As/Nzs7000 Standard Electrical and Mechanical Design of Insulators

28/06/2011
AS/NZS7000 STANDARD ELECTRICAL AND MECHANICAL DESIGN OF INSULATORS
Colin Lee Network Systems Development Manager, ENERGEX
Insulation Basics
Insulation is subjected to electrical and mechanical

stresses Electrical stresses include: Power frequency voltage Switching impulse voltage Lightning impulse voltage Mechanical stresses include: Tension loads (suspension and tension strings) Compressive loads (braced post insulators) Cantilever loads (post insulators)
Cigre Australian Panel B2- Overhead Line Seminar - AS/NZS7000:2010 Design of Overhead Lines Sydney 28-29 March 2011
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Line and Substation Coordination

Impulse flashover strength of overhead line insulator usually exceeds BIL of substation plant insulation 132 kV line insulation 650 to 700 kV, 132 kV BIL of substation plant 550 kV Line insulator is self restoring, substation insulation may result in destructive failure Measures need to be employed to protect substation plant from lightning surges Installation of OH earthwire Low tower footing resistance close to substation Installation of surge arresters
More on Electrical Stresses

Power frequency voltage Normal operating 1.1 p.u Maximum dynamic 1.4 p.u Switching impulse overvoltages Up to 3 p.u peak phase to ground Can be higher with single phase auto-reclosing Usually design for 3 p.u and when auto-reclosing is employed, install surge arresters Lightning performance Overvoltages will vary depending on the lightning current (average of 30 kA) and usually exceed line insulation Design for acceptable lightning flashover rate insulation influences shielding failure and backflashover rate
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More on Electrical Stresses
Design for Pollution Performance

Mechanism of Contamination Flashover Build up of contamination on insulator surface Light wetting of the pollution on the insulator surface build up of leakage current on the surface formation of scintillating arcs and associated audible noise level increases formation of dry bands and build up of electrical stress sparking discharges across the dry bands the joining of the discharges to form a complete flashover
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Ceramic Insulator Profiles
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GUIDE FOR SELECTING INSULATORS IN CONTAMINATED ENVIRONMENTS Minimum nominal specific creepage distance(2) mm/kV 16 20 25 31
Contamination severity
ESDD range(1) g/m
Light Medium Heavy Very Heavy

(1) (2)
0 to1.2 1.2 to 2.0 2.0 to 3.0 Above 3.0
ESDD is the equivalent salt deposit density. Ratio of leakage distance measured between phase and earth over the r.m.s phase to phase voltage of the highest voltage of the equipment. (3) Consideration should be given to increasing the creepage distances is areas where there are long periods without rainfall or very close to the marine coast
References 1. 2. 3. AS 1824.21985, Insulation coordination, Part 2: Application guide. IEC 60815, Guide for the selection of insulators in respect of polluted conditions. AS 4436 Guide for the selection insulators in respect of polluted conditions. (Identical to ISO Report 815). Cigre of Australian Panel B2- Overhead Line
Seminar - AS/NZS7000:2010 Design of Overhead Lines Sydney 28-29 March 2011

Example: Select a suitable disc insulator string for a 132 kV line subject to heavy contamination. Use normal or fog disc profiles where the creepage length is 292 mm normal and 432 mm for fog. System Highest Voltage = 145 kV (1.1 p.u) Minimum nominal specific creepage distance = 25 mm/kV for heavy contamination Required creepage distance for 145 kV = 3625 mm Number of normal discs = 3625/292 = 12 discs Number of fog discs = 3625/432 = 8 9 discs Note: Need to check switching surge (3 p.u) and power frequency (wet and dry) overvoltage conditions as well. Generally pollution performance governs.
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Composite Long Rod Insulator Design
Composite Insulator Design Aspects
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INSULATOR MECHANICAL DESIGN

TABLE CC1 - INSULATOR LOADING CONDITIONS
State Tension insulator condition Suspension and vee string insulator condition Weight span, 0 Pa wind Resultant load at serviceable wind or 500 Pa transverse load Resultant load for construction and maintenance Resultant load for ultimate conductor wind transverse load or failure containment load Post and pin insulator condition Weight span, 0 Pa wind Resultant load with serviceable wind or 500 Pa transverse + longitudinal unbalance load Resultant load for construction and maintenance Resultant load with ultimate transverse wind + longitudinal unbalance load or failure containment load
Everyday Serviceable working wind1
Serviceable Maintenance Ultimate load
Construction and maintenance loads Ultimate load
Notes:
The criteria for serviceable working wind is damage or deflection limit
Limit State Design

