Issue 80

Issue 80 Quarter 2 - 2008 Volume 16 - Number 2
INMR
Source of Information on International Developments in Transmission & Distribution
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Passing of Seraj ul Huda
July 25, 1937 /Noakhali, India (now Bangladesh) - March 24, 2008 /Istanbul, Turkey
My father passed away f kites during electrical doing exactly what he loved most. Faisal Huda INMR regrets to inform readers of the tragic passing of one of most passionate and colourful personalities. was lost; horseshoe Seraj Huda, founder and President of CSL Silicones, died suddenly while on a business trip to promote of a horseshoe, his company's RTV coatings in Turkey. Last year, at our World Congress in Rio de Janeiro, I saw Seraj again - sadly for the last time. We sat at a table enjoying liquid refreshments after a long day of meetings and discussions. There was a special glint in his eye as he sat surrounded by his children and colleague, Panos Meletacos from Greece. But the glint it turned out was not because of one of his achievements that day but rather one of mine. I had just finished my first novel and Seraj was fascinated to know the plot and, even more so, what had motivated me to become a writer. Reading Faisal's eulogy to his father, I discovered that Seraj had himself always wanted to write a book, in his case on the topic of wisdom. Apparently, he was a deeply religious man who looked to God and the natural world around us for inspiration on all types of themes. He saw a need to share his perceived wisdom to help others, just as he felt sharing his technical knowledge with electric power suppliers would benefit them. To me, this is a true indication of the man he really was. INMR extends sincere condolences to Seraj's wife Niloufer, his son Faisal and his daughters Saira and Sophia.
The great scientist and flyer
torms, Benjamin Franklin, nce wrote: For want of a the insulator industry's
Quality & Performance ...To the Core!

At the core of every composite insulator's performance is the FRP rod which provides for its long-lasting and reliable mechanical strength - under any service conditions. Rods from Taporel are based on our patented production technology which results in rods with superior bonding properties to the silicone outer sheath. This means no need for pre-treatment of the rod and enhances the entire production and moulding process. Go with Taporel and realize all the benefits which years of experience have given us as the leading rod manufacturer in China and one of the fastest-growing suppliers in the world.
nail, the
or want
he horse Although I have known his son Faisal for more than a decade, was lost; for want
I the rider only lost. f a horse,first met Seraj wasin 2005 at our World Congress in Hong Kong. I was immediately struck by what an interesting and his company and for the technology he was convinced would
n this simple metaphor, full of zeal and passion for his family, for colourful man he was - he
aptures so ensure more reliable electricity supply for everyone. help
well the essence of how
Indeed, the research and expertise he oversaw at his company has revitalized and improved mall, seemingly insignifi- a technology that has existed for some time but never really been fully understood, appreciated ant items can have full potential. or utilized to its an
mportance
Seraj's style of expressing and conducting himself was in many ways trademark o a system whicha is far of a driven type of individual who truly believe in what they do. Yes, owners of companies are eyond their perceived always trying to improve their sales and bottom line. But in his case there items. alue as individual was another driver - a strong belief that the technology being offered was one that must be shared for the or manybenefit of everyone. utilin the electric
Marvin L. Zimmerman
ty industry, the insulator een
has for much of its existence
een as little more than an
nert chunk of ceramic
material which costs rela-
ively little yet lasts
or at least should last) ut, for those in the US $ 2 illion-a-year industry
eemingly forever.
TAPOREL ELECTRICAL INSULATOR TECHNOLOGY CO., LTD

No.8 Jingwei 10th Road, Jinghe Industrial Zone, Xi'an, 710204, China Tel: +86-29-86031628 Fax: +86-29-86031253 www.xatpr.com E-mail: wuyamin@xatpr.com taporel@126.com
which produces them, the ifferent light. These manu-
nsulator is seen in quite a
acturers regard it as a high-
y-sophisticated component
0 2 INMR Q2 2008
which, notwithstanding its

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A large Product & Technology Exhibition A large Product & Technology Exhibition
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Organized Technical Visits to:
A large substation with widespread anti-pollution measures An insulator test station located directly on the Mediterranean
A wind generation project

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Issue 80 Quarter Two - 2008
Volume 16 - Number 2
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02 Passing of Seraj ul Huda 08 Editorial
Shake-up Ahead for Hollow Core Insulators
Click on Articles or Buttons o f t h i s i s s at bottom u e of page Cover: Ultrasonic testing to verify thickness of silicone sheath on insulators after injection moulding.
Utility Practice & Experience

24 Service Experience & Future Plans for
Line Insulators in Lithuania
30 Case Studies for Reducing Outage Time by

Improved Insulation Practices on Distribution Lines in Portugal
10 Reporting from CIGRE

Assessing Composite Insulators After Service
Insulators
40 Equipment Manufacturer Aims to Boost
Productivity of Insulator Molding Cycle
12 Transient Thoughts
The Little Engine that Could
Arresters
46 HV Arrester Manufacturer Secures Quality by
Extended Testing in Production
14 Ravis Column
Steep-Front Impulse Test for Insulators
50 Externally Gapped Line Arresters:

A Comprehensive Design & Application Review
Bushings
16 Scene from China
From Pollution on Porcelain to Creepage Distance of Composite Insulators
56 Manufacturer See Continuing Growth Ahead

for Bushings Business
Spotlight on China
62 Overhead Line Insulators: A Skyrocketing
Business in China
18 Pigini Commentary
India: Caged Tiger No More?
64 Insulator Supplier Establishes Leading Position

in Chinese Market
20 From the Research View

Need for More Research on New Material Formulations
70 Chinese Insulator Supplier Prepares for Move

into New Factory
Testing
74 Testing Laboratory Builds Business Around
Specialized Capabilities
22 Woodworth on Arresters
Arrester Energy Conundrum
ADVERTISERS IN THIS ISSUE

ABB Components & Insulation Materials Bushings 33 ABB HV Power Products, Arresters Outside Back Cover Areva T&D Passoni & Villa 19 Balestro 37 CSL Silicones 13 DTR Corporation 7 Dalian Insulator 63 FCI Composite Insulator 39 GLP Hi-Tech Power Products 37 Glasforms 7 Hidro Jet Equipamentos Hidraulicos 37 Hubbell Power Systems Inside Back Cover Hubbell Quadri*Sil 27 Isoelectric 15 Klckner Desma Elastomertechnic 9 Maschinenfabrik Reinhausen 43 Maxwell Technologies 11 Nantong Shenma Electric Technology 1 Shaanxi Century Metal Industries 9 Shaanxi Taporel Electrical Insulator Technology 3 Siemens, Arresters Div Inside Front Cover Sun Electric Insulator & Apparatus 9 Tridelta Surge Arresters 23 Vogel Machines & Moulds 21 Volani Metais 7 W.S. Industries 77 Zibo Taiguang Electrical Equipment 17
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f kites during electrical

also explains why the numbers of suppliers in this segment has remained quite small. But all this may now be about to change. One of the firms which offers machinery necessary to manufacture hollow core composite insulators has just announced a new technology for increasing the productivity of the moulding process by up to 30 percent (see article on p. 40). That is a significant change and can profoundly affect the economics of selecting a composite versus a porcelain insulator. At the same time, it makes the business of manufacturing hollow core composite insulators that much more attractive for potential new investors in this segment. Indeed, by all accounts there are already a growing number of firms who are either already committed to enter this business or who are actively evaluating it. More suppliers will lead to more competition, which in turn will mean lower prices, which will invariably result in more sales.
As an observer of the insulator industry for one interesting anomaly has always struck me: the relatively rapid acceptance nce wrote: For want of a of composite insulator technology for transmission lines but their nail, the horseshoefar slower application at the substation level. The comparatively was lost; reason for my surprise is because the advantages of these or want of a horseshoe, weight and improved pollution insulators (e.g. light he horse performance) are equally compelling and perhaps even stronger was lost; for want when it comes to HV equipment. In addition they offer the f a horse, the rider was lost. important added benefit of improved safety for personnel a factor n this simplethat does not reallyhe in decision-making for overhead metaphor, figure line insulators.
torms, Benjamin Franklin,years, almost 20
aptures so
Although the demand for hollow core composite insulators has well the essence increased over the past few years, these types of definitely of how insulators insignifimall, seeminglyprobably still account for less than 10 percent of all such applications, still heavily dominated by porcelain. Whatever ant items canthere has an in polymeric insulator technology applied growth have been at substations seems to have been rather in moulded-on
mportance
o a system
which is
ar beyond
heir per-
eived
Hollow composite insulators seem poised to finally dramatically increase their share of this business.
Even while changes are afoot in terms of improving the productivity of manufacturing composite hollow core insulators, there are also indications that utilities are now preferring and in some cases even insisting on this insulator technology. In Sweden, for example, according to informed sources, all new HV substations within the national grid must now be designed only with silicone-housed equipment. Apparently, the major reason behind this decision is safety. Whatever eventually happens, one thing seems certain. Hollow composite insulators seem poised to finally start to dramatically increase their share of this business.
alue as
such as popular new designs of silicone-housed HV arresters and resin-impregnated paper (RIP) bushings.
ndividual items. components
or many in the electric util-
The the insulator ty industry, explanation that seemed
has for een
een as
to make the most sense for this situation is simple economics. Composite hollow core insulators muchtypically been more expensive than porcelain, particularly at have of its existence voltages below 230 kV. Manufacturers of electrical apparatus such as bushings, arresters, transformers, etc. are extremely sensitive to little price of the insulators they buy, especially so since they the more than an themselves compete in a very cost-conscious utility market.
Although, there relamaterial which costshave been efforts over the years to reduce the price differential between porcelain and composite equipment basic disparity has remained. Manufacturing hollow core composite insulators is a complex and costly process, least should last) involving expensive machinery and high price raw materials. This
ively little yet lasts insulators, the
Photo: INMR
The great scientist and flyer of kites during electrical storms, Benjamin Franklin, once wrote: For want of a nail, the horseshoe was lost; for want of a horseshoe, the horse was lost; for want of a horse, the rider was lost. In this simple metaphor, he captures so well the essence of how small, eemingly insignificant items can have an importance to a system which is far beyond their pereived value as individual items. Shake-up Ahead for Hollow Core Insulators? The great scientist and flyer
Editorial
or at
eemingly forever.
Marvin L. Zimmerman mzimmerman@inmr.com
But, for those in the US $ 2 illion-a-year industry

INMR Quarterly Review I S S U E 8 0 www.inmr.com
ISSN 1198-7332 P.O. Box 95, Westmount (Montral), Qubec, Canada H3Z 2T1 Telephone: (514) 939-9540 Telefax: (514) 939-6151 E-mail: info@inmr.com E d i t o r & A d v e r t i s i n g S a l e s : Marvin L. Zimmerman M a g a z i n e D e s i g n : Cusmano Design and Communication Inc (514) 509-0888 E-mail: corrado@cusmanodesign.com Contents of this publication are protected by international copyrights and treaties. Reproduction of the publication, in whole or in part, without express written permission of the publishers is prohibited. While every effort is made to verify the data and information contained in this publication, the publishers accept no liability, direct or implied, for the accuracy of all information presented.
which produces them, the
different light. These manu0 8 INMR Q2 2008
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Reporting from CIGRE

Assessing Composite Insulators After Service
f kites during electrical Conventional Insulators Assessing
Photo: INMR
by Dr. Frank Schmuck

From the available documents and related work, a possible general test structure can be formulated as shown in Table 1. often quickly identified. The Dye Penetration Test, applied to cut sections of the insulator, shows the integrity of the rod itself and of the interface between housing/rod. Investigation of the Housing is quite challenging because of the complex interaction between housing material and environmental and electrical stresses. Material Analysis, e.g. taking a material fingerprint of new reference insulators, is well-accepted as a means to identify materials and any possible changes of the housing after service. Also Raster Electron Microscope (REM) techniques can be used to check for interface changes (see Figure 1). Accelerated Ageing Tests are costly and time-consuming. For investigating insulator housings, the Inclined Plane Test or Wheel Test appear suitable compromises. Hydrophobicity of the housing is a vital property to prevent housing damage caused by ageing or remedial cleaning, especially for severe pollution service conditions.To quantify contact angle, IEC 62073 offers useful guidance. However, the dynamic behaviour of hydrophobicity (i.e. transfer into pollution layer) is not covered. Ongoing work by CIGRE WG D1.14 on TB 255 examines this property and related scientific research aims at a reproducible test procedure to quantify such transfer within bothun-agedand aged specimens. Outlook Composite insulators after service can have widely different appearance, depending on their generation, design, quality of materials, etc. Because of the large variety in designs, manufacturing methods and materials as well as service conditions, a universally applicable test regimen does not exist.The test methodology should therefore be adjusted according to the status of the insulators. CIGRE WG B2.21 is in charge of preparing a proposal for such a versatile applicable test philosophy.
In the first Reporting from CIGRE, a brief overview torms, Benjamin Franklin, Brochure Guide for the assessment of the Technical of nce wrote: For made of porcelain & pin and long-rod transmission line wantold cap or glass was provided by Working of a insulators Group (WG) B2.03. This was on nail, the horseshoe was lost; based testhaving performed many test series using well-established philosophies from the corresponding IEC standards. Test specimens were insulators in or want of a horseshoe, service from 11 to 45 years. Also within this document, a test he horse procedure wasfor want to determine the status of old was lost; established insulators and to decide on the best time to replace them.
Table 1: Example of General Test Matrix for Evaluating Matured Composite Insulators
Visual Evaluation Evaluation Damage Appearance (CIGRE TB 333) Global Surface Hydrophobicity (IEC 62073) Pollution Analysis (IEC 60815) Mechanical Strength SML/Ultimate Strength (IEC 61109) Load Time Test (IEC 61109) End Fitting Corrosion (Galvanizing: IEC 60383) Electrical Strength Insulator Flashover and RIV/Corona Measurements (IEC 60383) Set Interfaces Housing Boiling & Steep Material Analysis Front Voltage Test (FTIR etc.) (IEC 61109) Dye Penetration Test (IEC 61109) Ageing Test (IEC 60587 or IEC 62217) Hydrophobicity (IEC 62073, CIGRE TB 255)
f a horse, the rider was lost. Assessing Composite Insulators
With regard to composite insulators, there are now applications n this simple metaphor, he
that have had a service period of 30 or more years as well. However, technology, various technical stages occurred in their development. among other things, corrosion-resistant glass fibres within the FRP
it aptures sois well known that, during the evolution of composite insulator
Todays third how well the essence ofgeneration of these insulators is characterized by, of high performing polymeric materials combining hydrophobic
mall, seemingly insignifi- crimp technology and housings made core rod, highly reproducible
Detailed Investigation 1. Visual Investigation Visual Evaluation of insulators serves to formally identify the insulator, its year of manufacture, batch number, etc. and looks at Damage and overall Appearance. This first step is considered very important for the selection of appropriate tests as well as final assessment of expected lifetime. Guidance for qualitative classification of damage or ageing can be found in CIGRE TB 333. Simple visual evaluation of Global Surface Hydrophobicity provides the first information on any possible surface changes. A targeted investigation of any such changes is recommended and, of course, is applied only to housings that are recognized to be hydrophobic because of the material used. Pollution Analysis provides additional information of value, e.g. about the main pollutants, the accuracy of the applied pollution map and the suitability of the insulator design specified (i.e. specific creepage distance, shed profile, etc.) Mechanical Strength Evaluating Mechanical Strength permits verification of whether or not the insulators suffered any reduction in tensile strength. This has been introduced with the revision of IEC 61109 (Edition 2) and can only occur in cases where the damage limit has been exceeded or the rod has suffered from environmental attack (e.g. stress corrosion). Electrical Strength In this example, electrical strength is differentiated into three fields of interest: Measurement of Flashover and RIV/Corona of the Insulator Set is a repetition of the type test and results can be compared to the values obtained before service exposure. If insulator hardware taken from service is included in the test, additional information can be obtained, e.g. whether environmental attack (e. g. corrosion) or damage by power arc have reduced the RIV/Corona performance. Investigation of the Interfaces is considered very important because any reduction of interface integrity, such as loss of bonding, followed by a flashunder etc. is not easily identified. It is well known that the application of prestressing by Boiling followed by numerous Steep Front Voltage stress cycles is a severe test regimen. As a result, any weak bonding between housing/rod or housing/end fitting is
Figure 1: REM-photos of intersection (left) and bulk material (right) at 2000x magnification.
ant items can have an tracking and erosion resistance. behaviour as well as high
These mportance factors have led to a situation where different generations of composite insulators might be installed within a network and from one another. This in turn has created the need for a test when assessing these insulators after service. CIGRE WG B2.21
o a system which is far their manufacturing methods and materials can be quite different
Dr. Frank Schmuck frank.schmuck@sefag.ch
eyond their perceived philosophy and methodology that takes this fact into account
alue as individual items. that TB 306 has been completed. has taken on this task now
or manyDecisive Properties Toutilin the electric Be Tested

The important properties to be tested are determined by the complex than conventional insulators. Typically, composite
ty industry, the insulator insulator, which is generally more construction of a composite een
has for much of its characterized by a number of interfaces, both insulators are existence
macroscopic and microscopic. Examples for macroscopic interfaces include: the interface between housing/rod or between rod/end fitting.Typical an een as little more than microscopic interfaces are: the area formed between glass fibres of different sizes and the resin, as well as radial and axial moulding nert chunk of ceramic areas of the housings manufactured by injection moulding. All these interfaces are critical in determining reliable costs relamaterial whichperformance and this remains the case over the entire expected service life. For example, if the rod/housing interface ively little yet lasts moisture can penetrate and tracking can quickly loses tightness, begin below the housing. Such damage represents an irreversible or at least should last) progress steadily to breakdown failure of sign of ageing and will the insulator. Therefore, in addition to the application of test eemingly forever. standard technical values such as mechanical procedures for strength or electrical behaviour, any suitable test But, for those in the US state-of-the-art of the relevantphilosophy $2 should also assess the interfaces.
illion-a-year industryMethods Overview Of Test

