Piedmont Bushings & Insulators, LLC
“Quality Products at Competitive Prices”
ANSI Silicone Distribution
Dead End and Suspension
Insulator Catalog
Piedmont Bushings & Insulators, LLC
251 Harris Bridge Road
Woodruff, SC 29388 USA
Phone: (864) 476-6360
FAX: (864) 476-6376
Piedmont Bushings & Insulators, LLC
“Quality Products At Competitive Prices”
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
251 Harris Bridge Road
P.O. Box 849
Woodruff, SC 29388
Phone: (864) 476-6360
FAX: (864) 476-6376
Piedmont Bushings & Insulators, LLC
“Quality Products at Competitive Prices”
ANSI Silicone
Dead-End
Insulators
Data Sheet – Silicone Distribution
Dead-Ends
Piedmont Bushings & Insulators, LLC
251 Harris Bridge Road
P.O. Box 849
Woodruff, SC 29388
Phone: (864) 476-6360
FAX: (864) 476-6376
Piedmont Bushings & Insulators, LLC
“Quality Products at Competitive Prices”
Catalog Number
Silicone Distribution
Dead-Ends
15kV, 25kV, 35kV
9510015
9510025
9510035
15
65
90
150
15
10
15000
7500
40
12.5
16.5
7.5
Silicone
Forged Steel
25
110
130
220
20
10
15000
7500
40
17.5
24.5
11.0
Silicone
Forged Steel
35
130
145
250
30
10
15000
7500
40
20.5
31.0
14.5
Silicone
Forged Steel
Specifications
Voltage Class, kV
Low Frequency Wet Flashover (kV)
Low Frequency Dry Flashover (kV)
Critical Impulse Flashover - Positive (kV)
Radio Influence Test Voltage (kV)
Maximum RIV @ 1000 kHz (Microvolts)
Specified mechanical Load (Lbs)
Tension Proof Load (Lbs)
Torsional Strength (Ft-Lbs)
Unit Length (Inches)
Minimum Creepage Distance (Inches)
Minimum Dry Arcing Distance (Inches)
Shed Material
End Fitting Material
Piedmont Bushings & Insulators, LLC
251 Harris Bridge Road
P.O. Box 849
Woodruff, SC 29388
Phone: (864) 476-6360
FAX: (864) 476-6376
Piedmont Bushings & Insulators, LLC
“Quality Products at Competitive Prices”
ANSI Silicone
Dead-End
Insulators
Silicone Distribution Dead-End
Drawings
Piedmont Bushings & Insulators, LLC
251 Harris Bridge Road
P.O. Box 849
Woodruff, SC 29388
Phone: (864) 476-6360
FAX: (864) 476-6376
Piedmont Bushings & Insulators, LLC
“Quality Products At Competitive Prices”
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.
Piedmont Bushings & Insulators, LLC
251 Harris Bridge Road
P.O. Box 849
Woodruff, SC 29388
Phone: (864) 476-6360
FAX: (864) 476-6376
Piedmont Bushings & Insulators, LLC
“Quality Products at Competitive Prices”
ANSI Silicone
Suspension
Insulators
Data Sheet - Silicone Suspensions
Piedmont Bushings & Insulators, LLC
251 Harris Bridge Road
P.O. Box 849
Woodruff, SC 29388
Phone: (864) 476-6360
FAX: (864) 476-6376
Piedmont Bushings & Insulators, LLC
“Quality Products at Competitive Prices”
Silicone Shed
Composite Suspension
Insulators
69kV, 115kV, 230kV, 500kV
Part Number
9710010
9710013
9710017
9710019
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
Specifications
Piedmont Bushings & Insulators, LLC
251 Harris Bridge Road
P.O. Box 849
Woodruff, SC 29388
Phone: (864) 476-6360
FAX: (864) 476-6376
Piedmont Bushings & Insulators, LLC
“Quality Products at Competitive Prices”
ANSI Silicone
Suspension
Insulators
Silicone Suspension Drawings
Piedmont Bushings & Insulators, LLC
251 Harris Bridge Road
P.O. Box 849
Woodruff, SC 29388
Phone: (864) 476-6360
FAX: (864) 476-6376
Drawing Number: 9710010
Piedmont
Bushings &
Insulators
Revision Desription
Date:
Catalog Number:
Description:
November 12, 2003
69kV - 20,000 Lb. Silicone Shed Composite Suspension Insulator
Reference:
Tolerances Unless Otherwise Noted
Revision Date
.XXX: 0.005
.XX: 0.01
FRACTION: 1/32
ANGLE: 1 Degree
Specifications
Materials
Core Rod
Sheds
Metal Fittings
Dimensional Data
Unit Length - (Inches) [mm]
Major Shed Diameter - (Inches) [mm]
Minor Shed Diameter - (Inches) [mm]
Leakage Distance (Inches) [mm]
Arcing Distance (Inches) [mm]
Coupling Type
Mechanical Data
Specified Mechanical Load (Lbs.) [kN]
Tension Proof Load (Lbs.) [kN]
Electrical Data
Voltage Class (kV)
Low Frequency Dry Flashover (kV)
Low Frequency Wet Flashover (kV)
Critical Impulse Flashover - Positive (kV)
Critical Impulse Flashover - Negative (kV)
Approved By:
Drawn By: T. Martin
ECR Fiberglass
Light Gray Silicone
Hot Dip Galvanized Forged Steel
37.00 [940]
5.75 [146]
4.45 [113]
74.8 [1900]
27.6 [700]
Ball and Socket
2°-3°
20000 [100]
10000 [50]
69
220
185
360
390
Detail A
4.45 [113]
5.75 [146]
37.00 [940]
Detail A
Piedmont
Bushings &
Insulators
Revision Desription
Drawing Number: 9710013
Date:
Catalog Number:
Description:
November 12, 2003
115kV - 20,000 Lb. Silicone Shed Composite Suspension Insulator
Reference:
Tolerances Unless Otherwise Noted
Revision Date
.XXX: 0.005
.XX: 0.01
FRACTION: 1/32
ANGLE: 1 Degree
Specifications
Materials
Core Rod
Sheds
Metal Fittings
Dimensional Data
Unit Length - (Inches) [mm]
Major Shed Diameter - (Inches) [mm]
Minor Shed Diameter - (Inches) [mm]
Leakage Distance (Inches) [mm]
Arcing Distance (Inches) [mm]
Coupling Type
Mechanical Data
Specified Mechanical Load (Lbs.) [kN]
Tension Proof Load (Lbs.) [kN]
Electrical Data
Voltage Class (kV)
Low Frequency Dry Flashover (kV)
Low Frequency Wet Flashover (kV)
Critical Impulse Flashover - Positive (kV)
