OVERHEAD LINES

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CIRED 17th International Conference on Electricity Distribution
NEW SOLUTIONS WITH COMPOSITE INSULATORS AND COMPOSITE STRUCTURES FOR
COMPACT LINES
B. BURKHARDT G. BAETTIG G.P. TERRASI
NOK – Switzerland SACAC AG - Switzerland
bkt@nok.ch terrasi@sacac.ch
1 SUMMARY
Lines for transmission and distribution network play a vital
role for the reliability of the energy supply. The today's
needs consist of cost reduction for energy transport simul-
taneously with increased transmission capacity of existing
lines, installation of conductors in spare systems, recon-
figuration of conductors and installation of high-capacity
lines on the routes of old lines, and new lines as well. This
must be balanced with an increased insulation reliability
and environmental aspects. The paper discusses solutions,
which have been applied to transmission and distribution
levels during the last years and have gained a raising in-
terest among international utilities.
2 INTRODUCTION
Composite materials made of resins reinforced with glass
or carbon play an important role for the substitution of
conventional materials especially in cases of required
weight reduction or negligible corrosion susceptibility. For
electrical applications the principle of “composite insula-
tors” incorporates glass fibre-reinforced resin cores mean-
while carbon fibres are suitable for components replacing
steel structures.
Composite insulators are today in service for approxi-
mately 30 years and a comprehensive knowledge for insu-
lator design and about selection criteria for reliable materi-
als could be collected. With the introduced standards such
as IEC 61109 for polymeric line insulators, IEC 61462 for
polymeric hollow core insulators as well as IEC 61952 for
polymeric line post insulators, there exist a technical basis
for the definition of minimum requirements under consid-
eration of in-situ stresses. Other standards such as
IEC 62217 will harmonise the above mentioned standards
and the IEC 60815 is under reconstruction to provide guid-
ance for composite insulators as well. The paper shows the
application of compact structures with composite insulators
for 420kV arrangements, analogous construction principles
mostly without bracing longrod insulator are applied to
distribution levels. The enhanced reliability of compact
solutions with polymeric posts is documented by the safe
failure mode. The positive effect of the post versus pin
construction superimposed by the effect of the hydropho-
bicity in the case of polymeric posts is discussed.
Steel pole structures in lines can suffer from corrosion
SEF_Schmuck_A1.doc Session 1 Paper No
Barcelona, 12-15 May 2003
K. O. PAPAILIOU F. SCHMUCK
SEFAG AG - Switzerland
frank_schmuck@sefag.ch
damage after years in service depending on the environ-
mental conditions after a service time well below the
planned life time of the line. This requires expensive main-
tenance measures. Lattice steel pylons for electrical power
transmission typically need to be treated with expensive
protection coatings after 15–20 years, leading to consider-
able costs and pollution. Reinforced concrete elements –
such as spun concrete pylons – are recognized to be corro-
sion-resistant. The corrosion protection can only be guaran-
teed, if the steel reinforcement is embedded in the concrete
with a minimum protecting layer thickness of 30 mm to the
atmosphere, which makes the poles quite heavy. However,
if carbon-fibre reinforced plastic (CFRP) is used instead of
steel, such protecting layer (cover) is not required. CFRP
does not corrode and, when used in conjunction with high-
strength concrete, allows a marked reduction in weight. In
the paper the development and application state of a corre-
sponding technique is discussed.
3 APPLICATIONS
3. 1 High Voltage Compact Arrangements
Due to increased energy demand, the voltage up-grade of
existing transmission lines has become a popular way for
utilities to react on the situation. The increase of voltage is
19 m
comparison between steel lattice
tower of existing 125kV-line and
new compact tower for 9m
400kV/132kV-line as well
as standard design
64 m
9m
56 m
29 m
Figure 1: appearance of tower designs with/without compact design
-1-
CIRED 17th International Conference on Electricity Distribution
related to wider Right of Way (ROW) for conventional
route designs, which causes problems in densely populated
areas. As reported in /1/, a 125kV-line was up-graded to
420 kV in Switzerland operated by the Swiss utility Ener-
gie Ouest Suisse (EOS) nearby Lausanne. The solution
consisted in the introduction of a compact line design for 3
towers employing horizontal vee insulating crossarms
(figure 1). Extensively mechanical tests have been per-
formed to investigate the static and dynamic behaviour of
the arrangement for both, porcelain and composite solu-
Figure 2: front view of the compact tower
tions. Finally, the tested performance of the composite
solution simultaneously with the known general advantages
led to the choice of the composite solution under recogni-
tion of the first application for this voltage level. During
testing as basis and reference, the static values have been
determined to simulate the material limits of the individual
components. Afterwards the complete crossarm was tested
with simultaneous recording of specific stresses. All the
time, the stresses have been in the elastic phase. Consider-
ing this result and the safety factor of at least 3.1, the utility
became confident into the solution to use polymeric insula-
tors. The post type insulator is made of a hollow core to
provide sufficient mechanical resistance against buckling
for the compression forces in axial post direction. The
internal space of the hollow core has been filled with a
permanent-elastic material to prevent condensation and
internal partial discharges. The line (figure 2) is energized
for approximately 4 years and withstood the heavy storm in
December 1999 without any problems as well as pleases
the community because of low radio interference distur-
bance.
For another 420kV project, the solution with solid core post
SEF_Schmuck_A1.doc Session 1 Paper No
Barcelona, 12-15 May 2003
Figure 3: test of vertically braced 420kV-line post arrangement
insulators has been designed and comprehensively tested
(figure 3). There exist no specific standard for this applica-
tion, hence the utility defined a complex specification un-
der the consideration of the specific stress factors. The tests
consisted of electrical and mechanical procedures and can
be summarized as follows:
• dielectric testing (BIL, SIL, RIV/corona, 50Hz wet)
• power arc testing with following mechanical diagnostic
• mechanical testing for light and heavy load cases
The dielectric tests have been passed without particulari-
ties. The test part under dry conditions was determined by
the hardware design and the striking distance. In the test
with simultaneous voltage and moisture stressing, the hy-
drophobic surface behaviour of the silicone rubber housing
provided a significant safety margin in comparison to the
specified values, which have been on the basis of conven-
tional glass/porcelain insulators. In the power arc testing
with 30kA, the performance of the complete arrangement
with arcing horns was proven. The proper design of the
horns guided the prolonging arc that the extinction length
was achieved before the specified time of 1 second was
passed. The following dielectric and mechanical tests
showed unambiguously that the arrangement pre-tested
with the arc did not suffer from any damage (housing tight-
ness, mechanical strength). The mechanical testing of the
light load case showed so high safety margins that the tests
for heavy load cases have been applied to the light load
arrangement. These additional and very stressing tests have
been almost passed the only limitation was due to the test
equipment in conjunction with the high but elastic deflex-
ion of the arrangement. The results of this comprehensive
test programme enhanced the utility’s confidence into the
composite technology and initiated further optimization
work for cost savings.
3. 2 Cantilever Support Insulators
From 1979 to 1992, the Swiss railway company Bern Loet-
schberg Simplon (BLS) expanded their 240 km track sys-
tem to be a double track /2/. Approximately 40 km of the
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CIRED 17th International Conference on Electricity Distribution Barcelona, 12-15 May 2003

