Saudi Electricity Company

SEC DISTRIBUTION MATERIALS SPECIFICATION

15-SDMS-02 DATE: 11-06-2011G

15-SDMS-02

SPECIFICATION FOR
OVERHEAD LINE POLYMERIC INSULATORS

This specification is property of SEC and subject to change or modification without any notice

Saudi Electricity Company

SEC DISTRIBUTION MATERIALS SPECIFICATION

15-SDMS-02 DATE: 11-06-2011G

TABLE OF CONTENTS 1- SCOPE 2- CROSS REFERENCES 3- APPLICABLE CODES AND STANDARDS 4- DESIGN AND CONSTRUCTION REQUIREMENTS 4.1 GENERAL 4.2 DESIGN CRITERIA 4.3 MATERIALS 4.4 CONSTRUCTION 4.5 MOUNTING 4.6 MARKING 5- TESTING AND INSPECTION 5.1 DESIGN TEST 5.2 TYPE TESTS 5.3 SAMPLE TESTS 5.4 ROUTINE TESTS 5.5 SPECIAL TESTS 5.6 INSPECTION 6- PACKING AND SHIPMENT 7- GUARANTEE 8- SUBMITTALS 9- TECHNICAL DATA SCHEDULE 10- DRAWINGS 2 2 2 5 5 5 6 7 9 9 10 10 10 11 11 11 12 12 12 13 14 18

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Saudi Electricity Company

SEC DISTRIBUTION MATERIALS SPECIFICATION

15-SDMS-02 DATE: 11-06-2011G

1.0

SCOPE This SEC Distribution Materials Specification (SDMS) specifies the minimum technical requirement for design, materials, manufacturing, testing, and performance of the following polymeric insulators: 1.1 1.2 13.8 & 33 KV Line post type insulators 13.8 & 33 KV Suspension/Tension type insulators

These insulators are intended to be used in the overhead line distribution system of the Saudi Electricity Company (SEC) mainly in coastal and highly polluted areas. 2.0 CROSS REFERENCES 2.1 This SDMS shall always be read in conjunction with SEC General Specification No. 01-SDMS-01 (Latest Revision) titled General Requirements for all Equipment/Materials, which shall be considered as an integral part of this SDMS. 2.2 For service conditions/system parameters refer to SEC General Specification No. 01-SDMS-01 (Latest Revision). 2.3 This SDMS shall also be read in conjunction with SEC Purchase Order or Contract Schedules and the Scope of Work and Technical Specifications for projects, as applicable. 3.0 APPLICABLE CODES AND STANDARDS The latest revision of the following codes and standards shall be applicable for the equipment/material covered in this SDMS. In case of any deviation, the vendor/ manufacturer may propose equipment/ material, conforming to an alternate code or standard. However, the provisions of SEC standards shall supersede the provisions of these alternate standards in case of any difference.

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Saudi Electricity Company

SEC DISTRIBUTION MATERIALS SPECIFICATION

15-SDMS-02 DATE: 11-06-2011G

IEC IEC 60273

International Electrotechnical Commission Characteristics of indoor and outdoor post insulators and post insulator units for systems with nominal voltages greater than 1000V. Radio interference test on high voltage insulators. Characteristics of clevis and tongue couplings of string insulator units. Artificial pollution tests on high voltage insulators to be used on AC systems. Thermal Mechanical performance test and mechanical performance test on string insulator units. Characteristics of line post insulators. Selection and dimensioning of high voltage insulators intended for use in polluted conditions Part 1: Definitions, information and principles. Selection and dimensioning of high voltage insulators intended for use in polluted conditions Part 3: Polymer insulators for a. c. systems. Electrical insulating materials used under severe ambient conditions Test methods for evaluating resistance to tracking and erosion. Insulators for overhead lines composite suspension and tension Insulators for AC systems with nominal voltage greater than 1000V Definitions, test methods and acceptance criteria. Composite string insulator units for overhead lines with a nominal voltage greater than 1000V Part 1: Standard strength classes and fittings.

