies to all the types of high voltage insulators
Rated values are single-phase line-to-ground voltages.
Dry FOV values are function of dry arc distance and test configuration.
Wet FOV values function of dry arc distance and insulator shape,
leakage distance, material and test configuration.
Tests are conducted in accordance with IEEE STD 4-1995 except
test values are corrected to standard conditions in ANSI C29.1.
-Temperature 25 C
- Barometric Pressure 29.92 ins. of Hg
- Vapor Pressure 0.6085 ins. of Hg
- For wet tests: rate 5 0.5 mm/min, resistivity 178 27m, 10 sec. ws
Dry Arcing Distance
Shortest distance through the surrounding medium between terminal

electrodes , or the sum of distances between intermediate electrodes ,
whichever is shortest, with the insulator mounted for dry flashover test.
Electrical Ratings
Product is designed to have a specified average flashover.
This is the manufacturers rated value, R.
Samples are electrically tested in accordance with standard
This is the tested value, T.
Due to uncontrollable elements during the test such as atmospheric
fluctuations, minor differences in test configuration, water spray
fluctuations, etc. the test value can be less than the rated value.
Does T satisfy the requirements for the rating R?
If T/R Yes
where
= 0.95 for Low-frequency Dry flashover tests
= 0.90 for Low-frequency Wet flashover tests
= 0.92 for Impulse flashover tests
Electrical Ratings
Dry 60 Hz Flashover Data
1400
1200
Suspension Insulator
Flashover (kV)
1000
800
Station Post and Line Post
600
400
200
0
0
20
40
60
80
100
Dry Arcing Distance (inches)
120
140
160
Electrical Ratings
ANSI C2 Insulation Level Requirements
ANSI C2-2007, Table 273-1
1400
1200
1000
800
Rated Dry
FOV, kV
600
400
200
0
0
100
200
300
400
500
600
Nominal Phase-to-Phase Voltage, kV
700
800
900
Higher insulation levels required in areas where severe lightning, high

atmospheric contamination, or other unfavorable conditions exist
Electrical Ratings - Application

Customer determines needs and specifies electrical
requirements:
- 60 Hz Dry & wet flashover
- Impulse flashover and/or withstand
- Leakage distance
Does offered product meet customers specification S?
If R S and T R
yes, otherwise no.
Mechanical Ratings
Sample & Routine Mechanical Tests
are based on the primary in-service loading conditions
STD. No.
C 29.2
Insulator Type
Ceramic Suspension
Sample test
Routine test
M&E
Tension
C29.6
Pin Type
Cantilever
-----
C29.7
Line Post
Cantilever
4 quad. cantilever
C29.8
Cap & Pin
Cantilever
Torsion
Tension
Tension
Station Post
Cantilever
Tension
Tension, Cantilever or
Bending Moment
SML
Tension
C29.9
C29.12
Composite Suspension
C29.13
Deadend
SML
Tension
C29.17
Line Post
Cantilever
Tension
Tension
C29.18
Dist. Line Post
Cantilever
Tension
Mechanical Ratings
M&E Test
Ceramic Suspensions
Bending Tests
Composite Posts
Kinectrics
Hubbell Power Systems
ANSI C29 High Voltage Insulator Standards

Std.
No.
Insulator
Type
Ult. Strength
QC Test
Combined M&E strength
of 10 units
Lot Acceptance
Criteria
Ave. Std. dev. = S
X10 R +1.2 S
s10 1.72 S
C29.2
Ceramic
Suspension
C29.7
3 sec. tension
at 50% of R
Ceramic
Line post
Cantilever strength
of 3 units
X3 R
no one xi .85 R
4 quad. bending
at 40% of R
C29.8
Ceramic Apparatus
Cap & Pin
Cantilever, tension, & torsion strength

of 3 units each
X3 R
no one xi .85 R
C29.9
Ceramic Apparatus
Post Type
Cantilever & tension strengths

of 3 units each
X3 R
no one xi .85 R
3 sec. tension
at specified value
Tension
at 50% of R
or
4 quad. bending
at 40% of R
C29.12
Composite
Suspension
Specified Mech. Load (SML)

test of 3 units
xi .R
C29.13
Composite
Distribution Deadend
SML test
of 3 units
C29.17
Composite
Line Post
Cantilever strength of 1 unit

Tension test of 1 unit
Strength R
10 sec. tension
at 50% of R
C29.18
Composite
Distribution Line Post
Cantilever strength of 1 unit
Strength R
10 sec. tension
at 50% of R
xi .SML rating
Routine
Test
10 sec. tension
at 50% of R
10 sec. tension
at 50% of R
Lot Acceptance Criteria ANSI C29.2

Lot acceptance according to ANSI C 29.2.
Select ten random units from lot and subject to M&E test.
Requirements are:
M&E rating X10 1.2SH
&
s10 1.72SH
s10 is std. dev. of the 10 units
SH is historical std. dev.
If s10= SH then for minimally acceptable lot, ~ 11.5% of
units in lot could have strengths below the rated value.
Lot Acceptance Criteria ANSI C29.2

