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Composite insulators have a reputation for high reliability in polluted environments, but some conflict with environmental regulations. The 275kv transmission lines incorporate compact designs using modem composite suspension and line post' insulators of both EPDM and Silicon Rubber. The leakage current monitor was developed by The QEC to gain a better knowledge of the deterioration of the insulators over time. A double circuit 275kV tower situated between two cooling towers at the Swanbank Power Station was chosen for testing
Composite insulators have a reputation for high reliability in polluted environments, but some conflict with environmental regulations. The 275kv transmission lines incorporate compact designs using modem composite suspension and line post' insulators of both EPDM and Silicon Rubber. The leakage current monitor was developed by The QEC to gain a better knowledge of the deterioration of the insulators over time. A double circuit 275kV tower situated between two cooling towers at the Swanbank Power Station was chosen for testing
Composite insulators have a reputation for high reliability in polluted environments, but some conflict with environmental regulations. The 275kv transmission lines incorporate compact designs using modem composite suspension and line post' insulators of both EPDM and Silicon Rubber. The leakage current monitor was developed by The QEC to gain a better knowledge of the deterioration of the insulators over time. A double circuit 275kV tower situated between two cooling towers at the Swanbank Power Station was chosen for testing
July 34.19Y4, BnIbsIle Aumaha ILZXKAGE CURRENT MONlTORING OF COMposlTE LONG ROD lNSULAToRs Brian Pokaner Colin Lee Don Hawker Queensland Electricity Commission Line Design Branch Austrelia A bst mci The Queensland Electricity Commission (QEC) has had over 15 years of field experience with various types of composite insulators on 1 lOkV to 275kV lines. Most of the insulators were first generetion composites installed in a variety of contaminated environments. In the heaq contaminated arcas. various forms of damage to the sheath and sheds were observed and a number of insulators flashed over. These failures have also been experienced in other pans of the world. To gain a better knowledge of the deterioration of the composite insulators over time and to evaluate the pollution performance of the various types of polymers, the QEC developed a sensitive high voltage leakage current monitor and set up a test program for testing these insulators. In the test. a double circuit 275kV tower situated between two cooling towers at the Swanbank Power Station was chosen for trialing of the composite insulators . The main polymer types, Ethlene Propylene Diene Monomer (EPDM), Ethylene Silicon Polymer (ESP) and Silicon Rubber were tested over a I5 month period. This paper discusses the development of the leakage current monitor and results from the monitoring program. Intmduetion The Queensland Electricity Commission has recently designed high voltage 275 kV transmission lines for use in urban and sensitive environmental areas of Queensland. These lines incorporate compact designs using modem composite suspension and line post' insulators of both Ethylene Diene Monomer (EPDM) and Silicon Rubber (SIR). Improvements in material, design and manufacturing methods for composite insulators have gained them a reputation for high reliability in medium polluted environments, but some conflicting opinions remain as to the better polymer type for long term performance. The QEC installed the first composite insulators in 1978 and has been closely monitoring their performance since then. Following several failures of the early generation Composite insulators in salt and high polluted areas in Australia and overseas in the 1980's. the QEC initiated a project to develop a leakage current monitor. It's primary purpose was to evaluate the short and long term pollution performance of a number of composite and ceramic insulator types at a test site in a highly polluted ma. The test site chosen was a double circuit 275 kV tower situated between cooling towers at the Swanbank Power Station. This tower had previously experienced two pollution induced flashovers, one of them involving two circuits. The tower also enabled analysis of pollulion performance at a higher than usual voltage stress as most published data has been camcd out at lower transmission voltages of around 132 kV. The two main types of polymer materials normally used at transmission voltages. EPDM and SIR. have been included in the evaluation. as well as an EPDM type blended with silicon oils. Leakage current measurements began at the test site in October 1992 with six samples of insulators being monitored. Four more samples were added in February 1994. Test Si t e The tower chosen as the test site was on a double circuit section of the 275kV transmission system supplying Queensland's largest tourist centre. Energised in 1974 and insulated with high creepage length fog discs the tower experienced pollution induced flashovers in 1981 and 1988, the latter involving both circuits and causing catastrophic insulator failure and widespread blackouts. The tower is surrounded by four forced draft cooling towers associated with the Swanbank B Power Station and is continually engulfed in vapours containing high concentrations of minerals and salts. Regular bum offs of coal slag piles also add to the pollution. The site was considered preferable over coastal 132kV alternatives because of it's proximity to the QEC research centre. It also enabled the investigation to concentrate on industrial type pollution at 275kV. The majority of published research data addresses the