2010, 12th International Conference on Optimization of Electrical and Electronic Equipment, OPTIM 2010

High-Voltage Ceramic Station Post Insulators

- Least-Effort Determination of Bending Strength
under Short-Circuit -
Norbert Stein*, Amir M. Miri**

* FGH Forschungsgemeinschaft für elektrische Anlagen und Stromwirtschaft

Hallenweg 40, D-68219 Mannheim, Germany. email: norbert.stein@fgh-ma.de

** Universität Karlsruhe, IEH, D-76128 Karlsruhe, Germany

email: miri@ieh.etec.uni-karlsruhe.de

Abstract - Stress concentrations due to the rather abrupt
variation of the cross-section at the transitions from core to
shed have an important influence on the elastic material
stresses and the allowable loading of ceramic insulators.
For the user the effect is of immediate relevance only for the
non-quasi-static dynamic bending case, which is the
prevailing short-circuit loading of the post insulators of a
substation. It can be described in terms of local stress-
concentration factors.
The paper reports on a special Finite-Element calculation
method allowing to determine the required sets of
concentration factors of insulator types with least
discretisation- and computing effort possible. It thus
becomes feasible to determine the static local stress maxima
between sheds along the insulator and to derive from their
maximum value together with the rated value of Minimum
Breaking Load MBL the value of allowable material stress
inherently assigned to the insulator by the manufacturer. It
may be named Minimum Breaking Stress MBS. Since [1]
rates dynamic material strength as not lower than static, a
general dynamic strength analysis can be performed.
Exemplary results from static and dynamic studies on a
standard type 110 kV post insulator are presented, that are
supported by static test results.
The studies show that the dynamic cros-sectional stress
distribution differs from the static case and results in higher
stress-concentration factors than the respective static. Yet,
test experience [2, 3, 4] have shown that the slow dynamic
response of the insulator may compensate fast loading
effects as regards its strength. Yet, this particular influence
requires more and closer study to come to a simplified
determination of the Equivalent Static Loads (ESL) for the
dynamic short-circuit case.
computational effort and in the interest of the simplicity
of the calculation method, the structural analysis of a
complex large-scale system as an open-air substation
requires restrictions in the detailedness of modelling of
the structural components sufficient to achieve so-called
global identity of the dynamic behaviour, i.e. displace -
ments, of the complete mechanical structure – the system
of conductors and their supporting elements and sub-
structures.
In the case of a post insulator, that, on short-circuit, is
subjected to bending, this results in its reduction to a
cylindrical or conical, even, that is shed-less, beam of
identical lateral oscillatory behaviour. This procedure
fully satisfies the immediate purposes.
Problems may arise in the subsequent consideration of
strength, i.e. the withstand to the calculated short-circuit
loadings, where the ceramic post insulators represent a
particularly sensitive component. Ceramic material,
unlike that of the metallic structural components, does not
possess their ductile phase strength reserve, so that
overloading will immediately result in failure.
The general insulator strength consideration requires
the knowledge of
- the absolute maximum value of material constraints
of the insulator over the local and time domains and
- the respective maximum allowable stress value.
A. Maximum Material Stress

Tests and calculations [4, 5, 6], and in particular this

I. INTRODUCTION
paper, show that the sheds of insulators, due the rather
abrupt variation of the cross section at the transitions
The state of the art of assessing the mechanical effects
between core and shed, result in massive stress
of short-circuit currents in high-voltage substations is col-
concentrations of a size that, on cantilever loading, has an
lected in [3] prepared by the ESCC-TF of CIGRE 23-11.
important impact on the local cross-sectional stress
For reasons of practical feasibility in preparatory and
maxima. The same effect, while existing to a lesser

