Types of Electrical Insulator | Overhead

Insulator
There are mainly three types of insulator used as overhead insulator likewise

1. Pin Insulator
2. Suspension Insulator
3. Strain Insulator
In addition to that there are other two types of electrical insulator available
mainly for low voltage application, e.i. Stay Insulator and Shackle Insulator.

Pin Insulator
Pin Insulator is earliest developed overhead insulator, but still popularly used in
power network up to 33 KV system. Pin type insulator can be one part, two parts
or three parts type, depending upon application voltage. In 11 KV system we
generally use one part type insulator where whole pin insulator is one piece of
properly shaped porcelain or glass. As the leakage path of insulator is through its
surface, it is desirable to increase the vertical length of the insulator surface area
for lengthening leakage path.

In order to obtain lengthy leakage path, one, tow or more rain sheds or petticoats
are provided on the insulator body. In addition to that rain shed or petticoats on an
insulator serve another purpose. These rain sheds or petticoats are so designed, that
during raining the outer surface of the rain shed becomes wet but the inner surface
remains dry and non-conductive. So there will be discontinuations of conducting
path through the wet pin insulator surface. In higher voltage like 33KV and 66KV
manufacturing of one part porcelain pin insulator becomes difficult. Because in
higher voltage, the thickness of the insulator become more and a quite thick single
piece porcelain insulator can not manufactured practically. In this case we use
multiple part pin insulator, where a number of properly designed porcelain shells
are fixed together by Portland cement to form one complete insulator unit. For
33KV tow parts and for 66KV three parts pin insulator are generally used.

Designing Consideration of Electrical Insulator

The live conductor attached to the top of the pin insulator is at a potential and
bottom of the insulator fixed to supporting structure of earth potential. The
insulator has to withstand the potential stresses between conductor and earth. The
shortest distance between conductor and earth, surrounding the insulator body,
along which electrical discharge may take place through air, is known as flash over
distance.

1. When insulator is wet, its outer surface becomes almost conducting. Hence the
flash over distance of insulator is decreased. The design of an electrical
insulator should be such that the decrease of flash over distance is minimum
when the insulator is wet. That is why the upper most petticoat of a pin
insulator has umbrella type designed so that it can protect, the rest lower part
of the insulator from rain. The upper surface of top most petticoat is inclined as
less as possible to maintain maximum flash over voltage during raining.
2. To keep the inner side of the insulator dry, the rain sheds are made in order
that these rain sheds should not disturb the voltage distribution they are so
designed that their subsurface at right angle to the electromagnetic lines of
force.
Post Insulator

Post insulator is more or less similar to Pin

insulator but former is suitable for higher voltage application. Post insulator has
higher numbers of petticoats and has greater height. This type of insulator can be
mounted on supporting structure horizontally as well as vertically. The insulator is
made of one piece of porcelain but has fixing clamp arrangement are in both top
and bottom end. The main differences between pin insulator and post insulator are,

SL Pin Insulator Post Insulator

It is suitable for lower voltage and

1 It is generally used up to 33KV system
also for higher voltage

It can be single stag as well as

2 It is single stag
multiple stags

Conductor is fixed on the top of the Conductor is fixed on the top of the
3
insulator by binding insulator with help of connector clamp

Two or more insulators can be fixed

Two insulators cannot be fixed
4 together one above other for higher
together for higher voltage application
voltage application

Metallic fixing arrangement provided

Metallic fixing arrangement provided
4 on both top and bottom ends of the
only on bottom end of the insulator
insulator
Suspension Insulator

In higher voltage, beyond 33KV,

it becomes uneconomical to use pin insulator because size, weight of the insulator
become more. Handling and replacing bigger size single unit insulator are quite
difficult task. For overcoming these difficulties, suspension insulator was
developed. In suspension insulator numbers of insulators are connected in series
to form a string and the line conductor is carried by the bottom most insulator.
Each insulator of a suspension string is called disc insulator because of their disc
like shape.
Advantages of Suspension Insulator
1. Each suspension disc is designed for normal voltage rating 11KV (Higher
voltage rating 15KV), so by using different numbers of discs, a suspension
string can be made suitable for any voltage level.
2. If any one of the disc insulators in a suspension string is damaged, it can be
replaced much easily.
3. Mechanical stresses on the suspension insulator is less since the line hanged on

a flexible suspension string.

4. As the current carrying conductors are suspended from supporting structure by
suspension string, the height of the conductor position is always less than the
total height of the supporting structure. Therefore, the conductors may be safe
from lightening.
Disadvantages of Suspension Insulator
1. Suspension insulator string costlier than pin and post type insulator.
2. Suspension string requires more height of supporting structure than that for pin
or post insulator to maintain same ground clearance of current conductor.
3. The amplitude of free swing of conductors is larger in suspension insulator
system, hence, more spacing between conductors should be provided.
Strain Insulator
When suspension string is used to sustain extraordinary tensile load of conductor it
is referred as string insulator. When there is a dead end or there is a sharp corner
in transmission line, the line has to sustain a great tensile load of conductor or
strain. A strain insulator must have considerable mechanical strength as well as
the necessary electrical insulating properties.