Critical Impulse Flashover - Negative (kV)
Approved By:
Drawn By: T. Martin
ECR Fiberglass
Light Gray Silicone
Hot Dip Galvanized Forged Steel
48.82 [1240]
5.83 [148]
4.45 [113]
111.0 [2820]
39.4 [1000]
Ball and Socket
2°-3°
20000 [100]
10000 [50]
115
270
230
550
570
Detail A
4.45 [113]
5.83 [148]
48.82 [1240]
Detail A
Drawing Number: 9710017
Piedmont
Bushings &
Insulators
Revision Desription
Date:
Catalog Number:
Description:
November 12, 2003
230kV - 20,000 Lb. Silicone Shed Composite Suspension Insulator
Reference:
Tolerances Unless Otherwise Noted
Revision Date
.XXX: 0.005
.XX: 0.01
FRACTION: 1/32
ANGLE: 1 Degree
Specifications
Materials
Core Rod
Sheds
Metal Fittings
Dimensional Data
Unit Length - (Inches) [mm]
Major Shed Diameter - (Inches) [mm]
Minor Shed Diameter - (Inches) [mm]
Leakage Distance (Inches) [mm]
Arcing Distance (Inches) [mm]
Coupling Type
Mechanical Data
Specified Mechanical Load (Lbs.) [kN]
Tension Proof Load (Lbs.) [kN]
Electrical Data
Voltage Class (kV)
Low Frequency Dry Flashover (kV)
Low Frequency Wet Flashover (kV)
Critical Impulse Flashover - Positive (kV)
Critical Impulse Flashover - Negative (kV)
Approved By:
Drawn By: T. Martin
ECR Fiberglass
Light Gray Silicone
Hot Dip Galvanized Forged Steel
88.19 [2240]
5.83 [148]
4.45 [113]
193.0 [4908]
74.8 [1900]
Ball and Socket
2°-3°
20000 [100]
10000 [50]
230
425
395
1000
1030
Detail A
4.45 [113]
5.83 [148]
88.19 [2240]
Detail A
Drawing Number: 9710019
Piedmont
Bushings &
Insulators
Revision Desription
Date:
Catalog Number:
Description:
November 12, 2003
500kV - 36,000 Lb. Silicone Shed Composite Suspension Insulator
Reference:
Tolerances Unless Otherwise Noted
Revision Date
.XXX: 0.005
.XX: 0.01
FRACTION: 1/32
ANGLE: 1 Degree
Specifications
Materials
Core Rod
Sheds
Metal Fittings
Dimensional Data
Unit Length - (Inches) [mm]
Major Shed Diameter - (Inches) [mm]
Minor Shed Diameter - (Inches) [mm]
Leakage Distance (Inches) [mm]
Arcing Distance (Inches) [mm]
Coupling Type
Mechanical Data
Specified Mechanical Load (Lbs.) [kN]
Tension Proof Load (Lbs.) [kN]
Electrical Data
Voltage Class (kV)
Low Frequency Dry Withstand (kV)
Low Frequency Wet Withstand (kV)
Critical Impulse Flashover - Positive (kV)
Critical Impulse Flashover - Negative (kV)
Switching Impulse Withstand (kV)
Approved By:
Drawn By: T. Martin
ECR Fiberglass
Light Gray Silicone
Hot Dip Galvanized Forged Steel
175.20 [4450]
6.06 [154]
4.68 [119]
496.1 [12600]
157.5 [4000]
Ball and Socket
2°-3°
36000 [160]
18000 [80]
500
920
740
2240
2260
1240
Detail A
4.68 [119]
6.06 [154]
175.20 [4450]
Detail A
Piedmont Bushings & Insulators, LLC
“Quality Products at Competitive Prices”
ANSI Silicone
Suspension
Insulators
Test Reports – Silicone Suspensions
Piedmont Bushings & Insulators, LLC
251 Harris Bridge Road
P.O. Box 849
Woodruff, SC 29388
Phone: (864) 476-6360
FAX: (864) 476-6376
Piedmont Bushings & Insulators, LLC
“Quality Products At Competitive Prices”
Test Report
Test Unit: 69kV – 20,000 Lb. Composite Suspension Insulator
Piedmont Bushings and Insulators, LLC
Phone: (864) 476-6360
251 Harris Bridge Road
Woodruff, SC 29388
FAX: (864) 476-6376
Page 1 of 12
Test Unit:
OEP Part Number:
Test Type:
Referenced Standards:
69kV – 20,000 Lb. Composite Suspension Insulator
9710010
Prototype, Design and Sample Test
ANSI C29.11-1989
ANSI C29.12-1997
ANSI C29.13-2000
IEC61109-1992
Date of Test:
Date Report Was Prepared:
Report Prepared By:
September 12, 1998 through November 20, 1998
December 31, 2003
Tom J. Martin
Testing Conclusion:
All units tested passed the testing according to all applicable requirements of the referenced standards.
Piedmont Bushings and Insulators, LLC
Phone: (864) 476-6360
251 Harris Bridge Road
Woodruff, SC 29388
FAX: (864) 476-6376
Page 2 of 12
Table of Contents:
1.0 General Unit Design and Specifications
2.0 Prototype Tests
2.1 Test Unit
2.2 Tests On Interfaces and Connections of Metal Fittings
2.2.1 Power Frequency Voltage Test
2.2.2 Sudden Load Release Test
2.2.3 Thermal-Mechanical Test
2.2.4 Water PenetrationTest
2.2.5 Verification Tests
2.2.5.1 Visual Examination
2.2.5.2 Steep Front Impulse Voltage Test
2.2.5.3 Power Frequency Voltage Test
2.3 Core Time-Load Test
2.3.1 Test Specimens
2.3.2 Determination of Average Failing Load of The Core
2.3.3 Core Time Load Test
2.4 Housing Tracking and Erosion Test
2.5 Core Material Tests
2.5.1 Dye Penetration Test
2.5.2 Water Diffusion Test
2.5.2.1 Prestressing
2.5.2.2 Voltage Test
3.0 Design Tests
3.1 Test Unit
3.2 Lightning Impulse Withstand Test (Positive)
3.3 Low-Frequency Wet Withstand
4.0 Sample Tests
4.1 Visual Inspection and Dimensional Verification
4.2 Verification of Locking System
4.3 Mechanical Load Test
4.4 Galvanizing Test
Piedmont Bushings and Insulators, LLC
Phone: (864) 476-6360
251 Harris Bridge Road
Woodruff, SC 29388
4
4
4
4
4
4
5
5
5
5
5
6
6
6
6
7
7
8
8
8
8
8
9
9
9
9
10
10
10
11
11
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Page 3 of 12
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
Kd = 0.981
Tw = 69.8 °F
Kh = 0.940
Sample Number
1
2
3
Average Value
(kV)
323.9
321.9
329.8
P = 14.674 Psi.
