An Investigation on Composite Insulators; Development and Testing

M.J.Geramian , F.Estifa ,A.Tajian , B. Elmdoust

Niroo Research Institute(NRI), IRAN

SUMMARY

This paper presents the result of investigation made KEYWORDS: Composite Insulator, Shed, Sheath, End
on composite insulators used for the power fittings, Creepage distance
distribution systems.
In the first step of this research, Composite
Insulators were thoroughly designed according to the
existing standards. Afterwards a manufacturing
technique was selected according to the mentioned
design features and different insulator’s components
such as sheds, housing, and the end-fittings were
made. The sheds were installed on the housing with
the help of primer and external pressure, the end-
fittings were then fixed at both ends by the sewage
process.
A special manufacturing technique was selected due
to its overall advantages over the common methods:
the ability to manufacture composite insulators with
the minimum amount of waste and to produce the
sheds for a range of power distribution levels with
only one mold.
For the manufactured insulators to be safely applied
to the power distribution lines in such harsh
environments as southern and northern parts of Iran,
where all influential parameters exist, including high
relative humidity, temperature, and high levels of
pollution (mainly salt deposit), they must have
successfully passed the series of tests specified by
the standards.
The insulators were therefore subjected to all
necessary tests and their results were compared to
those obtained from other insulators. Satisfactory
performance of the manufactured composite
insulators were indicated.
AN INVESTIGATION ON COMPOSITE INSULATORS; DEVELOPMENT AND TESTING
M.J.Geramian, F.Estifa, A.Tajian, B.Elmdoust
Niroo Research Institute,Iran
ABSTRACT
In the first step of this research, complete designing of
Composite Insulators used for the power distribution
levels was accomplished, according to the existing
standards.
A special manufacturing technique was selected due to
its overall advantages over the common methods: the
ability to manufacture composite insulators with the
minimum amount of waste and to produce the sheds for
a range of power distribution levels with only one
mold.
For the manufactured insulators to be safely applied to
the power distribution lines in such harsh environments
as southern and northern parts of Iran, where all
influential parameters -including high relative
humidity, temperature, and high levels of pollution
(mainly salt deposit)- exist, , they must have
successfully passed the series of tests specified by the
standards.
The insulators were therefore subjected to all necessary
tests and their results were compared to those obtained
from other insulators. Satisfactory performance of the
manufactured composite insulators was indicated.
INTRODUCTION
The need for non-ceramic composite insulators having
characteristics such as light weight and good electrical
and mechanical properties, for use in transmission
lines, was greatly felt about 40 years ago.
Today composite insulators have adequately replaced
porcelain and glass insulators and are extensively used
in high voltage lines. The use of composite insulators,
with a 20% lower weight than their porcelain
counterparts has become possible in mega volt lines
[1], [2].
The principle of composite insulators manufacturing is
based on a composite rod that should resist the
mechanical stress applied by the cable and transfers this
load to the tower. In order to protect this rod against
weathering and environmental effects and also to
increase the bearable creepage voltage [3], the rod is
covered with silicone rubber and the end-fittings are
then joined at both ends with a special process [4].
A range of adhesives, curing agents and sealers are also
used for this purpose [5].
PRINCIPLES OF ELECTRICAL DESIGN
What comes hereafter is a brief outlook at different
electrical design steps and the calculations for 17.5,
20(24) and 63 (72.5) Kv lines.
As it will be stated, the IEC standard document has
been used as the prevalent standard in extracting these
terms.
So that by keeping with one specific documentation
the insulation coordination principle will be met.
However in finding the effect of parameters regarding
over-voltages (such as lightning) referring to other
standards such as IEEE, BS and ASTM was inevitable.
A- Determination of over-voltages
This is important, since it can be used as a reference in
selecting the proper “Insulation Level”.
We are familiar with all kinds of over-voltages in
distribution and transmission lines. The most important
over-voltages that can affect the performance of
insulators are: lightning and switching (the effect of the
normal over-voltages with the normal tolerances ± 5%
and also short circuit over-voltages are not significant).
Therefore the reference voltages used in the selection
