High Strength Polymer Post Insulators Enable

Economical Transmission Lines With

Low Environmental Impact
J .T. Burnham
P.S. Givens
Transmission Line Department
Florida Power and Light
J uno Beach, FL
Abstract - In todays operational environment, uti&
transmission engineers are beuig challenged with a new set of
design parameters. In addition to the traditional objective of
system reliabilily, new issues of paramount importance have
evolved. These include the reduction of construction cos&,
addressing transmisswn line aesthetics, and optimizuig power
delivery within restricted right of way. This document describes a
design approach which enables the engineer to maximize these
criteria without sacriyxbig system reliabilily. A laboratory test
method for poijmer post uisulators is also presented which
eflectively simulates combuied mechanical bad conditions expected
in application, thus ahwing the utility enguieer to optimize span
lengths, conductor size, and uisulator selection. Polymer hktory
and benef& associated with compact file design are also reviewed.
I. INTRODUCTION
The use of horizontal line posts (HLPs) to nunimize
ROW has been well documented [1][2][3]. The acceptance
of polymer posts has increased their usage due to enhanced
electrical and mechanical performance capabilities. Polymer
insulators have been utilized by Florida Power and Light
(FPL) since 1977 (at 138kV) to develop new structures which
reduce construction costs, relieve ROW limitations, mitigate
against cascade failures from porcelain HLPs, and are
environmentally pleasing.
The development of larger diameter fiberglass rods, on-
going design improvements, and polymer materials testing
has given FPL the confidence to apply polymer posts at
higher voltages and longer spans. The development of single
pole construction at 230kV, utilizing unbraced polymer posts,
has demonstrated the same functional capacities as H-frame
T.M. Grisham
Reliable Power Products
Franklin Park, IL
structures at greatly reduced construction costs. Additionally,
the use of silicone materials has significantly reduced outages,
while the new designs allow more options in construction to
minimize environmental impact.
Due to the unique mechanical properties of polymer posts,
e.g., high strength under bending, the ability to absorb shock
or vibratory loads, deflection under loading, and an elastic
limit near the ultimate strength, the need to develop applica-
tion guidelines which clearly define the ultimate strength
capabilities of polymers is required to maximize cost savings
in construction. Historically, laboratory testing of polymers
has provided limited product capability information due to the
variability of the test methods employed. Insulator design
ratings have added to this uncertainty since a standard rating
method has yet to be agreed upon. Subsequently, FPL was
forced to apply polymer post insulators utilizing conservative
loading parameters which prevented full product optimization
for cost savings, i.e., resulting pole spans were shorter than
optimum.
To address this shortcoming, a laboratory test program
was devised to simulate actual field load conditions, thus
allowing FPL to more clearly define insulator loading limits,
maximize cost savings and maintain desired safety and
operational integrity.
A. History of Compact Trarisnrission Designs at FPL
The increasing cost of obtaining new ROW in densely
populated areas of Florida prompted the development of
compact transmission line designs. In the early 1960s, FPL
began constructing 69kV and 138kV lines with porcelain post
insulators. This design concept was extended to include
230kV lines in the late 1960s.
Porcelain post insulators, being brittle, are subject to
mechanical failures [4]. When one porcelain post insulator
breaks and falls it can create an impact load on adjacent
structures, resulting in a cascade failure. FPL has experi-
enced 10 separate instances in the past 30 years in which 6 or
more ceramic post insulators cascaded and dropped conductor
from transmission lines. Initiating causes of these failures
include high winds, cars hitting poles, lightning strikes,
construction crew techniques, and excessive conductor
0-7803-1 883-8$04.00019941EEE
494
tension. In these 10 instances, a total of approximately 550
ceramic posts failed dropping about 40 miles of conductor.
Although porcelain post insulators provided the desired
line compaction, it became evident that they could not
perform satisfactorily when subjected to extraordinary
mechanical loads. The application of polymer posts was
investigated as a possible solution.
Polymer posts incorporate a fiberglass reinforced resin
rod as the main strength member. This results in a mechani-
cally resilient insulator which is less prone to cascading
failures. For these reasons, FPL constructed two 138kV
lines using a total of 567 polymer post insulators as a trial in
1977.