Number of disc insulator used

Rated System Number of disc insulator used in
in strain type tension
Voltage suspension insulator string
insulator string

33KV 3 3

66KV 5 4

132KV 9 8

220KV 15 14

Stay Insulator

For low voltage lines, the stays

are to be insulated from ground at a height. The insulator used in the stay wire is
called as the stay insulator and is usually of porcelain and is so designed that in
case of breakage of the insulator the guy-wire will not fall to the ground.

Shackle Insulator or Spool Insulator

The shackle insulator or spool insulator is usually used in low voltage
distribution network. It can be used both in horizontal and vertical position. The
use of such insulator has decreased recently after increasing the using of
underground cable for distribution purpose. The tapered hole of the spool
insulator distributes the load more evenly and minimizes the possibility of
breakage when heavily loaded. The conductor in the groove of shackle insulator
is fixed with the help of soft binding wire.

Electrical Insulator | Insulating Material |

Porcelain Glass Polymer Insulator
Electrical Insulator must be used in electrical system to prevent unwanted flow of
current to the earth from its supporting points. The insulator plays a vital role in
electrical system. Electrical Insulator is a very high resistive path through which
practically no current can flow. In transmission and distribution system, the
overhead conductors are generally supported by supporting towers or poles. The
towers and poles both are properly grounded. So there must be insulator between
tower or pole body and current carrying conductors to prevent the flow of current
from conductor to earth through the grounded supporting towers or poles.

Insulating Material
The main cause of failure of overhead line insulator, is flash over, occurs in
between line and earth during abnormal over voltage in the system. During this
flash over, the huge heat produced by arcing, causes puncher in insulator body.
Viewing this phenomenon the materials used for electrical insulator, has to posses
some specific properties.
Properties of Insulating Material
The materials generally used for insulating purpose is called insulating material.
For successful utilization, this material should have some specific properties as
listed below-

1. It must be mechanically strong enough to carry tension and weight of

conductors.
2. It must have very high dielectric strength to withstand the voltage stresses in
High Voltage system.
3. It must possesses high Insulation Resistance to prevent leakage current to the
earth.
4. The insulating material must be free from unwanted impurities.
5. It should not be porous.
6. There must not be any entrance on the surface of electrical insulator so that the
moisture or gases can enter in it.
7. There physical as well as electrical properties must be less effected by
changing temperature.
Porcelain Insulator

Porcelain in most commonly used material for

over head insulator in present days. The porcelain is aluminium silicate. The
aluminium silicate is mixed with plastic kaolin, feldspar and quartz to obtain final
hard and glazed porcelain insulator material. The surface of the insulator should
be glazed enough so that water should not be traced on it. Porcelain also should be
free from porosity since porosity is the main cause of deterioration of its dielectric
property. It must also be free from any impurity and air bubble inside the material
which may affect the insulator properties.
Properties of Porcelain Insulator
Property Value(Approximate)

Dielectric Straingth 60 KV / cm

Compressive Strength 70,000 Kg / cm2

Tensile Strength 500 Kg / cm2

Glass Insulator
Now days glass insulator has become popular in transmission and distribution
system. Annealed tough glass is used for insulating purpose. Glass insulator has
numbers of advantages over conventional porcelain insulator<

Advantages of Glass Insulator

1. It has very high dielectric strength compared to porcelain.
2. Its resistivity is also very high.
3. It has low coefficient of thermal expansion.
4. It has higher tensile strength compared to porcelain insulator.
5. As it is transparent in nature the is not heated up in sunlight as porcelain.
6. The impurities and air bubble can be easily detected inside the glass insulator
body because of its transparency.
7. Glass has very long service life as because mechanical and electrical properties
of glass do not be affected by ageing.
8. After all, glass is cheaper than porcelain.
Disadvantages of Glass Insulator
1. Moisture can easily condensed on glass surface and hence air dust will be
deposited on the wed glass surface which will provide path to the leakage
current of the system.
 2. For higher voltage glass can not be cast in irregular shapes since due to
irregular cooling internal cooling internal strains are caused.
Properties of Glass Insulator
Property Value(Approximate)

Dielectric Straingth 140 KV / cm

Compressive Strength 10,000 Kg / cm2

Tensile Strength 35,000 Kg / cm2

Polymer Insulator
In a polymer insulator has two parts, one is glass fiber reinforced epoxy resin rod
shaped core and other is silicone rubber or EPDM (Ethylene Propylene Diene
Monomer) made weather sheds. Rod shaped core is covered by weather sheds.
Weather sheds protect the insulator core from outside environment. As it is made
of two parts, core and weather sheds, polymer insulator is also called composite
insulator. The rod shaped core is fixed with Hop dip galvanized cast steel made
end fittings in both sides.

