INNOVATIONS & NEW DEVELOPMENTS OF COMPOSITE INSULATORS. CIGRE, North Africa Regional Conference, Tunis, Tunesia,

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1 INNOVATIONS & NEW DEVELOPMENTS OF COMPOSITE INSULATORS CIGRE, North Africa Regional Conference, Tunis, Tunesia, Dr. Jens M. Seifert R&D and Quality Engineering LAPP Insulator GmbH & Co. KG Wunsiedel, Germany Composite Insulator Generations I-IV (DE - JP) Innovation Level CIP, KAIZEN CIP,??? R&D 1965: Invention DE Innovation 1988: ISO9001 Innovation CIP Reviews Audits Universities EU Funding Innovation JP Idea Management Innovation I II III IV 1

2 SUMMARY 1. History & General Design Features of RODURFLEX 2. Advantages 3. Generation III (since 1979) 4. Innovations in Design & Development, New Design Tools 5. Generation IV (Video) 6. New Products (Insulating Crossarms, Station Posts, Heavy CLPs) 7. Impact of New Standards 8. Present & Future R&D work 1. History & General Design Features of RODURFLEX 2. Advantages 3. Generation III (since 1979) 2

3 REASONS TO APPLY COMPOSITE INSULATORS: Why they came into existence? 1955: USA, Light weight insulator concept for economic insulation designs of OHTL system voltages > 345kV, real inventors, cheap & dirty (bad) materials (PVC etc.) & bad designs 1963: Epoxies in Outdoor applications (CEP) 1965: RTV Silicone Composite Insulators invented by Martin Kuhl / Rosenthal Insulators, Germany; Strongly supported by Rosenthal Management Dr. Kärner [Generation I] : the trial years (hydrolysis, brittle fractures, sealing issues) [Generation II] 1979 [Generation III] HTV, compression type fittings, meta sealing 1989: HTV, after several (10) years of excellent long-term service experience under severe pollution conditions, Prof. Kindersberger published 1st paper on Hydrophobicity Transfer (HTM), Serial Production, Turn Over > 1 Mio DM [Generation III] today: (+) light weight, contamination/pollution resistance, vandalism proof and ability to design economic compact OHTLs, extended serial production, ISO 9001, New IEC standards, multi-supplier situation, turn over >20 Mio EURO [Development of Generation IV] Development of Insulator Technology in Europe

4 Production Process porcelain composite Body preparation Extrusion Drying Rod pultrusion Grinding Extrusion Shaping Drying Shed mounting and vulcanization Glazing Firing Cutting Grinding Assembling Assembling Sealing What makes a good composite insulator? bad Materials good bad Impossible Usual Case Design good Very difficult Know how needed RODURFLEX Kaerner s Matrix (1994) 4

5 Design of Rodurflex Generation III ECR INTRODUCTION HTV silicone 1979 FORMULATION Forged steel 1985 chemical bonding HTV silicone 1979 FORMULATION silicone rubber sealing 1982 End Fitting Assembly 5

6 Triple Point Designs 6

7 Failure Modes of Generations I and II A. Sprödbruch B. Kriechspurbildung A. Brittle Fracture B. Tracking & Erosion C. GFK-Stabdurchschlag D. Interface-Durchschlag C. FRP Puncture D. Interfacial Breakdown Failures in Design History Gen III: NCI Life expectancy: 40 50a 7

8 RODURFLEX 1967 and today Through the Generations Quality is back! Back to Quality! No Quality - No Business! 8

9 ISO 9001: Serial Production - Quality Management - Quality Engineering Features of Generation III BRITTLE FRACTURE Resistant ECR/FRP Rod since 1983 HTV Silicone Housing, chemical bonded interfaces since 1979 Compression Type forged steel (C45E) end fittings since 1983 Metastable silicone sealing system since 1981 No significant design changes since 1983 (service experience!) Continous Quality Control for all process steps for large scale serial production acc. to ISO 9000 since 1980/1992 9

