Influence of Shed Profile on the Pollution
Performance of Porcelain Insulators
Ramkumar N V Chandramouleeswaran A.S
Design and Development Techno-Commercial
Modern Insulators Ltd, Modern Insulators Ltd,
Rajasthan, India Rajasthan, India
nvramkumar@moderninsulators.com asc@moderninsulators.com
Abstract— Over the years, pollution performance of
insulators have become synonymous with the creepage distance
of the insulators. Accordingly, the utility specifications insist
the requirement of creepage distance as an important
parameter when specifying insulator requirements. This has
led to a belief that the increase in creepage by default
guarantees improved pollution performance of insulators.
Though this is true to an extent, the underlying factors that
actually lead to this improved performance have not been fully
studied and understood. However, the IEC standards
pertaining to selection & dimensioning of insulators specify
certain key parameters that influence the pollution
performance of the insulators under different service
conditions. This paper attempts to elaborate on the various
parameters of shed profile and their impact in determining the
pollution performance of porcelain insulators. The influence of
the s/p ratio in particular has been analyzed in detail and the
results of artificial pollution testing are reported.
Keywords— porcelain insulators, shed profile, pollution
performance
I. INTRODUCTION
The performance of insulators under polluted conditions has
been the subject of many studies that helped us in framing
the specifications for the insulator when the pollution is
known. Alternatively, the past experience of actual
performance of insulators in service in the same region
which has been operating at the same or at a higher system
voltage has also been used in defining the specification
requirements.
While doing so, the effect of total creepage distance of
insulators was considered to play the most important role in
pollution performance apart from hydrophobicity. However,
some studies have also shown that increase in creepage
distance alone does not provide the required pollution
performance. These studies laid the ground work for
specifying a few parameters that characterize the profile of
the insulators. Based on the same IEC standard has provided
a guideline on the dimensional aspects of these parameters
that define a good profile.
In this paper, we have tried to establish a concrete
relationship between one such parameter and its effect on
pollution performance. This is established through pollution
performance withstand calculations, artificial pollution
testing using Salt fog method and on the field experience of
insulators in service
II. CREEPAGE CLASSIFICATION AND DIMENSIONAL
CHARACTERISTICS REQUIREMENTS
Insulators are classified as standard, aerodynamic, anti-fog
and alternate according to their shed profiles (based on the
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shed / rib design). The length and diameter determines the
total creepage distance offered by an insulator. The rib /
shed design is influenced by the specific creepage
requirement. The requirements of specific creepage distance
as specified in IEC: 60815-1 are given in Table I.
TABLE 1: CREEPAGE CLASSIFICATIONS
Pollution level Specific Unified specific creepage
creepage distance (USCD) (mm/kV)
(mm/kV)
Very light 12.7 22
Light 16 27.8
Medium 20 34.7
Heavy 25 43.3
Very Heavy 31 53.7
The unified specific creepage distance is calculated
considering the system line to ground voltage (Us/√3). In
practice, very light to medium pollution levels are normally
not considered, especially in tropical climatic conditions and
with the tremendous increase in natural pollutions due to
various types of industry only heavy and very heavy
pollution levels are being specified. The insulators, from
the pollution performance perspective, are defined based on
the creepage requirements and this is in turn governed by
the limitations regarding the length and diameter of the
insulator. However, the creepage distance as mentioned in
the standard is not the only parameter to be taken into
account for meeting this requirement as the same is only a
benchmark/guidance given to manufacturers while
designing the insulators.
In order to achieve the required creepage the sheds / ribs can
be spaced closely which can adversely impact the pollution
performance rather than improving it. Likewise, other
dimensions like diameter shed angle etc. has an impact on
the pollution performance.
Accordingly, to ensure that the insulators meet the intended
performance requirement, IEC standard specifies the
following parameters that have an influence on the pollution
behavior:
• Minimum distance, c, between sheds
• Ratio s/p between spacing and shed overhang
• Ratio ld/d between creepage distance and clearance
• Inclination of sheds
• Type of sheds ( standard / alternate / aerodynamic)
• Effective diameter
• Parameters characterizing the entire insulator:
 Creepage factor
 Profile factor
 III. PROFILE PARAMETERS AND THEIR The critical profile parameters of the selected insulator types
SIGNIFICANCE are specified in Table III.
