UNIVERSITI TUN HUSSEIN ONN MALAYSIA

FACULTY OF ELECTRICAL AND ELECTRONIC ENGINEERING

HIGH VOLTAGE ENGINEERING (BEV40403)

SEMESTER 2 SESI 2021/2022

PROJECT REPORT

GROUP MEMBERS:
NO NAME MATRIC NUMBER

1. AHMAD FHIRDAUS BIN AHMAD FUAD DE190121

2. ARIF ZUHDY BIN ZULLKELA DE190102

3. MUHAMMAD HANIF AIMAN BIN SAMSUL DE190107

BAHRI
4. NITHIYAAN A/L RAJA CE190043

SECTION: 1

NAME OF LECTURER:
Prof. Madya Dr. MD NOR RAMDON BIN BAHAROM
 ABSTRACT

In this project, the students designed an insulator which is often used in overhead
line towers. This insulator is used to separate electrical conductors without allowing current
to pass through them, and it also serves as a safety measure during maintenance.
Insulators for overhead lines are essential for a power system's operation. Poles or towers
are needed to support the overhead line cables. Line conductors must be appropriately
insulated from supports to avoid current flowing to the ground. The insulator protects the
transmission line from overvoltage produced by lightning, switching, or other crucial
conditions. Glass surface of the glass insulator has high mechanical strength, the surface
is not easy to crack. Then, a suitable creepage clearance distance needs to be suitable
with the level of pollution.

The purpose of this project is to develop a suspension type overhead line insulator as well
as simulate and analyse the normal voltage and electric field distributions on the prototype.
The insulator property and capability will be analysed and tested utilising Finite Element
Method Magnetics (FEMM) Software. It's created with 3D drawing tools such SketchUp,
and the material for the insulator is chosen. Because the system voltage is 132kV, we
used insulator properties such as suspension string as the type of insulator, glass as the
insulator material, and cap and pins as fittings. The findings of the study are based on
overhead line insulator theory, as well as an analysis of the best materials for each
situation in terms of electrical and mechanical properties, environmental performance,
costing, and the advantages and disadvantages of the chosen prototype.
1.0 COMPANY INFORMATION
1.1 COMPANY BACKGROUND
1.1.1 INTRODUCTION

Figure 1: Company Logo

Empire Power Engineering (EPE) Sdn Bhd is located in Parit Raja, Batu Pahat,
Johor. This company was established in January 2020 as an Electrical and Mechanical
Contractor. The main goal of this company is to meet the needs of the construction
industry as a capable and competent firm. With exceptional experience, capabilities and
skills, it is necessary to achieve and meet all project requirements to the highest standards.
These different abilities are developed over time working as a team, primarily to maintain a
consistent high standard of work.

The company is steadfastly committed to giving team projects and full team
support top priority when working on projects. Empire Power Engineering (EPE) Sdn Bhd
has always prioritised the use of resources, machinery, and materials as part of its
corporate philosophy. Every project undertaken will be guaranteed and delivered on time
with the application of a strict quality assurance plan. Additionally, the business offers
premium materials at affordable prices.

Empire Power Engineering (EPE) Sdn Bhd is confident that with the current team,
the company can complete projects on schedule and to the satisfaction of the customer
given its experience and management skills in understanding customer needs.

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1.1.2 COMPANY VISION

Vision for Empire Power Engineering Sdn Bhd is as follows:

“Becoming as a Main International Organization in the Field of Mechanical and

Power Electrical”

1.1.3 COMPANY MISSION

Mission for Empire Power Engineering Sdn Bhd are as follows:

1. Conduct business in power distribution system with quality, reliability and

security.
2. To serve with proactive service.
3. To continue to develop and improve efficiency.
4. Develop organizational management with sustainability and responsibility for
society and the environment.

1.1.4 COMPANY MOTTO

“We will make electricity so cheap that only the rich will burn candles”

1.1.5 COMPANY PHILOSOPHY

Philosophy for Empire Power Engineering Sdn Bhd are as follows:

1. We are committed towards proving quality, efficient and excellence

specialized services to clients.
2. We attribute our success to building strategic partnerships.
3. We are treating customers the way we want to be treated.

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 1.1.6 COMPANY ORGANIZATION CHART

DIRECTOR
NITHIYAAN A/L RAJA

DESIGN ENGINEER PRODUCTION ENGINEER MATERIAL ENGINEER

AHMAD FHIRDAUS ARIF ZUHDY MUHAMMAD HANIF AIMAN

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1.2 PROJECT INTRODUCTION

Transmission lines are primarily exposed to nature's hostile climate in the air, which
causes a variety of issues. Thunder, rain, lightning, flashover, winter ice, fog, fog stick on
the insulator, and pollution all contribute to poor contact insulators and transmitters. The
support tower is separated from the conductor by an insulator, which is a nonconductive
material. The quality of the insulator will deteriorate over time as a result of contamination
in the surrounding environment. Contamination effects are a type of pollution that occurs at
the surface of the insulator as a result of the natural environment or factory smoke. The
contamination effect can cause overhead transmission line failures such as faults, corona
effect, and flashover. This project is designed to investigate the electrical performance of
the surrounding insulator in relation to the available options. As a result, the primary goal
of this project is to design and test the performance of insulator string in both clean and
contaminated environments.

