Insulators 101 July 2009

“Insulators 101”
Section A – Introduction
Presented by Andy Schwalm

IEEE Chairman, Lightning and Insulator Subcommittee
Presented to the IEEE Working Group for

Towers, Poles and Conductors
IEEE/PES General Meeting in Calgary, Canada

July 28, 2009
IEEE T&D – Insulators 101

What Is an Insulator?
 An insulator is a “dam***” poor conductor!
And more, technically speaking!
 An insulator is a mechanical support!

 Primary function - support the “line” mechanically
 Secondary function– electrical
Air is the insulator
Outer shells/surfaces are designed to increase
leakage distance and strike distance

What Does an Insulator Do?
Maintains an Air Gap

 Separates Line from Ground
length of air gap depends primarily on system voltage,
modified by desired safety margin, contamination, etc.
 Resists Mechanical Stresses
“everyday” loads, extreme loads
 Resists Electrical Stresses
system voltage/fields, overvoltages
 Resists Environmental Stresses
heat, cold, UV, contamination, etc.

Where Did Insulators Come From?
Basically grew out of the needs of the telegraph

industry – starting in the late 1700s, early 1800s
Early history centers around what today we would

consider very low DC voltages
Gradually technical needs increased as AC

voltages grew with the development of the electric
power industry

History
Glass plates used to insulate telegraph line DC to

Baltimore
Glass insulators became the ”norm” soon

thereafter – typical collector’s items today
Many, many trials with different materials – wood –

cement – porcelain - beeswax soaked rag wrapped
around the wire, etc.
Ultimately porcelain and glass prevailed

History
 Wet process porcelain developed for high voltage

applications
 Porcelain insulator industry started
 Application voltages increased

 Insulator designs became larger, more complex
Ceramics (porcelain, glass) still only choices at
high voltages

History
 US trials of first “NCIs” – cycloaliphatic based

 Not successful, but others soon became interested
and a new industry started up
 Europeans develop “modern” style NCI – fiberglass

rod with various polymeric sheds
 Now considered “First generation”

History
 NCI insulator industry really begins in US with field

trials of insulators
 Since that 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.

History
 Domestic manufacturing of insulators decreases,

shift to offshore (all types)
 Engineers need to develop knowledge and skills

necessary to evaluate and compare suppliers and
products from many different countries
An understanding of the basics of insulator

manufacturing, design and application is more
essential than ever before

Insulator Types
 For simplicity will discuss in terms of three broad

applications:
 Distribution lines (thru 69 kV)
 Transmission lines (69 kV and up)
 Substations (all voltages)

Insulator Types
 Distribution lines
 Pin type insulators -mainly porcelain, growing use

of polymeric (HDPE – high density polyethylene),
limited use of glass (in US at least)
 Line post insulators – porcelain, polymeric
 Dead end insulators – polymeric, porcelain, glass
 Spool insulators – porcelain, polymeric
 Strain insulators, polymeric, porcelain

Types of Insulators – Distribution

Insulator Types
 Transmission lines
 Suspension insulators - new installations mainly

NCIs, porcelain and glass now used less frequently
 Line post insulators – mainly NCIs for new lines

and installations, porcelain much less frequent now

Types of Insulators – Transmission

Insulator Types
 Substations
 Post insulators – porcelain primarily, NCIs growing

in use at lower voltages (~161 kV and below)
 Suspension insulators –NCIs (primarily), ceramic
 Cap and Pin insulators – “legacy” type

Types of Insulators – Substation

Insulator Types - Comparisons
Ceramic Non Ceramic

• Porcelain or toughened • Typically fiberglass rod with
glass rubber (EPDM or Silicone)
• Metal components fixed with sheath and weather sheds
cement • HDPE line insulator
• ANSI Standards C29.1 applications
through C29.10 • Cycloaliphatic (epoxies)
station applications, some
line applications
• Metal components normally
crimped
• ANSI Standards C29.11 –
C29.19


• Materials very resistant to • Hydrophobic materials
UV, contaminant degradation, improve contamination
electric field degradation performance
• Strong in tension, weaker in
• Materials strong in compression
compression, weaker in
• Deflection under load can be
tension an issue
• High modulus of elasticity - • Lighter – easier to handle
stiff • Electric field stresses must
• Brittle, require more careful be considered
handling
• Heavier than NCIs


