Insulators 101 Panel Final A

Section A Introduction
Presented by Andy Schwalm IEEE Chairman, Lightning and Insulator Subcommittee
Insulators 101
IEEE/PES 2010 Transmission and Distribution Conference and Exposition New Orleans, Louisiana April 20, 2010
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 collectors 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 Porcelain or toughened glass Metal components fixed with cement ANSI Standards C29.1 through C29.10
Non Ceramic Typically fiberglass rod with rubber (EPDM or Silicone) sheath and weather sheds HDPE line insulator applications Cycloaliphatic (epoxies) station applications, some line applications Metal components normally crimped ANSI Standards C29.11 C29.19
Ceramic Materials very resistant to UV, contaminant degradation, electric field degradation Materials strong in compression, weaker in tension High modulus of elasticity stiff Brittle, require more careful handling Heavier than NCIs
Non Ceramic Hydrophobic materials improve contamination performance Strong in tension, weaker in compression Deflection under load can be an issue Lighter easier to handle Electric field stresses must be considered

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

Presented by Al Bernstorf IEEE Chairman, Insulator Working Group
Insulators
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
VERTICAL LOAD, LBF
2500 2000 1500 1000 500 0 -3000

Compression
0 Longitudinal 500 Longitudinal 1000 Longitudinal 1500 Longitudinal 2000 Longitudinal 0 1000 2000 3000 LINE POST APPLICATION CURVES 9-12-05
-2000
-1000
TRANSVERSE LOAD, LBF

Ten sion
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
IEEE Std 100 - 1992

PICKING A SUITABLE INSULATOR
ELECTRICAL PARAMETERS A. NOMINAL SYSTEM LINE-TO-LINE VOLTAGE 69 kV (rms) 41.8 kV (rms) 59.1 kV (peak)
Define peak l-g kV Determine Leakage Distance Required Switching Over-voltage Requirements Impulse Over-voltage
B. MAXIMUM SYSTEM LINE-TO-GROUND VOLTAGE (line A/1.732)*1.05 C. MAXIMUM PEAK LINE-TO-GROUND VOLTAGE (e) e=(line B * 1.414) LEAKAGE DISTANCE REQUIREMENTS CONTAMINATION LEVEL (typical values) D. ZERO E. LIGHT F. MODERATE G. HEAVY Enter inches/kV -
SUGGESTED LEAKAGE (inches/(kV line-to-ground)) UP TO 1.00 1.00 - 1.25 1.50 - 1.75 2.00 - 2.50 1
H. INSULATOR LEAKAGE (MIN.) (line B)*(inches/kV) =
41.8 inches
SWITCHING OVERVOLTAGE REQUIREMENTS I. SSV = (line B) * 3.0 IMPULSE OVERVOLTAGE REQUIREMENTS 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 = SELECT INSULATOR BASED ON REQUIREMENTS: SYSTEM REQUIREMENT H. LEAKAGE DISTANCE I. SWITCHING SURGE VOLTAGE K. IMPULSE WITHSTAND T. SELECT INSULATOR VALUE FROM PAGE 1 41.8 125 359 NUMBER OF POLYMER VALUES PORCELAIN BELLS 359 kV 125 kV (peak)
Chart Courtesy of Ohio Brass/HPS EU1429-H
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

Whats an appropriate Leakage Distance?
Empirical Determination
- Whats 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 ESDD (mg/cm2) Site Severity Leakage Distance I-string/V-string (/kV l-g) 0.94/0.8 1.18/0.97 1.34/1.05 1.59/1.19
0 0.03 0.03 0.06 0.06 0.1 >0.1
Very Light Light Moderate Heavy


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

Leakage Distance Recommendations
2.5
2 IEEE V
Leak ("/kV l-g)
1.5
IEEE I IEC Poly. (IEC)
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
Flashover Voltage
200
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
Where do I get these values? Leakage Distance or Creepage Distance Manufacturers Catalog Switching Surge Wet W/S ((Wet Switching Surge W/S)/2) 60 Hz Wet Flashover (r.m.s.) Peak Wet 60 Hz value will be lower than Switching Surge 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
PICKING A SUITABLE INSULATOR
Select the 69 kV Insulator shown at right. I-string Mechanical

