ADOPTION OF COMPOSITE

SILICONE INSULATORS FOR EHV

SUBSTATION EQUIPMENTS
 DRAWBACKS ASSOCIATED WITH PORCELAIN EQUIPMENT
INSULATORS

 So far we have been using porcelain insulators for substation equipments like circuit breakers,
isolators, current transformers, capacitive voltage transformers, surge arresters, transformer and
reactor bushings etc.

 These porcelain insulators suffer from the following disadvantages –

 A) They are brittle and pose the risk of explosion in case of internal pressure build up or failure
thus endangering nearby equipment and personnel.

 B) the surface of these porcelain insulators is hydrophilic i.e. a continuous film of water can form
on their surface leading to a increase in leakage current.

 C) The porcelain insulators are prone to contamination ( coastal , desert like, industrial etc). The
contaminants form a layer on the surface of the porcelain insulator. This layer of contaminants
can absorb water and become electrically conducting leading to dry band arcing, corona
discharges and eventually flashover. During the process the surface of the insulator also
deteriorates.
 DRAWBACKS ASSOCIATED WITH PORCELAIN EQUIPMENT
INSULATORS

 D) In view of C) above they need regular maintenance like hot line washing in order to keep
the surface clean.

 E) The porcelain insulators are heavy in weight and involve considerable handling and
transportation costs and also require heavy steel structures to support them.

 F) Being brittle they are liable to damage during transportation and this increases their cost.

The above drawbacks prompted search for better alternatives which did not suffer from the
above drawbacks.. A number of alternatives have been investigated over a period of time.
These include –
 SEARCH FOR OTHER ALTERNATIVES

A) Silicon Rubber ( SR) – Room Temperature Vulcanising (RTV), High temperature Vulcanising
and Liquid silicone rubber ( LSR).

B) Ethylene Propylene Rubber ( EPR) , Ethylene Propylene Monomer ( EPM). Ethylene Propylene
Dien Monomer ( EPDM)

C) Epoxy Resin – Bisphenol, cycloaliphat

D) Polyurethene

E) Polyfluor carbons – Teflon, PTFE

 Experience and investigations with the above alternatives has led to the narrowing of the
choice to silicone rubber as a reliable option for outdoor insulation material. Present research
is therefore focused on silicone rubber composite insulators with the aim of improving their
performance as an outdoor insulating material.
 ADVANTAGES OF COMPOSITE HOLLOW EQUIPMENT INSULATORS
OVER PORCELAIN INSULATORS
 As compared to porcelain insulators silicone rubber composite insulators offer the following advantages-

 A) The silicone rubber insulators are not brittle like porcelain and thus do not break like porcelain insulators
in the event of an internal pressure build up or when exposed to vandalism.

 B) In case of an internal pressure build up the silicone composite insulators fail by way of delamination i.e.
the pressure release starts by way of sweating of the insulator surface and then slowly the insulator
releases the pressure by rupture of its various layers instead of sudden burst of pressure as in porcelain
insulators. Thus composite insulators do not pose any risk to adjoining equipment or nearby personnel.

 C) They are much lighter in weight compared to porcelain counterparts ( as little as 1/10 th of the electrical
equivalent in porcelain) thus significantly reducing handling and transportation costs and weight of steel
structures and foundations required to support them.

 D) In contrast to porcelain insulators the external surface of composite insulators is hydrophobic in nature.
That is, it is not possible for water to form a continuous film on the surface of a clean composite silicone
insulator, instead a stream of water on the surface of this insulator breaks into drops isolated from each
other. This greatly increases the electrical resistance offered to surface leakage current and thus leakage
current is greatly reduced leading to reduced chances of flashover.
 ADVANTAGES OF COMPOSITE HOLLOW EQUIPMENT
INSULATORS OVER PORCELAIN INSULATORS

 E) The hydrophobic behavior of surface of composite silicone insulators is due primarily to the
diffusion of low molecular weight Polydimethyl – siloxane ( PDMS) compounds which are present
in the bulk of silicone rubber housing to the surface of the insulator. These PDMS have a
tendency to reside on the surface of the silicone housing of the insulator. The presence of these
compounds on the surface make the surface hydrophobic.

 F) Even in the face of severe contamination collecting on the surface of the composite silicone
insulator , they retain their hydrophobic character at the surface. This is possible because the
PDMS compound responsible for hydrophobicity of the clean surface is able to diffuse through
the layer of contaminants and keeps itself above the contamination layer.

 G) Because of reasons cited above the pollution performance of composite insulators is much
superior than that of porcelain insulators.

 H) These insulators offer high mechanical strength in relation to weight.

 I) They are ultra violet resistant i.e. there composition does not change on exposure to
ultraviolet rays.
 ADVANTAGES OF COMPOSITE HOLLOW EQUIPMENT
INSULATORS OVER PORCELAIN INSULATORS

 J) These insulators offer high resistance to power arcs.