10 Hydrophobicity Transfer Mechanism (HTM), CIGRE D1.14 pollution layer water repellent low leakage currents low risk of flashover low line losses no cleaning required Prof. Kindersberger (1989) Hydrophobicity Transfer Mechanism (HTM), CIGRE D1.14 Wetting angle ϑ [deg] s = Prof. Kindersberger (1989) Time [days] 10

11 Dynamics & Long Term Stability of HTM years 10 years Receding Angle h 350 Transfer Time Static Contact Angle HTM Different Materials (CIGRE D1.14) Generation III/IV HTV- PDMS / ATH filled RTV-2 RTV-1 HTV-Gen III/IV HTV-Gen II HTV-Gen I LSR d 16 Transfer Time 11

12 Pollution Performance - Comparison Required geometrical Creepage distances to obtain the same electrical performance under pollution (KIWIT 1970: Practical Experience with Outdoor Insulation) Silicone Rubber Composite Porcelain Longrod Glass/Porcelain Disk 75% 100% 120% -45% reference CONCLUSION: To operate under same pollution conditions, a silicone rubber composite insulator only requires % of the CD required for Glass/Porcelain Disks. A silicone rubber composite is Therefore more economical or can withstand a level of 2 pollution classes higher than glass. HTM impact on LCC and Service Costs 250 [$/year] 200 Silicone insulator coated ceramic disc ceramic disc with washing kv line 275 kv line Calculated by M/s Powerlink, Australia 12

13 Glass/Porcelain Disks: not hydrophobic surface high Leakage currents DC component in Leakage current galvanic cell PIN CORROSION Pin Corrosion Silicone rubber composite with HTM & hydrophobic surface: not hydrophobic surface very low Leakage currents no DC component in Leakage current no galvanic cell NO PROBLEMS Maintenance costs, lower lifetime, worse LCA Life expectancy: 17 30a Composite Insulators System Rodurflex Composite insulators offer low weight => low transport and installation costs Introduction 13

14 LCA Comparison Glass Disks vs. Silicone Rubber Composite 420kV OHTL LCA Glass Disks vs. Silicone Rubber Composite NCI Life expectancy: 40 50a 120% 100% Initial Purchase Costs 0a Glass Disks Initial Purchase Costs 0a RODURFLEX p.u costs per intial purchase costs 80% 60% 40% 45a Initial Purchase Costs 0a Initial Purchase Costs 0a Washing Costs 10a Glass Disks Washing Costs 10a RODURFLEX Washing Costs 10a Washing Costs 10a Maintenance Costs 15a Glass Disks Maintenance Costs 15a RODURFLEX Maintenance Costs 15a Replacement Costs 25a Glass Disks Replacement Costs 25a RODURFLEX 20% Replacement Costs 25a Washing Costs 35a Glass Disks Washing Costs 35a RODURFLEX 0% Washing Costs 35a Glass Disks RODURFLEX Initial Purchase Glass Disks RODURFLEX Glass Disks RODURFLEX Glass Disks RODURFLEX Glass Disks RODURFLEX Washing Costs 10a Maintenance Replacement Washing Glass Disks RODURFLEX Glass Disks RODURFLEX Maintenance Replacement Maintenance Costs 40a Glass Disks Maintenance Costs 40a RODURFLEX Maintenance Costs 40a Replacement Costs 45a Glass Disks Replacement Costs 45a RODURFLEX Costs 0a Costs 15a Costs 25a Costs 35a Costs 40a Costs 45a years Main Advantages (Summary): 14

