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Abstract. This paper discusses the current practice for selecting II. INTRODUCTION
high voltage insulators and the changes needed to accommodate
Load Resistance Factor Design. Conversion of insulator rated
strength, defined according to ANSI C29 Standards, to damage
limit strength to provide the service limit resistance required by
H igh-voltage insulators for electrically insulating and
mechanically supporting energized conductors on
transmission and distribution line structures are selected on the
LRFD is discussed. Specific values of service limit resistance and basis of their rated strength. Line loading and strength
strength factors for different types of high voltage insulators are
regulations governing insulator selection differ around the
presented for further consideration by those responsible for
revising current line loading and strength regulations and world and this paper is limited to selecting insulators to satisfy
insulator standards. the requirements of the National Electric Safety Code (NESC)
and American National Standards Institute (ANSI) high
Index Terms – Allowed stress design, ceramic insulators, damage voltage insulator product standards [1], [2]. Current NESC
limit, load resistance factor design, non-ceramic insulators, practice is to limit district maximum design line loads defined
service limit resistance, strength limit resistance. in the code to an allowable percentage of rated strength for a
particular insulator as defined in the ANSI C29 series of
I. NOMENCLATURE
insulator standards
Damage limit (RDL). Strength of a component below ultimate
This practice is similar to an allowed stress design (ASD) for
corresponding to a defined limit of permanent damage or
a strength limit resistance in which all loads are considered to
deformation.
be equally probable without variation, and the ultimate
Rated strength (R). Strength rating of a component based on
resistance to these loads is divided by an assigned safety
compliance with a given standard.
factor to obtain a specified safety margin. Real loads and
Service limit resistance. Limit of a component’s resistance to a
resistances though are variable not single-valued and, if an
load without permanent damage or deformation being
assessment of risk is desired, this variability must be taken
initiated.
into account. Risk of failure is considered for load resistance
Strength limit resistance. Limit of the ability of a component
factor design (LRFD) which requires an evaluation of the
to resist a load and remain in service.
expected variation in service loads and service limit
Combined Mechanical and Electrical Rating (M&E). The
resistances along with appropriate factors to obtain a desired
mechanical load at which a ceramic suspension type insulator
margin of safety [3].
fails to perform its function, either electrically or
Other than insulators, the current NESC already requires
mechanically, when voltage and mechanical stress are applied
many line components to be selected on the basis of LRFD.
simultaneously.
Consideration of the requirements for these other components
Specified Mechanical Load (SML). A rating for suspension
can aid in the development of recommendations for loading
type non-ceramic insulators that has to be verified during a
limits needed to include the selection of insulators according
tensile load test. It forms the tensile loading basis for selection
to LRFD in the regulations.
of non-ceramic (composite) suspension type insulators.
In the following a brief review of current practice for
Specified Cantilever Load (SCL). A rating for post type non-
selecting insulators, and the differing requirements regarding
ceramic insulators that has to be verified during a cantilever
ASD and LRFD, shows that the current practice based on
load test. It forms the cantilever loading basis for the selection
strength limit resistance must be changed to one based on
of non-ceramic post type insulators .
service limit resistance for insulators to accommodate LRFD.
Specified Tensile Load (STL). The tensile load a post type non-
The mechanical strength value assigned by a manufacturer
ceramic insulator can withstand for one minute without
for a particular insulator is qualified as meeting a rating
failure.
according to ANSI C29 insulator standards by conducting and
Manuscript submitted August 19, 2011 for presentation at the panel session meeting specified test requirements. Mechanical rating
“Mechanical Load Limits for High Voltage Insulators” at the IEEE PES T&D qualification tests are ultimate strength tests and so are related
Conference and Exposition, Orlando, FL, May 7-10, 2012. to a strength limit resistance.
A. C. Baker is with K-Line Insulators USA Inc., Rochester, NY USA 14624
e-mail: tbaker@k-line.net
Cumulative distribution
0.8
indicaation of the riskk of failure. 0.7
Loads and resistaances are often n normally distrributed and thee 0.6
LRFD D method in such
s cases is better
b expresseed as shown in n 0.5
Fig. 3 where norm mal probability density curvees representing g 0.4
load aand resistance are shown. The upper portiion of the load d 0.3
curvee is shown heere overlappin ng the lower portion
p of thee 0.2
servicce limit resistaance curve indiicating a regio on of failure. Itt 0.1
may be for some cases that th here is no reggion of failuree 0
suggeesting an ineffficient design because
b even for
f the highestt 0 2 4 6 8 10 12
2 14 16
load, regardless of o its improb bability of occurring,
o thee Load (LL) or Resistancee (R)
resisttance would no ot be exceeded.
Fig. 4.. Cumulative distrributions for Fig. 33.
