98-E-HVS-437

Surface Degradation of Outdoor Polymeric Insulators Resulting from

Electrical and Environmental Stress

Morteza Ehsani1, Gholam Reza Bakhshandeh1, Jalil Morshedian1, Hossein Borsi2, Ernst Gockenbach2
1
Iran Polymer and Petrochemical Institute, Tehran, Iran,
2University of Hannover, Institute of Electric Power System (Schering-institute), Germany

Key Words: Insulator, Tracking, Hydrophobicity, Silicone Rubber, EPDM, Erosion

Abstract: The use of polymer material in
outdoor insulation applications has been
steadily increasing over time. This paper
reports on experimental investigation on
electrical and surface properties of new
polymeric alloy compared with silicone
rubber (SIR), ethylene-propylene–diene
monomer (EPDM), and alloy of SIR-EPDM.
In this study a few kinds of a ternary blend of
silicone rubber - ethylene-propylene diene
monomer -TP (Thermoplastic polymer) with
many different proportions were prepared and
consequently the surface and electrical
(tracking and erosion resistance) properties of
them have been studied. The results of tests
showed that the surface properties such as
water repellency and electrical properties such
as tracking and erosion resistance in different
condition (UV aging, water salinity aging,
and humidity salt spray stress) are improved
compared to known polymeric insulators.
Introduction
The Electrical insulator is very important
component in the electrical power system
such as sub-station and distribution &
transmission lines. Insulators are the devices
which are used on electricity supply networks
to support, separate or contain conductors at
high voltage. All insulators have dual
functions, mechanical and electrical, which
commonly present opposing demands to the
designer. The most serious complicating
factor is the impossibility, in practice, of
providing an ideally nonconductive element.
All insulators have external surfaces which
will become contaminated to some extent in
service. The contamination will carry leakage
current; the surface layer, on a typically
polluted insulator, will contain inert mineral
matter, electronic conductive dusts like
carbon or metal oxides, soluble salts and
water. This layer will behave as a highly
variable and nonlinear resistor, in most cases
unstable in the presence of electric field. The
leakage current which it carries will give rise
to heat, electrochemical products of
electrolysis and electrical discharge.
Secondary consequence will range from
electrochemical erosion through discharge
ablation to complete by passing of the
electrical insulation by flashover. Leakage
current and its consequences largely
administrate the design of an insulator,
especially one which is to be used outdoors in
atmospheric wetting and pollution. The result
of the interrelation between electrical,
mechanical and environmental variables has
demonstrated to be the unsuitability of

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 Surface Degradation of Outdoor Polymeric Insulators Resulting from Electrical and Environmental Stress
20th International Power System Conference
completely designing an outdoor insulator on
purely theoretical bases [1]. Outdoor
insulating bodies have traditionally been
made out of glass or porcelain materials. Both
glass and porcelain insulators had their start
when local potteries began making telegraph
insulators in the 1850's and 1860's [1]. The
electric and mechanical stresses which
telegraph insulators were required to
withstand were evidently negligible in
comparison with those from power line duty.
From around 1915, the porcelain insulator
virtually replaced by glass all electrical
distribution, even at low voltages, as the
superiority was demonstrated in both
insulation quality and strength. The new
demands soon disclosed serious shortcomings
in both the materials and designs of insulator.
However, there is a long time experience with
glass and porcelain insulators, but they suffer
from some problems such as: puncture
breakage, erosion, pin erosion, long term
mechanical & electrical strength reduction,
coupling hardware corrosion, weight,
pollution performance.
Figure 1 shows the reasons of default of
porcelain insulators on distribution lines in
Iran. It can be seen that more failures are
related to puncture interface in porcelains [2].
It can be seen also from Figure 2 that most
reason of failure in glass insulators is due to
mechanical problem [2].
5% 1% 1%
16%
Interfacial puncture 77 %
Mechanical failure 16 %
Pollution flashover 5 %
Lightning flashover 1 %
Other causes 1 %
77%
Figure 1. Reasons for failure of porcelain insulators
on distribution lines in Iran
Since the 1960s, non-ceramic insulators
were advanced and its improvements in think
up and producing have made them interesting
to public service [3]. The use of non-ceramic
insulation systems is increasingly capturing a
large share of the market. In the U.S.A
2
polymer insulators represent approximately
60-70% of all new installations of HV
insulators and their share of the market
continues to grow [4]. In the Ireland 75% of
all upgraded 20 kV lines will employ
composite insulators in place of glass [3]. In
1997, Hydro-Quebec in Canada installed on a
16 Km section of 735 kV transmission line
282 composite insulators made by three
different manufactures in equal proportions.
The history of polymeric insulators began in
the 1940s when organic insulating materials
were used to manufacture high voltage indoor
electrical insulators from epoxy resins [5].
These materials were light weight, impact
resistance, and could be used to form large
complex parts.
1%
2%
1% Mechanical failure 94 %
2%
Interface punctute 2 %
Pollution flashover 2 %
Lightning flashover 1 %
Other reasons 1 %
94%
Figure 2. Statistics on the failure of glass insulators
on distribution lines in Iran.
Different polymers were used in the
manufacture of composite polymeric
insulators. At the beginning, non-ceramic
insulators contained ethylene propylene
rubbers (EPR) which were made by different
companies such as Ceraver of France (1975),
Ohio Brass of U.S.A (1976), Sedivar of
U.S.A (1977) and Lap of U.S.A (1980). At
1976, Rosenthal Co and Reliable Co of the
U.S.A in 1983 presented silicone rubber (SIR)
[5]. The suppliers have developed an alloy
consisting of EPDM with silicone rubber.
Ohio Brass (1986) produced a blend of
ethylene propylene (EPR) and silicone which
was subsequently changed to ethylene
propylene diene monomer (EPDM) and SIR
compound in 1989. The alloy of EPDM and
SIR may make it possible to combine the
properties of two materials [4].
It was reported that one company has
produced commercially with the alloys of
 Surface Degradation of Outdoor Polymeric Insulators Resulting from Electrical and Environmental Stress
20th International Power System Conference

