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A3-303

CIGRE 2012

Design and application of composite insulators in AC and DC systems with

special attention to severe environment
E.MOAL
MPF
France

G. ROCCHETTIA.
MPS
USA

PIGINI
Consultant
Italy

SUMMARY
Composite housings are becoming the preferred solutions for most of the EHV and UHV applications
due to their many advantages especially in severe environment.
Specific reference is made in the paper to composite housings with extruded sheds: a technology
which guarantees the maximum flexibility and adaptability to the different applications.
Results of experimental investigations are reported to confirm the good performance of the solution
in laboratory with special attention to severe environment.
The laboratory god experience is confirmed by the experience in test stations and by the return of
service experience. Field feed-back indicates that composite insulators, correctly dimensioned
according to laboratory test results and taking correctly into account the site pollution, present a
satisfactory short and long term performance.
Then the design optimization aspect is analyzed both in AC and DC with particular reference to
pollution. It is shown that pollution determines the design especially in DC, thus needing a specific
detailed accurate design approach.
From the analysis the benefits of the composites over the ceramic solution clearly appear, especially
for applications in the UHVDC range.

KEYWORDS
Composite Insulators- Station Insulators-Pollution-Direct Current-Alternate Voltage-UHV
Applications

emoal@macleanpower.fr
1

INTRODUCTION
Composite housing are becoming the preferred solutions for most of the EHV and UHV applications
due to their many advantages [1], [2], [3]. In the paper, after a brief description of the specific
technology considered (composites with extruded housing), the electrical performance of the solution
is analyzed on the basis of laboratory and field information. Advantages are then described with
respect to the ceramic alternative both for AC and for DC applications, showing how composites can
help to optimize the design.
HV composite housing have been produced since 20 years according to a patented process where HTV
(High temperature vulcanized) Silicone weather sheds are extruded, vulcanized and bonded over an
FRP (Fiberglass Reinforced Polymer) tube with aluminum alloy fittings, fully in agreement with [4].
In particular insulators with extruded HTV housing for apparatus applications are qualified by Utilities
in France, Italy, UK, Spain, USA, Canada, South Africa, Brazil, UAE, and Algeria and used in all the
world by Utilities and manufacturers. More than ten thousand extruded type insulators were already
installed before the year 2000. Today, more than one hundred thousand hollow core insulators with
extruded sheds have been manufactured: the majority for the highest range of system voltage (greater
than 245 kV). In particular hollow core insulators for all types of AC and DC High Voltage
applications for all voltage ratings up to the highest system voltages were produced as specified here
below [3]:

Breakers (up to 800 kV)

Cable terminations (up to 550 kV)
Measuring transformers (up to 800 kV)
Bushings (up to 800 kV AC and 550 kV DC)
DC transformer bushings (up to 550 kV)
Capacitors (up to 800 kV)
Station posts and bus bars supports (up to 800 kV)
Optical insulators (up to 800 kV)

COMPOSITE HOUSINGS: THE EXTRUSION TECHNOLOGY

The tube is manufactured with a wet filament winding technique. Glass fibers are wetted with an
epoxy resin and wound according to the specific angle and to the specific thickness to conform with
the required mechanical characteristics taking into account the insulator function. The used materials
are resin, fibers and glue, which have been developed and qualified to resist mechanically and
electrically for the entire life of the equipment under severe temperature and dynamic mechanical
stresses. In the case of SF6 gas insulation, a special non-glass liner is added inside the housing as a
protection against SF6s byproducts, that may be generated by arcing processes.
HTV silicone charged with ATH (alumina trihydrate) is used for the housing because it has a strong
resistance to arcing and erosion. The sheds are extruded and wound onto the FRP tube, rolled and
pressed according to the a patented process [4], leading to the so called helical profile (see Fig. 1).

Scheme of the process

Actual manufacturing process

Fig.1 Extrusion process

One particular advantage of the extrusion process is its extreme flexibility, much higher than for the
molding processes. In particular the process allows the production of a variety of profiles designed to
meet leakage distances specified by end-users, with spacing, shed shape, overhang and inclination
according to the specific requirements and environmental conditions. Examples of developed shed
profiles are shown in Fig. 2. The insulators may be supplied with simple sheds or alternate sheds to
withstand the most severe environmental conditions.