1.2.1 PROBLEM STATEMENT

One of the factors contributing to the poor electrical performance of overhead

transmission lines was the insulator pollution level. Disturbances on insulator
surfaces can result in serious incidents, jeopardising the safety of civilians in the
surrounding area. A polluted insulator also increases the risk of lightning, making
flashover more likely. The higher the pollution level, the greater the electric field of
the insulator, which causes corona discharge and thus causes flashover. If the
highly contaminated insulator is still used, there will be a significant number of
casualties and the maintenance fee will rise throughout the year. This project is to
design a prototype overhead line insulator. To be installed on the selected EHV
overhead lines towers, which are erected within an industrially polluted area, this
insulator must meet all expected criteria.

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1.2.2 OBJECTIVES

The main objectives of this project are stated as below:

1. To design HV insulators by considering appropriate method.

2. Able to draw the proposal designs using 2D/3D drawing software.

3. Able to simulate the HV and EM fields distribution and analyse the performance
of the prototype when stresses by environmental impact.

1.2.3 SCOPES

This project is limited to only a few areas.

1. This project focuses on creating a 2D insulator using AutoCAD and Google

Sketch.

2. At 132 kV line voltage, the design suspension insulator string is made up of a

series of disc insulators.

3. Glass has been chosen as the insulator for this investigation. For both types of
insulators, the data is evaluated using COMSOL Multiphysics software's Finite
Element Method (FEM), and the comparison is observed and analysed.

1.2.4 PRELIMINARY OUTCOMES

The preliminary outcomes of this project are as below:

1. Able to design HV insulators by considering appropriate method.

2. Able to draw the proposal designs professionally using 2D/3D drawing software
such as SketchUp.

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2.0 DESIGN PLANNING

In term of designing and selecting suitable components and value, there are a few
studies related to the glass insulator as the insulator for transmission line grid. Toughened
glass insulators have advantages such as steady mechanical strength, self-exposure of
faults, and so on, which offset disadvantages such as tedious insulation resistance
detection in porcelain insulators, fast ageing of composite insulators, and easy string
falling. Since its introduction into the power grid, it has sparked widespread interest, with
disc suspension glass insulators accounting for up to 70% of transmission line insulators
[1] . High voltage tests were conducted on a batch of aged transmission line glazed glass
cap and pin insulator to measure the insulator self-capacitance, surface resistance, critical
flashover voltage and corona inception voltage in order to evaluate transmission line
insulator [2].

Cap and pin insulator is taken as research object with contaminant layer are
modelled on the surface of the insulator. This distorted field will expedite the premature
aging process that may lead to flashover and result in power system network interrupted. It
is believed that the calculated field would help in improving the insulator design especially
for contaminated areas with various climates [3] . Rainfall decreases insulator
contamination, which is linked to the electrical performance of high-voltage transmission
line outside insulators because it minimises the possibility of pollution flashover. An
artificial rainfall experiment platform was devised, manufactured, and tested to investigate
the washing effect of rainfall on contamination of porcelain and glass insulators. It has the
ability to alter rainfall strength, flushing angle, duration, and homogenous. Suspension
insulator string rain experiments have been conducted. Comparison of experimental
results shows that the effect of rainfall's flushing angle on washing insulators'
contamination is the biggest, next is rainfall's intensity, and the minimal is rainfall's duration
[4].

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3.0 ANALYSIS OF PROPOSAL DESIGN
3.1 CONCEPT OF THE DESIGN

3.1.1 PROPOSED DESIGN

The number of suspension glass discs insulator that have been design can be
calculated by using the formula below:

Formula:
𝑉𝐿
𝑁= + 𝑆𝑓
3 × 11

Where:
𝑁 = 𝑁𝑢𝑚𝑏𝑒𝑟 𝑜𝑓 𝑠𝑢𝑠𝑝𝑒𝑛𝑠𝑖𝑜𝑛 𝑔𝑙𝑎𝑠𝑠 𝑑𝑖𝑠𝑐𝑠 𝑖𝑛𝑠𝑢𝑙𝑎𝑡𝑜𝑟
𝑉𝐿 = 𝑆𝑦𝑠𝑡𝑒𝑚 𝑣𝑜𝑙𝑡𝑎𝑔𝑒 (𝑖𝑛 𝑘𝑉)
𝑆𝑓 = 𝑀𝑒𝑐ℎ𝑎𝑛𝑖𝑐𝑎𝑙 𝑠𝑎𝑓𝑒𝑡𝑦 𝑓𝑎𝑐𝑡𝑜𝑟 (𝑈𝑠𝑢𝑎𝑙𝑙𝑦 𝑡ℎ𝑒 𝑣𝑎𝑙𝑢𝑒 𝑜𝑓 𝑆𝑓 𝑖𝑠 1 𝑜𝑟 2)

Therefore, we consider 𝑆𝑓 = 1

Calculation:
𝑉𝐿
𝑁= + 𝑆𝑓
3 × 11
132
𝑁= + 𝑆𝑓
3 × 11
𝑁 ≈ 7 + 𝑆𝑓
𝑁 ≈ 7+1
𝑁=8

Therefore, the number of suspension glass discs insulator required is 8.