15 Methods Used in China to Assess Composite Insulators after Years in Service LIANG Xidong1, WANG Jiafu1, SHEN Qinghe2, ZHANG Yibo1, LI Yan3 1. State Key Lab of Power System, Dept. of Electrical Engineering, Tsinghua University, Beijing , China; 2. Shandong Electric Power Research Institute, Ji nan , China; 3. Technology Research Center, China Southern Power Grid Co., LTD., Guangzhou , China. Abstract: Maintenance on silicone rubber insulators is quite different from that on porcelain and glass insulators. Sampling result based maintenance is a widely used method for silicone rubber composite insulator maintenance in China. The principle, test items, measures and other details were introduced in the present paper. Key Words: Composite insulator; Maintenance; Sampling result based maintenance; Maintenance-free period Sampling Result Based Maintenance The first maintenancefree period The second maintenance-free period The third maintenance-free period 5~8 years based on manufacture quality and operation experience 5~8 years* based on sampling results 4~6 years* based on sampling results Advantages of RODURFLEX Composite Insulators Enables new OHTL Insulation Design (Crossarms,Crossropes etc.) Superior Pollution Performance (Hydrophobicity Transfer Mechanism) Extreme UV, Weather and Environmental Resistant HTV Silicone Housing Enables Extreme Creepage Designs (Patented Underrib Sheds) Earthquake Resistant Brittle Fracture Resistant (ECR Glass Epoxy FRP Core) Fail-safe meta stable sealing system Extreme strength classes SML up to 2000 kn possible for single unit Vandalism Proof Able to withstand Extreme Dynamic and Impact loads Light Weight: Easy Transport, Handling, Installation Light Weight: offers EHV OHTL designs Short Lead-Time Flexible in Design Reduced Life-Cycle Costs Proven since more than 40 years 15

16 Generation III: Applications Worldwide up to Um=1100kV 4. Innovations in Design & Development 5. Generation IV (Video) 16

17 Hydrophobicity Transfer Mechanism (HTM), CIGRE D1.14 Wetting angle ϑ [deg] s = Prof. Kindersberger (1989) Time [days] Resistance against Tracking & Erosion - ATH Content 10 Mass Loss in % 1 0,1 0,01 Test Duration: 6h 48% 55% 60% ATH Content 3,5 kv 4,5 kv 17

18 Outdoor Perfomance of HTV Silicone Rubber Compounds Leistung des Hydrophobietransfers HTV RODURFLEX T&E Erosionsbeständigkeit 30-35% PDMS 60-70% ATH Freiluftverhalten Zu hoch gefülltes Silikon 80% PDMS 10% ATH RTV2/LSR 41% PDMS 58% ATH 0% PDMS 100% ATH 100% PDMS 0% ATH ATH Anteil in Gewichts % Silikonanteil in Gewichts % Lapp Material p.u. 0,9 0,8 0,7 Performance 0,6 0,5 0,4 0,3 0,2 0,1 0 HTM Tracking & Erosion Resistance Outdoor performance % ATH content (by weight) 18

19 0 Rotation in 90 steps Cooling period Energized period Suspension type insulator Grounded insulator support wheel Drip period Dip period 10/03/2010 Test Methods A. Material B. Insulators C. Field / Test Stations HV Salt water IEC IEC KIPTS IEC Erosion Resistance (IEC 60587, HK: VDE 0441) Max. Erosion depth in mm 1,2 1 0,8 0,6 0,4 0,2 0 IEC mod, Variation U 2,5 3 3,5 3,75 4 4,25 4,5 Test Voltage Ueff in kv Erosion depth in mm IEC mod, Variation χ 0,8 4,0 ms/cm 2,5 ms/cm 1,5 ms/cm 0,7 0,6 0,5 0,4 0,3 0,2 0,1 0 2,5 2,75 3 3,25 3,5 3,75 4 4,25 4,5 4,75 5 Test voltage in kv Screening required! 19

20 Erosion Resistance Screening Results 4 depth of erosion [mm] 3,5 3 2,5 2 1,5 1 3,5 kv 4,5 kv 0,5 0 LR1 LR2 LR3 LR4 HCR1 HCR2 HCR3 LSR HTV IEC (HL: VDE 0441): Screening Results 99,8 99, HTV HCR-1 probability [%] LSR ,5 0,2 LR 2 LR time to failure [s] 20