Single

Double

Double with the drop effect

Fig. 2 Shed profile example

Due the technology flexibility it was possible to respond fast to the UHV needs as shown by the
prototype in Fig 3, set up in view of the development of the 1100 kV DC bushings.
The prototype has a total length of 12,5 m, a minimal leakage distance of 48 m, a maximum external
diameter of about 1,2 m and an approximate total weight of 2.4 tons: it is made of a single piece.

Fig. 3 Prototype of 1100 kV DC housing

LABORATORY AND FIELD EXPERIENCE WITH COMPOSITES

MANUFACTURED ACCORDING TO THE EXTRUDED TECHNOLOGY
Doubts were raised about the pollution performance of the helical profile resulting by the extrusion
process [5], on the basis of results obtained on old porcelain insulators as the Spirelec ones whose
manufacture was since long stopped and whose profile is not conforming with IEC 60815
recommendations [7], [8].
The inadequacy of the Spirelec profile was known since the 90 as confirmed by the results in Fig. 4
reporting a comparison of the performance under salt fog of Spirelec ceramic insulators [5], [6] with
that of ceramic insulators and of silicon insulators with helical profile complying with IEC [7]. As
evident from the Figure, the Spirelec profile, remarkably deviating from IEC indications, is extremely

inefficient, as it is indicated by the fact that the required unified specific creepage distance, USCD, is
much higher than for conventional porcelain station insulators.
On the contrary silicon insulators with a helical profile complying with IEC 60815 indications shows
much better performance than Spirelec insulators. The performance is even better than that of
ceramic insulators with a conventional profile conforming with IEC, due to the HTM (hydrophobic
transfer material) characteristics of silicon insulators, and this in spite of the severe testing procedure
used in [7] to determine the pollution withstand. The advantage of the helical profile versus the
porcelain solution is even greater for large diameter insulators, due to the well known less dependence
of USCD on the insulator diameter for HTM materials [7].
The results confirm that the unsatisfactory performance of old spiral insulators was due to their
inadequate profile and cannot be extrapolated to insulators with helical profile conforming with IEC.
All the helical type silicon insulators manufactured to-day strictly conform IEC 60815 indications.

USCD( mm/kV)

100

porcelain Spirelec (not IEC profile) [6]

porcelain Spirelec (not IEC profile) [5]
porcelain (IEC profile) [7]
silicon helicoidal (IEC Profile) [7]

10
10

100
S (Kg/m3)

Fig. 4 Salt fog tests. AC voltage. USCD as a function of test salinity

The good performance of the composite insulators with helical profile conforming to IEC is
confirmed by the performance under rain tests as shown by Fig. 5 which compares the dielectric
strength reduction due to rain of composite and porcelain station insulators of short length (about 1.5
m long) as a function of the insulator diameter [7]. Again the Figure indicates that the influence of
wetting is lower for composites with helical profile than for porcelain with a conventional profile. It
has however to be noted that luckily the influence of wetting remarkably decreases for longer units
and actual configurations both for ceramic and composite solutions [9].
1,1

Uwet/Udry

1
0,9
0,8
0,7

porcelain
composite

0,6
0,5
0

100

200

300
D (mm)

400

500

600

Fig. 5 - SI (Switching Impulse) tests, positive polarity voltage. Flashover voltage ratio under wet and
dry conditions versus the insulator external diameter. Comparison between composite and ceramic
housing data.
The good laboratory performance of composites is confirmed by experiences in experimental stations
characterized by severe environments [3]. As an example a severe test experience was carried out at