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 3.1.2 CREEPAGE CLEARANCE

Table 1: Data of the Insulator Creepage Clearance

System Voltage 132 kV

Type Insulator Option Stacked Insulator Strings
(Suspension Strings)
Environment Issue Medium
Minimum Nominal Specific Creepage Clearance 20.0 𝑚𝑚/𝑘𝑉2
Nominal Specific Creepage Clearance 21.82 𝑚𝑚/𝑘𝑉2
Creepage Clearance Distance 2.88 m
Fitting Option Cap and pins
Number of Sheds 4 large + 4 small = 8
Length of the insulator 1.464
Total length of the insulator (+ 0.5 m fittings) 1.964

Calculation for Creepage Clearance Distance

Leakage (mm) = 400, 320
N = 4+4 (Number of suspension glass discs insulator)

𝐶𝑟𝑒𝑒𝑝𝑎𝑔𝑒 𝐶𝑙𝑒𝑎𝑟𝑎𝑛𝑐𝑒 𝐷𝑖𝑠𝑡𝑎𝑛𝑐𝑒 = 𝑙𝑒𝑎𝑘𝑎𝑔𝑒 × 𝑁

𝐶𝑟𝑒𝑒𝑝𝑎𝑔𝑒 𝐶𝑙𝑒𝑎𝑟𝑎𝑛𝑐𝑒 𝐷𝑖𝑠𝑡𝑎𝑛𝑐𝑒 = 400 𝑚𝑚 × 4 + (320 𝑚𝑚 × 4 )
𝐶𝑟𝑒𝑒𝑝𝑎𝑔𝑒 𝐶𝑙𝑒𝑎𝑟𝑎𝑛𝑐𝑒 𝐷𝑖𝑠𝑡𝑎𝑛𝑐𝑒 = 2.88 𝑚

Calculation for Nominal Specific Creepage Clearance based on Calculated

Creepage Clearance Distance
System voltage = 132 (in kV)
Creepage Clearance Distance (CCD) = 2.88 m

𝑁𝑜𝑚𝑖𝑛𝑎𝑙 𝑆𝑝𝑒𝑐𝑖𝑓𝑖𝑐 𝐶𝑟𝑒𝑒𝑝𝑎𝑔𝑒 𝐶𝑙𝑒𝑎𝑟𝑎𝑛𝑐𝑒 = 𝐶𝐶𝐷 ÷ 𝑆𝑦𝑠𝑡𝑒𝑚 𝑉𝑜𝑙𝑡𝑎𝑔𝑒

𝑁𝑜𝑚𝑖𝑛𝑎𝑙 𝑆𝑝𝑒𝑐𝑖𝑓𝑖𝑐 𝐶𝑟𝑒𝑒𝑝𝑎𝑔𝑒 𝐶𝑙𝑒𝑎𝑟𝑎𝑛𝑐𝑒 = 2.88 𝑚 ÷ 132
𝑁𝑜𝑚𝑖𝑛𝑎𝑙 𝑆𝑝𝑒𝑐𝑖𝑓𝑖𝑐 𝐶𝑟𝑒𝑒𝑝𝑎𝑔𝑒 𝐶𝑙𝑒𝑎𝑟𝑎𝑛𝑐𝑒 = 21.82 𝑚𝑚/𝑘𝑉2

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3.2 2D & 3D
DRAWING

Figure 2: 2D insulator design

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Figure 3: 3D insulator Design

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Figure 4: 2D and 3D stacking insulator design

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3.3 MATERIAL PROPERTIES

3.3.1 TYPE OF INSULATOR

Based on its benefits, it was chosen to apply stacked insulator string, which is a
suspension type overhead line, for this project. The following are some of the
benefits of stacked insulator strings:

1. Suspension type insulators give more flexibility to the line and mechanical
stresses due to wind and other factors are reduced in this suspension type
insulator arrangement.

2. Disc can be replaced easily if there is any damage.

3. Suspension insulators are cheaper in cost compared to pin type insulators for
operating voltage above 50kV

3.3.2 MATERIAL USED FOR INSULATOR

The material used for the design insulator is glass. Glass is a material that has high
dielectric strength that can insulate conductive material which is efficient for high
voltage conductors. The advantage that glass material has as an insulator is stated
below:

1. Surface of the glass insulator has high mechanical strength, the surface is not
easy to crack.

2. It has a very long service life, because the mechanical and electrical functions
of the glass are not affected by aging.

3. The use of glass insulators can eliminate the routine preventive testing of the
insulators during operation.

4. The raw materials used to manufacture glass insulators are more stable

5. Because of its transparency, impurities and bubbles can be easily detected in

the glass disc insulator.

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3.4 ELECTRICAL CHARACTERISTICS

1. It has a very high dielectric strength compared to porcelain.

2. Its resistivity is also very high.

3. It has a low coefficient of thermal expansion.

4. It has a higher tensile strength compared to porcelain insulator.

Table 2: Properties of Glass Insulator

Property Value (Approximate)

Dielectric Strength 140 kV / cm

Compressive Strength 10,000 Kg / cm2

Tensile Strength 35,000 Kg / cm2

3.5 MECHANICAL CHARACTERISTICS

The method for determining the strength rating of composite and ceramic insulators is the
same. A composite insulator can immediately replace porcelain or glass insulators based
on strength alone. The strength rating of composite insulators is defined in table 3.
Because all materials have a time-load characteristic that reduces their residual strength
over time, a two-to-one safety factor has traditionally been utilised when selecting an
insulator's strength rating. Composite insulators are typically rated at a maximum working
load of 50% of the Ultimate Load rating.

Table 3: Insulator Strength Rating Definition

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Insulators are often made of toughened glass. To make the shell, melted glass is poured
into a mould. The shells are cooled by dipping into hot and cold baths.

