The 20th International Symposium on High Voltage Engineering, Buenos Aires, Argentina, August 27 – September 01, 2017

INNOVATIVE POLLUTION AND ICE TESTING OF DC COMPOSITE

INSULATORS FOR ±525 KV DC LINE
1 1 2 2*
B. Thorsteinsson , K. Halsan , M. Gullo and I. Gutman
1
Statnett, Box 5192, N-0302, Oslo, Norway
2
STRI, Box 707, SE-771 80, Ludvika, Sweden
*Email: igor.gutman@stri.se

Abstract: Norwegian TSO Statnett has selected outdoor insulation for a new ±525 kV
HVDC project, NordLink, between Norway and Germany. Part of this link will be overhead
line close to the Norwegian coast and it was decided to use composite insulators for this
line. In order to verify the pollution and ice performance of the insulators intended for
relatively cold, humid and coastal area a special test program was developed and
included the pollution testing and ice testing.

At present there is no standard IEC pollution test method available for composite
insulators and, especially, for DC applications. The innovative specially-developed
pollution test presented in this paper used the CIGRE-recommended for AC procedure
described in CIGRE TB 555, which comprises the following steps: gentle cleaning of the
insulators, pre-conditioning of the surface by dry kaolin powder and application of the
pollution layer by spraying. While the standard voltage application was used for the
withstand test, the flashover voltage tests were performed in accordance with the Rapid
Flashover Test. This procedure is described only in the draft of coming in 2017 CIGRE
Technical Brochure and earlier was mostly applied for AC insulators. Detailed description
of different practical steps of new procedures applied for DC composite insulators is
presented in the paper.

For the ice test there is also no standard IEC procedure and thus the test was
constructed as a combination of relevant IEEE Standard for ice testing and IEC pollution
test requirements for ceramic insulators. One V-shaped insulation structure with insulator
length of more than 6 m was tested. The glaze type of ice was accreted using a structure
of aluminium beams, mirroring the V-shaped insulator structure, which was hung from the
crane in the climate test hall. Detailed description of different practical steps of new
procedure applied for DC composite insulators is presented in the paper.

The knowledge obtained as a result of the application of innovative pollution and ice tests
is essential for the ongoing discussions within IEEE/CIGRE/IEC.

1 INTRODUCTION there are no IEC standards for pollution or icing

Statnett is going ahead with a new submarine
interconnection between Norway and Germany, i.e.
525 kV HVDC project NordLink. Part of this link will
be an overhead line close to the Norwegian coast.
Statnett and STRI made a few collaborative
projects on careful statistical dimensioning of
composite insulators decided for this line, which
already resulted in two scientific publications [1],
[2]. During the next stage it was considered a
verification of two possible designs of these
insulators both from pollution and ice points of view.
tests of composite insulators, especially at DC
voltage.
3 POLLUTION TESTING
3.1 Test samples
Two shorter insulators of slightly different profile of
1,5 m insulation height were used for flashover
pollution testing. Full-scale insulators of the same
two profiles of 5,7-6,2 m insulation height were
used for withstand pollution testing.