track length are within a tunnel. This tunnel has been

equipped with porcelain insulators since 1913 and is char-
acterized by very severe pollution conditions and required
considerable maintenance of the network. The single phase
to ground voltage is 15 kV at the railway-typical frequency
of 162/3 Hz. The specific requirements for the substitution
of the porcelain by polymeric posts have been:

• reduced weight for increased train speed

• high failing load
• maintenance-free insulator

The weight has been reduced by more than factor 2 and the
mechanical strength (Maximum Design Cantilever Load)
was specified to be 2.5 kN corresponding to the porcelain
posts. The Specified Cantilever Load of the polymeric post
is 25 kN, which provides a high safety margin, while the
diameter of the load-bearing rod had to be selected for a
limited deflexion. The request for maintenance-free insula-
tion was a sophisticated challenge at this time – the hydro-
phobic behaviour of polymeric housing materials was ini-
tially known, but the lifetime of this property as well as
appropriate artificial tests to evaluate the expected service
performance were not available. So the use of Silicone
Rubber housing was a visionary decision at this time. Due
to the uncertainty about lifetime, the creepage length has
been increased in comparison to the porcelain design
(1115 mm instead of 700 mm). Using the terminology of
IEC 60815, a specific creepage length of 43 mm/kV was
designed, because the 27 mm/kV of the porcelain post has
not been sufficient and required cleaning at least twice a
year. A scientific test programme was launched to investi-
gate the electrical and mechanical performance of the insu-
lators after up to 20 years of service under these conditions.
Initial measurements of the pollution layer provided
ESDD-values up to 0.6 mg/cm2 and NSDD-values up to
17 mg/cm2, which gives an indication about the specific
pollution containing dirt, brake dust and abraded particles
from the catenary commutator. In-service measurements of
hydrophobicity have been carried out by using a cable loop
with SR-terminations placed as reference source in the
Figure 4: catenary system with silicone rubber post
took place above the base end fitting and was associated
with a physical separation. The test of the polymeric post,
which incorporates a glass-fibre reinforced resin rod,
showed the failure at 40 kN. The failure mode was signifi-
cantly different to the previously tested specimen: There
was no physical breakage of the insulator, which indicates
that the risk for line drop would be very low. This property
was further investigated and could be confirmed by numer-
ous tests /4/. This behaviour led to the introduction of the
term “safe-failure-mode” for polymeric posts with glass
fibre reinforced resin rod and appropriate design of the end
fittings. The following conclusions were deduced from the
investigations also under consideration of the test philoso-
phy of IEC 61952:
50
40
silicone post
30
force in kN

tunnel. It shows that the hydrophobicity is still measurable

after 20 years, despite the visual appearance that the sur- 20
face is fully covered by a pollution layer /3/. Today there porcelain
post epoxy
are more than 4000 post insulators installed in this tunnel 10
post

