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Pin-type porcelain insulators are still considered traditional in Brazil. Despite their low cost, these insulators have undergone non-programmed shutdowns caused by defects in the dieleztric material. This paper presents and discusses pin-type polymeric insulators manufactured with castor oilbased polyurethane resins.
Pin-type porcelain insulators are still considered traditional in Brazil. Despite their low cost, these insulators have undergone non-programmed shutdowns caused by defects in the dieleztric material. This paper presents and discusses pin-type polymeric insulators manufactured with castor oilbased polyurethane resins.
Pin-type porcelain insulators are still considered traditional in Brazil. Despite their low cost, these insulators have undergone non-programmed shutdowns caused by defects in the dieleztric material. This paper presents and discusses pin-type polymeric insulators manufactured with castor oilbased polyurethane resins.
Proceedings of the 7th International Conference on
Properties and Applications of Dielectric Materials
J une 1-5 2003 Nagoya P4-34 Study of Pin-type Polymeric Electric Insulators: Manufacturing Process, Tomographic Analyses, and Electrical and Mechanical Tests C.R. Murakami" R.A.C. Altafim' A. Bonomo' P. 1. Cruvinel * G.O. Chierice3 J.A.M. Agnelli4 Slo Carlos School of Engineering, University of Slo Paulo, SP, Brazil * Agricultural Instrumentation Company, Slo Carlos, SP, Brazil Slo Carlos Institute of Chemistry, University of Slo Paulo, SP, Brazil Department of Materials Engineering, Federal University of Slo Carlos, SP, Brazil * cacilda@sel.eesc.sc.usp.br Absttract: Unlike other countries, pin-type porcelain insulators are still considered traditional in Brazil and are applied on a large scale in electric power distribution lines, in a predominantly aerial type configuration. Despite their low and therefore competitive cost, these insulators have undergone non- programmed shutdowns caused by defects in the dieleztric material. A description is given herein not only of the manufacturing process of pin-type polymeric insulators, but also of computerized tomography-based analyses of these insulators to verify the homogeneity of the dielectric material's composition, as well as the results of alternating e l d c current tests and mechanical flexure tests before and after accelerated aging. This paper reports on a preliminary study, presenting and discussing pin- type polymeric insulators manufactured with castor oil- based polyurethane resins and comparing them with porcelain insulators. The results revealed that the aged and nonaged electric insulators displayed the same el edcal behavior under alternating electric current, while the aged insulators showed greater mechanical rigidity. predominantly aerial type configuration. This has resulted in a very significant proportion of failures of this type of insulator [2]. Inspection records indicate the occurrence of defects such as cracking, damaged glass layers, and mechanical breakdown of the upper portion of the insulators, caused by dilation strains in the set (thread and pin), etc. These defects usually lead to current leakage, transitory interruptions and subsequently to permanent stoppages, often causing the breakdown of conductors. This paper presents a preliminary study of alternative polymeric pin-type insulators and describes the electrical and mechanical characteristics of the new polymeric insulators manufactured with two kinds of polyurethanetype insulating resins derived fkomcastor oil (scientific name: Ricinus communis), whose laboratory codes are RI 1 and RI 2. The physicochemical characteristics of these resins are described in [2]. The insulator samples were classified i n each test according to the material used in their fabrication, as: RI 1 and RI 2, the former made of pure resins (without fillers) and the latter of porcelain. ]EXPERIMENTAL PROCEDURES INTRODUCTION Power supply companies face high transmission and distribution line maintenance costs caused by faulty electric insulators. Insulator performance-related problems have therefore been the subject of several technical bulletins, and their importance was the motivating factor for the research reported on here. Vandalism and atmospheric discharges have been identified as the major causes of failure of glass and porcelain insulators, although pollution and corrosion have also been relevant causes of failure in several coastal regions [l]. Vandalism has been combated through the systematic use of polymeric insulators in the critical regions where most insulator breakage has occurred [2]. This measure, in addition to proving economically viable, has also resulted in the increased quality of the service provided by these companies. Unlike other countries, pin-type porcelain insulators are still considered traditional in Brazil and are applied on a large scale in electric power distribution lines, in a Preparation of the insulator specimens ldanually molded, conventional Pin-type polymeric insulators were used as test specimens. The rnanufacturing process of these insulators was carried out on a laboratory scale and began with the weighing of the poly01 on a semi-analytic scale, to which the pre- polymer was added in a mass proportion of 1 : 1, in the case of resin RI 1, and of 1:1.75 in that of resin RI 2. After these two components