Corrected Value
(kV)
310.4
308.4
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
1
2
3
Specification
Temperature
(°F)
-7.6
-7.6
-7.6
-4 ~ -13
Load Value
(Lbs.)
6744.0
6744.0
6744.0
6744.0
Load
Releases
5
5
5
5
Results
Testing Passed
Testing Passed
Testing Passed
No Damage
Table 2
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Page 4 of 12
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
Number
1
2
3
Sample Length (Inches)
Before Test
After Test
43.98
43.98
43.91
43.91
43.84
43.84
Change
(Inches)
0.0
0.0
0.0
Table 3
Sample
Number
1
2
3
Specification
First Cycle
TC
TH
(°F)
(°F)
-29.2
122
-29.2
122
-29.2
122
-31.0 122.0
Table 4
Second Cycle
Third Cycle
Fourth Cycle
Testing
TC
TH
TC
TH
TC
TH
Results
(°F)
(°F)
(°F)
(°F)
(°F)
(°F)
-27.4
122
-29.2
122
-31.0
122
Passed
-27.4
122
-29.2
122
-31.0
122
Passed
-27.4
122
-29.2
122
-31.0
122
Passed
-31.0 122.0 -31.0 122.0 -31.0 122.0 No Failure
(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.
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Phone: (864) 476-6360
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Woodruff, SC 29388
FAX: (864) 476-6376
Page 5 of 12
Sample
Number
1
2
3
Specification
Sample
Sections
2
2
2
-
Wave Front
Slope
(kV/µS)
1206~1312
≥ 1000
Test Cycles
Positive
Negative
Polarity
Polarity
25
25
25
25
25
25
25
25
Testing Results
No Puncture
No Puncture
No Puncture
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
Kd = 1.025
Sample
Number
1
2
3
90% of Base
Value From
Section 2.2.1
279.4
277.6
284.4
Tw = 49.1 °F
Kh = 1.035
Average Value
(kV)
298.6
302.4
304.8
P = 14.786 Psi.
Corrected Value
(kV)
301.5
305.4
307.8
Results
Passed
Passed
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
1
2
3
Specification
Insulation Length
(Inches)
31.52
31.52
31.52
≥ 31.50
Failing Load
(Lbs.)
28459.7
29831.0
28684.5
-
Failure Mode
Core Breakage
Core Breakage
Core Breakage
-
Average Value
(Lbs.)
28991.6
-
Table 7
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FAX: (864) 476-6376
Page 6 of 12
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
1
2
3
Specification
Table 8
Insulation
Length
(Inches)
60% of Average
Failing Load
(Lbs.)
~ 31.69
17394.9
≥ 31.5
-
Withstand
Time
(Hours)
96
96
96
96
Results
Passed
Passed
Passed
No Damage
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
Sample
Number
1
2
Table 9
Structure Creepage
Core
Length
Distance Diameter
(Inches) (Inches) (Inches)
18.52
20.87
0.94
18.52
20.87
0.94
Sample
Number
1
2
Specification
Table 10
Test
Voltage
(kV)
15.3
15.3
14~20
Cycle
Time
(Hours)
1000
1000
1000
Large Shed Details
Diameter Number In
(Inches)
Sample
5.71
2
5.71
2
Cycle
Interruptions
2
2
≤6
Interruption
Time
(Minutes)
10,10
10,10
≤ 15
Piedmont Bushings and Insulators, LLC
Sample
Orientation
Horizontal
Vertical
Both
Maximum
OverCurrent
Trips
Results
0
Passed
0
Passed
3
Passed
Phone: (864) 476-6360
251 Harris Bridge Road
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Small Shed Details
Diameter Number In
(Inches)
Sample
4.33
1
4.33
1
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Page 7 of 12
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
1
2
3
4
5
6
7
8
9
10
Specification
Specimen Length
(Inches)
0.396
0.397
0.398
0.399
0.400
0.386
0.402
0.387
0.398
0.394
0.394 ± 0.02
Sample Immersion Time
(Minutes)
15
15
15
15
15
15
15
15
15
15
15
Results
No Penetration
No Penetration
No Penetration
No Penetration
No Penetration
No Penetration
No Penetration
No Penetration
No Penetration
No Penetration
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.
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Specimen
Number
1
2
3
4
5
6
Specimen
Length
(Inches)
1.183
1.186
1.188
1.183
1.183
1.187
Boiling
Time
(Hours)
100
100
100
100
100
100
Test
Voltage
(kV)
12
12
12
12
12
12
Withstand
Time
(Minutes)
1
1
1
1
1
1
Leakage
Current
(mA)
0.1
0.1
0.1
0.1
0.1
0.1
Specification
1.182 ± 0.020
100
12
1
≤1
Results
Passed
Passed
Passed
Passed
Passed
Passed
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.
Test Conditions: Td = 63.1 °F
Kd = 1.018
Sample #
1
2
3
Specification
Test Wave
(µs)
1.15
1.15
1.15
1.2 ± 30%
Tw = 58.1 °F
Kh = 1.000
P = 14.88 Psi.
Positive Polarity
Withstand Test Value Corrected Value
(kV)
(kV)
420.0
417.4
421.0
423.0
360.0
360.0
Withstand Time
(Seconds)
15
15
15
15
Results
No Flashover
No Flashover
No Flashover
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.
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Test Conditions: Td = 53.6 °F
Kd = 1.025
Tw = 49.1 °F
Kh = 1.035
P = 14.786 Psi.