(figure 4), they have never been cleaned and have shown
neither a mechanical nor electrical failure. Part of the men- 0
tioned test programme was the comparing investigation of 0 50 100 150 200 250 300
the cantilever performance after service. The following load time in s

specimen were investigated:

Figure 5: cantilever breakage test of different post insulators

• porcelain post for 13 years in service

• epoxy post for 2 years in service
In the case of an overload, a well-designed post insulator
• silicone post for 13 years in service
shows a safe failure mode. There is no physical breakage
leading to a part separation. The failed insulator can be
Increasing a cantilever bending force to an insulator in post
detected by visual maintenance inspection, due to its over-
type application, it will break at a certain level. This is
proportional deflexion.
valid for brittle materials such as porcelain or epoxy resin.
This was confirmed by the tests, both insulators made of
Despite the over-proportional deflexion, the mechanical
these materials broke at 20 kN (figure 5). The breakage
(bending) performance of the insulator remains on a certain

SEF_Schmuck_A1.doc Session 1 Paper No -3-

CIRED 17th International Conference on Electricity Distribution Barcelona, 12-15 May 2003

level, which keeps the conductor in place, due to the high

residual strength capability of the post. • not puncturable
• hydrophobic
Hybrid solutions, incorporating porcelain or epoxy cores • safe failure mode in bending
might have an effect for pollution performance, but do not
have a safe failure mode.

3. 3 Advantages of polymeric Posts for Covered and

Bare Conductor Systems

Pin/post type insulators are an appropriate way for compact

line designs, which can be in combination with covered
conductor systems. Covered conductor systems (CCS) are
recognized as an important improvement for compact line
arrangements, corrosion problems and against earth faults
induced by broken trees /5/. The application of polymeric
posts provides significant advantages over porcelain pin
and post insulators as follows:
Figure 6. 2: principle consideration of silicone post type insulator
due to the smaller average diameter of the polymeric post
(it becomes only effective when the hydrophobicity is
lost!). These aspects can solve problems with wood pole
fires as well in areas, where the fire is ignited by high leak-
age currents across the insulator surface.

A pin-type insulator (figure 6. 1) provides a relatively high
creepage and striking distance for a certain insulators
height. This makes the design susceptible for puncture. In
the intact state, the short distance between thimble and
conductor can lead to high stresses to conductor insulation
• puncturable
• hydrophilic
• brittle
Mechanically as briefly described in chapter 3. 2, the safe
failure mode of polymeric posts with glass fibre reinforced
resin rods prevents line drops and cascade failures.
3. 4 Spun Concrete Pole with Carbon Fibre
Reinforcement
The spun concrete element plant SACAC AG, in Lenzburg,
Switzerland, has participated since 1994 in a research pro-
ject for the Swiss Federal Laboratories for Material Testing
and Research (EMPA), supported by the Commission for
Technology and Innovation of the Swiss Confederation.
The aim of this four-year project was to study the feasibil-
ity of using light, corrosion-resistant high-strength spun
concrete pylons prestressed and fully reinforced with
CFRP.

In 1999, this project was awarded the European Innovation

Prize for Textile Technology at the Techtextil Fair in
Frankfurt, Germany. The basic research phase at the insti-
Figure 6. 1: principle consideration of porcelain pin type insulator

of covered conductor systems resulting in high surface

leakage currents with possible insulation erosion and radio
interference disturbance.

A post type insulator is typically not puncturable but can

flash over. Due to the higher distance between bottom and
high voltage fitting, the dielectric stress to covered conduc-
tor systems is small.

A polymeric post (figure 6. 2) versus a ceramic post shows

another important and additional feature: Due to the hydro-
phobicity the leakage currents across the insulator surface
are significantly lower, especially for posts with Silicone
Rubber housing also under severe pollution and without Figure 7: CFRP reinforcement cage (‘skeleton’) of the pylon
maintenance. Another factor of leakage current limitation is