Worst Case 6,000 lbs Suspension: 12k min ultimate
ELECTRICAL PARAMETERS A. NOMINAL SYSTEM LINE-TO-LINE VOLTAGE B. MAXIMUM SYSTEM LINE-TO-GROUND VOLTAGE (line A/1.732)*1.05 C. MAXIMUM PEAK LINE-TO-GROUND VOLTAGE (e) e=(line B * 1.414) LEAKAGE DISTANCE REQUIREMENTS CONTAMINATION LEVEL (typical values) D. ZERO E. LIGHT F. MODERATE G. HEAVY Enter inches/kV SUGGESTED LEAKAGE (inches/(kV line-to-ground)) UP TO 1.00 1.00 - 1.25 1.50 - 1.75 2.00 - 2.50 1 69 kV (rms) 41.8 kV (rms) 59.1 kV (peak)
H. INSULATOR LEAKAGE (MIN.) (line B)*(inches/kV) =
41.8 inches
SWITCHING OVERVOLTAGE REQUIREMENTS I. SSV = (line B) * 3.0 125 kV (peak)
Leakage Distance 42 Switching Surge 125 kV Impulse Withstand 359 kV
IMPULSE OVERVOLTAGE REQUIREMENTS 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 = SELECT INSULATOR BASED ON REQUIREMENTS: SYSTEM REQUIREMENT H. LEAKAGE DISTANCE I. SWITCHING SURGE VOLTAGE K. IMPULSE WITHSTAND T. SELECT INSULATOR VALUE FROM PAGE 1 41.8 125 359 NUMBER OF POLYMER VALUES PORCELAIN BELLS 359 kV
Insulator Selection
Porcelain 5-3/4 X 10 bells X 4 units
Characteristic Leakage Distance Wet Switching Surge W/S Required 42 Available 46
125 kV
240 kV
Impulse W/S
M&E
359 kV
12,000 lbs
374 kV
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 - Standards

Presented by Tony Baker IEEE Task Force Chairman, Insulator Loading
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 .1 .2 .3
ANSI C29 Insulator Standards (available on-line at nema.org) Insulator Test Methods Wet-process Porcelain & Toughened Glass - Suspensions Wet-process Porcelain Insulators - Spool Type
.4 .5 .6 .7 .8 .9
.10 .11 .12 .13 .17 .18 .19
- Strain Type - Low & Medium Voltage Pin Type - High Voltage Pin Type - High Voltage Line Post Type - Apparatus, Cap & Pin Type - Apparatus, Post Type
- Indoor Apparatus Type - Suspension Type - Distribution Deadend Type - Line Post Type - Distribution Line Post Type IEEE T&D Insulators 101 - Station Post Type (under development)
Composite Insulators Test Methods
ANSI C29 Insulator Standards

Applies to new insulators Definitions Materials Dimensions & Marking (interchangeability) Tests
1.
2. 3.
Prototype & Design, usually performed once for a given design.

(design, materials, manufacturing process, and technology).
Sample, performed on random samples from lot offered for acceptance. 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 50.5 mm/min, resistivity 17827m, 10 sec. ws
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.
Dry Arcing Distance
Electrical Ratings
Product is designed to have a specified average flashover. This is the manufacturers 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? If T/R Yes where = 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
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 Nominal Phase-to-Phase Voltage, kV 700 800 900
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 customers specification S? If R S and T R yes, otherwise no.
Mechanical Ratings
Sample & Routine Mechanical Tests are based on the primary in-service loading conditions
STD. No. C 29.2 C29.6 C29.7 Insulator Type Ceramic Suspension Pin Type Line Post Sample test M&E Cantilever Cantilever Routine test Tension ----4 quad. cantilever
C29.8
Cap & Pin
Cantilever Torsion Tension

Cantilever Tension
Tension
C29.9
Station Post
Tension, Cantilever or Bending Moment
C29.12
C29.13 C29.17 C29.18
Composite Suspension
Deadend Line Post
SML
SML Cantilever Tension Cantilever
Tension
Tension Tension Tension
Dist. Line Post
Mechanical Ratings
M&E Test Ceramic Suspensions
Bending Tests Composite Posts
Kinectrics
Hubbell Power Systems
ANSI C29 High Voltage Insulator Standards

