ANSI Silicone Distribution Dead End and Suspension Insulator … · 2005. 4. 7. · Referenced...

Piedmont Bushings & Insulators, LLC Phone: (864) 476-6360 251 Harris Bridge Road FAX: (864) 476-6376 Woodruff, SC 29388 USA

Piedmont Bushings & Insulators, LLC “Quality Products at Competitive Prices”

ANSI Silicone Distribution Dead End and Suspension

Insulator Catalog

Piedmont Bushings & Insulators, LLC “Quality Products At Competitive Prices”

Piedmont Bushings & Insulators, LLC Phone: (864) 476-6360 251 Harris Bridge Road FAX: (864) 476-6376 P.O. Box 849 Woodruff, SC 29388

PBI Supplies Silicone Shed Distribution Dead-End Insulators Manufactured to ANSI C29.13 Standards

In15kV, 25kV and 35kV Voltage Classes. Custom Designs are Available Upon Request.

Piedmont Bushings & Insulators, LLC

“Quality Products at Competitive Prices”

ANSI Silicone Dead-End Insulators


Data Sheet – Silicone Distribution Dead-Ends

Piedmont Bushings & Insulators, LLC“Quality Products at Competitive Prices”

Silicone Distribution Dead-Ends

15kV, 25kV, 35kV


Catalog Number 9510015 9510025 9510035 Specifications Voltage Class, kV 15 25 35 Low Frequency Wet Flashover (kV) 65 110 130 Low Frequency Dry Flashover (kV) 90 130 145 Critical Impulse Flashover - Positive (kV) 150 220 250 Radio Influence Test Voltage (kV) 15 20 30 Maximum RIV @ 1000 kHz (Microvolts) 10 10 10 Specified mechanical Load (Lbs) 15000 15000 15000 Tension Proof Load (Lbs) 7500 7500 7500 Torsional Strength (Ft-Lbs) 40 40 40 Unit Length (Inches) 12.5 17.5 20.5 Minimum Creepage Distance (Inches) 16.5 24.5 31.0 Minimum Dry Arcing Distance (Inches) 7.5 11.0 14.5 Shed Material Silicone Silicone Silicone End Fitting Material Forged Steel Forged Steel Forged Steel



ANSI Silicone Dead-End Insulators


Silicone Distribution Dead-End Drawings



PBI Supplies Silicone Shed Suspension Insulators Manufactured to ANSI C29.12 Standards In 69kV, 115kV, 230kV and 500kV Voltage Classes. Other

Voltage Classes are Available Upon Request.



ANSI Silicone Suspension Insulators


Data Sheet - Silicone Suspensions

Piedmont Bushings & Insulators, LLC “Quality Products at Competitive Prices”

Silicone Shed Composite Suspension

Insulators 69kV, 115kV, 230kV, 500kV


Part Number 9710010 9710013 9710017 9710019

Specifications

Voltage Class, kV 69 115 230 500

Low Frequency Wet Flashover (kV) 185 230 395 740

Low Frequency Dry Flashover (kV) 220 270 425 920

Critical Impulse Flashover - Positive (kV) 360 550 1000 2240

Specified mechanical Load (Lbs) 20000 20000 20000 36000

Tension Proof (Lbs) 10000 10000 10000 18000

Unit Length – L (Inches) 37.00 48.82 88.19 175.2

Minor Shed Diameter – D1 (Inches) 4.45 4.45 4.45 4.68

Major Shed Diameter – D2 (Inches) 5.75 5.83 5.83 6.06

Minimum Creepage Distance (Inches) 74.8 111.0 193.0 496.1

Minimum Dry Arcing Distance (Inches) 27.6 39.4 74.8 157.5

Shed Material Silicone Silicone Silicone Silicone

End Fitting Material Forged Steel

Forged Steel

Forged Steel

Forged Steel





Silicone Suspension Drawings

Description:Date:

Revision Desription Revision Date

Drawn By: Approved By:

Drawing Number: Catalog Number:

Reference:

ANGLE: 1 DegreeFRACTION: 1/32.XX: 0.01.XXX: 0.005

Tolerances Unless Otherwise Noted

9710010

November 12, 2003

T. Martin

Specifications

69kV - 20,000 Lb. Silicone Shed Composite Suspension Insulator

37.00 [940]

4.45 [113] 5.75 [146]

Light Gray SiliconeHot Dip Galvanized Forged Steel

Tension Proof Load (Lbs.) [kN] 10000 [50]

Low Frequency Dry Flashover (kV)Low Frequency Wet Flashover (kV)Critical Impulse Flashover - Positive (kV)Critical Impulse Flashover - Negative (kV)