Rn > Wn + 1.1 Gs +1.25 Gc +1.25 Ft
Calculate the applied limit state loads (LST at ultimate wind) Apply appropriate LSD multiplier (1.25 for conductor loads and 1.25 for for tension loads) Apply appropriate component strength factor
Porcelain or glass cap and pin string insulator units Strength 0.95 (verified from statistical testing) 0.8 (unverified) (electro-mechanical strength tested) Porcelain or glass insulators other than cap and pin string insulator units AS 3608
Strength
0.8
AS 3608
0.5 Synthetic composite suspension or strain insulators (See Note 2) Long term 0.7 Strength Short term ultimate (for one minute mechanical strength) 0.9 (maximum design cantilever load) Subject to further research AS 4435.1
Synthetic composite line post insulators (See Note 2) Other synthetic Panel B2- Overhead Line Cigre Australian composite insulators Seminar - AS/NZS7000:2010 Design of Overhead Lines Sydney 28-29 March 2011
Strength
AS 4435.4
Strength
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Example: 132 kV Suspension Insulator

Calculate the strength of a suspension composite long rod used to support Oxygen conductor with a weight of 0.925 kg/metre, weight and wind span of 400 metres, and strung to everyday tension of 20% CBL. For broken conductor condition assume a wind of 0.25 of ultimate wind (1300 Pa). Limit state condition - everyday load Conductor weight load = 0.925 * 9.806* 400 N = 3628 N Conductor weight multiplier = 1.25 Limit state conductor weight load = 4535 Assume no longitudinal load due to free swinging insulator Component strength factor for long rod insulator = 0.5 (Table 6.2 and long term strength) Insulator specified mechanical load = 4535 / 0.5 = 9070 N

Limit state condition - ultimate strength state under 1300 Pa wind Conductor weight = 0.925 * 9.806* 400 N = 3628 N Conductor weight multiplier = 1.25 Limit state conductor weight load = 4535 Assume no longitudinal load due to free swinging insulator Transverse load = 0.0238 * 1300 * 400 = 12376 N Tension load multiplier = 1.25 Limit state transverse load = 15470 N Resultant load = SQRT (4535^2 + 15470^2) = 16120 N Component strength factor for long rod insulator = 0.7 (Table 6.2 and short term strength) Insulator specified mechanical load = 16120 / 0.7 = 23028 N Limit state condition - failure containment load under broken conductor Longitudinal load = 18600 N (at 325 Pa wind) Residual Static Load = 0.7 Longitudinal load with load relief = 13000 N Tension load multiplier = 1.25 Limit state tension load = 16300 N Component strength factor for long rod insulator = 0.7 (Table 6.5 and short term strength) Insulator specified mechanical load = 16300 0.7 = 23300 Cigre Australian Panel B2-/Overhead Line N
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Comments: 1. The determining state is the ultimate strength state under 1300 Pa wind or broken conductor condition The minimum recommended size for the suspension insulator is 111 kN (specified mechanical load). The SML is a one minute withstand load. If a ceramic disc insulator would be used, then the recommended minimum size is 70 kN (minimum breaking load). The minimum recommended strengths are based on the requirement to achieve a design life comparable to other line components
2.
3.
4.
Composite Long Rod Insulator Design
28/06/2011
Composite Long Rod Insulator Rating
Example: 132 kV Post Insulator

Calculate the strength of a composite line post insulator used to support Oxygen conductor in a clamp top with a weight of 0.925 kg/metre, weight span of 200 metres, and strung to everyday tension of 20% CBL. Servicable wind is 500 Pa and Failure Containment 1300 Pa. Limit state load condition - everyday load Conductor weight force = 0.925 * 9.806* 200 = 1814 N Conductor load multiplier = 1.25 Limit State Vertical Load = 2270 N Longitudinal load for 3:1 adjacent span ratio, and max operating temperature of 75 deg C = 5200 N Conductor tension multiplier = 1.25 Limit state longitudinal design load = 6500 N Resultant bending moment load = SQRT (2270^2 + 6500^2) = 6900 N Component strength factor for composite post insulator = 0.9 (Table 6.2) Insulator ultimate design cantilever load = 6900 / 0.9 = 7650 N Note: The maximum design cantilever load of a post insulator is typically Cigre Australian Panel B2- Overhead Line 40 to 50% of the ultimate strength.
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Limit state condition - serviceable wind load at 500 Pa Conductor weight force = 0.925 * 9.806* 200 = 1814 N Conductor load multiplier = 1.25 Limit State Vertical Load = 2270 N Longitudinal load for 3:1 adjacent span ratio, and max operating temperature of 75 deg C = 5200 N Conductor tension multiplier = 1.25 Limit state longitudinal design load = 6500 N Resultant bending moment load = SQRT (2270^2 + 6500^2) = 6900 N Component strength factor for composite post insulator = 0.9 (Table 6.2) Insulator ultimate design cantilever load = 6900 / 0.9 = 7650 N Transverse compressive load = 0.0238*500*200 = 2380 N Compression load multiplier = 1.0 Limit state transverse compressive load = 2380 N Combining bending and compressive loads - simplified method: Compressive strength of 2.5 inch line post = 50 kN Need for derating for combined bending and compression loads Derating factor = 1-2380 / 50000 = 0.95 Insulator ultimate design cantilever load with transverse load = 7650 / 0.95 = Cigre Australian Panel B2- Overhead Line 8050 N

