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Dr. Subba Reddy B, Department of Electrical Engg, Indian Institute of Science, Bangalore - India
History of Transmission Insulators
• Basically grew out of the needs of telegraph industry – starting in the
late 1700s, early 1800s
During 1840-50s
• Glass plates used to insulate telegraph lines
Dr. Subba Reddy B, Department of Electrical Engg, Indian Institute of Science, Bangalore - India
During
• Wet process porcelain developed for high voltage applications
• Porcelain insulator industry started
During
• Application voltages increased
• Insulator designs became larger, more complex
• Ceramics (porcelain, glass) still only choices at high voltages
During
• US trials of first “NCIs” – Not successful, but others soon became
interested and a new industry started up
During
• Europeans develop “modern” style NCI – fiberglass rod with various
polymeric sheds - Now considered “First generation”.
Dr. Subba Reddy B, Department of Electrical Engg, Indian Institute of Science, Bangalore - India
During
• NCI insulator industry really begins in US with field trials of insulators
• Since the 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.
Dr. Subba Reddy B, Department of Electrical Engg, Indian Institute of Science, Bangalore - India
• Power transmission from Generating stations to load centers -- Overhead
lines
Dr. Subba Reddy B, Department of Electrical Engg, Indian Institute of Science, Bangalore - India
How an Insulator functions ? ?
• Maintains distance (Air Gap) between Line from Ground
- depends on system voltage, safety margin, contamination, etc.
Dr. Subba Reddy B, Department of Electrical Engg, Indian Institute of Science, Bangalore - India
INSULATION CO-ORDINATION
• The maximum over voltage occurs rarely and like wise insulation
strength very rarely decreases to its lowest value.
• The decrease in line cost must be weighed against the increased risk of
failure and the cost of such failures.
Dr. Subba Reddy B, Department of Electrical Engg, Indian Institute of Science, Bangalore - India
Dr. Subba Reddy B, Department of Electrical Engg, Indian Institute of Science, Bangalore - India
Design Criteria - Mechanical
– Its primary function is to support the line mechanically
– Estimate the maximum load the Insulator will ever see Including
Normal and Overload Factors.
Dr. Subba Reddy B, Department of Electrical Engg, Indian Institute of Science, Bangalore - India
Design Criteria - Mechanical
Porcelain / Ceramic Insulators
When the porcelain begins to crack, it electrically punctures.
Never Exceed 50% of the M&E Rating
Check for Cantilever Rating do not exceed >40%
Dr. Subba Reddy B, Department of Electrical Engg, Indian Institute of Science, Bangalore - India
Design Criteria - Electrical
Strike Distance (Dry Arcing Distance)
“The shortest distance through
the surrounding medium between
terminal electrodes….”
Dr. Subba Reddy B, Department of Electrical Engg, Indian Institute of Science, Bangalore - India
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.”
• Leakage distance helps to maintain the surface resistance of strike distance
Empirical Determination: What’s been used successfully? If Flashovers occur – add more leak?