Electrical Data

390

220185360

Unit Length - (Inches) [mm]Major Shed Diameter - (Inches) [mm]

Leakage Distance (Inches) [mm]

Specified Mechanical Load (Lbs.) [kN]

Dimensional Data

Mechanical Data

Materials

Metal FittingsSheds

37.00 [940]5.75 [146]

74.8 [1900]

20000 [100]

4.45 [113]Minor Shed Diameter - (Inches) [mm]

27.6 [700]Arcing Distance (Inches) [mm]Coupling Type Ball and Socket

Core Rod ECR Fiberglass

69Voltage Class (kV)

Detail A

2°-3°

Detail A

InsulatorsBushings &Piedmont

Description:Date:




Reference:



9710013

November 12, 2003

T. Martin

Specifications


48.82 [1240]

4.45 [113] 5.83 [148]




Electrical Data

570

270230550




Dimensional Data

Mechanical Data

Materials

Metal FittingsSheds

48.82 [1240]5.83 [148]

111.0 [2820]

20000 [100]





Detail A

2°-3°

Detail A

Bushings &Piedmont

Insulators

Description:Date:




Reference:



9710017

November 12, 2003

T. Martin

Specifications


88.19 [2240]

4.45 [113] 5.83 [148]




Electrical Data

1030

425395

1000




Dimensional Data

Mechanical Data

Materials

Metal FittingsSheds

88.19 [2240]5.83 [148]

193.0 [4908]

20000 [100]





Detail A

2°-3°

Detail A

Bushings &Piedmont

Insulators

Description:Date:




Reference:



9710019

November 12, 2003

T. Martin

Specifications


175.20 [4450]

4.68 [119] 6.06 [154]



Low Frequency Dry Withstand (kV)Low Frequency Wet Withstand (kV)Critical Impulse Flashover - Positive (kV)Critical Impulse Flashover - Negative (kV)

Electrical Data

2260

920740

2240




Dimensional Data

Mechanical Data

Materials

Metal FittingsSheds

175.20 [4450]6.06 [154]

496.1 [12600]

36000 [160]





Detail A

2°-3°

Detail A

1240Switching Impulse Withstand (kV)

Bushings &Piedmont

Insulators





Test Reports – Silicone Suspensions

Piedmont Bushings and Insulators, LLC Phone: (864) 476-6360 251 Harris Bridge Road FAX: (864) 476-6376 Woodruff, SC 29388 Page 1 of 12


Test Report

Test Unit: 69kV – 20,000 Lb. Composite Suspension Insulator


Test Unit: 69kV – 20,000 Lb. Composite Suspension Insulator OEP Part Number: 9710010 Test Type: Prototype, Design and Sample Test Referenced Standards: ANSI C29.11-1989

ANSI C29.12-1997 ANSI C29.13-2000 IEC61109-1992

Date of Test: September 12, 1998 through November 20, 1998 Date Report Was Prepared: December 31, 2003 Report Prepared By: Tom J. Martin

Testing Conclusion: All units tested passed the testing according to all applicable requirements of the referenced standards.


Table of Contents: 1.0 General Unit Design and Specifications 4 2.0 Prototype Tests 4 2.1 Test Unit 4 2.2 Tests On Interfaces and Connections of Metal Fittings 4 2.2.1 Power Frequency Voltage Test 4 2.2.2 Sudden Load Release Test 4 2.2.3 Thermal-Mechanical Test 5 2.2.4 Water PenetrationTest 5 2.2.5 Verification Tests 5 2.2.5.1 Visual Examination 5 2.2.5.2 Steep Front Impulse Voltage Test 5 2.2.5.3 Power Frequency Voltage Test 6 2.3 Core Time-Load Test 6 2.3.1 Test Specimens 6 2.3.2 Determination of Average Failing Load of The Core 6 2.3.3 Core Time Load Test 7 2.4 Housing Tracking and Erosion Test 7 2.5 Core Material Tests 8 2.5.1 Dye Penetration Test 8 2.5.2 Water Diffusion Test 8 2.5.2.1 Prestressing 8 2.5.2.2 Voltage Test 8 3.0 Design Tests 9 3.1 Test Unit 9 3.2 Lightning Impulse Withstand Test (Positive) 9 3.3 Low-Frequency Wet Withstand 9 4.0 Sample Tests 10 4.1 Visual Inspection and Dimensional Verification 10 4.2 Verification of Locking System 10 4.3 Mechanical Load Test 11 4.4 Galvanizing Test 11