978-1-4244-7020-4/10/$26.00 '2010 IEEE 118

degree for other types of loading, is of immediate
practical importance only in the considered case of
dynamic bending.
The maximum material constraints of the genuine
insulator with sheds are therefore relevantly higher than
the respective determined for the shed-less insulator
model.
B. Stress-Concentration Factor
The actual maximum bending constraint at a particular
coordinate transition area on the genuine insulator can be
expressed as the respective value on the same-diameter-
core model insulator multiplied by the local stress-
concentration factor. The factor relates to the insulator
type, the considered transition area on the insulator and
the type of loading - bending in our case. If cross-
sectional stress distribution varies between static and a
dynamic case, the respective factor also relates to the
loading time function.
The factor must also relate to the strength hypothesis to
be applied for the considered loading case and material.
C. Strength Hypothesis
For the case of brittle material, as ceramics, were
failing occurs without a marked plastic strain, the strength
hypothesis of maximum principal stress shall be applied.
Stress-concentration factors k must therefore relate onto
σ1, hence k1 .
D. Maximum allowable stress
As the sole mechanical rated value as regards bending
loadability of the post insulator the manufacturer assigns
the Minimum Breaking Load MBL , the permissible static
bending force at the insulator head and equivalent to
permissible bending moments. Although the MBL
inherently contains a static value of allowable material
stress MBS, this value is not known.
The inherent value of MBS could be easily determined
if the stress-concentration factors k1 of the insulator for
static bending were known.
After [1] and [4] the static value of porcelain material
strength may be also applied for the dynamic short-circuit
case.
E. Post-Insulator Strength
The withstand of a post insulator can so far only
judged for the cases of static to quasi- static bending. The
latter case may be assumed for quite a number of open-air
substation layouts. The fall-of-span of stranded conductors is a
119
good example for it, while the so-called pinch force of bundle
conductors is certainly not.
F. Dynamic strength
The designer needs a practicable, i.e. relatively
uncomplicated procedure for judging the dynamic
strength of a post insulator. This could be achieved by
furnishing a set of k-factors for the respective insulator
type. Then, it becomes possible to determine the relevant
genuine stress values on the insulator from the respective
values of the global approach and, on the other hand, the
required value of maximum allowable stress MBS
inherently given by the rated MBL. The subsequent
analysis must consider the domains of coordinates plus
time.
The following reports on the application, testing and
on exemplary results of a special Finite Element
technique, that represents the least-effort method - in
terms of least preparatory and computational effort
achievable – to determine the detailed stresses on a
genuine insulator with sheds for any form and material of
insulator and any loading time function.
II. CALCULATION METHOD
The insulator subjected to bending represents an axi-
symmetric structure under non-axisymmetric loading, i.e.
not a completely axisymmetric problem that could be
treated as plane. In principle the actual problem can be
solved applying 3-dimensional FEM elements.
Yet, a special FE type - the so-called Harmonic
Element – gives the possibility to treat our non-
axisymmetric problem in a quasi-axisymmetric manner
[8-15], thus allowing to make use of the really enormous
effort reducing advantages of the plane FE model. Only,
the application of that method brings the problem
solution into an affordable range for normal computers.
The harmonic element is called special in-so-far, as
only a small number of commercial FE-programs offer
this type of analysis.
The special feature of the harmonic elements is, that
the circumferential load need not be evenly distributed as
for a „plane“ problem and thus permits a non-
axisymmetric loading. For these elements a distributed
load F‘(θ) is developed into a Fourier series of harmonic
load functions, where θ is the circumferential coordinate:
F‘(θ) = A0+A1cosθ +B1sinθ + ........ + Ancos(nθ) +
Bnsin(nθ) (1)
In principle any load distribution can thus be modelled
using the appropiate number of terms, where each term
will require a separate analysis and the effects have to be
superimposed. If only the term A0 is specified, we have
the case of ideal axisymmetric loading. III. EXEMPLARY CALCULATIONS

The non-axisymmetric loading of the insulator with a
single bending force may be treated with just one term of
the first harmonic, using either one or two components,
see Fig.1, thus only requiring a single analysis per time
step. Version b) that defines a resultant uniform lateral
load in the global x-direction was used in the
calculations.
The first HE-studies on insulators, static as well as
dynamic, were performed on the 17 shed, 110 kV, 800 kp
MBL post insulator Z110N-800 DIN 48120 that had been
the object of [4] and [5] and of which, therefore, more
data than usual were known. On a remaining specimen
from [4] strain-gauge measurements of a higher precision
than in [5] were also done.

For comparison a second insulator of identical general

geometries (height, core diameters), fittings and MBL but
with the higher number of 23 sheds, alternating large and
smaller sheds, was then also analyzed with the intent to
increase experience, extend the number of sets of data
and to demonstrate trends.

The following general results of a more principial

nature relate to the 17 shed DIN insulator. The results of
the studies in terms of actual values, tendencies and
general conclusions are to be found in chapter IV. below.
Fig. 1 Versions of load distribution using the A1-term of Eq. (1)

In the present context, it is important to note that the

Harmonic-Element technique can also be applied for
modal analysis, the eigenfrequencies, that are, together
with the displacements, the essential and available control
data for checking the quality of any model. A further
effort reduction advantage is, that only half of the
longtudinal cross-section, see Fig.2, need be discretized.
The FE-analysis computer program used in the study was
ANSYS [14, 15] of Swanson Analysis Systems, Inc. .

A. Test versus analytically accessible data

A cylindrical beam, one end fixed, the other end free

can be assessed with precision by the analytical methods
of elastic theory. Therefore, the quality of the method
was checked for a not too finely discretized harmonic
element model of a beam versus the usual analysis of the
same beam, both with a perpendicular bending force at
the free end. Global geometries and material data were
those of the 110 kV insulators used in [4].