Dr. Subba Reddy B, Department of Electrical Engg, Indian Institute of Science, Bangalore - India
Designing / Selecting a Suitable Insulator
Electrical Parameters Calculation
A Heighest System Voltage 69.0 245
B System Line-Gnd Voltage (A/1.732) * 1.05 41.8 170
C Peak L-G Voltage (Pv) Pv=B * 1.414 59.1 220.5
Leakage distance Calculations
69 kV 220kV
41.8 inches 170 inches
I. Switching Over-voltages: (B * 3 - 5)
69 kV 220kV
System Approx Values Approx Values
125 850
Requirement 66kV system 220kV system
J. Lightning Over-voltages: ( I(t)*R(f)+Pv Leakage distance 41.8 inches 170 inches
(typical values: I(t):20-50kA, R(f): 10-20 ohms Switching surge 125 kV 850 kV
69 kV (20*15+59.1) 220kV(44*19+220) (approx) Voltage
Lightning Impulse 359 kV 1056 kV
359 kV 1056 kV
withstand
Chart Courtesy of Ohio Brass/HPS – EU1429-H
Dr. Subba Reddy B, Department of Electrical Engg, Indian Institute of Science, Bangalore - India
Insulator Selection
Leakage
42” 46”
Distance
Wet Switching
125 kV 240 kV
Surge W/S
Dr. Subba Reddy B, Department of Electrical Engg, Indian Institute of Science, Bangalore - India
Design Criteria - Electrical
“Application Guide for Insulators in a Contaminated Environment”
by K. C. Holte et al – F77 639-8
Leakage Distance
ESDD (mg/cm2) Site Severity I-string/V-string
(“/kV l-g)
Leakage Distance
ESDD (mg/cm2) Site Severity
(“/kV l-g)
2.5
2
IEEE V
Leak ("/kV l-g)
1.5 IEEE I
IEC
Poly. (IEC)
1
Poly. (IEEE V)
Poly. (IEEE I)
0.5
0
0 0.1 0.2 0.3 0.4 0.5
ESDD (mg/cm^2)
Dr. Subba Reddy B, Department of Electrical Engg, Indian Institute of Science, Bangalore - India
Improved Contamination Performance
Flashover Vs ESDD
300
250
200
Flashover Voltage
Porcelain
New EPDM
150 Aged EPDM
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)
Dr. Subba Reddy B, Department of Electrical Engg, Indian Institute of Science, Bangalore - India
Improved Contamination Performance
Claims:
• Polymer insulators offer better contamination flashover performance
than porcelain ? ?
Dr. Subba Reddy B, Department of Electrical Engg, Indian Institute of Science, Bangalore - India
Grading Rings
• Simulate a larger, more spherical object
• Porcelain or Glass –
• 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
Dr. Subba Reddy B, Department of Electrical Engg, Indian Institute of Science, Bangalore - India
NCIs and CC-Rings
Dr. Subba Reddy B, Department of Electrical Engg, Indian Institute of Science, Bangalore - India
SERVICE EXPERIENCE
Dr. Subba Reddy B, Department of Electrical Engg, Indian Institute of Science, Bangalore - India
Ceramic / Porcelain Insulators
• Used since 1830s (for telegraph lines)
• Used at all voltages for line insulation
• Provides great flexibility (cap and pin)
• Strong in compression
• Available in various shapes (simple-complicated)
• High degree of standardization
Dr. Subba Reddy B, Department of Electrical Engg, Indian Institute of Science, Bangalore - India
Experience with Ceramic Insulators
Dr. Subba Reddy B, Department of Electrical Engg, Indian Institute of Science, Bangalore - India
2. Glass Suspension Insulators
Dr. Subba Reddy B, Department of Electrical Engg, Indian Institute of Science, Bangalore - India
3. Non Ceramic Insulators
* Introduced in 1960s for transmission (GE)
* Used for all voltages
* light flexible, high strength to weight ratio
* Strong in tension
* low degree of standardization
weather sheds
fiberglass core
end fittings
Dr. Subba Reddy B, Department of Electrical Engg, Indian Institute of Science, Bangalore - India
Service Experience with Polymers
• Surface degradation:
- UV, Electrical stress (tracking/treeing) , leakage current & arcing..
Result in - Flashover & mechanical failures
• Internal degradation:
- Cracked rod, bad coating between rod & sheath, void
between rod & sheath - water wicking between rod & sheath ….
