th

The 20 International Symposium on High Voltage Engineering, Buenos Aires, Argentina, August 27 – September 01, 2017

OPTIMIZED DESIGN OF HV- INSULATORS WITH RESPECT TO EX-

TREME POLLUTION FOR THE COAST OF SOUTH AND NORTH
AMERICA
1 2 1
Jan Schulte-Fischedick *, David Ernesto Gómez Torres , Norka Sotil-Bindels , Fabian
1 1 2
Lehretz , Jens Seifert , Juan Guillermo Maya Montoya ,
2
Juan Carlos Garcés Restrepo
1
Lapp Insulators GmbH, Bahnhofstraße 5, 95632 Wunsiedel, Germany
2
Interconexión Eléctrica S.A., Cl. 12 Sur #18-168, Medellín, Colombia
*Email: Jschulte@lappinsulators.com

Abstract: The western coast of both North and South America is dominated by the Pacif-
ic stream resulting in mainly landwards winds with high salinity. In addition huge industrial
areas and sea ports (Valparaiso, Los Angeles, Panama channel) are located along the
shore leading to significant air pollution. Therefore the insulator design has to focus both
on extended corrosion of the fittings and high partial discharge activity. The phenomenon
of corrosion amplifies significantly in those geographies where the following aspects are
additionally present: one, there is few rain that may wash away the pollution and second-
ly, tropical latitudes result in overall higher ambient temperatures and humidity. These are
ideal conditions for the electrochemical reactions accelerating both corrosion processes
and partial discharging. An example is the Peruvian coast. ISA and LAPP are jointly de-
veloping an insulator design for these regions. This shall be presented in this case study.
Zinc-coated steel fittings from standard construction steels like S355J2+N do not exhibit
sufficient long-term stability under the given local corrosion conditions. Investigations in
the corrosion properties of different ferritic and austenitic steel types enabled ISA to
demonstrate that the duplex steel 2205 (1.4462) is a cost efficient alternative to the oth-
erwise required highly alloyed austenitic steels. 2205 is characterized by a chromium con-
tent of 22 % resulting in corrosion properties similar to 904L with respect to PREN num-
ber. However, due to the duplex microstructure only 5.7 % in nickel content is required to
stabilize the microstructure compared to 20 % in the case of 904L. The reduced Ni- con-
tent restricts the surcharges of the fittings. The main drawback of duplex steel – the 375
°C embrittlement – does not pose any problems, as the operation temperature is well be-
low the usual operation limit of 200 °C reported in the literature.
The standard composite insulator body is overloaded by the described pollution condi-
tions, too. The hydrophobic properties together with Aluminium Trihydrate (ATH) filling of
high-temperature vulcanized silicone – in general seen as superior – needs in this case
an improvement to ensure the usual design life time of 40 years. Pollution induced partial
discharges lead to hot spots resulting in accelerated local degradation of the silicone
sheath. The formation of so called “morning stars” (puncture of the silicone sheath) allows
water/ steam entering the GFRP rod. Stress corrosion cracking and treeing, respectively,
then lead to a rapid mechanical failure of the insulator. For such site conditions Lapp has
developed an additional layer featuring microvaristors. Microvaristors are semi-conductive
nanocomposites that switches at a materials- controlled threshold from insulating to con-
ductive. This feature enables to restrict electric field to the threshold value thus offering
an effective protection for the composite insulator.
ISA and LAPP plan to test this promising solution at selected sites in vicinity to the coast-
line to demonstrate their suitability for the long-term use in the harsh conditions of west-
ern parts of South and North America.

1 INTRODUCTION onto the insulators is washed away. These condi-

The Peruvian coast results in heavy environmental
loadings to high-voltage insulators. These tropic
conditions comprise high salinity, relative humidity
of generally above 80% throughout the year and
an average temperature in excess of 30 ° C. These
areas are very aggressive from the point of view of
corrosion and pollution.
In addition, there is no rain on the Peruvian coast,
so it is not possible that the pollution deposited
tions strongly stress composite insulators as two
situations arise: Corrosion of their metallic end fit-
tings of the usually galvanized steel and the pres-
ence of partial discharges that degenerate the sili-
cone.
Figure 1 presents a composite insulator end fitting
of the 230 kV Sabanalarga - Bolivar line, property
of ISA, which is affected by corrosion, which had to
be replaced after 12 years in service in a "Very
High" level of corrosive aggressiveness according
to the classification defined by the methodology of
Integral Corrosion Management (MIC) structured
by ISA.