In 1982, FPL experienced a major cascade failure of a
230kV line with porcelain post insulators which resulted in
dropping a conductor onto the Florida Tollway injuring two
motorists. As a result of this event and the good experience
with 138kV polymer posts, FPL converted the 230kV designs
to polymer post insulators. To accommodate live line mainte-
nance safety clearance requirements, a longitudinal length of
60" (&-2") was specified at 138kV and a 90" ( f 2") was
specified at 230kV.
Originally, braced post assemblies were used at 230kV
and unbraced posts were used at 138kV. To reduce the
possibility of cascade failures on existing porcelain posts,
many structures in the FPL system were braced with organic
polymer (EPR) suspension insulators of several different
manufacturers.
B. Unbraced Polymer Post Used at 230kV
Initial polymer compact designs at 230kV utilized a
braced polymer post assembly with EPR material. Ap-
proximately 3,000 of these units were installed between 1982
and 1988. An evaluation of installed insulators revealed the
braced post units were applied at span lengths which used less
than 15% of useful cantilever strength. The insulators also
showed signs of early deterioration of the EPR polymer.
This was attributed to a combination of electrical stress (no
grading rings were used) and environmental conditions (UV
and salt contamination). The polymer degradation was
significant, and a decision was made to find a more suitable
polymer insulator for this application.
FPL operational experience with transmission polymer
insulators [ 5] [ 6] and FPL sponsored accelerated aging tests
[7] indicated that insulators comprised of silicone materials
would provide the best performance in the FPL service area.
It was also concluded that an unbraced design provided
adequate mechanical strength as well as reduced the cost of
the insulator assembly.
A11 U.S. suppliers of polymer posts were given the
opportunity to submit drawings for 230kV unbraced SIR
posts. Initially, one manufacturer submitted design drawings
for a silicone rubber (SIR) unit and was subsequently
approved as a supplier. Additional manufacturers have since
been approved.
A significant feature of the 230kV single circuit unbraced
post used by FPL is that it is shorter than the braced unit,
due to the increased contamination performance of SIR. The
previous 8 foot long braced EPR polymer post unit required
a grading ring on the line end of the suspension unit to reduce
corona damage to the EPR material. The SIR insulators
require no corona protection. As the grading ring effectively
shortened the post's air gap, the section length could now be
shortened to 7-1/2 feet. This reduction resulted in equivalent
air gap performance, reduced the cost of the unit, reduced the
deflection, and increased the useful cantilever loading range.
FPL has installed approximately 6,400 SIR units in the
past five years. Cost savings over the original braced
polymer assemblies exceed $2,300,000 on approximately 200
circuit miles. This represents a savings of about $12,000 per
line mile in insulator purchase and installation costs.
An independent audit of transmission line construction
costs conducted in 1993 demonstrated the 230kV unbraced
polymer post insulator used by FPL to be $425 less, per
structure, (material and labor), than an equivalent ceramic
horizontal vee assembly [8].
The anticipated improvement in contamination perfor-
mance of SIR at 220" leakage distance has been verified by
field experience of five years without any documented
flashovers. I t is signiticant to note this represents a Class I1
(medium pollution) design, per the IEC-815 standard,
although it is applied in a Class 111, high contamination
(coastal) environment .
An unexpected benefit of this insulator was realized
during the 1992 restoration of damaged structures from
Hurricane Andrew. Because of its light weight, high
strength, and availability, it was used extensively in tempo-
rary repairs to 230kV lines originally framed with a variety
of structure types [9]. Subsequently, FPL has created draw-
ings for any emergency restoration which now specify
polymer post insulators exclusively.
C. 7he Double Circuit 230kV Structure
The application of the newly designed unbraced polymer
post in a 230kV double circuit single pole StNChI fe was
delayed when maintenance supervisors indicated they could
not perform hot line work on a structure with both circuits
energized. They recommended that the polymer post
insulators be increased in length so that a bucket could be
safely positioned between the circuits.
Trial work was performed with members of the Barehand
Safety Committee (which is composed of both company and
union members) at FPL's transmission maintenance training
center to determine the length of post insulator required. To
allow hot stick work with both circuits energized while
complying with the National Electrical Safety Code (NESC)
495
minimum working distance of 60" specified in rule 441 [lo],
a minimum insulator length of 104" was needed.