The fundamental idea behind developing a suitable test
which produces them, the philosophy is evaluating well-established test procedures, e.g. as
introduced in nsulator is seen in IEC 61109aduring the 1990s, as well as in more quite recent scientific investigations, e.g. CIGRE WG D1.14.This has the long experience with the test procedures of IEC 61109;
following advantages: different light. These manu-
acturers regard it as of reference results, when new insulators were a high availability
use of new but scientifically precise tests methods to (such as hydrophobicity).
tested in the past; y-sophisticated component
which, notwithstanding properties of modern insulating materials quantify relevant its
elatively simple appearance,

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Editorial
Q2 2008
INMR 1 1
Transient Thoughts
The Little Engine that Could
f kites during electrical my favorite childhood stories was The Little One of
Photo: INMR

There are other interesting effects that can also be obtained with carbon/silicone mixtures. For example, with enough carbon in the bulk material, researchers at Tsinghua University in China were able to reduce the remarkably high surface impedance of a standard silicone coating to a level that was so low as to make it semiconductive.The desirable property of improved contact angle of water droplets was noted as well for the modified material. The carbonloaded silicone coating even changed the way ice builds up on insulator surfaces. The icing test results themselves were almost frightening: with the pollution levels used, a 115-kV system would require eleven or twelve discs to withstand simulated icing conditions rather than the normal six or seven. Clearly, this is an area where effective solutions to icing problems are needed in the short term. While I look forward to news of continuing developments from this work, it will likely take much time for nano-surface and carbon loading investigations to result in successful commercial products. In the meantime and possibly even for years after new products come to market, utilities will continue to use trusted old solutions such as existing types of silicone coatings. This is so partly because these old friends have performed well for years and partly because they have already passed fairly arcane tests, such as the 5000-hour salt fog exposure. Indeed, the inertia behind such a slow adoption process for innovation reflects the conservative nature of the electrical industry.The result is that there will be more uphill struggles ahead for those people, like Seraj Huda, who commercialize new technologies.
Engine that Could, about a small switch engine that torms, Benjamin Franklin, been over the mountain, but still had never managed nce wrote: For want of a to help a train full of toys, dolls and clowns. My father a train enthusiast read it to me many times and, my daughters too now lost; nail, the horseshoe was know the refrain from the end of the story: I think I can, I think I can I thought I could, I thought I could. I was somehow reminded of this story while meditating during the
or want of a horseshoe,
he horse recent funeral servicewant Huda, founder and President of was lost; for for Seraj
Canadian-based suddenly while f a horse, the rider CSL Silicones. Seraj passed away to the national was lost. on a business trip to promote silicone coatings about how Seraj tried to make the world a
electric metaphor, Turkey. n this simple utility company inhe His son Faisal spoke eloquently
better aptures so place. He also noted that his fathers
work to develop insulator coatings was only well the essence of how starting to be understood and adopted broadly by the electric power industry. This mall, seemingly insignifi- brought back my was the uphill struggle that childhood memories of the train story.
ant items can have an
Seraj mportance lived to see the day when glass and porcelain insulator manufacturers began to option. I am sure he was very proud of this
o a system whichcoatings as a factory-installed offer silicone is far eyond their perceived achievement. Unfortunately, he never lived
to see the day in alue as individualhis coatings failedwasservice. I items. know this for a fact since I closely severe pollution and icing environments in Ontario. To my knowledge, industry, the insulator such failures have not yet occurred.
or manyinvolved in electric util- the most in the applying them under
ty
has for much of its existence een
I had been looking forward to working directly with Seraj to test ways to recoat or replenish tired coatings after een as little more than an I five or ten or even more years of service. was privately also hoping to find the nert chunk of ceramic magic silicone finish for my swimsuit that would help me shave a few seconds off my best time material which costs rela- at 100 meters. Sadly, that will not happen now. At least not ively little yet lasts he leaves behind a vital with Seraj. Still, legacy in his company When the or at least should Ilast) and family.co-operate time comes, know they will with me to address the first of these tasks. eemingly forever.
With todays interest in nanometer scale surface treatments to improve insulator performance, the behavior of carbon black surface coatings on silicone is a promising direction for future research.
Im also writing this column on a personal milestone. Ive now been working a full year as contract Professor at the University of Quebec in Chicoutimi and my time here is nearly over. I used this time to prepare and teach a graduate course in lightning protection. It has been a whirlwind experience, meeting staff and students in the very large program - some 60 strong from more than 20 countries, all working in icing and high voltage.
left unresolved in my past discussions with Seraj is finding out why fine particles of carbon illion-a-year can make silicone surfaces better rather than worse over black industry time. This discovery was more-or-less by accident based on field which produces them,plants, first in Hamilton and later at other experience at steel the locations. nsulator is seenSources of this contaminant included dust from coal piles in quite a and also (especially from my own experience) leaks into a transformer substation downwind different light. These manu- from a manufacturing plant for carbon black materials. With todays interest in nanometer scale surface it as a to improve performance (e.g. through acturers regardtreatments highsuperhydrophobic shedding of water drops or through reduced y-sophisticated strength of ice), the behavior of carbon black surface adhesion component coatings on silicone materials is a promising direction for future which, notwithstanding its academic research.
Among the other coating mysteries But, for those in the US $ 2
In addition, along with Masoud Farzaneh, the Chair of the icing studies program here, Ive been working to complete my first retirement project a text on the electrical effects of ice on insulators. This has been a big challenge and we are nearly done. There have been days when 10 pages flowed easily and others when we struggled to complete just one table. Im very thankful for the valuable data, articles, comments and advice received so far from around the world, including many from readers of and contributors to INMR.
Dr. William A. Chisholm W.A.Chisholm@ieee.org

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RAVIS COLUMN
Steep-Front Impulse Test for Insulators
f kites during electrical insulator manufacturers on a regular basis Visiting
Photo: INMR

high enough), insulators can fail internally either in the bulk dielectric or along their various interfaces. The probability of puncture in a steep front test increases with defects and with the steepness of the applied voltage. In principle, even in the case of good insulators, one can keep increasing the steepness of the wave until the insulator will ultimately puncture. In porcelain insulators, internal defects stem from pores and microscopic cracks that are invariably found around quartz crystals. In addition, the heterogeneity of the porcelain formulation creates numerous interfaces between the grains. In glass insulators, inclusions and bubbles can lead to internal failures, although such defects will most likely lead to shattering of the shell before it is attached to the hardware. For composite insulators, imperfections in the fiberglass core rods can arise for various reasons (e.g. voids, impurities, dry fibers, improperly cured resin). A poor rod-housing interface can create air pockets along which breakdown can occur. These imperfections could originate due to poor quality materials or during improper processing of the finished product. So, if this single test answers so many questions about insulator performance, why is it not being more commonly used? The simple answer is cost. Obtaining high values of voltage (i.e. several hundred kV) at such a rapid rate is difficult for many laboratories. Moreover, the test equipment must have extremely low inductance, the grounding has to be good (no ground loops) and the connections have to be made with great care (pipes or braided conductors instead of thin wires).With typically 300-600 kV, one can test suspension porcelain and glass insulators due to their fixed and relatively small heights.
A Composite Insulator Supplier Whose Experience You Can Trust

There are many suppliers today who offer composite insulators. But, when you look at depth of service experience, this list quickly becomes much shorter. Isoelectric has three decades working with power supply companies worldwide to find the best design solutions for their networks.
gives me the unique opportunity to understand torms, Benjamin Franklin, from a number of practical aspects. their business Recently, nce wrote: For the following: if I had toone suchsingle test that yields the want of aduring pick the visit, a young engineer asked me most information on product quality and performance, what would nail, the horseshoe was lost; that be? After due consideration, I replied that it has to be the steepfront horseshoe, or want of aimpulse test. (porcelain and glass) insulators and in IEC 61109 for composite
he horse This test is includedwant was lost; for as a design test in IEC 61211 for ceramic f a horse, the rider was lost. insulators. It is essentially an impulse voltage test, except that the
voltage rises at a much faster rate than used in lightning and switching
n this simple metaphor, hein a lightning impulse test, the voltage impulse testing. For example,
rises zero to the peak in roughly one aptures so fromof a second (1 s).value of a few hundred kVtest, the voltage millionth In the switching impulse the steep-front test, however, the voltage rise
rises to this of value well the essence peakhowover a much longer time frame, i.e. 250 s. In insulators is 2500 kV/s while for composite
time specified in the standard mall, seemingly insignifi- for ceramic
insulators it is 1000 kV/s. ant items can have an
mportance Lightning and switching impulse tests are
usually performed to ensure that the air-gap is useful for insulation coordination of the system (simply eyond theira perceived that less expensive put, process assuring equipment flashes over alue as individual items. first, thereby protecting more expensive equipment). or manyUnless an insulator is grossly defective, arcing in the electric utilis always external to it. This is because air offers lower resistance ty industry, the insulator than the solid insulator dielectric, despite the fact that the has for much of its existenceelectrodes is external air gap between the longer than the electrode separation within een the insulator itself.
o a system whichadequate. This clearance is is far
In the steep-front impulse test, because of the rapidity of the surge, the path of least resistance may be through the body of the insulator and it is said to have punctured.
een as little more than antest, by contrast, In the steep-front impulse
of least resistance may be through the body of the insulator. In this case, the costs relamaterial which insulator is said to have punctured. The ceramic insulator standard calls for five shots of positive polarity followed by an equal number lasts ively little yet of shots of negative polarity. In the case of the composite insulator standard, there are 25 shots of each polarity. For an insulator or at least should last) the test voltage must always result only in to pass, application of external flashover.
because ceramic nert chunk of of the rapidity of the surge, the path
For composite insulators, the length of the sample specified is 500 mm or less and it is not practical to perform this test on longer insulators (such as post insulators). Puncture is not a typical mode of failure unless there is a gross material or manufacturing defect in which case other simpler tests exist to weed these out. My advice to the young engineer was to perform the steep front impulse test on a small sample size whenever making changes in material or component suppliers or if changing process controls even when product design remains unchanged. If the insulator passes this standard test, then increase the steepness until it punctures. Of course, every time an insulator punctures one has to dissect it to establish the root cause. But wouldnt it be the most convincing piece of information to establish if the changes made actually improved performance or not? I would even go one step further and suggest that this test could be used to evaluate the ageing of ceramic as well as composite insulators.
Whether overhead line insulators or substation support insulators, Isoelectric offers you products with demonstrated performance built into every single unit.
eemingly forever.
Breakdown of insulation But, for those in thea critical$(whether solid, liquid or gas) is related to US number of free-charged particles (electrons 2 the availability of and ions) in the space illion-a-year industry between the electrodes at different potential. This critical number is created through an avalanche process whereby energy from the applied electric field and collide with neutral
the few free electrons always which produces them, the present due to cosmic radiation, gain
molecules, in quite a nsulator is seen thereby liberating more free-charge carriers.
different light. These insulation is invariably due to the presence or Puncture of solid manu-
Contact us at both our facilities on two continents. Let us show you how we can help meet your line insulation needs, whatever these may be.
Isoelectric also offers you a full spectrum of epoxy resin insulators, railway insulators a n d h a r d w a r e a s w e l l a s p o l y m e r i c z i n c o x i d e s u r g e a r r e s t e r s u p t o 4 0 0 k V.
creation of gaseous inclusions (e.g. voids, bubbles, defective acturers regard it as asteepness of the voltage wave increases, the interfaces). As the highenergy gained can be sufficient to dislodge y-sophisticated component one can expectsufficient electrons in these imperfections.Therefore, insulators to flashover externally when the voltage which, notwithstanding its wave is rising slowly. But when the steepness increases (and assuming that the voltage magnitude is
Branch Office
Prof. Ravi S. Gorur, Arizona State University ravi.gorur@asu.edu
Brasil
via Lodi, 14 - 26010 Bagnolo Cremasco (CR) - Italy Tel: ++39 0373 23.43.11 Fax: ++39 0373 23.41.65 Web: www.isoelectric.it E-mail: info@isoelectric.it

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Av. Pref. Domingos Mocelin Neto 753 83.420.000 Quatro Barras - PR, Brasil Tel: ++55 41 35541514 Fax: ++55 41 35541473 Web: www.isoelectric.it E-mail: isoelectric@isoelectric.com.br
Scene From China

From Pollution on Porcelain to Creepage Distance of Composite Insulators
f kites during electrical Pollution
Photo: INMR

AC project, the proportion selected was about 85% to 90%. In the case of the projects heavy pollution areas, this proportion was lowered to 75% because insulator section length must be well controlled under such conditions.The required creepage distance for silicone bushings and post insulators have been similarly determined. In this sense, the creepage distance for the porcelain insulator has become a sort of transitional parameter linking the behavior of porcelain at a given pollution severity and the creepage distance required of a silicone insulator. By most logic, this seems unreasonable. Of course, the advantage of this method is that its simple and makes use of all the experience acquired using porcelain. But its disadvantage is also obvious namely that converting creepage distance between the two types of insulators according to some pre-selected proportion seems quite arbitrary. Moreover, since there is no clear rule to standardize this proportion, it can fluctuate across a relatively broad range, i.e. from 75% to 90% or higher. Therefore, it would seem appropriate to look for a procedure to determine a silicone insulators creepage based solely on the expected pollution severity affecting the siliconeinsulator itself. One possible way to do is: (1) determine the silicone insulators pollution severity, (2) collect data on its experience or withstand
The # 1 Manufacturer of Composite Transmission Insulators in all of China

1000 kV insulators on tower located in Wuhan
flashover voltage of an insulator is influenced by many factors, including type of torms, Benjamin Franklin, pollution, wetting conditions (rain or fog), insulator profile, insulator material and voltage applied, nce wrote: For want offactors can make correct dimensioning of a among others. These creepage distance a complex task nail, the horseshoe was lost; for utility engineers. standards have been prepared based on years of collecting and
However, several Chinese or want of a horseshoe, as well as international specifications or
More than 2 million insulators in service worldwide 35 kV to 1000 kV
he horse analyzing operating experience. For most of these standards, the was lost; for want f a horse, the rider wasbeen the same and consisted of a series of creepage distance has lost.
basic principle for establishing the dimensioning of an insulators distinct steps: (1) using a porcelain reference insulator to determine
n this simple metaphor, he or transmission line, (2) comparing pollution severity for a given site
that withstand voltage level aptures so insulators experience or pollution and (3) determining the under the pollution severity established, porcelain and glass insulators have been specified according to this
insulators of how well the essence required creepage for any given profile. Traditionally,
procedure. mall, seemingly insignifidifferent and determining ideal creepage distance is not quite so clear.
In regard to silicone ant items can have anrubber insulators, however, the situation is
mportance insulators are known for their superior pollution performance Silicone
The creepage distance for a porcelain insulator has become a sort of transitional parameter linking the behavior of porcelain at a given pollution which is severity and the creepage distance required of a silicone insulator.
more perceived eyond their years. Yet there is still no clear methodology to determine suitable creepage distance for them based on pollution conditions.As pollution severity collected on a porcelain insulators surface. This and huge quantities of these have been in use for from 10 to 20 or voltage under that pollution level, and (3) determine its ideal creepage distance.The problem, however, is that the first step in this process is very difficult. Pollution severity is classically described only by the pollution on a porcelain insulator according to all previous and present standards, e.g. IEC 815-1986, the new revised IEC 60815-1 and other national standards. It is almost impossible to plot a new pollution map based on pollution collected only on silicone insulators.And its equally unlikely to imagine utilities being in a position to plot two pollution maps simultaneously. Therefore, a second possible way would be as follows: (1) determine the porcelain insulators pollution severity, (2) calculate the silicone insulators pollution severity accordingly, and (3) determine the silicone insulators creepage distance based on its operating experience and pollution withstand voltage level. The most important step in this procedure is of course the second one, i.e. calculating the silicone insulators pollution severity based on the pollution affecting the porcelain insulator. The pollution accumulation ratio between silicone rubber and porcelain insulators could for example be obtained by measuring the pollution on both types of insulator in the same or in similar locations.This should not be too difficult since both types of insulator now have plenty of operational experience to draw on. Clearly, it seems a more reasonable methodology to transition from knowing the pollution affecting a porcelain insulator to selecting the ideal creepage distance for composite insulator installed in that service location. In any case, its obviously superior to the present arbitrary method of creepage distance conversion.
o a sys-
em
ar
alue as individual items. silicone insulators still depends on the a result, the creepage of most
or manyseems to make little sense since its obvious that a silicone insulators in the electric util-
creepage should ideally be on the expected pollution severity ty industry, the insulator based porcelains. collected on its surface and not
has for much of its existence een
een as
From the late 1980s to the beginning of the 1990s, silicone rubber insulators began their first trial use throughout China. The only available method for selecting creepage distance at the time was simply adopting that of an little more than porcelain based on how porcelain insulators behaved under the applicable pollution levels. Now, silicone insulators have been in widespread use on Chinese
material which costs rela-time. Both 500 kV HVAC and 500 kV power systems for some
HVDC being country for ively little yetsilicone insulators are alreadysiliconeused in thiswill account lasts almost a decade. And, most recently, insulators for about two-thirds or at least should last) of all suspension insulators for Chinas first 1000 kV AC line now under construction and planned to be in operation by eemingly forever.the end of this year. was: first of all to determine the required creepage distance for
Zibo Taiguang Electrical Equipment Factory Shandong Taiguang Electrical Equipment Company Limited
Address: Changguo East Road, Zhangdian District, Zibo City, Shandong, P.R.China Website: www.taiguang.com Contact Export Department: Tel: (86) 533 2888604 Fax: (86) 533 2888604 Mobile: (86) 139 5333 2212 E-mail: chinazbtg@vip.sina.com Regional Offices: Australia Tel: (61) 7 3826 6000 Fax: (61) 7 3826 6066 E-mail: ppearce@thew.com.au Middle East Tel: (962) 6 4389334 Fax: (962) 6 4389337 E-mail: khaldoun.victoria@gmail.com Brazil Tel: (55) 11 4161 6649 Fax: (55) 11 4168 6269 E-mail: duilio@eletrofittings.com.br Greece Tel: (30) 26510 49750 Fax: (30) 26510 67589 E-mail: kemco_ioannina@hotmail.com
The process for determining the But, for those in the US $ 2 creepage of these silicone insulators
illion-a-year industry the pollution map (plotted based on pollution porcelain according to
severity affecting porcelain insulator surfaces); and secondly produces them, the required creepage for silicone insulators converting this into the based simply on taking some proportion of the level for porcelain.
which
This proportion has not been different light. These manu- a strict value but rather has varied
acturers
anywhere from 75% to 85% in most cases and up to 90% or higher in other cases. For example, for regard it as a high- medium pollution areas of the UHV
Prof. Liang Xidong, Tsinghua University lxd-dea@tsinghua.edu.cn
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Pigini Commentary
India: Caged Tiger No More?
f kites during electrical past 30 years I was fortunate enough to Over the
Photo: INMR

