September 30, 2019

TRANSMISSION MATERIALS STANDARD SPECIFICATION 15-TMSS-02, Rev. 02

Page 10 of 16

Clause 5.3.j (Sample Tests / Steep Front-of-Wave Flashover Test

Acceptance criteria shall be as per following:

i. No electrical puncture (internal puncture) shall occur.

ii. Every steep front-of-wave impulse voltage application shall result in an

external flashover.

iii. The result of these tests shall equal or exceed the rated combined mechanical
and electrical strength/electro-mechanical failing load/mechanical failing
load. Insulators shall not shatter below the specified mechanical failing
load.

iv. All insulators shall fulfill the requirements of Clause 5.1.1.j (iii).

Page 11 of 16

Clause 5.4.a (Special Tests / Power Arc Test)

Power arc test shall be performed on a short string as per procedure & test set
up of IEC 61467 with following test description:

Test Short Circuit Number and duration

Circuit Current of test
D In = 12kA One of tn =0.1 sec
D In = 12kA One of tn =0.1 sec
D In = 12kA One of tn =0.1 sec

15TMSS02R02/MAT Date of Approval: September 30, 2019

June 27, 2016

27 June, 2016
TRANSMISSION MATERIALS STANDARD SPECIFICATION 15-TMSS-02, Rev. 02

TABLE OF CONTENTS

1.0 SCOPE

2.0 CROSS REFERENCES

3.0 APPLICABLE CODES AND STANDARDS

4.0 DESIGN AND CONSTRUCTION REQUIREMENTS

4.1 General
4.2 Design Criteria
4.3 Ratings
4.4 Materials
4.5 Fabrication
4.6 Dimensions
4.7 Markings

5.0 TESTS

5.1 Type (Design) Tests

5.2 Routine (Production) Tests
5.3 Sample (Quality Conformance) Tests
5.4 Special Tests

6.0 SHATTERING RATE (GLASS INSULATORS)

7.0 DATA SCHEDULE

15TMSS02R02/FAZ Date of Approval: June 27, 2016 PAGE 2 OF 16

TRANSMISSION MATERIALS STANDARD SPECIFICATION 15-TMSS-02, Rev. 02

1.0 SCOPE

This Transmission Material Standard Specification (TMSS) specifies the minimum technical
requirements for design, engineering, manufacture, inspection, testing and performance of
porcelain and toughened glass suspension insulators intended to be used on the
Transmission System of National Grid Saudi Arabia.

2.0 CROSS REFERENCES

This Material Standard Specification shall always be read in conjunction with the latest
revision of General Specification No. 01-TMSS-01, titled "General Requirements for All
Transmission Equipment/Materials", which shall be considered as an integral part of this
TMSS.

This TMSS shall also be read in conjunction with Purchase Order or Contract Schedules for
project, as applicable.

3.0 APPLICABLE CODES AND STANDARDS

The latest revision/amendments of the following Codes and Standards shall be applicable for
the equipment/material covered in this TMSS. In case of conflict, the vendor/manufacturer
may propose equipment/material conforming to one group of Industry Codes and Standards
quoted hereunder without jeopardizing the requirements of this TMSS.

3.1 ANSI/NEMA C29.1 Test Methods for Electrical Power Insulators

3.2 ANSI/NEMA C29.2B Insulators, Wet-Process Porcelain and Toughened

Glass - Transmission Suspension Type

3.3 IEC 60120 Dimensions of ball and socket couplings of string

insulator units

3.4 IEC 60305 Insulators for overhead lines with a nominal voltage
above 1000V- Ceramic or glass insulator units for
A.C. systems- Characteristics of insulator units of the
cap and pin type

3.5 IEC 60372 Locking devices for ball and socket couplings of string
insulator units - Dimensions and tests

3.6 IEC 60383-1 Insulators for overhead lines with a nominal voltage
above 1000V- Part 1: Ceramic or glass insulator units
for A.C. systems- Definitions, test methods and
acceptance criteria

3.7 IEC 60383-2 Insulators for overhead lines with a nominal voltage
above 1000V- Part 2: Insulator strings and insulator

