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P-8-96 DISC PORCELAIN Insulators
P-8-96 DISC PORCELAIN Insulators
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SPECIFICATION P-8:96
CLAUSE 8.1.8
Please replace the existing first sentence of this clause with the following:
“For power are test, ten insulators shall be selected at random from the first batch
consisting of at least 25% of ordered quantity of a purchase order/contract. This test will be
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carried out only once for each purchase order/contract.”
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C O N T E N T S
0. Foreword
1. Scope
2. Definitions
3. General
4. Material
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6. Galvanization
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7. Tests
10. Packing
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PRINTING HISTORY
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SPECIFICATION P-8:96
0 FOREWORD
(1) This specification has been prepared by Design Department (T&G) WAPDA and
lays down the requirements for disc type porcelain insulators with ball and
socket coupling for use on transmission system.
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(3) This edition is the fifth revised version of original specification introduced in
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1967. Major additions incorporated in this version are inclusion of steep wave
front test, power arc test and autoclave expansion test for Portland cement.
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(4) This specification is mainly based on following international standards in respect
of manufacturing and testing requirements. If, however, the requirements
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mentioned herein differ from those indicated in the relevant international
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standards, the requirements indicated herein shall prevail.
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ii) IEC Publication 372 (Locking devices for ball and socket
coupling of string insulator units:
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1 SCOPE
(1) This specification covers disc type porcelain insulators with ball and socket
coupling for use on over-head transmission system.
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2 DEFINITIONS
2.1 Flashover
2.3 Lot
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2.4 Mechanical Impact Strength
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The mechanical impact strength of an insulator is the impact which, under
specified conditions, the insulator can withstand without damage.
2.5 Puncture
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Puncture is a local or total destruction of the insulating material caused by a
discharge passing through it.
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considered a puncture.
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2.7 Sample
A sample of n items taken form a population of N items in such a way that all
possible combinations of n items have the same probability of being chosen.
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2.9 Standard Atmospheric Conditions
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2.11 Dry or Wet one-minute Power Frequency Test Voltage
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This is a power frequency voltage which the disc insulator can withstand for
one-minute dry or wet, under the conditions prescribed, and without flashover or
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puncture.
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2.12 24-Hour Mechanical Test Load of Disc Insulator
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This is a mechanical load which the disc type insulator can withstand for 24
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This is the mechanical load which, under the conditions prescribed, causes
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This is the mechanical load which, under the conditions prescribed, causes
separation of the metal parts.
The puncture voltage of an insulator is the voltage, which, under the conditions
prescribed, causes puncture.
3 GENERAL
3.1 Standard insulators shall conform in all respect to the requirements stated
hereinafter.
3.2 Manufacturer’s drawings shall be supplied and shall show the outline of the
insulator together with all pertinent dimensions. Any possible variation in these
dimensions due to manufacturing tolerance shall be indicated.
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4 MATERIAL
4.1 The insulators shall be made of good commercial grade wet process porcelain.
4.2 The entire surface of the insulators shall be smoothly glazed. The standard color
of the glaze shall be as indicated in Table-I. The entire surface shall be free
from imperfections.
4.3 Metal parts, except for split pins, shall be made of a good malleable iron, ductile
cast iron or open hearth or electric furnace steel, and galvanized according to
Clause-6.
4.4 The insulator unit shall be designed to inhibit the accelerated corrosion of metal
fittings due to leakage currents. A corrosion intercepting zinc sleeve shall be
used on the insulator coupling pin for Fog type insulators.
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4.5 The design of the isolator shall be “straight headed” with sanding of the
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porcelain internally and externally where the metal work is cemented to the
porcelain.
5.1
DIMENSIONS AND CHARACTERISTICS 0 16
Dimensions and Characteristics shall conform to values given in Fig-I and
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Table-I.
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5.2 Coupling
Dimensions of standard ball and socket coupling shall conform to the IEC
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Publication 120.
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Standard split pin locking device shall have the shapes and dimensions in
accordance with IEC Publication 372-1 and Fig: 2 of this Specification.
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5.3.1 Material
The material for split pin shall be standard quality stainless steel or bronze,
having quality of resistance to internal corrosion.