Obviously, such rapid growth will affect the Indian insulator industry, which will also require innovation in order to comply with the stringent and even extreme requirements of UHV transmission. The present insulator market in India is estimated at about USD 250 million (i.e. about one-tenth of the total world market) with an expected market increase of about 10% per annum. Domestic production at the moment is focused mainly on porcelain insulators for EHV applications and this market is served principally by six local porcelain insulator manufacturers. However, glass insulators (imported into India) appear to be increasing their penetration for transmission lines of 765 kV and higher. Usage of composite type insulators in India is still very low. The new UHV applications will require more research and development activity by this industry so as to: Develop insulators having higher mechanical strength, i.e. 320 kN and beyond as necessary for UHV; Be capable of producing insulators specifically designed for UHVDC and with total creepage distances which, depending on
visit India many times.This long perspective gave torms, Benjamin Franklin, me the opportunity to closely follow its progress, which nce wrote: supplywant offor years has been slowedto sustained and For of power an essential ingredient by limitations in a the rapid economic growth. nail, the horseshoe was lost; energy in order to keep pace with its increasingly world-class
India horseshoe, or want of a is in many respects acaged tiger. It desperately needs more
he horse scientific and technological communities. Those communities was lost; for want f a horse, the to the higher standard of living their level of innovation country rider was lost.
promises. must then have the infrastructure they rely on in order to lift the
n this simple metaphor, he
At time of my during the 1980s, the total installed aptures so the in India wasfirst visit50 GW (more or less the same as that power close to of China at the how well the essence of time).This came to the shocking figure of less than 50 watts per person. Looking at 2008 data, the amount of installed power in China has
mall, seemingly insignifi-
increased by about 15 ant items can have an times while the increase in India has been
mportance
Rapid growth o a system which is far
will affect the Indian insulator industry, which will require innovation in order to comply with eyond their perceived alue as individual items. the stringent requirements of UHV transmission.
only some three times. The Indian growth rate, however, is now is expected to be added over the next few years with a targeted application, may be well beyond 30 meters. Such insulators will have to offer creepage factors as high as possible, while also offering designs resistant to accumulation of contamination and at the same time having the dielectric strength required under the given pollution something that is no easy task; Be able to match demanding electrical requirements (i.e. very long insulator sets) with equally demanding mechanical requirements; Improve insulator quality in order to assure maximum reliability for very strategic UHV transmission systems, e.g. those carrying up to 6 GW per single circuit; Develop alternative solutions (e.g. composite insulator designs) that will be ideally suited for certain applications and service conditions, in particular UHVDC. Presently, the export of insulators from India is around 30% of total production, with station insulators representing the major category. The necessary growth in local R&D and application experience will probably also offer an opportunity for Indian suppliers to increase their share of the world market. Meanwhile, imports of insulators into India, especially for transmission lines, can also be expected to increase.
or many in the electric util-
changing. insulator ty industry, theFor example, an additional 80 GW of generation capacity
has for much of its existence be reached in about fifteen years. installed capacity of 600 GW to een
This rapid growth in generation will mean a parallel growth in transmission and distribution systems. In particular, present een as little moresystems in India are dominated by the 400 kV level, than an transmission with about 1600 km of nert chunk of ceramic 765 kV lines, 60,000 km of 400 kV lines and 220,000 km of 220/132 kV lines. In addition, there are three HVDC bi-poles costs relamaterial which and seven HVDC back-to-back links under operation. Projections indicate the need for some 35,000 km of new lines over the next lasts ively little yet five years. This will require enormous investment.
or at least should last) Beyond the strengthening of the EHV transmission system, there
will also be the need for UHV transmission lines, since primary eemingly forever. i.e. coal and hydro potential, are concentrated in energy resources, only a But, for those few areas. the particular, coal deposits are confinedlocated in the In country while hydropower potential is to the US $ 2 eastern portion of in the industry illion-a-year north eastern and far northern parts far from the main demand centres.Therefore, new development will include aSuper Gridwith them, the which produces implementation of 800 kV UHVDC and 1200 kV UVAC technology, expected to be among the most advanced in the world.
The new UHVDC lines will be necessary to transmit tens of GW the distant Himalayas to consumption centres in the west through the so-called chicken acturers regard narrow a highneck a it as and congested corridor between Bhutan and Bangladesh. The first 2000 km 800 kV UHVDC system will be y-sophisticated componentIn parallel, development of 1200 kV implemented by 2011-2012. UHVAC lines will be its which, notwithstanding initiated to transmit bulk power interregionally.
different light. These manu-from to connect hydropower
Alberto Pigini alberto.pigini@ieee.org alberto.pigini@areva-td.com

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From the Research View

f kites during electrical experience with composite insulators Long-term
Photo: INMR
by Dr. Stanislaw Gubanski
Need for More Research on New Material Formulations

moulds or by laser treatment. Preliminary research in this field has already shown encouraging results. In parallel, it will also be important to better understand the conditions governing release and production of LMW siloxane oligomers on silicone rubber surfaces. These are the primary source of the encapsulation of contamination particles and therefore for hydrophobic recovery of the surface. Among the other types of base polymers potentially able to secure superior hydrophobicity over PDMS are fluorosilicone compounds. However these are much more expensive and the question of material cost is of course very important when considering new types of fillers. Imparting a super-hydrophobic property onto insulator surfaces could also help increase resistance to biological fouling something which otherwise may need to be achieved by otherwise modifying the material with special fillers, e.g. zinc borate (ZnBO3). Different types of anti-fouling additives could also be used. However, we do not know if these types of additives might influence the long term ageing of such new material formulations. This way the circle of interactions becomes closed, i.e. future development of composite insulator technology will be dependent on obtaining reliable material modification through optimized quantities of high-quality fillers and additives. To be able to answer all of the above types of questions, new research activities will have to be initiated and supported by manufacturers of materials as well as their users. In addition, reliable testing methods will need to finally be standardized.
having different designs and made from new torms, Benjamin Franklin, types of housing materials has led to superior manufacturing techniques. At the same time, new nce wrote: For want of a materials have helped improve performance in the field. Yet the ongoing need better cope nail, the horseshoetowas lost;with service conditions continues to create further challenges ahead for the insulator industry. Silicone rubber is today by far the most widely used type of housing
or want of a horseshoe,
he horse for composite insulators. It will continue to maintain dominance of was lost; for want
this technology may f a horse, the riderin the future, although certain modifications such was lost. prove necessary. The main interest in this respect will relate to the material under diverse and special stress conditions; and 3. resistance to biological fouling.These issues, while seemingly require a multidisciplinary approach by scientists and engineers.
considerations as: 1. better understanding ageing mechanisms of n this simple metaphor, he
2. aptures sopreservation and recovery of the hydrophobic surface properties;
well the essence of how different, cannot be treated separately they are interrelated and
mall, seemingly insignifi-
composite mportance
principal interests today is applications of insulators for DC transmission, which is gradually being introduced more and o a system which is far more to the worlds electric power systems. DC stress imposes new requirements on eyond their perceived material properties. is improving
As regards ageing mechanisms, one of the ant items can have an
alue as individual items. Another growing area
field distribution and permit optimal design of high voltage apparatus. ty industry, the insulator In particular, obtaining required levels of electrical has for much of itsand dielectric response is conductivity existence important. This can be achieved by een incorporating new types of fillers and additives into the silicone een as little moreItthan foreseen thatrubber an formulation. is also nanofillers may prove advantageous. (For a more nert chunk of ceramic detailed description of this concept, readers are advised to see the material which costs rela-column in INMR Vol.14, No.3).
or many materials so as to better control electric in the electric util-
Future development of composite insulator technology will depend on obtaining reliable material modification through optimized quantities of high-quality fillers and additives.
ively little yet lasts
How all these new types of fillers, additives and required or at least shouldaffect long-term performance of changing wetting last) agents will silicone studies, involving variations in material composition and in applied
eeminglycompositions is unknown.This means that multi-parameter ageing forever. illion-a-year fillers can also New industry
Todays intense activity in this regard by CIGRE Working Group D1.14 provides hope that an adequate testing methodology will be proposed within a short time frame. The official document of this Group (CIGRE technical brochure No. 255) pointed to the important properties, including minimum requirements for polymeric materials used for housings, core rod and other structural elements of outdoor composite insulation. It also listed, where applicable, the standardized test methods that should be applied in each case.
stress in the US $ 2 But, for thosemust continue worldwide.
influence the hydrophobic properties of silicone. In nature, the self-cleaning properties of plant leaves, bird which produces them, the wings of certain insects, is due to fine feathers and the bodies and microstructures. In insulators, nsulator is seen in together with the it is the interaction of such a quite a microstructure roughness of the polluted surface and the These manudifferent light. inherent hydrophobic properties of low molecular weight PDMS (polydimethylsiloxane) species that contribute to the selfcleaning it as a silicone acturers regardproperties ofhigh- housings. Efforts should therefore be undertaken to make more use of this phenomenon to create y-sophisticated component even better hydrophobicity. For insulators characterized by example, a properly patterned insulator surface could result in sowhich, notwithstanding its a property that can be obtained by called super-hydrophobicity elatively adding special fillers, by micro-machining of surfaces in casting simple appearance,
For those properties not yet covered by appropriate standards, various test methods have been proposed. Today, these are being evaluated through extensive engagement by research laboratories worldwide. Frank Schmuck, Convener of this Group, wrote more about this recently (INMR Vol.16, No.1). When these testing procedures are finally ready, much work will need to be done to evaluate the usefulness of the various material compositions. We therefore have good reason to hope they will exhibit even better properties than the material formulations presently being used.
Prof. Stanislaw Gubanski, Chalmers University of Technology stanislaw.gubanski@chalmers.se
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Woodworth on Arresters
Arrester Energy Conundrum
in contradiction to seeking the better arrester. For a gapped-type MOV arrester which has significantly better (lower) discharge voltage, a joule energy rating is altogether inadequate. Progress CIGRE WG A3.17 met in Switzerland this past March and reviewed recent progress on work being done at Darmstadt Technical University to resolve this issue. It appears that the Klaus Ringler Energy Handling Equation, as published in a 1997 IEEE Transaction, has been reconfirmed however with surprising new findings using the 200 s lightning discharge impulse. Also, for the first time impulse degradation has been quantified usingVref. From the discussion, clear definitions of the two well-known energyhandling characteristics began to emerge. Both of these definitions were described in a CIGRE paper presented in Brazil in September 2007. I believe that at the Swiss meeting, it was realized for the first time that these new definitions needed to be integrated into the standards to resolve the conundrum. The two types of energy ratings discussed were Thermal Energy Absorption Limit and Single Impulse Energy Adsorption Limit. The Thermal Energy Absorption Limit is defined as the maximum level of energy injected into an arrester at which it can still cool back to its normal operating temperature while energized. The Single Impulse Energy Adsorption Limit is the energy in joules (current density or amp seconds) and duration of energy injection required to permanently damage the arrester. The damage can be at a macroscopic or microscopic level and, in either case, is measureable using Vref. These two characteristics need clear definitions and both should ideally be used to describe arrester energy handling capability not just one or the other. Rest of the Solution If such a two-part definition is accepted, then developing the tests to measure these characteristics would not be difficult. However, the unit of measurement still needs to be accepted. I have for years been proposing to specify or classify an arrester by the energy it absorbs instead of the charge it transfers, which I feel is not the correct measurement.The industry need to eradicate the joule rating from the solution to this energy handling issue. Specifier and Manufacturers Responsibility To resolve the energy handling issue, specifiers will need to adopt new specification methods that provide more information about the energy handling needs. In particular these will require a new section that describes the injection duration. Manufacturers will also need to adopt new specification procedures and not continue to respond to what I see as the incorrect joule-rating question. The Solution The eventual solution will then have new definitions of energy handling, new test procedures and new specification procedures. Once this occurs, it will also become imperative that all of the above be incorporated into IEC and IEEE standards as quickly as possible.
could offer the solution to the issue of arrester energy handling. But the best I can do is offer torms, Benjamin Franklin, of the conundrum and a bit of good a clarification news on nce wrote: For want of aprogress toward a solution. This issue of energy handling capability has been brewing for more than 10 years now yet we still was have a nail, the horseshoe do not lost; clear path ahead. Groups of arrester experts are working on it in Europe as well as in North America, so or want of a horseshoe, a reasonable resolution this year. perhaps we can come to
f kites during electrical I I wish
he horse The Issue for want was lost;

Engineers responsible for specifying arresters on power f a horse, the often need to know how much energyusedarrester can rider was lost. systems an
Unfortunately, no unified measurement of this characteristic has yet been set forth by the industry, so its not possible for users to easily compare arresters aptures so from different suppliers. It seems amazing that after more than a well the essence of how application to power systems, this 100 years of arrester characteristic has still not been adequately identified.
handle during normal operation. n this simple metaphor, he
mall, seemingly insignifiSurge Types
Many Dimensions of ant items can have an the Problem energy on a power system to earth and at the same time limit
The mportance fundamental function of an arrester is to transfer accumulated energy transfer, the arresters react to the energy input differently
o a system which on protected insulation. During the process of this voltage stress is far eyond their perceived based on energy waveshape and duration. Lightning events affect
Energy Limits
the arrester differently than alue as individual items. switching events.
or manyTherethe two types of util- overload limits but no accepted in are electric energy
limit is related to the thermomechanical impulse withstand of the arrester. All electro-ceramic material has a limit beyond which thermal mechanical failure or serious degradation may occur. Influence of Specifier
definition ty industry, thethat differentiates after whichfirstcannot operate to the insulator them. The it limit is related stably temperature of the arrester
while of its existence has for much energized. The second
een
een as little more than an
nert chunk of ceramic Those who specify arresters usually only ask for energy in joules.
Seldom is the duration of the surge specified making a realistic
material which to the specification impossible. response costs rela-
ively little yet lasts Measurement Methods

Manufacturers have devised a variety of ways to define and test some in three pulses, others do not define their method at all. Unit of Measurement
or at least should last) energy handling capability. Some measure the energy in one pulse,
eemingly forever.
But, for thoseisin the US $ 2 industry as to whether charge (amp There little agreement in the
seconds), current (amps), or energy adsorption (joules) should be illion-a-year industry the unit of measurement for durability. Each unit of measure has
its own positive and the which produces them, negative attributes. Neither IEC nor IEEE standards effectively address the subject of discharge tests, operating duty test and the latest lightning but in my view fall short.
Standards nsulator is seen in quite a
energy These manudifferent light.handling capability. High current tests, transmission line
acturers regard testas attempt to address the durability measurement, discharge it all a highConflicting Characteristics in joules, an arrester with a higher discharge voltage will have a higher energy rating. This is
y-sophisticated component
Jonathan Woodworth jwoodworth@arresterworks.com
which, notwithstanding its If energy absorption is measured

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UTILIT Y PRACTICE & EXPERIENCE
Service Experience & Future Plans for Line Insulators in

Figure 1: New and prospective interconnections of the Baltic transmission grid.
The company owns and operates a transmission grid consisting of 110 kV lines (4970 km in length and with 229 substations) and 330 kV lines (1670 km and having 12 substations). This company-controlled transmission system is interconnected by four 330 kV electric lines with Latvia, five with Belarus and three with Russia. One of the main objectives of the utility is the integration of Lithuanias power system into the Western European electricity market along with the development of related regional co-operation.
finalized and a joint application to the EU for funding drafted. Capacity would be about 700 MW and the estimated cost of the project (line and back-to-back converter, excluding the wind farm) would be about Euros 400 million.
Ageing Transmission System

Traditionally, some Euros 40 million are invested annually in the Lithuanian transmission grid. But this will not be enough over the coming 20 years, because most development of this grid took place during the 1970s. About 70% of network components and equipment will reach the end of their estimated service lives within only a few years (see Table 1). Currently, one 330 kV substation and about 7 to 8 of the 110 kV substations are being refurbished or reconstructed every year.
Interconnections With Neighboring Countries

A. Estonia Finland (Estlink) On December 4, 2006, two 105 km long undersea 150 kV DC cables connecting Estonia and Finland were inaugurated. Electricity trade via the cable started on January 4, 2007 with a capacity of 350 MW. Lietuvos Energijia is a shareholder in this project. B. Poland Lithuania Future expansion of the Lithuanian transmission grid is planned by interconnecting it with the Polish system. This interconnection project is of immense importance for the development of an integrated EU electricity market and for the improvement of reliability in supply. The interconnection will become a gate from the Baltic Electricity Market to the markets of the European Union. In fact, the EU has designated this Lithuania Poland power link a priority project eligible for financial support. The interconnection, a 1000 MW 400 kV double-circuit line with a backto-back converter, will have a total cost of some Euros 430 million. C. Sweden Lithuania (Swindlit) By utilizing the common capabilities of the power systems of the Baltic States, establishment of a Common Baltic Electricity Market is foreseen something which will be needed for successful integration of the Baltic States into the electricity markets of Western Europe and the Nordic countries. Swedish companies SEK, SwedPower and Airicole proposed taking part in a new project to link an offshore wind farm in the Baltic Sea with the Swedish and Lithuanian grids. The pre-feasibility study has been
Based on statistical research, the biggest annual number of failures on both 110 kV and 330 kV overhead lines within the Lithuanian transmission grid occur because of insulators.
of dust build up from an extended dry period with prolonged early morning fog. Visual inspection and analysis of flashovers revealed the main reasons behind such failures (see Table 3). About 50% of outages due to weather and climate have been insulation (porcelain and glass) related. Glass and porcelain insulators have shown similar levels of reliability and failures in service on transmission lines in Lithuania while, up to now, silicone insulators have been operating without any reported failures.
Transmission Network Development (2007 to 2016)