15TMSS02R02/FAZ Date of Approval: June 27, 2016 PAGE 3 OF 16

TRANSMISSION MATERIALS STANDARD SPECIFICATION 15-TMSS-02, Rev. 02

sets for A.C. systems- Definitions, test methods and

acceptance criteria

3.8 IEC 60437 Radio interference test on high voltage-insulators

3.9 IEC 60507 Artificial pollution tests on high voltage insulators to

be used on A.C. systems

3.10 IEC 60797 Residual strength of string insulator units of glass or

ceramic material for overhead lines after mechanical
damage of the dielectric

3.11 IEC/TS 60815-1 Selection and dimensioning of high-voltage insulators

intended for use in polluted conditions-Part 1:
Definition, information and general principles

3.12 IEC/TS 60815-2 Selection and dimensioning of high-voltage insulators

intended for use in polluted conditions-Part 1: Ceramic
and glass insulators for a.c. system

3.13 IEC 61211 Insulators of ceramic material or glass for overhead

lines with a nominal voltage greater than 1000V-
Impulse puncture testing in air

3.14 IEC 61467 Insulators for overhead lines - Insulator strings and sets
for lines with a nominal voltage greater than 1000V-
A.C. power arc tests

4.0 DESIGN AND CONSTRUCTION REQUIREMENTS

4.1 General

4.1.1 The insulators shall have insulating parts made from either wet-process
aluminous porcelain or toughened glass and shall meet or exceed the
requirements of this specification in all respects.

4.1.2 The manufacturer’s design drawings, as required in 01-TMSS-01, shall show

the outline of the suspension insulators, together with all pertinent
dimensions. Any variations in these dimensions due to manufacturing
tolerances shall be indicated. The drawings shall have a minimum of two
views with an appropriate scale. Following information shall be given on the
drawings:

a. Type and/or Catalogue number

b. Principal dimensions
c. Combined Mechanical and Electrical (M & E) Strength/Electro-
mechanical Failing Load (Porcelain)
d. Mechanical Failing Load (Glass)
e. Electrical data

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TRANSMISSION MATERIALS STANDARD SPECIFICATION 15-TMSS-02, Rev. 02

f. Creepage (Leakage) distance

g. Weight
h. Zinc coating thickness
i. List of materials
j. All marking

4.1.3 The insulators shall be able to withstand the mechanical stresses which can
occur during transport, handling and installation temperatures as low as
minus (-) 5oC, in addition to the mechanical stresses which can occur during
the lifetime of the overhead line at temperatures from - 5oC to 93oC/210oC ~
230oC (maximum temperature for conventional and heat resistant conductors
respectively).

4.2 Design Criteria

4.2.1 Service conditions referenced in 01-TMSS-01 shall be the basis of design

criteria.

4.2.2 The wet-process aluminous porcelain or toughened glass insulator design

shall be fog, super fog, or aero form (open profile) type with ball and socket
couplings. These shall be designed to withstand water jet pressure of
3800kPa.

4.2.3 The ball and socket couplings of all insulators must be ANSI/NEMA or IEC
compatible.

4.2.4 The metal parts and the porcelain or glass parts shall be movable in relation
to each other to avoid large mechanical stresses due to difference in
coefficient of thermal expansion of the metallic parts, cement and the
porcelain or glass materials. Thus, the metal cap shall move up and down, in
an elastic manner under the external tension load, on the sloping surface of
the adjacent cement. The metal pin shall act in the same manner.

4.3 Ratings

The wet-process aluminous porcelain or toughened glass suspension insulators shall

have the minimum ratings as indicated in Table 01:

15TMSS02R02/FAZ Date of Approval: June 27, 2016 PAGE 5 OF 16

TRANSMISSION MATERIALS STANDARD SPECIFICATION 15-TMSS-02, Rev. 02

Table 01: Minimum Ratings for Insulators

Porcelain Glass
Ratings
Aero Form Fog/Super Fog Aero Form Fog
Combined Mechanical and Electrical
(M & E) Strength/Electro-
111/160/210* 111/160/210* 111/160/210* 111/160/210*
mechanical Failing Load /
Mechanical Failing Load, kN
50% of Combined Mechanical and Electrical (M & E) Strength/
Tension Proof Load
Electro-mechanical Failing Load/Mechanical Failing Load
Impact Strength (N-m) 7/10/10

Low Frequency Dry 80 95 65/75/75 95

Flashover, kV Wet 50 55 50 55

Critical Impulse Positive 105 135 95/105/105 135

Flashover, kV Negative 105 145 95/105/105 145
Low Frequency Puncture Voltage,
110 110 125 125
kV
RIV Low Frequency Test Voltage
10
(rms to ground), kV
Maximum RIV at 1000kHz, µV 50
70% of Combined Mechanical and Electrical (M & E) Strength/
Residual-Strength Test
Electro-mechanical Failing Load/Mechanical Failing Load
* The required insulator type and rating shall be specified in the Data Schedule.