Advantages of Polymer Insulator

1. It is very light weight compared to porcelain and glass insulator.
2. As the composite insulator is flexible the chance of breakage becomes
minimum.
3. Because of lighter in weight and smaller in size, this insulator has lower
installation cost.
4. It has higher tensile strength compared to porcelain insulator.
5. Its performance is better particularly in polluted areas.
6. Due to lighter weight polymer insulator imposes less load to the supporting
structure.
7. Less cleaning is required due to hydrophobic nature of the insulator.
Disadvantages of Polymer Insulator
1. Moisture may enter in the core if there is any unwanted gap between core and
weather sheds. This may cause electrical failure of the insulator.
2. Over crimping in end fittings may result to cracks in the core which leads to
mechanical failure of polymer insulator.
In addition to these, some other disadvantages might be experienced. Let us give a
practical example where many difficulties are faced in maintaining a distribution
network in Victoria Australia due to polymeric insulator. There are many
Cockatoos, Galahs and Parrots in that area of Australia, which love to chew on
polymeric strain insulators. Here, the 22 KV network has many of polymeric strain
insulators installed and now after a few years of installing polymeric strain
insulators, the authority is now replacing many of them back with Glass disc
insulators. Another disadvantage is that they have had post type polymeric
insulators melt and bend in bush fire areas. They have a concrete pole and a steel
cross arm that survives a bush fire, however the polymers in some cases fail. This
would not be the case with glass or porcelain insulators. They have also had
polymeric insulators fail in areas close to the ocean coastline where there are high
salt levels in the air.

1. Subject to bird attack by Parrots, Cockatoos and Galahs.

2. Not resilient to bushfire temperatures.
3. Not recommended for location near surf beaches due to salt spray.
The information is contributed by Robert Lancaster of Australian Electricity
Supply Industry

Types of Insulator
There are mainly three types of insulator likewise

1. Pin Insulator
2. Suspension Insulator
3. Stray Insulator
In addition to that there are other two types of electrical insulator available mainly
for low voltage application, e.i. stay insulator and shackle insulator.

Insulation Coordination in Power System

Insulation Coordination in Power System was introduced to arrange the
electrical insulation levels of different components in the electrical power system
including transmission network, in such a manner, that the failure of insulator, if
occurs,confindes to the place where it would result in the least danmage of the
system, easy to repair and replace, and results least disturbance to the power
supply. When any over voltage appears in the electrical power system, then there
may be a chance of failure of its insulation system. Probability of failure of
insulation, is high at the weakest insulation point nearest to the source of over
voltage. In power system and transmission networks, insulation is provided to the
all equipment and components.

Insulators in some points are easily replaceable and repairable compared to other.
Insulation in some points are not so easily replaceable and repairable and the
replacement and repairing may be highly expensive and require long interruption
of power. Moreover failure of insulator at these points may causes bigger part of
electrical network to be out of service. So, it is desirable that in situation of
insulator failure, only the easily replaceable and repairable insulator fails. The
overall aim of insulation coordination is to reduce to an economically and
operationally acceptable level the cost and disturbance caused by insulation failure.
In insulation coordination method, the insulation of the various parts of the system
must be so graded that flash over if occurs it must be at intended points. For proper
understanding the insulation coordination we have to understand first, some basic
terminologies of the electrical power system. Let us have a discussion.
Nominal System Voltage
Nominal System Voltage is the phase to phase voltage of the system for which the
system is normally designed. Such as 11 KV, 33 KV, 132 KV, 220 KV, 400 KV
systems.
Maximum System Voltage
Maximum System Voltage is the maximum allowable power frequency voltage
which can occurs may be for long time during no load or low load condition of the
power system. It is also measured in phase to phase manner. List of different
nominal system voltage and their corresponding maximum system voltage is
given below for reference,

Nominal System Voltage in KV 11 33 66 132 220 400

Maximum System Voltage in KV 12 36 72.5 145 245 420

NB - It is observed from above table that generally maximum system voltage is

110 % of corresponding nominal system voltage up to voltage level of 220 KV,
and for 400 KV and above it is 105 %.
Factor of Earthing
This is the ratio of the highest rms phase to earth power frequency voltage on a
sound phase during an earth fault to the rms phase to phase power frequency
voltage which would be obtained at the selected location without the fault.

This ratio characterizes, in general terms, the earthing conditions of a system as

viewed from the selected fault location.
Effectively Earthed System
A system is said to be effectively earthed if the factor of earthing does not exceed
80 % and non-effectively earthed if it does. Factor of earthing is 100 % for an
isolated neutral system, while it is 57.7 % (1/3 = 0.577) for solidly earthed
system.
Insulation Level
Every electrical equipment has to undergo different abnormal transient over
voltage situation in different times during its total service life period. The
equipment may have to withstand lightning impulses, switching impulses and/or
short duration power frequency over voltages. Depending upon the maximum
level of impulse voltages and short duration power frequency over voltages that
one power system component can withstand, the insulation level of high voltage
power system is determined. During determining the insulation level of the system
rated less than 300 KV, the lightning impulse withstand voltage and short
duration power frequency withstand voltage are considered. For equipment
rated more or equal 300 KV, switching impulse withstand voltage and short
duration power frequency withstand voltage are considered.