This thermal treatment shrinks the glass's surface and puts pressure on the body,
increasing the glass's mechanical strength. The glass will break into little fragments if
exposed to sudden mechanical pressures, such as a hammer blow or bullets. Alumina
cement is used to secure the metal end-fitting.

3.6 ENVIRONMENTAL PERFORMANCES

Figure 5: Transmission Line Tower at Kolej Kediaman Bestari (KKB) Parit Raja, Batu
Pahat

As shown in the figure 5 above, the location chosen for this project is at Kolej
Kediaman Bestari (KKB) Parit Raja, Batu Pahat. This area consists with average number
of houses and is several kilometres from the nearest coastal area which is Pantai Minyak
Beku. This location of the project is also subjected to frequent winds and/or rainfall. This
area also consist of industries not particularly producing polluting smoke.So, the design of
the suspension type insulator proposed will be implemented at this location which can be
said with medium level of pollution.

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4.0 TECHNICAL SUMMARY METHODOLOGY OF FEA SIMULATION SOFTWARE

Procedures and techniques for simulating the project to build that the appropriate
results and data can be collected and analysed. There are a few things to think about
before starting the simulation process. The students in each group must choose the
insulators that will be tested. Research and study of material characteristics are required
before deciding the type of insulator.

Finite Element Analysis, or FEA, is the numerical mathematical process of

simulating a physical phenomenon. It uses the Finite Element Method, or FEM. In order to
optimise the designs, the FEM is used to run virtual tests and reduce the number of
physical rototypes. In this model, the area that is encircled by a circle represents the state
of the air. In particular for this study on electrostatic force, FEMM software is a frequently
utilised tool for resolving engineering and mathematical model issues. The FEM's ability to
handle complex geometries (and boundaries) with relative ease is one of its most alluring
features.

Next, the partial differential equation can be solved numerically by meshing the
model. When geometry is broken into smaller units known as elements, linear behavior
can be assumed for each unit, which can then transform the entire system into a system of
linear equations stated by a matrix and solved by software to get the closest approximation
to the system equation. In essence, meshing the model converts it into a set of linear
equations that can be used to resolve the electrical issues. The best way to produce a
more accurate result is with a finer mesh, but the disadvantage is that it takes more time to
compute.

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5.0 WORKFLOW FEA SIMULATION ON THE PROTOTYPE

Figure 6: Flowchart of FEA simulation for the prototype insulator

16
6.0 TECHNICAL SUMMARY METHODOLOGY OF FEA SIMULATION ON THE
PROTOTYPE

This project uses a cap-and-pin fitting with a 132 kV system voltage. Toughness
glass was used as the insulator material in a contaminated environment. The insulating
component of this project has 2 size that with a diameter of 172 mm and 141 mm, and a
creepage distance of 400 mm and 320 mm. Based on the toughness glass material, the
relative electric permittivity values for the material characteristics are 10 and the values of
electric conductivity (S/m) is 0 while the steel conductor has 1100000 relative permittivity
with 132000 voltages. The standard and data profile of toughness glass insulator as well
as steel conductor also must be studied. Then, we had to build a geometry. The insulator
that we chose is the prototype that we are going to simulate in FEMM. It can be in
cartesian or planar and it should be in 2 dimensions (2D). For our group, we sketch the
insulator in 2D by using FEMM simulation software.

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7.0 SIMULATION

7.1 DRY TEST

7.1.1 Big Size Single Disc Insulator (Dry Test)

Figure shows the field intensity of a big size of single disc glass insulator in a dry condition.
The field intensity at the bottom of the disc more focused and higher at the steel pin that is
connected to the 11 kV high voltage terminal. It is only connected to 11 kV because this is
only the single disc and not stacked yet.

Figure 7: Mesh model of the big size single insulator

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 Figure 8: Field intensity simulation of big size single disc insulator for dry test

Figure shows the electric potential of a single disc insulator that is measured from
the high voltage side. From the graph, the electric potential is constant until around 80 mm
and starting to drop to 0V at around 130-140 mm.

Figure 9: Graph of voltage versus length for big size single disc insulator

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 Figure shows the field intensity graph of the single disc insulator starting to spike at
around 80-90 mm at more than 30000 V/m and slowly dropping below than 200000 V/m
before drop to 0 V/m at around 130-140 mm.

Figure 10: Graph of field intensity versus length for big size single disc insulator

7.1.2 Small Size Single Disc Insulator (Dry Test)

Figure shows the field intensity of the small size glass insulator where the focused
and more intense area are quite similar to the big size of glass insulator for dry condition.
The field more intense at the bottom of the insulator at the area of steel pin and small
intensity at cap steel area.

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 Figure 11:Mesh model of the small size single insulator for dry test

Figure 12: Field intensity simulation of small size single disc insulator for dry test

21
 Figure shows the electric potential graph for small size of disc insulator in dry
condition. The value of initial electric potential is constant at 11 kV from 0 mm before
starting to drop slowly until 0 V from 90 mm until around 160 mm.

Figure 13: Graph of voltage versus length for small size single disc insulator

Figure shows the field intensity of the small size of the glass insulator disc. The field
intensity on this glass did not have a sharp turn as the big size glass insulator as this
insulator move smoothly to the peak of intensity level before going down to zero at the end
of insulator.

Figure 14: Graph of field intensity versus length for small size single disc insulator

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7.1.3 Stacked Disc Insulator (Dry Test)

The figure below shows the field intensity of the stacked glass insulator in a dry test. The
above level and the bottom level of the insulator has been zoomed in to give a clear
information of the results of the simulation. The below level of the insulator shows the high
intensity field of 132 kV and at the end of the stacked insulator which is the top level of
insulator, it shows that there is no more field intensity at the area showing that the stacked
insulator has a good insulation.