of “Insulation Level” are “rated lightning impulse
withstand voltage”, “rated switching Impulse withstand
voltage” (phase to earth and phase to phase) and “rated
(short duration) power frequency”.
According to the IEC standard, only the lightning
impulse over-voltage will be considered (this is due to
the probability of occurrence of each phenomenon
which makes it unreasonable to assume that all three
phenomena occur at the same time, specially in the low
voltage levels).
B- Creepage Distance (Insulation level)
According to IEC71-3 [7],a creepage distance of 220
mm has been recommended for the rated lightning
impulse of 125 kv. IEC 61466-2 [8] which specifically
discusses composite insulators, gives a minimum value
of 210 mm for this parameters with the pre-assumption
of specific creepage distance (S.C.D) to be 16 mm/kv.
Finally we can refer to experimental relations.
The “pairs formula” is one of the most popular:
3.3384
V=k (1)
1+ 8
d
In which, V is the withstand voltage in MV, d is the
creepage distance in meters, k is the constant factor
proportionate to the electrodes form. By placing the
values for k and v , k = 1.35 and v= 0.125, the
creepage distance will be equal to 0.225 m or 225 mm.
Thus among the data , St =220 mm has been used.
C- Other Parameters
Parameters such as shed diameter, fittings length, rod
diameter and housing thickness are generally
experimental and are obtained through other factors
such as mechanical loads, swage (crimping) factors,
etc. There is no particular standard for these parameters
only in some cases a range has been stated (such that
the shed diameter for 24 kv and 72.5(63) kv lines
should not exceed 200 mm) [8].
According to definition:
creepage distance between shed =AB+BN+NC=L
STF (Shed To Fitting) =EM=GD
Upper creepage =AM+ME
Lower creepage =CD+DG
r = shed tip Radius
C= d= AQ
Ld =AB+BN+NQ
α=The angle between lower surface of the shed and X
axis
α′=The angle between lower surface of the shed in
assumed cross section
β=The angle between upper surface of the shed and X
axis
β′=The angle between upper surface of the shed in
assumed cross section
P=59mm
According standard s/p›0.8 and thus s =46mm is
favored if n= The number of shed, then “Clearance
Phase to Earth” is Hc=2STF+(n-1) s+d1
(2)
According to St=220mm,s=46mm, it is necessary to
find out the correct amounts for n , STF which satisfy
the general condition and equation (2)
D- Controlling the values according to the standard
Conditions have been set in IEC 815 [9] to control the
values and distances between components for porcelain
and glass composites, which due to their nature, these
values can be also used for composite insulators.
The minimum creepage distance (mm) is equal to
performance voltage (kv) × specific creepage distance
(mm/kv) and the specific creepage distance is defined
by the environment’s pollution [9], so that in light,
medium heavy and very heavy environments, the
specific creepage voltage is respectively equal to 16,
20, 25, 31 mm/kv. Therefore in the 24 kv level, the
minimum creepage distance in the heavy area (what we
considered for the design) would be equal to 600 mm.
The geometrical methods used in these calculations
have been abandoned and only the obtained questions
are discussed (the curves on the sheds have been
assumed straight lines, so there is an error of 0.3% in
the calculations).
creepage distance between shed:
1 + sin α ’ 1 − sin β ’ π
L=P( + )+ r +s (3)
cos α ’ cos β ’ 2
c=s.cos β ’ (4)
1 + sin α ’ 1 − sin β ’
L d =P( + )+s(1-sin β ’ )+Hc (5)
cos α ’ cos β ’
Total creepage distance L t =
upper creepage distance + (n-1) creepage distance
between shed + lower creepage distance =
1 + sin α ’ 1 − sin β ’ nrπ
np( + )+ +S t (6)
cos α ’ cos β ’ 2
Table (1) contains information on standard relative
factors in comparison with the data considered for the
design.
As it can be seen, all the considered parameters meet
the conditions set by the standard; of course this alone
cannot be regarded as a confirmation on the
performance of the insulators and they should also pass
the standard tests successfully.
MANUFACTURING AND ASSEMBLY PROCESS
OF COMPOSITE INSULATORS
In principle, there are three techniques mainly used for
the manufacture of composite insulators:
1- The composite rod / covering the rod with sheath
by extrusion , injection or compression molding-
manufacturing of sheds separately / assembling
the sheds on the sheath / joining the end fittings to
both ends -sealing.
2- The composite rod / joining end fittings to both
ends placing the housing together with the sheds
using the injection or compression molding
method.
3- The composite rod / placing the sheath together with
the sheds by injection or compression molding
method / joining the end fitting to both ends-
sealing.
The first technique has been applied in the present
study to manufacture a composite insulator. There are
 Table 1- Standard comparative coefficients in electrical design insulators

