TYPE TESTS ON DISC INSULATOR

UNITS & STRINGS

 TYPE TESTS ON DISC INSULATOR
UNITS & STRINGS

1.1) On single units

Sl Nature of test Reference: standard/document

no
1 Verification of dimensions Approved drawing
Disc diameter - do -
Unit spacing - do -
Creepage distance - do -
Radial & axial run out - do -
2 Thermal Mechanical Powergrid tech specn & Cl 20 of IEC 383-
performance test 1/93
3 PF Voltage withstand and Powergrid approved GTP & Cl 20 of IEC
flashover test (Dry & Wet) 383-1/93
4 LI withstand and flashover Powergrid approved GTP & Cl 20 of IEC
test (Dry) 383-1/93
5 Visible discharge & RIV Powergrid approved GTP, IS 731/71 &
test IEC 437/97
6 Residual strength IEC 797
7 Steep wave front test Powergrid tech specn
8 Impact test Powergrid tech specn & ANSI C 29.2
1.2) On string with hardware fittings

Sl Nature of test Reference: standard/document

no
1 PF voltage withstand Cl 10 of IEC 383-2
(Wet)
2 SI voltage withstand Cl 11 of IEC 383-2
(Wet) - only on strings
used for 400 kV & above
3 LI voltage withstand & Cl 9 of IEC 383-2
flashover test (Dry)
4 Voltage distribution Powergrid tech specn
5 Mechanical strength test Powergrid tech specn
6 Vibration test Powergrid tech specn
7 Power arc test IEC 1467
8 Artificial Pollution test IEC 507
(only on anti fog discs)
 TYPE TEST PROCEDURE

TEST ON SINGLE UNITS

1) Verification of dimensions

Following physical dimensions shall be checked on 10 samples in

accordance with the drawing approved by Powergrid.

a) Disc diameter
b) Unit spacing
c) Creepage distance
d) Verification of eccentricity
e) Gauge check of socket cap & Ball pin

Disc diameter

a) Reference standard Approved drawing

a) Purpose/critically of Influences the creepage distance of the single unit and

testing also gap between insulator strings in case of double,
triple & quad strings
b) Test procedure Check the outer diameter of disc & verify compliance
with the drawing
c) Acceptance criteria 120 kN – 255 +/- 11mm, 160 kN & 210 kN 280 +/- 12
mm, 120 kN A/F – 280 +/- 12 mm, 160 kN A/F – 305 +/-
13 mm
d) Instruments used Out side caliper & scale
Unit spacing

a) Reference standard Approved drawing

b) Purpose/critically of Influences the overall length of the string and hence the
testing phase to ground clearances.

c) Test procedure Check the ball pin to ball pin distance of the single unit
& verify compliance with the drawing
d) Acceptance criteria 120 kN – 145 +/- 4 mm, 160 kN & 210 kN 170 +/- 5 mm.
e) Instruments used Marking block & vernier height gauge

Creepage distance

a) Reference: standard Approved drawing

b) Purpose/critically of Influences the electrical performance especially under

testing pollution

c) Test procedure Using adhesive tape the shortest distance between the
socket cap & pin is measured accounting only the
porcelain surface.
d) Acceptance criteria Normal disc
120 kN – 315 mm + 60/- 0
160 kN – 330 mm + 40/- 0
Anti fog
120 kN – 430 mm + 60/- 0
160 kN – 475 mm + 40/- 0
e) Instruments used Steel scale & adhesive tape

Radial & axial run out

a) Reference standard Approved drawing

b) Purpose/critically of It is a measure of alignment of socket cap, porcelain and

testing ball pin. Influences the mechanical strength of the unit

c) Test procedure The insulator is placed under light tension between

suitably mounted coupling pieces. The two coupling pieces
shall be on the same axis and shall be free to rotate. Two
dial gauges are arranged as shown so that they make
contact with the maximum diameter and at the tip of the
outer most rib. The insulator is rotated through 360 deg
and the max variation in the readings of the dial gauges is
recorded.
d) Acceptance criteria Radial run out - < 3 % of disc dia
Axial run out - < 4 % of disc dia
e) Instruments used Dial gauge
Gauge check for ball & socket coupling

a) Reference standard IEC 120

b) Purpose/critically of It is carried out to verify the compliance of the ball &

testing socket coupling with relevant gauges.