• Brittle fracture
is a stress corrosion failures of fiberglass rod,
factors: Water in the rod, Mechanical loads, Electrical stress
Dr. Subba Reddy B, Department of Electrical Engg, Indian Institute of Science, Bangalore - India
Dr. Subba Reddy B, Department of Electrical Engg, Indian Institute of Science, Bangalore - India
Ceramic vs. Polymeric Insulators
Ceramic
• Made from inorganic materials Þ do not age
• 80 years of experience
• Flexibility in length
• High leakage distance profiles
• Can be coated and washed
Polymeric
• Made from Organic materials Þ age
• Approx: 30years, latest designs < 10years
• Lighter, less susceptible to vandalism
• Smaller viewing profile
• Good short term performance in polluted environments
• 90% weight reduction, Reduced breakage, lower installation costs
• Aesthetically more pleasing, improved power frequency insulation
Dr. Subba Reddy B, Department of Electrical Engg, Indian Institute of Science, Bangalore - India
Comparison of attributes of Insulators
Insulator Positive Attributes Negative Attributes
Non Weight (60-90% reduction) Reduced strike distance
Ceramic/Polymeric Contamination withstand Susceptible to aging
Low installed cost Susceptible to arcing damage
Impact strength Brittle fracture possible
Small profile/ Cost -? Not easily inter changeable
(1.5times - 1985-86 Limited Experience,Handling,Storing,Transporting
0.5times 1997-98) Live line techniques to be developed
Performance quantified Weight
Porcelain/Ceramic Long history of use Pin corrosion
Post cascade failures
Hidden defects
“Fun” to shoot
Price
RG Porcelain Contamination withstand Power loss
Dr. Subba Reddy B, Department of Electrical Engg, Indian Institute of Science, Bangalore - India
The Reliability of modern high voltage power transmission system has been seriously
affected by pollution induced flashover, which occurs at normal operating voltage itself.
1600
1200 +1265
1000
250x2500 us Switching surge
. +875 dry Figure shows greatest threat of
800 . 785 dry flashover at nominal voltage for
.+750 Wet Porcelain / glass insulators is
600 .565 Wet } Clean
under polluted conditions
400
Polluted
Normal 230kV Operating Voltage 206
200
186
Considering this, high voltage laboratory at IISc has been conducting research both on
Expt & Simulation/Modelling on performance of outdoor insulators under normal &
pollution conditions.
- A Novel field control element / electrode is developed.
Dr. Subba Reddy B, Department of Electrical Engg, Indian Institute of Science, Bangalore - India
Pollution types
• Marine
• Industrial
• Desert
• Mixed
• Agricultural
• Fog/Ice etc
Dr. Subba Reddy B, Department of Electrical Engg, Indian Institute of Science, Bangalore - India
Pollution flashover phenomena
Deposition of pollutants
ß
wetting & flow of current
ß
non uniform heat generation & non uniform drying
ß
inception of scintillation / partial arcs
ß
Elongation of partial arcs -- -> complete flashover
Þ Spatial distribution of electric field is a governing factor
Region around pin forms the high field zone => scintillations
Dr. Subba Reddy B, Department of Electrical Engg, Indian Institute of Science, Bangalore - India
Pollution/Contamination Flashover
§ Flashover of polluted insulators is a complex phenomena
- Theoretically difficult to comprehend
§ A relatively slow electro-thermal process
- Experimentation difficulties
§ Influencing parameters : wetting rate, pollution type, wind its direction,
type of insulator etc
Dr. Subba Reddy B, Department of Electrical Engg, Indian Institute of Science, Bangalore - India
Experimentation- Pollution Flashover studies
Dr. Subba Reddy B, Department of Electrical Engg, Indian Institute of Science, Bangalore - India
Dr. Subba Reddy B, Department of Electrical Engg, Indian Institute of Science, Bangalore - India
Potential and Electric Field Distribution in a Ceramic
Disc Insulator String with Faulty Insulators
Dr. Subba Reddy B, Department of Electrical Engg, Indian Institute of Science, Bangalore - India
Detection and replacement of faulty insulator disc in a string of
insulators is necessary to ensure reliable power supply.