1.0 General Unit Design and Specifications See Appendix A 2.0 Prototype Tests

2.1 Test Unit The test unit used for this Prototype Testing was a Composite Suspension insulator design representing the entire class of Silicone Composite Suspension Insulators from 69kV to 230kV. As per the requirement of Clause 7.1.1 of ANSI C29.11-1989, the composite insulator samples used for this Prototype Testing had a metal-to-metal spacing of at least 800mm in length. The actual insulation length of the test units was a minimum of 31.69” (805mm). 2.2 Tests On Interfaces and Connections of Metal Fittings

2.2.1 Power Frequency Voltage Test Three assembled units were randomly selected and subjected to a Power Frequency Voltage Test per Clause 7.1.2 of ANSI C29.11-1989 and Clause 5.1.2 of IEC 61109-1992. The results of this testing are shown in Table 1 below.

Test Conditions: Td = 75.2 °F Tw = 69.8 °F P = 14.674 Psi. Kd = 0.981 Kh = 0.940

Sample Number

Average Value (kV)

Corrected Value (kV)

1 323.9 310.4 2 321.9 308.4 3 329.8 316.0

Table 1

2.2.2 Sudden Load Release Test The three samples from the Power Frequency Voltage Test were subjected to a sudden load release test according to Clause 7.1.3 of ANSI C29.11-1989 and Clause 5.1.3.1 of IEC61109-1992. Each sample was subjected to 30% of the unit’s Specified Mechanical Load (SML) which was then suddenly released. The results of this testing are shown in Table 2 below.

Sample Number

Temperature (°F)

Load Value (Lbs.)

Load Releases

Results

1 -7.6 6744.0 5 Testing Passed 2 -7.6 6744.0 5 Testing Passed 3 -7.6 6744.0 5 Testing Passed

Specification -4 ~ -13 6744.0 5 No Damage Table 2


2.2.3 Thermal-Mechanical Test

Three samples were subjected to temperature variations under a mechanical load of 11240 Lbs. or A minimum of 50% of the SML Rating according to Clause 7.1.4 of ANSI C29.11-1989 and Clause 5.1.3.2 of IEC61109-1992. The temperature range from cold to hot during each 24 hour cycle was -31 +/- 5 °F to 122 +/- 5 °F. The 24 hour temperature cycles were repeated 4 times per the standard requirements. The initial and final dimensions of the samples are shown in Table 3 below while the results of the testing are shown in Table 4 below.

Sample Length (Inches) Sample

Number Before Test After Test Change (Inches)

1 43.98 43.98 0.0 2 43.91 43.91 0.0 3 43.84 43.84 0.0

Table 3

First Cycle Second Cycle Third Cycle Fourth Cycle Sample Number

TC (°F)

TH (°F)

TC (°F)

TH (°F)

TC (°F)

TH (°F)

TC (°F)

TH (°F)

Testing Results

1 -29.2 122 -27.4 122 -29.2 122 -31.0 122 Passed 2 -29.2 122 -27.4 122 -29.2 122 -31.0 122 Passed 3 -29.2 122 -27.4 122 -29.2 122 -31.0 122 Passed

Specification -31.0 122.0 -31.0 122.0 -31.0 122.0 -31.0 122.0 No Failure Table 4 (Note: TC = Cold Temperature, TH = Hot Temperature)

2.2.4 Water Penetration Test

Samples 1, 2 and 3 from previous tests were immersed in boiling deionized water, containing 0.1 % by weight of Sodium Chloride, for 42 hours per Clause 7.1.5 of ANSI C29.11-1989 and Clause 5.1.3.3 of IEC61109-1992. The samples were then retained in the water while the temperature was lowered to 122 °F. These samples were visually inspected and were found to have no signs of damage. These units were subsequently used for the verification testing in Section 2.2.5.

2.2.5 Verification Tests

2.2.5.1 Visual Examination

Samples 1, 2 and 3 from the Water Penetration test were reexamined for any signs of damage prior to proceeding with testing in Sections 2.2.5.2 and 2.2.5.3. No damage was observed.

2.2.5.2 Steep Front Impulse Voltage Test

The three test samples from the previous tests were fitted with a sharp edged electrode dividing each sample into two equal length sections according to Clause 7.1.6.2 of ANSI C29.11-1989 and Clause 5.1.4.2 of IEC61109-1992. These samples were then subjected to an Impulse Voltage having a rate of rise of at least 1000 kV/µS for 25 positive and negative polarity impulses. The results of this testing are shown in Table 5 below.