• Generally designs are • “Material properties have
“mature” been improved – UV
resistance much improved
• Limited flexibility of for example
dimensions • Standardized product lines
• Process limitations on sizes now exist
and shapes • Balancing act - leakage
• Applications/handling distance/field stress – take
methods generally well advantage of hydrophobicity
understood • Application parameters still
being developed
• Line design implications
(lighter weight, improved
shock resistance)

“Insulators
101”
Section B - Design Criteria
Presented by Al Bernstorf
IEEE Chairman, Insulator Working Group


July 28, 2009

Design Criteria - Mechanical
An insulator is a mechanical support!
• Its primary function is to support the line

mechanically
• Electrical Characteristics are an afterthought.
• Will the insulator support your line?
• Determine The Maximum Load the Insulator Will

Ever See Including NESC Overload Factors.

Suspension Insulators
• Porcelain
- M&E (Mechanical & Electrical) Rating
Represents a mechanical test of the unit while energized.
When the porcelain begins to crack, it electrically punctures.
Average ultimate strength will exceed the M&E Rating when new.
- Never Exceed 50% of the M&E Rating
• NCIs (Polymer Insulators)

- S.M.L. – Specified Mechanical Load
Guaranteed minimum ultimate strength when new.
R.T.L. – Routine Test Load – Proof test applied to each NCI.
- Never Load beyond the R.T.L.

Line Post insulators
• Porcelain
- Cantilever Rating
Represents the Average Ultimate Strength in Cantilever – when new.
Minimum Ultimate Cantilever of a single unit may be as low as 85%.
- Never Exceed 40% of the Cantilever Rating – Proof Test Load
• NCIs (Polymer Insulators)

- S.C.L. (Specified Cantilever Load)
Not based upon lot testing
Based upon manufacturer testing
- R.C.L. (Rated Cantilever Load) or MDC or MDCL (Maximum Design
Cantilever Load) or MCWL or WCL (Working Cantilever Load)
- Never Exceed RCL or MDC or MDCL or MCWL or WCL
- S.T.L. (Specified Tensile Load)
- Tensile Proof Test=(STL/2)
Other Considerations
• Suspensions and Deadends – Only apply tension loads
• Line Posts –
- Cantilever is only one load
- Transverse (tension or compression) on line post – loading
transverse to the direction of the line.
- Longitudinal – in the direction of travel of the line
- Combined Loading Curve –
Contour curves representing various Longitudinal loads
Available Vertical load as a function of Transverse loading
Manufacturers have different safety factors!!!

69 kV Post - 2.5" Rod
2500
VERTICAL LOAD, LBF
2000 0 Longitudinal
500 Longitudinal
1500
1000 Longitudinal
1000
1500 Longitudinal
500 2000 Longitudinal
0
-3000 -2000 -1000 0 1000 2000 3000 LINE POST APPLICATION
Compression
TRANSVERSE LOAD, LBF CURVES
Ten sion
9-12-05

Design Criteria - Electrical
An Insulator is a mechanical support!

Air imparts Electrical Characteristics
Strike Distance (Dry Arcing Distance) is the
principal constituent to electrical values.
• Dry 60 Hz F/O and Impulse F/O – based on strike distance.
• Wet 60 Hz F/O
- Some would argue leakage distance as a principal factor.
- At the extremes that argument fails – although it does play a role.
- Leakage distance helps to maintain the surface resistance of the
strike distance.
Leakage Requirements do play a role!!!

Dry Arcing Distance –

(Strike Distance) – “The
shortest distance through
the surrounding medium
between terminal
electrodes….” 1
1– IEEE Std 100 - 1992

PICKING A SUITABLE INSULATOR
ELECTRICAL PARAMETERS
A. NOMINAL SYSTEM LINE-TO-LINE VOLTAGE 69 kV (rms)
B. MAXIMUM SYSTEM LINE-TO-GROUND VOLTAGE 41.8 kV (rms)
Define peak l-g kV

(line A/1.732)*1.05
C. MAXIMUM PEAK LINE-TO-GROUND VOLTAGE (e) 59.1 kV (rms)
e=(line B * 1.414)
LEAKAGE DISTANCE REQUIREMENTS
CONTAMINATION LEVEL SUGGESTED LEAKAGE
Determine Leakage Distance

(typical values) (inches/(kV line-to-ground))
D. ZERO UP TO 1.00
E. LIGHT 1.00 - 1.25
F. MODERATE 1.50 - 1.75
Required G. HEAVY
Enter inches/kV -
2.00 - 2.50
1
H. INSULATOR LEAKAGE (MIN.)

