Development of Post

and Disc Insulators for

1200kV AC System






Somasundaram Iyer
[Aditya Birla Insulators]
[30-10-2010]

DEVELOPMENT OF POST & DISC INSULATORS FOR 1200 kV AC SYSTEM


INTRODUCTION

The ever-increasing complexity of Power Systems in India, the increasing demand to meet the
growth needs and the desire to minimize the losses have driven the country to move to higher
system voltages. In 11
th
Five Year plan, the focus on 765kV system is clear and plans for laying
down 1200kV network is concrete. The central utility has partnered with key equipment
manufacturers for supply of equipment and material, and Aditya Birla Insulators (ABI), along with
other major insulator manufacturers from the country, have partnered with PGCIL in this initiative.

ABI is Indias largest and worlds 4
th
largest manufactures of Porcelain Insulators, and covers
entire range of Insulators for T&D and Substation applications, including Apparatus Insulators for
Circuit Breakers, Instrument Transformers etc. ABI has a combined capacity of 57000 MT at its
two plants, one in Rishra (West Bengal) which caters to Transmission segment and another in
Halol (Gujarat) which caters to Substation Segment. The major customers are PGCIL, NTPC,
SEBs and global OEMs. ABI exports around 25% of its output to Europe, North America, Asia
and Africa, and has received Capexil Top export award for 22 years in last three decades.


BUS POST & DISC INSULATOR REQUIREMENT FOR 1200KV SYSTEM

The Bus Post Insulator (BPI) for 1200kV system has significantly larger challenges
than its nearest insulator, which is for 765kV. The major differences from
manufacturing point of view are highlighted below:

Particulars 765kV Bus Post
Insulator
1200kV Bus Post
Insulator
Maximum height of a single column 5700 mm 9000 mm
No. of Insulators per Stack 4 6
Minimum Creepage (@25mm/kV) 20000 30000
Maximum Diameter 340 mm 350 mm

Above differences have lead to significant changes in the manufacturing of
insulators, which are indicated below schematic:













EXTRUSION
Special
Extrusion set-
up was
required to
extrude the
blanks with
larger
diameter
DRYING
The cycle
time for
drying
operation has
increased,
thereby
leading to
lesser
utilization of
capacity
KILN FIRING
The cycle
time for firing
operation
increased by
10% to
achieve
proper
vitrification of
insulator with
higher
diameter.
TESTING
Special
Testing Bed is
required to
accommodate
an insulator of
9meter height.
Industry is
still preparing
to establish
that capacity.


The Disc Insulator for 1200kV System has a
mechanical strength of 320kN against the maximum
mechanical strength of 210kN used for 765kV System.
Following challenges were faced after the first design
was made:

Head diameter had to be increased and multiple ceramic bodies were developed to achieve
strength
Ball Pin design was changed at the bearing portion with different combinations of
Porcelain Head Diameter, Ceramic Bodies and Ceramic Glaze
Problems were faced in Ball pin Galvanizing also.


PRODUCT DEVELOPMENT: ( POST & DISC INSULATOR )

Porcelain insulators have three major component Ceramic Part
Metal Flanges / Hard ware
Cement





Metal Flange
Ceramic Component
Cement Joint
A TYPICAL STATION POST INSULATOR
TYPICAL DISC INSULATOR DESIGN














The development has taken place through designing of suitable Ceramic recipe, Control on
Dimensional requirements, Upgrading the Capability of the machineries, Tools & Jigs, Optimizing
the Sintering & the Assembly process.

Metal Flange & Hard wares were developed to meet the requirements with enhanced Zinc coating
thickness. Fasteners specs were reviewed for improved performance level.

CERAMIC COMPONENT

The Ceramic component for this high performance insulators need to meet IEC 60672 - C 130
Type . High Strength Alumina Body was designed to meet the requirement.

The ceramic base was made in combination of Alfa Alumina blended with > 25% of Super Plastic
Ball Clays to withstand Stresses at various manufacturing stages.

The key parameters like Particle Size distribution, Rhelogical properties, the delta of Thermal
Coefficient of Body & the Glaze were fixed for enhanced Performance.

The final recipe was developed considering various parameters achieved in line with the Drying
and Kiln firing Cycle.

Typical Values of Ceramic Recipe for 1200 kV Porcelain Insulator

Sr
No
PROPERTIES UOM SPECIFIED
( IEC 60672 -3 )
ABI DESIGN
DATA
01 Open Porosity Vol % 0.0 0.0
02 Bulk Density Mg /m3 2.5 2.55 min
03 Flexural Strength - Unglazed MPa 140 150 +
04 Flexural Strength - Glazed Mpa 160 180 +
05 Modulus of Elasticity GPa 100 105 +
06 Coefficient of Linear Expansion
( 30 deg to 600 deg Cel )

10
-6
K
-1


5 - 7

5 7
07 Di-Electric Strength kV /mm 20 > 25

The Post Insulators design was controlled by CNC machines for dimensional accuracy &
reliability. In house CNC programme were made to minimize the stress concentrations.

The Disc insulators were formed in automated machines. Based on Plant trials Disc Head
diameter was optimized. Ball Pin load bearing points were modified.