SEF_Schmuck_A1.doc Session 1 Paper No -4-

CIRED 17th International Conference on Electricity Distribution
tute EMPA finished in 1998 and proved the practicability
of the concept. Following, the utility Nordschweizerische
Kraftwerke AG (NOK) decided to erect the first full-scale
pylon in their 110 kV electric power distribution network.
In September 2000 the first CFRP prestressed spun con-
crete pylon for an electric power line was manufactured /6/.
This 27 m pylon was used as a support mast in the renewed
power line section from Beznau to Baden, which has been
upgraded from 50 kV to 110 kV. The high corrosion resis-
tance of the CFRP reinforcement cage allows the concrete
cover to be reduced – in this case the wall thickness is only
45 mm, compared to about 100 mm with steel reinforce-
ment. In addition, with a density of just 1600 kg/m3, a fifth
that of steel, and a tensile strength of 3000 N/mm2, twice
that of a prestressing steel, using carbon-fibre leads to a
90 % reduction in the weight of reinforcement. A high-
strength spun concrete of strength class B120 is used,
thereby permitting cross-sectional dimensions to be mini-
mised. The predicted maintenance-free life is around
50 years. The total weight saving is 40 % – six tonnes per
pylon as against ten tonnes for traditional spun reinforced
Figure 8: CFRP prestressed concrete pylon compact arrangment
concrete pylons – and so transport and installation costs are
lower. The 27 m high pylon is prestressed by 40 carbon-
fibre plastic rods with a diameter of 5 mm at a prestressing
level in concrete of Ic,i = 10 N/mm2 at the base and
15 N/mm2 at the top.
The pylon’s taper is 1.175 %, resulting in a variation of the
outer diameter from 850 mm (base) to 530 mm (top) with a
constant wall thickness of only 45 mm ± 5 mm. The pas-
sive shear reinforcement of the pylon consists of a 13 mm
wide carbon-fibre tape spiral 0.5 mm thick in the central
pole region and 1mm thick in the prestress transfer zone at
the ends, with a constant pitch of 45 mm. To validate the
static calculation methods, several static tests were under-
SEF_Schmuck_A1.doc Session 1 Paper No
Barcelona, 12-15 May 2003
taken on the completed mast to a maximum of 70 % of the
designed bending resistance. The pylon met all expecta-
tions /6/. After installation in summer 2001, long-term in-
situ monitoring has been carried out by direct electrical
resistance strain measurements of the carbon-fibre pre-
tensioning rods, along with conventional strain-gauge
measurements.
The combination of carbon-fibre reinforced plastic and
high-strength concrete has led to a new manufacturing
process for components and structural element design. It
will enable thin-walled, light, delicate and highly durable
concrete elements with very low consumption of raw mate-
rial to be produced. In particular, SACAC AG is also look-
ing at the possibility of producing other standard structural
elements, such as lighting poles, mobile phone antennae
poles, poles for supporting wind turbines, and applications
such as special structural elements for housing.
4 CONCLUSION
The paper discusses selected advantages of composite
insulators and structures for lines with compact require-
ments. Beside the recognized properties of Silicone Rubber
insulators in polluted areas, the mechanical performance
offers with the safe failure mode a feature that improves the
line reliability significantly and permits suitable arrange-
ments for areas with limited right of ways. In respect to the
principle performance, the shown examples for transmis-
sion level are applicable to distribution level as well. The
substitution of steel as reinforcing material by carbon fibres
is shown on the example of an 110kV pole for a line up-
grade from 52 kV.
5 REFERENCES
/1/ Ammann, M. a. o.: A new 400 kV line with compact
towers and composite insulated crossarms. CIGRE
1998, Paper 22/33/36-06
/2/ Kocher, M.: Experience with Silicone Composite Insu-
lators in the Tunnels of BLS Lötschberg Railway
/3/ Schmuck, F. a o.: Increased installation performance
and applications using composite insulators – a manu-
facturer’s philosophy. World Insulator Congress 2001,
Shanghai
/4/ Papailiou, K. O. a. o.: On the raising application of
polymeric post insulators. CIGRE Meeting in Prague
2000
/5/ Proceedings of the 4th International Covered Conductor
Conference Covered Conductor Electrical Systems
2000, Helsinki
/6/ Terrasi G. P., Bättig G., Brönnimann R.: High-strength
spun concrete poles prestressed with CFRP, FRPRCS 5
“Non-Metallic Reinforcement for Concrete Structures”,
ISBN 07277-3009-6, University of Cambridge, England
16 – 18 Jul 2001, pp. 1103-1112
-5-
21, rue d'Artois, F-75008 Paris
http://www.cigre.org B2-304 Session 2004
© CIGRÉ

FURTHER DEVELOPMENTS OF COMPACT LINES FOR 420 KV

WITH SILICONE INSULATORS AND THEIR ADVANTAGES
FOR APPLICATIONS IN EMERGENCY RESTORATION SYSTEMS

F. SCHMUCK K. O. PAPAILIOU P. J. KOLMEIJER J. F. VAN WOLVEN

SEFAG PFISTERER AMEC SPIE KEMA

Switzerland Germany Netherlands

ABSTRACT

The paper describes the test programme and results of a 420 kV braced line post arrange-
ment manufactured from composite insulators. In comparison to a previously installed ar-
rangement, a solution with solid core post has been introduced. The test results have shown
impressively the high safety margins of glass-fibre reinforced structures and the technical po-
tential for an increased reliability of compact lines. Further advantages are shown on the ex-
ample of an Emergency Restoration System.