Std. No.
C29.2
Insulator Type
Ceramic Suspension Ceramic Line post Ceramic Apparatus Cap & Pin
Ult. Strength QC Test

Combined M&E strength of 10 units Cantilever strength of 3 units Cantilever, tension, & torsion strength of 3 units each
Lot Acceptance Criteria Ave. Std. dev. = S X10 R +1.2 S s10 1.72 S
X3 R no one xi .85 R X3 R no one xi .85 R
Routine Test
3 sec. tension at 50% of R 4 quad. bending at 40% of R 3 sec. tension at specified value Tension at 50% of R or 4 quad. bending at 40% of R 10 sec. tension at 50% of R 10 sec. tension at 50% of R 10 sec. tension at 50% of R 10 sec. tension at 50% of R
C29.7
C29.8
C29.9
Ceramic Apparatus Post Type
Cantilever & tension strengths of 3 units each
X3 R no one xi .85 R
C29.12
Composite Suspension Composite Distribution Deadend Composite Line Post Composite Distribution Line Post
Specified Mech. Load (SML) test of 3 units SML test of 3 units Cantilever strength of 1 unit Tension test of 1 unit Cantilever strength of 1 unit
xi .R
C29.13
xi .SML rating Strength R
C29.17
C29.18
Strength R
Lot Acceptance Criteria ANSI C29.2

Lot acceptance according to ANSI C 29.2. Select ten random units from lot and subject to M&E test. Requirements are: M&E rating X10 -1.2SH & s10 1.72SH s10 is std. dev. of the 10 units SH is historical std. dev. If s10= SH then 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 ceramic suspension units in a lot minimally acceptable according to ANSI C29.2
Coefficient of variation, vR 5% 10% 15%
Strength value at -3 90% of M&E rating 79% of M&E rating 67% of M&E rating
Possible low strengths for ceramic suspension units in a lot minimally acceptable according to CSA C411.1 Requirements Rating XS 3s
Lot Acceptance Criteria CSA C411.1
& 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 Possible low strengths for ceramic units in a lot minimally acceptable according to ANSI C29.7, C29.8 & C29.9
Cantilever rating X3 & no xi< 85% of rating
Coefficient of variation, vR 5% 10% 15%
Strength value at -3 85% of Cantilever rating 70% of Cantilever rating 55% 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
% 50% 40% 50% 40% 50% 40% 50% 50% 50% 50% Strength Rating
Insulator Type
Ref. ANSI Std. C29.2-1992 C29.7-1996
Ceramic
Suspension Line Post
Combined mechanical & electrical strength (M&E)

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

----------
Composite
Suspension Line Post Station Post
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.
IEEE T&D Insulators 101 IEEE T&D Insulators 101
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
Section D Achieving Quality
Presented by Tom Grisham
IEEE Task Force Chairman, Insulators 101
IEEE/PES T&D Conference and Exposition New Orleans, LA April 20, 2010
Objectives of Quality Presentation

Present ideas to verify the supplier qualification, purchasing requirements, manufacturer inspections of lots, shipment approval, material handling, and training information for personnel Routine inspection of the installation
Identify steps to analyze field complaints

To stimulate Quality improvement
Quality Defined
QUALITY An inherent, basic or distinguishing characteristic; an essential property or nature. QUALITY CONTROL A system of ensuring the proper maintenance of written standards; especially by the random inspection of manufactured goods.
What Is Needed in a Quality Plan?

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 All aspects defined by the company plan
What Documents Should Be Included?

Catalog specifications and changes Supplier audit records and lot certification 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 (where, by whom, why?) Interchangeability with other suppliers product
Handling methods (consult manufacturer) Installation requirements and techniques

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 NCIs
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 Cotter keys for ball sockets should be inspected identically to the instructions for ceramic insulators The maximum combined loads should not exceed the RTL Normal operating temperature is 40 to 150 Degrees F 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 Bending, twisting and cantilever loading should be avoided during construction and maintenance
Line outage Failures

Your objective is to find the problem, quickly!
Inspection Techniques
Subjective: What you already know
Outage related Visual methods from the ground Previous problem Thermal camera (NCI live line)
Objective: Answer is not obvious

Leakage current measurements Daycor camera for live line inspections (live) Mechanical and electrical evaluations
Porcelain and Glass Failures

Failures are typically visible or have a new history or upgrade on the site? New products may not be your Grandfathers Oldsmobile, however! Have the insulators deteriorated?
Perform thermal-mechanical test before failing load and compare to ultimate failing load Determine current ultimate strength versus new
Should the insulators be replaced?