The relative deviations of the characteristic values

determined with the HE-model against the analytic
calculation are convincingly small:

- Maximum displacement 0.85 %

- Maximum bending stress 0.43 %
- First eigenfrequency 0.27 %
- Second eigenfrequency 3.3 %
- Third eigenfrequency 7.3 %

In a further stage of the study, method and calculation Fig.2 Harmonic-element model of Z110N-800 DIN 48120,
were also checked against strain-gauge measurements on lower part with sheds S1 to S5 shown
one of the exemplary insulator types; see III.C below.

120
A. Harmonic-element insulator model
The DIN-insulator was discretized into a harmonic-
element model of ca. 3500 elements and 4500 nodes,
requiring a CPU time of ca. 20 s for a static run on a
2.5 GHz PC. Fig.2 shows the lower part of the
insulating body.
B. Static calculation
The results of a static run for a bending load of 1,75
kN in terms of the principal stresses σ1 along the surface
of the insulating body is shown in Fig. 3 . Coordinate h
is the coordinate Y of Fig.2 .
Fig.3 Calculated principal stress σ1 on the insulator surface and
reference value σ1r for the shed-less insulator of same
core diameter
Fig. 4 shows the resulting stress-concentration factors
k1 = σ /σ1r for the values of Fig. 3 . The absolute
maximum directly above shed S1 is 1.6 , while the
maxima upwards from this point are constant with values
of 1.5 .
Fig.4 Calculated stress-concentration factors k1
It should be noted that even the cylindrical parts
between sheds show an increase of bending stress of
nearly 10% against the shedless insulator. The stress-
concentration factors to be applied in actual strength
considerations are the regional maxima.
121
Fig. 5 , showing iso-stress lines for the region of the
lowest sheds S1 and S2, demonstrates the stress
concentrations at the transitions from core to shed, giving
also the respective values of k1 .
Fig. 5 Calculated iso-stress lines for region of lowest sheds S1
and S2 and values k1 at the transition points
C. Test of calculated against measured values
The calculation could be checked against measure-
ments from bending tests performed on the same
insulator. By means of strain gauges the specific material
elongation on the porcelain surface - strain - can be
measured.
Between the lower sheds S1 and S2, where calculation
had shown the highest material contraints, the
outer fibre strains in the principal bending plane were
measured with applied chains of strain gauges. The
chains consisted each of 10 individual strain gauges with
an active length of 1.5 mm that were spaced at 2 mm. The
parameters used for the tests corresponded to those of the
calculation.
The tangential strain of the FE analysis ε is to be
determined with
εyy = 1/E {σyy - ν (σxx +σzz)} (2)
Due to the modelling technique the tensor component
σyy of the calculation is always tangential to the surface
and σyy and εyy are unidirectional. E was taken from [4]
with 89000 N/mm2 and Poisson‘s ratio ν was applied with
0.3 .
Fig.6 a) shows the calculated values of surface strain
against the strain-gauge measurements from 4 separate
tests in 6 b). The agreement satisfies in all respects and
in particular for the absolute maximum value near shed
S1. Small differences near shed S2 can be explained by
the slight geometrical differences between the DIN
insulator used for calculation and the actual insulator
used for tests.
 IV. DYNAMIC CALCULATION

The performance of the harmonic FE-model in the

static and modal analysis shows its suitability also to
simulate the dynamic. Beside their value as criterion for
compatibility, the eigenfrequencies give indications as to
requirements as to integration time steps.

A. Time-function of the loading

For the dynamic analysis the time function of the

dynamic tests [4] was adopted. It is based on the two-
phase short-circuit time function of force for a maximum
force value of 8000 N, which is the MBL of the
considered insulator – see Fig. 7 . The rate-of-rise dF/dt
of the bending force represents one of the possible
extrema of the short-circuit dynamic range. Pinch forces
of bundled conductors could form another, higher one.

Fig. 6 Outer fibre strain ε between lowest sheds S1 and S2

a) Calculation with Harmonic Elements
Fig. 7 Dyn. bending force on the post insulator of 8 kN MBL
b) Measurement with strain-gauge chains in 4 separate 1 2-phase short-circuit force
test series 2 Time function of the applied bending force

D. Modal Analysis B. Damping

Besides the displacements, the modal analysis of the
HE-model of the genuine insulator against the global
technique reference model, represents the most important
feature for checking the conformity in their oscillatory
properties and behaviour and, hence, for the practical
applicability of the stress-concentration factors.
After test calculations without damping and structural
damping ratios of 3% and 7% , the following calculations
used a realistic value of 3%, also proposed in [7] .
C. Dynamic Stresses

For all specimen of the post insulators used in [4] the Fig. 8 gives the results of a dynamic run in terms of the
first eigenfrequencies were measured and also on some principal stresses σ1 for a number of significant time
the second and the third. steps.

