2012 IEEE 10th international Conference on the Properties and Applications of Dielectric Materials

July 24-28,2012,Bangalore,india

Comparative Performance of Silicone Rubber Insulators with IEC Stipulated Test Methods

N.Vasudevl, S.Vynatheya', R.T.Senthilkumar2

1 Central Power Research Institute, Bangalore
lvasu@cpri.in
2
K.S.Rangasamy college of Technology, Tiruchengode

2senthilpowersystems@gmail.com

Abstract: IEC standard 61109 /62217 stipulates
alternatives for design tests for polymeric insulators, namely
(a) tracking and erosion test(lOOOhours), (b) track wheel test
(3 0,000 cycles) and (c) multi- stress ageing test (5000 hours).
The minimum requirement for the insulator to comply with
the design test is compliance with any one of these tests.
However, experience in carrying out these tests in CPR!
indicate that the assess the relative merits of the tracking and
three these two characteristics using accelerated aging tests. The
paper describes the experimental studies carried out on of
33 kV polymeric insulators using both the IEC 62217 salt
water dip test and the IEC 61109 salt-fog test with some
emphasis on the practical difficulties of using these tests and
the results of each test methods [2.3].
EXPERIMENTAL SET UP & TEST PROCEDURES

erosion test and the track wheel test, both the tests were
Test Specimens for Salt fog and track wheel test
carried out on a 33 kV polymeric insulator. Both the tests
In the present study, six identical clean samples of silicone
were terminated after 1000 hours. The results indicate track
rubber polymeric insulator and six numbers of hydro carbon
wheel test is severe. Analytical tests such as hydrophobicity
polluted insulators were subjected to tracking and erosion
test, EDX and XRD tests were performed to check the
test and tracking wheel test. Fig.l & 2 shows the specimen of
degree of degradation of the insulator material.
clean insulator and hydrocarbon pollutant insulator
respectively used for salt fog and track wheel tests.
Keywords - accelerated ageing, pollution, polymeric
insulator, rotating wheel dip test, salt fog test.

INTRODUCTION

Polymeric insulator has been widely used in power

transmission and distribution systems. Polymeric insulator
Fig.l Virgin Fig.2 Polluted insulator
has more advantages over ceramic insulator which are given
as follows: 90% weight reduction, reduced breakage, lower Salt Fog Test
installation cost, aesthetically more pleasing, improved Schematic diagram of salt-fog chamber is illustrated in
resistance to vandalism, improved handling of shocked Figure 3 . Two test specimens of same creepage distance
loads, improved power frequency insulation and improved were used for the study. One of the test specimens was
contamination performance. Though there are advantages , coated with hydro carbon pollution for comparison purpose.
the limitation of polymeric insulator are also there in the Leakage currents were monitored every 100 hours. The
form of aging. Accelerated aging tests such as tracking test, salinity used for the study is 16 milli Siemens /cm.
salt fog test can simulate the real life degradation of
I-����;N�- ------,
RESISTOR

polymeric insulator. Aging is still one of the main causes of ,------"--,

failures of polymer insulators in the field [1].
Consequently, to improve both materials and insulator
SALTWATER uv
designs, it is important to understand the mechanisms of TANK

aging, as well as the factors surrounding aging. The best

way to do this is through actual field experience. However,
the problem with field experience is that it often requires a
very long time before any noticeable changes become
evident.
The two most important characteristics of polymer Fig. 3. Schematic diagram for salt fog test

materials are their hydrophobicity, which prevents the water

Tracking Wheel Test
filming and their by reducing the surface leakage current
Test methods for salt water dip wheel test were based on
(LC), and their resistance to the degradation process that can
IEC 62217. Test was conducted continuously for 1000 hours
ensure when hydrophobicity is lost, either temporarily as in
to compare the two methods prescribed in the standard. The
the case of silicone and silicone co-polymers These two
present study is to compare the performance of the insulators
characteristics are also interrelated with the profile of the
with salt fog as well as wheel test. Each of the test cycle
insulator. As a result, it is important to evaluate the
takes 192 second and includes 4 test positions, energized,
performance of polymer insulators and materials based on

978-1-4673-2851-7/12/$31.00 ©2012 IEEE

de-energized, salt water dip and de-energized, respectively.
For each position, test specimen remains stationary for about
40 second and takes 8 second for rotating to the next
position. Salt water was renewed every week and renewing
time was less than 1 hour. Test arrangement for wheel test
is shown in Fig. 4 and the specimen arrangement is shown in
Fig. 5. The test voltage applied to the insulators was 25.6 kV
which is equivalent to 20 mmlkV as used in salt fog test.
Fig.6 Hydrophobicity of Polluted Insulator
Leakage currents of each insulator were monitored at the
The leakage current is one of the methods for assessing
start and end of the ageing test. Leakage current was
the degradation of insulator material. The growth of leakage
measured with 100 ohms shunt and wave form recorded in a
current during the test shows how the deterioration takes
digital oscilloscope.
place on the surface of insulating material. Fig.7 shows the
Position 3
Voltago Applied leakage currents of insulator with and without hydro carbon
polluted insulators. It is seen from the pattern that the
leakage current increased slightly with the ageing of the
insulators. This could be due to slight degradation of the

