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ASOCIACIÓN / COLEGIO
NACIONAL DE INGENIEROS
DEL ICAI (https://www.icai.es/)
(/articulo-revista)
Sobre el autor
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Participation:
• President of Insulator IEC Spanish Committee (TC36),
• Member of Spanish IEC TC 42 “High Voltage Techniques”,
• Member of Spanish IEC TC 210 “CISPR”,
• Convenor of IEC MT23
• Member of IEC MT15 & MT20
• CIGRE member
• IEEE member.
Publications:
• Javier GARCIA / Philippe Platteau. Glass insulators in polluted
environment: design, test, experiences and benchmarking with
other materials. CIGRE regional meeting outdoor insulation.
Tunisia, 2010.
• Javier GARCIA. Las perturbaciones radioeléctricas en los
aisladores. Jornadas Técnicas del Comité Nacional de CIGRE.
Madrid, 2016.
• I. Serrano / D. Blanco / Javier Garcia / H. de Santos. Aisladores
de vidrio con recubrimiento de silicona. Estudio de evaluación de
comportamiento. XVII ERIAC. Decimoséptimo encuentro
regional iberoamericano de CIGRÉ. Paraguay, 2017.
• Raouf ZNAIDI / Faisal HUDA / Javier GARCIA. Optimization of
RTV Silicone Application. Techniques in Harsh Service
Conditions. INMR Congress. Sitges 2017
• Javier GARCIA. Insulators requirements: design criteria,
operation parameters and standards review. INMR Congress.
Sitges 2017
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MECHANICAL CONSIDERATIONS
An insulator is a mechanical support. After the mechanical aspects of a design have been nalized,
electrical characteristics are added. If the insulator doesn’t keep your line in the air, all electrical
characteristics in the world mean nothing. Mechanical characteristics are so important to the
functioning of an insulator that they’re the one commonality in the marking of all insulator.
Another question to take in account is the consequences of a mechanical failure: Loss of leakage
distance only or cable fall. This depend of the design of the insulator. IEC 60797 stablish the
mechanical residual test methods and acceptance criteria for glass or porcelain string insulators
with the dielectric part breakage.
The use must determine the maximum loading that the line will ever apply to its insulator,
including conductor weight, hardware weight, ice and wing
Weloading, and -other
are offline Send overload factors.
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Suspension insulators are rated in terms of their Speci ed Mechanical Load (SML). Most
manufacturers recommend that you never load the insulator to more than 50% of the Speci ed
Mechanical Load (SML). The SML rating is a guaranteed minimum ultimate strength rating. Each
batch of insulators produced is sampled for mechanical strength and all samples must meet or
exceed the stated SML value and the statistical criteria. The routine test load is the proof load
applied to each unit and also the maximum load that the insulator should ever see in service.
IEC 60383-1 & IEC 61109 stablish the mechanical test methods and acceptance criteria for
Ceramic or glass insulators units and Composite insulators respectively.
ELECTRICAL CONSIDERATIONS
The electrical characteristics of the insulator are imparted by the air around it. This is principally
de ned by the arcing distance of the insulator de ned as “shortest distance in the air external to
the insulator between the metallic parts which normally have the operating voltage between
them”.
The impulse withstand/ ashover characteristics and dry power frequency characteristics are all
based upon the dry arcing distance.
Some would argue that the wet power frequency withstand/ ashover characteristics are
determined by leakage distance, but that argument only holds within a narrow band of leakage
distances. Leakage distance plays a role, but only as a contributing factor.
IEC 60071-1 recommend the withstand voltages associated with the highest voltage for the
equipment
The applicability of each approach depends on available data, time and economics involved in the
project.
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Some of the parameters required for these approaches are mentioned on the following sub-
chapter:
If the site pollution severities (SPS) are available, it is recommended to take a RUSCD (reference
uni ed speci c creepage distance) which corresponds to the position of the site pollution severity
(SPS) measurements within the class by following the curve in Figure 1.
(https://www.icai.es/wp-content/uploads/2018/02/Figure-1.png)
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c: Medium
d: Heavy
e: Very heavy
For Type A pollution (inland, desert or industrially polluted areas), SPS is calculated from
ESDD/NSDD values.
For Type B pollution (coastal areas where salt water or conductive fog is deposited onto the
insulator surface), SPS is calculated from SES (site equivalent salinity)
IEC TS 60815-2 – Table 1 below shows a brief summary of the principal advantages and
disadvantages of the main pro le types with respect to pollution performance.