Martigues test station in France. This test station is characterized by very severe marine/industrial
pollutions. The level of pollution at Martigues is equivalent to a very heavy contamination, thus
requiring a USCD of 53,7 mm/kV or higher [8]. In addition Marseilles region offers a high level of
sunlight with typically more than 3000 hours of sunshine per year. Cable terminations with helical
profile has been energized at the Martigues test station for more than 10 years (experience initiated in
1998 and ended 2009) without flashover. No washing was necessary. Several other field experiences
have been made with positive results as that at the Dunkerque test station for 11 years.
Finally a good service performance of the examined composite solution can be reported. Insulators are
installed in many parts of the world including many heavily polluted areas. As an example more than
one hundred SF6 insulated CT are installed in South Africa 275kV Network since 1995 in a severe
pollution environment with good performance.
The performance of insulators are satisfactory also when considering other aspects than pollution.
Insulators are used with satisfactory performance for generator circuit breakers since many years.
These breakers are characterized by a rated current up to 26 kA and short-circuit current up to 210 kA.
Insulators installed in these breakers are highly stressed due to important mechanical loads during
short-circuit operations and high continuous working temperature (105 C) due to the very high
nominal current.
Positive experience is reported on insulators installed on laboratory circuit breakers that are subjected
to severe stresses in terms of arc generated byproducts confirming the arc resistance of the inner
design, protected by a polyester film.
Thousands of insulators are installed in seismic areas after having been qualified by means of severe
seismic testing.
Not to be forgiven the fact that, in contrast to the porcelain solutions, the composite solution is
explosion proof: this is one of the main reasons why the composite solution is becoming the preferred
solutions of many utilities in the world.

DESIGN OPTIMISATION FOR AC APPLICATIONS

The design for AC application is analyzed in the following with the aim to compare ceramic and
composite solutions. The design example is made with reference to the specific application of
bushings, following the specifications in [10] and in the forthcoming new edition which extends the
Standard to UHV. Two switching impulse (SI) levels are considered in the application and namely the
maximum and the minimum foreseen in [10] for each system voltage. The arcing distances necessary
to comply with the required SI are reported in Fig. 6 and 7 for ceramic and composite insulators
respectively, where Lmax corresponds to the SI maximum and Lmin corresponds to the SI minimum
considered in [10]. The evaluation of L under SI is made in agreement with [9]. As far as
contaminations is concerned the evaluation is made with reference to the indications in [8] and to the
USCD specified for each pollution level: Very Light (LPVL), Light (LPL), Medium (LPM), Heavy
(LPH) and very heavy (LPVH). The arcing distances evaluated for each level are reported in Fig. 6
and 7 for the porcelain and composite solutions.
The calculation is made assuming for each pollution class the maximum creepage factor CF which,
according to [8], guarantees a high efficiency of the profile. As an example for LPVH a maximum
creepage factor of 4 is suggested for the ceramic solution while a higher value (4.8) is considered for
composites. In the evaluation, in agreement with [8], a lower dependence of the required USCD on the
insulator diameter is considered for composite than for ceramic insulators. Conservatively, as
indicated in [8], the same USCD is assumed for porcelain and composite insulators, neglecting the
benefits for composites deriving from their HTM (Hydrophopic Transfer Material) characteristics of
the material used for the housing.
As it appears from Fig. 6, for ceramic housing the design is dominated by SI when reference is made
to the maximum values foreseen in [10], while pollution dominates the design for the more severe
pollution conditions when lower SI levels are considered in design.

14

Lmax (SI)

14

Lmin (SI)

12

LP VL

12

LP VL

10

LP L

10

LP L

LP M

LP H

LP VH

L(m)

L(m)

Similar evaluations are made for the composite solutions and the results are reported in Fig. 7.
In this case SI dominates the design both in the case of SI maximum and minimum, allowing to take a
real benefit of the overvoltage control in all the environmental conditions.

LP M

LP H

LP VH

0
0

500

1000

1500

500

Um (kV)

a) Maximum SI level foreseen in [10]

1000

1500

Um (kV)

b) Minimum SI foreseen in [10]

Fig. 6 Bushing application; AC. Ceramic housing. Required arcing distance as a function of the
system voltage.
12

Lmax (SI)

10

LP VL

L(m)

L(m)

LP L

LP M

LP H

LP VH

2
0
0

500

1000

1500

9
8
7
6
5
4
3
2
1
0

Lmin (SI)
LP VL
LP L
LP M
LP H
LP VH

1000

1500

Um (kV)

Um (kV)

a) Maximum SI level foreseen in [10]

500

b) Minimum SI foreseen in [10]

Fig. 7 Bushing application; AC. Composite housing. Required arcing distance as a function of the
system voltage.