4.4 Materials

All insulator shells shall be sound and free from defects that might adversely affect
the insulator. Metal parts, except for cotter keys, shall be made of the best
commercial grade of malleable iron, ductile iron or steel, galvanized in accordance
with 01-TMSS-01. The thickness of zinc coating on the insulator caps and pins shall
not be less than 0.110 mm (equivalent to 770 g/m²) and 0.053 mm (equivalent to 381
g/m²) respectively.

Insulators shall be furnished with a positive locking device of the split cotter key
type. The cotter keys shall be made of bronze, brass or austenitic stainless steel. In
addition, specific requirements as stated below shall be met.

4.4.1 Porcelain Insulators:

The insulator shells shall be made of the highest grade, dense, homogeneous
wet-process aluminous porcelain. The entire exposed wet-process aluminous
porcelain surface of the insulator shell shall be glazed, relatively smooth and
free from imperfections. The porcelain used shall be non-porous with high
dielectric strength, chemically inert and high fusion point.

The color of the porcelain glaze shall be brown and of uniform coverage and
thickness.

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TRANSMISSION MATERIALS STANDARD SPECIFICATION 15-TMSS-02, Rev. 02

4.4.2 Glass Insulators

The entire glass surface of the insulator shell shall be toughened, smooth and
free from imperfections. The toughened glass used, shall have no surface
defects such as folds, blowholes, prejudicial to satisfactory performance in
service and there shall be no bubbles in the glass greater than 5 mm in
diameter.

4.4.3 Alumina cement shall be used as the bonding agent between the wet-process
porcelain/toughened glass and the metal parts. Sulfur based cement shall not
be used.

4.5 Fabrication

4.5.1 The cap and pin shall be cemented on the porcelain or glass with load
distribution evenly throughout the porcelain or glass. Before cementing, the
cap and pin surface in contact with the cement shall be coated with
bituminous compound.

4.5.2 The contours of the metal and porcelain or glass parts shall be such as to
eliminate areas of high electrical stress concentrations.

4.5.3 The axial and radial displacements of the insulator and their verification shall
be in accordance with IEC 60383-1.

4.5.4 To inhibit the accelerated corrosion of insulator pin due to leakage currents, a
corrosion intercepting zinc sleeve fused to the pin shall be provided at the
point where the steel pin emerges from the cement. The zinc sleeve shall
protect the pin from corrosion for the entire service life of insulator.

4.5.5 Cotter keys shall be humped to maintain the key in the locked and unlocked
positions and shall have prongs spread to prevent complete withdrawal from
the socket. The design of the keys shall be such that their engagement and
disengagement can be achieved with the use of standard transmission hot line
tools without excessive force required.

4.5.6 For 111kN insulators, ball and socket couplings shall be Type J as per
ANSI/NEMA C29.2B or Size 16A as per IEC 60120.

4.5.7 For 160 kN and 210 kN insulators, ball and socket couplings shall be Type K
as per ANSI/NEMA C29.2B or Size 20 as per IEC 60120.

4.6 Dimensions

The dimensions of the suspension insulators shall be as specified in Data Schedule

and as shown in the Table 02:

15TMSS02R02/FAZ Date of Approval: June 27, 2016 PAGE 7 OF 16

TRANSMISSION MATERIALS STANDARD SPECIFICATION 15-TMSS-02, Rev. 02

Table 02

Combined Mechanical and Minimum Creepage

Maximum Shell Nominal Spacing
Electrical (M & E) Strength/ (Leakage) Distance
Diameter (mm) Distance (mm)
Electro-mechanical Failing (mm)
Load/Mechanical Failing Super Aero Super Aero Super Aero
Fog Fog Fog
Load, kN Fog Form Fog Form Fog Form
111 432 612 335 280 330 380 146 146 146
111 545 330 146
160 432 300 156
160 545 - 335 330 - 420 156 - 146
210 545 - 335 330 - 420 170 - 170
Note:
i While replacing or using insulators on existing transmission lines/existing design of structures it must be
ensured that specified clearances to structures/ground are maintained.
ii A nominal spacing of 127mm may be used for 111kN Aero form type insulators for maintenance
purposes on existing and/or modification of existing transmission lines provided this spacing was
considered in the design of existing structures and the conditions of Note i above are satisfied.