 K) Do not need frequent maintenance to keep the surface clean.

 L) Being non – brittle there is lesser damage to silicone insulators compared to porcelain
insulators during transportation.

 M) Under normal pollution conditions ( i.e. heavy pollution severity site normally specified by us)
for 400 KV system the nominal creepage distance would be 10,500 mm for porcelain insulators.
However if we specify composite silicon insulators the required creepage distance under same
site conditions would be 8415 mm. Thus silicon insulators offer the advantage of reduced
creepage distance due to their hydrophobic nature.
 COMPOSITION OF COMPOSITE SILICONE INSULATORS

 The composite silicone insulators derive their name from the fact that they are made of two
different components, each performing a different function and chemically joined together. These
two components are –

 A) An internal core composed of glass fiber reinforced with resin which basically provides the
mechanical strength and internal insulation requirements of the complete insulator. This internal
core cannot withstand exposure to external environment and its basic purpose is to provide
mechanical strength and in case of hollow composite insulators the internal insulation strength.

 B) The second component of the composite silicone insulator is the outdoor silicone rubber
housing which is cast on top of the internal core. The purpose of this silicone housing is protect
the internal core from external environment and provide the external insulation.

 In addition to above two components the composite insulators consist of the end flanges which
are used for fixing them to the supports.
 A LOOK AT MANUFACTURING PROCESS OF SILICONE

COMPOSITE INSULATORS

 A) The internal core of the silicone composite insulators is formed by impregnating

E glass or ECR glass ( electrolytic corrosion resistant glass) fiber with epoxy resin and
these impregnated fibers are wound into hollow tubes ( GFRR tubes) on steel
mandrels. E glass and ECR glass are used because of their high constancy of the
mechanical strength and the latter shows little susceptibility to corrosion processes.

 B) After curing the GFRR tube is removed from the mandrel and the next step
involves attachment of flanges to the tube. The flanges may be fixed to the tube by
a chemical caused connection between the GFRR tube and flanges using primer
systems. Some manufacturers use crimping to attach flanges to the internal core.
Before fixing of the flanges the GFRR tube and flanges are ultrasonically cleaned to
remove any metal particles or conducting dust that may be present.

 C) After attachment of flanges the final major step in the manufacturing process
involves casting the silicone rubber shed housing on the GFRR tube.
 A LOOK AT MANUFACTURING PROCESS OF SILICONE
COMPOSITE INSULATORS

 D) Many different types of silicone rubber formulations are available for casting of silicone
housing on the GFRR tube. These include the low viscosity liquid silicon rubber formulations or
high viscosity silicone rubber paste. The high viscosity silicone formulation permits mixing of
higher amounts of useful fillers ( fillers – are substances added to silicone rubber to increase
electrical resistance, arcing resistance, tracking resistance, bending strength and other
characteristics).

 E) Generally the properties of the GFRR tube can be influenced by the following parameters –

 i) impregnation technology ( vacuum impregnation or wet winding)

 ii) Reinforcing material ( glass , polyester aramid)
 iii) Winding angle
 iv) Resin system
 SUPERIRIORITY OF COMPOSITE INSULATORS

ESTABLISHED THROUGH RESEARCH AND EXPERIENCE

 The superiority of composite insulators over porcelain insulators has been established worldwide
through experience and experimentation. Some of the findings with the use of composite
insulators are –

 A) Composite insulators were pressurized and subject to shooting to judge if they explode as
did the porcelain insulators. The only thing that happened on shooting was a puncture in the
insulator which makes them safe for personnel and other nearby equipment.

 B) Wettability is defined as the ability of a surface to be wetted by a liquid. Hydrophobic surfaces

exhibit low level of wettability by water of a surface. A hydrophobic surface has a low surface
tension and thus is water repellant. Hydrophilic surfaces exhibit high degree of wettability by
water. A hydrophilic surface has a high surface tension and thus is wetted by water.

 C) IEC – 62073 defines seven wettability classes ( WC) , WC 1 to WC 7. WC 1 corresponds to

the most hydrophobic surface and WC 7 to the most hydrophilic surface. These classes are
defined based on receding contact angles of water droplets on the surface.
 SUPERIRIORITY OF COMPOSITE INSULATORS
ESTABLISHED THROUGH RESEARCH AND EXPERIENCE
Wettability Class Description

WC 1 Only discrete droplets are formed. Their shape when viewed perpendicular to the surface is
practically circular. Receding angle equal to greater than 80 degrees.

WC 2 Only discrete droplets are formed. The major part of the surface is covered by droplets with
a shape as seen perpendicular to the surface still regular but deviates from circular form.
Receding angle between 50 degrees and 80 degrees.

WC 3 Only discrete droplets are formed. The major part of the surface is covered by droplets with
an irregular shape. Receding angle between 20 degrees and 50 degrees.