IEC 60437 IEC 60471

IEC 60507

IEC 60575

IEC60720 IEC /TS 60815-1

IEC /TS 60815-3

IEC 60587

IEC 61109

IEC 61466-1

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SEC DISTRIBUTION MATERIALS SPECIFICATION

15-SDMS-02 DATE: 11-06-2011G

IEC 611466-2

Composite string insulator units for overhead lines with a nominal voltage greater than 1000V Part 2: Dimensional and electrical characteristics. Insulators for overhead lines Insulator strings and sets for lines with nominal voltage above 1000V AC power arc tests. Insulators for overhead lines Composite line post insulators for A. C. systems with a nominal voltage greater than 1000V Definitions, test methods and acceptance criteria. Guidance on the measurement of wettability of insulator surfaces. Polymeric insulators for indoor and outdoor use with a nominal voltage greater than 1000V General definitions, test methods and acceptance criteria. Selection guide for polymeric materials for outdoor use under HV stress. American National Standards Institute Test methods for electrical power insulators. Insulators Composite Distribution Dead End Type. Insulators Composite Distribution Line Post Type. American Society for Testing & Materials Standard specification for Zinc coating (Hot Dip) on iron and steel hardware. Standard Test Method for Rubber Property Durometer Hardness.

IEC 61467

IEC 61952

IEC TS 62073

IEC 62217

IEC TR 62039 ANSI ANSI C29.1 ANSI C29.13 ANSI C29.18 ASTM ASTM- A153

ASTM-D2240

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Saudi Electricity Company

SEC DISTRIBUTION MATERIALS SPECIFICATION

15-SDMS-02 DATE: 11-06-2011G

BS BS 3288

British Standards Institute Insulators and conductor fittings for overhead power lines (Parts 1 and 2). Galvanizing.

BS 729 IEEE IEEE Std. 957 IEEE Std. 987 4.0 4.1

IEEE Guide for Cleaning Insulators. IEEE Guide for Application of Composite Insulators.

DESIGN AND CONSTRUCTION REQUIREMENTS General 4.1.1 All types of insulators shall meet or exceed the requirements of this specification in all respects and shall consist of a single piece of silicon rubber together with the core and its metal parts to form a rigid assembly. Manufacturers drawings, as required in 01-SDMS-01, shall show the outline of the insulators together with all pertinent dimensions. Any variations in these dimensions due to manufacturing tolerances shall be indicated.

4.1.2

4.2

Design Criteria 4.2.1 Unless otherwise specified, the insulators shall be manufactured and tested in accordance with the relevant standards mentioned in clause No.3. All types of insulators should be designed according to the system parameters and service conditions given in specification 01SDMS-01. All types of insulators shall have the mechanical, electrical and insulation class ratings as given in the technical data schedules of this SDMS.

4.2.2

4.2.3

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SEC DISTRIBUTION MATERIALS SPECIFICATION

15-SDMS-02 DATE: 11-06-2011G

4.2.4

The design shall be such that stresses due to expansion and contraction in any part of the insulator shall not lead to any deterioration. Precautions shall be taken to avoid any chemical reaction between insulator parts and fitting material. Suspension/tension insulators shall be Clevis type ANSI class 52-4 The creepage distance shall be 40 mm/KV for all types of polymeric insulators. The diameter of the polymeric insulator sheds shall not exceed 200 mm. The two types of polymeric insulators (line post and suspension/tension insulators) with creepage distance based on 40 mm/KV shall be as follows: - With total creepage distance of 552 mm for 13.8 kV. - With total creepage distance of 1320 mm for 33kV.