Position 2
insulator surface of the hydro carbon polluted insulator [7].
O ..lpplng

Position'
Dipped In Saline

....,
B
Solution

.9
Fig.4 Schematic diagram for rotating wheel test
�
-Cl ..... n Insul .. tor

Time in Hours

Fig.7 Leakage Current of Clean and polluted insulator

X-ray Diffraction Analysis

Fig.5 Specimen arrangement during dip wheel test The analysis was used to study the changes in the physical
structure of the polymer with ageing. A copper anode sealed
X-ray tube operated at 40 kV/ 30 rnA provided the X-ray
RESULTS & DISCUSSIONS
source and a Xcelerator detector were used for the detection.
The diffraction data on each polymer sample was obtained
1000 hours salt fog test
from 5 to 100 degree 2-theta, with a sampling interval of
The salt fog ageing tests conducted on silicone rubber
0.02 degrees and a scan rate of 2 degrees per minute. Data
insulator with and without hydro carbon pollution showed no
reduction was carried out using the software provided by the
traces of tracking and erosion on the insulators. Both the
manufacturer. This includes removal of K-alpha component
insulators withstood the tests as per IEC 61109.
of the copper radiation prior to peak identification. The
diffraction pattern obtained is a plot of the intensity vs. theta
The hydrophobicity is the main characteristics of the
angle. The degree of crystallinity can be determined, if the
excellent performance of the insulator under polluted
crystalline and amorphous scattering in the diffraction
conditions for the composite insulators. Loss of
pattern can be separated from each other.
hydrophobicity is due to the dry band arcing on the surface.
The wide angle scans of the virgin before contamination,
Before the test both the insulators after pollution coating
after contamination with Oxy-acetylene, it could be seen
exhibited hydrophobicity of HCl based on STRI
from the hump between 10° to 17° in the wide angle scans
classifications. During the aging process and after the test
that both polluted insulators were tending towards
both the insulators exhibited hydrophobicity of HC2 or HC3 .
crystallinity as compared to the respective virgin samples.
Figure. 6 show the hydrophobicity of the insulators after the
test. This recovery of hydrophobicity during the test is due to
diffusion of low molecular weight polymer chain from bulk Energy Dispersive X-Ray
This technique is used to demonstrate the depletion of low
to the surface. Hydrophobicity on the polluted layer was
molecular weight polymers on the surface of the aged
better even after the ageing.
material. The X-Ray mapping is a method by which the
characteristic X-Rays collected from EDX measurement is
correspondingly mapped on to a computer screen based on
the secondary electron image. Because the mapping
technique uses signals obtained from X-Ray collection. It
therefore operates only when distinct elemental peaks are insulators) exhibited hydrophobicity of HCl. During the
detected by EDX. aging process within 50 hours all the insulators lost its
The pieces of 1cm x 1cm were cut from virgin and aged hydrophobicity. The loss of hydrophobicity is due to the
samples were subjected to EDX analysis. The results of the rotation of insulator in the salt water bath in each cycle. The
analysis made on the Virgin and aged samples are tabulated insulator weather sheds experiences a vertical thrust during
as shown in rubber insulators with different hydrocarbon the rotation of each cycle and there by losing the
pollution. This shows that the material is getting degraded. hydrophobic property. This process have resulted in surface
This is due to the depletion of large amount of low molecular roughness and hence the loss of hydrophobicity [10].
weight polymer chains on the top of the insulator surface,
which indicates the degradation of the material [9]. The Leakage current measurement
increase in sodium and chlorine contents indicates that the Leakage currents of clean and hydrocarbon pollutant
deposition of these elements may accelerate the degradation insulators were monitored during the process of ageing. A
of the material shown in Table II. typical wave form is shown in Fig.10.

TABLE II
Elemental Details of the Virgin and Aged Samples using

Sample C 0 Na
I SIS
EDX anal\
Mg
'
AI Si CI K
I
Virgin
Clean
Aged 1
6.1
9.5
1l.2 0.2 0.1
33
25.9
65
60.3 0.9 0.16 �.
M.".,,,.
�alu •
• talu,
J
Polluted 6.3 18.9 2.7 3.4 10.5 41.2 1l.8 1.0
Aged 2 Leakage current: 3 .6 IlA
Fig.10 LC measurement of insulator

1- Shows the elemental analysis of aged samples (before ageing)

without hydrocarbons.
2- Shows the elemental analysis of aged samples with
hydrocarbons (oxy-acetylene).