Test Cycles Sample Number

Sample Sections

Wave Front Slope

(kV/µS) Positive Polarity

Negative Polarity Testing Results

1 2 25 25 No Puncture 2 2 25 25 No Puncture 3 2

1206~1312 25 25 No Puncture

Specification - ≥ 1000 25 25 No Puncture Table 5

2.2.5.3 Power Frequency Voltage Test

The three test samples from previous tests were subjected to a Dry Power Frequency Flashover Voltage Test per Clause 7.1.6.3 of ANSI C29.11-1989 and Clause 5.1.4.3 of IEC 61109-1992. The average value for this test was required to be a minimum of 90% of the initial values determined in Section 2.2.1 of this report. The results of this testing are shown in Table 6 below.

Test Conditions: Td = 53.6 °F Tw = 49.1 °F P = 14.786 Psi.

Kd = 1.025 Kh = 1.035

Sample Number

90% of Base Value From Section 2.2.1

Average Value (kV)

Corrected Value (kV) Results

1 279.4 298.6 301.5 Passed 2 277.6 302.4 305.4 Passed 3 284.4 304.8 307.8 Passed

Table 6

2.3 Core Time Load Test

2.3.1 Test Specimens Six specimens were obtained from a larger group of samples. These specimens were dived into two groups of three for the following test in Sections 2.3.2 and 2.3.3 of this report. 2.3.2 Determination of Average Failing Load of The Core

Three units from Section 2.3.1 above were subjected to an Average Failing Load Test according to Clause 7.2.2 of ANSI C29.11-1989 and Clause 5.2.2.1 of IEC 61109-1992 and. The results of this testing are shown in Table 7 below. These values will be used as base values for Section 2.3.3 of this report.

Sample Number

Insulation Length (Inches)

Failing Load (Lbs.) Failure Mode

Average Value (Lbs.)

1 31.52 28459.7 Core Breakage 2 31.52 29831.0 Core Breakage 3 31.52 28684.5 Core Breakage

28991.6

Specification ≥ 31.50 - - - Table 7


2.3.3 Core Time Load Test

Three units from Section 2.3.1 above were subjected to a load equal to 60% of the Average Failing Load from Section 2.3.2 and maintained for a period of 96 hours according to Clause 7.2.3 of ANSI C29.11-1989 and Clause 5.2.2.2 of IEC 61109-1992. The results of this testing are shown in Table 8 below.

Sample Number


60% of Average Failing Load

(Lbs.)

Withstand Time

(Hours) Results 1 96 Passed 2 96 Passed 3

~ 31.69 17394.9 96 Passed

Specification ≥ 31.5 - 96 No Damage Table 8

2.4 Housing Tracking and Erosion Test Two assembled units were subjected to a tracking and erosion test according to Clause 7.3 of ANSI C29.11-1989 and Clause 5.3 of IEC 61109-1992 and. The physical details of the test samples are shown in Table 9 below while the results of the testing are shown in Table 10 below. Test Conditions: Water Flow Rate (kg/m3 x h) = 0.32 – 0.35

Size of Droplets (µm) = 5 - 10 NaCl Content of Water (kg/m3) = 9.5 – 10.0 Fog Chamber Temperature (°C) = 22.0 – 24.0

Large Shed Details Small Shed Details

Sample Number

Structure Length (Inches)

Creepage Distance (Inches)

Core Diameter(Inches)

Diameter (Inches)

Number In Sample

Diameter (Inches)

Number In Sample

1 18.52 20.87 0.94 5.71 2 4.33 1 2 18.52 20.87 0.94 5.71 2 4.33 1

Table 9

Sample Number

Test Voltage

(kV)

Cycle Time

(Hours) Cycle

Interruptions

Interruption Time

(Minutes) Sample

Orientation

Maximum Over-

Current Trips Results

1 15.3 1000 2 10,10 Horizontal 0 Passed 2 15.3 1000 2 10,10 Vertical 0 Passed

Specification 14~20 1000 ≤ 6 ≤ 15 Both 3 Passed Table 10


2.5 Core Material Tests

2.5.1 Dye Penetration Test Ten specimens were cut from a randomly sampled production insulator and tested for dye penetration according to Clause 7.4.1 of ANSI C29.11-1989 and Clause 5.4.1 of IEC 61109-1992. These specimens, measuring 0.944 inches in diameter and 0.394 inches in length were placed upright on a layer of steel balls and a 1% alcohol and fuchsin dye solution was poured into the glass vessel until the dye level was 0.098 inches higher than the surface of the steel balls. The samples remained in the glass vessel for a period of 15 minutes per the standard requirements with no signs of penetration. The details of the samples and the test results are shown in Table 11 below.