It was additionally determined that vertical phase spacing
had to be increased from the traditional 8 to 10 feet to
accommodate standard hot sticks in use at FPL. The
increased phase spacing will have additional benefits such as
reduced corona noise and losses, improved reliability through
fewer phase to phase outages, and reduced electrical stress on
thepolymer posts, a major aging factor for EPR polymer
materials.
-1' I m S29 759 87s'
95 500 69s 875'
D. Rebuilding Existing Lines with the Double Circuit 230kV
Structure
FPL has approximately 800 miles of 230kV transmission
lines constructed with wood sparlarm H-frame structures.
These lines were built primarily in the 1950's through the
1970's in rural areas where ROW was inexpensive to acquire.
This structure uses a wide ROW, typically 100 feet. When
two circuits of this structure are on a ROW, the minimum
width is 150 feet. These structures are becoming costly to
maintain, as they are subject to rot in the warm moist climate
of Florida, damage due to woodpeckers, and contamination
flashovers of the porcelain insulators.
The new double circuit single pole structure is so much
more compact when compared to the wood spar/arm H-
frames, that it is possible to replace one existing circuit with
two, double circuit, single pole structures on an existing
ROW (see Fig. 1). The potential benefits of doing this are
significant. Since FPL already owns the ROW, there is no
cost of obtaining new ROW. Environmental permitting and
siting procedures, and associated costs, are also reduced.
Wood H-Frame,
Single Circuit
(550 Feet Typical Span)
ROW =110 Feet
Two Double Circuit,
Single Pole
(750 Feet Typical Span)
ROW =115 Feet
l l l l
Fig. 1
Right of Way for H-Frame vs. Single
Pole Construction
Cost comparison of removing existing structures and
conductor and adding two double circuit single pole lines
(four circuits) on the same easements are calculated to be---
$158,000 less than building four circuits on two concrete
H-frames on new right of way, assuming a 750 foot span.
Since the new circuits are closer together, EMF is
reduced at the edge of the right of way to about one-half of
the strength for the single existing circuit. A typical reduc-
tion was calculated to be 130 to 60 milligauss.
11. DEFINING MECHANICAL STRENGTH
FOR UNBRACED POLYMER PARTS
Strength requirements for line posts in Florida's climate
are optimized by unbraced polymer insulators. Since there is
no ice loading, the rated cantilever is determined by the
nom1 loading factors of vertical, transverse (tension or
compression), and nominal longitudinal loads. Extraordinary
loading was defined by hurricane conditions which generate
115 mile per hour (mph) sustained winds at 30 feet above
ground level for a period of three hours, adding to the
transverse loading. The intent of adding an extraordinary
load during testing is to demonstrate the ability of the poly-
mer to violate working ratings for temporary periods without
damage or line loss.
A. Single Pole Construction Strength Matched by Polymer
FPL's experience in the past 30 years has led to the
development of high strength concrete poles. Table I defines
the maximum allowable span lengths for various wind zones
in the FPL territory. The upper span lengths are equivalent
to those of the current concrete H-frame designs now in use
and were obtained using various pole sizes, 1431 4517
ACSR/AW Bobolink conductor with a 25 foot minimum
ground clearance.
SPREAD GWED SIDE GUYED ZONE UNGUYED
(MPH) I5 KIP POLE 12 KIP POLE I5 KIP POLE
I
I15 350 452
110 I 350 I 509 I 823 II
395 574 823
455 612 875'
105 395 574 823
455 612 875'
Note 1: Maximum span length is constrained by clearance
requirement of 25 feet.
Table I: Maximum Allowable Span (Feet)
far Various Wind Zones
496
Knowing the capabilities and constraints of the concrete
poles, a suitable polymer insulator can be selected for span
optimization, In order to accomplish this, a testing program
was devised to quantify the mechanical strength of the 3 inch
diamebr polymer insulator.