2 GOAL 3.2 Test program

The goal of this investigation was to develop
innovative pollution and ice test methods to verify
the applicability of the preliminary chosen insulator
options for the specific environment. The test
methods should be innovative, because at present
The basic test procedure complied with the solid
layer test procedure described in the IEC 61245
[3]. This standard, however, covers only glass and
ceramic insulators, thus to achieve the pollution
application on composite insulators a special pre-
conditioning procedure was applied according to
CIGRE Technical Brochure (TB) 555 [4]. It is
virtually impossible to contaminate composite
insulators without such procedure. It was also
decided to test the insulators without providing
specific recovery time for hydrophobicity (i.e.
elapsed time between the application of pollution
and voltage application). This was rather
conservative approach assuming cold and humid
Norwegian environment. The CIGRE-
recommended procedure [4] comprises the
following steps: gentle cleaning of the insulators;
pre-conditioning of the surface by dry kaolin
powder; application of the pollution layer (e.g. by
spraying).
Before the contamination the insulators were
thoroughly cleaned by warm water and a sponge,
Further pre-conditioning was performed by
applying by brush a dry inert material in powder
form (in this case kaolin) on the clean and dry
insulator surface, see a close look in Figure 1.
This layer was applied as uniformly as possible
taking special care at the transition areas from
sheath to the sheds. After the application, most of
the powder was blown off by compressed air until
only a very thin layer remained on the insulator
surface. The adequacy of this layer was controlled
visually. The pre-conditioning temporarily masked
sufficiently the surface hydrophobicity of the
composite insulators allowing their further
contamination by spraying (standard method
according to the IEC 61245). The suspension
comprised a mixture of tap water, kaolin and salt
(NaCl). The amount of salt was chosen to achieve
the target Salt Deposit Density (SDD). The density
of suspension was adjusted for the target value of
Non-soluble Deposit Density (NSDD). The
specially prepared suspension was sprayed onto
the insulator, see Figure 2.
Figure 1: Pre-conditioning of the surface of the
insulator by dry kaolin (close look).
Figure 2: Insulator contaminated by spraying
method after pre-conditioning by dry kaolin.
The final actual SDD/NSDD levels were measured
on a large and small sheds and on the sheath of
the polluted insulators and then averaged.
Comparison between the target and actual results
is presented in Table 1. The SDD values were fully
in correspondence with the target values, while the
NSDD values were slightly higher, however within
the acceptable margin (about 25%).
Table 1: Target/actual average pollution levels
Target Actual
Test
SDD/NSDD, SDD, NSDD,
objects 2 2 2
mg/cm mgcm mgcm
Short
0,03/0,1-0,2 0,03 0,25
insulators
Short
insulators
0,12/0,1-0,2 0,11 0,24
Full-scale
0,10/0,1-0,2 0,10 0,25
insulators
Flashover voltage tests on shorter insulators tested
in vertical operating position were performed using
the Rapid Flashover Test method [5], [6]. The
polluted and dried insulators were placed into the
test hall as shown in the set-up presented in
Figure 3. Voltage of negative polarity was applied
at the preliminary chosen starting level and the
insulators were wetted by letting steam fog of
standard intensity according to the IEC 61245 into
the hall.
Before the first flashover on the insulator the
procedure was as follows. After 15 minutes of
wetting the voltage was increased by the voltage
equal to two pre-chosen voltage steps, where one
voltage step was decided as 5% of the starting
voltage. Every five minutes the voltage was then
increased by two voltage steps until flashover. In
case of a flashover the voltage was tripped to zero,
but then was immediately reapplied at the level of
voltage defined as the preceding level decreased
by one voltage step. After the first flashover, the
voltage was further changed only by one voltage
step every five minutes until flashover. The speed
of voltage ramping was about 5 kV/s. The test was
continued until the flashover level started to
increase, indicating washing of the pollution from
the insulators. The total test duration was about 60
minutes in all tests.

The U50%-values for the flashover voltage were

calculated from the so-called U-curves as the level
of the minimum withstand voltage plus half a
voltage step (see example in Figure 4). This
approach is the best approach for the time being
agreed by CIGRE and included in the draft of
CIGRE TB [6].

For the full scale tests of V-shaped string the SDD

2
was decided as 0,069x1,4=0,10 mg/cm , where
2
0,069 mg/cm is an actual design pollution level
proposed in [1] and the correction factor 1,4 takes
into account many parallel installed insulator in
service in comparison to one insulator tested in the
laboratory [7], [8]. The tests were performed at the Figure 5: Test set-up for full-scale test.
test voltage of 525 kV DC of negative polarity. The
voltage was applied on the dry V-shaped insulator 3.3 Test results
arrangement (see set-up in Figure 5) and was
maintained through the whole test while steam fog The results of flashover tests obtained on shorter
of standard intensity (as per IEC 61245) was let insulators were used to create the flashover
into the hall. The acceptance criterion was as per performance curves presented in Figure 6.
IEC 61245. Because the difference in insulator profile was not
significant for two insulators tested, the results are
very similar.

Figure 3: Test set-up for shorter insulators.