Specimen Number

Specimen Length (Inches)

Sample Immersion Time (Minutes) Results

1 0.396 15 No Penetration 2 0.397 15 No Penetration 3 0.398 15 No Penetration 4 0.399 15 No Penetration 5 0.400 15 No Penetration 6 0.386 15 No Penetration 7 0.402 15 No Penetration 8 0.387 15 No Penetration 9 0.398 15 No Penetration

10 0.394 15 No Penetration Specification 0.394 ± 0.02 15 No Penetration

Table 11

2.5.2 Water Diffusion Test

2.5.2.1 Prestressing Six specimens were cut from the same type of production insulator used in the dye penetration testing and tested for water diffusion according to Clause 7.4.2.2 of ANSI C29.11-1989 and Clause 5.4.2.2 of IEC 61109-1992. These specimens, measuring 0.944 inches in diameter and 1.181 inches in length, were boiled in a glass vessel containing deinonized water and 0.1 % by weight of Sodium Chloride, for 100 hours. The specimens were removed from the boiling water and placed in ambient temperature deionized water until cooled. 2.5.2.2 Voltage Test

The specimens from Section 2.5.2.1 above were removed from the deinoized water, dried with filter paper and subjected to a voltage test according to Clause 7.4.2.3 of ANSI C29.11-1989 and Clause 5.4.2.3 of IEC 61109-1992 less than 3 hours after removal from the boiling water. The results of this testing are shown in Table 12 below.


Specimen Number


Boiling Time

(Hours)

Test Voltage

(kV)

Withstand Time

(Minutes)

Leakage Current (mA) Results

1 1.183 100 12 1 0.1 Passed 2 1.186 100 12 1 0.1 Passed 3 1.188 100 12 1 0.1 Passed 4 1.183 100 12 1 0.1 Passed 5 1.183 100 12 1 0.1 Passed 6 1.187 100 12 1 0.1 Passed

Specification 1.182 ± 0.020 100 12 1 ≤ 1 No Puncture or Flashover

Table 12 3.0 Design Tests

3.1 Test Unit The test unit used for this Design Testing was the Composite Suspension insulator design shown in Appendix A. The unit tested met the requirements of Clause 4.1 of ANSI C29.11-1989 thereby permitting the use of the Prototype Test results detailed above for this unit. 3.2 Lightning Impulse Withstand Test

Three sample Composite Suspension Insulators were subjected to a Lightning Impulse Withstand Test according to Clause 6.1 IEC 61109-1992. The results of this testing are shown in Table 14 below. As the results show, the units withstood the minimum Critical-Impulse Flashover requirement from Table 2 of ANSI C29.13-2000.


Positive Polarity

Sample # Test Wave

(µs) Withstand Test Value

(kV) Corrected Value

(kV) Withstand Time

(Seconds) Results 1 1.15 420.0 15 No Flashover 2 1.15 421.0 15 No Flashover 3 1.15 423.0

417.4 15 No Flashover

Specification 1.2 ± 30% 360.0 360.0 15 No Flashover Table 13

3.3 Low-Frequency Wet Withstand Test

Three sample Composite Suspension Insulators were subjected to a Low-Frequency Wet Withstand Test according to Clause 6.2 IEC 61109-1992. The results of this testing are shown in Table 14 below. As the results show, the units withstood the minimum Low-Frequency Wet Flashover specification requirement.



Kd = 1.025 Kh = 1.035

Rain Water Resistivity: ρ20.0 = 100.0Ω-m Rain Rate: 1.4 mm/min (Horizontal and Vertical)

Sample # Applied Voltage

(kV) Corrected Values

(kV) Withstand Time

(Min) Results 1 187.0 1 Passed 2 187.0 1 Passed 3 187.0

185.9 1 Passed

Specification 185.0 185.0 1 Passed Table 14 4.0 Sample Tests

4.1 Visual Inspection and Dimensional Verification Nine samples were taken from the group of units and visually inspected to verify the quality and were measured to verify the actual dimensions against the design dimensions according to Clause 9.2 of ANSI C29.11-1989 and Clause 7.2 of IEC 61109-1992. The quality of the units observed during visual inspection was good. The galvanizing on the end fittings was consistent and the injection molding was good. The results of the dimensional verification are shown in Table 15 below.