B, Laboratory Twting Procedure Developed to Simulate
Installation Loading
An extensive structural testing program was performed
for the 3" diameter polymer post by applying various
longitudinal and transverse loads. Then vertical loads were
incrsswd from normal to destruction or as limited by test
The overall approach was to mount the insulators in a
specially designed space frame (see Fig. 2). Forces were
applied by hydraulic cylinders operated by independent
controls. The cylinders were mounted within self-contained
space frames to eliminate deflection variation on the insula-
tor,
fixturing,
C. Direction of Loading Determined for Ense of Analysis
For application of the compressive loads. a trolley,
mountad on a system of two channels, was installed so that
the compression force was applied as a tension pulling toward
the insulator base, perpendicular to the axis of the pole. As
the vertical load was applied, the insulator would bend and
the trolley would reposition itself to maintain proper force
rpplication to simulate a horizontal wind component.
To properly apply tension forces, it was necessary to
make use of a fourth hydraulic cylinder with a free-running
pulley on the outward end of the cylinder. The flexible steel
cable applying the tension force was passed through this
pulley, thereby permitting the tension cable to be realigned
throughout the period of application so as to be in line with
the axis of the insulator rod. The hydraulic cylinders
controlling the application of the tension force and the
position of the fm-running pulley were controlled by manual
valves. An electric light system was developed, controlled by
a micro witch sensing cable alignment. The operator could
then alternately apply power to the two cylinders to maintain
alignment.
This "in-line" application of the tension force was consid-
ered essential to cause the bending moment produced by the
tension force to add, in a realistic way, the bending moment
caused by the vertical load. This increased the stress at the
insulator base, causing failure of the insulator at lower
vertical loads than those found when there was no tension
load.
Longitudinal forces were applied on the line end fitting at
the point of line connection. This location tends to apply
torsional loading which is offset by vertical forces.
D. Conversion of Test Results to Field Application
Investigation of the combined load failing data yields a
significant result, namely, the effects of longitudinal forces
have minimal influence on cantilever strength ratings (see
Fig. 3). With proper analysis of this data, it is possible to
provide the transmission engineer with applicable information
such as a standard working load based on testing and
correlation to actual installation.
Using the cantilever breaking loads, rated cantilever load
(RCL) can bederived (see Fig. 4). The pertinent methodolo-
gy is summarized below:
A.B.L. x 0.98 =S.C.L.
S.C.L. x 0.50 =R.C.L.
Where A.B.L. =Average Breaking Load
S.C.L. =Specified Cantilever Load
R.C.L. =Rated Cantilever Load
(Note: The above terms are those defined in the pro-
posed revision (#a) of ANSI C29.11 to include composite
line post insulators.)
It is important to note that the compression curves in Fig.
4 do not represent the maximum capabilities of the unit. This
is due to limitations of the equipment which did not allow
testing of the insulators to failure. Instead, the compression
portion of the maximum working load curve was developed
using data accumulated during the extraordinary "hurricane"
load tests.
Comparison of the derived maximum working load with
FPL insulator specifications demonstrates that the strength of
the polymer line posts surpasses the FPL strength require-
ments. In addition, by plotting the recommended pole
strength limits from Table I onto the graph, it is apparent that
the maximumworking load of the insulators exceeds the pole
loading limitations (seeFig. 5) .
The principal implication of Fig. 5 is that the 3 inch
horizontal line post can be applied in any wind zone up to the
maximumlimits of any of the poles in Table 1. From this
information it can be concluded that span distance can be
increased until the maximum loading limit of the pole is
reached. By increasing the spans, and thus placing fewer
structures per mile, two positive benefits are achieved: 1)
line cost is reduced and 2) environmental impact is mini-
mized.
Examination of a specific field application clearly
demonstrates the benefits that can be realized. For demon-
strative purposes, a conductor turning a comer has been
chosen to illustrate the worst case loading situation. For this
calculation, the following FPL loading conditions have been
utilized: 1431 4517 ACSR/AW Bobolink conductor, side
guyed 12 kip pole, comer span lengths of 350 feet, maximum
497
turning angle of 15 degrees, stringing tension of 3,750
pounds, and wind loading of 115 miles per hour. In addition,
a total safety factor of 2 is applied to the results.
The resulting calculations yield a maximum vertical load
of 565 pounds and a compressive load of 2,355 pounds. In
comparison with the combined load rating chart (Fig. 3), it
is evident that the insulator loading is well below the RCL of
the 3 inch line post. Utilizing the recommended working
loads described in Fig. 3, the span length may beincreased
to 692 feet, discounting extraordinary loading effects of
humcane conditions. This increase in span length translates
into a cost savings and minimizes the overall environmental
impact.