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(https://www.icai.es/wp-content/uploads/2018/02/Table-1.png)
(https://www.icai.es/wp-
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3.png)
Standard pro le
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(https://www.icai.es/wp-
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4.png)
Aerodynamic or open
pro les
(https://www.icai.es/wp-content/uploads/2018/02/Figure-5.png)
(https://www.icai.es/wp-content/uploads/2018/02/Figure-6.png)
Below tables show a brief summary of the principal advantages and disadvantages of the main
pro le types with respect to pollution performance.
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Creepage factor.
IEC 60507 prescribe procedures for arti cial pollution tests applicable to ceramic and glass
insulators for overhead lines.
Two categories of pollution test methods are recommended for standards tests:
Salt fog method in which the insulators is subjected to a de ned ambient pollution:
Solid layer method in which a fairly uniform layer of a de ned solid pollution is deposited on
the insulators surface.
This standardized laboratory pollution test methods are not applicable for composite (polymeric)
or RTV-coated insulators. A proposal for a test method for arti cially polluted composite
insulators is covered by the recent CIGRE TB 555: “Arti cial Pollution Test for Polymer Insulators”.
In the case of naturally polluted insulators removed from the service a recent CIGRE TB 691 (WG
D1.44), “Pollution Test of Naturally and Arti cially contaminated insulators” summarizes the
recent experience with so-called rapid ashover test methods:
Rapid ashover Test (RFO, based on IEC 60507 solid layer test).
Quick ashover (QF, based on IEC 60507 salt fog test).
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Both tests can be applied for both ceramic (glass and porcelain) and composite insulators for both
AC and DC.
The objective of these tests is a need for reliable diagnostic of naturally polluted insulators to
evaluate their residual dielectric strength and also a general trend to make testing more cost-
effective and time-ef cient, even for the case of arti cially polluted insulators.
The evaluation of insulator performance in naturally polluted outdoor test stations is becoming
more important and popular. Although involving a longer test duration, and still requiring care in
the correct interpretation of the test data, the results tend to be accepted with more con dence.
Outdoor test stations is also a good tool for new insulation technologies in which there is as yet no
technical or normative speci cation for its testing or characterization.
CIGRE Technical Brochure No. 333, 2007 “Guide for the establishment of naturally polluted
insulator testing stations” serve as a general guide for the establishment of natural test stations
which will facilitate the overall comparison of various insulators designs, the explorations of
particular aspects of insulator performance and/or the selections of the most appropriate
insulation for a particular application. It is relates speci cally to insulators intended for use under
AC conditions but aspects are applicable to DC stations as well.
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The severity of the pollution and the prevailing climate must be examined and should be
representative of conditions found on the system. As is the case for laboratory tests, an over-
acceleration of the ambient stresses can produce misleading results. Contamination severity
assessment by means of ESSD and NSDD measurements and/or directional dust deposit gauges
should be undertaken to ensure that an appropriate site is selected.
Insulator test stations have a wide range of size and sophistication and may be categorized as:
Research station;
Simpli ed, on-line station;
In service Test Structure;
Mobile insulator Test Station.
(https://www.icai.es/wp-
content/uploads/2018/02/Photo-1.png)
Photo 1: Permanent
insulator research
station at Martigues
(France) and examples
of Verescence La
Granja Insulators tests
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(https://www.icai.es/wp-content/uploads/2018/02/Photo-1b.png)
(https://www.icai.es/wp-content/uploads/2018/02/Photo-2.png)
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(https://www.icai.es/wp-content/uploads/2018/02/Photo-4.png)
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Leakage current activity (include number of ashovers experienced), climatic effects and pollution
severity are usually monitored. In addition, the performance of the test samples should be judged
by a regular inspection of the insulators: Close visual examination of the surface; an assessment of
the hydrophobicity of the dielectric material and the viewing of electrical activity.
When the insulators surface is covered by deposit wet pollution, leakage currents start. Its
amplitude is a function of the degree of pollution (the amount of soluble salts).
Polluted and wet insulators energized with AC voltage display a biased leakage current having a
DC component that causes electrolytic corrosion of the pins.
Leakage currents effects are even more harmful when the frequency and duration of wet periods
are high (humid tropical climate) and also when pollution nds a hygroscopic surface (Hence the
importance of inert contaminants that absorb or retain humidity).
This corrosion is most important on DC voltage than AC voltage for same site, due to current
unidirectional and electrostatic phenomena that cause the most important pollution deposition
formation.
