Insulation Strength Characteristics

Procedure for Insulation Coordination in Four Steps
Flow chart acc. to IEC 60071-1 (Figure 1)
[IEC 60071-1]
Fachgebiet Hochspannungstechnik
Overvoltage Protection and Insulation Coordination / Chapter 6
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Procedure for Insulation Coordination in Four Steps

Determination of the coordination withstand voltages Ucw The coordination withstand voltages are the lowest values of withstand voltages of each overvoltage class, for which the expected low failure rate of the equipment is not exceeded over its full lifetime. Derived from the representative overvoltages Urp by the coordination factor Kc.
Typical for Germany: 0.1% per year 1 failure in 1000 years
[IEC 60071-1]
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Insulation Strength Characteristics

Factors influencing the dielectric strength of the insulation: Factors influencing the dielectric strength of the insulation:
magnitude, shape, duration and polarity of the applied voltage magnitude, shape, duration and polarity of the applied voltage electric field distribution in the insulation electric field distribution in the insulation homogeneous or non-homogeneous electric field homogeneous or non-homogeneous electric field electrodes adjacent to the considered gap and their potential electrodes adjacent to the considered gap and their potential type of insulation type of insulation gaseous gaseous liquid liquid solid solid combination of two or all of them combination of two or all of them impurity content and the presence of local inhomogeneities impurity content and the presence of local inhomogeneities physical state of the insulation physical state of the insulation temperature temperature pressure pressure other ambient conditions other ambient conditions mechanical stress mechanical stress history of the insulation (aging, damage) history of the insulation (aging, damage) chemical effects chemical effects conductor surface effects conductor surface effects
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Standard atmospheric conditions acc. to IEC 60060-1
Temperature: Pressure: Absolute humidity:
20 C 1013 hPa 3 11 g/m3
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Topics to be covered in the following: Insulators under polluted conditions Probability of flashover (Normal and Weibull distributions) Behavior of parallel insulation Coordination procedure: deterministic and statistical approach Correction with altitude of installation Clearances in air; "gap factors"
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Performance of Insulators under Pollution

Pre-conditions Pre-conditions
Surface layers dust dust carbon black carbon black salt (coastal areas) salt (coastal areas) chemicals (industry, rural areas: fertilizers) chemicals (industry, rural areas: fertilizers) no problem in dry condition after long rain periods: only moderate effect on flashover performance most critical: Humidification after a long dry period Humidification after a long dry period typical time of the day for insulator flashovers: morning hours (dew!)
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Development of pollution flashover Development of pollution flashover
dry zone by inhomogeneity of the layer enlargement of the dry zone by heating of the zone edges (increased current density)
dry band
flashover of the dry band
enlargement of the dry band by arc heating (max. temperature at foot points)
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Development of pollution flashover Development of pollution flashover
a) with dry bands b) dry bands bridged by partial arcs
voltage drop increased voltage bridged
Voltage distribution for further details see HVT 2!

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Influence of layer conductivity Influence of layer conductivity
for details see IEC 60507
Layer conductivity K is the most important parameter! Layer conductivity K is the most important parameter! K = ds
... specific layer conductivity

ds ... thickness of layer
K = 5 S K = 10 S K = 40 S
"light to medium pollution" "medium to heavy pollution" "very heavy pollution"
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Determination of layer conductivity from Determination of layer conductivity from measured conductance and insulator geometry measured conductance and insulator geometry
shed core creepage distance lk
Measurement of conductance G of the full insulator