DESIGN OPTIMISATION FOR DC APPLICATIONS

As shown in the previous paragraph the AC insulation design for EHV and UHV systems is generally
dominated by switching overvoltages. On the contrary, in DC the insulation design is dominated by
pollution requirements. This is essentially due to the following three reasons:
the contamination deposit is generally higher on insulators subjected to DC voltage than on
those subjected to AC [11];
for the same voltage stress the creepage distance required for DC at a given insulator
contamination condition is higher than for AC [11];
the magnitude of switching overvoltages in DC systems is much lower than in AC, in p.u. [12]
In particular a comparison of the reference curves (for line insulators) relating the required USCD to
the equivalent pollution severity SDD (salt deposit density) in AC and DC are reported in Fig. 8 for
ceramic insulators (continuous curves) and composite insulators (dotted curves). The data for
composite insulators conservatively refer to the insulator performance after service exploitation,
leading to a partial loss of hydrophobicity: HR assumed as 4-5 in the evaluation [11],[13]. The Figure
clearly illustrates how DC may be more demanding than AC especially at high pollution severity
values. Furthermore the better performance of composite solutions at high pollution severities is
enlightened.

100
USCD (mm/kV)

DC
AC
AC ceramic

AC composite HR 4-5

DC ceramic

DC composite HR 4-5

10
0,01

0,1
SDD (mg/cm2)

Fig. 8 Required USCD versus SDD

40
35
30
25
20
15
10
5
0

L(SI)
LP VL
LP L

L(m)

L(m)

An example of application to bushing design is made following the simplified methodology used in
[8] for AC, adopting discrete USCD values for the different pollution levels [11], assuming the same
influence of the diameter on the required USCD as in AC and assuming a CF of 4 for ceramic and 4.4
for composites. Furthermore a design SI voltage value of 2.2 p.u. is assumed. Differently from AC, the
benefits of composites with respect to ceramic in terms of specific creepage distance needs are taken
into account in the calculations.
The results of the calculations are shown in Fig. 9 for the ceramic and composite case.
In the case of porcelain housings (Fig. 9 a), the simplified application approach confirms that,
differently from AC, pollution dominates the design, leading to extremely long bushings. Thus the
adoption of porcelain insulators leads to unpractical and unfeasible solutions, especially in the UHV
range.
More reasonable insulator lengths result in the case of composite housing (fig. 9 b). The example
indicates however that also in this case pollution may dominate the design especially for the most
severe contamination conditions.

LP M
LP H
LP VH

200

400

600

800

1000

1200

20
18
16
14
12
10
8
6
4
2
0

L(SI)
LP VL
LP L
LP M
LP H
LP VH

200

400

800

1000

1200

Um (kV)

Um (kV)

9a) ceramic case

600

9b) composite case

Fig. 9 Bushing application; DC. Required arcing distance as a function of the system voltage.
Being pollution the dominating design condition, a simplified approach as in Fig. 9 is not
recommended in DC: the simplified approach has been used just to put into evidence the relevance of
pollution in DC and to compare the ceramic and composites solutions. To minimize the uncertainties
when performing insulation design, a detailed accurate approach needs to be followed to quantify all
the aspects that may impact on the insulator dimensions and should include the following activities:
Statistical site severity assessment through an accurate mapping of the area concerned based
on long term data with reference to the DC condition (AC data are not directly applicable ! ).

Assessment of the pollution performance of the insulator selected by means of laboratory tests
(tests on short units may be sufficient, since the results can be linearly extrapolated).
Setting up of an acceptance performance criterion in terms of an acceptable risk of flashover
A more detailed description of the methodology and examples of applications are given in [11] and
[14].

CONCLUSIONS

The composite solution is becoming the prevailing solution for station insulator housings due
to its many advantages, such as its explosion proof characteristics. However another important
advantage is the good performance in severe environment.
A very flexible composite housing solution has been developed, based on extrusion process.
The satisfactory performance of the solution has been confirmed by laboratory tests, long
term experience in severe testing stations and by the wide return of service experience.
The use of the composite solution is essential to optimise the design in severe environment.
For AC applications composites may be essential to develop compact apparatus solutions,
whenever the SI level are contained.
Composites are becoming the preferred solutions for DC applications due to their better
performance in the contamination conditions, allowing to develop UHV applications which
could not be feasible with the ceramic solution.
Due to the criticality of pollution for DC applications, the simplified design approach used for
AC applications, is not recommended for DC insulator design. A detailed statistical design
approach is to be used for design optimization

BIBLIOGRAPHY
[1]
[2]
[3]
[4]
[5]
[6]
[7]
[8]
[9]
[10]
[11]
[12]
[13]
[14]

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