(line B)*(inches/kV) = 41.8 inches
Switching Over-voltage SWITCHING OVERVOLTAGE REQUIREMENTS
Requirements I. SSV = (line B) * 3.0
IMPULSE OVERVOLTAGE REQUIREMENTS

125 kV (rms)
J. PEAK IMPULSE WITHSTAND = (I(t) * R(f))+e

I(t) = 20 kA (typical value = 50 kA)
R(f) = 15 ohm (typical value = 10 - 20 ohm)
Impulse Over-voltage e=
K. IMPULSE WITHSTAND =
59.1 (line C)
359 kV
SELECT INSULATOR BASED ON REQUIREMENTS:
SYSTEM VALUE FROM PAGE NUMBER OF

REQUIREMENT 1 POLYMER VALUES PORCELAIN BELLS
H. LEAKAGE
DISTANCE (INCHES) 41.8
I. SWITCHING
SURGE VOLTAGE 125
K. IMPULSE
WITHSTAND 359
T. SELECT
Chart Courtesy of Ohio Brass/HPS – EU1429-H INSULATOR

Design Criteria – Leakage Distance
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.” 1
 1 – IEEE Std 100 - 1992

What’s an appropriate Leakage Distance?
• Empirical Determination
- What’s been used successfully?
- If Flashovers occur – add more leak?
• ESDD (Equivalent Salt Deposit Density) Determination

- Measure ESDD
Pollution Monitors
Dummy Insulators
Remove in-service insulators
- Evaluate ESDD and select appropriate Leakage Distance

“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)
0 – 0.03 Very Light 0.94/0.8
0.03 – 0.06 Light 1.18/0.97
0.06 – 0.1 Moderate 1.34/1.05
>0.1 Heavy 1.59/1.19

IEC 60815 Standards
Leakage Distance
ESDD (mg/cm2) Site Severity
(“/kV l-g)
<0.01 Very Light 0.87
0.01 – 0.04 Light 1.09
0.04 – 0.15 Medium 1.37
0.15 – 0.40 Heavy 1.70
>0.40 Very Heavy 2.11

Leakage Distance Recommendations
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)

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)
Polymer insulators offer better contamination

flashover performance than porcelain?
Smaller core and weathershed diameter increase

leakage current density.
Higher leakage current density means more

Ohmic Heating.
Ohmic Heating helps to dry the contaminant layer

and reduce leakage currents.
In addition, hydrophobicity helps to minimize

filming
“the contamination performance of composite

insulators exceeds that of their porcelain counterparts”
“the contamination flashover performance of silicone

insulators exceeds that of EPDM units”
“the V50 of polymer insulators increases in proportion

to the leakage distance”
CEA 280 T 621, “Leakage Distance Requirements for Composite Insulators Designed for Transmission Lines”

Insulator Selection
PICKING A SUITABLE INSULATOR
Select the 69 kV Insulator

ELECTRICAL PARAMETERS
A. NOMINAL SYSTEM LINE-TO-LINE VOLTAGE 69 kV (rms)
shown at right. B. MAXIMUM SYSTEM LINE-TO-GROUND VOLTAGE

(line A/1.732)*1.05
C. MAXIMUM PEAK LINE-TO-GROUND VOLTAGE (e)
41.8 kV (rms)
59.1 kV (rms)
e=(line B * 1.414)
LEAKAGE DISTANCE REQUIREMENTS
I-string – Mechanical
CONTAMINATION LEVEL SUGGESTED LEAKAGE
(typical values) (inches/(kV line-to-ground))
D. ZERO UP TO 1.00
E. LIGHT 1.00 - 1.25
• Worst Case – 6,000 lbs F. MODERATE

G. HEAVY
Enter inches/kV -
1.50 - 1.75
2.00 - 2.50
1
• Suspension: ≥ 12k min H. INSULATOR LEAKAGE (MIN.)

(line B)*(inches/kV) = 41.8 inches
ultimate SWITCHING OVERVOLTAGE REQUIREMENTS
I. SSV = (line B) * 3.0 125 kV (rms)
IMPULSE OVERVOLTAGE REQUIREMENTS
Leakage Distance ≥ 42” J. PEAK IMPULSE WITHSTAND = (I(t) * R(f))+e