Considering the criticality of the wall thickness and the core dia, the products were processed
through fully computer controlled Humidity dryers to minimize drying stresses & controlled
shrinkage during drying. Dimension accuracy was monitored. Moisture controls & apparent
porosity were controlled & monitored

Special Glazing processes like Flood Glazing, Automated Head Glazing were employed for the
Disc Insulators to control the Glaze thickness at locations of High stress points to enhance the
Product performance and reliability.

Mechanized Grog applications were used for imparting consistency in achieving high mechanical
strength.

At ABI, the Firing process is totally automated with sophisticated controls on Fuel & Air volumes,
Kiln pressure and rate of heating.




Temperature & Atmospheric conditions are controlled precisely by
Computers by regulating Fuel & Air Volume in Predetermined qty.

100
200
300
400
500
600
700
800
900
1000
1100
1200
1300
Oxidation Reduction
Neutral
Heating Zone Cooling Zone Preheating Zone
E
n
t
r
y

E
x
i
t


Kiln heat schedule . and Atmospheric conditions
Heating
Cycle Cooling
Cycle
Kiln firing cycles were reviewed to match the Ceramic base and its compatibility with the actual
product. The Fired insulators were subjected to following tests for soundness of the Porcelain.
Sr
No
APPLICABLE TESTS SPECIFIED ACTUAL
01 Mallet Test ( For Post ) No breakage Did not break
02 Porosity Test No dye penetration Passed the test
03 Ultrasonic Test ( for Post ) No peaks for the Flaw No flaw observed
04 Dimensional requirement As per the drawing Meeting all the
dimensional requirement
05 Temperature Cycle Test No failure due to
thermal shock / other
flaws
Porcelain was intact
without any breakage

The Metal Flange & Hardware for these porcelains need to be of higher standard.
SGI components were preferred for improved mechanical characteristics. Another component is
Fasteners for Post insulators. Interactions with various agencies helped in arriving at the correct
materials selection.


SS Grade

SHEAR STRESS
(MPa )

TENSILE STRENGTH
( N/mm2)
ELONGATION
AFTER
FRACTURE (% )
5.6 310 500 20
5.8 322 500 10
8.8 515 800 12
( Ref : IS 1369 Part -3 )

Grade 8.8 has been selected for the fasteners to improve the rigidity & performance.

Assembly of Porcelain with the Metal Flanges is very critical. Special assembly booth was created
with precise innovative fixtures with magnetic holding device for the Flanges. Steam curing was
employed for accelerated curing to avoid stresses in Handling.

Operating rod Insulators were also underwent similar processes to achieve the desired parameters
and were meeting the requirements.

Disc insulator development underwent lot of improvement to over come the problem of Visual
defects, inconsistency in Mechanical Strength, Ball Pin Forgebility issues, Zinc adhesion problem.
Disc insulators also underwent various stringent process controls. Multistage Screening coupled
with three stage Ferro Filtering process were employed for the Ceramic Slurry to eliminate
unwanted / metallic particles.

Disc insulators were tested for following test at the sophisticated Testing Lab at Rishra.
1) Mechanical performance
2) Vibration Test with Fittings
3) Thermal Mechanical Performance Test
4) Steep Wave Front Tests on Units
Post Insulators including Operating Rod Insulators also subjected to various stringent Tests apart
from the standard routine tests as applicable.

1) Temperature Cycle Test
2) Bending test at 8 directions
3) Torsion Strength Test

ABIs BUS POST INSULATOR DESIGN FOR 1200 kV AC
SYSTEM




Insulator Unit
Corona Ring
(Intermediate Toroids)
Corona Ring
( Large Toroids ) -
Under optimization stage



The finalization on the design of Larger toroids are in final stages in collaboration with CPRI.
The units were tested for various parameters as per the table attached.

Sr
No
PARAMETERS REQUIREMENT ACHIEVED
01 Visual & Dimensional

As per the STD & the
Spec
Meets all the
parameters
02 Total Height 9000 +/- 10mm 9005 mm
03 Ht of Individual units 1500 mm 1500 +/1 1.5 mm

04 Total Creepage Distance 30000 mm ( min ) 30605 mm
05 Electrical tests for System
requirement
As per PGCIL spec At CPRI for tests


ABIs DISC INSULATOR DESIGN FOR 1200 kV AC SYSTEM



Unit Type test has successfully been conducted at CPRI and witnessed by PGCIL experts. The
String test for 1200kV will be completed as soon as hardware fittings get ready.

4800 no of 320 kN insulators have been supplied PGCIL in the past for special application.







CONCLUSION

The Teams of ABI Units at Rishra & Halol Plants have has successfully developed the Insulators
for 1200 kV AC system application through indigenous Design & Development of Ceramic
Body, Fixing Components & suitable manufacturing processes. The parameters achieved at
various stage inspections & on controls has established its potential to become major supplier for
Insulators in 1200 kV System application.

ACKNOWLEDGEMENT

We thankfully acknowledge the contributions of PGCIL and CPRI in developing the technical
understanding and making ABI part of this initiative of national importance.

We also thankfully acknowledge the contribution of its key technical member Mr. D N Joshi, Mr.
A Muralidhar, Mr. D B Choudhari and Mr. Debashis Chakraborty.

REFERENCES

Indian Standards & IEC Standards
PGCIL guidelines and MOMs
CPRI reports on Corona ring