Standard 72.5 17.5

Parameter Name Symbol Unite Reason for the limits 24 kv
limited Kv kv
Total creepage Lt mm Min:1575,600 To dissipate creepage currents 1990 613 459
distance ,438
Prevention an increase in creepage
Height to radius ratio S/P - Min : 0.65 distance maintain self proportions 0.81 0.78 0.71
proper self-cleaning
Creepage distance to
Prevention short circuit between two
permissible distance Ld/d - Max : 5 3.19 3.24 3.68
adjacent sheds
ratio
Creepage factor CF =Lt/St - Max : 4 Prevention an improper increase in 3.56 3.13 3.25
shed area
2F=2P+
Form factor - Min : 0.8 Maintain shape proportions 0.97 0.97 0.97
S/Lt
Minimum distance Prevention short circuit between
C mm Min ; 30 47 45 40.4
between two sheds sheds in bad weather condition
Keeping shape proportion and good
Upper surface slope - % Min : 8.7 27.56 27.56 27.56
self- cleaning

certain advantages to the chosen technique over the
others including minimum waste and the ability to
manufacture insulators for various levels of
distributions with one mould.
1st- Rod Manufacturing
The rod of a composite insulator is made up of two
phases: the matrix and the reinforcing fibers. The
matrix is an epoxy resin and the fiber is usually E-glass,
The fibers are situated lengthwise so as to make a
unidirectional composite. The composite is generally
made by pultrusion in order to achieve the 70-75
%fiber weight fraction.
2nd- Shed manufacturing
The sheds are made by the compression molding of
HTV silicone rubber. The rubber is first mixed with a
certain amount of fillers, including ATH 25-60%wt,
using a Banbury mixer, the curing agent (dcp) is then
added to the compound on the Two roll-mill and is
compounded for about 15 minutes to obtain a
homogenous mix.
A certain amount of the compound is later placed in the
preheated mould and the mould is placed under the hot
press. Mould temperature and the stay time of material
under the press is optimized by the data obtained from
the Rheometer.
3rd- Sheath Manufacturing
One of the most established methods for applying the
sheath on the rod, is extrusion. In the present work,
Compression moulding has been used. In this method
the surface of the rod is treated prior to the application
of sheath. The surface is first roughened and then the
primer is sprayed evenly on the surface. The primer is
used to ensure complete bonding between the silicone
rubber sheath and the composite rod. The sheath has
the exact same formulation as the sheds and thus the
same manufacturing method has been exploited.
4th- End fitting Manufacturing
The end-fittings are made by forging and machining
according to the plan. Since the fittings are joined to
the composite rod, in order to achieve optimum
bonding between the rod and the fittings, an adhesive
has been used along with the application of pressure
(swage).
The inner surface of the fittings has been formed with
fine protrusions to increase the contact surface between
the rod and the adhesive and thus enhance the bond
quality.
It has been observed that under the same pressure, the
tensile strength of the insulator was increased by 15%
due to these protrusions.
5th- Components assembly
First, the sheds are placed on predetermined positions
with calculated distances on the housing, using a proper
adhesive. Then the whole part is cured in the oven
at
200-210°C for 2-4 hr. Afterwards the fittings are joined
to both ends with the process mentioned before. To
prevent moisture diffusion into the rod, the gap
between the rod and the fittings is completely sealed
(using silicone as sealant) and after 24 hr the insulator
is ready to be tested.
 Table 2- The results of electrical tests of NRI Insulators
Level 17.5 kv Level 24 kv Level 72.5(63)kv
Test Reference: IEC 383(1983)
Standard Test result standard Test result Standard Test result
Dry Lightning Impulse withstand voltage test
+ 75 114 125 187 325 362
(P )
Dry power frequency withstand
voltage Test 38 71.1 50 94 140 >192

Wet power frequency withstand

30 38 40 75 112 155
voltage Test
P=634 mmHg T=13 Co
Moisture (h)= 35% ⇒ k≅0.83

manufactured insulators on the three mentioned levels.