I(t) = 20 kA (typical value = 50 kA)
R(f) = 15 ohm (typical value = 10 - 20 ohm)
e= 59.1 (line C)
K. IMPULSE WITHSTAND = 359 kV
Switching Surge ≥ 125 kV SELECT INSULATOR BASED ON REQUIREMENTS:
SYSTEM VALUE FROM PAGE NUMBER OF

REQUIREMENT 1 POLYMER VALUES PORCELAIN BELLS
H. LEAKAGE
DISTANCE (INCHES) 41.8
I. SWITCHING
Impulse Withstand ≥359

SURGE VOLTAGE 125
K. IMPULSE
WITHSTAND 359
T. SELECT
kV INSULATOR

Insulator Selection
Where do I get these values?
Leakage Distance or Creepage Distance

• Manufacturer’s Catalog
Switching Surge
• Wet W/S
• ((Wet Switching Surge W/S)/√2) ≤ 60 Hz Wet Flashover
• Peak Wet 60 Hz value will be lower than SS wet W/S
Impulse Withstand
• Take Positive or Negative Polarity, whichever is lower
• If only Critical Impulse Flashover is available – assume 90%
(safe estimate for withstand)

Insulator Selection
Porcelain – 5-3/4 X 10” bells X 4 units
Characteristic Required Available
Leakage
42” 46”
Distance
Wet Switching
125 kV 240 kV
Surge W/S
Impulse W/S 359 kV 374 kV
M&E 12,000 lbs 15,000 lbs

Grading Rings
Simulate a larger, more spherical object
Reduce the gradients associated with the shielded object
Reduction in gradients helps to minimize RIV & TVI

Porcelain or Glass –
• Inorganic – breaks down very slowly
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
NCIs and Rings
Grading (Corona) Rings
• Due to “corona cutting” and water droplet corona – NCIs may

require the application of rings to grade the field on the
polymer material of the weathershed housing.
• Rings must be:

- Properly positioned relative to the end fitting on which they are
mounted.
- Oriented to provide grading to the polymer material.
• Consult the manufacturer for appropriate instructions.
• As a general rule – rings should be over the polymer –

brackets should be on the hardware.

Questions?

“Insulators 101”
Section C – Achieving ‘Quality’
Presented by Tom Grisham

IEEE Task Force Chairman, “Insulators 101”


July 28, 2009

Objectives of Section C Presentation
Establish a documentation record for the

qualification, purchase, manufacture, receipt and
installation of electrical insulators
Review material handling basics for installation
Identify critical steps when analyzing field

complaints

What Is Quality Control?
Identifying critical design parameters
Qualifying ‘new’ suppliers
Evaluating current suppliers
Establishing internal specifications
Monitoring standards compliance (audits)
Understanding installation requirements
Establishing end-of-life criteria
Ensuring safety of line workers
Communicating and training

What Documents Should Be Included?
Product catalog specifications
Supplier audit records
Qualification testing of the design
• Utility-specific testing
• Additional supplier testing for insulators (vibration,
temperature, long-term performance, etc)
• ANSI or equivalent design reports
Storage methods
• Installation records
• Interchangeability with other suppliers product
Handling methods

‘Proven’ Installation Procedures

Handling of Ceramics – NEMA HV2-1984
Insulators should not be dropped or thrown…..
Insulators strings should not be bent…..
Insulator strings are not ladders…..
Insulators with chips or cracks should be discarded and
companion units should be carefully inspected…..
Cotter keys should be individually inspected for twisting,
flattening or indentations. If found, replace keys and
retest the insulator…..
The maximum combined load, including safety
requirements of NESC, must not exceed the rating…..
Normal operating temperature range for ceramics is
defined as –40 to 150 Degrees F…..
Handling of NCI’s
NEMA is working on a ‘new’ application guide for NCI
products. It will likely include……………………
• “Insulators should not be dropped, thrown, or bent…”
• “Insulators should not be used as ladders…”
• “Insulators should not be used as rope supports…”
• “Units with damaged housings that expose the core rod should be
replaced and discarded…”
• “Units with cut or torn weathersheds should be inspected by the
manufacturer…”
• “Cotter keys for ball sockets should be inspected identically to the
instructions for ceramic insulators…”
• “The maximum combined loads should not exceed the RTL…”
• “Bending, twisting and cantilever loading should be avoided during
construction and maintenance…”
• Normal operating temperature is –40 to 150 Degrees F…”
What To Do for an Insulator Failure?
Inspection of Failure Supplier Involvement
• What happened? • Verification of production date?
• Extraordinary factors? • Available production records?
• Save every piece of the unit! • Determination of ‘root’ cause?
• Take lots of pictures! • Recommended action?
• Inspect other insulators! • Safety requirements?