Possible low strengths for ceramic suspension
units in a lot minimally acceptable according
to ANSI C29.2
Coefficient
of variation, vR
5%
10%
15%
Strength value
at -3
90% of M&E rating
79% of M&E rating
67% of M&E rating
Lot Acceptance Criteria CSA C411.1
Possible low strengths for ceramic suspension

units in a lot minimally acceptable according to
CSA C411.1
Requirements
Rating
S
i
On a -3 sigma basis , minimum strength

that could be expected in a lot is the rated
value regardless of the coefficient of
variation for the manufacturing process
that produced the lot.
Lot Acceptance Criteria ANSI C29

Possible low strengths for ceramic units in a lot
minimally acceptable according to
ANSI C29.7, C29.8 & C29.9
Cantilever rating X3 & no xi< 85% of rating
Coefficient
of variation, vR
5%
10%
15%
Strength value
at -3
85% of Cantilever rating
Lot Acceptance Criteria

ANSI C29 Composite Insulators
Random samples selected from an offered lot.
Ultimate strength tests on samples.
Requirement is:
xi Rating
The rated value is assigned by the manufacturer based
on ultimate strength tests during design.
However for a lot minimally acceptable according to the
standard, statistical inference for the strength distribution
for entire lot not possible.
Composite Insulators have a well defined damage limit
providing good application direction.
Mechanical Ratings Application Limits

NESC ANSI C Table 277-1
Allowed percentages of strength ratings
Insulator Type
Strength Rating
Ref. ANSI Std.
Suspension
50%
Combined
mechanical & electrical strength (M&E)
C29.2-1992
Line Post
40%
50%
40%
50%
40%
50%
Cantilever strength
Tension/compression strength
Cantilever strength
Tension/compression/torsion strength
Cantilever strength
Tension/compression/torsion strength
50%
Specified mechanical load (SML)
50%
50%
Specified cantilever load (SCL) or

specified tension load (STL)
All strength ratings
Ceramic
Station Post4
Station
Cap & Pin
Composite
Suspension
Line Post
Station Post
C29.7-1996
C29.9-1983
C29.8-1985
C29.12-1997
C29.13-2000
C29.17-2002
C29.18-2003
----------
Worst loading case load (% Table 277-1)(Insulator Rating)

In most cases , % from Table 277-1 is equal to the routine
proof -test load.
Bending tests on a production basis are not practicable in
some cases, (large stacking posts, cap & pins , and polymer
posts) and tension proof-load tests are specified.

Composite Post Insulators Combined Loading

Composite Post Insulators Combined Loading
Recent Developments for Application Limits

Component strength cumulative distribution function FR and
probability density function of maximum loads fQ.
Component Damage Limit

DAMAGE LIMIT
Strength of a component below ultimate corresponding to a
defined limit of permanent damage or deformation.
For composites the damage limit is fairly well understood.

Component Damage Limit

Defining Damage Limit for ceramics more difficult to
define as shown by comparing stress-strain curves for
brittle and ductile materials.
L&I WG on Insulators is addressing this problem now

Insulators 101
Section D Achieving Quality
Presented by Tom Grisham
IEEE Task Force Chairman, Insulators 101

IEEE/PES T&D Conference and Exposition
New Orleans, LA
April 20, 2010
Objectives of Quality Presentation

Present ideas to verify the supplier
qualification, purchasing requirements,
manufacturer inspections of lots,
shipment approval, material handling,
and training information for personnel
Routine inspection of the installation
Identify steps to analyze field complaints
To stimulate Quality improvement
Quality Defined
QUALITY An inherent, basic or
distinguishing characteristic; an
essential property or nature.
QUALITY CONTROL A system of
ensuring the proper maintenance of
written standards; especially by the
random inspection of manufactured
goods.
What Is Needed in a Quality Plan?

Identifying critical design parameters
Qualifying new suppliers
Evaluating current suppliers
Establishing internal specifications
Monitoring standards compliance (audits)
Understanding installation requirements
Establishing end-of-life criteria
Ensuring safety of line workers
Communicating and training
All aspects defined by the company plan
What Documents Should Be Included?