For insulators, dominant electrolytic corrosion effects add to those of atmospheric corrosion and
those due to the formation of oxidising agents caused by the presence of arcs near ttings. These
last ones can be initiated and maintained during periods of humidi cation and drying that
precedes and succeeds in critical conditions or when the insulator is more humid. Protection eld
dispatcher accessories can be bene cial to limit these phenomena of humidi cation and drying
periods which are a factor of acceleration of the insulator ttings corrosion for those pieces that
are more electrically forced.
The most severe corrosion cases occur especially in the tropical areas very near to the sea or
marine pollution and areas where the pollution by dust accumulation happen for long periods
without rain, plus the high environment humidity.
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To affect the mechanical resistance of the insulator: This applies particularly to the pin of
the insulator when the section of the corroded part becomes reduced (example: reduction
of the diameter of the pin).
To affect the electrical resistance due to the formation of a deposit of rust on the insulating
surface. This deposit may also cause damage in the insulating part due to a concentration of
electric eld around this new electrode.
To cause the breakage of the dielectric due to the expansion of the pin corroded. This
phenomenon is speci c for porcelain cap and pin insulators.
(https://www.icai.es/wp-content/uploads/2018/02/Photo-5.png)
They consist of reinforced galvanized ttings and of a sacri cial zinc sleeve protection.
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increase until 140µm for insulators to be install on very high corrosion area. This permit
increase the estimated end of life.
(https://www.icai.es/wp-content/uploads/2018/02/Figure-9.png)
The zinc sleeve is galvanically positive and has a large potential difference from iron. It
works like as a sacri cial electrode at the cement boundary where the current ows. The
zinc sleeve is free from accumulation of corrosive products.
(https://www.icai.es/wp-
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10.jpg)
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(https://www.icai.es/wp-content/uploads/2018/02/Figure-
10b.png)
IEC-61365 speci es the minimum requirements for the zinc sleeve; anyway, it can be improved to
increase it behaviour.
(https://www.icai.es/wp-content/uploads/2018/02/Imagen1.png)
(https://www.icai.es/wp-content/uploads/2018/02/Figure-11b.png)
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(https://www.icai.es/wp-content/uploads/2018/02/Figure-11.png)
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Also IEC-61365 speci es test method for the zinc sleeve control. Future work of normalization
would have to be to include the zinc sleeve requirements and the tests methods on the IEC-
60383-1 (for a.c. lines)
OPERATION PARAMETERS
The main objective of the overhead line maintenance policy in an electric company is to maintain
the number of fault outages at reasonable values. A Data Base with the principal information of
the insulation is an ef ciency tool for the evaluation of performance. The information that this
database should contain is:
Number of faults
Insulator breakage rate
Washing frequency
Aerial inspection
Patrol inspection
HD recording
Infrared inspection
The evolution of maintenance indicators together with the results of inspections linked with the
data base of the line help both the decision making regarding the maintenance or replacement of
the insulation and the valuation / comparison of the different types of materials, pro les and
manufacturers quality.
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An insulator comes to the end of its working life either when it fails mechanically, ashover at
unacceptably high frequency or gives evidence of deterioration to a condition likely to lower its
factor of safety in service. All insulators are affected to some extend by impact, cycling but thermal
and mechanical, deterioration from weathering and electrothermal causes, exure and torsion,
ionic motion, corrosion and dement growth.
Determinate the exactly time to replace if it necessary is important to optimise the cost of
maintenance. There are a fairly large number of degradation modes. Some modes are easily
detectable by visual inspection other, especially for porcelain insulators, need sophisticated
methods. Degradation modes causes by easily detectable mechanism like slip of metal tting, pin
corrosion or surface erosion are considered to be reason for replacement of insulators.
CIGRE has established a test procedure to determinate the state of cap and pin and long-rod
insulators and to decide on the safe time for their replacement: “Guide for the assessment of old
cap and pin and long-rod transmission line insulators made of porcelain or glass: What to check
and when to replace”. CIGRE Technical Brochure No. 306, 2006.
This document stablishes a testing sequence with a number of non-destructive tests as visual tests
(e.g. degree of corrosion) as well as dimension and thermal and the combined thermal-mechanical
tests. This rst series of tests is followed by destructive mechanical tests. A probability diagram
based on normal distribution is used to analyse the failing load test results. With the probability
(risk) for failure on the ordinate and the failing load on the abscissa, the failing load characteristics
are represented as straight lines. In that way changes in strength become easily visible.