E. Extraordinary Loading of Hurricanes Evaluated
To determine if the design specification could be safely
increased, it was necessary to simulate time-loading condi-
tions for humcane conditions. For this testing, the conditions
of humcane Andrew were applied to the insulator in both the
tension and compression directions. The insulators were
loaded at 125 % of the specified vertical load for three hours.
The tension and compression force of 4,677 pounds is
calculated to be the equivalent of a 145 mile per hour wind.
At the end of the three hours, no damage was evident on
this insulators. The vertical loads were then increased to
failure. The breaking loads were the same as new units, i.e.,
the units were unaffected by the extreme loading.
111. CONCLUSION
Polymer posts are enabling new designs which allow
lower cost construction and reduce the environmental impact,
while maintaining live line capability and increasing the
potential to increase power flow or existing ROW.
The use of polymers has been a continual process at FPL.
At this time, the cost of polymer insulators alone is not a
consideration when compared to porcelain, as the manufactur-
ers have proven the design to be cost competitive. The
application of polymers has been based on superior electrical
and mechanical performance.
The cooperative development of a combined load test
procedure, coupled with agreement on working and extraordi-
nary loading factors, indicates the polymer post exceeds the
capability of the pole design. This was verified by visual
inspection following the aftermath of hurricane Andrew.
FPL, with the support of manufacturers, will continue to
investigate cost reduction potential with unbraced, polymer
posts. Analysis of this testing program indicates the need to
establish standard methods for defining post strength, testing
to specified procedures, and field installations which are
based on sound engineering principles to achieve maximum
cost reduction potential.
[31
[41
151
161
171
181
191
IV. REFERENCFS
T. Goodwin, "Compact Line Design and Upgrad-
ing" Presented at the Southeast Electric Exchange
Engineering & Operations Group Meeting, May
1990.
D. Doubley, "The Use of Polymer Horizontal Vee
Arms for 120kV to 230kV Conversion" From the
Proceedings of the American Power Conference,
Vol. 53-11, Page 1179.
S.M. Foty, "Conversion of a 115kV Line to 230kV
Operation Using Free Piveting Braced Composite
Line Posts, " Presemed at the Canadian Electrical
Association Imulator Symposium, March 1990.
E.A. Chemey and C. Altomare, "Failures of
porcelain line post insulators on the Ontario Hydro
distribution system," Presented at the Canadian
Electrical Association Spring Meeting, March 1988.
J .T. Burnham, "Silicone rubber insulators used to
improve transmission line performance in Florida, "
Trcinstrrission and Distribution, vol. 44, no. 8, Au-
gust 1992, pp. 20-25.
J .T. Burnham, D.W. Busch, and J .D. Renowden,
"FPL's Christmas 199 1 Transmission Outages,"
WPM 094-3 presented at the IEEE PES Winter
Power Meeting, Columbus, Ohio, February 1993.
H.M. Schneider, W. W. Guidi, J .T. Burnham, R.S.
Gorur, and J .F. Hall, "Accelerated Aging and
Flashover Tests on 138kV Nonceramic Line Post
Insulators," 92 WPM 264-2 PWRD presented at the
IEEE PES Winter Power Meeting, J anuary 1992.
"230kV Transmission Line Study: Prepared for
Florida Power & Light," Sargeant & Lundy, 1993.
J . Wong, J .T. Burnham, and M. Eby, "Hurricane
Andrew's Challenge to FPL's Transmission Line
Depart mint, " Transnrission and Distribution,
September 1993.
"Institute of Electrical and Electronic Engineers,"
1993 Ndonal Electric Sajiety Code, New Yo&,
IEEE, 1992.
498
v. BIOGRAPHIES
Jeffrey T. Burnham received the Bachelor of Engineering
Degree from Midwest College of Engineering in 1984. He
is Senior Engineer in the Transmission Line Department of
Florida Power and Light Company.
Thomas M. Grisham received the BSME Degree from
Bradley University in 1970. He is Manager of New Product
Development and Testing for Reliable Power Products.
Phillip A. Givens received the BSEE Degree from the
University of Florida in 1984. He is a Senior Engineer in the
Transmission Line Department of Florida Power and Light
Company.
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