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a certain distance from ground; and electrically it also provides the necessary
insulation. Therefore, one way to define insulator failure is when either or both of these
functions are no longer being fulfilled. A less technical way to define failure is to say
that an insulator has failed whenever it is removed from service either because of
Alternative insulator types fail in different ways. The failure modes of toughened glass
or porcelain insulators, for example, are entirely different from the failure modes of
composite insulators and this could have consequences for continuity of service. It is
Many factors can bring about failure. The insulator can contain a manufacturing defect
that grows over time and lead to failure. Such a defect can be within the dielectric
material, the metal end fittings or in the materials used to keep the dielectric and fitting
together. Failure can also be caused by extreme service conditions such as when an
insulator separates due to heavy ice accretion or high winds that cause applied
fittings, thereby preventing the insulator from fulfilling its electrical or mechanical
functions.
A flashover leading to a power arc of extended duration can also bring about the failure
Various acts of vandalism can cause severe insulator damage or even failure. Finally, an
insulator can fail if it was not properly designed for its intended service environment,
such as having too little creepage or even too much creepage since both can prove
or external factors:
1. Radial Cracking
1. Radial Cracking
This type of failure can be attributed to the phenomenon of cement growth and applies
mainly to porcelain insulators that have been assembled using overly expansive
cement.
2. Pin Corrosion
2. Pin Corrosion
Problems of pin corrosion could occur in places with severe contamination and are
basically independent of bulk dielectric. Use of newer designs with sacrificial zinc
sleeves for corrosion protection has been proven to limit onset of corrosion but of
course has no impact on ageing of any existing discs from earlier generations.
3. Brittle Fracture
3. Brittle Fracture
Brittle fracture of a composite insulator leads to mechanical separation of the fiberglass
core rod and is characterized by the presence of some smooth fracture surfaces. This
failure mode was first reported in early generation insulators and attributed to attack on
the rod by nitric acid produced by corona in a moist environment. The exact source of
the acid later became a topic of debate. While there is evidence that electrical stress is
not required for brittle fracture to occur, it can accelerate the process. It has also been
produce acids, even without moisture from the outside. Still, it is commonly accepted
that effective sealing of the rod from the environment and the use of corrosion resistant
rods is the most effective way to minimize risk of such failure. In the end, brittle
fracture could be due to a combination of factors and not always explained by any
single mechanism.
The type of failure shown in these breaker bushings affects mostly porcelain insulators
and is most typically caused by vandalism. Unlike toughened glass insulators that can
disintegrate under sharp external stress, only sections of porcelain sheds are broken
off. Still, while the insulators continue to operate, they should ideally be replaced as
soon as possible since any related internal cracking cannot easily be determined.
5. Spontaneous Shattering
5. Spontaneous Shattering
This failure mode applies only to glass disc insulators and is due to sudden release of
internal stresses induced in the shell during the toughening process. The incidence of
the problem is linked to inferior quality control such as the presence of inclusions (hard
particles that have not fully melted in the furnace) or impurities in the tensile zone of
the glass body. Since the average size of these impurities is less than 100 microns,
there is no practical method to detect them other than to screen out glass shells
containing inclusions through thermal shocks prior to assembly of fittings. Even though
the thermal shock test is carried out twice during production, there is a very low
probability that some shells containing inclusions survive and shatter subsequently
during service. The time when this finally happens can be triggered by a variety of
reveal that typical annual rates of spontaneous shattering are on the order of up to 1
6. Flashunder
Unlike porcelain disc insulators, composite insulators are not normally at risk of internal
puncture since the electrodes of different potential are separated by a long fiberglass
core rod. However, punctures in the housing have been detected or occur due to
possible mishandling or other factors such as bird pecking and these can provide access
Tracking along the rod under the housing material has then been known to occur,
not be able to support the electrical stress and the rod will carbonize along its length.
This failure mechanism has appeared on some composite insulator designs in recent
years and has been linked to moisture penetration into the core along with poor
bonding along the rod-to-housing interface. While it may be termed brittle fracture at
first glance, it is actually quite distinct since there is an absence of any planar fracture
surfaces.
8. Explosive Shattering
8. Explosive Shattering
potential safety threat to workers and the public as well as a risk factor to any nearby
equipment. Here bushings have ruptured violently from flashover shock triggered by
contact with wildlife. Explosive failures of this type are also due to internal failures that
9. Shed Tearing
This type of failure was first reported in northwestern China where constant sheer by
winds caused larger diameter sheds to tear. The solution, still being researched, is
ensuring composite insulator geometries are adapted for service in areas of frequent
high wind.
10. Erosion
10. Erosion
Insulators that are not properly specified in terms of geometry and specific creepage for
the pollution severity of their service environment may experience excessive leakage
current activity that eventually triggers erosion of the polymeric housing. When such
damage occurs on sheds, repair is possible but if the damage is to the shank, the