insulator length l
general:
G=
V
l
2 r d s K dG = = dl d l / 2 r
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Determination of layer conductivity from Determination of layer conductivity from measured conductance and insulator geometry measured conductance and insulator geometry
G=
K
lk
dl 2 r 0
G ... conductance of total insulator surface
dl F = 2 r 0
K = FG K = FG
lk
form factor" form factor"
(IEC 60507*)) form factor to be determined by graphical procedure, described in IEC 60507
*) IEC 60507, 2nd Ed. 1991-04: "Artificial pollution tests on high-voltage insulators to be used on a.c. systems"
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Decrease in flashover voltage by conductive layers Decrease in flashover voltage by conductive layers
fo, rain 0.7 ... 0.9 fo, dry Ufo, polluted 0.2 ... 0.3 Ufo,dry
An overhead line insulator must be desigend about five times as long as An overhead line insulator must be desigend about five times as long as required to withstand operating stresses under dry conditions! required to withstand operating stresses under dry conditions!
Um = 123 kV L-E = 100 kV d = 5 kV/cm l = 20 cm would be sufficient (dry!)
Actual length: ca. 1100 mm

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Countermeasures Countermeasures
p
Sheds Sheds Terms ... s ... flashover or arcing distance lk ... creepage distance li ... insulator length p ... shed overhang t ... shed spacing
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p
Reference value is Um, ,i.e. Reference value is Um i.e. the phase to-phase-voltage! the phase to-phase-voltage! li derived from required standard lightning impulse voltage strength (ud, LI ca. 5.5 kV/cm) lk from requirement on specific creepage distance (IEC 60815*))
Note: IEC 60815 applicable to porcelain insulators; so far no standard on polymeric insulators available
= 20%
31 mm/kV 31 mm/kV 25 mm/kV 25 mm/kV 20 mm/kV 20 mm/kV 16 mm/kV 16 mm/kV
for very heavy" pollution severity (IV) for very heavy" pollution severity (IV) for heavy" pollution severity (III) for heavy" pollution severity (III) for "medium" pollution severity (II) for "medium" pollution severity (II) for "light" pollution severity (I) for "light" pollution severity (I)
*) IEC 60815, 1st Ed. 1986: "Guide for the selection of insulators in respect of polluted conditions"
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31 mm/kV 31 mm/kV 25 mm/kV 25 mm/kV 20 mm/kV 20 mm/kV 16 mm/kV 16 mm/kV for very heavy" pollution severity (IV) for very heavy" pollution severity (IV) for heavy" pollution severity (III) for heavy" pollution severity (III) for "medium" pollution severity (II) for "medium" pollution severity (II) for "light" pollution severity (I) for "light" pollution severity (I)
Correction of these values necessary depending on insulator's average diameter Dm *) Correction factor kD (derived from service experience):
Dm (mm) < 300 300 - 500 > 500
kD 1 1.1 1.2
Pollution performance gets worse with increasing diameter!
*) for definition of Dm see IEC 60815