Figure 2: Composite isolator affected by partial

discharges.

Figure 1: Corrosion-degraded composite insulator 2 LITERATURE REVIEW

end fitting [1]
The experiences of ISA have clearly demonstrated
This methodology considers three levels of corro- that standard construction steels as material for the
sion in metallic elements: Grade 1 (Loss of zinc fittings are not sufficient. Thus a cost-efficient
coating), grade 2 (Loss of up to 20% of the diame- stainless steel variant, 2205 duplex steel, has been
ter of the part) and grade 3 (Loss greater than 20% selected. Duplex steels are – simply speaking –
of the diameter of the part). The end fitting of Fig- steels with equally weighted ferritic and austenitic
ure 1 represents corrosion grade 3, resulting in a content exhibiting no phase transformation from
severe decrease in its mechanical integrity [1]. It is solidification to room temperature. Due to the ferrit-
important to note that the data presented in Table ic/ austenitic mixture the nickel content (to stabilize
1 also apply in assessing the risk of the poles due the austenitic microstructure) is only 5% compared
to marine pollution. to 8-25 % in the case of purely austenitic steels [2].
This results in reduced surcharges keeping costs
Table 1 shows the levels of corrosive aggressive- on an acceptable level. Regarding corrosion re-
ness used to classify the level of corrosion risk of sistance it has to be noted that stainless steels in
each pole due to its proximity to the sea. general do not show an area-wide, but localized
corrosion progressing deeply into thickness. This is
much more hazardous as it results in crack-like
Distance to the sea structures. The risk of corrosion may be assessed
Corrosion level Color ID
[km]
by a simple balance of the volume content of the
0≤X≤5 Extremely severe elements Cr, Mo and N as rule-of-thumb – the Pit-
ting Resistance Equivalent Number (“PREN”).
5 < X ≤ 10 Very severe 2205 has the same PREN number as the highly
10 < X ≤ 15 Severe chromium- alloyed and costly 904L steel grade
15 < X ≤ 20 Very high with 22% Cr [2]. Thus it can be expected, that the
corrosion behaviour is similar. This, however, re-
20 < X ≤ 25 High quires verification.
25 < X ≤ 30 Slightly moderate
X > 30 moderate - low While duplex steels exhibits a good optimum be-
tween costs and corrosion resistance, there is
generally one big disadvantage of duplex steels:
Table 1 Levels of corrosive aggressiveness ac- they exhibit significant embrittlement down to ce-
cording to the MIC (Integral Corrosion Manage- ramic level in case of prolonged heating at temper-
ment) atures between 200 °C and 550 °C. However,
OHTL are operated at ambient temperatures. The
Figure 2 corresponds to the failure of a composite so-called “475 °C- embrittlement” does not have to
be taken into account [3].
insulator by partial discharges. This situation oc-
curred in the 500 kV Chinú substation owned by
ISA. With respect to degradation of silicone housings
due to partial discharge activity the development
targets at a specific layer of microvaristors. These
These situations led to developing a new type of
particles consist in the given case of positively
composite insulator capable of withstanding the
doped ZnO sub-particles joint with a negatively
severe environmental loadings.
doped interphase made from Bi2O3- Sb2O3 (see
Figure 3). The interfaces between interphase and
ZnO constitute a band gap resulting in semi-
conducting properties. Microvaristors switch be-
tween insulating and conductive mode at certain
breakthrough voltages [4]. The latter is constituted
by the microstructure and can therefore been
tailored. I-E characteristics of the used microvaris-
tor type at different volume contents are given in
Figure 4. To fully exploit the varistor effect a weight
content of at least 75 % is required.
Figure 3: Microvaristor particle (left) and inter-
phase region (right)
Figure 4: E-J- characteristics of microvaristor/ sili-
cone materials depending on the weight content of
microvaristors
Microvaristor filled HTV- silicone and epoxy has
recently been demonstrated to be able to improve
the electric aging characteristics of OHTL insula-
tors [5] and substation bushings. In the latter case
a slim bushing was developed and successfully
commissioned with only 70% of the standard di-
ameter [6]. A layer of microvaristors in epoxy in the
interface between silicone and GFRP tube was
able to intercept 50% over-voltages as required by
IEC 60137 [7].
3 EXPERIMENTAL PROCEDURE
3.1 DUPLEX STEELS FITTINGS
For the experimental process, five samples of
stainless steel fittings have been taken from ISA
Group transmission lines, located in areas of high
corrosive aggressiveness. Figure 5 shows some of
the fittings used in the analysis.
To determine the type of stainless steel of each
part, composition and microstructure have been
analyzed according to ASTM E3 and ASTM E407
and the macrostructure according to ASTM E340
standards.
Figure 5: Fittings collected for analysis [2]
Conducting an analysis of composition, microstruc-
ture and macrostructure, it has been establish that
the types of stainless steels used in the manufac-
ture of these parts has been AISI SAE 430 (Ferrit-
ic), 17-4 PH (Martensitic) and SAF2205 (Duplex).
In addition, it has been decided to include in the
analysis a sample of 316L stainless steel (austenit-
ic), in order to have a greater range of these steels.
Test specimens have been produced according to
ASTM G38 standard.
Evaluating the corrosion resistance of a stainless
steel is of vital importance. Different techniques are
used for this. However, there are conditions in
which the parts, in addition to the corrosive attack,
are subjected to high mechanical stresses known
as phenomena of corrosion under tension and the