Establish internal criteria by location
Non-Ceramic (NCI) Failures

Cause of failures may NOT be visible!
More subjective methods used for live line replacement Some external deterioration may NOT be harmful Visual examples of critical issues are available to you
Imperative to involve the supplier!

Evaluate your expertise to define root cause condition Verify an effective corrective action is in place Utilize other sources in the utility industry
Establish subjective baselines for new installations as future reference! Porcelain and glass, also!
What To Do for an Insulator Failure?

Inspection of Failure
What happened? Extraordinary factors? Save every piece of the unit! Take lots of pictures!
Supplier Involvement
Verification of production date? Available production records? Determination of root cause? Recommended action?
Inspect other insulators!
Safety requirements?
Summary of Quality Presentation

In todays environment, this presentation suggests that the use of a well documented quality program improves long term performance and reduces outages. Application information that is communicated in the organization will help to minimize installation issues and reduce costs. Actively and accurately defining the condition, or determining the root cause of a failure, will assist in determining end-of-life decisions.
Source of Presentation
http://ewh.ieee.org/soc/pes/iwg/

Insulators 101 Panel Final A

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Insulators 101 Panel Final A

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Section A Introduction

Presented by Andy Schwalm IEEE Chairman, Lightning and Insulator Subcommittee

IEEE T&D Insulators 101

What Does an Insulator Do? Maintains an Air Gap

Resists Mechanical Stresses

Resists Electrical Stresses

Resists Environmental Stresses

Where Did Insulators Come From?

NCI insulator industry really begins in US with field

Domestic manufacturing of insulators decreases, shift to offshore (all types)

For simplicity will discuss in terms of three broad applications:

Substations (all voltages)

Types of Insulators Distribution

Types of Insulators Transmission

Cap and Pin insulators legacy type

Types of Insulators Substation

Insulator Types - Comparisons

Insulator Types - Comparisons

Insulator Types - Comparisons

101 Section B - Design Criteria

IEEE T&D Insulators 101

Design Criteria - Mechanical

Electrical Characteristics are an afterthought.

Design Criteria - Mechanical

- Never Exceed 50% of the M&E Rating

NCIs (Polymer Insulators)

- Never Load beyond the R.T.L.

IEEE T&D Insulators 101

Design Criteria - Mechanical

- Never Exceed 40% of the Cantilever Rating Proof Test Load

NCIs (Polymer Insulators)

IEEE T&D Insulators 101

Design Criteria - Mechanical

IEEE T&D Insulators 101

Design Criteria - Mechanical

2500 2000 1500 1000 500 0 -3000

TRANSVERSE LOAD, LBF

Design Criteria - Electrical

Leakage Requirements do play a role!!!

IEEE T&D Insulators 101

Design Criteria - Electrical

IEEE Std 100 - 1992

IEEE T&D Insulators 101

Design Criteria - Electrical

H. INSULATOR LEAKAGE (MIN.) (line B)*(inches/kV) =

Chart Courtesy of Ohio Brass/HPS EU1429-H

IEEE T&D Insulators 101

Design Criteria Leakage Distance

1 IEEE Std 100 - 1992

IEEE T&D Insulators 101

Design Criteria - Electrical

ESDD (Equivalent Salt Deposit Density) Determination

- Evaluate ESDD and select appropriate Leakage Distance

IEEE T&D Insulators 101

Design Criteria - Electrical

0 0.03 0.03 0.06 0.06 0.1 >0.1

Very Light Light Moderate Heavy

Design Criteria - Electrical

IEEE T&D Insulators 101

Design Criteria - Electrical

Leak ("/kV l-g)

IEEE I IEC Poly. (IEC)

Poly. (IEEE V) Poly. (IEEE I)