Insulators 101
Section D - Standards
Presented by Tony Baker
IEEE Task Force Chairman, Insulator Loading
Towers, Poles, and Conductors
July 28, 2009

American National Standards
Consensus standards
Standards writing bodies must include representatives from
materially affected and interested parties.
Public review
Anybody may comment.
Comments must be evaluated, responded to, and if found to be
appropriate, included in the standard .
Right to appeal
By anyone believing due process lacking.
Objective is to ensure that ANS Standards are developed in an
environment that is equitable, accessible, and responsive to the
requirements of various stakeholders*.
* The American National Standards Process, ANSI March 24, 2005

American Standards Committee
on Insulators for Electric Power Lines
ASC C-29
EL&P Group
IEEE
NEMA
Independents
C29 ANSI C29 Insulator Standards (available on-line at nema.org)
.1 Insulator Test Methods
.2 Wet-process Porcelain & Toughened Glass - Suspensions
.3 Wet-process Porcelain Insulators - Spool Type
.4 “ - Strain Type
.5 “ - Low & Medium Voltage Pin Type
.6 “ - High Voltage Pin Type
.7 “ - High Voltage Line Post Type
.8 “ - Apparatus, Cap & Pin Type
.9 “ - Apparatus, Post Type
.10 “ - Indoor Apparatus Type
.11 Composite Insulators – Test Methods
.12 “ - Suspension Type
.13 “ - Distribution Deadend Type
.17 “ - Line Post Type
.18 “ - Distribution Line Post Type
.19 “ - Station Post Type (under development)
ANSI C29 Insulator Standards
Applies to new insulators

Definitions
Materials
Dimensions & Marking (interchangeability)
Tests
1. Prototype & Design, usually performed once for a given design.
(design, materials, manufacturing process, and technology).
2. Sample, performed on random samples from lot offered for
acceptance.
3. Routine, performed on each insulator to eliminate defects from lot.

ANSI C 29 Insulator Standard Ratings
Electrical & Mechanical Ratings
How are they assigned?
How is conformance demonstrated?
What are application limits?

Electrical Ratings
Average flashover values
Low-frequency Dry & Wet
Critical impulse, positive & negative
 Impulse withstand
Radio-influence voltage
Applies to all the types of high voltage insulators
Rated values are single-phase line-to-ground voltages.
Dry FOV values are function of dry arc distance and test configuration.
Wet FOV values function of dry arc distance and insulator shape,
leakage distance, material and test configuration.
 Tests are conducted in accordance with IEEE STD 4-1995 except
test values are corrected to standard conditions in ANSI C29.1.
-Temperature 25° C
- Barometric Pressure 29.92 ins. of Hg
- Vapor Pressure 0.6085 ins. of Hg
- For wet tests: rate 5±0.5 mm/min, resistivity 178±27Ωm, 10 sec. ws
Dry Arcing Distance
Shortest distance through the surrounding medium between terminal
electrodes , or the sum of distances between intermediate electrodes ,
whichever is shortest, with the insulator mounted for dry flashover test.

Electrical Ratings
 Manufacturer designs product to have a specified average flashover.
• This is the rated value, R.
 Samples are electrically tested in accordance with standard

• This is the tested value, T.
 Due to uncontrollable elements during the test such as atmospheric

fluctuations, minor differences in test configuration, water spray
fluctuations, etc. the test value can be less than the rated value.
 Does T satisfy the requirements for the rating R?

• Is T/R≥ 𝝃 ?
where 𝝃 = 0.95 for Low-frequency Dry flashover tests
= 0.90 for Low-frequency Wet flashover tests
= 0.92 for Impulse flashover tests

Electrical Ratings
Dry 60 Hz Flashover Data
1400
1200
Suspension Insulator
1000
Flashover (kV)
800
Station Post and Line Post
600
400
200
0
0 20 40 60 80 100 120 140 160
Dry Arcing Distance (inches)

Electrical Ratings
ANSI C2 Insulation Level Requirements
ANSI C2-2007, Table 273-1
1400
1200
1000
800
Rated Dry
FOV, kV
600
400
200
0
0 100 200 300 400 500 600 700 800 900
Nominal Phase-to-Phase Voltage, kV
Higher insulation levels required in areas where severe

lightning, high atmospheric contamination, or other
unfavorable conditions exist

Electrical Ratings - Application
Customer determines needs and specifies electrical

requirements:
- 60 Hz Dry & wet flashover
- Impulse flashover and/or withstand
- Leakage distance
Does offered product meet customer’s specification S?