4.7 Markings

4.7.1 Each wet-process porcelain or toughened glass insulator shall bear a legible
and durable marking in accordance with IEC or ANSI/NEMA Standards,
identifying the following:

a. Manufacturer's Name
b. Year of Manufacture
c. Combined Mechanical and Electrical (M & E) Strength/Electro -
mechanical Failing Load (Porcelain) and Mechanical Failing Load
(Glass) "M"
d. Tension Proof Test Load, "TEST"
e. Country of Origin

4.7.2 Crate or Pallet Marking (whichever is applicable)

a. Insulator Shell (Porcelain/Toughened Glass)

b. Insulator Type (Fog/Super Fog/Aero Form)
c. Purchase Order Number/Contract Number
d. 15-TMSS-02
e. Manufacturer’s Catalogue No.
f. Number of insulators in the Pallet and Crate
g. Weight of pallet/crate
h. Country of Origin

The markings shall be legible and durable.

15TMSS02R02/FAZ Date of Approval: June 27, 2016 PAGE 8 OF 16

TRANSMISSION MATERIALS STANDARD SPECIFICATION 15-TMSS-02, Rev. 02

5.0 TESTS

All test results shall be provided for review and acceptance by National Grid Saudi Arabia.

5.1 Type (Design) Tests

5.1.1 In lieu of the actual type/design tests, certified test reports of design (type)
tests performed on a unit of identical design and rating may be submitted to
National Grid Saudi Arabia for review and approval during bidding stage.

All type/design tests prescribed in the relevant ANSI/NEMA or IEC

standards including, but not limited to the followings shall be performed on
the first production lot/batch of insulators of every new design to be supplied
to National Grid Saudi Arabia.

a. Low Frequency Dry Flashover Test

b. Low Frequency Wet Flashover Test

c. Critical Impulse (Positive/Negative) Flashover Test

d. Radio-Influence Voltage Test

e. Thermal Shock Test

f. Residual-Strength Test

g. Impact Strength Test

h. Cotter Key Test

i. Combined Mechanical and Electrical (M & E) Strength/Electro-

mechanical Failing Load/Mechanical Failing Load Test. Acceptance
criteria shall be as be as defined under Clause 5.1.1.j (iii & iv).

j. Thermal-Mechanical Performance/Load Cycle Test

The temperature variation for thermal-mechanical performance/load

cycle test on string insulator units shall be minus five degrees
centigrade (-5oC) to plus sixty-five degrees centigrade (+65oC) A
tensile load equal to 60% of the rated mechanical strength of
insulators shall be applied during the test. The acceptance criteria
shall be as below:

i. Test results shall match that of the ordinary combined

mechanical and electrical strength/electro-mechanical failing
load/mechanical failing load test.

ii. All insulators subjected to combined mechanical and electrical

strength/electro-mechanical failing load/mechanical failing

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TRANSMISSION MATERIALS STANDARD SPECIFICATION 15-TMSS-02, Rev. 02

load test shall be equal or exceed the rated combined

mechanical and electrical strength/electro-mechanical failing
load/mechanical failing load.

iii. For all insulators:

X > Rating + 3S

Where:
X = average value obtained on the sample insulators tested
Rating = rated mechanical strength of sample insulators
S = standard deviation obtained on the sample insulators
tested

iv. Electrical puncture (for porcelain insulators) shall not occur

before the ultimate fracture

5.2 Routine (Production) Tests

All routine (production) tests prescribed in the relevant IEC or ANSI/NEMA

standards shall be performed on all units prior to delivery to National Grid Saudi
Arabia.