WC 4 Both discrete droplets and wetted traces from water runnels or water film are observed ( i.e
receding angle is zero for some droplets). Less than 10 % of the observed area is covered
by runnels or film.
WC 5 Both discrete droplets and wetted traces from the water runnels or water film are observed.
More than 10 % but less than 90 % of the observed area is covered by water runnels or
film.
WC 6 More than 90 % but less than 100% of the observed area is covered by water runnels or
film ( i.e small non – wetted areas / spots/ traces are still observed).

WC 7 Continuous water film is formed over the whole observed area.

 SUPERIRIORITY OF COMPOSITE INSULATORS
ESTABLISHED THROUGH RESEARCH AND EXPERIENCE

 D) Even under severe pollution conditions silicone composite insulators have been found to be
always one wettability class better than porcelain insulators of EHV substation equipment. This
has also been confirmed by leakage current measurements. Transfer of hydrophobicity through
the pollution layer has also shown high values.

 E) A key factor to improving the contamination performance of substation equipment insulators

and station post insulators is minimizing the electric field strength at the charged end of the
insulator . This can be done in the following ways –

 a) increasing the length of the insulator i.e the arcing distance

 b) Increasing the creepage distance of the insulator by using alternate long and short sheds or
ribbed sheds

 c) Using hydrophobic coating on porcelain insulators or composite insulators.

 SUPERIRIORITY OF COMPOSITE INSULATORS
ESTABLISHED THROUGH RESEARCH AND EXPERIENCE

 F) Electric field calculations were performed on 230 KV porcelain insulators having different BIL
and hence different insulator lengths. The study revealed that increasing the length of the
insulator has only a marginal effect on reducing the electric field intensity. A large increase in
height is required to obtain substantial reduction in electric field near the charged end of the
insulator and this raises cost issues.
 SUPERIRIORITY OF COMPOSITE INSULATORS
ESTABLISHED THROUGH RESEARCH AND EXPERIENCE
( TABLE : EFFECT OF INCREASE IN LEGTH OF INSULATOR HAS ONLY MARGINAL EFFECT ON ELECTRIC FIELD
INTENSITY)

Voltage KV BIL KV Length E (max), E (max),

mm. Dry Wet
KV/cm KV/cm
230 750 1575 6.49 26.45

230 900 2032 6.63 24.69

230 1050 2337 6.63 23.90

 SUPERIRIORITY OF COMPOSITE INSULATORS
ESTABLISHED THROUGH RESEARCH AND EXPERIENCE

 G) Electric field calculations were also carried out to compare the insulation with ribbed sheds
and hence increased leakage distance with insulators without under ribs. The additional
creepage distance of ribbed insulators was 10 % higher than that of non ribbed insulators.
Computations performed for 138 KV porcelain insulators revealed that increased creepage
distance provides significant reduction in electric field strength. Higher creepage reduces the
region where the electric field strength exceeds the corona threshold value from 65% to 40 %
of distance from the energized end.

 H) Next electric field calculations were performed for insulators with hydrophobic coatings. The
table below summarizes the percentage length for which the electric field exceeds corona
threshold for porcelain insulators with hydrophobic coatings.
 SUPERIRIORITY OF COMPOSITE INSULATORS
ESTABLISHED THROUGH RESEARCH AND EXPERIENCE
( TABLE : EFFECT OF COATING OF HYDROPHOBIC MATERIAL ON THE ELECTRIC FIELD INTENSITY IS
SUBSTANTIAL)

Voltage KV % length for which E >

E threshold
138 0
230 3
345 6
500 8.5
765 10
 SUPERIRIORITY OF COMPOSITE INSULATORS
ESTABLISHED THROUGH RESEARCH AND EXPERIENCE

 I) Though the above study was carried out on station post insulators it reveals the essential
advantages of higher creepage and hydrophobic surface in reducing the electric field strength at
the live end of the insulator which in turn would lead to better contamination performance. The
results of the study can well be applied to equipment composite insulators also.
 Present status of manufacturing in India

 Presently the following companies in India are making equipment composite silicone
insulators –

 M / S Tyco Electronics, Banglore is manufacturing surge arresters with composite insulators.

 M/S BHEL has manufactured and type tested 145 KV CT ( oil filled) with composite
insulators.

 M/S Siemens , India has manufactured and supplied 245 KV CTs ( SF6 filled) and 420 KV
CTs ( SF6 filled) and 245 KV CVTs.

 M/S Stork Phobos Electrical Private Ltd , M / S Deccan Enterprises Private Ltd , M / S Lamco
Industries Pvt. Ltd. are in manufacturing of LV / MV/EHV composite post insulators.

M/S Yamuna Power and M/S Goldstone Infratech Limited are other manufacturers of
silicone profile insulators.
Composite Insulator Design