Load
L Duuctile materialss like metal fitttings exhibit a well-defined
d,
and sometimes oobservable, seervice limit bby yielding in n
respoonse to loccal stress aas depicted in Fig. 5. 5
Resistance
R
X
Brittle Ultimate
material stress
=4 = 8.5 Regiion of
σ=1 σ = 1.5 faiilure X
Stress
Ductile
Yieeld material
streess
Fig 3. PProbability density
y functions for norrmally distributed loads and Proportional
resistannces. limit
4
R DL as a percent of R in C29 Standards 1 permitted stress. The permitted stress is the strength multiplied
by the strength (resistance) factors given in Section 26. This
0.8 can be expressed as in (6) and (7) provided the symbol < is
c=4 understood to mean must withstand, i.e., the particular
component can not suffer irreversible damage at the permitted
0.6 c =3 stress.
c = 1.2 (Loads) (Load Factors) < Permitted Stress (6)
0.4
c=0
Permitted Stress = (Withstand Strength) (Strength Factors) (7)
0.2
Considering Grade B construction requirements for line
components, other than high voltage insulators, load factors
0 from Section 25 of the code are summarized in Table IV and
0.00 0.05 0.10 0.15 strength factors for crossarms and braces made from different
Coefficient of variation, v materials taken from Section 26 of the code are summarized in
Fig. 7. Damage limits as a percent of rated strength for ceramic insulators for Table V [1].
manufacturing processes with a coefficients of variation in the range 0-15%.
TABLE IV
As shown in Fig. 7, the effect of v on RDL is reduced as the LOAD FACTORS FOR GRADE B CONSTRUCTION
FOR STRUCTURES, CROSSARMS, SUPPORT HARDWARE,
constant c is increased suggesting changes that should be
GUYS, FOUNDATIONS, AND ANCHORS*
considered when the standards are revised. Load Grade B
B. Non-ceramic Insulators Classification Load Factors
Non-ceramic insulators are qualified as meeting strength Combined ice & wind district loading (Rule 250B)
Vertical loads 1.50
ratings by ultimate strength withstand tests and this precludes Transverse loads -Wind 2.50
a statistically based loading limit recommendation. However, -Wire tension 1.65
the damage limit concept is well established for this type of Longitudinal loads -In general 1.10
-At deadends 1.65
insulator
Extreme wind loading (Rule 250C ) 1.00
As discussed in [5], fiberglass resin-reinforced rods, which Extreme ice with concurrent wind loading (Rule 250D) 1.00
provided the means for supporting mechanical loads for non- *Taken from Table 253-1 NESC C2-2012 [1].
ceramic insulators, are made up of unidirectional glass fibers
TABLE V
and a resin reinforcement usually made by a pultrusion STRENGTH FACTORS FOR CROSSARMS AND BRACES
process. Initially it was assumed that creep was the controlling FOR GRADE B CONSTRUCTION1
phenomenon with regard to long term performance, but Grade B Strength Factors Permitted
experiment and experience has demonstrated that if the load is Rule Rule 250C & Stress
Material 250B Loads2 250D Loads3 Strength4
kept below that point at which fiber breakage is initiated, the Metal 1.0 1.0 WS
delayed failure phenomenon disappears. Damage limits for Pre-stressed concrete 1.0 1.0 WS
non-ceramic insulators of the type included in the ANSI C29 Reinforced concrete 0.65 0.75 WS
Wood 0.65 0.75 DSF
series of product standards based on not initiating fiber Fiber-reinforced polymer 1.0 1.0 5% LEL
fracture are given in Table III as a percent of the specified Other material 0.65 0.75 WS
1
mechanical load (SML) or specified cantilever load (SCL) as 2
Taken from Section 26 and Table 261-1, NESC C2-2012 [1]
defined in [2f]. District loads (heavy, medium, light, and warm island loading)
3
Extreme wind loads and Extreme ice with wind loads
4
WS=Withstand strength, DSF=Designated fiber stress, 5% LEL=5% lower
TABLE III
exclusion level.
DAMAGE LIMITS (RDL) FOR NON-CERAMIC INSULATORS
AS A PERCENT OF RATED STRENGTH (R).
ANSI Std Type Damage Limit, RDL The withstand strength in Table V is a service limit
C 29.12 Transmission Suspension 0.68 Specified Mechanical Load resistance as required by LRFD and the strength factors are
C 29.13 Distribution Suspension “ lower for more variable strength material (e.g. wood compared
C 29 17 Transmission Line Post 0.55 Specified Cantilever Load
C 29.18 Distribution Line Post “ to metal).
Applying LRFD for the selection of high voltage insulators
VIII. RESISTANCE FACTORS could be accommodated by defining the withstand strength of
an insulator to be given by the damage limit as given in Table
Strength (resistance) requirements for supporting structures, II or III, and assigning a strength reduction factors dependent
foundations, crossarms, braces support hardware, and guy on the dielectric material and insulator type.
anchors, but not insulators, based on LRFD are given in The difficulty of including an allowance for process
Section 26 of the current edition of the NESC [1]. variation for ceramic insulators, though it could be reduced if
The requirements are that the line components must the constant (c) is increased in future revisions of the
withstand the appropriate loads multiplied by the load factors standards, requires a strength factor based on a cautious
given in Section 25 of the code without exceeding the assumption for the coefficient of variation in Table II. A lower
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strength factor for ceramic posts as compared to suspensions is X. REFERENCES
justified by the higher allowed strength variation for post
[1] ANSI C2 National Electrical Safety Code, ANSI Standard C2-2012,
insulators compared to suspensions in C29 standards.