effects of sea salt pollution on 132kV insulators. Industrial pollution has higher levels of sulphates which are more conductive than chloride based salts, and therefore produces higher leakage currents. The larger field stresses at 275kV are also expected to contribute to greater polymer degradation. Table I: Test Insulator Characteristics No. Shed Shed Coupl Dry-arc Material Diam Length Length (") (") (") I 2 3 4 5 6 7 8 9 IO SiR-I EPDM-1 EPDM-2 SiR-2 SiR-3 Ceramic EPDM-3 SiR-4 SIR-5 Ceramic 140 2490 140 2490 102 2535 134 2540 134 2515 254 2628 I l l 2434 I l l 2434 125 2655 225 2560 2247 2247 2128 2200 2092 2230 2230 2200 2196 Test Configuration The test insulators are installed in bridging positions on the tension tower at each of the three crossam levels. A high quality ceramic disc insulator is installed on top of the composite insulators t o shunt the leakage current to the Data Centre via primary protection circuitry. An earthing switch is also provided to shunt the ceramic disc and enable maintenance work to be carried out on the Data Centre. The Data Centre houses current transducers, an Analog to Digital converter, signal conditioning equipment and a Multiplexer. The Multiplexer sends signals via a fibre-optic cable to a Command Centre mounted on the ground. This Centre has a microcomputer which processes and stores the data onto memory cards. The fibre-optic cable was selected to shield electrical noise and for electrical isolation. Solar cells are installed at both locations to charge the power supplies in each of the centres. In addition to the leakage current monitor. a weather station has been installed adjacent to the Command Centre for recording the following environmental data: temperature humidity solar radiation ultra violet radiation . barometric pressure . rainfall Test Insirlotors Table I gives the characteristics of the composite and ceramic insulators being tested. Insulator types 1 to 6 were installed in August 1992, and types 7 to IO in February 1994. Insulator number 6 is a string of 18 porcelain discs and insulator number I O is a two piece porcelain long rod. This paper presents the results from the first 6 samples. The results from the latter 4 samples will be presented in a future paper. Leakage No of Dist Length Sheds Between Sheds (mm) (mm) 61 12 6112 5403 5255 4801 7776 6100 6100 6480 7800 49 49 56 36 28 I8 32 32 47 48 45 45 40 60 71 146 66 66 50 45 Identical insulators were installed, but not energised. alongside the test insulators for the purpose of allowing periodic analysis of the pollution. As recommended by the manufacturers each of the composite insulators were installed with grading rings to improve the electric stress distribution at the live end. Leakage Currents The amount of leakage current flowing along the surface of an insulator is dependent on many factors, the major ones being: . type of weathershed material . amount of pollution deposited . the hydrophobicity of the material the applied voltage . the environmental conditions The hydrophobic performance of the insulator will vary between the different polymer family types (EPDM or SiR) and between different types in each family group. Published research data for both indoor and outdoor tests indicates that silicon rubber exhibits the better hydrophobic properties in all pollution conditions. The major environmental conditions affecting leakage currents are humidity and rain. On a new clean insulator which has a high surface resistivity, the leakage current is usually low and primarily capacitive. When pollution builds up on the surface and the insulator becomes wetted by high humidity or rain, the resistivity reduces, and the leakage currents r i se and become resistive. The effects of the pollution on leakage current will depend on the amount of soluble and insoluble deposits on the surface layer. When soluble deposits become wet during rain, the solution will lower the surface resistivity and cause leakage currents to rise. Insoluble deposits do not per se cause leakage currents to increase, but will assist in holding soluble deposits on the surface. 531 Future QEC research will analyse the small cycle magnitude and phase angle variations for each insulator type at varying degrees of pollution and age. It is expected that each insulator will exhibit it's own signature for various degrees of pollution and polymer degradation. Test Results Leakage Current s: Leakage currents are continuously monitored and recorded as an integrated average over a 20 minute period. The 20 minute rainfall measurements were not made because the weather station only records rainfall on a daily basis. Rainy days were noted fromBureau of Meteorological data and fromthe weather station. It was found that rainfall has the largest effect on leakage currents followed by humidity. A comparative performance over a 24 hour period for a SiR, an EPDM and ceramic disc insulator is shown in Figure 1. The SIR insulators have lower leakage current than the EPDM, and both composite insulator types have currents less than a third that of the porcelain string. Figure 2 shows the long termtrend of leakage currents over a 15 month period. It compares the porcelain disc with an EPDM and SiR insulator. The SiR insulators exhibit negligible variations in leakage current over time, whereas the EPDM and ceramic materials show an upward trend, with the latter showing the largest increase over time. The first two months of recording coincided with a dry period and leakage currents on the ceramic insulator have increased with accumulation of pollution. After heavy rain in December and J anuary 1992, the discs have been washed and leakage currents have reduced to their initial value. 