Catalog specifications and changes
Supplier audit records and lot certification
Qualification testing of the design
Utility-specific testing
Additional supplier testing for insulators (vibration,
temperature, long-term performance, etc)
ANSI or equivalent design reports
Storage methods
Installation records (where, by whom, why?)
Interchangeability with other suppliers product
Handling methods (consult manufacturer)

Installation requirements and techniques
Proven Installation Procedures
Handling of Ceramics NEMA HV2-1984

Insulators should not be dropped or thrown..
Insulators strings should not be bent..
Insulator strings are not ladders..
Insulators with chips or cracks should be discarded and
companion units should be carefully inspected..
Cotter keys should be individually inspected for twisting,
flattening or indentations. If found, replace keys and
retest the insulator..
The maximum combined load, including safety
requirements of NESC, must not exceed the rating..
Normal operating temperature range for ceramics is
defined as 40 to 150 Degrees F..
Handling of NCIs
NEMA is working on a new application guide for NCI
products. It will likely include
Insulators should not be dropped, thrown, or bent
Insulators should not be used as ladders
Cotter keys for ball sockets should be inspected identically to the
instructions for ceramic insulators
The maximum combined loads should not exceed the RTL
Normal operating temperature is 40 to 150 Degrees F
Insulators should not be used as rope supports
Units with damaged housings that expose the core rod should
be replaced and discarded
Units with cut or torn weathersheds should be inspected by
the manufacturer
Bending, twisting and cantilever loading should be avoided
during construction and maintenance
Line outage Failures

Your objective is to find the problem, quickly!
Inspection Techniques
Subjective: What you already know
Outage related
Visual methods from the ground
Previous problem
Thermal camera (NCI live line)
Objective: Answer is not obvious

Leakage current measurements
Daycor camera for live line inspections (live)
Mechanical and electrical evaluations
Porcelain and Glass Failures

Failures are typically visible or have a
new history or upgrade on the site?
New products may not be your
Grandfathers Oldsmobile, however!
Have the insulators deteriorated?
Perform thermal-mechanical test before failing
load and compare to ultimate failing load
Determine current ultimate strength versus new
Should the insulators be replaced?

Establish internal criteria by location
Non-Ceramic (NCI) Failures

Cause of failures may NOT be visible!
More subjective methods used for live line replacement
Some external deterioration may NOT be harmful
Visual examples of critical issues are available to you
Imperative to involve the supplier!

Evaluate your expertise to define root cause condition
Verify an effective corrective action is in place
Utilize other sources in the utility industry
Establish subjective baselines for new

installations as future reference! Porcelain and
glass, also!
What To Do for an Insulator Failure?

Inspection of Failure
Supplier Involvement
What happened?
Verification of production date?
Extraordinary factors?
Available production records?
Save every piece of the unit!
Determination of root cause?
Take lots of pictures!
Recommended action?
Inspect other insulators!
Safety requirements?
Summary of Quality Presentation

In todays environment, this presentation suggests that
the use of a well documented quality program improves
long term performance and reduces outages.
Application information that is communicated in the
organization will help to minimize installation issues and
reduce costs.
Actively and accurately defining the condition, or
determining the root cause of a failure, will assist in
determining end-of-life decisions.
Source of Presentation
http://ewh.ieee.org/soc/pes/iwg/

Insulators 101

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Insulators 101

IEEE/PES 2010 Transmission and Distribution

IEEE T&D Insulators 101

What Does an Insulator Do?

Resists Mechanical Stresses

Resists Electrical Stresses

Resists Environmental Stresses

IEEE T&D Insulators 101

Where Did Insulators Come From?

IEEE T&D Insulators 101

Wet process porcelain developed for high voltage

Application voltages increased

IEEE T&D Insulators 101

US trials of first NCIs cycloaliphatic based

Europeans develop modern style NCI fiberglass

IEEE T&D Insulators 101

insulator industry really begins in US with field

IEEE T&D Insulators 101

Domestic manufacturing of insulators decreases,

IEEE T&D Insulators 101

For simplicity will discuss in terms of three broad

IEEE T&D Insulators 101

IEEE T&D Insulators 101

Types of Insulators Distribution

IEEE T&D Insulators 101

IEEE T&D Insulators 101

Types of Insulators Transmission

IEEE T&D Insulators 101

IEEE T&D Insulators 101

Types of Insulators Substation

IEEE T&D Insulators 101

Insulator Types - Comparisons

IEEE T&D Insulators 101

Insulator Types - Comparisons

IEEE T&D Insulators 101

Insulator Types - Comparisons

IEEE T&D Insulators 101

IEEE T&D Insulators 101

Design Criteria - Mechanical

IEEE T&D Insulators 101

Design Criteria - Mechanical

- Never Exceed 50% of the M&E Rating

NCIs (Polymer Insulators)

- Never Load beyond the R.T.L.

IEEE T&D Insulators 101

Design Criteria - Mechanical

- Never Exceed 40% of the Cantilever Rating Proof Test Load

NCIs (Polymer Insulators)

- R.C.L. (Rated Cantilever Load) or MDC or MDCL (Maximum Design

IEEE T&D Insulators 101

Design Criteria - Mechanical

IEEE T&D Insulators 101

Design Criteria - Mechanical

TRANSVERSE LOAD, LBF

3000 LINE POST APPLICATION

Design Criteria - Electrical

Leakage Requirements do play a role!!!

IEEE T&D Insulators 101

Design Criteria - Electrical

IEEE Std 100 - 1992

IEEE T&D Insulators 101

Design Criteria - Electrical

Define peak l-g kV

LEAKAGE DISTANCE REQUIREMENTS