RESULTS OF TRACKING WHEEL TEST

Visual observations
The visual observations of clean and hydrocarbon Leakage current: 75.5 rnA
pollutant tracking wheel aged insulators are shown in Fig.8 Fig. 11 LC measurement for clean insulator
and Fig.9. The tracking and erosion found more in the (after ageing)
tracking wheel aged insulators with clean and hydro carbon The maximum leakage current during the test is 890 rnA .
polluted insulators when compared to the salt fog test. The increase in leakage current is due to the degradation of
the silicon rubber material during the test. Surface
degradation of the material during the aging process
progressive as the duration of aging increased. More surface
roughness results more crystalline surface leading to high
leakage current. The aging test was tenninated as the
insulators were tracking and core was visible at the end of
1000 hours.

Fig. 8 clean insulator after aged Energy Dispersion X-ray (EDX)

The pieces of lcm x lcm were cut from virgin and aged
samples were subjected to EDX analysis. Figures 12 and 13
show the EDX spectrum and surface X-ray of clean insulator
aged and aged pollutant insulator.

Fig.9 hydrocarbon pollutant after aged

Hyd rophobicity
Evaluation of clean insulator before and after aged with
Fig.12 EDX Graph and Surface X-Ray of Clean Insulator
hydrophobicity is based on STRI guide. Before the ageing
Aged Sample
test all the insulators (with and without hydrocarbon polluted
 ...., .
Configuration on Deterioration of Silicone Rubber for
: Polymeric Insulator in Salt Fog Ageing Test", IEEE

iliJ�k ..
Transactions of Dielectrics and Electrical Insulation Vo1.l3,
No.1, pp.l29 -13 8,2006.
[2] De Torreil.C.H and P.J.Lambeth, -Aging of Composite
:J • 2 "'
��.&635_c..._.1",'(3oId.s)
,
'" Insulators: Simulation by Electrical Tests", IEEE
Fig.13 EDX Graph and Surface X-Ray of Polluted Transactions of Power Delivery, Vo1.5, No.3, pp.1558 -
Insulator Aged Sample 1567, 1990.
[3 ] Gorur.R.S, S.Sundhara Rajan and G.Amburgey,
X-Ray Diffraction Analysis -tontamination Performance of Polymeric Insulating
The wide angle scans of the virgin before contamination, Materials used for Outdoor Insulations Applications", IEEE
after contamination with hydro carbon pollution are Transactions of Electrical Insulation Vo1.24, No.4,
shown in fig. 14. It is evident from the results both polluted pp. 713 -716, 1989.
insulators were tending towards crystallinity as compared to [4] Guoxiang Xu, Paul B. Mc Grath and Clayton W. Bums,
the respective virgin samples. -Accelerated Environmental and Electrical Aging of Polymer
The degree of crystallanity is more for aged sample than Insulators", Proceedings of IEEE Conference on Electrical
the virgin. The aged hydrocarbon polluted insulator is Insulation and Dielectric Phenomena, pp. 404 -407, 1996.
showing more counts when compared to all the aged [5] IEC 60507: Artificial Pollution Test of High Voltage
samples. Insulators to be used on ac system.
[6] IEC 60815: Guide for the Selection of Insulator in
Cou-• • Respect of Polluted Conditions.

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40

[7] IEC 61109: Composite Insulators for AC Overhead

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0
H'VOR) c.,t.RBONPO..tJTANT AGED SAMPLE Lines with a Nominal Voltage Greater than 1000 V.

/ [8] IEC 62217: Polymeric Insulators for Indoor and

400
'00
0
H'VOR)CJ.RBONPO..tJTANT AGED SAMPLE 2
Outdoor use with a Nominal Voltage Greater than 1000 V.
40
�,
20
.T"" ����
CLEAIII NS Ll.ATCRAG EDSAUPLE ,
J,--- [9] Muhammad Amin and Muhammad Salman, -Aging of
Polymeric Insulator", Revised Adv. Material Science, pp.
J ....
100

93 -116, 2006.
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0
'"

j
i !<O
1 00 [10] STRI Hydrophobicity classification Guide 92/1.
'"

10

.?OSlt1OJ1o j'2T tal (Coppi<'.f (Cu)

Fig.l4 Wide Angle Scans of Analysis of All the Samples

CONCLUSION
Based on the salt fog test and tracking wheel test
conducted on Silicone rubber polymeric insulators, the
following conclusions were drawn.
1. The two tests methods compared have shown wide
variations in the test results.
2. The 1000 hours salt fog tests have not shown any
degradation of the insulators.
3. Track wheel tests have shown higher degree of tracking
and erosion of insulator material resulting in failure of
insulator.
4. Track wheel test is more severe for polymeric insulator
compared to 1000 hours test.
5. Leakage current measured after aging of tracking wheel
test is high compared to salt fog test.
6. Both polluted aged and clean aged sample insulators were
tending towards crystallinity as compared to virgin sample.
Track wheel tests are more severe than the tracking and
erosion test which is to be considered as the design test on
composite insulators.

REFERENCES

[1] Boonruang Marungsri,Hiroyuki Shinoko, Ryosuke

Matsuoko and Seiji Kumagai, -Effect of Specimen