Figure 6: Flashover performance curves.

The results of full-scale withstand tests showed

that one of the insulators formally passed the test
(no flashovers in three voltage applications), while
for the second insulator two flashovers in four
voltage applications were registered. Comparison
of the results of flashover and withstand tests is in
“Discussion” section of this paper.

4 ICE TESTING

4.1 Test samples

Figure 4: Example of U-curve used for the
calculation of flashover voltage: O = withstand; x = One full-scale V-shaped insulator of about 6 m
flashover. length was tested (the one, which withstood the
full-scale test).
4.2 Test program

The test procedure basically complied with the only

normative document on ice testing available at
present, i.e. IEEE Standard [9] (no IEC standards
are available). However, it was decided that the ice
accretion should be performed in de-energized
condition (which is the conservative case, because
part of ice can be melted if the accretion is under
voltage). The test procedure for the withstand test
was according to the standard IEC requirements,
e.g. as for the pollution test in IEC 61245 [3].

Target ice parameters were chosen based on

environment in the area of interest and were as Figure 8: Schematic drawing of complete spray
follows: system.

 Glaze type of ice (transparent ice with The ice was accreted using water with a
3
density 0,7-0,9 g/cm ) conductivity of approximately 100 S/cm, this
value corresponds to the maximum value
 Applied water conductivity 100 S/cm measured earlier at Statnett in service [10]. During
the ice application, the air temperature in the test
hall was kept around -8°C. The target ice thickness
 Ice load of 12 kg/m (on power line) which
at the standard rotating cylinder was specified as
corresponds to 23 mm thickness at the
23 mm, this was checked using this standard
standard rotating monitoring cylinder.
cylinder exposed to water spray in the same way
as insulators under the test. During the first ice
For each test the complete insulator arrangement
accretion, the time needed to get the required ice
was first subjected to the specified ice conditions,
thickness was defined. At the second and the third
and thereafter subjected to a voltage withstand
ice accretions, both the standard rotating cylinder
test. A special set-up was used for the application
and the estimated time were used to define the
of ice on the V-shaped insulator arrangement; see
duration of the ice accretion phase. Prior to the
front view of set-up in Figure 7. The glaze type of
start of each test, small samples of ice were
ice (clear transparent ice) was accreted using
removed from the insulators. The volume and
water spraying from approximately 1 m distance.
weight were measured by using cold oil in a
To allow for correct positioning of the spray
measuring cylinder and a scale. Some samples
system, a structure of aluminium beams, mirroring
were then thawed and the conductivity was
the V-shaped insulator structure, was hung from
measured when the thawed water had reached the
the crane and supported by the wall of the climate
room temperature.
test hall. The structure carried 4 arrays of fixed
spray nozzles fitted with special heaters for
Example of ice accretion on the insulation structure
temperature control and defrosting. The distance
just before the test is presented in Figure 9. It is
between the nozzles in each array was about 0,5
considered that the ice accretion simulated well the
m, and the complete installation comprised in total
service case, i.e. that the icicles grew downwards,
of 20 nozzles. A schematic drawing of complete
without bridging the shed spacing of the inclined
spay system is in Figure 8.
insulators of the V-string.

Figure 7: Set-up for full-scale ice test (front view).