c) Test procedure The socket cap & ball pin of the insulator shall be
checked with the relevant standard calibrated ‘GO’ &
‘NOT GO’ gauges. The samples shall comply with the
standard gauges.
d) Acceptance criteria Compliance with gauges
e) Instruments used Standard Calibrated Gauges
2) Thermal Mechanical performance test

a) Reference standard Powergrid tech specn &

Cl 20 of IEC 383-1/93
b) Purpose/critically of To check the mechanical performance of the samples
testing under simultaneous tensile loading and extreme varying
temperatures.
c) Test procedure This test is carried out on 20 samples. The test is carried
out in a specially constructed thermal chamber. A tensile
load equal to 70 % of the specified EM load shall be
applied and the temperature inside the chamber shall be
varied from – 30 deg to + 40 deg C in a duration of 24
hours. Minimum tensile load of 70 % shall be maintained
through out the 24 hours duration and shall be released
and reapplied after every 24 hours. After completing 4
cycles of 24 hours each, the tensile load shall be released &
temperature brought down to the ambient and the units
shall be subjected to EMS test. No failure during thermal
cycles or during EMS test is permitted. After EMS test,
Average (X) & Standard deviation (S) is calculated &
statistically evaluated.

d) Acceptance criteria No failure during thermal cycles or during EMS test is

permitted. The test results shall meet the following
criteria.
X ≥ (R + 3 σ) where R is the rated EM strength
e) Instruments used Thermal mechanical test M/c, Tensile testing M/c & PF
transformer
 TYPICAL LOAD & TEMPERATURE CURVE

3) PF Voltage flashover & withstand test

Dry condition
a) Reference standard IEC 383-1

b) Purpose/critically of To verify the flashover & withstand voltage of the single

testing unit using PF voltage under dry condition
 c) Test procedure The test is carried out on 3 samples. Voltage is applied to
the ball pin of the insulator & the socket cap is earthed. 5
flashovers are applied & average value obtained. The
voltage is reapplied and maintained at the specified value
for a duration of 1 minute & no flashover is permitted
during this interval.. The test values are corrected to the
standard atmospheric condition. The value obtained shall
be greater than the specified value
d) Acceptance criteria 120 kN – F/o >75 kV, W/s >70 kV
160 kN – F/o >80 kV, W/s > 75 kV
e) Instruments used PF testing transformer & arrangement for suspending the
insulator in vertical condition

Wet condition
a) Reference standard IEC 383-1

b) Purpose/critically of To verify the flashover & withstand voltage of the single

testing unit using PF voltage under Wet condition

c) Test procedure The test is carried out on 3 samples. Water of specified

resistivity & precipitation is sprayed on the test sample.
After wetting the sample for 5 minutes Voltage is applied
to the ball pin of the insulator & the socket cap is earthed.
5 flashovers are applied & average value obtained. The
voltage is reapplied and maintained at the specified value
for a duration of 1 minute & no flashover is permitted
during this interval.. The test values are corrected to the
standard atmospheric condition. The value obtained shall
be greater than the specified value.
d) Acceptance criteria 120 kN – F/o >45 kV, W/s >40 kV
160 kN – F/o >50 kV, W/s > 45 kV
e) Instruments used PF testing transformer, arrangement for suspending the
insulator in vertical condition, Rain making equipment
 4) Dry LI voltage flashover & withstand test

a) Reference standard IEC 383-1

b) Purpose/criticall To verify the flashover & withstand voltage of the

y of testing single unit using LI voltage under dry condition

c) Test procedure The test is carried out on 3 samples

d) Acceptance 120 kN – 110 kV/120 kV
criteria
e) Instruments Impulse Generator
used

5) Visible discharge & RIV test

a) Reference standard IEC 60-1 & 437

b) Purpose/critically To verify the specified test voltage

of testing

c) Test procedure The test is carried out on 3 samples

d) Acceptance Visible Discharge voltage > 18 kV
criteria RIV < 50 micro Volts
e) Instruments used PF testing Transformer, RIV meter
f) Residual strength test

a) Reference standard IEC 797

b) Purpose/critically of Verification of the minimum mechanical

testing strength of insulator stubs with out shed when
used in string.
c) Test procedure This test shall be carried out on 25 samples.
Samples shall be subjected to temperature cycle
test as per IEC 383-1. The sheds shall be broken
using hammer blows and no part of the broken
shed shall be greater than the maximum
diameter of the socket cap. The stubs shall then
be subjected to tensile load applied between the
metal fittings and value recorded. Average (X)
& Standard deviation (S) of the test values shall
be calculated and compared with the factor k
(0.65)

d) Acceptance criteria (X – 1.645 σ)/R ≥ 0.65

e) Instruments used Tensile testing machine
g) Steep Front Wave test

b) Reference Powergrid technical specification

standard

c) Purpose/critically To verify the puncture withstand capability of

of testing insulator in air when subjected to impulse voltage
of high rate of raise.
d) Test procedure This test is carried out on 10 samples. Each
insulator shall be subjected to 5 positive & 5
negative impulses with effective rate of raise of
2500 kV/micro sec. Subsequently the samples shall
be subjected to PF flashover test under Dry
condition.