Rain Water Resistivity: ρ20.0 = 100.0Ω-m
Rain Rate: 1.4 mm/min (Horizontal and Vertical)
Sample #
1
2
3
Specification
Applied Voltage
(kV)
187.0
187.0
187.0
185.0
Corrected Values
(kV)
185.9
185.0
Withstand Time
(Min)
1
1
1
1
Results
Passed
Passed
Passed
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.
Sample
Number
1
2
3
4
5
6
7
8
9
Specification
Unit Length
(Inches)
35.47
35.55
35.43
35.51
35.39
35.59
35.55
35.43
35.51
35.31 ± 0.59
Creepage
Distance
(Inches)
82.20
81.89
82.68
82.13
82.68
81.89
81.89
81.85
82.09
≥ 81.70
End Fitting Gauging
Socket
Ball
Go-Gauge No-Go Gauge
Go-Gauge
No-Go Gauge
Go
No-Go
Go
No-Go
Go
No-Go
Go
No-Go
Go
No-Go
Go
No-Go
Go
No-Go
Go
No-Go
Go
No-Go
Go
No-Go
Go
No-Go
Go
No-Go
Go
No-Go
Go
No-Go
Go
No-Go
Go
No-Go
Go
No-Go
Go
No-Go
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.
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Sample
Number
1
2
3
Specification
First
15.63
13.39
26.79
Moving Load (Lbs.)
Second
20.09
17.86
17.86
5.2 – 56.0
Results At 56Lb.
Maximum Load
No Uncoupling
No Uncoupling
No Uncoupling
No Uncoupling
Third
22.32
17.86
35.71
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
1
2
3
Specification
Tensile Load
(Lbs.)
22482
22482
22482
20000
Withstand Time
(Minutes)
1
1
1
1
Results
Passed
Passed
Passed
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.
Sample
Number
1
2
3
Specification
Thickness Values of Socket End Fitting
(Mils)
AA
SA
4.22
4.58
4.83
4.69
≥ 3.1
≥ 3.4
Thickness Values of Ball End Fitting
(Mils)
SA
AA
4.31
3.79
3.31
3.74
≥ 3.1
≥ 3.4
Table 18
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Appendix A
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Piedmont Bushings & Insulators, LLC
“Quality Products At Competitive Prices”
Test Report
Test Unit: 115kV – 20,000 Lb. Composite Suspension Insulator
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Test Unit:
OEP Part Number:
Test Type:
Referenced Standards:
115kV – 20,000 Lb. Composite Suspension Insulator
9710013
Prototype, Design and Sample Test
ANSI C29.11-1989
ANSI C29.12-1997
ANSI C29.13-2000
IEC61109-1992
Date of Test:
Date Report Was Prepared:
Report Prepared By:
September 12, 1998 through November 20, 1998
January 2, 2004
Tom J. Martin
Testing Conclusion:
All units tested passed the testing according to all applicable requirements of the referenced standards.
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Table of Contents:
1.0 General Unit Design and Specifications
2.0 Prototype Tests
2.1 Test Unit
2.2 Tests On Interfaces and Connections of Metal Fittings
2.2.1 Power Frequency Voltage Test
2.2.2 Sudden Load Release Test
2.2.3 Thermal-Mechanical Test
2.2.4 Water PenetrationTest
2.2.5 Verification Tests
2.2.5.1 Visual Examination
2.2.5.2 Steep Front Impulse Voltage Test
2.2.5.3 Power Frequency Voltage Test
2.3 Core Time-Load Test
2.3.1 Test Specimens
2.3.2 Determination of Average Failing Load of The Core
2.3.3 Core Time Load Test
2.4 Housing Tracking and Erosion Test
2.5 Core Material Tests
2.5.1 Dye Penetration Test
2.5.2 Water Diffusion Test
2.5.2.1 Prestressing
2.5.2.2 Voltage Test
3.0 Design Tests
3.1 Test Unit
3.2 Lightning Impulse Withstand Test (Positive)
3.3 Low-Frequency Wet Withstand
4.0 Sample Tests
4.1 Visual Inspection and Dimensional Verification
4.2 Verification of Locking System
4.3 Mechanical Load Test
4.4 Galvanizing Test
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4
4
4
4
4
4
5
5
5
5
5
6
6
6
6
7
7
8
8
8
8
8
9
9
9
9
10
10
10
11
11
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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
Kd = 0.981
Tw = 69.8 °F
Kh = 0.940
Sample Number
1
2
3
Average Value
(kV)
323.9
321.9
329.8
P = 14.674 Psi.
Corrected Value
(kV)
310.4
308.4
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
1
2
3
Specification
Temperature
(°F)
-7.6
-7.6
-7.6
-4 ~ -13
Load Value
(Lbs.)
6744.0
6744.0
6744.0
6744.0
Load
Releases
5
5
5
5
Results
Testing Passed
Testing Passed
Testing Passed
No Damage
Table 2
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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
Number
1
2
3
Sample Length (Inches)
Before Test
After Test
43.98
43.98
43.91
43.91
43.84
43.84
Change
(Inches)
0.0
0.0
0.0
Table 3
Sample
Number
1
2
3
Specification
First Cycle
TC
TH
(°F)
(°F)
-29.2
122
-29.2
122
-29.2
122
-31.0 122.0
Table 4
Second Cycle
Third Cycle
Fourth Cycle
Testing
TC
TH
TC
TH
TC
TH
Results
(°F)
(°F)
(°F)
(°F)
(°F)
(°F)
-27.4
122
-29.2
122
-31.0
122
Passed
-27.4
122
-29.2
122
-31.0
122
Passed
-27.4
122
-29.2
122
-31.0
122
Passed
-31.0 122.0 -31.0 122.0 -31.0 122.0 No Failure
(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.
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Sample
Number
1
2
3
Specification
Sample
Sections
2
2
2
-
Wave Front
Slope
(kV/µS)
1206~1312
≥ 1000
Test Cycles
Positive
Negative
Polarity
Polarity
25
25
25
25
25
25
25
25
Testing Results
No Puncture
No Puncture
No Puncture
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
Kd = 1.025
Sample
Number
1
2
3
90% of Base
Value From
Section 2.2.1
279.4
277.6
284.4
Tw = 49.1 °F
Kh = 1.035
Average Value
(kV)
298.6
302.4
304.8
P = 14.786 Psi.
Corrected Value
(kV)
301.5
305.4
307.8
Results
Passed
Passed
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
1
2
3
Specification
Insulation Length
(Inches)
31.52
31.52
31.52
≥ 31.50
Failing Load
(Lbs.)