If R ≥ S and T ≥ 𝝃R
yes, otherwise no.

Mechanical Ratings
Sample & Routine Test are based on the
primary in-service loading conditions
STD. No. Insulator Type Sample test Routine test
C 29.2 Ceramic Suspension M&E Tension
C29.6 “ Pin Type Cantilever
C29.7 “ Line Post Cantilever 4 quad. cantilever
C29.8 “ Cap & Pin Cantilever Tension
Torsion
Tension
C29.9 “ Station Post Cantilever Tension, Cantilever or
Tension Bending Moment
C29.12 Composite Suspension SML Tension
C29.13 “ Deadend SML Tension
C29.17 “ Line Post Cantilever Tension
Tension
C29.18 “ Dist. Line Post Cantilever Tension
Mechanical Ratings
M&E Test Bending Tests

Ceramic Suspensions Composite Posts
Hubbell Power Systems

Kinectrics

ANSI C29 High Voltage Insulator Standards
Std. Insulator Ult. Strength Lot Acceptance Routine
No. Type QC Test Criteria Test
Ave. Std. dev. = S
C29.2 Ceramic Combined M&E strength X10 ≥ R +1.2 S 3 sec. tension
Suspension of 10 units s10 ≤ 1.72 S at 50% of R
C29.7 Ceramic Cantilever strength X3≥ R 4 quad. bending

Line post of 3 units no one xi ≮ .85 R at 40% of R
C29.8 Ceramic Apparatus Cantilever, tension, & torsion strength X3≥ R 3 sec. tension
Cap & Pin of 3 units each no one xi ≮ .85 R at specified value
Tension
at 50% of R
C29.9 Ceramic Apparatus Cantilever & tension strengths X3 ≥ R or
Post Type of 3 units each no one xi ≮ .85 R 4 quad. bending
at 40% of R
C29.12 Composite Specified Mech. Load (SML) xi ≥ .R 10 sec. tension

Suspension test of 3 units at 50% of R
C29.13 Composite SML test 10 sec. tension

Distribution Deadend of 3 units xi ≥ .SML rating at 50% of R
C29.17 Composite Cantilever strength of 1 unit Strength ≥ R 10 sec. tension

Line Post Tension test of 1 unit at 50% of R
C29.18 Composite Cantilever strength of 1 unit Strength ≥ R 10 sec. tension

Distribution Line Post IEEE T&D – Insulators 101 at 50% of R
Lot Acceptance Criteria – ANSI C29.2
For a lot offered for acceptance according to ANSI C 29.2.
Ten units are selected at random and subjected
to M&E tests.
Requirements are:
M&E rating ≤ X10 -1.2SH
&
s10 ≤1.72SH
 For minimally acceptable lot, ~ 11.5% of units in lot could

have strengths below the rated value.

Lot Acceptance Criteria – ANSI C29.2
Possible low strengths for units in a lot

minimally acceptable according to ANSI C29.2
Coefficient Strength value
of variation, vR at -3σ
5% 90% of M&E rating

Lot Acceptance Criteria – CSA C411.1
minimally acceptable according to CSA C411.1
Requirements
Rating≤ XS – 3s
&
Xi ≥ R
 On a -3 sigma basis , minimum strength that
could be expected in a lot is the rated value
regardless of the coefficient of variation for the
manufacturing process that produced the lot.

Lot Acceptance Criteria – ANSI C29
minimally acceptable according to
ANSI C29.7, 8 & 9.
Cantilever rating ≤ X3 & no xi< 85% of rating
Coefficient Strength value

of variation, vR at -3 σ
5% 85% of Cantilever rating

Lot Acceptance Criteria
ANSI C29 –Composite Insulators
Random samples selected from an offered lot.
Ultimate strength tests on samples.
Requirement is:
xi ≥ Rating
The rated value is assigned by the manufacturer based
on ultimate strength tests during design.
 However for a lot minimally acceptable according to the
standard, statistical inference for the strength distribution
for entire lot not possible.
Composite Insulators have a well defined damage limit
providing good application direction.