21 p s Insulation utilisation factor η Insulation Capability Yield Factor 1 s/p 1.0 0,9 0,8 0,7 0,6 0,5 1 1,5 2 2,5 3 3,5 Ratio Creepage Distance/Arcing Distance s/p=2.13 s/p=1.05 s/p=0,70 21

22 Shed / Housing Design (Profiles) Standard Flat Underrib Shallow Underribs insulator type 1 insulator type 2 insulator type 3 standard housing profile flat profile underrib profile s/p** = 0,58 s/p** = 0,60 s/p** = 0,74 CD = 20,6 mm/kv CD = 20 mm/kv CD = 18,6 mm/kv Salt Fog Test IEC 62217: 1000h Test (CD) 22

23 Start of Erosion Leakage Current Local Arc Stability Material Damage Damage limit Creepage Distance 23

24 10/03/2010 MOSS LANDING 550 kv USA, Monterey, California Test Stations / Test Lines ( Full Scale ) Koeberg Insulator Test Station (KIPTS) 145kV 24

25 Design Study (KIPTS) Approach Shed Design h 1 [mm] cd [mm] s/p * s/p ** 145kV Standard CS120SB (22/23(160/126) / Varying s/p CD=25mm/kV=const Underrib CS120SB 22/16(170/130) / h1=const Flat CS120SB 22/23(155/120) / kV Standard CS120SB 22/31(160/126) / Varying s/p CD=31mm/kV=const Underrib CS120SB 22/22(170/130) h1=const Flat CS120SB 22/31(155/120) kV Standard CS120SB 22/21(160/126) s/p=1.0 ** CD=25mm/kV Underrib CS120SB 22/16(170/130) h1= as it results Flat CS120SB 22/21(155/120) kV Standard CS120SB 22/26(160/126) s/p=1.0 ** CD=31mm/kV Underrib CS120SB 22/20(170/130) h1= as it results Flat CS120SB 22/26(155/120) * s/p: in acc.with IEC for alternating sheds h 1: connection length (IEC 60815) ** s/p: if calculated between large and small shed cd: creepage distance of housing (IEC 60815) s: shed spacing acc. to IEC p: shed projection (IEC 60815) Design Study (KIPTS) Standard Flat Underrib Shallow Underribs 25

26 Bilder KIPTS 2007/2008 Evaluation Scheme (KIPTS) criterion erosion s/p** 0,75 slight erosion starting standard smooth alternating flat alternating underribbed alternating 25 mm/kv s/p** 1,0 no 31 mm/kv s/p** 0,58 slight erosion starting s/p** 1,0 no s/p** 0,8 slight erosion starting 25 mm/kv s/p** 1,0 no 31 mm/kv s/p** 0,6 slight erosion starting s/p** 1,0 no 25 mm/kv s/p** 1,0 no 31 mm/kv s/p** 0,74 slight erosion starting s/p** 1,0 no HC DBA yes yes yes yes yes yes yes yes yes yes yes pollution yes medium yes heavy yes medium yes heavy heavy yes heavy crazing no in poll. layer in poll. layer in poll. layer in poll. layer in poll. layer in poll. layer in poll. layer in poll. layer in poll. layer in poll. layer 26

27 LIGHT MEDIUM HEAVY standard smooth 1 04K3195* CS120SB (22/23(160/126) kV alternating Varying s/p underribbed 06K6519 CS120SB 22/16(170/130)1485 CD=25mm/kV=const alternating h1=const flat 06K6520 CS120SB 22/23(155/120)1485 alternating standard smooth 04K CS120SB 22/31(160/126) kV alternating Varying s/p underribbed 05K4209* CS120SB 22/22(170/130)1480 CD=31mm/kV=const alternating h1=const flat 06K6521* CS120SB 22/31(155/120)1485 alternating K6522 standard smooth CS120SB 22/21(160/126) alternating kVs/p=1 underribbed 06K6519 CS120SB 22/16(170/130)1485 CD=25mm/kV alternating h1= as it results flat 06K6523 CS120SB 22/21(155/120)1700 alternating standard smooth 06K6524 CS120SB 22/26(160/126) kV alternating s/p=1 underribbed 06K6525 CS120SB 22/20(170/130)1730 CD=31mm/kV alternating h1= as it results flat 06K6526 CS120SB 22/26(155/120)2060 alternating