All the data is given in kv.
ELECTRICAL AND MECHANICAL TESTS
2nd- Mechanical test

The electrical tests were carried out first on the
manufactured insulators and the mechanical tests
followed.
1st- The Main Electrical tests
These tests were carried out on both the individual
components and on the complete insulator. Only those
tests that were performed on the complete insulator, are
mentioned here.
The mechanical test procedures are based on IEC 1109
standard. Six complete insulators have been prepared .
The first three samples were tested under load, the
fracture occurred after about 1 minute (SML). In the
next step , a load equal to 0.7 of the obtained load from
the previous step was applied to the other three samples
for 96 hr.
No fracture occurred, which means that the line slope
was lower than 8% and the result was successful.

A-1 Dry Lightning Impulse withstand voltage test CONCLUSIONS

This is a type test (it is performed in order to
determine the major characteristics of the insulator
such as parameters regarding form and size). Testing
method and conditions have been explained by IEC
383.
A-2 Dry power frequency withstand voltage Test
This is a design test (which is carried out to determine
the quality of design, material and production method).
This test is usually performed on three samples, the
mean value of the results is then corrected with a
correction factor.
A-3 Wet power frequency withstand voltage Test
This is again a type test. The insulator is to be placed
in the position shown in IEC 60-1, 75% of withstand
voltage is applied to the insulator, which is increased
by 2% every second so as to reach the testing voltage
and then it remains under these conditions for one
minute.
The appropriate frequency is 45-65 Hz and the
required humidity (artificial rain) is provided by two
horizontal and vertical nozzles. When the results are
obtained a correction factor will be applied.
Table (2) shows the limits set by the standard and
gives the data from experiments carried out on
Due to all the advantages of composite insulators,
proved in various researches, their application in
distribution and transmission lines in Iran, especially in
heavy areas has become a necessity.
Thus, a series of composite Insulators have been
designed, prototyped and manufactured in Niroo
Research Institute of Iran (NRI) , with a much less cost
than their industrial counterparts and have been
successfully tested.
It is our hope that in the future the same manufacturing
process is developed to the industrial scale, which due
to the low cost of labor in Iran and low investment
required, it would be an economic and efficient
method.
ACKNOWLEDGMENT
Our great thanks go to A.R.Shirani, A.R.Moradian,
F.Azimi, M.Oskouie, M.R.Shariati, D.Mohammadi
M.Mohseni, M.Rezaei, S.Dolatshahi for all their
contribution.
REFERENCES

1. Arian S. Jagtiani, Nov.1997, “ American Electric

Power Company’s Experience with Ceramic & Non-
ceramic Insulators”, Symp. of Florida
2. R.A. Bernstorf, Nov.1997,“ Non-ceramic
Insulators – State of the Art”, Symp. of Florida
3. E.A. Cherney,1996, “ Non-ceramic Insulators :
ASimple Design That Requires Careful Analysis”,
IEEE, 12, 715
4. S.Kuneida, T. Shogo,1996, “ Metal Fittings for
Composite Insulators”, US Patent No. 5539155
5. Kaczerginsks, Alexandre,1987, “ Method of
manufacturing a Composite Insulator”, US Patent No.
4702873
6. IEC 1109, 1992, “Composite Insulators for AC
overhead Lines With a Nominal Voltage Greater Than
1000V”
7. IEC 71-1,2,3, 1982, “Insulation Coordination”
8. IEC 815, 1986, “ Composite String Insulator Units
for Overhead Lines With a Nominal Voltage Greater
Than 1000V; Dimensional and Electrical
Characteristics”
9. IEC 815, 1986, “Guide for the selection of
insulators in respect of polluted condition”
10. IEC 383, 1983, “ Tests on Insulators of Ceramic
Material or Glass for Overhead Lines With a Nominal
Voltage Greater Than 1000V”

(a)

(b)

Fig 2 – The Moulds of (a) the Shed and (b) the Sheath
Fig 1-Assumed cross sectional view of the insulator