Figure 15: Mesh model of the stacked disc insulator

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 Figure 16: Field intensity simulation of stacked disc insulator for dry test

Figure 17 and Figure 18: Zoom in view for the stacked disc insulator in dry condition

The both graphs below show the electric potential graph and the field intensity graph of the
stacked glass insulator. The electric potential shows that the voltage from 132 kV
decreasing slowly until reaching 0V at the end of the insulator giving the information that

24
this insulator could prevent the electric potential to get pass through. The field intensity at
the beginning of the insulator spike quite high and then slowly decreasing along the
insulator at the end of the insulator.

Figure 19: Graph of voltage versus length for stacked disc insulator in dry condition

Figure 20: Graph of field intensity versus length for stacked disc insulator in dry condition

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7.2 WET TEST

7.2.1 Big Size Single Disc Insulator (Wet Test)

The simulation for wet test at big glass insulator showing that the field intensity of
the glass insulator while in wet condition is a little bit higher than in dry condition with
almost 400000 V/m of intensity field. But for the electric potential, the value remains the
same at 11 kV does not matter in wet or dry condition. The electric potential and the field
intensity are still decreasing after a certain distance until reaching the 0 level.

Figure 21: Mesh model of the big size single insulator for wet test

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Figure 22: Field intensity simulation of big size single disc insulator for wet test

Figure 23: Graph of voltage versus length for big size single disc insulator

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 Figure 24: Graph of field intensity versus length for big size single disc insulator

7.2.2 Small Size Single Disc Insulator (Wet Test)

The figure and graphs below show the simulation of small glass insulator in wet
condition. The field intensity of the small glass insulator shows that the value is a little bit
higher than the insulator while in dry condition at almost 300000 V/m while the electric
potential are remains the same as dry condition which is 11 kV. The value of both are
decreasing after a certain length of insulator.

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 Figure 25: Mesh model of the small size single insulator for wet test

Figure 26: Field intensity simulation of small size single disc insulator for wet test

29
 Figure 27: Graph of voltage versus length for small size single disc insulator

Figure 28: Graph of field intensity versus length for small size single disc insulator

7.2.3 Stacked Disc Insulator (Wet Test)

The figure and graph below show the simulation of the stacked glass insulator in
wet condition. The field intensity shows there is a spike when going through the steel and
the value of half of the insulator hit the same high of intensity. And going to 0 at the end on
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each insulator. The electric potential of the insulator in wet condition is seems to have a
similar value as the dry test at 132 kV. Both of the electric potential and field intensity are
going to zero after certain length of insulator.

Figure 29: Mesh model of the big size single insulator for wet test

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 Figure 30: Field intensity simulation of stacked disc insulator for wet test

Figure 31 and Figure 32: Zoom in view for the stacked disc insulator in wet condition

32
 Figure 33: Graph of voltage versus length for stacked disc insulator in wet condition

Figure 34: Graph of field intensity versus length for stacked disc insulator in wet condition

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7.3 Comparison Between Dry Test and Wet Test
7.3.1 Comparison Between Dry Test and Wet Test Big Size Single Disc Insulator

Figure 10 and figure 24 shows the graph of field intensity versus length for big size
single disc insulator. From the figures, it could be seen that the insulator when be done
wet test at figure 24 have a higher intensity than the insulator when it in dry condition.

7.3.2 Comparison Between Dry Test and Wet Test Small Size Single Disc Insulator

Figure 14 and figure 28 shows the graph of field intensity versus length for small
size single disc insulator. From the figures, compare to the big insulator the graph the
small insulator insulator have more vibrating than the big insulator. It also could be seen
that the insulator when be done wet test at figure 28 have a higher intensity than the
insulator when it in dry condition.

7.3.3 Comparison Between Dry Test and Wet Test Stacked Disc Insulator

Figure 20 and figure 28 shows the graph of field intensity versus length for stacked
disc insulator in dry condition average initial intensity level, in wet condition are higher than
the dry condition of the insulator.

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 Faculty of Electrical and Electronic Engineering

Department of Electrical Power Engineering

High Voltage Laboratory

Title of Experiment / Test: - HVDC with and without contamination test

Project / Academic Supervisor: - ASSOC. PROF. Dr Md Nor Ramdon bin Baharom

Name: - Muhammad Hanif Aiman Bin Samsul Bahri

Person Carrying Matrix No: - DE190107

Out the Experiment Contact No: - 0109625991

Email: - de190107@siswa.uthm.edu.my

Safety Documents Valid From: - 16 June 2022 to: - 23 June 2022

For continuous periods of experimentation only. Re-validation of this document is required for
breaks in experimentation greater than one month or when test circuit is dismantled and re-
assembled.

Level of Supervision: Choose one

(To be completed by Supervisor / Head of Laboratory) and tick
‘X’

Experimentation to be carried out in presence of student’s Supervisor X

Experimentation may be carried out providing AE / HoL is in the laboratory

*Head of Laboratory (HoL) or Assistant Engineer (AE) must always be in the
laboratory to permit experimentation to take place in the laboratory.

35
SACTION TO EXPERIMENT

EXPERIMENTER DECLARATION: I understand the contents of these safety documents. I am

aware that any change in the experiment beyond that identified in these safety documents means
that work must stop, the Risk Assessment reviewed and permission to resume has been given and
countersigned by the Project Supervisor or Head of Laboratory.