End Fitting Gauging Socket Ball Sample

Number Unit Length

(Inches)

Creepage Distance (Inches) Go-Gauge No-Go Gauge Go-Gauge No-Go Gauge

1 35.47 82.20 Go No-Go Go No-Go 2 35.55 81.89 Go No-Go Go No-Go 3 35.43 82.68 Go No-Go Go No-Go 4 35.51 82.13 Go No-Go Go No-Go 5 35.39 82.68 Go No-Go Go No-Go 6 35.59 81.89 Go No-Go Go No-Go 7 35.55 81.89 Go No-Go Go No-Go 8 35.43 81.85 Go No-Go Go No-Go 9 35.51 82.09 Go No-Go Go No-Go

Specification 35.31 ± 0.59 ≥ 81.70 Go No-Go Go No-Go Table 15

4.2 Verification of Locking System Locking System Verification testing was conducted on 3 samples taken from the group of units removed from production according to Clause 9.3 of ANSI C29.11-1989 and Clause 7.3 of IEC 61109-1992. The results of this testing are shown in Table 16 below.


Moving Load (Lbs.) Sample

Number First Second Third Results At 56Lb. Maximum Load

1 15.63 20.09 22.32 No Uncoupling 2 13.39 17.86 17.86 No Uncoupling 3 26.79 17.86 35.71 No Uncoupling

Specification 5.2 – 56.0 No Uncoupling Table 16

4.3 Mechanical Load Test The 3 samples, used in the previous verification testing, were subjected to mechanical load equivalent to the SML per Clause 9.4 of ANSI C29.11-1989 and Clause 7.4 of IEC 61109-1992. The results of this testing are shown in Table 17 below.

Sample Number

Tensile Load (Lbs.)

Withstand Time (Minutes) Results

1 22482 1 Passed 2 22482 1 Passed 3 22482 1 Passed

Specification 20000 1 No Failure Table 17

4.4 Galvanizing Test Galvanizing thickness testing was conducted on 3 samples taken from the group of units removed from production according to Clause 9.5 of ANSI C29.11-1989 and Clause 7.5 of IEC 61109-1992. The results of this thickness testing are shown in Table 18 below.

Thickness Values of Socket End Fitting

(Mils) Thickness Values of Ball End Fitting

(Mils) Sample Number SA AA SA AA

1 4.22 4.31 2 4.83 3.31 3 4.69

4.58 3.74

3.79

Specification ≥ 3.1 ≥ 3.4 ≥ 3.1 ≥ 3.4 Table 18


Appendix A



Test Report



Test Unit: 115kV – 20,000 Lb. Composite Suspension Insulator OEP Part Number: 9710013 Test Type: Prototype, Design and Sample Test Referenced Standards: ANSI C29.11-1989

ANSI C29.12-1997 ANSI C29.13-2000 IEC61109-1992

Date of Test: September 12, 1998 through November 20, 1998 Date Report Was Prepared: January 2, 2004 Report Prepared By: Tom J. Martin







Sample Number

Average Value (kV)


1 323.9 310.4 2 321.9 308.4 3 329.8 316.0

Table 1


Sample Number

Temperature (°F)

Load Value (Lbs.)

Load Releases

Results








1 43.98 43.98 0.0 2 43.91 43.91 0.0 3 43.84 43.84 0.0

Table 3


TC (°F)

TH (°F)

TC (°F)

TH (°F)

TC (°F)

TH (°F)

TC (°F)

TH (°F)

Testing Results











Test Cycles Sample Number

Sample Sections

Wave Front Slope




1206~1312 25 25 No Puncture





Kd = 1.025 Kh = 1.035

Sample Number


Average Value (kV)



Table 6




Sample Number





28991.6





Sample Number



(Lbs.)

Withstand Time


~ 31.69 17394.9 96 Passed





Sample Number




Diameter (Inches)

Number In Sample

Diameter (Inches)

Number In Sample

1 18.52 20.87 0.94 5.71 2 4.33 1 2 18.52 20.87 0.94 5.71 2 4.33 1

Table 9

Sample Number

Test Voltage

(kV)

Cycle Time

(Hours) Cycle

Interruptions

Interruption Time

(Minutes) Sample

Orientation

Maximum Over-







Specimen Number





Table 11





Specimen Number


Boiling Time

(Hours)

Test Voltage

(kV)

Withstand Time

(Minutes)






Three sample Composite Suspension Insulators were subjected to a Lightning Impulse Withstand Test according to Clause 6.1 IEC 61109-1992. The results of this testing are shown in Table 14 below. As the results show, the units withstood the minimum Critical-Impulse Flashover requirement.