Lightning Impulse Voltage

The system disturbances occur due to natural lightning, can be represented by three
different basic wave shapes. If a lightning impulse voltage travels some distance
along the transmission line before it reaches to a insulator its wave shaped
approaches to full wave, and this wave is referred as 1.2/50 wave. If during
travelling, the lightning disturbance wave causes flash over across an insulator the
shape of the wave becomes chopped wave. If a lightning stroke hits directly on the
insulator then the lightning impulse voltage may rise steep until it is relieved by
flash over, causing sudden, very steep collapse in voltage. These three waves are
quite different in duration and in shapes.

Switching Impulse
During switching operation there may be uni-polar voltage appears in the system.
The wave form of which may be periodically damped or oscillating one. Switching
impulse wave form has steep front and long damped oscillating tale.

Short Duration Power Frequency Withstand Voltage

Short duration power frequency withstand voltage is the prescribed rms value
of sinusoidal power frequency voltage that the electrical equipment shall withstand
for a specific period of time normally 60 seconds.

Protection Level Voltage of Protective Device

Over voltage protective device like surge arrestors or lightning arrestors are
designed to withstand a certain level of transient over voltage beyond which the
devices drain the surge energy to the ground and therefore maintain the level of
transient over voltage up to a specific level. Thus transient over voltage can not
exceed that level. The protection level of over voltage protective device is the
highest peak voltage value which should not be exceeded at the terminals of over
voltage protective device when switching impulses and lightening impulses are
applied.

Now let us discuss the insulation coordination methods one by one-

Using Shield Wire or Earth Wire

Lightning surge in over head transmission line may be caused due to direct hits of
lightening strokes. It can be protected by providing a shield wire or earth wire at a
suitable height from the top conductor of transmission line. If the conducting shield
wire is properly connected to transmission tower body and the tower is properly
earthed then direct lightning strokes can be avoided from all the conductors come
under the protective angle of earth wire. Over head earth wire or ground wire or
shield wire is also used to over the electrical substation to protect different
electrical equipment from lightning strokes.

Conventional Method of Insulation Coordination

 As we discussed above that a component of electrical power system may suffer
from different level of transient voltage stresses, switching impulse voltage and
lightning impulse voltage. The maximum amplitude of transient over voltages
reach the components, can be limited by using protecting device like lightning
arrestor in the system. If we maintain the insulation level of all the power system
component above the protection level of protective device, then ideally there will
be no chance of breakdown of insulation of any component. Since the transient
over voltage reaches at the insulation after crossing the surge protective devices
will have amplitude equals to protection level voltage and protection level voltage
< impulse insulation level of the components.

Generally, the impulse insulation level is established at 15 to 25 % above the

protective level voltage of protective devices.
Statistical Methods of Insulation Coordination

At higher transmission voltages, the length of the insulator strings and the
clearance in air do not increase linearly with voltage but approximately to V 1.6. The
required number of insulator disc in suspension string for different over voltages is
shown below. It is seen that increase in the number of disc is only slight for 220
KV system, with the increase in the over voltage factor from 2 to 3.5 but that there
is a rapid increase in the 750 kV system. Thus, while it may be economically
feasible to protect the lower voltage lines up to an over voltage factor of 3.5(say), it
is definitely not economically feasible to have an over voltage factor of more than
about 2 to 2.5 on the higher voltage lines. In the higher voltage systems, it is the
switching over voltages that is predominant. However, these may be controlled by
proper design of switching devices.

Electrical Transmission Tower Types and

Design
The main supporting unit of overhead transmission line is transmission tower.
Transmission towers have to carry the heavy transmission conductor at a sufficient
safe height from ground. In addition to that all towers have to sustain all kinds of
natural calamities. So transmission tower designing is an important engineering job
where all three basic engineering concepts, civil, mechanical and electrical
engineering concepts are equally applicable.A power transmission tower consists
of the following parts,
1. Peak of transmission tower
2. Cross arm of transmission tower
3. Boom of transmission tower
4. Cage of transmission tower
5. Transmission Tower Body
6. Leg of transmission tower
7. Stub/Anchor Bolt and Base plate assembly of transmission tower.
The main parts among these are shown in the pictures.
Peak of Transmission Tower
The portion above the top cross arm is called peak of transmission tower.
Generally earth shield wire connected to the tip of this peak.
Cross Arm of Transmission Tower
Cross arms of transmission tower hold the transmission conductor. The dimension
of cross arm depends on the level of transmission voltage, configuration and
minimum forming angle for stress distribution.
Cage of Transmission Tower
The portion between tower body and peak is known as cage of transmission tower.
This portion of the tower holds the cross arms.
Transmission Tower Body
The portion from bottom cross arms up to the ground level is called transmission
tower body. This portion of the tower plays a vital role for maintaining required
ground clearance of the bottom conductor of the transmission line.
Design of Transmission Tower