EPDM and SIR over 2.5 million distribution, Mixing and Molding
0.1 million transmission class line post Several formulations containing silicone
insulators and 0.4 million suspension rubber, TP and EPDM were prepared
insulators which are currently installed in (Table 1). Silicone rubber was blended
power systems in different parts of the world with EPDM and TP in a Haake internal
[4]. This gives a clear indication of a world mixer, model Sys9000, Germany, for 10
acceptance of this blend of materials. min at a rotor speed of 100 rpm for
In this paper, the results of the investigations preparation alloys of SIR-EPDM-LDPE.
in electrical and surface properties will be The individual elastomers and the blends
presented. The effect of type of polymer and were compound with peroxide in a roll mill
UV and water salinity on the tracking and at room temperature. Vulcanization has
erosion of the polymeric insulator systems for been performed with a hydraulically
outdoor high voltage will be discussed. operated press at 170 °C and 15 bar for
10 min.
Experimental
Materials Contact angle Measurements
All the materials used for this work were Hydrophobicity of a surface is
commercial products and they were used as intimately related to the so-called contact
received without further treatments and all angle. Consider an ideal axisymmetric
experiments were performed at Schering drop of water resting on an ideal flat
Institute: homogenous horizontal solid surface; the
a) Silicone rubber (SIR), contact angle is the angle θ which is
b) Ethylene propylene diene rubber formed by the air-water interface of the
(EPDM) with Diene (ethylene norbornene) drop and the solid surface at the three-
content 5.7 %; ethylene content 55.5 %; phase line of contact. The most
Moneny viscosity ML (1+8) at (125 °C) 82; commonly used method for contact angle
Density 0.86, measurements of surface hydrophobicity
c) Thermoplastic polymer with Melt flow is the sessile drop technique. A droplet of
index (MFI) = 2 g /10 min. a purified liquid (distillated water) is
d) The di cumyl peroxide (DCP) 98 %; placed on a surface using a syringe. The
resulting angle between the droplet is
Table 1. General description of materials evaluated measured, generally using a goniometer
Material (phr) or a charge coupled camera device
Sample SIR EPDM TP DCP (CCD) fitted onto a microscope (Figure
3). A drop shape analysis system G10
A
100 - - 2 (Kruss-USA) was used for hydrophobicity
studies.
B - 100 - 2
C 50 50 - 2
D 47.5 47.5 5 2
E 45 45 10 2
F 40 40 20 2
G 35 35 30 2
H 33.3 33.3 33.3 2

phr: parts per hundred parts of rubbers

Figure 3. Schematic set-up of the contact angle
measurement

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 Surface Degradation of Outdoor Polymeric Insulators Resulting from Electrical and Environmental Stress
20th International Power System Conference