Name of the student: Muhammad Hanif Aiman Bin Signed: Hanif Date: 23 June
Samsul Bahri

Name of the supervisor: ASSOC. PROF. Dr Md Nor Signed: Dr Ramdon Date: 23 June
Ramdon bin Baharom

Name of HoL: Signed: Date:

*HoL must be identified and sign here having confirmed the safety documents to be satisfactorily
completed.

Document Cancelled: Date: 23 June 2022

Name: ASSOC. PROF. Dr Md Nor Ramdon bin Baharom

Signature: Dr Ramdon

36
 METHOD STATEMENT

Title of Experiment / Test: - HVDC with and without contamination test

Prepared by: - Nithiyaan A/L Raja Date: - 22 June 2022

A. Purpose of Experiment: Test glass insulator durability upon electrical stress.

B. Equipment Being Used / Circuit Diagram (where appropriate):

APPENDIX A

HVDC generator

Glass insulator

Earthing rod

Nozzles

DC voltmeter

Control panel

C. Experimental Procedure:

1. For contamination test, the insulator was energized with both positive and negative
polarities of the applied voltage

2. DC voltages were applied and raised until flashover occurred.

3. Repeat process for five times to get the average breakdown voltages.

4. For contamination test, repeat contamination procedures.

37
 RISK ASSESSMENT

(Must address all hazards identified in hazard checklist)

Title Of Experiment / Test: - HVDC with and without contamination test Date: - 22 June 2022

Prepared By: - Arif Zuhdy bin Validated By: - PM Md. Dr. Ramdon Checked By: - PM Md. Dr. Ramdon bin
Zullkela bin Baharom Baharom

38
(In addition to this risk assessment, a safety commissioning checklist is attached to this document. This checklist is to be completed before HV
supplies can be energised. It is relevant to the ‘Electrical shock from high voltage’ and ‘Fire’ hazards described in the table below.

Residual risk with control

measures applied

Hazard (s) & Persons or Equipment at Risk Control measures applied to eliminate / minimise

Risk Acceptable?
Possible risk

Risk rating
Likelihood
Severity
Consequences

Proper equipment to be isolate from the ground or

other potentials and perform the operations on

Electrocution Person energized platforms. 4 2 8 Y

Equipment is interlocked so supplies are isolated

when door to cage is opened

39
 All leads leaving from cage have earthed sheath
(current measurements taken at earthed end of
sample, voltage measurement taken with commercial
voltage probe)

Earth stick applied to HV output of transformer when

entering cage

Warning lights and signs are placed on cage

Constants supervision is required to avoid any

overheating or spark that can ignite flammable
material.

Smoke detector placed above samples to provide

audible notification of any fire (in the event that this

Fire Equipment is sensitive to fumes, to be replaced by a heat 4 2 8 Y

detector)

Detector linked into control equipment to isolate HV

supplies in the event of operation

Fire extinguisher available in laboratory

Test equipment not to be left unattended when

40
 initially operated to confirm behaviour of samples

Heat detectors contained to main building fire alarm

system present within B20 laboratory

Slips (from loss of  Careful handling of water to take place with no

water used to wet Persons entering cage more than is required to be placed within cage 2 2 4 Y
samples)  Any liquid spillage to be mopped up immediately

Leads to be routed away from walkways where

possible
Trips Persons entering cage Any leads that cannot be routed away from 1 2 3 Y
walkways to be covered with rubber matting

Risk Assessment Matrix 1 – 5: Low: Tolerable – monitor and manage

Likelihood (1-5) x Severity (1-5) = Risk 6 – 8: Medium: Review, introduce further controls to reduce to as low as reasonably possible
(See attached matrix for guidance)
9 – 25: High: Intolerable. Do not commence work, further control measures required

41
 RECORD OF CHEMICAL USAGE WITHIN EXPERIMENT

Chemical Are Hazards Resulting from

Chemical Reason For Use Data Sheet Use Described In Risk Method Of Disposal
Attached? Assessment Table Above?

- - - - -

42
HAZARD CHECKLIST

You should indicate the hazards present in the experiment in the table below. If a hazard is present,
control measures should be stated on the risk assessment. Note that this list is not exhaustive.

Hazard Type Present Not Present

Electric Shock From High Voltage (1kV & Over) X

Electric Shock From Low Voltage (Under 1kV)

Tripping Hazards X

Slipping Hazards X

Fire X

High Temperatures X

Low Temperatures X

High Pressure X

Low Pressure X

Chemical Spillage X

Chemical Contact (Ingestion / Eye & Skin Contact) X

High Noise Levels X

Working At Height X

Head Height Hazards X

Production Of Dust & Fumes X

Manual Handling X

Production/Use Of Radiation X

Use Of Asphyxiating Gases X

Any Other Hazards X

43
RISK ASSESSMENT SEVERITY MATRIX

SEVERITY VALUE = Potential consequence of an incident/injury given current level

of controls.

5 Very High: - Death / Permanent incapacity / Widespread loss

4 High: - Major Injury (Reportable Category) / Severe Incapacity / Serious Loss
3 Moderate - Injury / Illness of 3 days or more absence (reportable category) / Moderate
loss
2 Slight: - Minor injury / Illness – Immediate 1st Aid only / slight loss
1 Negligible No injury or trivial injury / illness / loss

LIKELIHOOD = what is the potential of an incident or injury occurring given the

current level of controls.