were mixed for about 2 min, the mixture was placed in a glass chamber and subjected to a vacuum of 1.104 mbar for 3 min to t:xtract air bubbles. The resin thus prepared was poured into silicone molds and left there for about 6 hours, after which the insulators were removed fkom the molds. ]Electrical testing procedures Ih order to determine the withstand voltage of the polymeric insulators under service conditions, alternate 60 Hz sinusoidal voltages were applied. These voltages - 824 -- were increased at a uniformrate of 500 V/s, fiom0 volts up to the breakdown of one of the insulators or even of the air. During these tests, the temperature and relative humidity were kept at 296 K (23 C) and 49%, respectively. It should be noted that all the electrical tests were conducted on specimens in two conditions - nonaged and aged - in a critical accelerated process of 5,000 hours, simulating approximately 3.5 years of natural aging. The aging tests were carried out with an Atlas Weather-Ometer fiom the Atlas Electric Devices Company [2], with an acceleration factor equal to approximately six. The electrical tests were carried out on polymeric Pin- type insulator samples manufactured with resins RI 1 and RI 2, which were prepared by the above-described molding process and by the resin pin machining process, resulting in the insulator samples illustrated in Fig. 1. Figure 1: Insulators machined fiom RI 1 (right) and RI 2 (left) resin pins. Although these insulators can be produced by the machining process, this method was not used to prepare the other insulators subjected to the remaining tests discussed below. [3]. In order to evaluate the methodology for polymer insulator analysis by means of CT- 59.6 keV image processing, insulator samples made with two pure resins, RI 1 and RI 2, were prepared. Fig. 2 shows one of the positions analyzed in the Pin-type insulators. Figure 2: One of the sections of the Pin-type insulator analyzed by computerized tomography. RESULTS Electrical tests After aging, all the insulators were visually inspected to check for alterations in color, internal andor external cracks, microcracks and strains. The insulators showed only, as in [2], color alterations fiom light to dark yellow, with no visible type of strain or cracking. Considering the environmental conditions of the electrical tests before and after aging, which were performed on different days, and the fact that the flashovers occurred in the air, the variations between the results obtained lie within the measurement tolerances, with RMS withstand and instantaneous peak voltage values of around 60 kV and 80 kV, respectively. The results of the electrical tests before and after the accelerated aging test are shown in Fig. 3. Mechanical testing procedures An Instron Corporation, model 5500R, serial #7010, universal mechanical testing machine with a 25 ton capacity and a data acquisition systembased on Merlin Version 4.0 software were used for the mechanical flexural tests. In order to reproduce the same service conditions as those to which polymeric insulators are subjected, a testing device was prepared for use in the flexural tests, with a screw systembuilt to fix the insulators, ensuring high resistance during testing. The flexural test speed was set at 5mm/min for an average testing time of 300 seconds. Analysis of Polymeric Insulators using Computerized y-Ray Tomography Hardware and software employed for tomographic measurements were organized by using a CT miniscanner having the following characteristics: an 2 4 1 ~ gamma ray source with approximately 1.2~10 Bq, 300 mCi; spatial resolution of about 1 mm2; and lead collimators for spatial resolution of about 2 mm2 s 9 Type of insulator (b) Figure 3: Electrical tests: (a) flashover; and (b) results of insulators beforeand after accelerated aging. - 825 - The insulator pin itself, bare conducting wire and eiectric field equalizing balls were used for the electrical test on the Pm-type insulators, as illustrated in Fig. 34a). Behavior of the insulator under flexural loads The rupture loads of the insulators fiibricated with pure RI 1 resin could not bedetermined due to the material's rigidity and the limitations of the testing machine, whose maximum is 25 tons. However, the insulators procluced with the RI 2 resin broke, displaying lower flexural load strength than those prepared with the RI 1 resin and the porcelain insulator. Fig. 4 portrays the behavior of these insulators. (a) (b) Figure 4 Mechanical flexural test on aged insulators produced with (a) RI I resin, and (b) RI 2 resin. The specific strain value of the insulator in the device developed for this test ( SA) is given in mmand the results of the test are shown in Table 1. Ta - Typeof Maximum breakdown Duration S.d insulator load oftest (mm) CkM (SI RI 1 >19.63 316.14 26.34 R[l-%ed >19.61 164.07 13.67 RI 2 4.46 448.00 37.33 RIZ-aged 7.08 504.00 42.00 F'orcelain 10.00 * - Notc:: *According to the Brazilian ABNT standard NBR 71 10 _. 