The following assembles the values from the modal The parameter of the curves is time. It can be clearly
analysis performed on the HE-model versus the distinguished, how the point of highest stress moves into
measurements of [4]. The good agreement is obvious. and through the structure starting from the top.

Calculated Measured At t = 10 ms a „static“ distribution is reached. This

1. Eigenfrequency/Hz 44 41-47; mean 44 time coincides with the moment, where the maximum of
2. Eigenfrequency/Hz 287 264-278 the dynamic stress-concentration factor k1(t) curve is
3. Eigenfrequency/Hz 788 769-773 reached – see D below .

122
D. Dynamic stress-concentration factor
For the determination of dynamic k-factors also the
reference model has to be subjected to the same time
functions. To be applicable in practice, the reference
insulator of identical core diameters had to be modelled
with the usual beam elements to identical oscillatory
behaviour – displacements, eigenfrequencies, damping.
Beside their known variations with the coordinate of
height, the dynamic factors also vary with time, as it is
Fig. 8 Calculated principal stress σ1 on the insulator surface at
dynamic loading . Parameter: time step
shown in Fig. 9 for the node of highest stress just above
shed S1. The maximum is reached at about 10 ms –
compare the loading time function.
Fig. 9 Variation of the local stress-concentration factor k1 with
time
123
In principle, it seems reasonable to apply these regional
dynamic maximum values k1(t and h), that could be
named k1max , for the practical assessment of dynamic
maximum stress. They have the rate-of-rise of the
loading time function as upper limiting parameter.
As shown in exemplary form in Fig. 10 a) for the DIN
insulator and in Fig. 10 b) for the 26 shed insulator of
same height mentioned 2nd paragraph of chapter III. ,
analysed under completely identical parameters, the
regional dynamic maximum values k1max are distinctly
above the respective static values. The values 1.6 and 1.7
for the 17 shed and the 23 shed insulator are the absolute
static maxima. The respective ratios dynamic/static are
quite considerable 1.18 and 1.23 .
The fact that the dynamic cross-sectional stress
distributions are different from the static makes strength
considerations more complicated in an unexpected and so
far undefined extent.
Fig. 10 Comparison of static and dynamic k1 factors
a) 17 shed DIN post insulator
b) 23 shed post insulator
V. SUMMARY, REQUIREMENT FOR FURTHER
WORK, FINAL REMARKS
The studies were designed to find the principle of a
practicable general access to the assessment of the
dynamic short-circuit strength for high-volltage post
insulators, i.e. the easier access to the determination of
the so-called Equivalent Static Load ESL defining the
ultimate allowable dynamic loading
 The applied Finite Element technique of Harmonic
Elements has been successfully tested and found
particularly suited to tackle the problem with least effort
in terms of preparation and solution of the structural
analysis problem, particularly on smaller computers.
The achieved calculation results have been shown to
be extremely accurate and have been checked against test
results.
The results of the voluminous study have brought the
intended aim considerably nearer, yet, have also detected
unforseen new problems – the dependency of stress-con-
centration factors on the loading time function - that need
to be object of further studies. In so far, only a narrower
spectrum than hoped for, but covering the applications
with rigid conductors, was achieved.
Studies on other insulator types, faster (pinch force)
time functions, as well as a closer look on the transitions
of the insulating body to the metal fittings, in particular at
the bottom end are needed. The, at once, safe and
economic selection of post - insulators is of particular
importance and the complicating influence of part of the
studies needs to be discussed among experts.
Test experience [2, 3] has shown that the slow dyna-
mic response of the insulator will usually compensate
fast loading effects as regards its strength, which may
have the consequence of a lower value of Equivalent
Static Load than the actual maximum dynamic load. Yet,
also this particular influence requires more and closer
study. Since the most effective method for further
studies is now available, tested and found most accurate,
these studies will not require a too high effort.
A consecutive study on the adaptive optimization of
the form of the problematic transitions, while keeping
creeping distances and core diameters, has been
performed after this study and has resulted, for instance,
in a reduction of the static maximum concentration factor
of the DIN- insulator by 22 % from 1.6 down to 1.25 .
Composite insulators, that are in growing use for new
substations [16], do not face the same problem as ceramic
insulators due to their silicone surface and sheds. The
elasticity of these parts is considerably higher than that of
their core and thus stress concentration is no problem at
all. Additionally composite insulators possess a so-called
safe failure mode, which is an advantage in the case of
overloading. It is envisaged to investigate in a future
study their dynamic properties under short-circuit. The
present study will keep its relevance for refurbishment,
uprating and special cases.
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