The significance of the profile parameters are clearly
TABLE III: TYPCIAL PROFILE PARAMETERS
explained in IEC: 60815-2 and the relevant general limits Parameter PLRI SCPI Railway
for each parameter is clearly spelt out in Table II c > 50 >50 >50
s/p >1 >1 1
TABLE II. PROFILE PARAMETERS AND RANGE ld/d <4.6 <4 <4.6
Parameter Limits Significance l/s <3.65 <3.1 <3.6
Shed overhang P1– P2 > 15 for Combined with shed Dm <140 <210 <150
alternating angle has an impact on
sheds and P1– ice, snow and heavy rain
P2 < 15 for conditions for vertical
The shed profiles of the insulators selected for testing were
normal sheds insulator applications designed using the above guideline values. Exact
Sped spacing vs. >0.75 for Avoids “shorting-out” of dimensions of the shed parameters were fixed considering
shed overhang under-rib creepage distance due to not only the above values but also parameters like shed
(S/P) sheds & >0.65 bridging of shed to shed
for other shed arcing.
angle, root and tip radii, as well as overall form factor of the
Minimum > 30 Impacts shed-to-shed insulator. The form factor value is used in calculating the
distance “c” b/w arcing. theoretical flashover value of insulators under Salt fog
sheds pollution testing. The typical profiles are given in Figs. 1 to
Creepage distance < 5 Avoids risk of bridging or 4
vs. clearance (l/d) arcs due to dry band as
well as localized pollution
build up.
Shed top angle < 25 Improves natural washing
by ensuring excess water
run-off.
Creepage factor 2.5 to 4.0 Ensures adequate spacing
l/s between sheds

In addition, IEC: 60815-1 also states the following:

The choice and performance of insulators for polluted
environments is very often expressed solely in terms of the
creepage distance necessary to withstand the polluted
conditions under the system voltage. This may lead to the
comparison of insulators in terms of necessary creepage Fig.1 PLRI profile 20mm/kV
distance per unit voltage. However, the use of creepage
distance alone to establish orders of merit does not take into
account other factors which depend on the creepage distance
available per unit length of the insulator. This point is worth
being borne in mind when choosing insulators, notably for
applications where insulator length is a minor constraint.
Conversely, if insulator length or height is a major constraint,
increasing the creepage distance in the available space may
not give the full improvement in performance expected, due
to reduced profile efficiency. Additionally, for polymer
materials, such an increase of creepage or reduction of shed
spacing may result in aggravated ageing effects
Fig.2 PLRI profile 23.5mm/kV
IV. FIXING PROFILE PARAMETERS TO ACHIEVE
SUPERIOR POLLUTION PERFORMANCE

Based on the service experience and laboratory tests, a

correlation between the artificial pollution performance and
the shed profile could be clearly established. It was observed
that the pollution performance relate mainly to the type of
shed and shed profile of the insulators.
Accordingly, MIL developed a special profile that in most
cases exceeds the minimum requirements specified in IEC.
This profile was developed for the following types of
insulators:
a. Porcelain long rod insulators (PLRI). Fig. 3 SCPI profile 25mm/kV
b. Porcelain Solidcore Post insulators and (SCPI)
c. Porcelain post insulators for railway traction
applications (Railway).
 Fig.4. Railway profile 20mm/kV
The actual dimensions of the profile parameters are given
below as graphs:
Graph 1: Minimum clearance “c”
Graph 2: Ratio of shed spacing to shed overhang “s/p”
Graph 3: Ratio of creepage to clearance “l/d”
Graph 4: Mean diameter “Dm”
V. TESTING AND VALIDATION
The above profile parameters were developed for both
20mm/kV and 25mm/kV specific creepage distance
requirements. Four new designs of PLRI, SCPI and Railway
insulators were taken for prototype development. All these
four designs were then subjected to artificial pollution tests
strictly in accordance with IEC: 60507 – 2013.