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IEC 60815, Table 1 IEC 60815, Table 1
Pollution level Examples of typical environments - Areas without industries and with low density of houses equipped with heating plants - Areas with low density of industries or houses but subjected to frequent winds and/or rainfall - Agricultural areas 1) - Mountainous areas All these areas shall be situated at least 10 km to 20 km from the sea and shall not be exposed to winds directly from the sea 2) - Areas with industries not producing particularly polluting smoke and/or with average density of houses equipped with heating plants - Areas with high density of houses and/or industries but subjected to frequent winds and/or rainfall - Areas exposed to wind from the sea but not too close to the coast (at least several kilometres distant) 2) - Areas with high density of industries and suburbs of large cities with high density of heating plants producing pollution - Areas close to the sea or in any case exposed to relatively strong winds from the sea 2) - Areas generally of moderate extent, subjected to conductive dusts and to industrial smoke producing particularly thick conductive deposits - Areas generally of moderate extent, very close to the coast and exposed to sea-spray or to very strong and polluting winds from the sea - Desert areas, characterized by no rain for long periods, exposed to strong winds carrying sand and salt, and subjected to regular condensation
I - Light
II - Medium
III - Heavy
IV - Very heavy
1) Use of fertilizers by spraying, or the burning of crop residues, can lead to a higher pollution level due to dispersal by wind. 2) Distances from sea coast depend on the topography of the coastal area and on the extreme wind conditions.
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Shed profiles Shed profiles
IEC 60815
Some typical shed profiles (from IEC 60815; explanation of the parameters see there). Some typical shed profiles (from IEC 60815; explanation of the parameters see there). From left to right: normal shed profile, alternating shed profile, underrib sheds (fog profile), From left to right: normal shed profile, alternating shed profile, underrib sheds (fog profile), cap-and-pin insulators cap-and-pin insulators
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c 30 mm p1 p2 15 mm s/p1 0.65 (in case of plain, non-underripped sheds) lx/dx < 5 C.F. 3.5 (pollution classes I + II) 4 (pollution classes III + IV)
C.F.= creepage factor = lt/st lt = total creepage distance st = arcing distance (arcing horns not considered)
Recommendations of IEC 60815 - Example
IEC 60815
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Recommendations of IEC 60815 - Example
5 specified No specification for bottom side angle; however, 2 "advisable" in case of sheds without underribs
IEC 60815
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Example of user's experience
From: Raouf Znaidi: "Service Experience and Maintenance Requirements for Different Types of Insulators in Tunisia", World Congress on Insulators, Arresters and Bushings, Hong Kong, Nov. 27-30, 2005
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Cleaning, greasing, coating of insulators Cleaning, greasing, coating of insulators
Some particular sites require regular cleaning of the insulators. Extreme situation: Extreme situation: Maritime desert climate with industrial pollution Maritime desert climate with industrial pollution (e.g.: petrochemical facilities in Saudi-Arabia) (e.g.: petrochemical facilities in Saudi-Arabia) But also in Middle Europe in the vicinity of industrial facilities (steel works, petrochemistry)
for further details see HVT 2!

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Semi-conducting glazing Semi-conducting glazing
Idea: to avoid dry-band arcing by resistive bypass
surface current Drawback: stable semiconducting glazing difficult to produce
No flashover due to bypass current

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Semi-conducting glazing Semi-conducting glazing
Under development: for composite insulators by coating filled with micro-varistors
-varistors
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Composite insulators Composite insulators
FRP core extruded SIR sheath
Shed material: EPDM (Ethylene-PropyleneDiene-Monomer) only in distribution Silicone rubber (SIR)

crimped-on metal end fitting push-over SIR sheds
introduced in the beginning of the 1970s today virtually" state of the art problems": long time performance not yet clear, "brittle fracture", animal attacks
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From an EPRI Questionnaire in North America (publ. in 2003)
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compare this with the "bathtub curve"of failure no evidence for aging
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Hydrophobicity Hydrophobicity
One of the most important properties of composite insulators with regard to pollution performance is Hydrophobicity Hydrophobicity
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Receding angle Receding angle = most important for characterization = most important for characterization of hydrophobicity of hydrophobicity
Advancing angle
Properties change under the influence of electrical field
actual research!
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Draft IEC 62073 Hydrophobicity classes*)
*) Based on the "STRI Guide" (of STRI, Ludvika/Sweden)

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Silicone rubber as insulator material Silicone rubber as insulator material
Hydrophobicity only with silicone rubber Hydrophobicity only with silicone rubber Hydrophobicity transfer to pollution layers Hydrophobicity transfer to pollution layers Dynamics of hydrophobicity Dynamics of hydrophobicity Excellent tracking resistance Excellent tracking resistance
Excellent service record so far (only few exceptions where silicone rubber is not optimal, Excellent service record so far (only few exceptions where silicone rubber is not optimal, e.g. under extreme coastal conditions, i.e. heavy salt layers) e.g. under extreme coastal conditions, i.e. heavy salt layers)
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Weather Aging Tests for Polymeric Insulators

Natural Test Sites Natural Test Sites
Realistic test conditions, but no acceleration factors long test times necessary (several years) "(In)famous" test sites: Koeburg, RSA (Atlantic Ocean) Dungeness, UK (The Channel) Martiguez, F (Mediterranean Sea)
*)
*) NOTE: often the term NCI = non ceramic insulators is being used
Example: Koeburg, RSA