During design of transmission

tower the following points to be considered in mind,

The minimum ground clearance of the lowest conductor point above the
ground level.
The length of the insulator string.
The minimum clearance to be maintained between conductors and between
conductor and tower.
The location of ground wire with respect to outer most conductors.
The mid span clearance required from considerations of the dynamic behavior
of conductor and lightening protection of the line.
To determine the actual transmission tower height by considering the above points,
we have divided the total height of tower in four parts,

1. Minimum permissible ground clearance (H1)

2. Maximum sag of the conductor (H2)
3. Vertical spacing between top and bottom conductors (H3)
4. Vertical clearance between ground wire and top conductor (H4).
Types of Transmission Tower
According to different considerations, there are different types of transmission
towers. The transmission line goes as per available corridors. Due to unavailability
of shortest distance straight corridor transmission line has to deviate from its
straight way when obstruction comes. In total length of a long transmission line
there may be several deviation points. According to the angle of deviation there are
four types of transmission tower-

1. A type tower angle of deviation 0o to 2o.

2. B type tower angle of deviation 2o to 15o.
3. C type tower angle of deviation 15o to 30o.
4. D type tower angle of deviation 30o to 60o.
As per the force applied by the conductor on the cross arms, the transmission
towers can be categorized in another way-

1. Tangent suspension tower and it is generally A - type tower.

2. Angle tower or tension tower or sometime it is called section tower. All B, C
and D types of transmission towers come under this category.
Apart from the above customized type of tower, the tower is designed to meet

special usages listed below, These are called

special type tower

1. River crossing tower

2. Railway/ Highway crossing tower
3. Transposition tower
Based on numbers of circuits carried by a transmission tower, it can be classisfied
as-

1. Single circuit tower

2. Double circuit tower
3. Multi circuit tower.

Types of Overhead Conductor

Conductor is a physical medium to carry electrical energy form one place to other.
It is an important component of overhead and underground electrical transmission
and distribution systems. The choice of conductor depends on the cost and
efficiency. An ideal conductor has following features.

1. It has maximum conductivity

2. It has high tensile strength
3. It has least specific gravity i.e. weight / unit volume
4. It has least cost without sacrificing other factors
Types of Overhead Conductor
In early days copper Cu was used for transmitting energy in stranded hard drawn
form to increase tensile strength. But now it has been replaced by aluminum Al
due to following reasons:

1. It has lesser cost than copper.

2. It offers larger diameter for same amount of current which reduces corona.
Corona: is ionization of air due to higher voltage (usually voltage above critical
voltage) which causes violating light around the conductor and hissing sound. It
also produce ozone gas therefor it is undesirable condition
Aluminium also has some disadvantages over copper i.e.

1. It has lesser conductivity

2. It has larger diameter which increase surface area to air pressure thus it swings
more in air than copper so larger cross arms required which increases the cost.
3. It has lesser tensile strength ultimately larger sag
4. It has lesser specific gravity (2.71gm/cc) than copper (8.9 gm/cc) cc = cubic
centimeter
Due to lower tensile strength aluminium is used with some other materials or its
alloys

AAC (All Aluminium Conductor)

It has lesser strength and more sag per span length than any other category
Therefore, it is used for lesser span i.e. it is applicable at distribution level
It has slightly better conductivity at lower voltages than ACSR i.e. at
distribution level
Cost of ACSR is equal to AAC.
ACAR (Aluminium Conductor, Aluminium Reinforce)
It is cheaper than AAAC but pro to corrosion.
It is most expansive.
AAAC (All Aluminium Alloy Conductor)

It has same construction as AAC except the alloy.

Its strength is equal to ACSR but due to absence of steel it is light in weight.
The presence of formation of alloy makes it expensive.
Due to stronger tensile strength than AAC, it is used for longer spans.
It can be used in distribution level i.e. river crossing.
It has lesser sag than AAC.
The difference between ACSR and AAAC is the weight. Being lighter in
weight, it is used in transmission and sub-transmission where lighter support
structure is required such as mountains, swamps etc.

ACSR (Aluminium Conductor Steel Reinforced)

It is used for longer spans keeping sag minimum.