Over the next 10 years, there are plans to build three new 330 kV overhead lines (Klaipeda-Telsiai, Musa-Panevezys and Vilnius-Neris) as well as a new 330 kV substation. Moreover, there are also plans to erect three new 110 kV lines, six new cables and 14 substations, five of which will connect wind generation plants to the countrys transmission grid.
ituated in northern Europe, Lithuania is the largest of the Baltic states with a climate dominated by marine influences and a broad range of temperatures from as low as -35 C in winter to as high as +30 C in summer.
Because of a growing electricity demand as well as an ageing network infrastructure, the countrys main transmission operator, Lietuvos Energija, now faces important decisions regarding new lines and how best to equip them from an insulation point of view. This article, contributed by Vidmantas Grusas, Director of the Electric Grid Department, looks at historic service experience with insulators on the Lithuanian overhead power grid and the factors driving future decisions for these components.
Overhead Transmission Line Failures

Insulation, as one of the key elements affecting overall system reliability, plays an important role in all interconnecting as well as internal transmission lines in Lithuania. Therefore, historic service experience with different kinds of insulators is considered valuable information for future decision-making. Based on statistical research, the biggest annual number of failures on both 110 kV and 330 kV overhead lines within the Lithuanian transmission grid occur on insulators which have flashed over (refer to Table 2). These flashovers are thought to be triggered by surface tracking resulting from early dew formed because of sharp variations in temperature between day and night, especially at the turn of each season. In particular, flashovers have been found to result from the combination
Countermeasures Against Failures

While the large majority of overhead lines in Lithuania are still insulated with porcelain and glass, the past five years have seen a growing interest in composite insulators as a countermeasure against flashover (Fig. 7 depicts this growth). At present, silicone insulators are used mainly in the western coastal parts of the country. Service experience in many countries worldwide has demonstrated that installing silicone composite insulators is among the most effective means to resolve flashover and maintenance problems on overhead lines. In this regard, over the past
Introduction
Lietuvos Energija is the main company in Lithuanias electricity sector functioning as the owner of the countrys transmission grid (110 & 330 kV), as well as system and market operator with the following responsibilities: Maintaining and developing the national transmission system; Ensuring a balance between electricity production and consumption as well as electricity transmission from Lithuanian power plants to the various distribution companies; and Coordinating the operation of Lithuanias power plants to guarantee reliable electricity supply to consumers and, together with neighboring power systems, being involved in electricity export, import and transit. Lietuvos Energija is also one of the constituent parts within the parallel power systems of the Baltic States, Russia and Belarus and manages energy flows vital to meeting both industrial and domestic needs. The mission of the company is having reliable and efficient transmission as well as a stable power system.
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Service Experience & Future Plans for Line Insulators in Lithuania
Q2 2008
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FIGURE 2: FUTURE TRANSMISSION NETWORK DEVELOPMENT IN LITHUANIA.

five years Lietuvos Energija has been assessing the self-cleaning properties of such insulators on its 110 kV lines. So far, this work has confirmed these benefits. As a result, the utility supports greater application of composite insulators, i.e. the silicone rubber variety, as a means of improving the performance of insulation of its overhead lines under conditions of pollution. At the same time, these types of insulators are gradually also being used in clean or light pollution areas due to their light weight, which makes transportation and installation less costly. In general, the main factors determining choice of insulators are: contamination level of the area; climatic conditions; nominal voltage; clearances between wires and ground; insulator load. Specification of insulators by Lietuvos Energija therefore includes many of the main parameters of the transmission grid and environmental conditions (Table 4). Aside from these specifications, the choice of insulators used on the Lithuanian transmission grid is based on the following: 1. Electrical construction regulations, (Lithuania, 2001);
2. IEC 60071 Insulation coordination; 3. IEC 60815 Guide for selection of insulators in respect to polluted conditions; 4. IEC 61109 Composite insulators for a. c. overhead lines with a nominal voltage greater than 1000 V definitions, test method and acceptance criteria; 5. IEC 61466 Composite string insulator units for overhead lines with a nominal voltage greater than 1000 V Part 1 and 2: Standard strength classes and end fittings;
Table 1: AGE OF EXISTING TRANSMISSION NETWORK EQUIPMENT Overhead Lines

Voltage (kV) 330 110 Length (km) 1670 4970 Number (units) 30 339 0-20 20% (6) 13% (45) Age (years) 20-40 53% (16) 61% (207) 40-60 27% (8) 26% (87)
6. IEC 61462/TR2 Composite insulators Hollow insulators for use in outdoor and indoor electrical equipment Definitions, test methods, acceptance criteria and design recommendations. 7. IEC 61952 Insulators for overhead lines. Composite line post insulators for more than 1000 V. 8. IEC 62217 Polymeric insulators for indoor and outdoor use with nominal voltage greater than 1000 V General definition, test methods, and acceptance criteria. 9. IEC 62231 Composite Station Post Insulators for substation with voltage greater than 1000 V up to 245 kV Definitions, test methods and acceptance criteria.
Cable Lines
Voltage (kV) 110 Length (km) 21 Number (units) 10 0-20 100% (21) Age (years) 20-40 40-60
Substations
Voltage (kV) 330 110 Number (units) 13 221 0-20 33% (4) 18% (38) Age (years) 20-40 59% (8) 68% (144) 40-60 8% (1) 14% (29)
Figure 3: Example of vandalism on Lithuanian power network.
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Table 2: Failures on 110 kV & 330 kV Overhead Lines in Lithuania

Towers Wires Insulators 2001 Flashovers Mechanical Failures Other 8 19 0 1 2002 4 7 22 1 2 2003 3 7 14 0 0 2004 11 11 47 2 1 2005 5 11 23 2 0 2006 4 8 22 1 0 Average per Year 4.5 8.7 24.5 1.0 0.66
Figure 5: Distribution of transmission line insulators in Lithuania: by type.
flashovers and various other maintenance problems. Given these findings, the operator of the Lithuanian transmission grid has commissioned research to obtain greater information about the application of silicone insulators on its 330 kV lines as well.
Table 3: Analysis of Flashovers (2001 to 2006)

Reason for Flashover
Fire Surface tracking Environmental impact Trees Birds Construction Montage Ageing Vandalism Design Total
120000 100000 80000 60000 40000 20000 0
110383
Quantity
5993 Glass insulators strings Porcelain insulators strings
1601 Silicone insulators
Conclusions
1. The application of silicone rubber insulators on the Lithuanian 110 kV transmission grid has already resulted in a significant decrease in flashovers as well as lower maintenance cost compared to porcelain. 2. Glass insulators are to be replaced by silicone rubber insulators only on problematic lines. 3. The short-term development plan for the Lithuanian transmission grid includes a number of new 330 kV and 110 kV lines. Therefore, the choice of a proper type of insulator has become increasingly important. 4. New 110 kV lines are to be equipped with composite
Figure 10: Examples of silicone insulators used in Lithuania.
Successful Re-closure
1 170 6 9 71 3 1 2 27 290
Unsuccessful Re-closure
15 21 29 4 3 1 31 2 106
Successful & Unsuccessful Re-closure

1 185 27 38 75 3 4 3 58 2 396
Figure 6: Failures after unsuccessful re-closure of lines: 2001-2006 3 2,5 Figure 4: Example of bird-triggered outage.
Failures (100 km OHL)
2 1,5 1 0,5 0
2001 1 2002 1 1 2003 1 1 2004 2 3 2005 1 1 2006 2 1
c. purchasing cost; d. maintenance cost; e. actual cost of failure. Table 5 shows this calculated value for Lithuania (in USD) for porcelain, glass and silicone insulators on 100 km of 110 kV lines (based on an expected lifetime of 40 years). Based on the data in Table 5, silicone insulators demonstrate a lower life cycle cost than porcelain but almost the same as glass. Still, silicone insulation is the most appropriate choice since it also allows resolving
Porcelain 1 Glass
Maintenance & Service Experience

The Lithuanian transmission grid employs a variety of diagnostic procedures to monitor the condition and ageing of insulators, depending on type: a. In the case of porcelain discs, a live line high voltage voltmeter is used to measure the voltage across each disc in a string. A voltage profile is drawn and the number of electrically-sound porcelain discs is determined; b. In the case of glass discs, if the shell is intact, the disc is considered to be both mechanically and electrically sound. Visual inspection is therefore the main method of assessment for glass insulators; c. In the case of silicone insulators, visual inspection is also the main method of assessment. Infrared thermography is used to check the presence of hot spots on insulators, which could indicate heating from excessive leakage current. Corona cameras are not yet available. All insulators used on the Lithuanian transmission grid are visually inspected from the ground every year. In addition,
all types of insulators, poles and wires are inspected once every six years with the lines dead. Based on experience so far, the application of silicone rubber insulators on the 110 kV overhead network in Lithuania has brought two main benefits: a. An improvement in network reliability; b. Significant savings on insulator acquisition, maintenance and line construction costs. As a result, all Lithuanian utilities have been eager to explore new approaches as a means of ensuring an even higher quality of power supply. Change of insulators is usually carried out on lines out of service. Well developed Lithuanian transmission network allows doing that. The real life cycle cost (LCC) of insulators is basically the sum of three main components:
insulators due to their lighter weight, slim design and superior reliability. 5. The Lithuanian transmission grid has just started to investigate the application of composite insulators to its 330 kV lines. 6. Reliable methods of evaluating the condition of silicone insulators in service and safe mounting of these insulators under live conditions have become increasingly important considerations for Lietuvos Energija.
Figure 7: Growth in composite insulators on Lithuanian transmission grid.
Table 4: Main Parameters of Glass & Silicone Insulators

1.800 1.600 1.400 1.200 1.000 800 600 400 200 0
1.601
No. 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15.
Quantity
1.023
524 203 2003 2004 2005 Years 2006
Requirements Equipment manufacturers must be certified by ISO and present the copy Standard Ambient conditions Electric withstand to pollution according to IEC 60815 for medium level Maximal continuous voltage of network Neutral of network Rated frequency Lighting impulse withstand voltage Withstand voltage in rain (50 Hz, 1 min.) Specified breaking mechanical load Creepage distance Diameter of shell Spacing Couplings according to IEC 60120 Contamination level
Glass Insulators ISO 9001 IEC -35 - +50 C 2 123 kV Earthed 50 Hz 100 kV 40 kV 70/120 kN 303 mm 255 mm 127/146 mm 16 A II
Silicone Insulators ISO 9001 IEC -35 - +50 C 2 123 kV Earthed 50 Hz 550kV 230kV 80/120 kN 3870 mm 1340 mm 16 A II
Table 5: Life Cycle Cost of Different Insulators for 100 km of 110 kV Lines in Lithuania
Cost in USD Purchasing Maintenance Failure Total: Porcelain 311,538 1,489,231 931 1,801,700 Glass 311,538 104,615 507 416,660 Silicone 342,308 104,615 0 446,923
Figure 8: Example of thermography of tower and insulators.
Figure 9: For maintenance and repair, terrain vehicle platforms (left) and special line gear have been used.
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UTILIT Y PRACTICE & EXPERIENCE
Case Studies for Reducing Outage Time by Improved Insulation Practices On Distribution Lines in Portugal
equipment failures involving insulators, spark gaps and grounding. Because of this, it was felt that there existed many opportunities to reduce outage time by improving insulation practices.
Figure 1: Equivalent interruption time of installed capacity on MV network (2000 to 2005).
standards imposed regarding expected service quality. While EDP Distribuio has met those required standards, areas were nevertheless identified where there still existed possibilities for continued improvement. In this regard, an extensive program was launched in 2003 having as one of its main objectives reducing the outage time by improving insulation practices. The project included a comprehensive investigation of the insulation coordination philosophy on both MV and HV lines as well as at substations. Evolution over a six-year period of the parameter Equivalent Outage Time of Installed Capacity on the MV network (or, using the utilitys designation, TIEPI MT) is shown in Fig. 1. This chart illustrates the success achieved since TIEPI MT has dropped by more than 50%.
program aimed at analysing and improving the performance of its distribution network. As part of this process, a significant number of outages were discovered to be related either to environmental factors (e.g. lightning, pollution and birdlife) or to
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TIEPI MT*
700 600 500
minutes
626 454
400 300 200 100 0
419,9
369,54
215,36 184,17
ENVIRONMENTAL CONDITIONS AFFECTING THE NETWORK

The isokeraunic level (Td) in Portugal ranges from about 3 to 24 days. The corresponding ground flash density is relatively low and on the order of 0.16 to 2.1 flashes/km2/year comparable to most other countries within Europe. From a birdlife point of view, there is a significant presence of white storks throughout the country and a study was conducted in 2004 to characterize their nesting population. Since this species became protected, efforts to deal with their impact on overhead networks have been coordinated
n recent years, the Portuguese
utility, EDP Distribuio, has devoted much effort to a
2000
2001
2002
2003
2004
2005
Several background studies were made of overhead line performance from the perspectives of lightning, pollution and birdlife. Similarly, laboratory tests of insulators were carried out in order to evaluate the basic lightning insulation level to be used for equipment on the network. This edited article, contributed by Antnio Oliveria Chaleira of EDP Distribuio and Pedro Nunes of associated testing facility, Labelec, summarizes the findings of this evaluation. It also discusses individual case studies highlighting the improved insulation co-ordination methodology now being adopted by the utility.
Distribution System Operator (DSO) responsible for the distribution of electrical energy throughout Portugal. The system voltage levels are 132 and 60 kV (HV network) and 30, 15, 10 and 6 kV (MV network). In 1999, the first steps were taken toward liberalization of the electricity market in Portugal, with high
Table 1: Insulation Levels for HV and MV Lines at EDP Distribuio

VOLTAGE LEVEL [kV rms] STANDARD HIGHEST VOLTAGE STANDARD SHORT MINIMUM FOR EQUIPMENT DURATION POWER LIGHTNING CLEARANCE [mm] [kV rms] FREQUENCY IMPULSE WITHSTAND WITHSTAND VOLTAGE [kV rms] VOLTAGE [kV PEAK] 72.5 36 17.5 12 140 70 38 28 325 170 95 75 630 320 160 120
INTRODUCTION
EDP Distribuio, created in 2000 by merging four separate regional distribution utilities, is now the
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Table 2: Pollution Performance Requirements for Insulation in Portugal

POLLUTION LEVEL Medium Heavy Very Heavy MINIMUM NOMINAL SPECIFIC CREEPAGE DISTANCE [mm/kV] 20.0 25.0 31.0
Table 3: Electrical & Dimensional Characteristics of Cap & Pin Insulators Used by EDP Distribuio
REFERENCE MAX SPACING CREEPAGE DIAMETER [mm] DISTANCE [mm] [mm] MINIMUM ELECTROMECHANICAL FAILING LOAD [kN] 40 70 100 100 WITHSTAND VOLTAGE
POWER LIGHTNING FREQUENCY, WET IMPULSE, DRY [kV rms] / UNIT [kV PEAK] / UNIT
A40 U70BS U100BS U100BLP
200 255 255 280
110 127 127 146
210 295 295 445
35 40 40 50
95 100 100 110
Table 4: Electrical & Dimensional Characteristics of Pin-Type Insulators Used at EDP Distribuio
REFERENCE SIDE NECK CREEPAGE MINIMUM GROOVE DIAMETER DISTANCE ELECTRORADIUS [mm] [mm] MECHANICAL [mm] FAILING LOAD [daN] 12.5 73 600 1000 WITHSTAND VOLTAGE
POWER FREQUENCY, WET [kV rms] LIGHTNING IMPULSE, DRY [kV PEAK]
R-85 Vertical axis R-102 Vertical axis R-85 Horizontal axis R-102 Horizontal axis
85
170
12.5
73
690
1000
102
200
12.5
50
420
1000
85
125
12.5
50
650
1000
102
145
Figure 2: Example of concrete pole in MV network.
Figure 4: Cap & pin insulator (A40).
Figure 6: Cap & pin insulator (U00BS).
Figure 3: Example of steel lattice pole used in MV network.
Figure 5: Cap & pin insulator (U70BS).
Figure 7: Cap & pin insulator (U100BLP).
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between EDP Distribuio and various nature conservation groups. With climate change, such storks, which used to migrate in winter to warmer countries, now tend to remain in the same location all year. As a result, their population has been growing steadily as has their impact on the overhead network.
with 50, 90, 160, 235 and 325 mm2 nominal cross sections. However there are also cases where copper conductors are still in service. A considerable diversity of insulators can be found on distribution lines in Portugal. Historically, EDP has used porcelain insulators cap & pin as well as pin-type. However glass cap & pin insulators are now being put into service on a large scale since with these it becomes easier to identify cracked/shattered units. It is also felt that they offer superior performance in contaminated areas. On HV distribution lines, the standard configuration consists of using a six-unit insulator string with spark gaps. In the case of MV lines, there are usually two or three cap & pin insulators and pin-type insulators having a vertical (R-70, R-85 and R-102) or horizontal (RH-55, RH-85 and RH-102) axis. The characteristics of these various insulators used by EDP Distribuio are presented in Tables 3 and 4. Together with its testing unit, Labelec, EDP Distribuio carried out tests in order to characterize the basic lightning impulse insulation level (BIL) of all various insulators string combinations (2, 3 and 4 insulators with and without spark gaps) as well as for pin type insulators. Figures 12 to 15 show these insulators under lightning impulse testing.
Figure 16: TIEPI and outages for the Carrascal-Coruche 60 kV line (2002-2006).
Significant investments, especially in 2003 and 2004, were carried out to improve the performance of this line. Figure 17 shows the correlation between TIEPI MT, the number of outages and these various preventive and corrective maintenance investments. Figures 18 and 19, respectively, indicate the corrective and preventive maintenance actions carried out between 2002 and 2006. The major investments affecting this line basically involved: Installing new 7 unit glass insulator strings (U100BLP) with spark gaps due to the heavy pollution environment of the line (see Figure 20) Relocating stork nests or installing alternative nesting sites on separate platforms.
Figure 8: Pin insulator (R-85).
Another environmental concern, given that Portugal is a maritime country with an 1800 km long coastline, are flashovers due to sea salt carried by dominant north-westerly winds and depositing on insulators. In addition, industrial pollution, bird excrement and sprayed agriculture fertilizers are additional sources of contamination.
EQUIPMENT CHARACTERISTICS
Insulation coordination practices followed by EDP Distribuio for its HV and MV overhead lines are in accordance with usual international norms. The standard power frequency and lightning impulse withstand voltages as well as required clearances for most of the utilitys overhead lines are shown in Table 1. Pollution performance requirements for outdoor insulation in Portugal, as followed for medium and heavy pollution levels, are described in Table 2. Most HV and MV overhead lines within the network of EDP Distribuio are mounted on concrete or lattice steel poles. Shield wires are used only in the case of HV lines. In addition, at present EDP Distribuio uses mainly aluminiumsteel and aluminium alloy conductors
Figure 9: Pin insulator (R-102).
the assessment phase, a number of problematic HV and MV lines were identified where corrective measures were required to improve performance in regard to lightning, pollution and existing birdlife. Several such case studies are reported below. Improvements in the performance of these lines is shown together with the corrective measures that were taken to achieve this. Line performance is evaluated according to reported outages as well as TIEPI MT, as recorded in the utilitys Outages Management System (OMS) database.
mounted on concrete poles. This circa 32 km long line runs from Carrascal Substation, near the Tejo estuary (a protected birdlife area) to Coruche Substation located in an agricultural region with many rice fields. Figure 16 depicts the reduction in TIEPI on this line between 2002 and 2006 as a result of investments made in 2003 to find and implement better insulation practices. The major cause of recorded outages affecting the Carrascal-Coruche line was identified as related to surrounding birdlife, in particular stork nests. Table 5 provides a summary of relevant OMS Database records from 2002 to 2006.
CASE STUDY B: PINHO-SABROSA LINE