faults in these cases can be of intergranular type
(along the grain boundaries of the metal) or trans-
granular (through the grains). In order to determine
the types of stainless steels selected and to find
the one with best performance under aggressive
atmospheres, the following types of tests have
been performed on the test specimens: [8]
• Alternating immersion test in saline environment
according to ASTM G44 standard.
• Saline fog chamber tests according to ASTM
B117 standard.
• Intergranular attack susceptibility tests according
to the electrochemical method of ASTM G108
standard.
3.2 MICROVARISTOR LAYER ENHANCED
COMPOSITE INSULATORS
Microvaristor layers have to be designed according
to geometric features as well as to the break-
through voltage. In the given case a breakthrough
voltage of 500 V/mm has been selected. Nonlinear
FEM has been developed based on the quasi-
static assumption and demonstrated to accurately
predict the behaviour of microvaristor layers [9].
This tool has been used to design the insulators.
Afterwards prototypical OHTL insulators have been
produced using a microvaristor enhanced layer
between the GFRP and the silicone sheath with a
microvaristor content of 75 wt.-%. These proto-
types have been tested in the High-Voltage Labor-
atory of TU Darmstadt [9]. While energizing the
insulators have been monitored using UV daylight
camera thus being able to determine the corona
activity.
4 RESULTS
4.1 DUPLEX STEELS FITTINGS
4.1.1 Alternate corrosion test in saline environment
The tests have been performed in NaCl solution at
5%, according to ASTM G44 standard, on all spec-
imens. Each material has been evaluated in tripli-
cate. According to ASTM G44 standard, immer-
sion-drying cycles of 10 and 50 minutes, respec-
tively, under controlled conditions of relative hu-
midity (45 ± 10%) and temperature (27 ± 1 °C)
have been conducted. The specimens have been
inspected twice a week with the help of a magnify-
ing glass, in order to look for signs of cracking in
the central area of the specimen. In total the sam-
ples have been exposed for 2160 cycles corre-
sponding to 3 months of testing. None of the sam-
ples have exhibited any cracking. [8]
4.1.2 Saline Fog Chamber Tests
Conventional salt fog tests have been performed in
NaCl solution at 5%, according to ASTM B117, on
all specimens. Each material has been evaluated
in triplicate. The specimens have been daily in-
spected with the help of a magnifying glass, in or-
der to look for signs of cracking in the central area
of the specimen. In total the samples have been
exposed for four months corresponding to 2880
hours. None of the samples has exhibited cracking,
but slight changes in the surface of the specimens
have been evident. [8]
4.1.3 Tests for susceptibility to intergranular corro-
sion
4.1.3.1 Potentiodynamic polarization tests with re-
turn cycle.
Potentiodynamic polarization curves have been
conducted in duplicate for commercial stainless
steel sample electrodes (AISI SAE 316L, 430 and
17-4 PH and SAF 2205) in a chloride solution at
3%. The measurements have been carried out us-
ing a three-electrode electrochemical cell: platinum
auxiliary electrode, calomel reference electrode,
and stainless steel working electrode. [8]
The curves has been performed in a potentiostat
AUTOLAB at a scanning range of 100 mV from the
cathode zone, up to 600 mV in the anode zone
with respect to the open circuit potential. [1]
In the case of austenitic stainless steel, a positive
hysteresis has been observed on both electrodes
(return currents have been found to be little higher
than the departure ones). This means that if the
material is corroded by localized corrosion, re-
passivation would be difficult. This situation is pre-
sented in the same way for martensitic and ferritic
steels. The duplex stainless steel is the only mate-
rial that presented a trend of re-passivation in the
middle of chlorides.
4.1.3.1 Potentiokinetic reactivation method.
Potentiokinetic reactivation tests have been per-
formed in order to obtain the degree of sensitiza-
tion of each material in the medium of exposure
suggested by the ASTM G 108 standard. This test
has been performed on all samples, both without
and with mechanical stresses. The results obtained
are presented in Table 1. [8]
Table 1: Electrochemical Reactivation [8]
Corrosion Corrosion
Steel grade
potential [V] current [A]
-5
SAF2205 0.06 2x10
-5
AISI SAE 430 -0.40 5x10
-5
17-4 PH -0.37 6x10
316L -0.31 8x10
-5
According to the results presented in Table 1, the
steel exhibiting the best behavior, i.e. having the
lowest corrosion currents and lowest corrosion po-
tential during potentiokinetic reactivation was SAF
2205 duplex steel.
Considering all the tests carried out, it is concluded
that stainless steel SAF2205 (Duplex) exhibits the
best behavior under corrosive atmospheres, so it
shall be used for the construction of the end fittings
of the composite insulators.
In order to evaluate the technical and economic
feasibility of manufacturing the end fittings of
composite insulators in SAF2205 (Duplex) stain-
less steel, their mechanical characteristics has
been analyzed with respect to galvanized steel
(ASTM A-536), being found to be significantly su-
perior. [10]
This is quite relevant, since it allows maintaining
the geometry of the parts that are required to re-
place the end fittings of galvanized steel insulator.
Table 2 presents the comparison of mechanical
characteristics of different steels, including evaluating the optimum thickness of an ATH filled
SAF2205. top layer of silicone and an appropriate production
sequence.
From Table 2 it can be concluded that the mechan-
ical characteristics of SAF2205 stainless steel are
superior to those of galvanized steels, so it is pos-
sible to preserve the geometry of the elements.