It may consists of 7 or 19 strands of steel surrounding by aluminium strands
concentrically. The number of strands are shown by x/y/z, where x is number
of aluminium strands, y is number of steel strands and z is diameter of each
strand.
Strands provide flexibility, prevent breakage and minimize skin effect.
The number of strands depends on the application, they may be 7, 19, 37, 61,
91 or more.
If the Al and St strands are separated by a filler such as paper then this kind of
ACSR is used in EHV lines and called expanded ACSR.
Expanded ACSR has larger diameter and hence lower corona losses.
IACS (International Annealed Copper Stand)
It is 100 % pure conductor and it is standard for reference.
Voltage in Power Electric Lines
In generating station electrical power is generated at medium voltage level that
ranges from 11 kV to 25 kV. This generated power is sent to the generating step up
transformer to make the voltage level higher. From this point to the user end
voltage level varies in different levels. We can realize this voltage level variation
step by step.
At 11 kV or more than that up to 25 kV voltage level is maintained at
alternator stator terminals to generate electrical power in the generating station.
This generated power is fed to the generating step up transformer to make this
medium voltage level to higher level, i.e. up to 33 kV.
Power at 33 kV is sent to the generating substation. There the transformer
increases the voltage level to 66 kV or 132 kV.
From this generating substation power is sent to the nearer substation to
increase the voltage level higher than previous. This level of voltage is
increased at different suitable levels, it may be at 400 kV or 765 kV or 1000
kV. This high voltage or extra high voltage level is maintained to transmit
the power to a long distant substation. It is call primary transmission of
power.
At the end point of primary transmission of power, in the substation, the step
down transformers are used to step down the voltage level to 132 kV.
Secondary transmission of power starts from this substation.
Power transformer at the end of the secondary transmission, just makes 132
kV voltage level steps down to 33 kv or 11 kV as per requirement. From this
point, primary distribution of power starts to distribute power to different
distribution stations.
At the end of primary distribution, the distribution stations receive this
power and step down this voltage level of 11 kV or 33 kV to 415 V (Line
Voltage). From these distribution stations to consumer ends, 415 V is kept
to sustain for utilization purpose.
Type of Power Lines
From the very beginning of power generation to the user end transmission lines are
broadly classified based on different voltage levels.

Why High Voltage is used for Long Transmission Line?

Generally long distant transmission lines are designed to operate at high voltage,
extra high or ultra high voltage level. It is because of line power loss reduction
purpose. Practically long distant transmission line resistance is comparatively more
than medium and short transmission line. Due to this higher valued transmission
line resistance considerable amount of power is lost. So we need to decrease the
amount of current through each conductor by making the operating voltage very
high for same amount of power transmission. We know that the power in AC

system to transmit is Total power

loss PLoss = 3IL R considering three phases altogether. R is the resistance in ohm per
2

phase of the transmission line. Now, rearranging Equation (1) we get,

So,

Again in DC system, there is no phase difference between voltage and current, i.e.
cos = 1, and only two conductors (positive and negative) are used. So, in DC

system transmitted power P = VI, and power loss

From equation (2) and (3), it is clear that power loss in transmission line is
inversely proportional to the square of line voltage. The higher value of line
voltage the lesser amount of power loss occurs. Hence transmission line conductor
is used with less diameter, hence savings of conductor material.
Why HVAC is Used for Long Transmission Line?
Now a days electrical energy is generated, transmitted and distributed in AC
form. Especially for long distant transmission line High Voltage AC is transmitted
for several reasons, they are:

1. AC voltage can be stepped up or down as per requirement easily by

transformer.
2. Maintenance of AC substation is easy and cheaper.
3. Throughout electrical power system AC voltage is handled. So no extra hazard
of rectification or inversion like DC voltage transmission.
Why HVDC is Used for Long Transmission Line?
High Voltage DC is used at extra or ultra high voltage level. HVDC transmission is
used at fixed level of voltage in primary transmission only as it cannot be stepped
up or down by transformer. Only in long distant transmission line it is used only,
because

1. Only two conductors (positive and negative) are required as compared to three
of AC transmission..
2. Absence of inductance, capacitance and phase displacement power loss is very
less. Hence better voltage regulation.
3. Surge problem never occurs.
4. No skin effect.
5. Less insulation requires due to less potential stress.
6. Less corona effect, thus less power loss.
7. Highly stabilized and synchronized.
Why Low and Medium Voltage is Used in Distribution Line?
In primary distribution, power is handled at 11 kV or 33 kV. As voltage level gets
stepped down from 132 kV to 11 kV or 33 kV, current level gets higher valued.
But this high valued current distributed among various local distribution stations
(distribution transformers) nearby. These distribution transformers again steps
down the voltage to 415 V. It is because; Power at 415 V is used at the user end.
Distance between these distribution transformers and the primary distribution
stations is very short, hence conductor resistance is not large. Very small amount
of power is lost in this section.

Disadvantages of AC or HVAC Transmission

The main disadvantages of AC transmission are

1. AC lines require more conductor material than DC.

2. AC transmission line construction is more complicated than DC.
3. Effective resistance is increased due to skin effect, hence power loss.
4. Continuous power loss due to charging current because of line capacitance.
Disadvantages of DC or HVDC Transmission
The main disadvantages of DC transmission are

1. Electric power is not generated in HVDC form due to commutation problem.

Only HVDC is achieved for transmission from HVAC by rectification. So
special arrangement is required for this conversion.
2. DC voltage cannot be stepped up or down for transmission.
3. DC switches and circuit breakers are expensive and with certain limitations.