Tracking and Erosion Resistance virgin state and after salt solution spray aging
The tracking resistance is evaluated (5% NaCL solution in 500 Hrs at 30°C). Salt
according to IEC 60587 method [6]. The fog spray aging was performed according to
setup according to IEC 60587 tracking and ASTM B117 at 95-98% humidity. It can be
erosion test is shown in Figure 4. The seen also in Table 2 that contact angle of
contamination electrolyte used in this study samples varies after UV aging. The used UV
was a 0.1% ammonium chloride solution carbon arc lamp as a light source has a wave
(NH4CL) and 0.02% Isooctyl- length between 300 and 400 nm which is
phenoxypolyethoxyethanol (a non-ionic more than 90% of the whole spectrum. The
wetting agent) in de ionized water (Triton X- test condition was maintained as 50 ± 5 %RH
100). The conductivity of the contaminant and 30 ± 3 °C, and samples were subjected to
was measured with a conductivity meter UV light for 1200 Hrs. It is generally assumed
(Schott Geräte CG 858). It was 2530 µs / cm that 200 hours under these testing conditions
at 23 °C. The samples were slab – shaped (12 is equivalent to one year of actual outdoor
cm x 5 cm x 6 mm). The distance between the exposure, considering that only the UV wave
top and the bottom electrodes was 5 cm. An length in the range 300-400 nm causes
AC load of 3 kV was applied over the 5 cm deterioration of polymers [7]. The thickness
distance, which created average electric field of samples for the hydrophobicity test and
strength of 600 V / cm. The flow rate of the aging in both salt spray and in UV light was 1
contaminant was controlled with a peristatic mm.
pump, at 0.3 (ml/min). The tracking time was It can be seen that contact angle of (H) is
defined as the time of which the leakage higher for silicone rubber than EPDM and
current is exceeded 60 mA and sustained for a their blend (50 /50), both before and after UV
period of 2 sec. aging. The reduction in contact angle after
aging means that the methyl groups,
Contamination responsible for the hydrophobic nature of
High Voltage
Feed silicone rubber were destroyed by the photon
Transformer 22 kΩ energy of short wavelength. It is known that
Sample
hydroxyl and carboxyl groups are produced
Top Electrode on silicone and EPDM surfaces by UV
220V irradiation. As a result, the wet ability
~
AC Bottom Electrode
increases with the duration of UV radiation.
Variable Ratio
Transformer
Table 2. Contact angle of virgin and aged samples
Sample C a1 C a2 C a3
s
Figure 4. Experimental set-up of the tracking and
erosion test A 115.9 106.1 80
B 100.8 96.6 70
C 108.9 104.1 78
D 105 100.1 95
E 108 103.2 75
Results and Discussion F 108.5 104 80
Hydrophobicity Studies G 109 101.8 85
Hydrophobicity can be estimated using the H 111.5 105.6 92
C a1: Contact angle in virgin in degree
contact angle variation. If the contact angle of C a2: Contact angle after salt spray fog aging
the material increases above 90°, it indicates C a3: Contact angle after UV aging
that the material is hydrophobic. Table 2
shows the contact angle of the samples in the

4
 Surface Degradation of Outdoor Polymeric Insulators Resulting from Electrical and Environmental Stress
A B
120
Contact angle, Degrees
105
90
75
60
45
30
15
0 across dried regions, or bands. This
0 500 1000
UV aging, h
Figure 5. Variation of contact angle with duration of
UV aging for test samples
It can be seen from Figure 5 that reduction
of contact angle for H is slower than for
silicone rubber and EPDM and their blend
(50/50) after UV aging. These results mean
that the methyl group having the hydrophobic
property in silicone rubber was damaged by
the photon energy of short wavelength. It was
well known (the result of FTIR measurement)
that hydroxyl and carboxyl groups were made
on silicone surface by UV irradiation. The
hydroxyl and carboxyl groups were formed,
when Si-CH3 and C-H were broken by photon
energy and then bonds are formed at this
broken site. Therefore the polar groups were
formed more and more with the duration of
UV radiation. As a result, the wettability
gradually increases with the duration of UV
radiation. The decrease of hydrophobicity for
EPDM (B) after UV aging can be the result
from formation of polar oxidation products,
principally alcohols and hydroperoxides. The
main failure reason of EPDM insulators has
been attributed to loss of hydrophobicity. This
eventually causes the surface of the insulator
to become conductive as it is wet by water,
resulting in flashover and irreparable damage.
Tracking and Erosion Resistance
Evaluation
When subjected to polluted atmospheres,
insulators attain deposits of airborne solid
contaminants, usually containing some ionic
20th International Power System Conference
C H substances which form electrolytes and give
rise to surface leakage currents under moist
conditions such as fog, rain, dew or mist. In
regions of high current density differential
evaporation of the moisture from the surface
layer produces local voltage gradients
(electrical stresses) greater than the
breakdown stresses for the surrounding
atmosphere (air). The discharges propagate
1500 mechanism is known as dry band formation.
These types of electrical discharges may
occur in service under the influence of dirt,
moisture, and deposited conductive salts.
Discharge inception under the above
conditions is the consequence of several
sequential processes:
a) The coating of the insulator with ionic
deposits
b) Formation of an electrolyte by the
absorption of moisture
c) Surface leakage currents and localized
drying of the electrolyte (dry band
formation).
Processes (a) and (b) are dependent on the
environment, and may even be combined as
in the case of salt storms in coastal regions,
whereas (c) is dependent on the rate of
formation of the ionic conduction on the
surface. The degrading effect of these
processes is simulated by the tracking test.
Tracking and erosion are serious degradation
modes for non-ceramic insulators that reduce
their insulating properties and mechanical
strength considerably.
Table 3- Tracking test conditions
Applied voltage 3.5 kV
Flow rate contamination 0.3 mL/min
Type of contamination NH4CL
Conductivity 2530 µs/cm
Surface electrical discharging ultimately
results from build up of leakage current on
insulating devices during wet contaminated
conditions. In this situation, the polymer
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 Surface Degradation of Outdoor Polymeric Insulators Resulting from Electrical and Environmental Stress
20th International Power System Conference