KEYWORDS

Compact – Line – Composite – Insulator – Solid Core – Post – Mechanical Strength – Elec-
trical Performance – Emergency Restoration System

1 INTRODUCTION

Compact lines are considered as an accepted solution to solve infrastructural constrains in

the cases of voltage upgrades of existing lines or for line routes passing through areas with
high population or infrastructural density. Composite insulators offer many well-known advan-
tages, which can be utilized for compact arrangements in an excellent way. Important criteria
are for the design stage, the lower weight in comparison to porcelain/glass insulators and the
flexibility/deflection of the glass-fibre reinforced structure in the case of cantilever loading.
For basic mechanical performance, IEC 61952 provides guidance for product qualification.
There are also CIGRE publications, which do consider the load performance under static /1/
and dynamic /2/ load conditions and deduce an average threshold for mechanical stresses
under working load conditions for a particular design. However, there exists no standard,
which defines the requirements and tests for compact arrangements consisting of composite
post and bracing longrod insulators, also called braced line post arrangement. For this rea-
son, data from calculations have to be confirmed by comprehensive tests for further develop-
ments of compact arrangements. This paper deals in the first part with the results of a re-

frank_schmuck@sefag.ch
cently tested solid core solution for the post. Basis for the design has been the experiences
collected since 1996, when the performance of a composite insulator solution for a 420 kV
compact line was comprehensively investigated /3/. At this time, the post insulator was
manufactured from a hollow core insulator. In the second part of the paper and on the exam-
ple of a compact 420 kV Emergency Restoration System (ERS), the savings for erection and
transportation are shown in comparison to a conventional solution. With the use of composite
insulators, the reliability and overall functionality of ERS were significantly improved.

2 DESIGN OF THE NEW 420 KV LINE WITH SOLID CORE INSULATORS

2. 1 REQUIREMENTS IN COMPARISON TO THE HOLLOW CORE DESIGN

A typical technique for designing braced line post assemblies includes the use of a pivoting
attachment between the assembly and the tower that optimizes the performance of the
installation. In the case of an unbalanced situation
caused by conductor breakage or uneven ice loading,
Tension the assembly would move in the direction of the
Insulator
applied force and be finally subjected to tensile
loading conditions. This reduces the bending force
requirements in comparison to a non-pivoted
alpha FZ attachment and it is possible to reduce the diameter of
FX
beta the post rod, thus, lowering the assembly weight and
cost. Early simulations and erections in the eighties
FY
FR have shown that the number of consecutive towers in
a line section using pivoting attachments for the
Post crossarms can be in the range of 14 /4/. In the design
Insulator stage of the actual project, the forces have been
superimposed (Figure 1). The equivalent situation to
Figure 1: Superimposition of Forces
service load conditions of the design is achieved, if
any pre-loading causes a (pre-) deflection that is rep-
resentative for the in-situ loads. This is true for the design and later proven by testing, be-
cause the applied compression component is out of the axis of the post. This causes a bend-
ing to the post insulator towards the brace side. Any buckling would follow this pre-stressing
and would result in a deformation upwards in the middle of the post (P-∆ model). The me-
chanical requirements were part of the specifications and submitted by the utilities (Figure 2).
For Arrangement 1, the normal load case was tested in a (quasi-static) load test with high
compression component and the broken wire was simulated by a fast release of a defined
unbalanced load. In contrast to, Arrangement 2 and 3 required quasi-static load testing for
normal load and broken wire cases.
Normalized Load Light Load Heavy Load
Condition Condition Condition
normal broken normal broken normal broken
load wire load I wire I load II wire II
Vertical Force FY in kN 107.3 70 34.3 77 38.3
performed /3/
dynamic test

Transversal Force FX in kN 11.4 39.3 11.8 69.8 23.8

Longitudinal Force FZ in kN 0 3.5 66.3 4.3 66.3
Resulting Force FR in kN 107.9 80.4 75.6 104 80.2
alpha in ° 84 60.7 71 47.8 58.2
beta in ° 0 2.5 61.3 2.4 55.8

Installed Design Hollow Core Post

Single Solid Double Solid
Drafted Design
Core Post Core Post
Used Terminology Arrangement 1 Arrangement 2 Arrangement 3

Figure 2: Comparison between installed and new 420 kV-Design

2
2. 2 PROPOSALS FOR NEW ARRANGEMENTS

The data of Figure 2 contain a safety factor to working loads of 3.1 and 2.5 respectively. Fig-
ure 3.1 shows the installed design of the Swiss line /3/, which was used as empirical basis
for the design work of the solid core posts. The post is made of a hollow core insulator (E-