Table 2: Mechanical properties of SAF2205 stain-

less steel and galvanized steel (ASTM A-536). [10]

elonga- Hard-
tensile Yield
Steel tion at ness
strength strength
grade fracture Brinell
[MPa] [MPa]
[%] [HB]

ASTM 448 310 12 217

A 536

SAF2205 620 450 25 290

The corrosion resistance of different commercial
stainless steels is shown in Figure 6. Note in the
red box that SAF2205 stainless steel (Duplex) is
located near high-alloyed stainless steels, which
makes it commercially very attractive.
Figure 7: analysis of the tangential electric field
along Rodurflex insulators.
Comparative experiments on MIVA insulators have
been conducted at 110 kV in the High Voltage La-
boratory of TU Darmstadt. UV monitoring clearly
demonstrated the feasibility of the MIVA solution
with respect to corona inception (see Figure 8).

Figure 6: Index of corrosion resistance of some

commercial stainless steels. [10]

4.2 MICROVARISTOR LAYER ENHANCED

COMPOSITE INSULATORS

Nonlinear FEM analysis has been carried out. In

this it has been shown that the thickness of the
layer is not a critical factor. However, the layer
stacking sequence is of high importance. If the mi-
crovaristor layer is covered by another silicon layer
of 3 mm in thickness, the effect is strongly inhibit- Figure 8: comparison of Rodurflex- insulator test-
ed. It seems to be that the top silicone layer acts ed at 110 kV in a high voltage laboratory: conven-
as a capacitant resistance. If on the other hand the tional (top) and MIVA insulators (bottom) during
microvaristor layer is placed as top (or single) lay- artificial rain
er, the simulation states that all peaks are cut at
the breakthrough voltage (see Figure 7). 5 CONCLUSIONS