28 Shed Profile: Why Underrib Sheds for Extreme Pollution? shallow UR offer high CD UR act as creepage extender s/p = 1.0 can be met with URs UR offer protected CD s/p = 1.0 avoids T&E efficient insulation at s/p = 1.0 excellent performance history RODURFLEX : High Pollution Applications China (525, 750 kv) Arabic Peninsula (420 kv*) UAE, Qatar, Saudi Arabia, Oman, Jemen REE Spain (420 kv*) USA California (525 kv*) USA Florida (525 kv*) South Africa (420, 765 kv*) India (420, 765 kv) Australia (525 kv*) North Africa (420 kv*) Chile, Peru (245 kv*) Iran (420 kv*) * up to 28

29 RODURFLEX : Static Load-Time Curves IEC IEC RODURFLEX : Static Load-Time Curves 29

30 30

31 6. Generation IV / New Products / Innovations Generation IV - D-Flex 31

32 Generation IV - D-Flex VIDEO D-Flex Max. Leakage Current in ma ,1 0,01 0,001 Generation IV: Advanced Materials, Process & Design Leakage Current vertical [ma] Leakage Current horizontal [ma] Gen IV Test Duration in h Standard after 285 h after 1000 h 1. ATH Content 2. LMW Content 3. Spec. Vulcanisation Tech. (Patent), LMW Generation Process 32

33 Insulating Crossarms - Braced Line Posts kV Insulating Crossarms Compact Lines 420 kv Suspension Tower Tension Tower 33

34 10/03/2010 Compact Lines Invisible Tower 420 kv Composite Station Posts kV Core [mm] [inch] Pollution Classes* [SCD, IEC 60815] Maximum Cantilever Moment** [kn m] Um*** [kv] mm/kv mm/kv mm/kv mm/kv mm/kv mm/kv

35 7. Impact of New Standards The Impact of Standards No Standard No Business 35

36 IEC Insulator Standard System Auslegung Schirmprofil/Verschmutzung IEC RODURFLEX : Design Tests IEC

37 RODURFLEX : Design Tests IEC Present & Future R&D Projects 37

38 R&D Partners Prof. Hinrichsen Prof. Clemens Prof. Kindersberger Prof. Kurrat Prof. Grossmann Prof. Bärsch R&D: New Design Tools (FEM) 38

39 R&D : FEM/BEM Tools R&D on Field Calculations (HSU Hamburg) 39

40 Mittelwert 1.Maximumsbereich: 42,46 (H*q), Max. bei 88 0,0 45,0 90,0 135,0 180,0 225,0 270,0 315,0 360,0 Mittelwert 1.Maximumsbereich : 48,51 (H*q), Max. bei 73,5 Phasenwinkel / Mittelwert 2. Maximumsbereich : 55,01(H*q), Max. bei 264 Mittelwert 2.Maximumsbereich : 46,53(H*q), Max. bei 261,5 0,0 45,0 90,0 135,0 180,0 225,0 270,0 315,0 360,0 Phasenwinkel / 10/03/2010 R&D at TU Braunschweig 1. Field Related Problems ( Water Drop Corona ) 2. Interfacial Phenomena in Composite Materials Tan Delta 0,05 0,045 0,04 0,035 0,03 0,025 0,02 0,015 0,01 0, Zeit / Tage hnq(phasenwinkel)/ q*n hnq(phasenwinkel) / q*n a) Bild 6Mit b) der Impulsladung gewichtete Häufichkeits- Randverteilung a)tag 0 b)tag 14 Dynamic Drop Test Present CIGRE D1.14 /.27 40