Figure 3.1: Installed Hollow Core De-

sign –Arrangement 1
Figure 3.2: Draft for Light Load
Condition-Arrangement 2

Modulus 21`000 N/mm2). There is no steel cross-

arm, thus an angle of ~50° is formed between post
and brace. The internal space of the hollow core
post is filled with an elastic compound to prevent in-
ternal discharges and condensation. The end fit-
tings are attached to the tube by using the well in-
troduced combination of gluing and heat-shrinking.
The hardware was designed for low radio interfer-
ence disturbance and power arc rating of 40kA/sec.
The line operates with twin ACSR conductors with a
diameter of 38 mm. The Light Load and Heavy Load
Conditions for the new design led to different design
proposals (Figures 3.2 and 3.3). In contrast to Ar-
rangement 1, the angle between post and brace is
90°, which reduces the compression component to
the post due to vertical loadings. The solid core post
(E-Modulus 34`000 N/mm2) does not require an in-
ternal filling and the end fittings are applied by using
Figure 3.3: Draft for Heavy Load crimping technology. The hardware was more sim-
Condition-Arrangement 3 plified and designed for a direct attachment to the
end fittings. The striking distance across the post is
adjusted to be smaller in comparison to the brace. The line will have triple bundle with AAAC
conductor of 31.7 mm. Due to the high compression load of the Heavy Load Condition, a
double post arrangement has been envisaged in this case following a conservative design
approach. All three designs use a pivoted attachment to the pole.

3
3 TEST RESULTS WITH SINGLE SOLID CORE (ARRANGEMENT 2)
3. 1 MECHANICAL TESTING

The mechanical test should “judge” the calculated results and give an indication on the suit-
ability of both arrangements to the forces requested by the specification. In a first step, it was
agreed to test only Arrangement 2 with the single
post. The insulators were tested without the Sili-
Tension
cone Rubber housing to detect cracks and plastic
Hydraulic
Insulator Jack deformations in an easier way. The set-up of the
test arrangement is shown in Figure 4. The force
was applied at the attachment point of the link to

ta rce
be Fo
the conductor yoke. The axis between jack and
F an ting
post have been adjusted under consideration of
ha ul
d
lp es

D
the angles “alpha” and “beta” defined by the
ra fr
de n o

D
specification (Figure 2). The applied force was
un tio
c

D measured by a calibrated load cell in the jack and

je
In

the displacement was measured of three positions

Post
Insulator and digitally recorded during measurement. A
number of tests sequences had to be made to
D = Displacement Probe
adapt the test equipment to the deflection of the
F = Force Probe
test object. Figures 5.1 and 5.2 show representa-
Figure 4: Diagnostic Measure- tive curves for Light Load Conditions. All test cy-
ments during Testing cles included a ramped load increase to 60% of
the specified value followed by load release and
an increase to the 100% value. This also takes
into consideration the “creeping” of the complete arrangement due to adaptation to the first
load exposure. Figure 5.1 shows that the 100% value was significantly exceeded without
failure followed by the passed test of the broken wire in Figure 5.2. This high performance
led to the decision to apply the Heavy Load Condition to the single post solution as well (Fig-
ures 6.1 and 6.2).
140 90 Broken Wire Test I applied to Set-up of Light Load Condition
Normal Load Test I applied to Set-up of Light Load Condition
(single solid core) (single solid core)
kN kN

70 F>80.5 kN
100 F>126.5 kN no failure
no failure 60 test stopped
Force in kN

Force in kN

test stopped
80
50

60 40

30
40
20
20
10

0 0
0 200 400 600 800 1000 1200 1400 1600 1800 0 200 400 600 800 1000 1200
time in s time in s

Figure 5.1: Normal Load I - Arrangement 2 Figure 5.2: Broken Wire I - Arrangement 2

120 90
Normal Load Test II applied to Set-up of Light Load Condition Broken Wire Test II applied to Set-up of Light Load Condition
110 (single solid core) (single solid core)
kN
kN F>106.6 kN
no failure 70 F>69.7 kN
90
test stopped no failure
80 60 test stopped
Force in kN

Force in kN

70
50
60
40
50
40 30
30
20
20
10 10

0 0
0 200 400 600 800 1000 1200 0 200 400 600 800 1000 1200
time in s time in s

Figure 6.1: Normal Load II - Arrangement 2 Figure 6.2: Broken Wire II - Arrangement 2

4
A summary of the test results of Arrangement 2 is shown in Figure 7. The %-values docu-
ment the relation to the specified values, which already contain a safety factor of 2.5. It
should be mentioned that all tests were performed with one specimen. An interesting option
can be deduced from the results that
200 Arrangement 2 could also cover the
required value in kN
180 requirements of Arrangement 3. Both,
proven value in kN for the relatively small excess of the speci-
Single Solid Core Post
160
fied values for broken wire I and nor-
mal load II as well as the non-
Force in kN