4.2.5 4.2.6

4.2.7

4.2.8

4.3

Materials 4.3.1 The complete polymeric insulators shall consist of a Fiberglass Reinforced Plastic (FRP) core having superior electrical and mechanical performance, sheath (housing), sheds and mechanical fittings. To reduce the risk of brittle fracture the FRP core of polymeric insulators shall be electrical corrosion resistant (ECR) glass rod that shall achieve the specified electrical and mechanical characteristics. The FRP core shall be resistant against hydrolysis under service conditions. The polymeric insulators sheath and sheds material shall have a chemical structure of 100 percent silicone rubber before adding fillers. The finished product shall be ultraviolet (UV) radiation exposure resistant. The finished product shall not be affected by atmospheric conditions due to weather, proximity to the coast, fumes, ozone, acids, alkalis, dust or rapid changes in air temperature. There should be no material degradation such as
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4.3.2

4.3.3

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SEC DISTRIBUTION MATERIALS SPECIFICATION

15-SDMS-02 DATE: 11-06-2011G

development of surface cracks and increase in surface hardness, etc. 4.3.4 Metal parts shall be made of a good commercial grade of malleable iron, ductile iron or steel, galvanized in accordance with specification 01-SDMS-01. The track resistance of the sheath and shed materials shall meet the requirements of IEC 60587 Method 1 Class 1A4.5 or 1B4.5 or Method 2 Class 2A4.5. The sheath and shed materials of insulators fabricated from high temperature vulcanized silicone rubber shall have a Shore 'A" hardness of not less than 60.

4.3.5

4.3.6

4.4

Construction 4.4.1 The polymeric insulator surface shall be shaped and spaced for effective natural cleaning and effective use of creepage distance for coastal and desert conditions. The polymeric insulators shall be of alternating shed design with aerodynamic type profile and without any under-ribs. Sheds shall be at intervals to provide optimum electrical performance and shed design shall provide a protected bottom surface that tends to keep dry in wet conditions. The contours of the metal and polymer parts shall be such as to eliminate areas of high electrical stress concentrations. The polymeric insulator core shall be electrically and mechanically sound, free of cracks and voids, foreign substances and manufacturing flaws. The design shall be such as to ensure that the core is totally encapsulated and fully sealed, from live end to earthed end, by the insulating material to prevent ingress of moisture. If any adhesive substances are used as sealers, they shall not be exposed to environmental conditions. There shall be no holes or splits in the housing at any point along the length of the insulators.

4.4.2

4.4.3

4.4.4

4.4.5

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Saudi Electricity Company

SEC DISTRIBUTION MATERIALS SPECIFICATION

15-SDMS-02 DATE: 11-06-2011G

4.4.6

The strength of the silicone rubber to FRP core and shed to sheath interface shall be greater than the tearing strength of the silicone rubber. The insulators shall be of sufficient length to provide the required creepage distance and the electrical performance in one single unit. Inline coupling of two or more units shall not be acceptable. No radial joints shall be made along the length of the sheath regardless of the distance between end fittings. The sheath shall be extended inside the end fittings to protect and hermetically seal the fiberglass core from moisture. The interface between the FRP core and end fittings shall be sealed to effectively eliminate the possibility of moisture ingress for the life of the insulator. A level of redundancy in design shall be demonstrated. The polymeric insulators thickness of the sheath or shed covering over the core shall be greater than 3.0 mm. The contours of metal parts of polymeric insulators shall be such as to eliminate areas of high electrical stress concentrations. The polymeric insulators shall be capable of withstanding high pressure power washing. The polymeric suspension/tension insulator end fittings shall be designed to transmit the mechanical load to FRP core and to develop uniform and consistent mechanical strength of the insulators. The polymeric insulator end fittings shall be attached to the FRP core through compression crimping process so that the end fittings uniformly transmit the mechanical load to the FRP core. The crimping process shall be controlled by a specific method such as Acoustic Emission Detector to ensure that there is no damage to the core during the compression crimping operation. The end fittings of the polymeric insulators after complete assembly with the FRP core shall be coaxial with one another. The insulator shall be radio interference free at operating voltage.

4.4.7

4.4.8

4.4.9

4.4.10

4.4.11

4.4.12

4.4.13

4.4.14

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SEC DISTRIBUTION MATERIALS SPECIFICATION

15-SDMS-02 DATE: 11-06-2011G

4.4.15

All ferrous components except those made of stainless steel shall be galvanized.