material can undergo various chemical thermal degradation of HTV-silicone rubber

reactions leading to deterioration of
mechanical and electrical properties. One
method of degradation is the formation of a
carbonaceous conducting path on the surface
of the insulation, due to heat generated by
discharges. These start locally across the dry
bands formed on the surface of a sample,
when sufficient contamination is accumulated
in the surface regions between the electrodes.
The carbonized conduction path finally forms
over the short circuited path. Another mode of
damage is the progressive loss of material
because of the formation of degradation
products due to a localized reaction, resulting
in erosion of the insulting surface. The mode
of degradation may vary according to the
chemical composition of the polymer, type of
contamination, and the type of the discharge
activity.
Table 3 and 4 show the condition of
tracking test and the tracking and erosion
resistance of polymers, respectively. It can be
seen from Table 4 that silicone rubber has a
poor tracking resistance and has high erosion
losses compared to other polymers.
It can be seen from Table 4 that with
increase TP content in ternary blends, time of
tracking is increased and erosion is decreased.
It is also found that TP improved tracking
resistance and surface discharge properties of
Natural rubber compounds [8].
[9]. Silicone rubber subjected to thermal
decomposition is known to form cyclic
dimethylsiloxane (DMS) together with a
small amount of linear DMS (∼1%wt). The
molecular units of most formed cyclic DMS
(∼90%wt) are D3 to D6 [9, 10-12]. It has been
shown already that electrical discharges
increase the number of cyclic silicone
oligomers of 4 to 6 unites (D4 to D6) on the
surface of HTV silicone rubber [13]. Cyclic
silicone oligomers of low unite would
increase at the surface with the duration of the
inclined plane tracking and erosion test. Table
5 shows that low unit silicone oligomers
possess low boiling temperatures, with those
of D4 to D6 ranging from 173 °C to 245 °C
[13]. When dry-band arcing is concentrated in
one point, formed the oligomers D4 to D6 are
volatilized due to their low flash points (Table
5). Therefore, the increase of tracking
resistance of ternary blends can be the result
of reduction of LMW silicone ologomers in
theirs.
Table 5. Boiling points (B.P [°C]) and flash points (F.P
[°C]) of silicone oligomers of low molar mass
Type chemical structure F.P B.P
D3 (Si O (CH3)2)3 39 135
D4 (Si O (CH3)2)4 69 173
D5 (Si O (CH3)2)5 93 207

Table 4. Tracking time, weight loss and maximum D6 (Si O (CH3)2)6 - 245
erosion depth for samples
Sample T Weight Maximum 400
360
(min) loss % erosion 350
Virgin samples
depth (mm) Water Salinity
300
A 40 1.5 3
T racking time, min.