Pinho-Sabrosa is a 105 km long single circuit 30 kV line equipped with 160 mm2 cross-section conductors on the principal line and 40 and 50 mm2 cross-section conductors in branches mounted on concrete poles. This line is located in northeast Portugal, at the upper margin of the Douro River and the surrounding area is mountainous (about 500 to 800m above sea level). Isokeraunic level (Td) is about 15 to 16 days per year. Figure 22 shows the trend for TIEPI MT for this line from 2001 to 2006 and its correlation with the numbers of outages. The decrease is directly related to investments aimed at applying the best insulation practices as identified in the study. The principal source of outages identified as affecting TIEPI MT on this line involved damaged equipment, mainly pin type insulators, aluminium-steel conductors and jumper connections. The investments carried out to solve these problems included:
REDUCING OUTAGE TIME BY IMPROVING INSULATION

A major program targeting outage time reduction has been underway at EDP Distribuio for the past five years. During
CASE STUDY A: CARRASCAL-CORUCHE LINE

The 60 kV Carrascal-Coruche Line is a single circuit line equipped with 325mm2 cross-section conductors
Figure 10: Pin insulator (RH-85).
Table 5: OMS Database for Carrascal-Coruche Line (2002 to 2006)

YEAR 2002 CAUSE OF OUTAGE OUTAGE UNKNOWN CAUSE BROKEN INSULATORS OUTAGE UNKNOWN CAUSE NEST ACTIVITY NEST LIGHTNING BROKEN INSULATORS NEST ACTIVITY MAINTENANCE OUTAGE UNKNOWN CAUSE OUTAGE UNKNOWN CAUSE MANEUVERS TIEPI [MINUTES] 7.92 6.04 6.25 2.35 0.09 0.13 3.4 0.14 0.8 0.16 1.34 1.57 N OUTAGES 17 1 11 16 1 1 1 2 4 2 2 1
2003
Figure 11: Pin insulator (RH-102).
Figure 12: MV insulator string under test.
Figure 13: HV standard insulator string being tested.
Figure 14: Pin insulator under testing.
Figure 15: Testing MV insulator string.
2004 2005 2006
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Figure 17: Correlation between TIEPI, investments and number of outages.
TIEPIMT [minutes]
Figure 20: Concrete pole mounted with tension insulator string using 7 glass insulators (U100BLP).
Figure 18: Corrective maintenance actions (2002 to 2006).

Corrective Maintenance Actions Visual Inspections 32.9% 49.4%
Replacing old SiC surge arresters by zinc oxide types; Replacing the earth electrodes on pole top transformers; Installing automatic circuit reclosers. It was observed that in 2006, especially in July, a significant number of outages occurred due to lightning. These would certainly have resulted in a higher TIEPI MT had no such investments been made. In fact, in spite of the adverse atmospheric conditions, the TIEPI MT for this line that year was just 2.22 minutes the lowest in seven years.
I Visual Inspection - no actions I Visual Inspection - insulators replacement and 2 stork nests removed I Visual Inspection with ultrasounds: 2 broken insulator and 23 nests in 16 poles
17.7%
Figure 19: Preventive maintenance actions (2002 to 2006).

Preventive Maintenance Actions SM - Systematic Maintenance CM - Conditional Maintenance
3.5%
12.8% 6.2%
I SM - Visual Inspection - no actions I SM - Termography I CM - Insulators and nests I CM - Others
77.5%
Figure 21: Pole top transformer on Pinho-Sabrosa line.
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Figure 22: Overhead line TIEPI MT and number of outages (2001 to 2006).
CASE STUIDY D: S. MARTINHO DO CAMPO PIDRE 2 LINE

The 23 km long 15 kV So Martinho do Campo-Pidre line is a single circuit line mounted on lattice steel poles and located in the north of Portugal where isokeraunic level (Td) is about 15 to 18 days per year. The line is located in a semi-urban/rural area crossing agricultures areas such as vineyards, forest with fast growing trees (eucalyptus) and industrials areas (stones manufacturers) where insulators pollution contamination is present. Figure 24 presents the TIEPI MT evolution from 2002 to 2006 and the correlation with number of outages.
A line inspection was carried out allowing identification of the most relevant issues affecting performance of this line. Figures 25 and 26 present examples of identified weak points in line insulation on MV poles such as very heavy pollution sites and flashover marks on insulators. The remedial investments carried out on this line included: Replacing conductors by aluminium-steel with crosssections of 90 and 160 mm2; Reinforcing line insulation; Installing automatic circuit reclosers.
whose goal is improving insulation coordination on HV and MV overhead distribution networks. One of the more important of these is related to a new standard lightning impulse withstand voltage of 250 kV for MV overhead lines due to the occurrence of line tripping related to induced overvoltage flashover. Also the application of polymeric insulators is growing and EDP Distribuio is actively considering this alternative. Currently some test applications are in place, e.g. the experience with polymeric line posts for support of jumper connections is being evaluated. Furthermore, the utility is considering new technologies such as UV corona detection to allow for more efficient identification of punctured or shattered insulators.
This is seen as an important step toward the improvement of preventive maintenance planning.
FURTHER DEVELOPMENTS
Currently, EDP Distribuio is involved in several international task forces
CASE STUDY C: MONTEMOR-CIBORRO LINE

The 30 kV Montemor-Ciborro line is a 105 km single circuit line with 90 mm2 cross section conductors mounted on concrete poles and located in southern Portugal. The isokeraunic level (Td) is about 12 to 15 days per year. The surrounding area is mainly flat rural land with significant agriculture and cattle ranches. In 2001 and 2002, birds were the main contributors to the numbers of outages as well as to TIEPI MT (3.93 minutes in 2001 and 6.37 minutes in 2002). Several remedial measures were taken to reduce the adverse impact on this line of the regions large population of storks. One example of this involved using concrete poles with a nest platform and installed parallel to the line (see Figure 23). As a direct result, TIEPI MT was reduced to 2.7 minutes in 2005 and to 2.22 minutes in 2006 (these times also include preventive maintenance work).
Figure 26: Insulators with flashover burns.
Figure 23: Example of reducing impact of stork nesting.
Figure 25: Very heavy pollution affecting line.
Figure 24: TIEPI MT and number of outages (2002 to 2006).
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I N S U L ATO R S
Equipment Manufacturer Aims to Boost Productivity of Insulator Molding Cycle
Today, says Gerhard Mais, customers in the electrical equipment industry are looking for more standardization. Therefore, it seems only natural that suppliers of manufacturing equipment, such as ourselves, should increase their focus on the issue of productivity. Mais is General Manager of Swiss-based Vogel, a subsidiary of the Hedrich Group with some 250 employees and other manufacturing operations in Germany and China. Vogel specializes in clamping machines as well as dosing equipment and molds for producing silicone insulators, particularly the hollow core type. Hedrich, a supplier of customized production lines for casting epoxy as well as vacuum impregnation and drying of transformers, acquired Vogel in 1995 and has watched this business expand rapidly since that time. Managing Director Ralf Hedrich explains, the high voltage sector is now growing very fast for us and at a much higher rate than we ever expected. And we still see even more opportunities for further expansion, especially in places such as China and India.
uring the past 15 years, the number of manufacturers of composite long rod insulators for overhead line applications has literally exploded. By some estimates, there are already some two hundred such firms scattered throughout the world mainly in China. Yet, surprisingly, during this same time interval, the number of suppliers of hollow core composite insulators has remained more or less the same little more than a handful.
Because customers in the electrical equipment industry today are looking for more standardization, it seems only natural that suppliers of manufacturing equipment should increase their focus on the issue of productivity.
most economical and also the most productive from an equipment utilization point of view. Rainer Rder, a former executive with one of the worlds leading suppliers of
hollow core composite insulators and now a consultant to Vogel, agrees. Says Rder, today, some ninety percent of all hollow core insulators are required by customers in only a narrow range of different diameters, creepage distances and shed geometries typically a single shed versus an alternating shed design. All this contributes to growing emphasis on standardization and more efforts to enhance productivity in manufacturing. Another variable of the different manufacturing processes for hollow core composite insulators is attachment of the end flanges. Mais and Rder note that flange specifications are today the most variable element of the product requirement specified by an individual customer. In one production technology, the silicone housing is molded over the tube prior to attachment of flanges. In the second technology, the flanges are glued to the tube before the molding step.
Left: Mold section ready for use (right) in insulator production. Bottom: Modern machining center for mold production.
It is hard to know for certain whether this unusual situation developed because the demand for hollow core composite insulators was relatively small. Or, alternatively, whether this comparatively low demand was due to the fact that only a small number of suppliers were actively promoting this technology. Whatever the case, there are efforts now to make the manufacturing process for hollow core (as well as other types of polymeric components) far more productive something which is expected to expand the number of suppliers and potentially also significantly increase their market penetration. INMR visits a Swiss-based supplier of production equipment for insulators and looks at a new technology intended to increase productivity by shortening the molding cycle.
Pistons provide necessary clamping force to mold during injection and vulcanization of silicone.
Photo: INMR
Photo: INMR
Mais reviews the alternative production methods available for manufacturing hollow core composite insulators. These range from the most common, i.e. molding the entire unit in a single injection shot, to various other methods of casting, extruding or gluing the unit shed-by-shed over the hollow FRP tube. He concludes that the single injection process is by far the
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Injection molding machine for hollow core insulator in process of being assembled. According to Rder, the second production method is preferable from an electrical performance point of view. I am sure that this is how most hollow core insulators will be manufactured in the future, he predicts. Mais explains that one of the factors behind Vogels success has been that they were among the first to offer production equipment in this category, going back to 1985. Over those years, he notes that the size requirements of hollow core composite insulators have continued to grow. He also remarks that this fact has driven efforts to develop ever larger molds allowing an insulator to be produced in as few molding injection shots as possible. The less shots, the better, he emphasizes, because there are less potential problems of adherence and also fewer interfaces to deal with. Basically, the most economical and effective way to produce such insulators, except for units having extremely long lengths, is in only one shot. 4 2 INMR Q2 2008
Mais notes that clamping force is typically one of the determinants of the capabilities and cost of molding equipment. We designed our equipment with 160 tonnes of force, he says, which is a sufficiently high value when looking at the requirements for molding hollow core insulators. Lower clamping force equipment is a less expensive solution, but not one that we feel is optimal over the long run. Mais points out that the typical size of one of Vogels molding machines is 2.65 meters which allows a 230 kV insulator to be molded in a single injection shot and a 500 kV unit in only two shots. But, he says, to enhance productivity, a 3.5 meters machine is now going to be offered which can hold two molds side-byside. Mais also states that Vogel molds offer the potential for different block lengths so as to better adjust to the dimensional requirements of the insulator within a single molding machine. But the innovation that Vogel is now actively promoting to the insulator industry worldwide relates not to molds
or to the molding machine but rather to the silicone material and how it is treated as part of the injection cycle. Referred to as advanced vulcanization technology (AVT), this patented process is based on technology originally developed by Hedrich and used for casting epoxy. Mais explains that this technology is based on pre-heating the silicone material using hot water to increase its reactivity and thereby lower molding cycle times. The end result is that, with exactly the same equipment resources, the manufacturer can produce more insulators each day. The silicone used in manufacturing composite insulators is normally processed at room temperature, says Mais. The heat required for vulcanization is then added in the mold, usually by electrical heating to about 80C. But, he adds, if a way can be found to pre-heat the silicone before filling the mold, cycle time will be reduced and cooling down after molding can take place during the normal waiting period.
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Dosing and metering system for two component LSR
mold is less, lower clamping force is necessary to resist the pressures typically built up during this process. Winter goes on to explain that LSR is ideal for this application because of its low viscosity and because of its reactivity, meaning that it does not cure excessively fast something that would not be desirable. He also notes that the specific LSR formulation being used in AVT technology is an especially low viscosity material, close in some respects to RTV2 and specially-adapted for this process. This low viscosity also ensures consistent void free filling of the mold. Says Winter, it is not easy to produce such a low viscosity LSR while still keeping good mechanical properties as required from the insulator performance point of view. But there are techniques and expertise originally used for RTV2 which we have found can then also be applied to LSR. According to Rder, the majority of hollow core composite insulators being manufactured today are made with LSR versus high consistency rubber (HCR). He claims that LSR is ideal for this type of an insulator since high-pressure during molding, as would be required with an HCR silicone, risks causing distortion to the critical flange-tube interface, assuming the flange has been
attached before the molding cycle. Another advantage of LSR, claims Rder, is a lower risk of trapped air as might be found in a thick, pressed HCR material. He and Winter state that, beginning from the original formulation of RTV2, LSR has now accumulated the most service experience for hollow core insulators and for this reason is preferred by European-based users. Rder observes that each insulator manufacturer basically has to decide what is the ideal material for the application. And, he adds, this is often a question of superior processability during manufacturing. He also goes on to note that when comparing LSR to HCR, what matters most from an economic point of view is price to
Photo: INMR
volume and not the price to weight ratio. Mais agrees. For us as a machine builder, he remarks, low viscosity is preferred since it makes for an easier and superior overall molding process. AVT technology is now being offered either as a stand alone technology incorporated into any new dosing and molding equipment from Vogel or as a retrofit to existing such equipment, even if from a different supplier. Mais estimates that the incremental investment cost of this technology is about 20-25 percent of usual production line costs. Yet he points out that for those manufacturers faced with the need to increase output by 30 percent due to growing market demand, AVT gives them a solution where this can be accomplished without the need to buy another molding machine. From the quality perspective, Mais and Rder indicate that there is absolutely no difference in final product performance. Says Mais, AVT is only an issue of productivity. So far, Vogel has identified that the types of components which can benefit most from this productivityenhancing technology include hollow core composite insulators and siliconebased cable accessories such as joints and stress cones. The reason for this is that the volumes of silicone material being molded for these tend to be far greater than for other types of insulators. Says Mais, the larger and
thicker the component to be molded, the greater the relative benefit of AVT. For example, a 145 kV hollow core composite insulator can require about 8 liters of silicone material to be molded compared to only about 0.5 l needed for manufacturing a typical composite long rod. Applying AVT therefore translates into much greater productivity gains, i.e. 30-40 percent for the hollow core versus about 20 percent for the long rod. Looking to the future, Mais expects that the market for silicone insulators will continue to grow in many substation applications. He mentions live tank
Mais and Rder emphasize that the pre-heating of the rubber is done preferably using hot water versus electrical heating which is far less efficient when it comes to rapid cooling. This is especially important when looking at insulators having larger tube diameters. With our new technology, says Mais, each section of the mold is water-heated and then water-cooled. The maximum temperature normally encountered during molding is then about 110C since beyond this there is a risk of exceeding the usual tg or glass transition temperature of a standard tube. One of the keys to AVT technology is the physical properties of the housing material used which, in this case, is a very low viscosity liquid silicone rubber (LSR) formulation. Hans-Jrg Winter, a technical specialist with Wacker Chemie in Germany, explains that silicone is a material which has low thermal conductivity. This means that heat transfer through the silicone material is slower and becomes a limiting factor in determining the time normally required for molding. By starting off with an LSR pre-heated to 80C (versus the more normal room temperature i.e. 20C), he says that vulcanization can proceed more rapidly. Also because the expansion from the incremental heating in the
For those manufacturers faced with the need to increase output by 30 percent due to growing market demand, AVT gives them a solution where this can be accomplished without the need to buy another molding machine.
breakers as one piece of equipment where thicker tubes are required and where there has already been considerable positive experience with composite insulators in place of traditional porcelain. With this anticipated growth will come more needs for molding equipment to produce such insulators. Indeed, this expectation has already driven the decision to build an entirely new Swiss plant to replace the existing Vogel facility, which is now operating at capacity. Says Mais, we are quite confident that AVT will prove successful in the marketplace since it provides something every insulator manufacturer wants to realize these days enhanced factory productivity. In this respect its a highly desirable add-on from the customers point of view. Rder underlines this sentiment by stating that he is now in discussion with a growing number of new manufacturers, even in such distant places as India, who intend to offer hollow core composite insulators incorporating AVT production technology.
Photo: INMR
New AVT equipment
Higher temperature of silicone results in reduced curing time and increased productivity of injection molding equipment.
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ARRESTERS
New test area at Ludvika plant allows impulse testing up to 245 kV and 10 kA.
HV Arrester Manufacturer Secures Quality by Extended Testing in Production