The artificial pollution tests using Saltfog method were
carried out in Central Power Research Institute (CPRI),
Bengaluru and Ultra High Voltage Research Institute
(UHVRL), Hyderabad. The tests were carried out on new
insulators. The insulators underwent a pre-conditioning
sequence of 8 flashovers and were followed by three one
hour withstand tests each. The results of the artificial
pollution tests are provided in Table IV.
TABLE IV. SPECIFIC CREEPAGE VS MAXIMUM
Insulator type Specific Maximum withstand
creepage mm/kV salinity kg/m3
PLRI 20 160
PLRI 23.5 224
SCPI 25 224
Railway 20 224
The tests at maximum withstand salinity were also
repeated to ensure reproducibility. All the insulator designs
successfully withstood the repeat tests. In few instances, the
test were repeated on the same insulator subjected to earlier
tests. These tests clearly establish the impact of the shed
profile on the pollution performance. The form factor
efficiency of these insulators have also been established
through pollution withstand voltage calculations.
Further to the testing the validation of these profiles was
also carried out by installing these insulators in service and
monitoring their performance. The insulators were supplied
to MSETCL and installed in 2015 and have continued to give
uninterrupted service since then. The details of the service
conditions are provided below
VI. FIELD EXPERIENCE
SYSTEM VOLTAGE: 400 kV transmission lines in foggy
area.
PROBLEM: Frequent tripping's of the lines faced by
MSETCL with the conventional Disc Insulators due to
heavy tracking across the insulator strings because of the
intense fog in that area. Even Composite Polymer insulators
did not sustain in that area.
OUTCOME: After replacing the conventional Disc &
Polymer Insulators with porcelain longrod Insulators of the
tested profile (our drg nos. 111-C-614 and 111-C-615), no
tripping's have been experienced till date. Based on this
trouble-free performance offed by Porcelain Long Rod
Insulators of MIL make, MSETCL has gone ahead with the
same designs for their additional requirements as well as
installations in their other lines. All these Porcelain Long
Rod Insulators are giving satisfactory performance as on
date which is the undisputed proof of field performance for
the shed profile efficiency of porcelain Longrod insulators
in actual service conditions.
Based on the performance of the PLRI in artificial pollution
tests and its successful service in MSETCL, test installations
has been taken up by Powergrid Corporation of India
Limited (PGCIL) for a section of their 400kV Kolhapur –
Mapusa line and by APTRANSCO in their Vizag section of
the 400kV line. Both the test installations are working
successfully till the time of this paper going to print.
VII. CONCLUSIONS
With the consistent results in laboratory tests as well as
actual performance of these insulators under field
conditions, it is certain that the profile of sheds of the
insulator play a very important role in the performance of
the insulators under polluted conditions. Though the table in
relevant IS/IEC standards gives an indication of the
minimum creepage distances for insulators, ideally profile
of insulator plays a vital role in deciding the pollution
withstand capabilities than just the creepage distance of
insulators. The impact of profile parameters like “s/p”,
“ld/d”, “c’ etc. has clearly been established in the pollution
tests carried out on the insulator designs discussed in this
paper and more so by the 20mm/kV railway insulator which
was able to withstand 224kg/m3 salinity at a test voltage of
30kV.
Hence, for polluted atmospheric conditions, more than the
creepage distance, profile of the insulators really matters
much for pollution withstand capabilities. Accordingly, to
ensure reliable and uninterrupted service it is more pertinent
and appropriate for utilities to specify the pollution
withstand level as their requirements especially for heavy
and very heavy pollution environments instead of just
creepage distance.
ACKNOWLEDGEMENT
The authors would like to acknowledge with thanks the
support extended by the management and team of Modern
Insulators Limited for making this project feasible. Thanks
are also due to the personnel of CPRI and UHVRL for
extending their support and co-operation in carrying out the
tests.
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