e) Acceptance Average of 3 PF flashovers shall not be lesser than

criteria 95 % of the specified Dry PF flashover voltage. No
puncture shall occur either during Impulse or PF
voltage application
f) Instruments used LI generator, PF test transformer

Typical wave shape

Calculation of steepness

Steepness = Voltage/Raise time

Voltage = Y x Voltage scale x divider ratio x attenuation

Where Y is the peak value measured on oscillogram

Voltage scale, divider ratio & attenuation depends on the measuring system

Raise Time = T x 2.5 x time scale

Where T is time from 50 to 90 % measured on the oscilligram.
2.5 is the factor to get 100 % time. Time scale depends on the measuring system.

h) Impact test
i) Reference Powergrid tech specn & ANSI C 29.2
standard

j) Purpose/critically To verify the withstand capability of insulator

of testing shed when subjected to mechanical impact.

k) Test procedure 3 samples shall be subjected to specified Impact

load applied to the outer most rim of the
insulator. No breakage of the insulator shed is
permitted. Subsequently the samples shall also
pass PF frequent flashover test. No puncture shall
occur during flashover test
.
l) Acceptance 7 N-m for up to 120 kN. 10N-m for above 160 kN
criteria disc insulators
m) Instruments used Impact testing machine & PF test transformer

TEST ON STRINGS WITH HARDWARE FITTINGS

a. PF voltage withstand (Wet)
a) Reference standard Cl 10 of IEC 383-2

b) Purpose/critically To verify the specified withstand voltage of the

of testing insulator string

c) Test procedure In accordance with IEC

d) Acceptance 220 kV – 460 kV, 400 kV - 680 kV
criteria
e) Instruments used PF Testing transformer

b. SI voltage withstand (Wet)

a) Reference standard Cl 11 of IEC 383-2

b) Purpose/critically To verify the specified withstand voltage of the

of testing insulator string under wet condition

c) Test procedure In accordance with IEC

d) Acceptance 400 kV - 1050 kVp
criteria
e) Instruments used Impulse Generator, Rain making equipment

c. LI voltage withstand test (Dry)

a) Reference standard Cl 9 of IEC 383-2

b) Purpose/critically To verify the specified withstand voltage of the

of testing insulator string

c) Test procedure In accordance with IEC

d) Acceptance 400 kV - 1450 kVp
criteria
e) Instruments used Impulse Generator

d. Voltage distribution (Dry)

a) Reference standard Powergrid tech specn

b) Purpose/critically To measure the distribution of voltage across an

of testing energized disc insulator string

c) Test procedure Sphere gap method, % VD = E/Vn x 100

d) Acceptance 400 kV < 10 %
criteria
e) Instruments used PF Testing transformer, Calibrated spheres
 e. Radio Interference Voltage test

a) Reference standard Powergrid tech specn

b) Purpose/critically To measure the Radio noise generated by the test

of testing sample when subjected to HV stress.

c) Test procedure IEC 60437

d) Acceptance Noise level < 60 dB @ 305 kV for 400 kV strings
criteria
e) Instruments used PF Testing transformer, Coupling capacitor,
Radio noise meter

f. Corona test

a) Reference standard Powergrid tech specn

b) Purpose/critically To measure the Corona Inception & extinction

of testing voltage on the test sample

c) Test procedure IS 731-1971

d) Acceptance Extinction voltage > 320 kV for 400 kV strings
criteria
e) Instruments used PF Testing transformer, dark test hall

g. Mechanical strength

a) Reference standard Powergrid tech specn

b) Purpose/critically To verify the Mechanical strength of the insulator

of testing set under tensile load

c) Test procedure Powergrid spec

d) Acceptance Depends on the insulator rating
criteria
e) Instruments used Tensile testing machine
 h. Vibration test

a) Reference standard Powergrid tech specn

b) Purpose/critically To verify the performance of the insulator set

of testing under Dynamic loading

c) Test procedure Powergrid spec

d) Acceptance Shall withstand 10 million cycles of vibration
criteria under specified conditions
e) Instruments used Vibration inducing equipment
 i. Power Arc test

a) Reference standard IEC 1467

b) Purpose/critically To verify the performance of the insulator set

of testing when subjected to Power Arcs

c) Test procedure IEC 1467

d) Acceptance The string shall not separate after subjected to 3
criteria shots of 40 kA for a duration of 0.2 s, 0.2 s & 0.5 s.
Subsequently the string shall withstand 80 % of
the rated tensile load
e) Instruments used Short circuit generator
 j. Artificial Pollution withstand test

a) Reference standard IEC 507

b) Purpose/critically To verify the performance of the insulators under

of testing polluted condition

c) Test procedure IEC 507, Salt fog Method & Clean fog method
d) Acceptance The string shall withstand 3 voltage applications
criteria at specified Pollution level & testing conditions
e) Instruments used PF testing transformer, Pollution chamber