+
+
)+ r
2
+s (3)
c=s.cos (4)
L
d
=P(
cos
sin 1
+
+
cos
sin 1
)+s(1-sin )+H
c
(5)
Total creepage distance L
t
=
upper creepage distance + (n-1) creepage distance
between shed + lower creepage distance =
np(
cos
sin 1
+
+
cos
sin 1
)+
2
nr
+S
t
(6)
Table (1) contains information on standard relative
factors in comparison with the data considered for the
design.
As it can be seen, all the considered parameters meet
the conditions set by the standard; of course this alone
cannot be regarded as a confirmation on the
performance of the insulators and they should also pass
the standard tests successfully.
MANUFACTURING AND ASSEMBLY PROCESS
OF COMPOSITE INSULATORS
In principle, there are three techniques mainly used for
the manufacture of composite insulators:
1- The composite rod / covering the rod with sheath
by extrusion , injection or compression molding-
manufacturing of sheds separately / assembling
the sheds on the sheath / joining the end fittings to
both ends -sealing.
2- The composite rod / joining end fittings to both
ends placing the housing together with the sheds
using the injection or compression molding
method.
3- The composite rod / placing the sheath together with
the sheds by injection or compression molding
method / joining the end fitting to both ends-
sealing.
The first technique has been applied in the present
study to manufacture a composite insulator. There are
Table 1- Standard comparative coefficients in electrical design insulators
Parameter Name Symbol Unite
Standard
limited
Reason for the limits
72.5
Kv
24 kv
17.5
kv
Total creepage
distance
L
t
mm Min:1575,600
,438
To dissipate creepage currents 1990 613 459
Height to radius ratio S/P - Min : 0.65
Prevention an increase in creepage
distance maintain self proportions
proper self-cleaning
0.81 0.78 0.71
Creepage distance to
permissible distance
ratio
L
d
/d - Max : 5
Prevention short circuit between two
adjacent sheds
3.19 3.24 3.68
Creepage factor CF =L
t
/S
t
- Max : 4 Prevention an improper increase in
shed area
3.56 3.13 3.25
Form factor
2F=2P+
S/L
t
- Min : 0.8 Maintain shape proportions 0.97 0.97 0.97
Minimum distance
between two sheds
C mm Min ; 30
Prevention short circuit between
sheds in bad weather condition
47 45 40.4
Upper surface slope - % Min : 8.7
Keeping shape proportion and good
self- cleaning
27.56 27.56 27.56
certain advantages to the chosen technique over the
others including minimum waste and the ability to
manufacture insulators for various levels of
distributions with one mould.
1st- Rod Manufacturing
The rod of a composite insulator is made up of two
phases: the matrix and the reinforcing fibers. The
matrix is an epoxy resin and the fiber is usually E-glass,
The fibers are situated lengthwise so as to make a
unidirectional composite. The composite is generally
made by pultrusion in order to achieve the 70-75
%fiber weight fraction.
2nd- Shed manufacturing
The sheds are made by the compression molding of
HTV silicone rubber. The rubber is first mixed with a
certain amount of fillers, including ATH 25-60%wt,
using a Banbury mixer, the curing agent (dcp) is then
added to the compound on the Two roll-mill and is
compounded for about 15 minutes to obtain a
homogenous mix.
A certain amount of the compound is later placed in the
preheated mould and the mould is placed under the hot
press. Mould temperature and the stay time of material
under the press is optimized by the data obtained from
the Rheometer.
3rd- Sheath Manufacturing
One of the most established methods for applying the
sheath on the rod, is extrusion. In the present work,
Compression moulding has been used. In this method
the surface of the rod is treated prior to the application
of sheath. The surface is first roughened and then the
primer is sprayed evenly on the surface. The primer is
used to ensure complete bonding between the silicone
rubber sheath and the composite rod. The sheath has
the exact same formulation as the sheds and thus the
same manufacturing method has been exploited.
4th- End fitting Manufacturing
The end-fittings are made by forging and machining
according to the plan. Since the fittings are joined to
the composite rod, in order to achieve optimum
bonding between the rod and the fittings, an adhesive
has been used along with the application of pressure
(swage).
The inner surface of the fittings has been formed with
fine protrusions to increase the contact surface between
the rod and the adhesive and thus enhance the bond
quality.
It has been observed that under the same pressure, the
tensile strength of the insulator was increased by 15%
due to these protrusions.
5th- Components assembly
First, the sheds are placed on predetermined positions
with calculated distances on the housing, using a proper
adhesive. Then the whole part is cured in the oven
at
200-210C for 2-4 hr. Afterwards the fittings are joined
to both ends with the process mentioned before. To
prevent moisture diffusion into the rod, the gap
between the rod and the fittings is completely sealed
(using silicone as sealant) and after 24 hr the insulator
is ready to be tested.