1111 , 1 ll I L II I - 111 Figure 2 They began increasing again to double the initial value until a year later when the downward trend resumed during the wet season months of December and J anuary. The washing after a year only causes a marginal reduction of leakage current as the pollution hardens on the sheds and remains partially insoluble. Also, virtually no washing occurs on the undersides of the sheds which constitutes approximately two thirds of the creepage length. The pollution performance of the SiR composite insulators has been good with no signs of degradation of the polymer. Even with a variation in leakage lengths on the three SiR insulators from 4801 to 6112 mm, there were only small differences between the leakage currents. The leakage current on the EPDM composite insulators are up to two times higher than the SIR insulators. The currents did however, drop to a comparable level after a prolonged period of heavy rain. The pollution performance of these insulators is still acceptable in these conditions. The EPDM-2 insulator has shown some evidence of changes occurring to the polymer housing. White discolouration is appearing on a number of sheds (towards the live end) with the apparent leeching out of filler or silicon additive. This effect is not evident on the unenergised insulator hanging at the same location. The string of porcelain discs has performed poorly when compared with the composite insulators. Figure 1. Table 11: Analysis of Pollution Polymer Chemical Compound (pglcm) Equiv. Ty Pe Salt Sodium Potassium Magnesium Calcium Chloride Sulphate Density EPDM-T 2.32 .I 5 0.49 0.81 2.93 2.7 14.13 EPDM-U 4.81 .34 1.45 2.49 8.55 11.1 33.71 SiR-T 2.90 2.5 0.80 1.70 3.83 6.15 20.58 SiR-U 5.28 .29 1.28 4.48 6.96 19.8 31.99 Note: EPDM-T denotes the top surface of the weathershed and EPDM-U, the undersides of the sheds. It has the highest leakage length of the tested samples, 7776. but produces leakage currents 3 times higher than SIR insulators during normal weather conditions and up to 7 times higher during rainfall. The long term trends show an increase in leakage current with time. This is indicative of pollution buildup on the discs as the leakage currents do not retum to their initial values after heavy rain. Pol l ut i on A nal ysi s: Two unenergised insulators (one EPDM and the other Sin) were recovered in February 1994 after a period of heavy rain. There were considerable amounts of wind-bome dust (of aluminium and silica) which had to be removed before an analysis of the soluble pollutants could be made. This analysis is given in Table 11. The results show the EPDM and SiR insulators attracting similar types of pollutants with the main ones being, Sulphates and Chlorides of Sodium, Potassium, Calcium and Magnesium. The wind-bome dust was more difficult to remove fromthe SIR insulator. The silicon material attracts and holds the non soluble dust (by encapsulating with its oils), making it difficult to remove. The equivalent salt deposit density was measured in the range 14.13 pg/cm to 33.71 pg/cm, which is generally regarded as light pollution. This contrasts with what is known for porcelain discs on this tower which require washing every 18 months. Clearly, the composite insulators have a lower pollution retention than the porcelain discs, and consequently, lower leakage currents. The equivalent salt deposit density measurements show much higher levels of pollution on the undersides of the sheds. This is because the insulators are hung in suspension and the top surfaces are washed by rain. There is a similar level of pollution on the undersides of both insulator types, but on the top surfaces, the silicon material has higher values. Despite this, the silicon material has produced lower leakage currents, thus supporting the manufacturers claim that the silicon oil continually migrates to the surface to maintain the materials hydrophobicity. Envi ronment al Effects: There has been no visible evidence of polymer degradation from solar or U.V. radiation in this period of analysis. There have been only small variations of temperature and barometric pressure which has not significantly affected the leakage currents. Concl usi ons At this stage, the test results show the SiR family of insulators are performing better than the EPDM and ceramic insulators. The initial values of leakage current for the SiR insulators were approximately half of those for the EPDM and a quarter of those for ceramic insulators and there is less variation in leakage currents over time. The low variations show that the SiR insulators have consistently maintained hydrophobicity. The EPDM insulators have provided mixed results. EPDM-I has performed reasonably well in the conditions, but there is some concern over the performance of the EPDM-2 insulator under heavy pollution and storm conditions. The insulator is showing some evidence of degradation on the polymer housing with white discolouration on a number of sheds towards the line end. This appears to be due to the leeching out of the tri-alumina hydrate or the silicon oil. The analysis of pollution from the sheds of unenergised insulators indicates that the composite insulators are retaining lower levels of surface pollution than the ceramic discs. The ceramic disc has consequently not performed as well as the composite insulators. Leakage currents were at much higher levels and have increased with time. The difficulty with removing the dust from the SIR material suggests the material is attracting and holding the pollution to the surface. This effect has not affected the material maintaining its hydrophobicity in the short term. A cknowl edgment The authors wish to thank the QEC for permission to publish this paper. The assistance of the QEC Northgate Test Section for developing the leakage current monitor is also acknowledged. 533