5.3 Sample (Quality Conformance) Tests

All sample (quality conformance) tests prescribed in the relevant IEC and
ANSI/NEMA standards including but not limited to followings shall be performed
on each lot of insulators prior to delivery to National Grid Saudi Arabia:

a. Verification of dimensions
b. Galvanization Test
c. Verification of axial and radial displacement
d. Verification of the locking system
e. Combined Mechanical and Electrical (M & E) Strength/Electro-mechanical
Failing Load/Mechanical Failing Load test.
f. Puncture Test (puncture testing in oil)
g. Porosity Test (porcelain insulators only)
h. Temperature Cycle Test (porcelain insulators only)
i. Residual-Strength Test
j. Steep Front-of-Wave Flashover Test (impulse puncture testing in air)

Ten (10) insulator units shall be selected at random from each production
lot/batch (less than 10,000 units) manufactured to verify insulator
characteristics and the quality of material used. Each insulator unit shall be
subjected to a series of five (5) positive & five (5) negative and five (5)
positive & five (5) negative (20 impulses) with a wave front having a
minimum effective rate of rise of 2500kV per microsecond in accordance
with IEC 61211.

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TRANSMISSION MATERIALS STANDARD SPECIFICATION 15-TMSS-02, Rev. 02

After steep front-of-wave test, all insulators shall be subjected to combined

mechanical and electrical strength/electro-mechanical failing
load/mechanical failing load test as per relevant ANSI/NEMA or IEC
standards.

Acceptance criteria shall be as follows:

i. No electrical puncture (internal puncture) shall occur.

ii. Every steep front-of-wave impulse voltage application shall result in

an external flashover.

iii. The result of these tests shall equal or exceed the rated combined
mechanical and electrical strength/electro-mechanical failing
load/mechanical failing load.

The failure of any one insulator unit either in the front-of-wave or subsequent
combined mechanical and electrical strength/electro-mechanical failing
load/mechanical failing load test shall require testing an additional 20 units.
Failure of more than one unit from the total so tested shall constitute failure
to meet the requirements of this specification.

5.4 Special Tests

In addition to the above ANSI/NEMA or IEC type test requirements, the following
special tests shall be carried out on the insulators to be supplied to National Grid
Saudi Arabia.

a. Power Arc Test

This test shall be performed at manufacturer’s own laboratory or at an

accredited Independent Testing Laboratory in the presence of National Grid
Saudi Arabia representative. This test shall be carried out on the first
production lot/batch of insulators. The test results shall be considered valid
for a period of five years only, after which these tests shall be repeated in
case of any further supply from the same manufacturer and from the same
manufacturing plant. This test may also be repeated at any time within a five
years period, if National Grid Saudi Arabia considers it necessary for a
particular project as specified in Data Schedule.

Power arc test shall be performed on a short string as per procedure & test set
up of IEC 61467 except as below:

Test Short Circuit Number and

Circuit Current duration of test
D In = 6 kA 2 shots, tn =0.2 sec

The insulators shall be operationally safe after the conclusion of the test and
shall meet the following criteria in addition to that specified in IEC 61467:

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TRANSMISSION MATERIALS STANDARD SPECIFICATION 15-TMSS-02, Rev. 02

i. There shall be no separation of metal components from

porcelain/glass body.

ii. The insulators shall not have an electrical puncture (porcelain

insulators) and the flashover shall be external when subjected to dry
flashover test.

iii. The mechanical strength of insulators shall not be reduced below 70%
of combined mechanical and electrical strength/electro-mechanical
failing load/mechanical failing load test.

Failure of any one insulator unit in the test shall be the cause for testing
another short string.

Failure of more than one insulator unit from the short strings so tested shall
constitute failure of the insulator design to meet the requirements of the
specification.

b. Pollution Test

The pollution test shall be performed only on the insulators of new design
and this test shall be carried out in accordance with IEC 60507 and as per
below:

i. Salt fog method (to simulate coastal pollution) for fog type insulators
(the value of salinity shall be 80 kg/m3).

ii. Solid layer method (to simulate inland pollution) for aero form type
insulators (the value of ESDD shall be 0.3 mg/cm2).

6.0 SHATTERING RATE (GLASS INSULATORS)

The shattering rate shall not exceed one insulator unit per ten (10) thousand insulators per
year (1/10000/year). The manufacturer shall guarantee and submit documentary evidence
and shall introduce necessary quality control measures to achieve the specified
requirements.