141. The characteristic curves of the flexural test on the insulators produced with the RI 1 and RI 2 resins are given in figure 5-(a) and 5-(b>, respectively. Because the insulators made of the RI I resin displayed a highly rigid behavior, a flexural load of 15.0 kN was applied five times, individually, on the aged RI 1 and on the RI 1 nonaged insulators at 10 minute intervals between applications. Fig. 5-(a) illustrates the results of this test, showing that they did not break and that the aged insulator possessed greater mechanicai rigidity for the same specific strain of polymeric insulators in the device developed for this test. 16a)(l, I ,12080 ~,,, f 8008 U boat Moo 0 0 2 4 6 8 I O 12 S.d. (mm) (4 m Figure 5: Flexural load vs. specific st f ai n of polymeric insulators in the devicedeveloped for this test (S-d.) and produced with (a) RI 1 resin; and (b) RI 2 resin. Computerized y-Ray Tomography Several tomographic images wsre obtained for each insulator tested. These images are composed of dots on si gray scale, indicating the material's density. Mer camputer processing, the mean linear and mass attenuation coefficients (p and k, respectively) were tletermined, showing a standard deviation of 0.001 to 0.003. These values were obtained point by point in the image and some of themare indicated in Fig. 6 and in Fig.7. 0.071 em-' =0.383 em +p =0.607 em-' + p =0 . ~ 6 1 em" % =0394 em-' +p =0.635 em-' 17igure 6: Identification of the values of the coefficients of linear attenuation of the pin-type insulators produced with porcelain. - 826 -- p =0.252 em-' p =0.1~0 em-' p =0347 em p =0.165 em-' Figare 7: Identification of the values of the coefficients of linear attenuation of the pin-typeinsulators produced with RI 1 resin Table 1 lists the properties of the insulators analyzed by computerized tomography. FromTable 1, it can be seen that the new polymeric Pin-type insulators have less than one half of the mass of the porcelain insulator, which represents an advantage of this newly developed insulator [ 5] fiom the standpoint of installation and transportation. Computerized y-Ray Tomography methodology is shown to be a powerful tool for analyzing polymer insulators. Thus, based on the results obtained with this technique and through a simple visual inspection, it can be seen that the polymeric insulators and the porcelain insulator under study presented neither defects nor voids and that the dielectric material of their internal parts is homogeneous. ACKNOWLEDGEMENTS Table 1: Properties of the analyzed insulators. Insalator Mass Volume Experimental pm on test (g) (cm3 Density (cm2/g) FU 1 547.8 496.0 1.104 0.182 (g/cm RI2 537.5 494.0 1.088 0.183 Porcelain 1,257.2 527.0 2.386 0.214 CONCLUSIONS The accelerated aging test caused only color alterations in the insulators, owing to the fact that the double bonds [2] in the chemical composition of the resins employed underwent an oxidation process when subjected to high temperatures. The results of the electrical tests revealed no change in the performance of the insulators subjected to accelerated aging, demonstrating RMS withstand voltages of around 60 kV and instantaneous peak voltages above 80 kV, at the industrial frequency of 60 Hz. However, since all the insulators passed the artificial aging and electrical tests, the results of the mechanical tests were the differentiating factor in the final and conclusive analysis of the insulators developed in this study. Hence, it was concluded that: - The insulators produced with RI 2 resin broke during the flexural test, displaying lower flexural strength than the porcelain insulator. - The insulators made of pure RI 1 resin did not break during the flexural test, displaying higher flexural strength than the porcelain insulators. Therefore, the application of the RI 1 resin-based polymeric insulator was approved in this preliminary study, fiom the standpoint of its electrical and mechanical characteristics determined so far. However, further testing in future studies should focus on the thermal resistance of these insulators under service conditions. This work was accomplished with the joint collaboration of the Laboratory of Tribology and Composites, Department of Mechanical Engineering, Sb Carlos School of Engineering (EESC), University of Sb Paul0 (USP), the Laboratory of Analytical Chemistry, Sb Carlos Institute of Chemistry (IQSC), USP, and the financial support of the research foundations FAPESP and CNPq (Brazil). REFERENCES Furtado, T.A.; Ferreira, S. and Filho, N.S., "Transmission LineInsulator Performance- A Brazilian Scenario", International Workshop onTransmission Line Insulators, Rio de Janeiro, Brazil, pp. 34-37, May 1998. Murakami, C. R, "Applications of Castor Oil-based PolyurethaneResins as Electrical Insulation Material", Doctoral thesis - Department of Electrical Engineering, Sb Carlos School of Engineering, University of Sb Paulo, Sb Carlos, Brazil, August 2002. Altafim, RAC.; Murakami, CA; Henmann Jr., P.S.P.; Naime, J.M.; Cruvinel, P.E. and Cardoso, L.P., " A New Methodology for the Analysis of Dielectric Materials Used in Polymeric Insulafors", 9th Regional Latin American Meeting of CIGRE (ERLAC), Foz de Iguap, Brazil, Study CommitteeNo. 15, May 2001. Brazilian Association of Technical Standards (ABNT), "NBR 7110: Porcelain or Glass Pin-TypeInsulators - Standardization of dimensions and characteristics", Rio de Janeiro, Brazil, 1998. R. Hackam, "Outdoor HV Composite Polymeric Insulators -Review", IEEE Transactions on Dielectrics and Electrical Insulation, vol. 6, no. 5, pp. 557-585, October 1999. Author's address: Cacilda Ribeiro Murakami, Researcher, Department of Electrical Engineering, Szio Carlos School of Engineering, University of Szio Paulo, C.Postal359 - CEP 13566-590 - Silo Carlos, SP, Brazil E-mail: cacilda@sel.eesc.sc.usp.br. - 827 -