Electrical Power Cable

Cables are mainly designed as per requirement. Power cables are mainly used for
power transmission and distribution purpose. It is an assembly of one or more
individually insulated electrical conductors, usually held together with an overall
sheath. The assembly is used for transmission and distribution of electrical power.
Electrical power cables may be installed as permanent wiring within buildings,
buried in the ground and run overhead or exposed. Flexible power cables are used
for portable devices, mobile tools and machinery. These are designed and
manufactured as per voltage, current to be carried, operating maximum
temperature and purpose of applications desired by customer. For mining, we give
extra mechanical strength to cable with double armouring. For wind power plant
customers generally require flexible and UV protected cable with mechanical
tough sheath so we design as per their requirement.

Rating of Power Cable

Short Circuit Rating
It happens frequently that the conductor size necessary for an installation is
dictated by its ability to carry short-circuit current rather than sustained current.
During a short circuit, there is a sudden inrush of current for a few cycles
followed by a steadier flow of current for a short period until the protection
switchgear operators, normally between 0.1-0.3 seconds

Operating
Short Circuit
Conductor Size and Material Insulation Material Maximum
Rating
Temperature

120 sq-mm Copper PVC Insulation 70 C 13.80 KA/SEC

conductor

120 sq-mm Aluminium

PVC Insulation 70 C 9.12 KA/SEC
conductor

120 sq-mm Copper

PVC Insulation 85 C 12.48 KA/SEC
conductor

120 sq-mm Aluminium

PVC Insulation 85 C 8.28 KA/SEC
conductor

Current Carrying Capacity

Current carrying capacity is an important aspect is the selection of the optimum
size of conductor. Voltage drop and short rating is also very important aspect to
select the economical and optimum size of conductor.

Continous Current Rating of (Cables laid singly) 2 Core 16 mm2 2 Core 25 mm2

(i) In Ground (Ground Temp 30C) 103 A 131 A

(ii) In Duct (Ground Temp 30C) 86 A 111 A

(iii) In Air (Ambient AirTemp 40C) 94 A 125 A

Voltage Drop
The allowable maximum voltage drops from source to load is another aspect of
power cable conductor design. As per Ohm's law, V = IR. The first is the choice of
material used for the wire. Copper is a better conductor than aluminium and will
have less voltage drop than aluminium for a given length and wire size. Wire size
is another important factor in determining voltage drop. Larger wire sizes (those
with a greater diameter) will have less voltage drop than smaller wire sizes of the
same length. In American wire gauge, every 6 gauge decrease gives a doubling of
the wire diameter, and every 3 gauge decrease doubles the wire cross sectional
area. In the Metric Gauge scale, the gauge is 10 times the diameter in millimetres,
so a 50 gauge metric wire would be 5 mm in diameter.

Construction of Power Cable

There are various parts of a cable to be taken care of during construction. The
power cable mainly consists of
1. Conductor
2. Insulation
3. LAY for Multicore cables only
4. Bedding
5. Beading/Armouring (if required)
6. Outer Sheath

Conductor
Conductors are the only power carrying path in a power cable. Conductors are of
different materials. Mainly in cable industry we use copper (ATC, ABC) and
aluminium conductors for power cables. There are different types of conductor as
Class 1: solid, Class 2 stranded, Class 5 flexible, Class 6 Extra flexible (Mostly
used for cords and welding) etc. Conductor sizes are identified with conductor
resistance.
Insulation
The insulation provided on each conductor of a cable by mainly PVC (Poly Vinyl
Cloride), XLPE (Crosslinked Polyethyelene), RUBBER (Various Types of
Rubber). Insulating material is based on operating temperature.

Maximum Operating
Insulation Material
Temperature

PVC TYPE A 75C

PVC TYPE B 85C

PVC TYPE C 85C

XLPE 90C

RUBBER EPR IE-1 90C

RUBBER EPR IE-2, EPR IE-3, EPR

150C
IE-4, SILICON IE-5

Cores are identified by colour coding by using different colours on insulation or by

number printing on cores
Beading (Inner Sheath)
This portion of the cable is also known as inner sheath. Mostly it is used in Multi
core cables. It works as binder for insulated conductors together in multi-core
power cables and provides bedding to armour/braid. This portion of the cable is
mainly made of PVC( PVC ST-1, PVC ST-2 ), RUBBER (CSP SE-3, CSP SE-4
and PCP SE-3, PCP SE-4, HOFR SE-3 HOFR SE-4, HD HOFR SE-3 ETC)
Armouring
There are mainly G.I. WIRE ARMOURING, G.I. STEEL STRIP armouring. It is
done by placing G.I. WIREs, GI or STEEL STRIPs one by one on inner sheath.
Armouring is a process which is done mainly for providing earthing shield to the
current carrying conductors as well as it is also used for earthing purpose of the
cable for safety. When there is any insulation failure in the conductor, the fault
current gets enough paths to flow through the armour if it is properly earthed.
Providing extra mechanical protection and strength to cable an important added
advantage of armouring. In MINING CABLES it is done for conductance
Beading
ANNEALED TINNED COPPER WIRE, NYLON BRAID, COTTON BRAID are
mainly used for this purpose. Braiding is the process which gives high mechanical
protection to cable and also used for earthing purpose. Significance of braiding is it
is more flexible in comparison to armouring.
Outer Sheath
This is outermost cover of the cable normally made of PVC (Poly Vinyl Cloride),
RUBBER (Various Types of Rubber) and often the same material as the bedding.
It is provided over the armour for overall mechanical, weather, chemical and
electrical protection. Outer sheath is protection offered to cable not much
electrically but more mechanically.
 Max Operating
Material Advantages Disadvantages
Temperature