140
+ 57%
compliance of broken wire II have been
120
+ 2.4% caused by the limitations of the test
100 equipment and not by the arrangement
80
+ 6.5% - 13% itself. For this reason, the failure of the
arrangement could not be achieved,
60 which would show the known safe fail-
40
ure mode /5/. Comparing the results of
the Swiss test program with the actual
20
procedure, the Arrangement 2 was
0 subjected to higher loads, which was
normal load I broken wire I normal load II broken wire II reflected by the higher deflection as
Light Load Condition Heavy Load Condition
well. The maximum measured deflec-
Figure 7: Summary of mechanical Test Results
tion of Arrangement 1 (hollow core so-
lution of Figure 3.1) was in the range of
38 mm; while Arrangement 2 (solid
core solution of Figure 3. 2) showed more than 200 mm without any damage. The results do
document the safety and design potential of fibre-reinforced structures. The preference is for
the solid core solution, because there is no filler required inside and the attachment techno-
logy permits a higher utilisation of the intrinsic rod properties.

3. 2 ELECTRICAL TESTING

The electrical withstand values were defined by the utilities to meet the local requirements for
insulation co-ordination and are summarized with the corresponding standards in Figure 8.
Figure 8 shows unambiguously that the electrical requirements are comprehensively covered
in the corresponding standards. The requirement for the Radio Interference Voltage had to
be fulfilled with a specially adapted combination of a corona/arc ring. After the power arc test,
various electrical and mechanical tests were performed to prove the integrity of the arrange-
ment.
Arrangement 2
Arrangement 1 applied Standard
Property Arrangement 3
Corona Test (extinction voltage) > 265 kV > 265 kV IEC 60383-2, IEC 60060-1
< 100 µV (40 dB/ IEC 60383-2, IEC 60437,
Radio Interference Test not measured
1 µV) at 278 kV CISPR 18-2
BIL 1.2/50 > 1425 kV > 1425 kV IEC 60383-2, IEC 60060-1
SIL Wet 250/2500 > 1050 kV > 1050 kV IEC 60383-2, IEC 60060-1
PF Wet Withstand Voltage > 630 kV > 520 kV IEC 60383-2, IEC 60060-1
no test hard- 30kA for 1 sec-
IEC 61467, IEC 60383-2,
Power Arc Test ware designed ond without de-
IEC 60060-1
for 40kA/sec struction

Figure 8: Required electrical Values

5
3. 2. 1 Results of High Voltage Testing

The high voltage tests were passed without particularities and showed high safety factors
(Figure 9). In the tests under dry conditions, the results, depending on hardware design and

2500
required value in kV
proven Value in kV
+ 40%
2000
Force in kN

1500
+ 24%

1000
+ 36%

500
+ 16% + 5%

0
Corona Radio Dry Lightning Wet Wet Power
Extinction Interference Withstand Switching Frequency
Voltage Voltage Voltage Impulse Withstand
Withstand Voltage
Voltage

Figure 9: Summary of electrical Test Results Figure 10: Wet Switching

Impulse Testing
striking distance, are comparable to conventional solutions. During testing of the simultane-
ous voltage and rain performance, the composite arrangement provided significantly higher
values in comparison to glass or porcelain. This can be attributed to the smaller diameter of
the composite insulators and the hydrophobic (water-repellent) effect of the Silicone Rubber.
Figure 10 shows the flashover during Wet Switching Impulse Testing. Despite the higher
striking distance of the brace, most of the flashes appeared across this insulator influenced
by the water direction of the artificial rain.

3. 2. 2 Results of High Power Testing – Power Arc

As required, 30 kA for 1 second has been given as test scenario. The short circuit was initi-
ated across the post insulator, because of its shorter striking distance. The test scenario “D”
of IEC 61467 was selected – unbalanced supply and return circuit. The calibration of the cir-

Figure 11.1: Calibration Shot Figure 11.2: Power Arc Current

cuit was made with cage shunts and provided 33 kA for 0.98 sec (Figure 11.1). This calibra-
tion test does not take into account the dynamic behaviour of the power arc and its interac-
tion to the test circuit. The arc current over time (Figure 11. 2) shows that the arc extin-
guished after 560 ms. This is attributed to the electromagnetic and thermal forces (dominat-
ing is the electromagnetic effect for this condition), which are used to guide the arc at the arc-
ing horns. In the test case, these effects do superimpose and prolong the power arc until ex-

6
tinction under the selected test conditions and available electrical energy (Figure 12.1). The
test specimen was still in position after the test, and the housing was blackened by the power
arc (Figure 12. 2). No part of the housing was damaged by thermal stress. The end fittings
were marked by the power arc roots but did not show a considerable loss of material. The
aluminium end fittings of the post exhibited a certain colour change but the following me-
chanical tests showed no reduction of strength at all.