28459.7
29831.0
28684.5
-
Failure Mode
Core Breakage
Core Breakage
Core Breakage
-
Average Value
(Lbs.)
28991.6
-
Table 7
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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
1
2
3
Specification
Table 8
Insulation
Length
(Inches)
60% of Average
Failing Load
(Lbs.)
~ 31.69
17394.9
≥ 31.5
-
Withstand
Time
(Hours)
96
96
96
96
Results
Passed
Passed
Passed
No Damage
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
Sample
Number
1
2
Table 9
Structure Creepage
Core
Length
Distance Diameter
(Inches) (Inches) (Inches)
18.52
20.87
0.94
18.52
20.87
0.94
Sample
Number
1
2
Specification
Table 10
Test
Voltage
(kV)
15.3
15.3
14~20
Cycle
Time
(Hours)
1000
1000
1000
Large Shed Details
Diameter Number In
(Inches)
Sample
5.71
2
5.71
2
Cycle
Interruptions
2
2
≤6
Interruption
Time
(Minutes)
10,10
10,10
≤ 15
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Orientation
Horizontal
Vertical
Both
Maximum
OverCurrent
Trips
Results
0
Passed
0
Passed
3
Passed
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Small Shed Details
Diameter Number In
(Inches)
Sample
4.33
1
4.33
1
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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
1
2
3
4
5
6
7
8
9
10
Specification
Specimen Length
(Inches)
0.396
0.397
0.398
0.399
0.400
0.386
0.402
0.387
0.398
0.394
0.394 ± 0.02
Sample Immersion Time
(Minutes)
15
15
15
15
15
15
15
15
15
15
15
Results
No Penetration
No Penetration
No Penetration
No Penetration
No Penetration
No Penetration
No Penetration
No Penetration
No Penetration
No Penetration
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.
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Specimen
Number
1
2
3
4
5
6
Specimen
Length
(Inches)
1.183
1.186
1.188
1.183
1.183
1.187
Boiling
Time
(Hours)
100
100
100
100
100
100
Test
Voltage
(kV)
12
12
12
12
12
12
Withstand
Time
(Minutes)
1
1
1
1
1
1
Leakage
Current
(mA)
0.1
0.1
0.1
0.1
0.1
0.1
Specification
1.182 ± 0.020
100
12
1
≤1
Results
Passed
Passed
Passed
Passed
Passed
Passed
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.
Test Conditions: Td = 63.1 °F
Kd = 1.018
Sample #
1
2
3
Specification
Test Wave
(µs)
1.15
1.15
1.15
1.2 ± 30%
Tw = 58.1 °F
Kh = 1.000
P = 14.88 Psi.
Positive Polarity
Withstand Test Value Corrected Value
(kV)
(kV)
571.0
559.9
573.0
571.0
550.0
550.0
Withstand Time
(Seconds)
15
15
15
15
Results
No Flashover
No Flashover
No Flashover
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.
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Test Conditions: Td = 53.6 °F
Kd = 1.025
Tw = 49.1 °F
Kh = 1.035
P = 14.786 Psi.
Rain Water Resistivity: ρ20.0 = 100.0Ω-m
Rain Rate: 1.4 mm/min (Horizontal and Vertical)
Sample #
1
2
3
Specification
Applied Voltage
(kV)
235.0
235.0
235.0
230.0
Corrected Values
(kV)
231.2
230.0
Withstand Time
(Min)
1
1
1
1
Results
Passed
Passed
Passed
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.
Sample
Number
1
2
3
4
5
6
7
8
9
Specification
Unit Length
(Inches)
48.82
48.62
48.74
48.82
48.62
48.82
48.82
48.82
48.62
48.26 ± 0.59
Creepage
Distance
(Inches)
114.57
114.76
114.76
114.96
114.76
114.88
114.65
114.96
114.37
≥ 113.19
End Fitting Gauging
Socket
Ball
Go-Gauge No-Go Gauge
Go-Gauge
No-Go Gauge
Go
No-Go
Go
No-Go
Go
No-Go
Go
No-Go
Go
No-Go
Go
No-Go
Go
No-Go
Go
No-Go
Go
No-Go
Go
No-Go
Go
No-Go
Go
No-Go
Go
No-Go
Go
No-Go
Go
No-Go
Go
No-Go
Go
No-Go
Go
No-Go
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.
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Sample
Number
1
2
3
Specification
First
17.86
13.39
15.63
Moving Load (Lbs.)
Second
8.93
29.02
24.55
5.2 – 56.0
Results At 56Lb.
Maximum Load
No Uncoupling
No Uncoupling
No Uncoupling
No Uncoupling
Third
22.32
24.55
17.86
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
1
2
3
Specification
Tensile Load
(Lbs.)
22482
22482
22482
20000
Withstand Time
(Minutes)
1
1
1
1
Results
Passed
Passed
Passed
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.
Sample
Number
1
2
3
Specification
Thickness Values of Socket End Fitting
(Mils)
AA
SA
3.46
3.96
4.35
4.06
≥ 3.1
≥ 3.4
Thickness Values of Ball End Fitting
(Mils)
SA
AA
3.85
3.66
3.68
3.44
≥ 3.1
≥ 3.4
Table 18
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Appendix A
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Piedmont Bushings & Insulators, LLC
“Quality Products At Competitive Prices”
Test Report
Test Unit: 230kV – 20,000 Lb. Composite Suspension Insulator
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Test Unit:
PBI Part Number:
Test Type:
Referenced Standards:
230kV – 20,000 Lb. Composite Suspension Insulator
9710017
Prototype, Design and Sample Test
ANSI C29.11-1989
ANSI C29.12-1997
ANSI C29.13-2000
IEC61109-1992
Date of Test:
Date Report Was Prepared:
Report Prepared By:
September 12, 1998 through November 20, 1998
January 2, 2004
Tom J. Martin
Testing Conclusion:
All units tested passed the testing according to all applicable requirements of the referenced standards.