Limit state condition - failure containment or ultimate load at 1300 Pa Conductor weight force = 0.925 * 9.806* 200 = 1814 N Conductor load multiplier = 1.25 Limit State Vertical Load = 2270 N Longitudinal load for 3:1 adjacent span ratio, and max operating temperature of 75 deg C = 5200 N Conductor tension multiplier = 1.25 Limit state longitudinal design load = 6500 N Resultant bending moment load = SQRT (2270^2 + 6500^2) = 6900 N Component strength factor for composite post insulator = 0.9 (Table 6.2) Insulator ultimate design cantilever load = 6900 / 0.9 = 7650 N Transverse compressive load = 0.0238*1300*200 = 6188 N Compression load multiplier = 1.00 Limit state transverse compressive load = 6188 N Combining bending and compressive loads - simplified method: Compressive strength of 2.5 inch line post = 50 kN Derating factor = 1- 6188 / 50000 = 0.88 Insulator ultimate design cantilever load = 7650 / 0.88 = 8690N
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Comments: The determining state is the failure containment load where the factored ultimate design cantilever load is 8690 N. A 2.5 inch post insulator is typically rated at 12.5 kN ultimate cantilever strength and is recommended for this ultimate load For spans much higher than 200 metres, the combined loads may exceed the 12.5 kN ultimate design cantilever strength. Design options to support the failure containment load for the long spans include: Brace 2.5 inch post with a long rod insulator Limit the line layout to an adjacent span ratio of 2 or less Use a 3 inch post which has a MDCL of around 9 kN
Composite Line Post Insulator Rating
Braced Post
12
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Ceramic Disc Failures
Composite Insulator Failures
13
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Composite Insulator Failures
Composite Insulator Failures UV Damage and Brittle Fracture
14
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Questions
15

As/Nzs7000 Standard Electrical and Mechanical Design of Insulators

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28/06/2011

AS/NZS7000 STANDARD ELECTRICAL AND MECHANICAL DESIGN OF INSULATORS

Colin Lee Network Systems Development Manager, ENERGEX

Insulation is subjected to electrical and mechanical

Line and Substation Coordination

More on Electrical Stresses

More on Electrical Stresses

Design for Pollution Performance

Design for Pollution Performance

Ceramic Insulator Profiles

Design for Pollution Performance

ESDD range(1) g/m

Light Medium Heavy Very Heavy

0 to1.2 1.2 to 2.0 2.0 to 3.0 Above 3.0

Seminar - AS/NZS7000:2010 Design of Overhead Lines Sydney 28-29 March 2011

Design for Pollution Performance

Composite Long Rod Insulator Design

Composite Insulator Design Aspects

INSULATOR MECHANICAL DESIGN

Everyday Serviceable working wind1

Serviceable Maintenance Ultimate load

Construction and maintenance loads Ultimate load

The criteria for serviceable working wind is damage or deflection limit

Limit State Design

Example: 132 kV Suspension Insulator

Example: 132 kV Suspension Insulator

Example: 132 kV Suspension Insulator

Composite Long Rod Insulator Design

Composite Long Rod Insulator Rating

Example: 132 kV Post Insulator

Example: 132 kV Post Insulator

Example: 132 kV Post Insulator

Example: 132 kV Post Insulator

Composite Line Post Insulator Rating

Ceramic Disc Failures

Composite Insulator Failures

Composite Insulator Failures

Composite Insulator Failures UV Damage and Brittle Fracture

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