Dr. Subba Reddy B, Department of Electrical Engg, Indian Institute of Science, Bangalore - India
SR.NO Method Common technique
1 Electrical • Field Measurement
• Voltage Distribution
• Insulation resistance measurement
2 Acoustic • Ultra Sonic Detection
• Corona Detection Gun
3 Visual • Eye sight
• Ultra Violet Enhancement
• Infra Red Camera
Dr. Subba Reddy B, Department of Electrical Engg, Indian Institute of Science, Bangalore - India
35
30 120N
healthy stirng
25 2nd disc faulty
20
potential in kV
15
10
-5
0 0.2 0.4 0.6 0.8 1 1.2 1.4 1.6 1.8 2
creapage distance in m
Surface gradient plot
12
10
120N
-2
0 0.2 0.4 0.6 0.8 1 1.2 1.4 1.6 1.8 2
Creepage distance measured from Pin end (m)
Dr. Subba Reddy B, Department of Electrical Engg, Indian Institute of Science, Bangalore - India
50
45 120N
healthy
40
2nd
35
k
2&3rd
V 30
/ 25 2&3&4th
c
m 20
15
10
5
0
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23
25 healthy
120N
12th
20
22nd
20&21&22nd
k
15
V 11&12&13th
/
c
10
m
0
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23
Disc number from the line end
Dr. Subba Reddy B, Department of Electrical Engg, Indian Institute of Science, Bangalore - India
120
100
160N Healthy
2nd
2&3rd
80
k 2&3&4th
V
/ 60
c
m 40
20
0
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35
Disc number from the line end
100
90
80
400N Healthy
2nd faulty
70
2&3rd faulty
k
60
V 2,3&4th faulty
/ 50
c
40
m
30
20
10
0
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29
Disc number from the line end
Dr. Subba Reddy B, Department of Electrical Engg, Indian Institute of Science, Bangalore - India
Dr. Subba Reddy B, Department of Electrical Engg, Indian Institute of Science, Bangalore - India
kV
Results for 23 disc string (400kV) 9.5 400
Distance in (m)
250
33%,
• 2nd & 3rd disc faulty, - enhancement 7.5
200
is ~ 68%
7
150
Ø enhancement in electric stress 120N
6.5
across normal insulators is minimal 100
when defective disc located is at
middle or at ground end of the string 6
50
5.5
0 0.1 0.2 0.3 0.4 0.5 0.6 0.7 0.8
Distance in (m)
Dr. Subba Reddy B, Department of Electrical Engg, Indian Institute of Science, Bangalore - India
Ø Similarly, electric stress enhancement for 2nd & 3rd defective discs is
~ 50 - 58% for 66 kV,
~ 15 - 60% for 132 kV,
~ 54 - 66% for 220 kV,
~ 30 - 68% for 400 kV and
~ 40 - 78% for 765 kV different insulator strings.
Ø For faults located at 2nd & 3rd & 4th discs from line end: enhancement
in electric stress across first disc from the line end is found to be
~ 48 - 102% for 400 kV and
~ 62 - 110% for 765 kV for various disc insulator strings
Dr. Subba Reddy B, Department of Electrical Engg, Indian Institute of Science, Bangalore - India
Table: percentage electric stress across the first disc from the line end in a string
with defective insulator discs in different location
Dr. Subba Reddy B, Department of Electrical Engg, Indian Institute of Science, Bangalore - India
Present Research activity
Dr. Subba Reddy B, Department of Electrical Engg, Indian Institute of Science, Bangalore - India
COMPOSITE INSULATORS
§ With increased use of synthetic insulators,
additional problems like tracking and
surface erosion arose.
§ As a result, new dimensions are added to
the area of performance of outdoor
insulators.
§ Further, with increased demand for the
power transmission, more number of HVDC
lines are planned in our country.
§ The pollution flashover problem is more
severe in DC than that with AC, which is
evident from lines operating in the country.
§ Significant research activities are
necessary to tackle this problem.
§ Considering this, it is intended the existing
AC pollution test facility was recently
augmented to 250kV DC test facility.