6 GALVANIZATION
6.1 Ferrous parts shall be hot dip galvanized with zinc coating conforming the tests
carried out as per WAPDA/NTDC Specification P-82.
6.2 Please add the following for “Class B Casting” at Page 3 after 2nd line in
WAPDA/NTDC Specification P-82:-
7.1.1 These tests are intended to verify the main electrical characteristics of an
insulator which depend primarily shape and size on its shape and size. They are
made once only on insulators.
7.1.2 Following type tests are to be carried out in accordance with the requirements
and methods laid down in the publications mentioned therewith.
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iv. Thermal-mechanical performance test (As per sub clause 8.1.5 of this
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specification)
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v. Radio influence voltage test (ANSI C29 1-1998)
insulator and the quality of the materials used. They are made on insulators
taken at random from batches offered for acceptance.
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7.2.2 Following sample tests shall be carried out in accordance with standard
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mentioned therewith:-
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(viii) Autoclave Expansion Test for Portland Cement (As indicated in sub-
clause 8.1.6 of this specification).
(ix) Steep Wave Front Impulse Test (as indicated in sub clause 8.1.7 of this
specification).
(x) Power Arc Test Front Impulse Test ( as indicated in sub clause 8.1.8 of
this specification).
This document is property of Design NTDC. No Part of this can be modified or used for any purpose other than its designated purpose.
7.2.3 Locking Device for Ball & Socket Coupling
Following sample tests are to be carried out in accordance with methods given
in IEC 372 and the Fig:2 of this specification:-
i. Visual Examination
ii. Verification of Dimensions
iii. Verification of Resistance to Bending
iv. Hardness Test
v. Operation Test
These tests are for the purpose of eliminating insulators with manufacturing
defects. They are made on every insulator offered for acceptance by the
manufacturer. Following routine tests are required in accordance with IEC 383:-
i. Visual Examination
ii. Mechanical Routine Tests
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iii. Electrical Routine Tests
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8 SAMPLING RULES, TEST METHODS AND ACCEPTANCE CRITERIA
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FOR SAMPLE TESTS
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8.1 Rules for Insulator Sampling and their Distribution for Tests
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8.1.1 For sample tests, insulators shall be offered in lots of 5000 units. The insulators
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intended for the sample tests shall be taken at random form each lot by the
inspector after performing routine tests of IEC Publication 383 and elimination of
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TABLE-II SAMPLING
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n n1 n2
14 10 4
The total sample of ‘n’ insulators is further divided into two partial samples
composed of “n1” and “n2” insulators.
8.1.3 The sample of “n1” insulators is subjected to the following tests of IEC Publication
383 which are applicable in the order indicated. The acceptance criteria shall be in
accordance with IEC-383 except for electro –mechanical test, for which, the
acceptance criteria mentioned in sub-clause 8.1.3.1 shall apply.
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8.1.3.1 While performing electro-mechanical test, the process for the decision of
acceptance shall be as follows:-
QS= R - RS
S
In this formula:
- Average value R = R1 + R2 + ………….. + Rn1
n1
R1, R2, R3,…………… Rn1 are the measured values of electric-mechanical
failing load.
- Rs: Specified value of the electric – mechanical failing load.
- Standard deviation:
S = ∑ ( R - R )2
n1- 1
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If QS > 3, the lot meets the acceptability criterion.
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If QS < 3, the lot close not meet the acceptability criterion.
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8.1.4 The sample of “2” insulators is subjected to the following tests of IEC Publication
383 which are applicable with the acceptance criteria specified in that
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Publication:
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(i) Verification of dimensions
(ii) Temperature cycle test
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8.1.5 For thermal-mechanical performance test, ten (10) insulator units of each type
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shall be selected at random from the first lot and tested in accordance with IEC
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a) The results of the performance tests shall match the results of ordinary
electro – mechanical failing load test. Thus the specified electro-mechanical
failing load that applies to the ordinary electro-mechanical failing load test
should be reached also in the performance tests.
b) Fracture pattern shall not change.
c) Electrical puncture or shattering should not occur before reaching the
maximum load and the ultimate fracture.
d) The acceptance criteria shall be same as for electromechanical test
indicated in sub-clause 8.1.3.1.