4.5

Mounting 4.5.1 Line Post Insulator a. The line post insulator bottom and the stud shall be serrated to lock the stud against loosening due to line vibration as shown in attached drawings. b. The stud for the line post insulator shall be hot- dip galvanized in accordance with appropriate industry standard and complete with nuts and washers for steel crossarm mounting. The size and dimensions are given in the attached drawing No. 5. c. Suspension/Tension Insulator shall be Clevis type as shown in the attached drawing No. 6.

4.6 Marking 4.6.1 Each insulator shall bear permanent marking in English and/or Arabic as per ANSI or IEC Standards, use of stickers/labels is not permitted. Following information shall be provided: a. b. c. d. Manufacturer name. Year of manufacturing. Designation number. Cantilever strength (Combined M&E strength suspension insulator). e. Country of origin. 4.6.2 Crate Marking (English and/or Arabic): a. b. c. d. e. f. Nominal System voltage. Type and number of insulators (Suspension and Line post). SEC purchase order number / contract number. 15-SDMS-02. SEC Item number. Manufacturers Catalog No.
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SEC DISTRIBUTION MATERIALS SPECIFICATION

15-SDMS-02 DATE: 11-06-2011G

g. Weight, Kg. h. Manufacturer's name / Country of origin. 5.0 TESTING AND INSPECTION All test results shall be provided for review and acceptance by SEC. 5.1 Design Tests Suspension / Tension Insulators (Clause 10 of IEC 61109) a) Tests of interface and connections of end fittings. b) Tests on shed and housing material. c) Tests on the core material. d) Assembled core load-time test. Post Insulators (Clause 10 of IEC 61952) a) Tests of interface and connections of end fittings. b) Tests on shed and housing material. c) Tests on the core material. d) Assembled core load-time test. 5.2 Type Tests Electrical Suspension / Tension Insulators (Clause 11.1 of IEC 61109) a) Dry lightning impulse withstand voltage test. b) Wet power-frequency test. Post Insulators (Clause 11.1 of IEC 61952) a) Dry lightning impulse withstand voltage test. b) Wet power-frequency test. Mechanical Suspension / Tension Insulators (Clause 11.2 of IEC 61109) Damage limit proof test of the tightness of the interface between end fittings and insulator housing.

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Saudi Electricity Company

SEC DISTRIBUTION MATERIALS SPECIFICATION

15-SDMS-02 DATE: 11-06-2011G

Post Insulators (Clause 11.2 of IEC 61952) Cantilever failing load test. 5.3 Sample Tests These tests are optional and shall be performed if requested by SEC. Suspension / Tension Insulators (Clause 12 of IEC 61109) a) Verification of dimensions. b) Verification of the locking system. c) Verification of the tightness of the interface between end fittings and insulator housing. d) Verification of the Specified Mechanical Load (SML). e) Galvanizing Test. Post Insulators (Clause 12 of IEC 61952) a) Verifications of dimensions. b) Galvanizing Test. c) Verification of Specified Cantilever Load (SCL). 5.4 Routine Tests Suspension / Tension Insulators (Clause 13 of IEC 61109) a) Mechanical routine test. b) Visual examination. Post Insulators (Clause 13 of IEC 61952) a) Tensile/cantilever load test. b) Visual Examination. 5.5 Special Tests 5.5.1 Salt Fog Test per Clause 7 of IEC 60507 with salt concentration of 224 Kg/m3 at 20 C. 5.5.2 Torsional Load Test per Clause 7.8 of ANSI C29.13. 5.5.3 Power Arc Test per Clause 7.5 of ANSI C29.13 for suspension/tension insulators or ANSI C29.18 for post insulators. 5.5.4 The resistance of FRP core against brittle fracture shall be proved by a test against stress corrosion. The test shall be similar to mechanical load time test per Clause 10.4.2.2 of IEC 61109 but with simultaneous
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SEC DISTRIBUTION MATERIALS SPECIFICATION