In the electrical industry today, there has been a systematic movement away from dependence mainly on national standards and instead toward reliance on common international standards. The major forces behind this trend have been the growing level of internationalization of this industry as well as the universal drive to reduce costs. Manufacturing electrical components to meet special requirements imposed by various local standards almost certainly results in shorter production runs, less purchasing efficiency and increased unit costs. Surge arresters too have recently been going through development of more such common international standards a process that generally combines the input of suppliers, users and independent testing laboratories. However, one of the problems has been that the definitions of how tests are to be performed within these new standards have not always been consistently interpreted. Among the suppliers that have tried to influence this process towards a more uniform type testing is ABB High Voltage Products one of the worlds largest suppliers of arresters for HV applications. INMR visits ABB in Ludvika and reports on how production of arresters and blocks has been organized around more testing than usually required within the industry.
ccording to Gunnar Persson, one of the problems faced by suppliers of HV surge arresters today is that the required performance during the type tests can be interpreted in different ways.
Gran Torshage, Product Manager for HV arresters at ABB, takes a similar view and explains that the hallmark of the arrester strategy at ABB is to offer extra value through, among other things, higher quality and more reliability. He sees this as the logical business response in a marketplace where customers are demanding more and more. Being an arrester supplier today is not easy, he sighs. For example, there is now a tendency for customers to require longer warranty periods, sometimes up to 10 years. In the face of this trend, Torshage says that ABB is working mainly on qualityrelated issues which impact service performance. We would like the user to realize, he says, that when they
Our customers usually ask for testing according to either IEC or IEEE. But, the problem begins when the test requirements can be interpreted in different ways.
Persson says that ABB participates actively on various standards committees for arresters. In his role as Technology Manager, he sees a growing need to better define testing criteria so as to make these more consistent from one supplier to the next. In their specifications to us, he remarks, our customers usually ask for testing according to either IEC or IEEE. But, the problem begins when the test requirements can be interpreted in different ways. This, we feel, has been a traditional problem which needs to be addressed at the grass roots level. For example, one of the areas where Persson notes that ABB is actively working to improve the standard is in regard to mechanical stresses in service as applicable to modern arrester designs.
Photo: INMR
All major steps from pressing of metal oxide power (left) to sintering cycle in tunnel kiln (center) to energy injection testing (right), are fully automated.
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If you want to have good availability of the network, arrester quality is important.
Production of porcelain-housed HV arresters continue to decrease in relation to polymeric designs.
case if only residual voltage is being measured. By testing at a higher level, we also get better statistical profiles of our products. For this same reason, we also conduct ageing testing on every batch of blocks to ensure consistently high quality. Torshage goes on to say that every block receives its own ID code after passing the energy test and as such becomes fully traceable. ABB claims to be the only European-based arrester manufacturer that produces its own varistor blocks, covering all IEC classes Torshage sees this as representing an additional opportunity to implement this quality-oriented philosophy. Indeed, according to Peter Hidman in Product Development, block manufacturing in Ludvika has gone through a significant change over recent years as the entire process has become almost fully-automated. Says Hidman, quality tends to increase the more automatic handling there is. With our current production arrangement, we rely mainly on robots and conveyor systems. No one handles the blocks until visual inspection and final packing. Hidman also notes that unlike other block manufacturers who rely on batch kilns, all sintering
at the Ludvika plant is made using a tunnel kiln, which he claims is superior for any such continuous production process. According to Torshage, some 75 percent of the HV arresters now being manufactured by ABB in Sweden are silicone-housed units a significant change from only five years ago when he estimates this proportion was only about 40 percent. Moreover, he expects this figure will probably rise to about 85 percent over the coming five years. While porcelain housings will probably never go away completely, he says, the growth today is mainly in the polymeric designs. The main driver for this change appears to be the issue of safety. Says Torshage, "the polymeric HV arrester design now being offered by ABB, consisting of fiberglass loops and belt windings, ensures the electrical and mechanical performance, both during normal service conditions as well as in the rare event of an arrester overload. These considerations apply even to accessories such as surge counters. For example, notes Torshage, we are pushing for these types of accessories to also be short-circuit tested since, from the issue of safety, it is the counter to which personnel are most exposed.
Another of the areas where ABB is trying to offer improved value added is in the area of reducing the environmental impact of its packaging. To this effect, Torshage says that recycled materials are used whenever possible to replace wooden crates, especially for orders from customers located within Europe. Torshage and Persson indicate that all these recent changes fall within the overall strategy of higher quality and more valued added for customers. Still, they see that it is the area of testing which most contributes to improved product performance in the field. For this reason, they are working within the international committees to drive arrester standards even higher. The trick for us, says Persson is to put more effort into products and processes than is required to simply meet the minimum requirements in the present standards. Ultimately, it all boils down to a power quality issue. If you want good availability of the network, arrester quality becomes very important.
Photo: INMR
After energy test, blocks are sent to arrester assembly or packed for shipment to other ABB plants.
specify our arrester, they are also buying improved safety, reduced environmental impact and better overall product performance. ABB performs a routine series of energy injection shots on every single block during the course of production. While this is not strictly required in the standards, we do this to ensure that all blocks manufactured are without any inherent defects as might be the Molding polymeric housing
Photo: INMR
Packaging of ABB arresters relies more and more on recycled materials.
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ARRESTERS
EXTERNALLY GAPPED LINE ARRESTERS
Background
The name externally gapped line arrester comes from the IEC TC37 Maintenance Team 4 activities. About 2001, the Japanese and the French National Committees introduced externally-gapped arresters as a new work item for MT4 to deal with. After several meetings, the acronym EGLA was adopted to give this style of arrester easier reference. Also, the term line was added since this arrester is most often applied for protection of distribution and transmission lines. As of April 2008, IEC TC37 MT4 is still actively working on a test standard for this design of arrester. The EGLA has been in use worldwide at many different line voltages and appears to find greatest usage in Japan, Korea, China, France, Italy and Brazil.
A COMPREHENSIVE DESIGN & APPLICATION REVIEW T

he externally gapped line arrester (EGLA) optimizes the positive characteristics of the oldest arrester design component a series gap and the newest arrester design component, namely the metal oxide varistor (MOV). Combining these two yields a significant improvement in line protection and reliability options for electric utilities. However due to the negative characteristics of gapped technology when used in series with earlier silicon carbide (SiC) arresters, the EGLA sometimes experiences problems with acceptance.
Figure 2: Fundamental components of the EGLA.
Application Overview
The most common application for these types of arresters is the protection of lines. If used on a transmission line, they can be dimensioned so they do not operate when a switching surge is present but rather only conduct when a lightning surge appears. Applied on a shielded line (with an overhead ground wire) and where the arrester is used primarily to mitigate back-flashover of insulators, they can be dimensioned to be quite small since the energy handling requirement is not as demanding as for unshielded lines. When applied to unshielded lines, the EGLAs size may need to be substantially larger to handle 100 percent of the lightning current. In all cases, application requirements drive the dimensioning of the arrester. It seems unlikely that this arrester will ever evolve to the point where it can be used to protect equipment unless there is a breakthrough in gap technology that eliminates front-ofwave sparkover issues. Such FOW issues are of course not applicable for the protection of self-restoring line insulation.
This article, contributed by Jonathan Woodworth, aims to clarify the differences between the two alternative line arrester technologies and to outline the fundamental characteristics that make this design attractive for so many line protection applications.
EGLAs in use on transmission line in Hong Kong.
Figure 3: Example of gap from circa 1960s era SiC arrester.
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Externally Gapped Line Arresters A Comprehensive Design & Application Review
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with 80 other gaps at 500 volts each. This degradation was repeated 80 times in the 40 kV arrester and is due entirely to the follow current experienced during the service life of the arrester. Such degradation, however, does not occur in newer generations of EGLA since only lightning current passes through the gap. Therefore, the gap performance of an EGLA will not be compromised over its lifetime due to the fact that its MOR component eliminates the damaging follow currents experienced in by old SiC gapped arresters.
achieving the lowest possible residual voltage per unit length of an MOV disk is reduced. Disks with higher residual voltage per unit can be used without compromising the overall margin of protection offered. 3. Reduced Volume of Housing Material With as much as 30 percent less creepage distance and 30 percent shorter MOV material, the volume of the housing material could be as much as 50 percent lower than a standard un-gapped line arrester. 4. Reduced Ageing of the Housing Another significant aspect of having a gap in series with the MOR housing is that ageing due to electrical stress will be virtually non-existent. Because there is no resistive dry band arcing on the surface of the housing, degradation should never be experienced due to this phenomenon. Moreover, the thickness of the housing could be reduced since there will also be no radial stresses. 5. Reduced Ageing of the MOV Material Metal oxide blocks found in the newest generation of arresters typically exhibit hardly any ageing due to advances in formulation and manufacturing process. However, these non-ageing formulations have come at a relatively high cost. It is possible that varistor block formulations for an EGLA could made more cost effective. 6. Zero Watts Loss This desirable characteristic in all HV equipment is inherent in the EGLA. Un-gapped arresters have both internal and external leakage currents. While the total losses are not substantial on a unit basis, if multiplied by the millions of arresters in service, the cost does add up. 7. Energy Handling Since the MOR is in series with a gap, there is no voltage across it during
Design Benefits of Series Gap

1. Reduced MOR Housing Creep Distance Figure 4: Difference in the power follow current through SiC series gapped arrester and newer generation EGLA. Since the MOR is in series with a gap, the voltage drop across the MOR and its housing during steady state operation is virtually zero. The most significant effect of low electrical stress on the MOR is that the housing does not need to have the same characteristics as a standard arrester, i.e. because of low long-term stress, the creepage distance of the MOR can be reduced. Since the MOR insulation is only called into duty during the 100 microsecond surge, it is possible that sheds are not even necessary. 2. Reduced Number of MOV Disks Another significant benefit of the series gap is that the MOR can have a reference voltage 20-30 percent lower than the direct connect arrester design. The reference voltage need only be high enough to fulfill its function to switch off the arrester after the surge has passed. This means the turn on voltage of the MOR can be just a few percent above the system voltage it will experience whenever the gap is effectively shorted during the surge. A lower reference voltage translates into fewer MOV disks or at least less MOV material. A second impact of potentially lower Vref is that with a shorter stack of disks, the resulting residual voltage will be lower. This means the longstanding and difficult goal of
steady state operation. This means that immediately following a surge event in an EGLA, the MOR is not required to withstand system voltage as in the case of an un-gapped arrester. Since there is no power frequency voltage stress across the MOR, it does not need to exhibit thermal stability as is the case in an un-gapped design. The limit of energy handling is determined only by the single impulse withstand capability, not by its thermal stability limit. It follows that, without thermal stability being an issue, disks of smaller dimensions may be used for this application. Because the energy handling capability of the EGLA is not a function of the joules adsorbed (as it is for un-gapped arresters), the only realistic means of measuring energy handling capability is by considering the charge transfer in coulombs or amp seconds. 8. TOV Withstand A historical shortcoming of un-gapped MOV arresters has been their sensitivity to power frequency swings. This was not a major issue for earlier generation SiC arresters because their internal gaps were often set to turn the arrester on at greater than 1.5 pu of system voltage. This capacity is again possible for the EGLA type of arrester and the gap setting can therefore make the arrester untouchable from most TOV events on a power line. 9. Surge Selection A unique and useful design feature of the EGLA is the option to design it so that it will not operate in the presence of a switching surge but only in the presence of a lightning surge. This has never been an option in earlier arrester designs (except those with external gaps). Since the gap is solely responsible for turning the arrester on, its gap distance determines at which voltage this occurs. If it is adjusted to a level just above the worst-case switching surge, it will only sparkover for a lightning surge. This also has an
Fundamental Design Review

The EGLA has two basic components as shown in Figure 1: the MOR and the gap. The MOR is a non-linear metal oxide resistor and has roughly the same characteristics as a standard MOV arrester. The gap is generally a single air gap in series with the arrester. It is important to note that each component of the EGLA is significantly different from earlier gapped arresters.
By contrast, the gap of an EGLA is used only for initiating an operation not ending it. Instead, the MOR has assumed this function of ending the surge. Due to its superior nonlinear characteristics, the MOR has also eliminated a very negative attribute of the series gap known as follow current ageing due to power frequency current flow. This is because in old SiC gapped arresters, the MOR consisted of silicon carbide blocks used to limit the power frequency current that
followed the surge through the arrester after impulse. These limited current levels protected the gaps from excessive damage and also made it possible for them to end the operation when voltage reached low levels. However, they also allowed enough current to follow through the arrester to degrade the gaps and gradually change their characteristics. Figure 5 provides a close up of the degradation of gaps in earlier generation series gapped arresters. In this example, the gap was in series
Advantages of EGLA Concept

The gap section of earlier generation SiC arresters consisted of hundreds of components including many series gaps, parallel resistors, field shaping coils, etc. These were always enclosed in a housing and were a highly engineered component. By contrast, the gap in an EGLA has only two terminals nothing more In the earlier generation SiC arrester designs, the gap section functioned as a switch that turned on at the moment of the surge and then turned off when the voltage across the gap was near zero. In this sense, the gap was used both for turning the arrester on and off.
Figure 5: Degraded 500 V gap of an SiC arrester.
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impact on the design test schedule since it follows that no switching surge or TLD type test will be necessary. 10. Inherent Fail Open Mode Because the external gap acts as an isolator of the arrester from the system after failure, there is virtually zero possibility of a sustained outage due to a fail short overload of the arrester. It is true that if the MOR fails short, then the BIL of the system near the failed unit will be limited by the sparkover level of the EGLA gap setting. This, however, seems to be a minor issue for a guaranteed fail open which means no sustained outage on the system due to a faulty or overloaded arrester. At the same time, this lower BIL issue does have a solution (see below). Another advantage of this fail open mode is that no insulating hanger is required for this arrester. The insulating hanger was a product of the fail-safe polymer-housed arrester designs. When such an arrester fails, it inherently fails short. This means that without some type of disconnecting device and some type of insulating hanger there would be an unwanted outage on the system. 11. Environmental Impact Without doubt, the EGLA is the most environmentally-friendly design to hit the market in years. Zero watts loss, less housing material, less MOV material, longer inherent life, less risk of sustained outages and perhaps lower manufacturing costs all add up to perhaps the greenest arrester available today. 12. Weight The shift from SiC arresters to MOV arresters during the late 1980s brought with it a major weight and size reduction for such components. The EGLA design offers yet another weight reduction, although not quite as significant. This reduced arrester weight also leads to mounting configurations that have not been popular in the past and which are nearly limitless for this type of arrester.
outage, the number of arresters installed does not impact the reliability equation at all.
Economic Considerations
If the EGLA can be manufactured at lower costs due to fewer parts and less materials than un-gapped arresters (as implied in this overview), then it follows that the cost of reliability improvement using the EGLA should become increasingly attractive.
Standards Activities
MT4 within TC37 is actively working on performance standards for this arrester. The first CD covering the testing of the EGLA has been circulated to the arrester community and is in the comment stage at the present time. IEC Document #60099-8 is apparently being reserved for this test standard. TC37 MT10 is writing the application section that covers the EGLA. The next version of the 60099-5 Application Guide is scheduled for publication in 2010. The IEEE has not specifically addressed this style of arrester. However, the current issue of C62.11 does include testing of gapped arresters although there are a number of considerations that still need to be addressed. For example, selection of the rating and ageing of the arrester need further coverage in the IEEE standard. The IEEE Application Guide C62.22 does not cover this type of arrester in any way and will need updating soon.
Figure 6: Using a ground lead disconnector (GLD) as a failure indicator for an EGLA.
13. Life Expectancy If one looks about on overhead networks in the United States today, it is surprising to find original surge arresters still in use on distribution lines over 50 years old. A very interesting item to note is that nearly all of these ancient arresters are externally-gapped and come from the expulsion arrester era when external gaps were necessary. It appears that newer generations of direct connect SiC arresters on distribution systems have by now all been replaced by MOV arresters. Yet the externally-gapped arresters seem to continue on in service. With relatively low dielectrically stressed materials, the life expectancy of the EGLA must be very long similar to that of an insulator.
overload and part or all of the gap electrode can fall away or be moved by gravity in some way. 2. Consistent Gap Spacing The second issue that needs a resolution for this arrester design is related to setting the gap. All EGLA installations require that the gap be set in the field. This then becomes the responsibility of the installer instead of the manufacturer. Fortunately, the gap spacing for line protection applications can have relatively wide variation and not affect system performance. Still, it is preferable that the spacing be somehow factory set.
Reliability Considerations
It is a well-known fact that the addition of line arresters can improve or eliminate outages associated with lightning. It is also a fact that in any reliability equation, arrester reliability needs to also be included. In this regard, an arrester having zero probability of causing a long-term outage has always been a desirable goal. The EGLA offers just that. The number of arresters is also a variable in the reliability equation. Generally, more arresters mean a higher probability of an outage due to arrester overload. However, in the case of the EGLA, which has a zero probability of causing a long-term
Design Issues to Overcome

