“Insulators ”

“Section – Introduction”
 What Is an Insulator?
An insulator is a “dam***” poor conductor!
And more, technically speaking!
An insulator is a mechanical support!
 Primary function - support the “line”
mechanically
 Secondary function– electrical
Air is the insulator
Outer shells/surfaces are designed to increase
leakage distance and strike distance
 What Does an Insulator Do?

Maintains an Air Gap

 Separates Line from Ground
length of air gap depends primarily on system voltage
, modified by desired safety margin, contamination, e
tc.
 Resists Mechanical Stresses
“everyday” loads, extreme loads
 Resists Electrical Stresses
system voltage/fields, overvoltages
 Resists Environmental Stresses
heat, cold, UV, contamination, etc.
 Where Did Insulators Come
From?
Basically grew out of the needs of the telegraph industry
– starting in the late 1700s, early 1800s

Early history centers around what today we would

consider very low DC voltages

Gradually technical needs increased as AC voltages

grew with the development of the electric power industry
 History
Glass plates used to insulate telegraph line DC to Baltimore

Glass insulators became the ”norm” soon thereafter – typical

collector’s items today

Many, many trials with different materials – wood – cement –

porcelain - beeswax soaked rag wrapped around the wire, etc.

Ultimately porcelain and glass prevailed

  Wet process porcelain developed for high voltage applications
 Porcelain insulator industry started

Application voltages increased

 Insulator designs became larger, more
complex
Ceramics (porcelain, glass) still only choices at
high voltages
 US trials of first “NCIs” – cycloaliphatic based
 Not successful, but others soon became interested and a
new industry started up

 Europeans develop “modern” style NCI – fiberglass rod with

various polymeric sheds
 Now considered “First generation”
 NCI insulator industry really begins in US with field trials of insulators
 Since that time - new manufacturers, new designs, new materials
NCIs at “generation X” – there have been so many improvements in
materials, end fitting designs, etc.
Change in materials have meant changes in line design practices,
maintenance practices, etc.
Ceramic manufacturers have not been idle either with development of
higher strength porcelains, RG glazes, etc.
Domestic manufacturing of insulators decreases, shift to offshore (all
types)

 Engineers need to develop knowledge and skills necessary to

evaluate and compare suppliers and products from many different
countries

An understanding of the basics of insulator manufacturing, design

and application is more essential than ever before
 Insulator Types
 For simplicity will discuss in terms of three
broad applications:

Distribution lines (thru 69 kV)

Transmission lines (69 kV and up)

Substations (all voltages)

 Distribution lines
 Pin type insulators -mainly porcelain, growing use of
polymeric (HDPE – high density polyethylene), limited
use of glass (in US at least)
 Line post insulators – porcelain, polymeric
 Dead end insulators – polymeric, porcelain, glass
 Spool insulators – porcelain, polymeric
 Strain insulators, polymeric, porcelain
Types of Insulators – Distribution
 Transmission lines
 Suspension insulators - new installations mainly NCIs,
porcelain and glass now used less frequently

 Line post insulators – mainly NCIs for new lines and

installations, porcelain much less frequent now
Types of Insulators – Transmission
Substations
 Post insulators – porcelain primarily, NCIs growing in
use at lower voltages (~161 kV and below)

 Suspension insulators –NCIs (primarily), ceramic

 Cap and Pin insulators – “legacy” type

Types of Insulators – Substation
 Insulator Types -
Comparisons
Ceramic Non Ceramic
• Porcelain or toughened • Typically fiberglass rod with
glass rubber (EPDM or Silicone)
sheath and weather sheds
• Metal components fixed • HDPE line insulator
with cement applications
• ANSI Standards C29.1 • Cycloaliphatic (epoxies) station
through C29.10 applications, some line
applications
• Metal components normally
crimped
• ANSI Standards C29.11 –
C29.19
Ceramic Non Ceramic
• Hydrophobic materials
• Materials very improve contamination
resistant to UV, performance
• Strong in tension, weaker in
contaminant compression
degradation, electric • Deflection under load can
field degradation be an issue
• Materials strong in • Lighter – easier to handle
compression, weaker in • Electric field stresses must
be considered
tension
• High modulus of
elasticity - stiff
• Brittle, require more
careful handling
Ceramic Non Ceramic
• “Material properties
• Generally designs are have been improved –
“mature” UV resistance much
• Limited flexibility of improved for example
dimensions • Standardized product
lines now exist
• Process limitations on
• Balancing act - leakage
sizes and shapes distance/field stress –
• Applications/handling take advantage of
methods generally hydrophobicity
well understood • Application parameters
still being developed
• Line design
implications (lighter
weight, improved shock
resistance)
 Dry Arcing Distance
Shortest distance through the surrounding medium
between terminal electrodes , or the sum of distances
between intermediate electrodes , whichever is shortest,
with the insulator mounted for dry flashover test.