However, according to [11] a microvaristor/ Sili- The reported investigations have been conducted
cone layer does not achieve the creepage re- to develop a solution that is able to withstand the
sistance seen as necessary for the use in highly specific site conditions of the Peruvian cost in the
polluted regions. LAPP is currently still engaged in long run. These dry, though very humid conditions
at high ambient temperatures in excess of 30 °C
result in significant corrosion to standard construc-
tion steels as well as significantly triggering partial
discharges on the silicon sheath. Thus lifetime of
composite insulators is currently restricted to ap-
proximately 10 years.
With respect to corrosion of fittings duplex steels
have been found as a promising solution. Corro-
sion behaviour is superior to that of 316L stainless
steels as confirmed by potentiometric measure-
ments. I.e. it has been proven that in contrast to
316L and other ferritic and martensitic candidates
2205 is able to re-passivate even if it has been
sensitized (for corrosion). This clearly demon-
strates its suitability for the given case, as 316(L) is
generally seen as reference for applications in vi-
cinity of sea shores. However, in contrast to 316L
duplex steels avoids high nickel contents thus limit-
ing alloy surcharges. Thus duplex steels can be
seen as a cost efficient and superior alternative to
the otherwise required austenitic stainless steels.
Microvaristors have been demonstrated to provide
a mean to level electric fields to uncritical levels.
Thus these particles significantly reduce the partial
discharge activity. While in principal the mecha-
nisms have been proven, the design of the mi-
crovaristor- enhanced insulator is an optimization
challenge between creepage resistance and su-
pressing partial discharge activity. This optimiza-
tion has not yet satisfactorily been solved.
[6] H. Ye, M. Clemens, J. Schulte-Fischedick and
J. M. Seifert, „Investigation of Electrical Field
Grading of Bushings with Microvaristor Filled
Epoxy Resin Components“, 2014 IEEE Int.
Power Modulators and High Volt. Conf., Santa
Fé, USA, June 2014
[7] IEC 60137, “Insulated bushings for alternating
voltages above 1 000 V”, 2008.
[8] C. Córdoba, J. Castaño, J. Calderón and F.
Echeverría, “Elaboración de Especificaciones
Técnicas de Control de Calidad para Herrajes
de Acero Inoxidable en Líneas de Transmisión
de Energía Eléctrica”, pp. 1- 75, 2012.
[9] D. Weida, J. Nevoigt, H. Ye, M. Clemens, D.
Stefanini and J. Seifert, "Effects of Microvaris-
tor Material on Partial Discharges upon Com-
posite Insulators in Rain Test," Int. Power
Modulators and High Voltage Conf. (IPMHVC
2010), May 2010, Atlanta, USA.
[10]J. Maya, “Herrajes de Acero Inoxidable para
Líneas de Transmisión de Energía Expuestas
en Atmósferas Marinas Agresivas”, pp. 1- 8,
2015.
[11]J. Debus, Untersuchung der Anwendungsmög-
lichkeiten mikrovaristorgefüllter Feldsteuerele-
mente in der elektrischen Energietechnik, PhD
thesis, 2014.

For the moment LAPP has already produced proto-

typical insulators with duplex steel fittings that will
be installed at the Peruvian coast. As soon as an
optimum stacking sequence of the microvaristor-
and standard ATH-filled silicone layers have been
determined, ISA and LAPP are going to test proto-
typical insulators to verify the long-term effect of
microvaristors in the lines, too.

REFERENCES
[1] D. Gómez, J. Maya, J. Garcés and L. Porras,
“Especificaciones Técnicas de Aisladores Po-
liméricos para Zonas de Alta Agresividad Cor-
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[2] Outokumpu Duplex Stainless Steel Datasheet,
"http://www.outokumpu.com/sitecollectiondocu
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sheet.pdf", last accessed: March 15, 2017.
nd
[3] A. J. Sedriks, Corrosion of Stainless Steels, 2
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[4] D. R. Clarke, “Varistor ceramics”, J. Am. Ce-
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