Two issues need some attention in the EGLA. 1. Indication of Failure Without the use of a disconnecting device, it is difficult to locate a failed arrester. One possible solution is for an indicating device to be designed into the configuration. A rough example of this can be seen in Figure 6. In this configuration the indicating device is activated (just like common disconnecting devices of today) by fault current in the event of an EGLA
Conclusions
The EGLA clearly represents a step forward in the never-ending quest to improve lightning induced outage rates on distribution and transmission lines. With a good potential of being more environmentally-friendly, having lower purchase price while offering improved reliability, longer service life and lower life cycle costs, it can well be considered to be the line arrester of the future.
EGLA installation on 400 kV line.
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BUSHINGS
Continuing Growth Ahead for Bushings Business
Manufacturer See
Even as a totally new UHV test laboratory takes shape just outside his office window, Thomas Andersson sees growth as the operative word when it comes to describing what is happening in his business area. Andersson is Product Marketing Manager at ABB in Sweden and oversees a broad portfolio of products covering from pressboard and composite laminate insulation, to electrical and mechanical components including bushings, insulators, tap changers and oil treatment equipment. This business unit (referred to internally as PG I&C) is an important part of the ABB empire, comprising 17 factories scattered across nine countries and with sales of roughly USD 700 million annually. Although Andersson notes that almost every area within PG I&C is now growing, this is particularly the case for bushings whose share of total sales has increased from just over a quarter to about a third. One recent piece of evidence of this growth is a totally new bushings plant now being finalized in India that, apart from traditional styles, will also produce the most technically-sophisticated types offered within the industry. Among the drivers behind the growth in Ludvika, not surprisingly, is the rapid development of the electrical grid within countries such as India and China, particularly in regard to UHV AC and DC projects. For example, ABB is among the suppliers of much of the sophisticated equipment being used on the Chinese power grid, including 800 kV DC transformer bushings. According to research specialist Ralf Hartings, the first testing for these bushings was performed in Ludvika in 2006 and involved electric field measurements conducted on 500 kV DC units. These initial tests revealed the existence of an interesting phenomenon, namely charge build-up and decay such that electric field across the bushing varies over time. Says Hartings, in AC styles, this is not an issue at all. Therefore many people still dont realize what a dramatic change net charging
Indeed, Hartings mentions that 2 hours of dry withstand tests were performed at 1456 kV DC in order to verify the final design selected. He also states that similar dry withstand tests were conducted on 800 kV wall bushings. The bushing is a critical part of the convertertransformer chain, he says. Therefore you need to ensure that it does not become the weakest link. Hartings emphasizes that dielectric withstand in such bushings is controlled by the electric field in the material as well as in the surrounding air, and the electric field is determined by the current in the material, as per Ohms law. Conductivity, he points out, can vary by up to five orders of magnitude with temperature and therefore it becomes a technical problem to control the internal performance of the bushing.
mong the components that have been recognized as a source of potential problems at substations is the bushing. Although a tireless workhorse that has performed reliably for many decades, the classical oil-impregnated paper (OIP) core, porcelain-housed style is nevertheless the one usually implicated whenever such rare problems do occur.
Test set-up for DC electric field measurements along transformer bushing (field probe in middle of red circle).
ne of the relatively new technologies intended to improve the performance of bushings is resin-impregnated paper (RIP) core technology, often referred to as dry-type bushings. When equipped with silicone housings, such units are seen by many in the industry as the ideal solution to avoid potential problems such as oil leakage/contamination or explosive shattering with danger to personnel and consequential damage to neighboring apparatus.
Measurement of 2-dimensional DC electric field along transformer bushing, during long duration test. Wooden structure used to put robot in parallel with bushing (position of probe indicated by red circle and it is remotely moved along the bushing).
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NMR visits the plant and discusses the background as well as recent developments.
represents when it comes to DC even though you clearly have to take this factor into account when designing such a transformer bushing.
When developing specialized bushings such as these for 800 kV, he says, you need to ensure that what youre testing is relevant.
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he ABB bushings plant in Ludvika, Sweden manufactures about 12,000 units every year and RIP styles, whose production at the plant started just ten years ago, already account for about 20 percent of this volume. Like at other such plants within ABB, management report that there has been strong growth in the bushings business over recent years
including sophisticated winding machines and impregnation vessels. Lars Jonsson, a senior specialist for technical support in the field of bushings, explains that the facilitys relatively new winding machines for RIP cores have been designed to optimize the winding speed. He says that the production philosophy employed here differs from the traditional one of finding just a single speed. Instead, he says, we have used a different approach of winding as fast as the heat of drying allows. This way we can maximize machine productivity. Once the core is wound, it is inserted into huge vertically-mounted Outdoor part of wall bushing during DC rain test indoors at 1030 kV.
impregnation vessels, either single or multi-unit type, depending on its voltage class. The core then remains in the vessel into which the epoxy is injected and curing takes place in a carefully controlled process. According to Jonsson, a great deal of know-how is involved in managing this curing cycle in such a way as to avoid any cracking or void inclusions within the large volume of cured resin. The need for such caution is obvious since, should any such defects occur, the core cannot be recycled upstream and is basically reduced to scrap. Says Jonsson, it is so sensitive a process that a lot of time must be taken to set all the parameters correctly. For this reason it makes sense to produce such condenser bodies in only a few
plants worldwide. ABB's largest RIP bushings plant in Switzerland has produced such bushings since the 1960s. The operation of adding the external housing is such that molding on of the sheds takes place directly over the RIP core in the case of smaller bushings. For the largest sizes, the core is fitted into a hollow core composite or porcelain insulator and the space between filled with compressible material that can take up any expansion or contraction due to temperature fluctuations. The relative proportions of OIP versus RIP bushings styles and porcelain versus composite types of insulators
One of the main drivers of the bushings business today is reducing collateral damage caused by any potential catastrophic failure.
made at the plant has been shifting over recent years, although not as dramatically as many had once predicted. Jonsson remarks that feedback from customers shows that one of the main drivers of the bushings business today is reducing collateral damage caused by any catastrophic failure. This, he says, is encouraging greater specification of dry type units with composite insulators. At the same time, this conversion is apparently still proceeding more slowly than for other types of substation equipment. For example, Roger Sundqvist, Marketing Manager for composite insulators at ABBs plant in Pite, reports that the application of hollow core composite
Because the time constant is so important, we tested at the higher temperatures normally encountered in valve halls so as to achieve a steady state distribution of the electric field, within a reasonable time span. He reports that twelve months of operation have confirmed the problemfree performance of the bushing design finally selected. This was verified by ongoing measurements and using a robotic arm set up to measure electric field along the bushing inside a simulated valve hall environment. Hartings claims that, to his knowledge, no other bushings suppliers have yet been tackling these types of issues and that ABB is therefore the first to apply this knowledge to the design of an 800 kV DC style. A walk through the large bushings production facility in Ludvika reveals the results of a ten year program to modernize the plant and to adapt it to the needs of producing both OIP and RIP designs to meet todays highest service voltages. The growing number of RIP designs being made each year at the plant has required a major investment in specialized production equipment for this technology,
Winding machine for RIP cores boosts productivity by optimized production parameters.
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Vertical impregnation vessels for producing RIP condenser bodies.
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insulators seems to be growing faster for circuit breakers than for bushings. Says Sundqvist, overall, we have seen a growing focus on safety and this is becoming the major force driving the changeover from porcelain to composite insulators. As substations continue to move closer and closer to residential areas, we feel this issue can only continue to grow in importance. Sundqvist also reports that ABB already has some 40,000 composite insulators in service worldwide many of which operate with only one third the gas leakage required of equivalent porcelain units which is much better from an environmental point of view. After the flange has been glued to the condenser body and testing performed using helium to measure tightness of the seal, the assembled bushing is ready for routine testing in an adjoining HV test hall. Our requirement for partial discharge activity, notes Jonsson, is tighter than specified in the bushings standard and we also have our own internal acceptance criteria which are more stringent than required by IEC. For example, we like to use a relatively narrow test tank to stress the bushing at the edges of the static shield. In our view, the bushings standards have lagged so we have tried to stay at the forefront. This same thinking now applies to our new 800 kV DC and 1100 kV AC units. In order to be able to conduct testing of these latter units, a totally new test hall is now going up just outside the bushings production area. This facility for UHV AC as well as DC testing will become the third in Ludvika, a town with a core population of only about 15,000, and certainly justifying its claim to be the worlds high voltage valley. According to Andersson, the decision to build the laboratory was made only recently and pushed forward by rapid developments in China, including the Xiangjiaba-Shanghai Testing bushings in Ludvika.
Photo: INMR
project a 2000 km long 6400 MW transmission line said to be the longest anywhere and expected to cost USD 1 billion by the time it is completed in 2010/2011. This latest ABB test facility, measuring 60 m (L) by 40 m (W) x 35 m (H) (indoor measures), will be operational by spring of next year and will permit testing such as 2000 kV DC (mainly for valves), 1700 kV AC, 3300 kV
lightning impulse and 2500 kV switching impulse. Says Andersson, with this new laboratory we will be able to perform all necessary tests for 1200 kV AC and 1000 kV DC. Hartings points out that the UHV levels covered by this laboratory created special demands to ensure accurate testing since failure of any apparatus at such voltages would
have a huge impact on any power system. For example, the facility has to be capable of detecting less than 5 picocoulombs of discharge activity at extremely high voltages and in equipment measuring up to 20 meters in size. Some of these needs included a shielded cage inside the building perimeter to prevent external disturbances as well as a special grounding arrangement for better overall shielding. Hartings remarks, we expect this laboratory to be one of the best in the world for DC, offering an ideal combination of voltage level and physical scale. He and others at ABB see a bright future ahead for HVDC, because it offers an effective and environmentally friendly technology for transporting power with minimal losses. Says Andersson, given this new facility and all the recent changes weve made in the factory, we hope to remain the market leader in bushings at all sizes. The first bushing ever was built here in 1908 and therefore we can say that the history of this component was written here. With these new investments, it continues to be so.
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Photo: INMR
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SPOTLIGHT ON CHINA
OVERHEAD LINE I N S U L ATO R S :
A SKYROCKETI NG BUSI N E SS I N CH I NA
The market for overhead line insulators in China has seen several years of stratospheric growth with current demand estimated by some in this industry to be in the area of RMB 1.5 billion (circa US $ 200 million) each year. Nor is this growth expected to slacken. Quite the contrary. Over the coming years, the numbers of new HV, EHV and UHV lines planned to be added to the Chinese power grid will far surpass that of most industrialized countries combined. Not surprisingly, given the scale of this business, a large number of local insulator manufacturers have started up operations, the majority of them during the 1990s. In most cases, these firms relied initially on production and design technology licensed from Chinese universities or research institutions. As these firms grew, their technical and application know-how grew as well. Today, most of Chinas main insulator suppliers have their own R&D departments, developing new designs and improved manufacturing processes. In addition, their business interests have also grown to cover an expanded range of insulator applications apart from overhead lines (e.g. from station posts to bushings) as well as a broadening number of foreign markets. As this overseas expansion progresses and accelerates, there is good reason to expect that Chinese manufacturers will very soon be among the leading players in this business worldwide. The SPOTLIGHT ON CHINA section of this issue of INMR looks at two of the largest line insulator manufacturers in China Zibo Taiguang Electrical Equipment, located in the northeastern Province of Shandong and Dongguan Gaoneng Industrial, based just outside of the southeastern city of Guangzhou.
A large range of insulators from China's best insulator supplier
AC/DC Composite insulator up to 800 kV
AC/DC Transmission line porcelain insulator up to 1000 kV
Substation post and hollow insulators up to 800 kV
Dalian Insulator Co., Ltd

No. 88, East Liao he Road, DD Port, Dalian 116600, China Tel: 86-411-84305786/84342270/84345370 Fax: 86-411-84305689 E-mail: dpiec@mail.dlptt.ln.cn www.insulators.cn
Photo: INMR
6 2 INMR Q2 2008
ISO 9001 certified plant

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S P OT L I G H T O N C H I N A S P OT L I G H T O N C H I N A
INSULATOR SUPPLIER ESTABLISHES
LEADING POSITION IN CHINESE MARKET

INMR visits Zibo Taiguang and reviews some of the factors behind this history.
Z
Photo: INMR
ibo Taiguang Electrical Equipment (Zibo Taiguang) is a company that in some ways defies expectations. Although based in a region famous for its myriad manufacturers of electrical porcelain, it is an insulator supplier that has built its success on replacing porcelain. And, while competing in a highly fragmented industry with literally hundreds of domestic suppliers, the firm has nevertheless managed to carve out and maintain a sizable share for itself in the worlds largest and fastest growing market for HV line insulators.
Over the years, there has been an ongoing debate within the industry about which production method is superior single injection of the housing or modular assembly.
Silicone rubber is extruded over core rod and then the entire unit is placed into curing chambers (background.
In a modern showroom located at the entrance to its sprawling original factory, Zibo Taiguang Electrical Equipment has installed a sample of a prototype HV composite station post. But perhaps even more intriguing than this new post insulator design is whats hanging on the wall directly behind it. This simple bar chart depicts the steady and dramatic growth of the company over a ten-year period from the time it first began operations in 1991. According to General Manager, Teng Guoli, this growth has continued unabated over the years after 2002 to the point where he says the privately-owned firm now accounts for nearly one-quarter of all the 220 to 500 kV composite insulators in service on the network of the Chinese State Grid. Moreover, Teng also points out that Zibo Taiguang has been selected as one of the principal suppliers for the countrys new 800 kV DC and 1000 kV AC lines, now under construction.
Sales growth from 1992 to 2002 has been as dramatic.
machine where the individual molded silicone sheds are positioned at pre-selected intervals along the rod, according to the design required.
Unlike many manufacturers of composite insulators in China and elsewhere which inject the entire housing in a single molding cycle, Zibo Taiguang produces most of its insulators using a different technology whereby individual sheds are fitted and attached over the silicone-covered core rod. Originally developed at Tsinghua University in Beijing and licensed to Zibo Taiguang at the time it began operations, this technology has also been used by certain insulator suppliers both in Europe and North America. The process essentially begins with extruding a silicone sheath directly over the fiberglass insulator core. After vulcanization in a curing chamber, the sheathed rod is inserted into a specialized assembly
Over the years, there has been an ongoing debate within the industry about which production method single injection of the housing or modular assembly is superior. Teng, for one, believes that the shedby-shed method offers a number of important advantages that make it the better choice of the two. First of all, he notes, with the modular process, we can inspect every single shed prior to final assembly in order to ensure that its free of any defect. In an injection process where the entire housing is molded on in a single step, such inspection is impossible. This means that if there is a problem with any shed, the process of re-injecting the unit risks damaging other existing sheds. Secondly, he continues, this process is more flexible to meet a customers special requirements in regard to insulator geometry and creepage so as to meet unique service conditions.
Molding of individual silicone sheds.
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Modular production of insulator by adding sheds to pre-sheathed rod.
Yet another important benefit, claims Teng, is being able to check the critical interface been the core rod and the silicone housing. In this regard, he notes that the bonding strength of the housing to the rod should be greater than the tearing strength of the material.
Teng says that for most transmission voltages and even up to 1000 kV applications, the majority of his customers indicate that they prefer shed-by-shed assembly over single injection. Among their reasons, he notes, is that an injection machine creates a somewhat greater risk of damage to the rod during molding while shed-by-shed assembly allows better control over the quality of the critical internal insulation.
At the time of the visit by INMR, a new nearly 7 meter long automated assembly machine was in the process of being installed in the production workshop. This machine, says Teng, has been designed to open automatically and lift the insulator for easy removal once the individual sheds have been fitted on. Like other manufacturers of composite insulators, Zibo Taiguang relies on acoustic emission tests during crimping of end fittings to check for any possible damage to the fibers in the core rod. The bonding strength of the HTV rubber
Cut sections of core rods tested for dye penetration.
after vulcanization is also verified during production. In addition, Teng indicates that the factory is equipped with extensive testing facilities to monitor the quality of all incoming materials and components, from rods to fittings. For example, every rod is power frequency checked prior to use. Also, samples of cut sections of rod are submitted to all the tests required by local Chinese standards as well as IEC. Apart from tests on all components from sub-suppliers, Teng indicates that Zibo Taiguang conducts tests on samples from every single batch of insulators made, including tracking and erosion according to all applicable standards. Xue Xiwei, Assistant General Manager in charge of international sales, reports that Zibo Taiguang has just completed building an entirely new factory located in the north-eastern city of Tsingdao and which will focus mainly on supplying the growing demand for the companys insulators by foreign customers.
Modular assembly of insulator allows the critical interface between sheath and rod to be more easily verified.
These insulators feature narrow sheds with relatively long inter-shed spacing.
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Photo: INMR
New modular assembly machine for insulators up to 1000 kV AC and 800 kV DC.
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Says Xue, our orders from markets outside China are rising rapidly and next year we expect will reach a level of about Euros 10 million. He points out that one of the main factors behind the companys growth in exports is that
it has already supplied insulators for projects outside China for several years now. This he says, means that there is growing service experience in these countries. This makes it easier for us to obtain new orders. In terms of future product development, Teng points to the composite station post in his showroom and notes that there is an increasing interest in China and elsewhere to replace porcelain. At 66 kV, he says,
Like most large composite insulator manufacturers in China, Zibo Taiguang compounds and tests samples of its own silicone formulation.
Customers from Chesf, a large utility in Brazil, recently visited Zibo to conduct quality inspection of transmission line insulators.
there is already a large demand for these and growth is now coming from 132 kV applications as well. Down the road, he expects there may even be interest at 230 kV, but at this voltage, the price of a composite alternative is still generally higher than for porcelain.
Crimping is routinely monitored by acoustic emission.
Photo: INMR
Teng and Xue also note that they expect growing use of their composite long rods in other overhead line applications besides suspension. For example, Teng explains that up to now most Chinese utilities do not specify composite insulators in tension for lines of 500 kV or higher. The concern, apparently, is the
mechanical performance of the crimped on end fitting. He says that Zibo Taiguang has now supplied 100 special 500 kV insulators with larger crimping length onto the rod, to test their performance in tension. To his knowledge, they are so far the only Chinese supplier to have done so. Looking at the factors behind the dramatic growth of his business, Teng attributes it mostly to quality issues that have created a high level of confidence among utilities across
China. The competition in this industry is fierce, he remarks. Without adequate concentration on quality control, its impossible to survive long, let alone maintain a leading position in this market.
Teng (left) and Xue examine new 1000 kV insulators (also on right).
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S P OT L I G H T O N C H I N A S P OT L I G H T O N C H I N A
Apparently, it has already been decided that the majority of the insulators for this project will be of composite type. Apart from the growth in the electrical grid, additional demand for insulators is coming from the rapidly expanding rail network across China. According to Zhang, the total length of this network will increase by 20,000 km in the coming Five-Year Plan and, because of the importance of speed, he claims that composite insulators will better meet the requirements than either porcelain or glass. Already Dongguan Gaoneng has supplied over 200,000 units for Zhang Dejin. Sees new opportunities for suspension and cantilever rail applications. UHV insulators. Zhang see future growth in the international market as well. During the past two years, sales have been developed to over a dozen different countries, including India, where nearly 13,000 units of 400 kV insulators have recently been supplied to Powergrid. Other important foreign markets include
Insulator Supplier Prepares for Move into New Factory