41 R&D: New Design Tools (STRI Insulator Selection Tool IST ) HVAC HVDC AC/DC Solid Layer AC / KIPTS 41

42 AC KIPTS Natural Pollution Performance 123kV Insulation Length (m) Insulation Length (m) 1,8 1,7 1,6 1,5 1,4 1,3 1,2 1,1 1,0 0,9 0,8 0,7 0,6 0,5 1,1 1,0 0,9 0,8 0,7 0,6 0,5 Glass Antifog 33mm/kV 0,001 0,01 0,1 1 Pollution Severity: 2% ESDD Level (mg/cm²) Rodurflex 31mm/kV 0,001 0,01 0,1 1 Pollution Severity: 2% ESDD Level (mg/cm²) Specific Creepage Distance (mm/kvsystem) Specific Creepage Distance (mm/kvsystem) Insulation Length (m) Insulation Length (m) 3,6 3,4 3,2 3,0 2,8 2,6 2,4 2,2 2,0 1,8 1,6 1,4 1,2 1,0 2,2 2,1 2,0 1,9 1,8 1,7 1,6 1,5 1,4 1,3 1,2 1,1 1,0 0,9 AC KIPTS Natural Pollution Performance 245kV Glass Antifog 29mm/kV 0,001 0,01 0,1 1 Pollution Severity: 2% ESDD Level (mg/cm²) Rodurflex 31mm/kV 0,001 0,01 0,1 1 Pollution Severity: 2% ESDD Level (mg/cm²) Specific Creepage Distance (mm/kvsystem) Specific Creepage Distance (mm/kvsystem) 42

43 Insulation Length (m) AC KIPTS Natural Pollution Performance 420kV 6,0 5,5 5,0 4,5 4,0 3,5 3,0 2,5 2,0 Glass Antifog 25mm/kV Specific Creepage Distance (mm/kvsystem) Insulation Length (m) 0,001 0,01 0,1 1 Pollution Severity: 2% ESDD Level (mg/cm²) 3,8 3,6 3,4 3,2 3,0 2,8 2,6 2,4 2,2 2,0 1,8 1,6 Rodurflex 25mm/kV 0,001 0,01 0,1 1 Pollution Severity: 2% ESDD Level (mg/cm²) Specific Creepage Distance (mm/kvsystem) AC KIPTS Natural Pollution Performance 550kV Insulation Length (m) 8,0 7,5 7,0 6,5 6,0 5,5 5,0 4,5 4,0 3,5 3,0 2,5 Glass Antifog 26mm/kV Specific Creepage Distance (mm/kvsystem) Insulation Length (m) 0,001 0,01 0,1 1 Pollution Severity: 2% ESDD Level (mg/cm²) 5,0 4,8 4,6 4,4 4,2 4,0 3,8 3,6 3,4 3,2 3,0 2,8 2,6 2,4 2,2 2,0 Rodurflex 28mm/kV 0,001 0,01 0,1 1 Pollution Severity: 2% ESDD Level (mg/cm²) Specific Creepage Distance (mm/kvsystem) 43

44 AC KIPTS Natural Pollution Performance 765/800kV Insulation Length (m) 12,0 11,5 11,0 10,5 10,0 9,5 9,0 8,5 8,0 7,5 7,0 6,5 6,0 5,5 5,0 4,5 4,0 3,5 Glass Antifog 24mm/kV Specific Creepage Distance (mm/kvsystem) Insulation Length (m) 7,0 6,5 6,0 5,5 5,0 4,5 4,0 3,5 3,0 0,001 0,01 0,1 1 Pollution Severity: 2% ESDD Level (mg/cm²) Rodurflex 24mm/kV 0,001 0,01 0,1 1 Pollution Severity: 2% ESDD Level (mg/cm²) Specific Creepage Distance (mm/kvsystem) THANK YOU FOR LISTENING! 44