To help the user, the document includes a number of typical cases of analysis of test result called
“Reference Scenarios”. They are useful for the assessment of the present condition of the insulator
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Fig. 5: Example: Reference scenario F1 The SFL (speci ed failing load) is marked with a
solid vertical line.
For the example of ”Reference scenario F1” the reductions in strength shown in this example
diagram are not representative of good quality products. Age and TMP-test have only negligible
in uence on good products.
It is based on a recommended sequence of testing on samples taken out different stress zones of
the line.
(https://www.icai.es/wp-content/uploads/2018/02/Figure-13.png)
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CONCLUSION
The selection of the insulator type is not a simple job, especially if the insulator will be install in a
high polluted area.
Numerous documentations (IEC Standards, CIGRE Technical Brochure…) are available to help on
the selection of the most appropriate insulator, for monitoring the behavior in operation and for
the determination of the nite insulator life.
Different solutions are available to improve the insulator performance on high corrosion areas.
BIBLIOGRAPHY
[2] IEC 60071-1: Insulation co-ordination – Part 1: De nitions, principles and rules
[3] IEC 60575: Arti cial pollution tests on high-voltage ceramic glass insulators to be used on a.c.
systems.
[4] IEC 60797: Residual strength of string insulator units of glass or ceramic material for overhead
lines after mechanical damage of the dielectric.
[5] IEC-60383-1: Insulators for overhead lines with a nominal voltage above 1 000V: Ceramic or
glass insulators units for a.c. systems – De nitions, test methods and acceptance criteria
[6] IEC/TS 60815-1: Selection and dimensioning of high-voltage insulators intended for use in
polluted condition – Part 1: De nitions, information and general principles
[7] IEC/TS 60815-2: Selection and dimensioning of high-voltage insulators indented for use in
polluted condition – Part 2: Ceramic and glass insulators for a.c. systems
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[8] IEC/TS 60815-3: Selection and dimensioning of high-voltage insulators indented for use in
polluted condition – Part 3: Polymer insulators for a.c. systems
[9] IEC 61109: Insulators for overhead lines – Composite suspensions and tension insulators for
a.c. systems with a nominal voltage greater than 1 000 V – De nitions, test methods and
acceptance criteria
[10] IEC-61365: Insulators for overhead lines with a nominal voltage above 1 000V: Ceramic or
glass insulators units for d.c. systems – De nitions, test methods and acceptance criteria
[11] I. Gutman, Wallace Vosloo, “Development of Time-and Cost-Effective Pollution Test Methods
Applicable for Difference Station Insulation Option”. IEEE Vol. 21, No. 6. TDEI submitted 2014.
[12] M. Marzinotto, J-M. George, S. Prat, C. Lumb, F. Virlogeux, I. Gutman, and J. Lundengard,
“Field Experience and Laboratory Investigation of glass Insulators Having a Factory-Applied
Silicone Coating”, TDEI submitted 2014.
[13] I. Gutman, J. Shamsujjoha, C. Lumb, J-M. George, and S. Roude: “Investigation of Rapid
ashover solid layer pollution testing as an alternative to current standard method”, IEEE ISEI-
2012, paper 17 pp.73-77
[14] CIGRE Task Force 33.04.07, “Natural and arti cial ageing and pollution testing of polymeric
insulators” CIGRE Technical Brochure No. 142, 1999
[15] CIGRE WG B2.03, “Guide for the assessment of old cap and pin and long-rod transmission line
insulators made of porcelain or glass: What to check and when to replace”. CIGRE Technical
Brochure No. 306, 2006
[16] CIGRE WG B2.03, “Guide for the establishment of naturally polluted insulator testing
stations” CIGRE Technical Brochure No. 333, 2007
[17] CIGRE WG B2.21, “Guide for the assessment of composite Insulators in the laboratory after
their removal from service”. CIGRE Technical Brochure No. 481, 2011
[18] CIGRE WG D1.44, “Pollution Test of Naturally and Arti cially contaminated insulators”
CIGRE Technical Brochure No. 691, 2017
[19] Javier GARCIA /Philippe Platteau. Glass insulators in polluted environment: design, test,
experiences and benchmarking with other materials. Cigre regional meeting outdoor insulation.
Tunisia, 2010
[20] R. García Fernández, M.A. Perez Louzao, I. Serrano “REE’s insulator global maintenance
policy”, CIGRE 2014; B2-206.
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