August 2011. IEEE, 3 Park Ave. New , NY 10016-5997.
As an aid in the effort to include requirements for selecting [2] ANSI C29 High voltage insulator standards, American National
insulators to be compatible with LRFD in future editions of Standard for-
the NESC, service limit resistances and factors for insulators (a) Electrical power insulators – Test methods C29.1-1988 (R2009)
(b) Wet process porcelain and toughened glass Suspension type C29.2-
given in Table VI, based upon an assumed 10% maximum
1992 (R2009).
coefficient of variation for ceramic insulators, are offered for (c) Wet-process porcelain insulators – high voltage Line Post type
discussion and consideration. C29.7-1996 (R2010).
(d) Wet-process insulators – Apparatus Cap & Pin type C29.8-1985
TABLE VI (R2010)
POSSIBLE SERVICE LIMIT STRENGTHS AND FACTORS (e) Wet-process porcelain insulators – Apparatus Post type C29.9-1983
FOR HIGH VOLTAGE INSULATORS (R2010).
Insulator Strength Service Limit Strength (f) Composite insulators – Test methods C29.11 under revision.
Type Rating Resistance Factor (g) Insulators –composite - Suspension type C29.12-1997 (R2002).
Ceramic (h) Insulators - composite - Distribution Deadend type C29.13-2000.
Suspension M&E rating 0.5 M&E 1.0 (i) Insulators – composite - Line Post type C29.17-2002.
Posts (Line & Station) Cantilever rating 0.5 Cantilever 0.8 (j) Insulators – composite - Distribution Line Post type C29.18-2003.
Non-ceramic Published by the National Electrical Manufacturers Association, Roslyn,
Suspension SML .7 SML 1.0 VA. Available at: nema.org/stds.
Posts (Line & Station) SCL .5 SCL 1.0 [3] Load and Resistance Factor Design (LRFD) for Highway Bridge
Substructures, Publication No. FHWA H1-98-032, Federal Highway
Combined loading conditions, especially important for Administration, May 2001.
properly applying non-ceramic post type insulators, are not [4] CIGRE SC22-03, “Study and conclusions from the results of the inquiry
on insulators: information on damages”, Electra No. 78, Oct. 1981.
considered in Table VI. This subject must be addressed before [5] A.C. Baker, R.A. Bernstorf, E.A. Cherney, R. Christman, R.S. Gorur,
LRFD can be fully adopted for the selection of high voltage R.J. Hill, Z. Lodi, S. Marra, D.G. Powell, A.E. Schwalm, D.H.
insulators. Shaffner, G.A. Stewart, and J. Varner, “ High voltage insulators
IX. CONCLUSIONS mechanical load limits – Part I Overhead line load and strength
requirements,” To be published in IEEE Trans on Power Delivery.
[6] E.A. Cherney, “Failures of porcelain line post insulators on the Ontario
Current practice for selecting high voltage insulators to meet Hydro distribution system,” Canadian Electrical Association Spring
the requirements of the NESC is an example of Allowed Stress Meeting, Montreal, Canada March 1988.
Design. Many line components, other than insulators, [7] Standardization Policies and Procedures of the National Electrical
according to the current NESC are selected based on Load Manufacturers Association, NEMA, Roslyn, VA July 7, 2008.
[8] A.C. Baker, R.A. Bernstorf, E.A. Cherney, R. Christman, R.S. Gorur,
Resistance Factor Design. R.J. Hill, Z. Lodi, S. Marra, D.G. Powell, A.E. Schwalm, D.H. Shaffner,
Selection of insulators to accommodate LRFD requires that G.A. Stewart, and J. Varner, “High voltage insulators mechanical load
a method be provided to convert the strength limit resistance, limits – Part II Standards and recommendations,” To be published in
corresponding to the rated strength according to the ANSI C29 IEEE Trans on Power Delivery.
series of standards, to a service limit resistance. The damage
limit of an insulator as described in [5] and [8] can be
considered a service limit resistance for insulators.
General recommendation for insulator loading limits must
be based on the minimum strengths allowed according to the
ANSI C29 series of insulator standards.
Strength factors for insulators required for LRFD must
account for different characteristics of ceramic and non-
ceramic insulators and for the variations in strength allowed
by ANSI C29 standards.
Service limit resistances and strength factors for high
voltage insulators to assist in the effort to add insulators to the
list of line components selected according to LRFD are
presented for further discussion. Combined loading
limitations, not considered here, must be addressed and
included in Table VI before LRFD can be fully implemented
for insulators.
The reader should take note that the above discussion
concerns only new insulators. Past practices for the selection
of insulators were conservative, but considering the variability
in the quality of insulators that are in service today and the
knowledge that many have lost strength over time, this
conservatism was well warranted.
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