70C for
general
Highest dielectric losses,
Cheap, Durable, purpose 85
PVC Melts at high temperatures,
Widely available C for heat
Contains halogens
resisting
purpose

Lowest dielectric
Highly sensitive to water
losses, High
PE treeing, Material breaks
initial dielectric
down at high temperatures
strength

Does not melt but thermal

Low dielectric
expansion occurs, Medium
losses, Improved
sensitivity to water treeing
XLPE material 90 C
(although some XLPE
properties at high
polymers are water-tree
temperatures
resistant)

Increased
flexibility,
Reduced thermal
Medium-High dielectric
expansion
EPR losses, Requires inorganic 90 C
(relative to
filler / additive
XLPE), Low
sensitivity to
water treeing

Low-Medium
High weight, High cost,
dielectric losses,
Requires hydraulic pressure /
Paper / Not harmed by
pumps for insulating fluid, 70 C
Oil DC testing,
Difficult to repair, Degrades
Known history of
with moisture
reliability
Mainly above 6 sq mm cables are called power cables but it depends upon the use
of cable. For PVC power cables we use IS:1554 and for XLPE power cables we
use IS:7098 and for Rubber based power cables we use IS:9968 and other relevant
specifications. Power cables are defined by voltage grade and nominal cross
sectional area.

Sag in Overhead Conductor

What is Sag?
Sag is defined as the different in level between points of supports and the lowest
point on the conductor.

Here AOB is the transmission line conductor. Two supports are at point A and at
point B. AB is the horizontal line and from this horizontal line to point O, S is the
sag when measured vertically.

Why Sag Provision is Mandatory in Transmission Line Conductors?

Sag is mandatory in transmission line conductor suspension. The conductors are
attached between two supports with perfect value of sag. It is because of providing
safety of the conductor from not to be subjected to excessive tension. In order to
permit safe tension in the conductor, conductors are not fully stretched; rather they
are allowed to have sag.

If the conductor is stretched fully during installation, wind exerts pressure on the
conductor, hence conductor gets chance to be broken or detached from its end
support. Thus sag is allowed to have during conductor suspension. Some important
points are to be mentioned:
1. When same leveled two supports hold the conductor, bend shape arises in the
conductor. Sag is very small with respect to the span of the conductor.
2. Sag span curve is like parabolic.
3. The tension in each point of the conductor acts always tangentially.

4. Again the horizontal component of the tension of conductor is constant

throughout conductor length.
5. The tension at supports is nearly equal to the tension at any point of the
conductor.
How to Calculate Sag?
Sag calculation is classified on two conditions.

1. When supports are at equal levels

2. When supports are not at equal levels
Now let us start discussion on two conditions.

Sag calculation for supports are at equal levels

Suppose,
AOB is the conductor. A and B are points of supports. Point O is the lowest point
and the midpoint. Let, L = length of the span, i.e. AB w is the weight per unit
length of the conductor T is the tension in the conductor. We have chosen any
point on conductor, say point P. The distance of point P from Lowest point O is x.
y is the height from point O to point P. Equating two moments of two forces about
point O as per the figure above we get,

Sag calculation for supports are at unequal levels

Suppose AOB is the conductor that has point O as the lowest point. L is the Span
of the conductor. h is the difference in height level between two supports. x1 is the
distance of support at the lower level point A from O. x2is the distance of support
at the upper level point B from O. T is the tension of the conductor. w is the weight
per unit length of the conductor. Now,
So, having calculated the value of x1 and x2, we can easily find out the value of sag
S1 and sagS2. The above formulae are used to calculate sag when the conductor is
in still air and ambient temperature is normal. Hence the weight of the conductor is
its own weight.
What is the Effect of Ice and Wind on Sag?
The weight per unit length of the conductor is changed when wind blows at a
certain force on the conductor and ice accumulate around the conductor.
Wind force acts on the conductor to change the conductor self weight per unit
length horizontally in the direction of the air flow.
Ice loading acts on the conductor to change the conductor self weight per unit
length vertically downward.
Considering wind force and ice loading both at a time, the conductor will have
a resultant weight per unit length.
The resultant weight will create an angle with the ice loading down ward
direction.
Let us assume, w is the weight of the conductor per unit length. w i is the weight of
ice per unit length wi= density of ice volume of ice per unit length
ww is the force of wind per unit length ww = wind pressure per unit area projected
area per unit length
So, the total weight of the conductor per unit length is

The sag in the conductor is given by So the vertical sag