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Silicone Rubber Insulators Withstand Desert Conditions

Byline: Ibrahim Y. Al-Hamoudi, Saudi Electricity Co., and Zakariya Al-Homouz, King Fahd
University of Pet

The electric network in the eastern region of Saudi Arabia operates under harsh environments that
include desert, marine and industrial pollution, along with high ambient temperatures. Such
conditions make insulator-contamination flashovers the main concern for the electric utility.

To control the pollution problem, the utility tried many solutions that significantly reduced
flashovers, but those solutions increased acquisition and maintenance costs of the insulators. The
utility began searching for an insulator with better pollution performance at a low life-cycle cost
(LCC). Silicone rubber (SiR) insulators appeared to be the most promising solution because of their
generally acknowledged superior pollution performance. However, their performance had to be
evaluated under different pollution conditions prior to application, because actual field conditions
cannot be accurately simulated in the laboratory. Therefore, with the main objective being the
improvement of the power transmission system reliability at minimum cost, the SiR insulators were
installed on a 230-kV line in desert area of Saudi Arabia to test their performance.

Insulator Performance Trial Program

Insulator pollution performance is the most important factor in selecting transmission line
insulators in the eastern region of Saudi Arabia. To maintain reliable electric power service under
harsh weather conditions, the Saudi Electricity Co. (SEC) performed extensive live-line high-
pressure water washing of insulators, increased the specific creepage distance of insulators, and
used different insulator designs and materials. These efforts resulted in significantly reduced
insulator contamination flashovers, but these measures were expensive, so SEC investigated cheaper
solutions.

The performance of ceramic insulators in desert environmental conditions is satisfactory compared

to their performance in other areas such as coastal and industrial. However, the expected
performance of SiR insulators is not well known because hydrophobic characteristics change with
time and fluid conditions. Therefore, in 1995, SiR insulators were installed in the eastern region
desert of Saudi Arabia to evaluate their performance over a six-year period. They were compared to
ceramic insulators and the former porcelain desert long rod (DLR) insulators installed on the same
line. Insulator washing (a major part of LCC) is not required in this desert, thus, the expected costs
will be low compared with that for other areas in this region.

Test Site and Test Line

SEC selected the Faras Power Plant - Khurais 230-kV line as a test line for the trial because the
complete line is located in desert. The prevalent pollution is characterized by blown salt-laden sand
and dust in a dry atmosphere. The temperature varies from 10[degrees]C to 22[degrees]C (50
[degrees]F to 72[degrees]F) between day and night during this hot-weather season extends more
than six months each year.

The performance of insulators installed on this 131-km (81-mile) line, erected on 310 towers some

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100 km (62 miles) inland from the Arabian Gulf, was considered to represent their performance in
desert conditions. This 230-kV line was insulated with DLR insulators when constructed in 1981 and
re-insulated with SiR insulators in February 1995. DLR insulators were installed on many 230-kV
transmission lines during the early 1980s in inland and coastal areas. They performed well in inland
areas where humidity is low without being washed, and they were cleaned by prevailing winds. For
coastal applications, however, they are being regularly washed to control the contamination-related
flashovers.

The test line experienced five failures of the DLR insulators between 1981 and 1995. Most were not
pollution related, but each time this line tripped, more than 200 MW of industrial load was lost
from the power system. The lost load mainly affected water pumping stations and some industrial
load from oil and gas production facilities. Reliable electrical power is critical because oil is the main
source of income for the country, and its production continuity is vital for the world.

The performance evaluation study of SiR insulators that continued until May 2001 was conducted in
two parts: a field trial on an in-service transmission line, followed by laboratory testing.

Field Trials

Prior to installation, all composite insulators were inspected for any damage to the sheath or to the
end seals where the rod enters the end fitting. The damage could result in moisture ingress to the
housing, causing the insulator to fail electrically. Any composite insulator with even minor damage,
cuts or indentations on the composite material surfaces (shed or sheath), or with its fiberglass rod
exposed, was discarded and replaced. The close proximity of the insulators elevated patrol
inspections that were conducted via bucket truck or climbing towers. The line was energized and all
damaged SiR insulators were replaced.

Day and night inspections of all the test insulators were made monthly. The insulators were
observed for audible noise from corona discharges, partial breakdowns, discoloration and
mechanical abnormalities. Binoculars were used as required, and a night viewer aided nighttime
corona inspections.