5 Almost certain to occur

4 Likely to occur
3 Quite possible to occur
2 Not likely to occur
1 Almost certain not to occur

The multiple of Likelihood with Severity is the risk classification value.

Severity
1 2 3 4 5

1
Likelihood

44
 5

Risk Classification Value

1–5: Low: Tolerable – monitor and manage

6–8: Medium: Review, introduce further controls to reduce to as low as reasonably possible

9–25: High: Intolerable. Do not commence work, further control measures required

45
HV TESTING PROPOSAL: CODE OF CONDUCT

The safety measures for the person conducting measurements on high voltage or
high-power sources of various types, such as power system lines, direct voltage
supplies, and lighting impulse generators, are discussed in this suggested HV testing.
The electrical hazard associated with temporary measuring rather than metering,
relaying, or normal line operations is addressed by this recommended practise. The
recommended practises are based on the IEEE Recommended Practices for High-
Voltage and High-Power Testing as well as other studies.

Testing Information

The majority of the time, outdoor insulators are contaminated by a variety of sources.
Pollution has become a serious threat to the insulation of power networks in some
areas. Dry contaminants will not be a problem on the insulating surface. On the
insulator surface, wet contamination is a major problem. Moisture in the form of light
rain moistens the pollution layer on the insulating surface. A pollution test can usually
be carried out in one of two ways. The first test is for natural pollution, and the
second is for man-made pollution. The insulator is powered to its operating voltage
and exposed to a naturally polluted environment while its performance is monitored
in a natural pollution test. An artificial pollution test has been devised by simulating
one of the natural weather conditions that causes pollution flash-over.

Electrical equipment must be able to function even if there is an overvoltage. As a

result, we must ensure that this is done using proper testing protocols. Insulating
material testing encompasses high voltage testing. The samples were prepared in
accordance with the IEC standard. The contamination layer was dispersed across
the insulator surface in a study of insulators that had been in the field for a long time
and had been exposed to numerous contaminants.

46
Schematic Diagram

The test setup for polymeric insulators at the High Voltage Laboratory is depicted
schematically in Figure 35. The test determines the resistance of the insulation
sample to electrical stress induced by positive and negative impulse voltages. An
impulse generator set provides either positive or negative impulse voltages to the
test circuit, and a capacitor divider monitors the output voltage. Positive lightning
impulses, as well as wet and dry conditions, were used to test polymer insulators to
see if they could withstand 132kV. Artificial rain is created using fog nozzles that
completely cover the sample surfaces. It complies with the criterion in terms of
conductivity and flow rate. It's used to produce pollution by conducting wet flashover
tests on insulators. Each test is subjected to voltages for about one to three minutes.
During the dry condition test, no artificial rain is applied to the sample surface. When
a voltage is supplied to a specimen during dry and wet testing, data is collected by
current and voltage measurements, visual corona creation on fittings/surfaces,
flashover, damage occurrence, and other methods.

Figure 35: Example schematic diagram for insulator testing

Test Setup

Figure 36 shows an example of an experimental setup for insulator HV testing.

Personnel in charge of the test areas should be reminded and cautioned that
dangerous charges can be induced on ungrounded capacitive elements as well as
ungrounded metallic items before using a direct voltage power source. A visible red-

47
light lamp lights the room when the supply is turned on, and danger signs are put on
the wire mesh to warn against unauthorized entry.

Leads must be sheathed in a grounded metallic sheath and terminated properly in a

grounded metallic enclosure before running from a test area. If this is not the case,
greater caution is necessary to guarantee the safety of the personnel. Protect the
equipment and circuitry using a surge-protection device that is the right size for the
job. Within the test area, temporary measurement circuits must be enclosed.
Temporary circuit control must be handled in the same way as measuring circuit
control is handled, which means it must be confined in a grounded box with all
access points accessible to the operator for ground potential management.

Apply the test voltage for one to three minutes after making all of the necessary
connections. The time interval is a standard in the industry that allows all readers to
take the reading at the same time. As a result, reading comparisons will be
informative because the test procedures are consistent, even though different people
take them. During this time, the resistance should drop or remain roughly constant.
The resistance value should be read and recorded after one minute. In hard
installation situations, such as those with temperature extremes and/or chemical
contamination, this process is expedited. This deterioration has the potential to
jeopardise power dependability as well as personnel safety. As a result, it is
essential to detect this deterioration as soon as possible in order to take corrective
action.

Figure 36: Example experimental Setup for Insulator HV testing

48
Details about safe ways of work for testing activities should be provided wherever it
is reasonably practical. All personnel should be involved in the development of safe
work systems in order to produce a workable system. When testing is confined to
diagnostic testing by electrically qualified employees on electrical distribution
systems and equipment (e.g., switchgear), the written records should include the
core safe operating principles.

The documented safe systems of work should include, at a minimum:

1. Information on who is permitted to conduct testing, how to reach a testing area,

and who should not approach the area, if relevant.

2. Isolation rules and how to keep the isolation secure.

3. The proper installation of supplemental protection measures to the equipment

under test while its covers are removed, such as flexible insulation. This risk should
be assessed as well if it is deemed necessary to apply insulation and remove covers
while the equipment is functioning.

4. What type of power supply should be used to power the equipment under test,
especially if doing so incorrectly could compromise safety.

5. What is expected of test staff in terms of pre-use inspection of test equipment and
how faults should be notified; (g) the appropriate operation of any warning devices
employed as part of the authorised test site's safety system.