8.1.6 The soundness of Portland cement to be used as the bonding agent for insulators
shall be tested in accordance with ASTM CI51 “ Standard Test Method for Auto
clave Expansion of Portland Cement. “ Six (6) samples of cement for the test
specimens shall be selected at random from the batch to be used for insulators.
The bars prepared from meat cement when subjected to high pressure steam at
295 psi for three hours at 216 deg.C shall not show an expansion of more than
This document is property of Design NTDC. No Part of this can be modified or used for any purpose other than its designated purpose.
0.12 percent. The expansion of cement more than 0.12 percent in the test shall
cause rejection of the whole batch of cement brought for acceptance.
Ten (10) insulator units of each type shall be selected at random from the first lot
and tested in accordance with ASTM C151-93a. After this test, each unit shall be
subjected to Electro-mechanical failing load test (IEC 383). The acceptance criteria
shall be the same as for electro-mechanical attest indicated in sub-clause 8.1.3.1.
8.1.7 For steep wave front impulse test, five (5) insulator units shall be selected at
random from the first lot brought for acceptance:-
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flash over test of ANSI C29.1 latest revision and shall pass a flash over test
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of not less than 95 PCT of the rated value.
c) In case of failure of any one unit of either of steep wave front or flash over
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tests, another ten units shall be picked and re-tested. Failure of any one unit
from this group of ten, to the test in (a) and (b) above, shall cause rejection
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of the lot brought fro acceptance.
d) In case of non acceptance of one lot, subsequent lots shall be tested till a
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successful test indicates the design of the insulators has been corrected.
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8.1.8 For power arc tests, ten insulators shall be selected at random from the first lot. Each
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unit shall be attached to the lower end of a vertical string of five other insulators. Each
string of six insulators thus formed shall be subjected to two flashovers of 12,000 rms
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symmetrical amperes for 5 cycles. The insulator string, when under test, shall be in
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the vertical position without conductor and arcing horn. The 50 cycle voltage shall be
applied to the bottom of the string with ground at the top of the string. The insulators
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shall be stressed to 40% of the rated strength of the insulator. The flashover shall be
initiated by a fuse wire connected from the cap of the top insulator to the pin of the
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bottom insulator. The mechanical strength of insulator units shall not be r educed
below 65 percent of their rated strength after breaking with the power arcs as
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described above.
9 MARKING
Each insulator unit shall bear symbols indentifying the manufacturer, year of
manufacture and the rated combined Electrical and Mechanical strength. The marking
shall be legible and durable.
10 PACKING
The following information/documents shall be supplied with the bid. Failure to supply
the same may cause disqualification of the bid:-
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i. Detailed fully dimensioned drawings of insulators.
ii. Specification giving material grade composition of all parts of the
insulators, and locking arrangements.
iii. Catalogues/Literature.
iv. Detail of manufacturing and testing facilities available with
manufacturer.
v. The information indicated in table-I of the specification.
vi. Certified type test reports, preferably from an independent laboratory.
All information indicated in sub clause 11.1 above shall be submitted for approval of the
Engineer prior to commencement of mass production.
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This document is property of Design NTDC. No Part of this can be modified or used for any purpose other than its designated purpose.
SPECIFICATION P-8:2008
TABLE-I
Normal Type Fog type
Disc Diameter
255 255 255 280 255 255 255 292
(D),mm
Disc spacing (P),mm 146 146 146 146 146 146 146 146
Minimum Creepage
Distance, mm 290 290 290 300 430 430 430 470
Standard Coupling
dia (dI), mm 20
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MECHNACIAL
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VALUES
Short-time Electro –
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mechanical breaking
load, KN 70 80 100 160 70 80 100 160
Mechanical Routine 28 32 40
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Test Load, KN
Mechanical Impact 6.2 11.3 11.3 6.2 6.2 11.3 11.3
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Strength, Nm
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ELECTRICAL
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VALUES
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Power Frequency
70 70 70 85 85 85 85
withstand voltage, 70
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KV
Wet power frequency
40 40 40 50 50 50 50
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withstand voltage, 40
KV
Impulse withstand 110 110 110 110 110 110 110
110
voltage, KV
Low frequency
110 110 110 110 130 130 130 130
puncture voltage, KV
RADIO NOISE
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