Table 2- The results of electrical tests of NRI Insulators
Level 17.5 kv Level 24 kv Level 72.5(63)kv
Test Reference: IEC 383(1983)
Standard Test result standard Test result Standard Test result
Dry Lightning Impulse withstand voltage test
(P
+
)
75 114 125 187 325 362
Dry power frequency withstand
voltage Test
38 71.1 50 94 140 >192
Wet power frequency withstand
voltage Test
30 38 40 75 112 155
P=634 mmHg T=13
o
C Moisture (h)= 35% k0.83
ELECTRICAL AND MECHANICAL TESTS
The electrical tests were carried out first on the
manufactured insulators and the mechanical tests
followed.
1st- The Main Electrical tests
These tests were carried out on both the individual
components and on the complete insulator. Only those
tests that were performed on the complete insulator, are
mentioned here.
A-1 Dry Lightning Impulse withstand voltage test
This is a type test (it is performed in order to
determine the major characteristics of the insulator
such as parameters regarding form and size). Testing
method and conditions have been explained by IEC
383.
A-2 Dry power frequency withstand voltage Test
This is a design test (which is carried out to determine
the quality of design, material and production method).
This test is usually performed on three samples, the
mean value of the results is then corrected with a
correction factor.
A-3 Wet power frequency withstand voltage Test
This is again a type test. The insulator is to be placed
in the position shown in IEC 60-1, 75% of withstand
voltage is applied to the insulator, which is increased
by 2% every second so as to reach the testing voltage
and then it remains under these conditions for one
minute.
The appropriate frequency is 45-65 Hz and the
required humidity (artificial rain) is provided by two
horizontal and vertical nozzles. When the results are
obtained a correction factor will be applied.
Table (2) shows the limits set by the standard and
gives the data from experiments carried out on
manufactured insulators on the three mentioned levels.
All the data is given in kv.
2nd- Mechanical test
The mechanical test procedures are based on IEC 1109
standard. Six complete insulators have been prepared .
The first three samples were tested under load, the
fracture occurred after about 1 minute (SML). In the
next step , a load equal to 0.7 of the obtained load from
the previous step was applied to the other three samples
for 96 hr.
No fracture occurred, which means that the line slope
was lower than 8% and the result was successful.
CONCLUSIONS
Due to all the advantages of composite insulators,
proved in various researches, their application in
distribution and transmission lines in Iran, especially in
heavy areas has become a necessity.
Thus, a series of composite Insulators have been
designed, prototyped and manufactured in Niroo
Research Institute of Iran (NRI) , with a much less cost
than their industrial counterparts and have been
successfully tested.
It is our hope that in the future the same manufacturing
process is developed to the industrial scale, which due
to the low cost of labor in Iran and low investment
required, it would be an economic and efficient
method.
ACKNOWLEDGMENT
Our great thanks go to A.R.Shirani, A.R.Moradian,
F.Azimi, M.Oskouie, M.R.Shariati, D.Mohammadi
M.Mohseni, M.Rezaei, S.Dolatshahi for all their
contribution.
REFERENCES
1. Arian S. Jagtiani, Nov.1997, American Electric
Power Companys Experience with Ceramic & Non-
ceramic Insulators, Symp. of Florida
2. R.A. Bernstorf, Nov.1997, Non-ceramic
Insulators State of the Art, Symp. of Florida
3. E.A. Cherney,1996, Non-ceramic Insulators :
ASimple Design That Requires Careful Analysis,
IEEE, 12, 715
4. S.Kuneida, T. Shogo,1996, Metal Fittings for
Composite Insulators, US Patent No. 5539155
5. Kaczerginsks, Alexandre,1987, Method of
manufacturing a Composite Insulator, US Patent No.
4702873
6. IEC 1109, 1992, Composite Insulators for AC
overhead Lines With a Nominal Voltage Greater Than
1000V
7. IEC 71-1,2,3, 1982, Insulation Coordination
8. IEC 815, 1986, Composite String Insulator Units
for Overhead Lines With a Nominal Voltage Greater
Than 1000V; Dimensional and Electrical
Characteristics
9. IEC 815, 1986, Guide for the selection of
insulators in respect of polluted condition
10. IEC 383, 1983, Tests on Insulators of Ceramic
Material or Glass for Overhead Lines With a Nominal
Voltage Greater Than 1000V
Fig 1-Assumed cross sectional view of the insulator
(a)
(b)
Fig 2 The Moulds of (a) the Shed and (b) the Sheath