The results of the field trials confirmed that the performance of SiR insulators was satisfactory. No
electrical and mechanical failures occurred, and detailed and precise inspection did not reveal any
mechanical damage, cracks or erosion in the rubber housing. Careful handling during installation of
SiR insulators contributes to longer service life.

Laboratory Investigations

Test insulator strings were removed from the line and sent to King Fahd University of Petroleum
and Minerals (KFUPM; Dhahran, Saudi Arabia) in addition to the manufacturer facilities and
universities abroad to perform chemical, electrical, mechanical and physical tests.

Three insulator samples (A, B and C) installed on the Faras Power Plant - Khurais 230-kV line were
considered adequate and representative for each laboratory test. Samples A and B were removed in
March 1998 and May 2001, respectively, and Sample C in May 2001. Two samples were sent abroad
for the electrical, physical and chemical tests. The third sample was subjected to electrical and
chemical tests at the KFUPM test facility.

A new insulator sample, designated as Sample R, also was tested at manufacturers' facilities for
physical and chemical properties only for comparative purposes. For electrical and mechanical

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strength tests, the insulator's rated values were used for comparison with the test results from the
other samples.

Electrical Tests were performed on the naturally polluted insulator Samples A, B and C, in
accordance with the IEC 507 Clean Fog Method. To fulfill the requirements of IEC 507 (minimum
short-circuit current), and because of the limitation of the test plant, the insulator Samples A, B and
C were partially short-circuited to obtain flashover and withstand level.

The wet power frequency flashover voltage (U [subscript]50% ) for Sample C is lower than that of
other samples (Fig. 1). This is attributed to the higher equivalent salt deposit density (ESDD) level of
Sample C (Fig. 2), which is almost twice that of Samples A and B. As a rule, the higher the insulator
contamination, the lower the flashover voltage. However, the measured flashover voltage values still
demonstrated good pollution performance of all three test samples. They are well above the 825-kV-
rated wet power frequency flashover voltage, and the risk of pollution flashover is still low.

Pollution Measurement. The ESDD and non-soluble deposit density (NSDD) were measured. Figure
2 shows that the pollution level had increased with the time, as the pollution level measured at
KFUPM for Sample C is higher than that measured abroad for Samples A and B. The lower levels
could be because of the loss of some of the deposits during transportation of the insulator abroad, as
both Sample B and Sample C were removed from the line on the same day.

Measurements of insulator pollution levels are vital because pollution could affect insulator
performance.

Mechanical Test. The aim of the mechanical time-load test was to check the mechanical strength of
the insulator for any reduction from the specified mechanical load (SML) at different in-service
years. Insulator Samples A and B were subjected to a failing load test per IEC 1109, and there was no
failure at 100% SML. The socket failed in both cases at load, but the value of failing load in each case
was well above the rated 90 kN SML value (Fig. 3).

Physical Properties were evaluated by measuring hardness, roughness and water drop receding
contact angle of SiR material of test Samples R, A and B.

The hardness was monitored to evaluate the possibility of the rubber cracking. Measurement results
showed an increase in hardness that could be attributed to oxidation or aging by ultraviolet (UV)
radiation, or the result of mineral-filler migration.

Surface hydrophobicity of the shed material of Samples R, A and B was classified as HC1, in
accordance with the STRI Classification Guide 92/1. Figure 4 shows water drop receding contact
angles as measured for each sample. The measurement results proved that hydrophobicity of the
tested samples was intact.

Generally, the surface roughness of an insulator will influence the hydrophobicity in a different

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manner depending on the materials. If the receding contact angle is below 70 degrees, a change in
surface condition is possible. This is because the low molecular silicone will migrate to the surface
and cover even the microscopic surface peaks of the pollution layer, making them hydrophobic.

Chemical Tests were performed to diagnose the rate and extent of aging of SiR material. A Fourier
Transform Infra-Red Spectroscopy (FTIR) test was performed to see if decomposition of alumina
tri-hydrate (ATH) occurred as a result of aging. The Electron Spectroscopy for Chemical Analysis
(ESCA) technique was used to analyze all the elements on the uppermost layers of the insulator
surface. The Scanning Electron Microscopy (SEM) technique was used to study the surface structure
and its roughness. SEM coupled with Energy Dispersive X-ray (EDX) was used to measure the
chemical composition of the surface area to check for any decrease in the low molecular weight
silicone (LMWS) and to recognize contamination. These tests did not show any appreciable
degradation of SiR material.