Safety Practices (Laboratory Work)

1. PERMANENT TEST AREA

Permanent test sites should be encircled by walls or some other physical barrier.
Because the gates are open, no test voltage should be applied to these areas.
Outside the gates, vital warning signs such as DANGER—HIGH VOLTAGE should
be displayed.

49
2. TEMPORARY TEST AREA

I. Portable fence with linked entrances that is installed on the ground.

II. Brightly coloured safety tape, approximately waist high, installed to suitable safety
signs. After the test has been completed and the test voltage has been withdrawn,
the tape must be removed before anyone can access this area. One or more
observers must be stationed to monitor the entire area if the operator lacks a
comprehensive view of the taped-off section. Never leave a taped-off area
unattended while using test power.

III. A loudspeaker system may be required on occasion to communicate with all

personnel present.

3. INTERLOCK SYSTEMS

Interlock systems should be constructed as fail-safe as practicable whenever

possible. If this isn't practicable, workers should be alerted about system faults using
visual or auditory signals.

4. ACCESS TO TEST AREAS

To ensure that no place is powered while a person is present, a systematic method

for managing access to the test locations must be established and implemented. It
may be required to place an observer within a test area in some cases. Only with
special approval and after establishing a safe working practise may this be done.
This procedure might be modelled after the one outlined in B. Alternatively, the
individual may be placed within or behind a grounded barrier, or they may sit or
stand on a specific switch that disconnects them from the high voltage if they move
away from it.

5. CONTROL OF SUBSTANCES HAZARDOUS TO HEALTH

(COSHH) HANDLING WITH CHEMICAL DATASHEET

50
The COSHH Regulations provide a framework for protecting workers' health against
hazards posed by job tasks that expose them to hazardous substances. A COSHH
assessment outlines the safety precautions that must be taken to avoid injury.
Unfortunately, there is a common misconception that risk assessment is the process
of determining a substance's hazardous features; hazardous properties refer to a
substance's ability to cause harm, whereas risk refers to the likelihood of injury under
actual use settings.

Assessors must be able to distinguish between these two concepts. The purpose of
a chemical risk assessment (the COSHH assessment) is to ensure that an educated
decision is made about the control measures that should be adopted to prevent or
restrict exposure to hazardous substances. A risk assessment, in practise, reveals
that suitable and sufficient judgement was employed to arrive at these conclusions.
Consumers can use safety data sheets to analyse the risks associated with chemical
commodities. They describe the chemical's risks and provide directions for handling,
storage, and emergency reaction in the event of an accident.

6. CORRECT TESTING AND MEASUREMENT PROCEDURES

In the pollutant performance testing, silicone rubber insulators were used. The IEC
insulator test protocol is used to conduct artificial pollution testing. The studies are
set up to mimic real-life scenarios.

Insulators are commonly used to separate the conductor from the pole in electrical
power transmission systems. Its purpose is to stop current from passing from a
conductor to the earth. Before employing the insulator, some parameters must be
examined. Insulator testing requires two types of electrical tests: wet flashover (a
one- to three-minute rain test) and dry flashover (one minute to three- minute dry
test).

 DRY FLASHOVER TEST

In the dry state, the test object is exposed to a high-frequency voltage. The power
voltage is boosted to the stated voltage rating of the insulator plate. This voltage

51
rating is kept for a set amount of time. The voltage is increased after one minute till
the flash happens. This method needs to be done five times. It is calculated the
average flashover voltage of the five flashes. The average voltage must not be less
than the power frequency's value.

 WET FLASHOVER TEST

Artificial rain is required to create a realistic rainy environment around the insulator.
A test voltage is applied to the insulator for a set amount of time, and rain can fall on
it. The voltage is raised to the point where there is a flashover. Voltage is provided
again after a few seconds. To calculate the average flashover voltage, repeat the
method five times more. The average voltage must not be less than the application's
stipulated wet flashover voltage.

52
8.0 CONCLUSION

In a nutshell, FEA simulation was used to accomplish the project's goals.

Furthermore, we may learn how to create an insulator model for finite element
analysis by utilising the Finite Element Method Magnetics (FEMM) programme,
which takes into account material characteristics, boundary conditions, and mesh
construction. Insulators serve a critical part in the production, transmission, and
distribution of electricity, since these high-voltage supplies need insulators of
different sorts and sizes. The aspects that may impact the insulator's efficiency and
capacities must be taken into account while designing the insulator. The design was
adequate, and the coating element of silicon rubber allowed the gadget to withstand
higher voltages.

In addition, we may determine the insulator's performance in the selected

environment. The insulator's most significant features are the Shed, rod, and
creepage distance. Every material has benefits and limitations, however based on
our research, we determined that the optimum material for producing a plate
insulator is Because the substation uses the majority of the insulator, this can be
shown. The grading material improved and uniformed the potential of the leakage
route and field distributions.

There will be various improvements made to the insulator version in the future to
improve the resistiveness to high voltage, which will be valuable for learning and
teaching approaches. The significance of increasing creepage and giving the
insulator impact follows next. Because the insulator material will be reduced while
the space between a conductive portion and the equipment's bounding surface will
be increased. In general, the design of this insulator was based on preparatory
theoretical research and understanding of dielectric materials gathered through
lecture courses and notes. The majority of the study was conducted using books,
with extra information coming from the internet and publications.

53
9.0 REFERENCES

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