15-SDMS-02 DATE: 11-06-2011G

application of 1mol/l nitric acid HNO3 directly in contact with the FRP core with a length of not less than 40 mm. 5.6 Inspection SEC may wish to witness tests or visit the factory during manufacture of any or all Items covered by this specification. Accordingly the supplier shall give the purchaser adequate notice of manufacturing program and tests to be witnessed. SEC may require certificates and data from the manufacturer/supplier on all pertinent aspects of the manufacturing process. However for detailed inspection conditions refer to the latest revision of the SEC general specification No 01-SDMS-01, clause 6 latest revision. 6.0 PACKING AND SHIPMENT In addition to the applicable items per 01-SDMS-01 latest revision, packing and shipping of the insulators shall conform to the following: a. All parts shall be carefully packed for transport in such a manner that they are protected against mechanical damage and climatic conditions during transportation or storage. b. Suppliers shall contact Materials Supply Department for additional packing, handling and shipment instructions, as applicable. c. Packing marking shall be as per clause 4.6.2 of this specification. 7.0 7.1 GUARANTEE Supplier shall guarantee the polymeric insulators against all defects arising out of faulty design, workmanship, or defective material for a period of two (2) years from date of delivery. If no exceptions are taken to this specification and no list of deviation is submitted, it shall be deemed that in every respect the offered insulators conform to this specification. SEC interpretation of this specification shall be accepted.

7.2

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SEC DISTRIBUTION MATERIALS SPECIFICATION

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8.0 8.1

SUBMITTALS Submittals required with tender: 8.1.1 The vendor shall complete and return one copy of the attached technical data schedule and clause by clause compliance statement to this specification with quotation. Detailed dimensional drawing of insulators. Type test certificates. Catalogues.

8.1.2 8.1.3 8.1.4 8.2

Submittals required following award of contract are given below. 8.2.1 8.2.2 Manufacturing schedule, progress report and test schedule. Test reports.

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SEC DISTRIBUTION MATERIALS SPECIFICATION

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9. TECHNICAL DATA SCHEDULE 9.1 LINE POST INSULATOR 13.8 kV CREEPAGE DISTANCE 552 mm
NO 1 2 3 4 5 6 7 8 9 10 11 DESCRIPTION NOMINAL SYSTEM VOLTAGE INSULATING MATERIAL COLOUR OF INSULATOR NUMBER OF SHEDS TIE TOP RADIUS SIDE TIE RADIUS NECK DIAMETER TOTAL LENGTH SHED DIAMETER MIN. CREEPAGE /KV TOTAL CREEPAGE DISTANCE DRY ARCING DISTANCE CANTILEVER STRENGTH FLASH OVER VOLTAGE POWER FREQUENCY (DRY) POWER FREQUENCY (WET) IMPULSE +VE IMPULSE VE WITHSTAND VOLTAGE POWER FREQUENCY (DRY) POWER FREQUENCY (WET) IMPULSE +VE IMPULSE VE MAX. R.I. VALUE AT TEST VOLTAGE OF 22 KV STUD SIZE COMPLETE WITH STUDS WEIGHT OF INSULATOR MARKING Kg mm mm mm mm mm mm mm mm KN UNIT kV SEC REQUIREMENTS 13.8 SILICONE RUBBER GRAY BY VENDOR 25 25 73 305 5 <200 40 552 241 12.5 110 85 180 205 90 65 150 150 100 M20 SHORT STUD BY VENDOR BY VENDOR BIDDER DATA