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Table of Contents:
1.0 General Unit Design and Specifications
2.0 Prototype Tests
2.1 Test Unit
2.2 Tests On Interfaces and Connections of Metal Fittings
2.2.1 Power Frequency Voltage Test
2.2.2 Sudden Load Release Test
2.2.3 Thermal-Mechanical Test
2.2.4 Water PenetrationTest
2.2.5 Verification Tests
2.2.5.1 Visual Examination
2.2.5.2 Steep Front Impulse Voltage Test
2.2.5.3 Power Frequency Voltage Test
2.3 Core Time-Load Test
2.3.1 Test Specimens
2.3.2 Determination of Average Failing Load of The Core
2.3.3 Core Time Load Test
2.4 Housing Tracking and Erosion Test
2.5 Core Material Tests
2.5.1 Dye Penetration Test
2.5.2 Water Diffusion Test
2.5.2.1 Prestressing
2.5.2.2 Voltage Test
3.0 Design Tests
3.1 Test Unit
3.2 Lightning Impulse Withstand Test (Positive)
3.3 Low-Frequency Wet Withstand
4.0 Sample Tests
4.1 Visual Inspection and Dimensional Verification
4.2 Verification of Locking System
4.3 Mechanical Load Test
4.4 Galvanizing Test
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4
4
4
4
4
4
5
5
5
5
5
6
6
6
6
7
7
8
8
8
8
8
9
9
9
9
10
10
10
11
11
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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
Kd = 0.981
Tw = 69.8 °F
Kh = 0.940
Sample Number
1
2
3
Average Value
(kV)
323.9
321.9
329.8
P = 14.674 Psi.
Corrected Value
(kV)
310.4
308.4
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
1
2
3
Specification
Temperature
(°F)
-7.6
-7.6
-7.6
-4 ~ -13
Load Value
(Lbs.)
6744.0
6744.0
6744.0
6744.0
Load
Releases
5
5
5
5
Results
Testing Passed
Testing Passed
Testing Passed
No Damage
Table 2
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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
Number
1
2
3
Sample Length (Inches)
Before Test
After Test
43.98
43.98
43.91
43.91
43.84
43.84
Change
(Inches)
0.0
0.0
0.0
Table 3
Sample
Number
1
2
3
Specification
First Cycle
TC
TH
(°F)
(°F)
-29.2
122
-29.2
122
-29.2
122
-31.0 122.0
Table 4
Second Cycle
Third Cycle
Fourth Cycle
Testing
TC
TH
TC
TH
TC
TH
Results
(°F)
(°F)
(°F)
(°F)
(°F)
(°F)
-27.4
122
-29.2
122
-31.0
122
Passed
-27.4
122
-29.2
122
-31.0
122
Passed
-27.4
122
-29.2
122
-31.0
122
Passed
-31.0 122.0 -31.0 122.0 -31.0 122.0 No Failure
(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.
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Sample
Number
1
2
3
Specification
Sample
Sections
2
2
2
-
Wave Front
Slope
(kV/µS)
1206~1312
≥ 1000
Test Cycles
Positive
Negative
Polarity
Polarity
25
25
25
25
25
25
25
25
Testing Results
No Puncture
No Puncture
No Puncture
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
Kd = 1.025
Sample
Number
1
2
3
90% of Base
Value From
Section 2.2.1
279.4
277.6
284.4
Tw = 49.1 °F
Kh = 1.035
Average Value
(kV)
298.6
302.4
304.8
P = 14.786 Psi.
Corrected Value
(kV)
301.5
305.4
307.8
Results
Passed
Passed
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
1
2
3
Specification
Insulation Length
(Inches)
31.52
31.52
31.52
≥ 31.50
Failing Load
(Lbs.)
28459.7
29831.0
28684.5
-
Failure Mode
Core Breakage
Core Breakage
Core Breakage
-
Average Value
(Lbs.)
28991.6
-
Table 7
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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
1
2
3
Specification
Table 8
Insulation
Length
(Inches)
60% of Average
Failing Load
(Lbs.)
~ 31.69
17394.9
≥ 31.5
-
Withstand
Time
(Hours)
96
96
96
96
Results
Passed
Passed
Passed
No Damage
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
Sample
Number
1
2
Table 9
Structure Creepage
Core
Length
Distance Diameter
(Inches) (Inches) (Inches)
18.52
20.87
0.94
18.52
20.87
0.94
Sample
Number
1
2
Specification
Table 10
Test
Voltage
(kV)
15.3
15.3
14~20
Cycle
Time
(Hours)
1000
1000
1000
Large Shed Details
Diameter Number In
(Inches)
Sample
5.71
2
5.71
2
Cycle
Interruptions
2
2
≤6
Interruption
Time
(Minutes)
10,10
10,10
≤ 15
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Orientation
Horizontal
Vertical
Both
Maximum
OverCurrent
Trips
Results
0
Passed
0
Passed
3
Passed
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Small Shed Details
Diameter Number In
(Inches)
Sample
4.33
1
4.33
1
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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
1
2
3
4
5
6
7
8
9
10
Specification
Specimen Length
(Inches)
0.396
0.397
0.398
0.399
0.400
0.386
0.402
0.387
0.398
0.394
0.394 ± 0.02
Sample Immersion Time
(Minutes)
15
15
15
15
15
15
15
15
15
15
15
Results
No Penetration
No Penetration
No Penetration
No Penetration
No Penetration
No Penetration
No Penetration
No Penetration
No Penetration
No Penetration
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.
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Specimen
Number
1
2
3
4
5
6
Specimen
Length
(Inches)
1.183
1.186
1.188
1.183
1.183
1.187
Boiling
Time
(Hours)
100
100
100
100
100
100
Test
Voltage
(kV)
12
12
12
12
12
12
Withstand
Time
(Minutes)
1
1
1
1
1
1
Leakage
Current
(mA)
0.1
0.1
0.1
0.1
0.1
0.1
Specification
1.182 ± 0.020
100
12
1
≤1
Results
Passed
Passed
Passed
Passed
Passed
Passed
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.
Test Conditions: Td = 63.1 °F
Kd = 1.018
Sample #
1
2
3
Specification
Test Wave
(µs)
1.15
1.15
1.15
1.2 ± 30%
Tw = 58.1 °F
Kh = 1.000
P = 14.88 Psi.
Positive Polarity
Withstand Test Value Corrected Value
(kV)
(kV)
1021.0
1018.0
1023.0
1024.0
1000.0
1000.0
Withstand Time
(Seconds)
15
15
15
15
Results
No Flashover
No Flashover
No Flashover
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.
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Test Conditions: Td = 53.6 °F
Kd = 1.025
Tw = 49.1 °F
Kh = 1.035
P = 14.786 Psi.