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Natural Test Sites Natural Test Sites
Example: Dungeness, UK (Excursion 2002)

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The "Tracking and Erosion Test" acc. to IEC 61109 The "Tracking and Erosion Test" acc. to IEC 61109
Similar test procedures specified e.g. for surge arresters (IEC 60099-4) and for polymeric insulators (IEC document 36/213/CDV: Project IEC 62217)
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Examples of test chambers

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Tracking Erosion
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Cyclic Tests Cyclic Tests
Cyclic tests usually consist in applying, in addition to voltage stress, various stresses in a cyclic manner: - solar radiation simulation; - artificial rain; - dry heat; - damp heat (near saturation); - high dampness at room temperature (saturation has to be obtained); - salt fog at low concentration. Furthermore, temperature variations may cause some degree of mechanical stress, especially at the level of insulator interfaces and also give rise to condensation phenomena, which are repeated several times in the course of a cycle. For power frequency test voltage, a test transformer shall be used. The test circuit when loaded with a resistive current of 250 mA (r.m.s.) on the high voltage side shall experience a maximum voltage drop of 5 %. The protection level shall be set at 1 A (r.m.s.). Problem: no general agreement on one particular test! Problem: no general agreement on one particular test!
Examples next slides:

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Practical test problem: rain and solar radiation at the same time!
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"EPRI" cycle: a year in service is considered to be represented by 10 days of summer cycle and 11 days of winter cycle. A duration of 5040 h is required for the whole test, 10 summer/winter cycles of 21 days each.
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Other Aging Tests for Polymeric Insulators

Wheel Test acc. to IEC 62217 Wheel Test acc. to IEC 62217
Extremely severe test!
The test specimens shall be cleaned with de-ionized water before starting the test. The test specimens are mounted on the wheel as shown in Figure A.1 below. They go through four positions in one cycle. Each test specimen remains stationary for about 40 s in each of the four positions. The 90 rotation from one position to the next takes about 8 s. In the first part of the cycle the insulator is dipped into a saline solution. The second part of the test cycle permits the excess saline solution to drip off the specimen ensuring that the light wetting of the surface gives rise to sparking across dry bands that will form during the third part of the cycle. In that part the specimen is submitted to a power frequency voltage. In the last part of the cycle the surface of the specimen that had been heated by the dry band sparking is allowed to cool.
Electrical stress: NaCl content of de-ionized water: Ambient temperature: Test duration: The power frequency test voltage in kV is determined by dividing the actual creepage distance in millimetres by 28,6. 1,40 kg/m 0,06 kg/m 20 5 K C 30 000 cycles
The test is regarded as passed, if on both test specimens: no tracking occurs for composite insulators: erosion depth is less than 3 mm and does not reach the core; if applicable for resin insulators: erosion depth is less than 3 mm; no shed, housing or interface is punctured.
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Other Aging Tests for Polymeric Insulators

Wheel Test Wheel Test
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"Silicone Bonus" "Silicone Bonus"
For NCIs with permanent (recovering) hydrophobic characteristics a "silicone bonus" may be applied as a reduction factor of creepage distance (C.D.) compared with ceramic insulators:
Class 1 : : 70 % 75 % of C.D. of ceramic insulators Class 1 70 % 75 % of C.D. of ceramic insulators Class 2 : : 80 % of C.D. of ceramic insulators (not applicable in coastal areas!) Class 2 80 % of C.D. of ceramic insulators (not applicable in coastal areas!) Class 3 : : same C.D. as for ceramic insulators Class 3 same C.D. as for ceramic insulators Class 4 : : in general, application of NCI should be carefully checked for each Class 4 in general, application of NCI should be carefully checked for each individual application individual application
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Performance of Polymeric Insulators