12

Kv

13

Kv

14 15 16 17 18

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9. TECHNICAL DATA SCHEDULE 9.2 LINE POST INSULATOR 33 kV CREEPAGE DISTANCE 1320 mm.
NO 1 2 3 4 5 6 7 8 9 10 11 DESCRIPTION NOMINAL SYSTEM VOLTAGE INSULATING MATERIAL COLOUR OF INSULATOR NUMBER OF SHEDS TIE TOP RADIUS SIDE TIE RADIUS NECK DIAMETER TOTAL LENGTH SHED DIAMETER MIN. CREEPAGE /KV TOTAL CREEPAGE DISTANCE DRY ARCING DISTANCE CANTILEVER STRENGTH FLASH OVER VOLTAGE POWER FREQUENCY (DRY) POWER FREQUENCY (WET) IMPULSE +VE IMPULSE -VE WITHSTAND VOLTAGE POWER FREQUENCY (DRY) POWER FREQUENCY (WET) IMPULSE +VE IMPULSE -VE MAX. R.I. VALUE AT TEST VOLTAGE OF 44 KV STUD SIZE COMPLETE WITH STUDS WEIGHT OF INSULATOR MARKING Kg mm mm mm mm mm mm mm mm KN UNIT KV SEC REQUIREMENTS 33 SILICONE RUBBER GRAY BY VENDOR 25 25 73 510 5 <200 40 1320 438 12.5 175 150 290 380 160 135 250 250 200 M20 SHORT STUD BY VENDOR BY VENDOR BIDDER DATA

12

kV

13

kV

14 15 16 17 18

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SEC DISTRIBUTION MATERIALS SPECIFICATION

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9. TECHNICAL DATA SCHEDULE 9.3 SUSPENSION/TENSION INSULATOR 13.8 kV CREEPAGE DISTANCE 552 mm.
NO 1 2 3 4 5 6 7 8 9 10 DESCRIPTION NOMINAL SYSTEM VOLTAGE INSULATING MATERIAL COLOUR OF INSULATOR NUMBER OF SHEDS TOTAL LENGTH SHED DIAMETER MIN. CREEPAGE /KV TOTAL CREEPAGE DISTANCE DRY ARCING DISTANCE TENSION STRENGTH FLASH OVER VOLTAGE POWER FREQUENCY (DRY) POWER FREQUENCY (WET) IMPULSE +VE IMPULSE VE WITHSTAND VOLTAGE POWER FREQUENCY (DRY) POWER FREQUENCY (WET) IMPULSE +VE IMPULSE VE MAX. R.I. VALUE AT TEST VOLTAGE OF 22 KV WEIGHT OF INSULATOR MARKING mm mm mm mm mm KN UNIT kV SEC REQUIREMENTS 13.8 SILICONE RUBBER GRAY BY VENDOR BY VENDOR <200 40 552 241 70 110 85 180 205 90 65 150 150 100 BY VENDOR BY VENDOR BIDDER DATA

11

Kv

12

Kv

13 14 15

V Kg

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SEC DISTRIBUTION MATERIALS SPECIFICATION

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9. TECHNICAL DATA SCHEDULE 9.4 SUSPENSION/TENSION INSULATOR 33 kV CREEPAGE DISTANCE 1320 mm.
SEC REQUIREMENTS 33 SILICONE RUBBER GRAY BY VENDOR mm mm mm mm mm KN BY VENDOR <200 40 1320 438 70 175 150 290 380 160 135 250 250 200 BY VENDOR BY VENDOR BIDDER DATA

NO 1 2 3 4 5 6 7 8 9 10

DESCRIPTION NOMINAL SYSTEM VOLTAGE INSULATING MATERIAL COLOUR OF INSULATOR NUMBER OF SHEDS TOTAL LENGTH SHED DIAMETER MIN. CREEPAGE /KV TOTAL CREEPAGE DISTANCE DRY ARCING DISTANCE TENSION STRENGTH FLASH OVER VOLTAGE POWER FREQUENCY (DRY) POWER FREQUENCY (WET) IMPULSE +VE IMPULSE -VE WITHSTAND VOLTAGE POWER FREQUENCY (DRY) POWER FREQUENCY (WET) IMPULSE +VE IMPULSE -VE MAX. R.I. VALUE AT TEST VOLTAGE OF 44 KV WEIGHT OF INSULATOR MARKING

UNIT KV

11

kV

12

kV

13 14 15

V Kg

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