The dramatic growth in demand for insulators to accommodate the rapid expansion of Chinas electrical grid has strained the production resources of most of the countrys domestic manufacturers. This in turn has created pressure to expand factory capacity even at a time when these same factories are being run to the limit just to meet existing orders. In some cases, this expansion has taken the form of new production machinery or added factory space. But in other cases, the growth in demand has been such that it was felt better to build another production facility on a totally different site. Dongguan Gaoneng Industrial (Dongguan Gaoneng) falls into the latter category. Last year, work began on a totally new plant and HV test laboratory offering a significantly expanded capacity over what is presently available. Now, this facility is almost complete and the move to it is scheduled before the summer. INMR visits Dongguan Gaoneng and reports on the companys business and expansion plans.
Self-cleaning insulator design with two short and one long shed.
For example, Zhang notes that within the blueprint of Chinas development strategy, the Southern China Power Grid (SGC) is planning to double capacity over the coming five years alone. This ambitious program, triggered by ongoing electricity shortages, will result in a multitude of new 750 kV and 1000 kV AC lines as well as 800 kV DC lines. Says Zhang, the dramatic expansion program at SGC is pushing development of UHV insulators and this offers a real opportunity for us since all our units have already passed the required type tests. We have also conducted pollution withstand testing under full voltage and at the actual insulator length. Already, notes Zhang, Dongguan Gaoneng has supplied over 100,000 insulators for 500 kV and above of which some 13,000 have been for DC applications. He also says that his firm has already been awarded two out of the four supply contracts for the new 1000 kV lines being constructed in China and involving a total of some 3600 such units. Zhangs optimism extends to UHVDC lines as well. He says that a tender will soon be issued by the SCG for supply of line insulators for its new 1400 km long 800 KV DC line.
Iran and the United Kingdom. Says Zhang, in spite of the rapid growth in our domestic demand, we see lots of future potential for our technology outside of China as well. Technical Department Manager, Zhao Tianren takes INMR on a visit through the original facilities which he says will continue to be used after the move to the new factory, but only for distribution insulators. Zhao claims that Dongguan Gaoneng is the manufacturer operating with the greatest number of injection molding machines for insulators in all of China, covering the entire range from 10 kV to 1000 kV. The largest such machine will be delivered to the new facility and will be able to handle an injection volume of 40,000 cc, allowing insulators up to 3500 mm long to be molded in a single shot. Notwithstanding this capability, Zhao stresses that research has confirmed that when multiple shots are necessary, one cannot find the interface visually or see any effect of it electrically.
There is perhaps no better testimony to just how rapid the growth in Chinas insulator industry has been than the fact that a company founded in 1994 would feel the need to completely re-locate facilities within only fifteen years. Yet, this was exactly the situation facing management at Dongguan Gaoneng one of Chinas largest insulator suppliers with a total population of over 2.2 million units in service by mid 2007. General Manager, Zhang Dejin, explains that the firm is now operating near capacity, with annual sales approaching RMB 250 million (circa US $ 35 million). The expanded production facilities offered by the new plant, he says, will permit sales to virtually double something he sees is quite attainable given the excellent future business prospects for insulators.
Pollution testing of full-length UHV insulators at STRI.
The manufacturing process for insulators at Dongguan Gaoneng involves use of a bar code system that allows every unit to be traceable all 1000 kV insulators after production and the way through the various steps of prior to final packing. the production process. Once
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carefully inspected, using power frequency, water immersion and leakage current testing. There is also an important visual examination to detect any internal voids or inclusions using fluorescent background lighting. Says Zhao, our methods to test rods have proven so successful that they have now been adopted into the Chinese national standard. Zhao also points out the Dongguan Gaoneng has used this screening approach for over ten years now and because of this, the quality of rods has improved steadily. When we first started he adds, more than 30 percent of incoming rods were rejected and returned to their manufacturer. Now, this number is only about 5 percent. So we see demanding quality control at our end as stimulating the quality of our suppliers. Injection molding machine for silicone insulators. According to Zhao, all insulators for 220 kV and higher are made using core rods of corrosion resistant glass while normal E-glass rods are used for insulators below this threshold limit. Apart from rods, every single incoming fitting for insulators at applications of 500 kV or higher is also tested.
Verifying dimensional accuracy of incoming EHV fittings.
Crimping force is monitored by acoustic emission for each insulator. (Right) New crimping machine for UHV insulators.
finished, each insulator passes through a laser marking system to identify its service voltage, mechanical strength, code number and date of manufacture.
Among the most important components within the composite insulator are the core rods and Zhao explains that the quality of every rod purchased from outside suppliers is
Apart from the investment made in constructing the new plant, Zhao explains that there have also been recent purchases of sophisticated production and test machinery, which will be transferred to the new plant. These include a crimping machine allowing 12,000 kN swaging force which has recently been delivered. Also a tensile load test machine for 2200 kN is now on site and allows units of up to 15 meters in length to be tested in the factory. Longitudinal and torsional
testing of units up to 5.5 m in length is also available in-house. Zhao notes that in its long-term testing of mechanical performance, Dongguan Gaoneng requires that testing is done for 96 hours at 80 percent of failure load versus the 60 percent figure typically required by most customers. We aim higher, he says. Among the noteworthy features of the new plant, located in another area of the Chinese city of Dongguan, near to
Guangzhou, is a huge new high voltage laboratory. Once completed and equipped, this on site laboratory will allow insulators to be tested up to 3600 kV impulse and 1350 kV steep front voltage. Zhao points out that testing of UHV insulators up to now has been conducted at the EPRI laboratory in Beijing as well as at STRI in Sweden. Editors Note: INMR will visit the new factory and report on the relocation in a future follow-up article.
Ultrasonic testing for minimum thickness of silicone housing after each injection shot. 7 2 INMR Q2 2008
Every insulator receives identification through laser marking on first shed.
Inspection of incoming rods. Rod at right rejected because of inclusion.
Mechanical testing equipment.
Photo: INMR
1000 kV insulators after final packing await shipment to customer.
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TE STING
he past several years have witnessed a dramatic turnaround in the fortunes of the HV testing business. Fueled in large part by the tremendous expansion of electrical infrastructure in countries such as China and India, laboratories worldwide have suddenly found themselves with an ever-growing volume of work on their order books. This has provided welcome relief after a difficult period of stagnant growth as well as excess capacity which had forced some laboratories to close and others to significantly cut back their operations. Today, by contrast, companies in the testing industry are again investing in building new laboratories or modernizing existing facilities to better meet the surge in demand for their services.
Growth, says Dan Wikstrm, has recently been the operative word at STRI. The Ludvika-based testing organization has seen a 30 percent increase in its business over the past few years alone and added new staff to meet these growing needs. We see an increasing future market for our services, says an optimistic Wikstrm, and this is coming not only from a greater number of clients but also from more internationallydiverse needs, especially when it comes to technology services.
Testing
Laboratory Builds Business Around Specialized Capabilities
7 4 INMR Q2 2008
Photo: INMR
STRIs new 800 kV DC test facility for outdoor and indoor equipment.
Among the testing organizations that have benefited from this development is STRI (formerly an acronym for the Swedish Transmission Research Institute but now its new corporate identification). During recent years, it has added an impressive new capability in HVDC testing and also expanded the range of services offered so as to better meet what it sees as the main business opportunities ahead.
Wikstrm explains that to better respond to the expanding requirements of its customers, STRI has re-structured its operations and increasingly relied on the concept of technology managers to oversee work in different service areas. The biggest such area, not surprisingly, is testing. But other areas include power system
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Testing Laboratory Builds Business Around Specialized Capabilities
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analysis as well as consulting services and specialized software aimed at satisfying needs that do not easily fit elsewhere. Says Marketing Manager, Carl Ohlen one of the recent arrivals we now define our mission as providing specialized HV services and this covers the borderline between R&D and various applications-related work. At the same time, we have grown more and more from AC into DC. Indeed, one of the first changes a visitor notices when arriving at STRI is that the area once used as a longterm outdoor exposure site for composite insulators has been replaced by an impressive new 800 kV DC test facility. Inaugurated in December of 2006, it belongs to STRI but up to now has been used almost exclusively by ABB for monitoring the performance of line
and apparatus insulators. Our assignment, indicates Wikstrm, was to build and operate this facility exclusively on their behalf. But it has also been used to some extent by other equipment manufacturers. According to insulation specialist Igor Gutman, this is the worlds first such installation and includes virtually all the major substation equipment both indoor and outdoor including bushings, busbar supports, disconnectors, reactor supports, breakers and arresters. In this respect, he says it offers a unique full-scale testing environment not found anywhere else. Although rated at 800 kV DC, Gutman notes that the insulation here all of it siliconehoused is actually being stressed at 850 kV DC. The indoor portion he adds is also stressed using a special chamber which allows temperature to
increase up to 50 C. We do this, he explains, to verify that the leading edge technology in this field can withstand both increased heat and higher voltage levels. Dong Wu, a long-time specialist in HVDC at ABB, explains that the driving force behind the new test area was to get as much information as possible so that ABB could identify any relevant new phenomena affecting its equipment design. Ideally, we want this type of information as early as possible in our projects, he says. One concrete example where the new test facility has already helped in this regard was in the development of HVDC bushings. Ralf Hartings, a former STRI research director who now works at ABB, explains that, as a result of this new testing capability, certain non-linear limiting physical phenomena
Set-up of testing for 800 kV DC porcelain V-string for Indian client. Insulators pre-treated for pollution.
We now define our mission as providing specialized HV services and this covers the borderline between R&D and various applicationsrelated work. At the same time, we have grown more and more from AC into DC.
Full scale composite insulator being readied for pollution testing. 7 6 INMR Q2 2008
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This program gave us the opportunity to propose a test which we see as a major procedure toward future standardization of pollution testing for composite insulators.
could be identified affecting both transformer and wall bushings used for 800 kV DC. Says Hartings, the test hall was built in such a way as to allow us to decrease the time constant from a matter of weeks to only hours. This way we could achieve a steady state DC field distribution. Why has such a large investment been made? Well, apart from the fast-growing demand for HVDC testing and expertise currently coming from China and India, Gutman notes that climate change is now making DC increasingly important worldwide. Distant hydroelectric generation will more and more be exploited to replace fossil fuels, says Wikstrm. Literally every potential hydro source on the globe will be utilized as part of this process and to use these resources effectively there will be a need for either 1000 kV or HVDC. Otherwise, the losses over the great distances involved will be too great. For example, Ohlen points out that there are efforts now underway in Europe to increase the HVDC link between Sweden and Finland as well as between Finland the Baltic States who are looking to diversify their power sources. He also notes that Norway and Sweden are strengthening their connections to the rest of Europe to sell hydroelectric power, seen as necessary in balancing the continents growing interest in wind power. In fact, Ohlen points out that one of the new service areas being offered by STRI is helping clients connect new wind power plants into their electrical grid in the most efficient way possible. The main drivers for HVDC at the moment, however, seem to be coming from the two fastest-growing economies in the world China and India. For example, as India increases its power generation from 140 GW in 2007 to a projected target of 210 GW by 2012, transmitting this additional power will require that the countrys AC lines be upgraded from 400 kV to 765 kV while DC transmission will have to move from 500 kV currently to 800 kV.
In the case of China, there has been important new business for STRI in providing pollution testing for insulators to be used on the countrys new 800 kV DC and 1000 kV AC networks. Says Gutman, the client in this case wanted full-scale testing of the composite insulators selected and this involved the cooperation of a team of experts from across China.
flashover voltage with insulator length. Linearity is very important in this case, he emphasizes, because we are dealing with a very long insulator of up to 8 meters. As such, it may well be that flashover voltage is not linear due to non-uniformity issues. The results of this testing program have contributed to a joint paper that will be presented at the upcoming CIGRE in Paris this summer. Ohlen sees this type of research as only growing in importance as more transmission lines are upgraded to higher AC voltages or to bi-polar HVDC. We are running several such projects at the moment, he reports, and these will allow clients to transfer more energy on their overhead networks. But, in all such cases, there will be a need to change insulation and because of the constant of the air gap, composite insulator technology will be the best way to go. Gutman notes that one of the problems in the industry at the moment is that there is still no standard pollution test available for composite insulators. This program, he states, therefore gave us the opportunity to propose a test which we see as a major procedural step towards future standardization. Gutman foresees that other testing now being done in places such as China, South Africa and Russia may finally result in such a standard by 2012. The important criterion of repeatability has already been checked here, he explains, while reproducibility was verified in cooperation with EPRI in Beijing which performed these same tests but at 500 kV DC. The recent testing of insulators at STRI for UHV applications covers India as well. At the time of the visit by INMR, work was underway to test the corona and pollution performance design of porcelain insulator strings and hardware manufactured in that country and intended for use on future HVDC lines. Says Gutman, this is basically a trial since it is the
Our traditional insulation expertise has led us to contacts for other work. Over the years, these have allowed us to identify and package logical related
Composite insulators being prepared prior to testing.
He explains that the test program began with deciding on the most appropriate contamination layer to employ, which in this case was Chinese kaolin material applied using their methods. The uniformity of the fog in the pollution test chamber was also verified as were other process parameters. What they finally got from us, remarks Gutman, was all the data required for final dimensioning of these insulators. Gutman goes on to emphasize that one of the key items of input data for the client was verification of the linearity of
Work underway to set up hardware for corona testing on UHV insulator string. 7 8 INMR Q2 2008 Testing Laboratory Builds Business Around Specialized Capabilities Q2 2008 INMR 7 9
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first time that such chains weighing up to 6 tonnes each and having a length of 12 meters are being used. The main requirement, he goes on to explain, will be performance under pollution typically the single most important requirement. Ohlen and Gutman claim that STRI won this job because it offers perhaps the best hall for pollution testing in the world in terms of a number of considerations, including stiffness of its power source. In this specific case, the 420 kN insulators are being tested after being pre-conditioned with an ESDD level of 0.085 mg/cm2 as required by the utility in India. NSDD, while not specified by the client, is at 0.100 mg/cm2. According to Gutman, the testing is being done at negative polarity and the insulator string must be able to withstand the series of scintillations due to dry band arcing. That, he says, is where profile and leakage distance really come into play. Ohlen notes that STRI also conducts 5000 hour accelerated ageing testing of insulators and offers this so that all relevant data can be conveniently accessed by clients over the internet. This way, he notes, they can better monitor results to see how leakage current develops over each of the different phases of the test.
Composite UHV V-string being tested.
Photo: INMR
different insulator alternatives when upgrading its lines from 300 kV to 400 kV. In addition, on-line web cameras were installed at this same client that, in combination with image analyzing software, have allowed the utility to anticipate potential problems such as ice accretions affecting lines. Another example of expanding the scope of traditional services beyond testing alone is a database-sharing program that STRI has pioneered to allow users to exchange information about insulator and conductor joint failures. Gutman says that this program, also internet-based, allows users not only to see their own results but also to ask specific questions or
to look at trends. Data are assembled by manufacturer, year of installation and type of climate in the service areas covered. Looking at the growing array of programs and services now being offered, Ohlen credits much of this development to STRIs longstanding research when it comes to the latest insulator technologies. Quite simply, he says, our traditional expertise in outdoor insulation has led us to contacts for other work as well. Over the years, these have allowed us to identify and package logical related services.
Apart from its testing activities, Ohlen states that STRI has also been promoting specialized software developed to optimize the design of transmission lines as well as to promote reliability centered maintenance. He mentions the case of the large grid company in Norway which used this software to compare
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Issue 80 Quarter 2 - 2008 Volume 16 - Number 2

Source of Information on International Developments in Transmission & Distribution

Passing of Seraj ul Huda

The great scientist and flyer

Quality & Performance ...To the Core!

aptures so ensure more reliable electricity supply for everyone. help

well the essence of how

ty industry, the insulator een

has for much of its existence

een as little more than an

nert chunk of ceramic

material which costs rela-

ively little yet lasts

or at least should last) ut, for those in the US $ 2 illion-a-year industry

TAPOREL ELECTRICAL INSULATOR TECHNOLOGY CO., LTD

which produces them, the ifferent light. These manu-

nsulator is seen in quite a

acturers regard it as a high-

which, notwithstanding its

More than 50 technical presentations

with over 60 Exhibitors from 20 countries

A wind generation project

Issue 80 Quarter Two - 2008

Utility Practice & Experience

30 Case Studies for Reducing Outage Time by

10 Reporting from CIGRE

50 Externally Gapped Line Arresters:

56 Manufacturer See Continuing Growth Ahead

64 Insulator Supplier Establishes Leading Position

20 From the Research View

70 Chinese Insulator Supplier Prepares for Move

ADVERTISERS IN THIS ISSUE

f kites during electrical

torms, Benjamin Franklin,years, almost 20

ndividual items. components

or many in the electric util-

The the insulator ty industry, explanation that seemed

has for een

nert chunk of ceramic

ively little yet lasts insulators, the

Marvin L. Zimmerman mzimmerman@inmr.com

But, for those in the US $ 2 illion-a-year industry

which produces them, the

nsulator is seen in quite a

different light. These manu0 8 INMR Q2 2008

Reporting from CIGRE

by Dr. Frank Schmuck

The great scientist and flyer

f a horse, the rider was lost. Assessing Composite Insulators

Dr. Frank Schmuck frank.schmuck@sefag.ch

or manyDecisive Properties Toutilin the electric Be Tested

illion-a-year industryMethods Overview Of Test

following advantages: different light. These manu-

tested in the past; y-sophisticated component

which, notwithstanding properties of modern insulating materials quantify relevant its

elatively simple appearance,

The great scientist and flyer

better aptures so place. He also noted that his fathers

ant items can have an

or manyinvolved in electric util- the most in the applying them under

has for much of its existence een

Among the other coating mysteries But, for those in the US $ 2

Dr. William A. Chisholm W.A.Chisholm@ieee.org