Table 1. Reliability Indices of Reference and Test Insulators

Table 2. Reference and Test Line Data

Power Transmission System Reliability Index

The power transmission line faults are caused by many reasons like lightning, contamination or
mechanical failures. However, it can be safely assumed that more than 90% of the line interruptions
are because of insulator failures. Therefore, the reliability of the transmission line is directly
proportional to the reliability of the insulators.

Traditionally, insulator failure rate (FR) is defined as the number of insulator failures per 10,000
insulators per year. In accordance with international practice, the failure rate acceptable to the
electric utilities worldwide is less than one. Failure is defined as the loss of ability of a device to
perform any of its intended functions. Therefore, actual insulator failures or flashovers, even if the
insulation is self restored, will be counted as insulator failures.

The following equation was developed to calculate the reliability index (RI) from the failure rate of
used SiR insulators as well as other used insulators:

RI = 1 / (1 + FR) where RI = 1

FR = Number of failed insulators per 10,000 insulators per year

The minimum acceptable value of reliability index is 0.5, corresponding to a failure rate of one as
mentioned above. It is best if the failure rate is zero, which corresponds to the reliability index of
unity. Therefore, it can be said that the reliability index closer to unity means better power-system
reliability.

Five DLR insulator strings failed in 14 years of service, while SiR insulators did not fail in about six
years (Table 1).

The reliability index of 0.25 for DLR insulators is low compared to what is generally acceptable to
electric utilities worldwide, which is above 0.5. However, the unity reliability index for SiR
insulators reveals their excellent performance.

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Cost Effectiveness of SiRs

The cost-effectiveness of the test insulators was determined by comparing the LCC of these
insulators with the LCC of the reference insulators. In general, the LCC of an insulator of an
overhead transmission line is defined as the sum of the purchase cost, initial installation cost and
lifetime maintenance cost (line-wash cost), over the expected life of the insulators. Insulator
maintenance costs other than wash costs are negligible. Reference and test lines data are shown in
Table 2.

The LCCs of the insulators are shown in Table 3 and calculated as follows using a 30-year life for
DLR insulators and a predicted life for SiR insulators of 25 year:

LCC = Purchase Cost + Replacement Cost + Lifetime Wash Cost

Also, each cost component as a percentage of LCC and LCC saving given by use of SiR insulators, are
shown along with LCC comparison in Table 3.

The above calculations show that the life-cycle cost of DLR insulators is about 1.5 times that of SiR
insulators. This means that the saving is the result of the difference in purchase cost (89% of LCC
for DLR insulators and 85% of LCC for SiR insulator). Nevertheless, other significant advantages of
SiR insulators include easier installation, transportation and improved power-system reliability.

Because of the technology of SiR insulators is relatively new, this development could still have
greater advantages over porcelain insulators as the benefits from improvements in materials and
design and the economies of mass production materialize. These potential benefits seem likely to
make SiR insulators the most cost-effective type of insulator in future, even for applications in
desert environments.

More Studies Needed

There was not a single incident of mechanical or electrical failure of the SiR insulators. Equally
important, the LCC was lower than that of the reference insulators.

SiR insulators may not yet be the best choice for inland desert areas. More field studies are
necessary to confirm that their inherent service life is equal to, or longer than, that of ceramic
insulators.

Table 3. Life-Cycle Costs Percentage Distribution and Comparison

Dr. Ibrahim Yousif Al-Hamoudi received a BSEE degree from Basrah University in 1976 and was
awarded a MS degree by Bath University (UK) in 1999. Al-Hamoudi joined Saudi Electricity Co.
(Eastern Region Branch) and has held several managerial positions in generation, system
operations and power transmission. Currently, he is vice president, Consolidated Transmission
Area, Eastern/Central Saudi Electricity Co. Al-Hamoudi has contributed technical papers to several
international professional conferences.

hamoudi.iy@se.com.sa

Dr. Zakariya Mahmoud Al-Homouz was awarded a BSEE degree from Yarmouk University (1986),
an MS degree from Jordan University of Science & Technology (1989), and a Ph.D. in electric power
engineering from King Fahd University of Petroleum & Minerals (KFUPM) in July 1994. Al-Homouz

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started his teaching career at the Jordan University of Science & Technology in 1986 and moved to
KFUPM in 1989. In 2000, he was appointed associate professor in the electrical engineering
department. Al-Homouz performs research, contributes to technical papers, and is a member of
professional engineering institutions and societies.

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