Figure 12.1: Arc Extension during Test Figure 12.2: End Fitting after Power Arc Test

Although the actual arc front extinguished earlier that the specification requires, it was
agreed in this particular case to consider the test as having been passed. This decision was
based on the physical evidence to the limited damage at the arc ring component, the excel-
lent guidance of the arc away from the insulator and calculations that determine a value limit
of energy in the end fitting area to be well below acceptable limits. Hence, a safe operation
also in a power arc case could be guaranteed. This extrapolation is only valid for the investi-
gated materials and end fitting design.

4 APPLICATION OF HIGH STRENGTH POST FOR EMERGENCY RESTORATION

SYSTEMS

The first designs of the ERS used V-shaped towers, hence the insulators were composite
tension insulators. Glass cap and pin insulators have not been considered because of their
higher weight. This design concept can be used for voltages up to 500kV /6/. A disadvantage
is the area consumption of such structures. With the availability of composite high strength
post insulators, compact designs such as braced line posts were developed and commis-
sioned. The properties of the insulators of the ERS are derived from the main design criteria
of the system, short erection time, light weight, endurance and limited number of parts.

The insulators of the ERS must therefore have the following properties: easy handling due to
low weight, low susceptibility against damages due to multiple assembly/disassembly, limited
number of individual parts, high insulating behaviour without any maintenance. These pro-
perties are met with solid core silicone insulators in an almost ideal way. The insulator ar-
rangement is fully equipped with combined arc/corona protection. The ERS is containerised
for easy transport to difficult areas, hence weight and volume consumption play a vital role.
The low susceptibility of the composite insulators against fractures does not require spare
parts in the container, which is a logistic advantage too. On the example of a typical 420 kV
system, the savings for erection and transportation can be estimated as follows: 55 % for
erection and 50 % for transportation. This saving could be demonstrated for a 420 kV ERS
by-pass system, installed in year 2000. For the crossing of the high speed rail connection be-
tween Antwerp and Amsterdam, the clearance of the line Krimpen – Zoetermeer between

7
tower #46 and #47 had to be increased by approximately 10 meters. For this, a new tower
was built next to the existing tower. One of the es-
sential project conditions was the limited outage
time of the 420 kV system to be three days maxi-
mum. The construction of the new tower did not
meet this requirement. As solution, the correspond-
ing part of the 420 kV line was re-routed via three
restoration towers (Figure 13). Due to the time con-
strains the conductors were pulled from the existing
towers to the restoration towers. For this purpose
special designed frames with rolling-out wheels and
conductor clamping devices were installed. The 4-
bundle conductors were released from the clamps
in the existing towers and brought to the required
length. The frames were positioned over the con-
ductors and took over phase by phase from the ex-
isting towers to the restoration towers. Finally the
conductors were clamped in the frames. The trans-
fer time could be realized within five hours, which
met the time requirements in an excellent way. The
simple and time-efficient take-over of the conductor
can only be applied with the braced line post ar-
rangements and not with the previous V-shape de-
sign. Figure 13: 420kV by pass with ERS

5 CONCLUSIONS

The known features of composite insulators can comprehensively be utilized for compact ar-
rangements. In the case of permanently installed arrangements, the lower weight leads to
saving for tower constructions and the overall performance and reliability takes benefit of
their pollution behaviour and safe failure modes. Within a comprehensive test programme,
the high safety factors of Silicone Rubber insulator components could be proven. For ERS,
the features of composite insulators have led to lower system weight and installation time,
which reduces costs in emergency cases. With the availability of high strength solid core post
insulators, optimized solutions for even higher voltage levels are in the design stage under
consideration of the presented test results.

6 REFERENCES

/1/ Electra 1996 Ref. No. 169(2): Cantilever load performance of composite line post in-
sulators.
/2/ Electra 2000. Ref. No. 192: Dynamic bending tests of composite line post insulators.
/3/ Ammann, M. et. al.: A new 400 kV line with compact towers and composite insulated
crossarms. CIGRE 1998, Paper 22/33/36-06
/4/ Voyazakis, J.: 150kV transmission lines on tapered steel poles supporting insulator
crossarms in Greece. International Conference on Overhead Line Design and Con-
struction: Theory and Practice (up to 150kV), November 1988, London, UK
/5/ Papailiou, K. O. at al: On the raising application of polymeric post insulators. CIGRE
SC 33 Conference "Development of insulation coordination and power system reliabil-
ity in central European countries", Prague, Czech Republic, September 7 - 8, 2003
/6/ Rhebergen, B. et al.: Experiences with 400 kV and 150 kV emergency restorations in
Belgium and the Netherlands. CIGRE 1998, Paris, Paper of SC 22