Positive Polarity

Sample # Test Wave



(kV) Withstand Time








Kd = 1.025 Kh = 1.035




(kV) Withstand Time


231.2 1 Passed




Number Unit Length

(Inches)











Sample Number

Tensile Load (Lbs.)





Thickness Values of Socket End Fitting (Mils)

Thickness Values of Ball End Fitting (Mils) Sample

Number SA AA SA AA 1 3.46 3.85 2 4.35 3.68 3 4.06

3.96 3.44

3.66



Appendix A



Test Report



Test Unit: 230kV – 20,000 Lb. Composite Suspension Insulator PBI Part Number: 9710017 Test Type: Prototype, Design and Sample Test Referenced Standards: ANSI C29.11-1989

ANSI C29.12-1997 ANSI C29.13-2000 IEC61109-1992








Sample Number

Average Value (kV)


1 323.9 310.4 2 321.9 308.4 3 329.8 316.0

Table 1


Sample Number

Temperature (°F)

Load Value (Lbs.)

Load Releases

Results








1 43.98 43.98 0.0 2 43.91 43.91 0.0 3 43.84 43.84 0.0

Table 3


TC (°F)

TH (°F)

TC (°F)

TH (°F)

TC (°F)

TH (°F)

TC (°F)

TH (°F)

Testing Results











Test Cycles

Sample Number

Sample Sections

Wave Front Slope




1206~1312 25 25 No Puncture





Kd = 1.025 Kh = 1.035

Sample Number


Average Value (kV)



Table 6




Sample Number





28991.6





Sample Number



(Lbs.)

Withstand Time


~ 31.69 17394.9 96 Passed





Sample Number




Diameter (Inches)

Number In Sample

Diameter (Inches)

Number In Sample

1 18.52 20.87 0.94 5.71 2 4.33 1 2 18.52 20.87 0.94 5.71 2 4.33 1

Table 9

Sample Number

Test Voltage

(kV)

Cycle Time

(Hours) Cycle

Interruptions

Interruption Time

(Minutes) Sample

Orientation

Maximum Over-







Specimen Number





Table 11





Specimen Number


Boiling Time

(Hours)

Test Voltage

(kV)

Withstand Time

(Minutes)








Positive Polarity

Sample # Test Wave



(kV) Withstand Time








Kd = 1.025 Kh = 1.035




(kV) Withstand Time


397.0 1 Passed




Number Unit Length

(Inches)











Sample Number

Tensile Load (Lbs.)





Thickness Values of Socket End Fitting (Mils)

Thickness Values of Ball End Fitting (Mils) Sample

Number SA AA SA AA 1 4.46 4.15 2 4.30 3.77 3 4.18

4.31 2.91

3.61



Appendix A



Test Report



Test Unit: 500kV – 36,000 Lb. Composite Suspension Insulator PBI Part Number: 9710019 Test Type: Prototype, Design and Sample Test Referenced Standards: ANSI C29.11-1989

ANSI C29.12-1997 ANSI C29.13-2000 IEC61109-1992




Table of Contents: 1.0 General Unit Design and Specifications 4 2.0 Prototype Tests 4 2.1 Test Unit 4 2.2 Tests On Interfaces and Connections of Metal Fittings 4 2.2.1 Power Frequency Voltage Test 4 2.2.2 Sudden Load Release Test 4 2.2.3 Thermal-Mechanical Test 5 2.2.4 Water PenetrationTest 5 2.2.5 Verification Tests 5 2.2.5.1 Visual Examination 5 2.2.5.2 Steep Front Impulse Voltage Test 5 2.2.5.3 Power Frequency Voltage Test 6 2.3 Core Time-Load Test 6 2.3.1 Test Specimens 6 2.3.2 Determination of Average Failing Load of The Core 6 2.3.3 Core Time Load Test 7 2.4 Housing Tracking and Erosion Test 7 2.5 Core Material Tests 8 2.5.1 Dye Penetration Test 8 2.5.2 Water Diffusion Test 8 2.5.2.1 Prestressing 8 2.5.2.2 Voltage Test 8 3.0 Design Tests 9 3.1 Test Unit 9 3.2 Lightning Impulse Withstand Test (Positive) 9 3.3 Low-Frequency Wet Withstand 9 3.4 Wet Switching Impulse Withstand 10 4.0 Sample Tests 10 4.1 Visual Inspection and Dimensional Verification 10 4.2 Verification of Locking System 10 4.3 Mechanical Load Test 11 4.4 Galvanizing Test 11



2.1 Test Unit The test unit used for this Prototype Testing was a Composite Suspension insulator design representing the entire class of 500kV Silicone Composite Suspension Insulators. As per the requirement of Clause 7.1.1 of ANSI C29.11-1989, the composite insulator samples used for this Prototype Testing had a metal-to-metal spacing of at least 800mm in length. The actual insulation length of the test units was a minimum of 31.69” (820mm). 2.2 Tests On Interfaces and Connections of Metal Fittings



Sample Number

Average Value (kV)


1 349.0 335.4 2 347.0 333.5 3 346.0 332.5

Table 1


Sample Number

Temperature (°F)

Load Value (Lbs.)