Rain Water Resistivity: ρ20.0 = 100.0Ω-m
Rain Rate: 1.4 mm/min (Horizontal and Vertical)
Sample #
1
2
3
Specification
Applied Voltage
(kV)
400.0
399.0
402.0
395.0
Corrected Values
(kV)
397.0
395.0
Withstand Time
(Min)
1
1
1
1
Results
Passed
Passed
Passed
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.
Sample
Number
1
2
3
4
5
6
7
8
9
Specification
Unit Length
(Inches)
84.33
84.25
84.45
84.17
84.25
84.25
84.06
84.25
84.17
84.44 ± 1.18
Creepage
Distance
(Inches)
220.47
222.44
220.47
223.62
224.41
220.47
223.62
222.44
220.47
≥ 193.22
End Fitting Gauging
Socket
Ball
Go-Gauge No-Go Gauge
Go-Gauge
No-Go Gauge
Go
No-Go
Go
No-Go
Go
No-Go
Go
No-Go
Go
No-Go
Go
No-Go
Go
No-Go
Go
No-Go
Go
No-Go
Go
No-Go
Go
No-Go
Go
No-Go
Go
No-Go
Go
No-Go
Go
No-Go
Go
No-Go
Go
No-Go
Go
No-Go
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.
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Sample
Number
1
2
3
Specification
First
31.25
17.86
26.79
Moving Load (Lbs.)
Second
20.09
26.79
40.18
5.2 – 56.0
Results At 56Lb.
Maximum Load
No Uncoupling
No Uncoupling
No Uncoupling
No Uncoupling
Third
22.32
26.79
20.09
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
1
2
3
Specification
Tensile Load
(Lbs.)
22482
22482
22482
20000
Withstand Time
(Minutes)
1
1
1
1
Results
Passed
Passed
Passed
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.
Sample
Number
1
2
3
Specification
Thickness Values of Socket End Fitting
(Mils)
AA
SA
4.46
4.31
4.30
4.18
≥ 3.1
≥ 3.4
Thickness Values of Ball End Fitting
(Mils)
SA
AA
4.15
3.61
3.77
2.91
≥ 3.1
≥ 3.4
Table 18
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Appendix A
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Piedmont Bushings & Insulators, LLC
“Quality Products At Competitive Prices”
Test Report
Test Unit: 500kV – 36,000 Lb. Composite Suspension Insulator
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Page 1 of 13
Test Unit:
PBI Part Number:
Test Type:
Referenced Standards:
500kV – 36,000 Lb. Composite Suspension Insulator
9710019
Prototype, Design and Sample Test
ANSI C29.11-1989
ANSI C29.12-1997
ANSI C29.13-2000
IEC61109-1992
Date of Test:
Date Report Was Prepared:
Report Prepared By:
September 12, 1998 through November 20, 1998
January 2, 2004
Tom J. Martin
Testing Conclusion:
All units tested passed the testing according to all applicable requirements of the referenced standards.
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Table of Contents:
1.0 General Unit Design and Specifications
2.0 Prototype Tests
2.1 Test Unit
2.2 Tests On Interfaces and Connections of Metal Fittings
2.2.1 Power Frequency Voltage Test
2.2.2 Sudden Load Release Test
2.2.3 Thermal-Mechanical Test
2.2.4 Water PenetrationTest
2.2.5 Verification Tests
2.2.5.1 Visual Examination
2.2.5.2 Steep Front Impulse Voltage Test
2.2.5.3 Power Frequency Voltage Test
2.3 Core Time-Load Test
2.3.1 Test Specimens
2.3.2 Determination of Average Failing Load of The Core
2.3.3 Core Time Load Test
2.4 Housing Tracking and Erosion Test
2.5 Core Material Tests
2.5.1 Dye Penetration Test
2.5.2 Water Diffusion Test
2.5.2.1 Prestressing
2.5.2.2 Voltage Test
3.0 Design Tests
3.1 Test Unit
3.2 Lightning Impulse Withstand Test (Positive)
3.3 Low-Frequency Wet Withstand
3.4 Wet Switching Impulse Withstand
4.0 Sample Tests
4.1 Visual Inspection and Dimensional Verification
4.2 Verification of Locking System
4.3 Mechanical Load Test
4.4 Galvanizing Test
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4
4
4
4
4
4
5
5
5
5
5
6
6
6
6
7
7
8
8
8
8
8
9
9
9
9
10
10
10
10
11
11
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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 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
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 = 71.6 °F
Kd = 0.981
Tw = 68.9 °F
Kh = 0.940
Sample Number
1
2
3
Average Value
(kV)
349.0
347.0
346.0
P = 14.713 Psi.
Corrected Value
(kV)
335.4
333.5
332.5
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
1
2
3
Specification
Temperature
(°F)
-9.4
-9.4
-9.4
-4 ~ -13
Load Value
(Lbs.)
10791.4
10791.4
10791.4
10791.4
Load
Releases
5
5
5
5
Results
Testing Passed
Testing Passed
Testing Passed
No Damage
Table 2
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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
Number
1
2
3
Sample Length (Inches)
Before Test
After Test
45.67
45.67
45.67
45.67
45.71
45.71
Change
(Inches)
0.0
0.0
0.0
Table 3
Sample
Number
1
2
3
Specification
First Cycle
TC
TH
(°F)
(°F)
-27.4 122.0
-29.2 122.0
-27.4 122.0
-31.0 122.0
Table 4
Second Cycle
Third Cycle
Fourth Cycle
Testing
TC
TH
TC
TH
TC
TH
Results
(°F)
(°F)
(°F)
(°F)
(°F)
(°F)
-29.2 122.0 -31.0 122.0 -27.4 122.0
Passed
-29.2 122.0 -29.2 122.0 -27.4 122.0
Passed
-31.0 122.0 -29.2 122.0 -27.4 122.0
Passed
-31.0 122.0 -31.0 122.0 -31.0 122.0 No Failure
(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.
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Sample
Number
1
2
3
Specification
Sample
Sections
2
2
2
-
Wave Front
Slope
(kV/µS)
1328~1410
≥ 1000
Test Cycles
Positive
Negative
Polarity
Polarity
25
25
25
25
25
25
25
25
Testing Results
No Puncture
No Puncture
No Puncture
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 = 78.8 °F
Kd = 1.025
Sample
Number
1
2
3
90% of Base
Value From
Section 2.2.1
301.8
300.2
299.3
Tw = 73.4 °F
Kh = 1.035
Average Value
(kV)
338.4
334.2
329.6
P = 14.728 Psi.