Other problems ....
Moss, algea
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Other problems .... Animal attack (parrots, cockattoos, termites) Example: Australia Example: Australia
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Other problems .... Animal attack (parrots, cockattoos, termites) Example: Australia Example: Australia
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Brittle fracture Brittle fracture
Countermeasures: ECR glass (electro-chemical resistant) quality of sealing at triple point field stress reduction by grading rings
From: M. Kuhl: "FRP Rods for Brittle Fracture Resistant Composite Insulators", http://www.lappinsulator.com/downloadcenter/technical.asp Fachgebiet Hochspannungstechnik
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Artificial pollution tests Artificial pollution tests
IEC standard 60507 IEC standard 60507 2 different methods: Salt fog method Salt fog method Solid layer method Solid layer method
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Salt fog method Salt fog method
Test specimen energized at operating voltage under conductive salt fog exposure Test specimen energized at operating voltage under conductive salt fog exposure Salt mass concentration between 2.5 kg/m33und 224 kg/m33 Salt mass concentration between 2.5 kg/m und 224 kg/m (1 kg/m3 corresponds to 1 g/l) Test specimen must not flash over within a specified time of exposure Test specimen must not flash over within a specified time of exposure Classification by withstand salt mass concentration Classification by withstand salt mass concentration
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Solid layer method Solid layer method
Solid layer of specified conductivity is applied in wet condition and dried Solid layer of specified conductivity is applied in wet condition and dried Layer conductivity between 3 S and 80 S Layer conductivity between 3 S and 80 S Salt Deposit Density (SDD) between 0.03 mg/cm22and 0.60 mg/cm22 Salt Deposit Density (SDD) between 0.03 mg/cm and 0.60 mg/cm Test specimen is energized in a cold Test specimen is energized in a cold fog chamber and then exposed to fog chamber and then exposed to humidity humidity Test specimen is exposed to Test specimen is exposed to humidity in a cold fog chamber humidity in a cold fog chamber and then energized and then energized
Test specimen must not flash over within a specified time of exposure Test specimen must not flash over within a specified time of exposure Classification by withstand layer conductivity or withstand salt deposit density Classification by withstand layer conductivity or withstand salt deposit density
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Artificial pollution tests Artificial pollution tests
Correlation between pollution level, recommended creepage distance and artificial pollution test parameters:
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Radial Field Stress under Pollution Radial Field Stress under Pollution
Arises if there is an internal active part with a given, constant axial voltage distribution; risk of internal PD in case of internal gas volume puncture in case of pure solid insulation
MO-Scheiben MO discs
MO column Gas or solid Solid Conductive layer
Uaxial, int Uradial

Photo: PD in a porcelain housed surge arrester
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Porzellangehuse-Innenwand porcelain housing, inner wall


Dielectric and Thermal Effects Dielectric and Thermal Effects
Example: 800-kV surge arrester
Outer surface discharges Outer surface discharges Internal partial Internal partial discharges discharges changes in internal changes in internal atmosphere atmosphere risk of deterioration risk of deterioration of all internal parts of all internal parts Risk of partial heating of Risk of partial heating of internal active elements internal active elements
Risk of external flashovers Risk of external flashovers
Risk of partial Risk of partial heating of internal heating of internal active elements active elements
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Emerging Insulator Standards
From: Claude de Tourreil: "New IEC standards: their Impact on future Selection of Composite Insulators", World Congress on Insulators, Arresters and Bushings, Hong Kong, Nov. 2730, 2005 Fachgebiet Hochspannungstechnik
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Insulation Strength Characteristics

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Procedure for Insulation Coordination in Four Steps

Flow chart acc. to IEC 60071-1 (Figure 1)

Overvoltage Protection and Insulation Coordination / Chapter 6

Procedure for Insulation Coordination in Four Steps

Typical for Germany: 0.1% per year 1 failure in 1000 years

Overvoltage Protection and Insulation Coordination / Chapter 6