Dr. Subba Reddy B, Department of Electrical Engg, Indian Institute of Science, Bangalore - India
Dr. Subba Reddy B, Department of Electrical Engg, Indian Institute of Science, Bangalore - India
The research work planned is broadly classified as:
Dr. Subba Reddy B, Department of Electrical Engg, Indian Institute of Science, Bangalore - India
Test methods for evaluating resistance to tracking and erosion IEC 60587
Dr. Subba Reddy B, Department of Electrical Engg, Indian Institute of Science, Bangalore - India
Method to evaluate the Resistance test to high-voltage, low-current arc
discharges as per the IEC 61621
Dr. Subba Reddy B, Department of Electrical Engg, Indian Institute of Science, Bangalore - India
as per IEC 60112
Dr. Subba Reddy B, Department of Electrical Engg, Indian Institute of Science, Bangalore - India
CORONA STUDIES – AC/DC COMPOSITE INSULATOR SAMPLES
Dr. Subba Reddy B, Department of Electrical Engg, Indian Institute of Science, Bangalore - India
Facility for conducting Multiple Stress as per IEC 60112
Dr. Subba Reddy B, Department of Electrical Engg, Indian Institute of Science, Bangalore - India
IMMEDIATE PLANS
Experimental Studies/ANALYSES on various polymer samples: to use
• FOURIER TRANSFORM INFRARED SPECTROSCOPY (FTIR)
• X-RAY PHOTOELECTRON SPECTROSCOPY (XPS)
• SCANNING ELECTRON MICROSCOPY (SCM)
• INFRARED SPECTROSCOPY
Dr. Subba Reddy B, Department of Electrical Engg, Indian Institute of Science, Bangalore - India
Selection of Insulators
Mechanical Parameters
• Selection of Ceramic/Glass and Composite is identical- based on strength a
composite insulator can replace porcelain or glass
• Generally Insulator strength rating a two to one safety factor is applied-
because all materials have a time-load characteristics that reduces residual
strength over time.
Mechanical Characteristics
• Specified Mechanical Load for Suspension Insulator
• Ultimate Cantilever load – for post or station post type
Dr. Subba Reddy B, Department of Electrical Engg, Indian Institute of Science, Bangalore - India
Electrical Parameters
• Selected to maintain economic balance between system performance and the
cost of over-insulation
• Increasing electrical parameters will provide greater system protection at a
higher price
• Consideration based on Individual basis because of uniqueness of power system
configuration, voltage levels, grounding techniques and protection schemes..
Insulator Characteristics
Service Conditions:
Weather, Pollution/Contamination, Altitude, Insulator Configuration,
Physical Characteristics:
Section Length, Dry Arc Distance, Leakage distance
Electrical Characteristics
Max System Voltage, System BIL, Min Dry/Wet Flashover, RIV/Corona
Dr. Subba Reddy B, Department of Electrical Engg, Indian Institute of Science, Bangalore - India
Note:
Dr. Subba Reddy B, Department of Electrical Engg, Indian Institute of Science, Bangalore - India
Concern for the Indian Insulator Industry:
• Domestic manufacturers are facing stiff competition owing to the increasing
import of insulators, particularly from China, at a lower cost.
manufacturing of insulators decreases, shift to offshore (all types)
Calls for:
• Better understanding of the basics of insulator manufacturing, design and
application is more essential than ever before
• Engineers need to develop knowledge and skills necessary to evaluate and
compare suppliers and products from different countries bringing at
par with global benchmark
• Develop manpower skills to support Industry’s future requirement.
• Improve competitiveness and be customer centric – effort by Industry to take
continuous feedback from utilities -- provide solutions.
Dr. Subba Reddy B, Department of Electrical Engg, Indian Institute of Science, Bangalore - India
Summary
• Performance of string insulators used in OH power transmission lines is
very critical & is dictated by electric field distribution prevailing under
different operating contingencies
• Simulation studies were carried using developed SCSM code - obtained
potential and surface field profiles for various discs used in our country
(earlier data was not available)
Dr. Subba Reddy B, Department of Electrical Engg, Indian Institute of Science, Bangalore - India