250 UV aging
B >60 Fire -
C 30 0.2 0.8 200

D 25 0.2 0.8 150 120

E 37 0.2 0.75 100
60 60
75 70 70
F 40 0.18 0.72 40 30 20 20
50 20
G 60 0.14 0.65 0
H 75 0.114 0.65 A B(Firing) C H

Samples
Gas Chromatography-Mass spectrometer Figure 6. Comparison of tracking time in different
(MS) shows the evolved gases during the condition

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 Surface Degradation of Outdoor Polymeric Insulators Resulting from Electrical and Environmental Stress
20th International Power System Conference

2.5
2.5 Virgin Water salinity UV aged
Although, tracking resistance for silicone
rubber improved by UV aging, but it should
2
be noted that the reduction of hydrophobicity
1.5 during UV aging causes accumulation
W eight loss % .

1.5
pollution on surface of polymer and flashover.
It can be seen from Figures 6 that the
1
tracking and erosion resistance have changed
0.35 0.23 after water salinity aging for the case of
0.5 0.3
0.23 0.2 silicone rubber. This can be the result of the
0.114 0.13
0 0 0 absorption of water during water salinity
0
A B (Firing) C H
aging.
Samples This reduction is clearly caused by an
Figure 7. Loss of weight samples after tracking test in expansion force during the boiling of
different condition absorbed water. Furthermore, if water is
injected into the bulk, ions or electrons in
The tracking resistance of polymer contaminated electrolyte can migrate into the
insulating materials can be offered by interior via absorbed water, and a current
environmental conditions such as UV develops through the bulk. The development
radiation, moisture, and acid rain. The of such current causes the boiling of absorbed
influence of water salinity and UV radiation water and, finally, promotes mechanical and
on tracking resistance of samples also studied. chemical erosion. It seems that NaCL in salt
Figures 6 -8 show the tracking resistance and water permeates into the samples and acts as
erosion parameters after UV and water ionic carrier, causing on increase in current
salinity aging. The samples were immersed in density.
water salinity (5% NaCL) for 1500 Hrs. The
polymers have also been exposed to UV for
1700 Hrs at 30 °C. Conclusion
Figures 6 and 7 show a comparison of New polymeric alloy for outdoor use of
tracking time and erosion parameters in high voltage insulator has been introduced
different condition for sample A, B, C, and H. and its electrical, mechanical, thermal and
It can be seen that sample H has good surface properties are compared to already
tracking and erosion resistance compared to known outdoor composite insulation in
silicone rubber, EPDM and blend of silicone- different conditions.
EPDM.
• Contact angle measurements have shown
3.5 that new alloy is more hydrophobic compared
3 3.3 to silicone rubber, EPDM and blend of
3 Virgin Water Salinity UV aged
silicone-EPDM after previous UV radiation
M a x e ro sio n d e p th , m m

2.5 stress. Its hydrophobicity is also comparable

with blend of silicone - EPDM after thermal
2
1.5 1.5
aging.
1.5 • The hydrophobicity of samples were
1 found to decrease with UV and thermal aging
1 0.8 0.7
0.65
0.5
which was due to the formation of polar
0.5 groups (such as carbonyl groups) and
0 0 0 damaged of hydrophobic groups (such as
0
A B (Firing) C H
methyl groups) on surface of polymers
• The results of the contact angle
Figure 8. Maximum erosion depth for samples in
different condition Samples measurement show that the water repellency

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 Surface Degradation of Outdoor Polymeric Insulators Resulting from Electrical and Environmental Stress
20th International Power System Conference

of polymers decrease with water salinity Erosion of Electrical Insulating Materials

conditions Under Severe Ambient Conditions”, 1982,
• The tracking resistance of silicone rubber Second Edition.
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could be the result of diffusion of water. Outdoor Degradation Characteristic of
• It was also shown that UV aging Polymer Concrete Insulator”, proceeding
decreases the tracking resistance of EPDM of the 4th ICPADM, Brisbane Australia,
and may be the result of loss of 1994, pp.511-514.
hydrophobicity at surface of EPDM. [8] M. A.M. Piah, A. Darus, “Leakage
It was also found that UV aging improves current and surface
the tracking and erosion resistance of silicone discharge phenomena: effect
rubber. This can be the result of disappearing on tracking and
carbon and increasing of oxygen because of morphological properties of
UV effect. This result means that oxygen LLDPE-natural rubber
binds to silicone polymers at the surface compounds”, Proceeding of 7th
instead of carbon in methyl groups (CH3). International Conference on Properties
When carbon that results in the formation of and Applications of Dielectric Materials,
conductive path decreases, therefore, tracking Nagoya, Vol. 1, 1-5 June 2003,
resistance increases. pp. 347- 350.
[9] T.H Thomas, T.C Kendrick, “Thermal
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[10] H Homma, T Koroyagi, K Izumi,”
Evaluation of Surface
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8