Load Releases

Results








1 45.67 45.67 0.0 2 45.67 45.67 0.0 3 45.71 45.71 0.0

Table 3


TC (°F)

TH (°F)

TC (°F)

TH (°F)

TC (°F)

TH (°F)

TC (°F)

TH (°F)

Testing Results

1 -27.4 122.0 -29.2 122.0 -31.0 122.0 -27.4 122.0 Passed 2 -29.2 122.0 -29.2 122.0 -29.2 122.0 -27.4 122.0 Passed 3 -27.4 122.0 -31.0 122.0 -29.2 122.0 -27.4 122.0 Passed










Test Cycles

Sample Number

Sample Sections

Wave Front Slope




1328~1410 25 25 No Puncture





Kd = 1.025 Kh = 1.035

Sample Number


Average Value (kV)



Table 6




Sample Number




1 31.52 50157.4 Core Pullout 2 31.52 50831.8 Core Breakage 3 31.52 49393.0 Core Pullout

50127.4




Three units from Section 2.3.1 above were subjected to a load equal to 70% of the Specified Mechanical Load Section 2.3.2 and maintained for a period of 96 hours according to Clause 7.2.3 of ANSI C29.11-1989 and Clause 5.2.2.2 of IEC 61109-1992. The results of this testing are shown in Table 8 below.

Sample Number



(Lbs.)

Withstand Time


~ 32.09 25179.9 96 Passed





Sample Number




Diameter (Inches)

Number In Sample

Diameter (Inches)

Number In Sample

1 17.72 20.87 0.94 6.14 2 4.69 1 2 17.72 20.87 0.94 6.14 2 4.69 1

Table 9

Sample Number

Test Voltage

(kV)

Cycle Time

(Hours) Cycle

Interruptions

Interruption Time

(Minutes) Sample

Orientation

Maximum Over-







Specimen Number





Table 11





Specimen Number


Boiling Time

(Hours)

Test Voltage

(kV)

Withstand Time

(Minutes)








Positive Polarity

Sample # Test Wave



(kV) Withstand Time








Kd = 1.025 Kh = 1.035




(kV) Withstand Time


735.6 1 Passed

Specification 740.0 1 Passed Table 14

3.4 Wet Switching Impulse Withstand Test Three samples were subjected to a Wet Switching Impulse Withstand Voltage Test per Clause 6.3 of IEC 61109-1992 and ANSI C29.11-1989 and Clause 8.3 of ANSI C29.11-1989. The results of this testing are shown in Table 15 below.

Test Conditions: Td = 70.0 °F Tw = 64.6 °F P = 14.728 Psi. Kd = 1.00

Rain Water Resistivity: ρ20.0 = 104.0 Ω.m

Rain Rate: 1.4 mm/min (Horizontal and Vertical)

Sample Number

Test Wave (µS)


Withstand Test Value

(kV)

Withstand Time (Sec) Results

1 1240.0 15 Passed 2 1240.0 15 Passed 3

260/2400 1240.0 1240.0 15 Passed

Specification 250 ± 20% / 2500 ± 60%

Sample should withstand 1240 kV ± 3% for 15 cycles with no flashovers.

Table 15 4.0 Sample Tests



End Fitting Gauging

Socket Ball Sample Number

Unit Length (Inches)





Moving Load (Lbs.) Sample Number First Second Third

Results At 56Lb. Maximum Load



4.3 Mechanical Load Test The three samples, used in the previous verification testing, were subjected to mechanical load equivalent to the SML per Clause 9.4 of ANSI C29.11-1989 and Clause 7.4 of IEC 61109-1992. The results of this testing are shown in Table 18 below.

Sample Number

Tensile Load (Lbs.)






Thickness Values of Socket End Fitting

(Mils) Thickness Values of Ball End Fitting

(Mils) Sample Number SA AA SA AA

1 4.10 3.61 2 3.83 3.98 3 4.26

4.06 3.78

3.79



Appendix A

ANSI Silicone Distribution Dead End and Suspension Insulator … · 2005. 4. 7. · Referenced...

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