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TRANSMISSION MATERIALS STANDARD SPECIFICATION 15-TMSS-02, Rev. 02

7.0 DATA SCHEDULE

SUSPENSION TYPE INSULATORS

Enquiry No. Date:

Purchase Order No. Date:

or Contract No.

PTS No./Project Title with J.O. No.

REFERENCE
SECTION NO. DESCRIPTION 'A' 'B' 'C'

3.0 APPLICABLE CODES AND STANDARDS

Applicable Industry Standards *

4.0 DESIGN AND CONSTRUCTION REQUIREMENTS

4.1 Insulator Material

Porcelain/Toughened Glass

4.2 Insulator design type

Fog/Super Fog/Aero Form

4.3 Ratings

Combined Mechanical and Electrical (M &

E) Strength/ Electro-mechanical Failing
Load/Mechanical Failing Load
(111kN/160kN/210kN)

Tension proof load

(55.5kN/80kN/105kN)

Impact strength (7 N-m/10 N-m)

'A'- NATIONAL GRID SAUDI ARABIA SPECIFIED DATA/PARAMETERS

'B'- BIDDER/SUPPLIER/VENDOR/CONTRACTOR PROPOSED DATA/PARAMETERS
'C'- REMARKS SUPPORTING THE PROPOSED DEVIATION IN COLUMN 'B'
*- DATA/PARAMETERS TO BE PROVIDED/PROPOSED BY THE BIDDER/SUPPLIER/
VENDOR/CONTRACTOR IN COLUMN 'B'

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TRANSMISSION MATERIALS STANDARD SPECIFICATION 15-TMSS-02, Rev. 02

7.0 DATA SCHEDULE

SUSPENSION TYPE INSULATORS

REFERENCE
SECTION NO. DESCRIPTION 'A' 'B' 'C'

Electrical Values (Porcelain Insulators)

Low frequency dry flashover (80kV/95kV) *

Low frequency wet flashover

(50kV/55kV) *

Critical impulse flashover, Positive

(105kV/135kV) *

Critical impulse flashover, negative

(105kV/145kV) *

Electrical Values (Glass Insulators)

Low frequency dry flashover

(65kV/75kV/95kV) *

Low frequency wet flashover

(55kV/50kV) *

Critical impulse flashover, Positive

(95kV/105kV/135kV) *

Critical impulse flashover, negative

(95kV/105kV/145kV) *

Low frequency puncture Voltage (kV) 110/125

RIV low frequency test voltage (rms to

ground) (kV) 10

Maximum RIV at 1000 KHz (µV) 50

Weight per unit (kg) *

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TRANSMISSION MATERIALS STANDARD SPECIFICATION 15-TMSS-02, Rev. 02

7.0 DATA SCHEDULE

SUSPENSION TYPE INSULATORS

REFERENCE
SECTION NO. DESCRIPTION 'A' 'B' 'C'

4.4 Color for Aluminous porcelain Brown Glaze

4.5 Coupling type (ANSI/NEMA size J/K) or

(IEC size 16A/20)

4.6 Dimension:

Creepage (Leakage) distance per unit (mm) *

Shell diameter (mm) *

Spacing distance (mm) *

5.0 TYPE/DESIGN TESTS

5.1 Are type/design tests required? Yes/No

Are type/design tests performed? * Yes/No

5.2 SPECIAL TESTS

Are special tests required? Yes/No

Are special tests performed? * Yes/No

6.0 Shattering rate for glass insulators

(per 10,000 units per year) 1

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TRANSMISSION MATERIALS STANDARD SPECIFICATION 15-TMSS-02, Rev. 02

7.0 DATA SCHEDULE

SUSPENSION TYPE INSULATORS

A. ADDITIONAL TECHNICAL INFORMATION OR FEATURES TO BE FURNISHED BY

NATIONAL GRID SAUDI ARABIA:

B. ADDITIONAL SUPPLEMENTARY DATA OR FEATURES PROPOSED BY

BIDDER/VENDOR/SUPPLIER/CONTRACTOR:

C. OTHER PARTICULARS TO BE FILLED UP BY BIDDER/VENDOR/SUPPLIER/

CONTRACTOR:

Actual Manufacturer Vendor/Supplier/

of Equipment/Material Contractor

Name of the Company

Location and address

Name and Signature of

authorized
representative
and date

Official Seal/Stamp
of the Company &
Date

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