Mechanical Ratings – Application Limits
NESC ANSI C Table 277-1
Allowed percentages of strength ratings
Insulator Type % Strength Rating Ref. ANSI Std.
Ceramic Combined
Suspension 50% mechanical & electrical strength (M&E) C29.2-1992
Line Post 40% Cantilever strength C29.7-1996

50% Tension/compression strength
40% Cantilever strength
Station Post4 50% Tension/compression/torsion strength C29.9-1983
Station 40% Cantilever strength
Cap & Pin 50% Tension/compression/torsion strength C29.8-1985
Nonceramic C29.12-1997
Suspension 50% Specified mechanical load (SML) C29.13-2000
Specified cantilever load (SCL) or C29.17-2002
Line Post 50% specified tension load (STL) C29.18-2003
Station Post 50% All strength ratings ----------

Worst loading case load ≤ (% Table 277-1)(Insulator Rating)
In most cases , % from Table 277-1 is equal to the routine

proof -test load.
 Bending tests on a production basis are not practicable in

some cases, (large stacking posts, cap & pins , and polymer
posts) and tension proof-load tests are specified.

Composite Post Insulators – Combined Loading

Composite Post Insulators – Combined Loading

Recent Developments for Application Limits
Component strength cumulative distribution function FR and

probability density function of maximum loads fQ.

Component Damage Limit
DAMAGE LIMIT
Strength of a component below ultimate corresponding to a
defined limit of permanent damage or deformation.
For composites the damage limit is fairly well understood.

Component Damage Limit
Defining Damage Limit for ceramics more difficult to
define as shown by comparing stress-strain curves for
brittle and ductile materials.
L&I WG on Insulators is addressing this problem now


Insulators 101 July 2009

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Insulators 101 July 2009

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“Insulators 101”

Presented by Andy Schwalm

Presented to the IEEE Working Group for

IEEE/PES General Meeting in Calgary, Canada

IEEE T&D – Insulators 101

 An insulator is a “dam***” poor conductor!

And more, technically speaking!

 An insulator is a mechanical support!

IEEE T&D – Insulators 101

Maintains an Air Gap

IEEE T&D – Insulators 101

Basically grew out of the needs of the telegraph

Early history centers around what today we would

Gradually technical needs increased as AC

IEEE T&D – Insulators 101

Glass plates used to insulate telegraph line DC to

Glass insulators became the ”norm” soon

Many, many trials with different materials – wood –

Ultimately porcelain and glass prevailed

IEEE T&D – Insulators 101

 Wet process porcelain developed for high voltage

 Application voltages increased

IEEE T&D – Insulators 101

 US trials of first “NCIs” – cycloaliphatic based

 Europeans develop “modern” style NCI – fiberglass

IEEE T&D – Insulators 101

 NCI insulator industry really begins in US with field

IEEE T&D – Insulators 101

 Domestic manufacturing of insulators decreases,

 Engineers need to develop knowledge and skills

An understanding of the basics of insulator

IEEE T&D – Insulators 101

 For simplicity will discuss in terms of three broad

 Distribution lines (thru 69 kV)

 Transmission lines (69 kV and up)

 Substations (all voltages)

IEEE T&D – Insulators 101

 Pin type insulators -mainly porcelain, growing use

IEEE T&D – Insulators 101

IEEE T&D – Insulators 101

 Suspension insulators - new installations mainly

 Line post insulators – mainly NCIs for new lines

IEEE T&D – Insulators 101

IEEE T&D – Insulators 101

 Post insulators – porcelain primarily, NCIs growing

 Suspension insulators –NCIs (primarily), ceramic

 Cap and Pin insulators – “legacy” type

IEEE T&D – Insulators 101

IEEE T&D – Insulators 101

Ceramic Non Ceramic

IEEE T&D – Insulators 101

Ceramic Non Ceramic

IEEE T&D – Insulators 101

Ceramic Non Ceramic

IEEE T&D – Insulators 101

Presented to the IEEE Working Group for

IEEE/PES General Meeting in Calgary, Canada

IEEE T&D – Insulators 101

An insulator is a mechanical support!

• Its primary function is to support the line

• Electrical Characteristics are an afterthought.

• Will the insulator support your line?

• Determine The Maximum Load the Insulator Will

IEEE T&D – Insulators 101