Corrected Value
(kV)
318.4
314.5
310.2
Results
Passed
Passed
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
1
2
3
Specification
Insulation Length
(Inches)
31.52
31.52
31.52
≥ 31.50
Failing Load
(Lbs.)
50157.4
50831.8
49393.0
-
Failure Mode
Core Pullout
Core Breakage
Core Pullout
-
Average Value
(Lbs.)
50127.4
-
Table 7
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2.3.3 Core Time Load Test
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
1
2
3
Specification
Table 8
Insulation
Length
(Inches)
60% of Average
Failing Load
(Lbs.)
~ 32.09
25179.9
≥ 31.5
-
Withstand
Time
(Hours)
96
96
96
96
Results
Passed
Passed
Passed
No Damage
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
Sample
Number
1
2
Table 9
Structure Creepage
Core
Length
Distance Diameter
(Inches) (Inches) (Inches)
17.72
20.87
0.94
17.72
20.87
0.94
Sample
Number
1
2
Specification
Table 10
Test
Voltage
(kV)
15.3
15.3
14~20
Cycle
Time
(Hours)
1000
1000
1000
Large Shed Details
Diameter Number In
(Inches)
Sample
6.14
2
6.14
2
Cycle
Interruptions
2
2
≤6
Interruption
Time
(Minutes)
12,10
12,10
≤ 15
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Sample
Orientation
Horizontal
Vertical
Both
Maximum
OverCurrent
Trips
Results
0
Passed
0
Passed
3
Passed
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Small Shed Details
Diameter Number In
(Inches)
Sample
4.69
1
4.69
1
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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
1
2
3
4
5
6
7
8
9
10
Specification
Specimen Length
(Inches)
0.402
0.402
0.400
0.400
0.406
0.402
0.401
0.402
0.403
0.405
0.394 ± 0.02
Sample Immersion Time
(Minutes)
15
15
15
15
15
15
15
15
15
15
15
Results
No Penetration
No Penetration
No Penetration
No Penetration
No Penetration
No Penetration
No Penetration
No Penetration
No Penetration
No Penetration
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.
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Specimen
Number
1
2
3
4
5
6
Specimen
Length
(Inches)
1.189
1.187
1.190
1.185
1.187
1.187
Boiling
Time
(Hours)
100
100
100
100
100
100
Test
Voltage
(kV)
12
12
12
12
12
12
Withstand
Time
(Minutes)
1
1
1
1
1
1
Leakage
Current
(mA)
0.1
0.1
0.1
0.1
0.1
0.1
Specification
1.182 ± 0.020
100
12
1
≤1
Results
Passed
Passed
Passed
Passed
Passed
Passed
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.
Test Conditions: Td = 69.8 °F
Kd = 1.018
Sample #
1
2
3
Specification
Test Wave
(µs)
1.15
1.15
1.15
1.2 ± 30%
Tw = 62.60 °F
Kh = 1.000
P = 14.734 Psi.
Positive Polarity
Withstand Test Value Corrected Value
(kV)
(kV)
2062.0
2060.4
2062.0
2062.0
2050.0
2050.0
Withstand Time
(Seconds)
15
15
15
15
Results
No Flashover
No Flashover
No Flashover
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.
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Test Conditions: Td = 71.1 °F
Kd = 1.025
Tw = 64.6 °F
Kh = 1.035
P = 14.696 Psi.
Rain Water Resistivity: ρ20.0 = 107.0Ω-m
Rain Rate: 1.4 mm/min (Horizontal and Vertical)
Sample #
1
2
3
Specification
Applied Voltage
(kV)
740.0
740.0
740.0
740.0
Corrected Values
(kV)
735.6
Withstand Time
(Min)
1
1
1
1
Results
Passed
Passed
Passed
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
Kd = 1.00
Tw = 64.6 °F
P = 14.728 Psi.
Rain Water Resistivity: ρ20.0 = 104.0 Ω.m
Rain Rate: 1.4 mm/min (Horizontal and Vertical)
Sample
Number
1
2
3
Specification
Test Wave
(µS)
260/2400
250 ± 20%
/ 2500 ± 60%
Corrected
Value
(kV)
Withstand
Withstand
Test Value
Time
(kV)
(Sec)
Results
1240.0
15
Passed
1240.0
1240.0
15
Passed
1240.0
15
Passed
Sample should withstand 1240 kV ± 3% for
15 cycles with no flashovers.
Table 15
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 16 below.
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Sample
Number
1
2
3
4
5
6
7
8
9
Specification
Unit Length
(Inches)
175.20
175.31
175.39
175.20
175.59
175.20
175.39
175.28
175.20
175.20 ± 1.97
Creepage
Distance
(Inches)
496.06
496.46
496.46
496.06
496.85
496.06
496.46
496.06
496.06
≥ 433.07
End Fitting Gauging
Go-Gauge
Go
Go
Go
Go
Go
Go
Go
Go
Go
Go
Socket
No-Go Gauge
No-Go
No-Go
No-Go
No-Go
No-Go
No-Go
No-Go
No-Go
No-Go
No-Go
Go-Gauge
Go
Go
Go
Go
Go
Go
Go
Go
Go
Go
Ball
No-Go Gauge
No-Go
No-Go
No-Go
No-Go
No-Go
No-Go
No-Go
No-Go
No-Go
No-Go
Table 16
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 17 below.
Sample
Number
1
2
3
Specification
First
24.55
40.18
22.32
Moving Load (Lbs.)
Second
26.79
40.18
42.41
5.2 – 56.0
Third
35.71
33.48
40.18
Results At 56Lb.
Maximum Load
No Uncoupling
No Uncoupling
No Uncoupling
No Uncoupling
Table 17
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
1
2
3
Specification
Tensile Load
(Lbs.)
36000
36000
36000
36000
Withstand Time
(Minutes)
1
1
1
1
Results
Passed
Passed
Passed
No Failure
Table 18
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 19 below.
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Sample
Number
1
2
3
Specification
Thickness Values of Socket End Fitting
(Mils)
AA
SA
4.10
4.06
3.83
4.26
≥ 3.1
≥ 3.4
Thickness Values of Ball End Fitting
(Mils)
SA
AA
3.61
3.79
3.98
3.78
≥ 3.1
≥ 3.4
Table 19
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Appendix A
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Page 13 of 13