Figure 9: Close look on ice accreted insulator just

before the start of voltage test.
It was decided to perform the tests for the worst
case, i.e. the so-called “melting regime” mode
according to the principles of IEEE 1783. This
simulates the “sun-rise” service case, i.e. ice
accreted on the insulator during the cold night and
melted in the morning due to increase of
temperature under sun. This case is worse that
alternative “freezing rain” test, because the
conductivity of the top melted layer of the ice will
be higher for the “sun-rise” service case. The
simulation of the “sun-rise” was done by increase
of the temperature in the climate test hall after
finalization of ice accretion. This was achieved by
letting in clean fog (steam) into the test hall with an Figure 10: Example of leakage current
additional flow of warm air from outside through the development during the test. Green and red
small door into the test hall, while fans at the roof corresponds to two different branches of V-string.
were slowly evacuating the air, creating a slight
draft. The gradient of the temperature increase in 5 DISCUSSION
the proximity to zero degrees C was about 1°C/h.
5.1 Pollution test
All voltage withstand tests were performed at the
test voltage of 525 kV DC of negative polarity. This The reason for the application of the Rapid
voltage was maintained through the whole melting Flashover tests is to provide data in much shorter
phase. time that using the standard up-and-down method
for voltage application, but ensuring similar results;
Target parameters together with actual measured this was verified earlier for ceramic and composite
values are summarized in Table 2 . insulators at AC [5]. In this paper this innovative
rapid technique was applied for composite
Table 2: Target parameters vs. measured values insulators at DC combining both new pollution
during the tests technique (pre-conditioning) and new technique for
DC voltage application. The pollution performance
Parameter Target value
Actual value curves (insulation strength) created using this
during the test technique can be directly used for statistical
dimensioning of insulators according to principles
Temperature
during ice Stable, ca -10oC Stable, ca -8oC
of IEC 60815-1 [11], see illustration of
accretion stress/strength concept adopted from the IEC in
Figure 11. The original requirement for the
Temperature Increased to about Increased to about reliability of the future overhead line was risk for
during voltage test 0oC 0oC
flashover determined as Mean Time Between
Type of ice Glaze Glaze Flashover (MTBF) 40 years. Our calculations
showed that both tested insulators provide MTBF >
Ice density 0,70-0,90 g/cm3 0,86-0,91 g/cm3 500 years and thus are applicable for service with
Amount of ice 23 mm at rotating 23 mm at rotating
a good margin. It is known from CIGRE TB that
cylinder cylinder “For DC systems, the application of a detailed
statistical design approach is considered beneficial
Applied water 100 S/cm 100±10 S/cm in view of the importance of an optimal insulation
conductivity
design with respect to pollution” [7].
DC test voltage -525 kV -525±5 kV

Leakage current NA Less than 2 mA

4.3 Test results

The target test parameters were fulfilled (see

Table 2) and full-scale V-shaped insulator
withstood the DC voltage test at 525 kV of
negative polarity (no flashovers after 3 separate
voltage tests). The leakage current was low
through the whole test, see Figure 10.

Figure 11: Stress/strength concept for calculation

of risk for pollution flashover.
At the same time the results of the withstand tests
were lower in comparison to the flashover pollution
tests. This might be explained by a number of
factors:
 Applicability of statistical factor 1,4 to
determine the test severity.
 Low accuracy of withstand tests based on
only 3-4 voltage applications in
comparison to multiple flashover/withstand
events for flashover tests.
 Poor knowledge on influence of V-string
configuration in comparison to I-string,
especially for composite insulators (two
parallel insulators would increase the
probability for flashover, while inclined
position might reduce it).
Nevertheless, the obtained results are of interest
for CIGRE, which is still looking into development
of pollution test methods for composite insulators.
5.2 Ice test
A new ice test method intended for rather
conservative service case, i.e. “sun-rise” was
applied for the complicated full-scale V-shaped
insulation structure. The test parameters fulfilled
the requirements and the insulators withstood the
test. The appearance of the icicles on V-string is
considered as representative for service conditions
and positive for the performance not allowing
bridging of the adjacent sheds. Thus, these
insulators are applicable for service.
5 CONCLUSIONS
To simulate the specific environmental conditions
for a new ±525 kV HVDC link close to the
Norwegian coast a special test program was
developed and included the pollution testing and
ice testing. Due to preliminary choice of composite
insulators, both test methods required new
innovative test methods. This was achieved using
a combination and further development of
IEC/CIGRE/IEEE standards and guidelines.
The test methods were pretty conservative, e.g.
not taking into account hydrophobic properties in
pollution test and simulation of the worst case of
“sun-rise” for ice tests, when the surface
conductivity on the top of ice will be higher than for
the “freezing rain” case.
The results of testing confirmed that the
preliminary chosen insulators are applicable for
service.
At the same time the test results provided some
input for CIGRE for further discussions about
requirements for pollution/ice tests for composite
insulators.
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TM
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