L. Kumosa

Failure analyses of nonceramic insulators. Part 1: Brittle fracture characteristics

Nonceramic insulators, also referred to as composite, polymer or polymeric insulators, are used in overhead transmission lines with line voltages in the range of 69 to 735 kV. Despite the many benefits that nonceramic insulators offer in comparison with their porcelain counterparts, they can fail mechanically in service by rod fracture. One of the mechanical failure modes of the insulators is a failure process called brittle fracture, which is caused by the stress corrosion cracking (SCC) of the GRP rods. The process is catastrophic and unpredictable, leading to the drop of energized transmission lines. The most important characteristics of the brittle fracture process, which can occasionally affect high voltage nonceramic transmission line insulators, leading to their catastrophic in-service failures, have been presented in this article. In addition, several experimental techniques were suggested for the simulation of brittle fracture under laboratory conditions. Only the most important aspects of brittle fracture process have been discussed here.

Causes and potential remedies of brittle fracture failure of composite (nonceramic) insulators

Existing brittle fracture models have been reviewed and their applicability to explain the in-service brittle fracture failure of composite (nonceramic) insulators is evaluated. It is shown that the only brittle fracture model that can explain all aspects of the brittle fracture process is a model based on the formation of nitric acid solutions in-service. The chemical cause of brittle fracture is identified in this work and recommendations are made on how to avoid brittle fracture in-service by proper selection of composite insulator rods resistant to brittle fracture. An attempt is made to clarify misconceptions that exist in the literature regarding the causes of brittle fracture and the most suitable prevention methods.

Failure analyses of nonceramic insulators: part II - the brittle fracture model and failure prevention

In this work, an improved version of a brittle fracture model, based on the formation of nitric acid in service through corona discharges, ozone, and moisture, is presented and is used to explain several different modes of brittle fracture. Similar to Part I, we refer throughout this article to the insulators as nonceramic insulators (NCIs). To prevent brittle fracture in-service, its causes must be first established. To prevent brittle fracture in-service, its causes must be first established.

FTIR analysis of non-ceramic composite insulators

The chemical environment responsible for the brittle fracture failure of composite (non-ceramic) insulators is determined. Also previously reported observations by the authors are verified. Five non-ceramic composite suspension insulators and one composite guide were subjected to FTIR analysis. Out of the six field failed units, five insulators showed significant levels of nitrate on their brittle fracture surfaces with small traces of nitrate also found on the fracture surfaces of the composite guide. The results strongly indicate that the most probable cause of brittle fracture failure of composite RV insulators in-service is the formation of nitrate and thus nitric acid. This is consistent with the observations and conclusions previously reported by the authors.

Resistance to brittle fracture of glass reinforced polymer composites used in composite (nonceramic) insulators

In this paper, the most important results are presented and discussed from a multiyear interdisciplinary study directed toward the identification of the most suitable glass/polymer composite systems with the highest resistance to brittle fracture for high voltage composite insulator applications. Several unidirectional glass/polymer composite systems, commonly used in composite insulators, based either on E-glass or ECR-glass fibers embedded in either polyester, epoxy, or vinyl ester resins have been investigated for their resistance to stress corrosion cracking in nitric acid. The most important factors (fiber and resin types, surface fiber exposure, polymer fracture toughness, moisture absorption, interfacial properties, sandblasting) affecting the resistance of the composites to brittle fracture have been identified and thoroughly analyzed. It has been shown that the brittle fracture process of composite (nonceramic) insulators can be successfully eliminated, or at least dramatically reduced, by the proper chemical optimization of composite rod materials for their resistance to stress corrosion cracking.

Water diffusion into and electrical testing of composite insulator GRP rods

This paper describes water diffusion into and electrical testing of unidirectional glass reinforced polymer (GRP) composite rods used as load bearing components in high voltage composite (non-ceramic) insulators. The tests were performed following ANSI standard C29.11 Section 7.4.2 that can be used to evaluate electrical properties of composites. The unidirectional composite rod materials based on either E-glass or ECR-glass fibers with modified polyester, epoxy and vinyl ester resins were investigated. Two types of ECR-glass fibers were considered, namely high and low seed (voids). The effects of composite surface sandblasting, mechanical pre-loading and nitric acid exposure on the electrical properties of the composites were studied. In addition to the required data of the ANSI standard, the specimen mass gain was also measured after boiling for 100 h. Most importantly, there was no correlation found between the mass gain and the leakage current for different composites. The materials with high seed ECR-glass fibers had much higher leakage currents and they absorbed less moisture than the composites based on either the low seed ECR-glass fibers or E-glass fibers. It was shown in this work that different types of sandblasting, as well as mechanical preloading with and without acid exposure had a negligible effect on the leakage currents and water mass gain of the composite specimens.

Determination of Interlaminar Residual Thermal Stresses in a Woven 8HS Graphite/PMR-15 Composite Using X-Ray Diffraction Measurements

This work is a continuation of the research recently presented in [1] and [2] on the determination of residual thermal stresses in graphite/polyimide composites with and without externally applied bending loads. In the previous work [1, 2] a combined experimental and numerical methodology for the determination of the residual stresses in unidirectional graphite/PMR-15 composites based on X-ray diffraction (XRD) measurements of residual strains in embedded aluminum (Al) and silver (Ag) inclusions has been presented. In this research, the previously developed approach has been applied to evaluate the residual thermal interlaminar stresses in an 8 harness satin (8HS) woven graphite/PMR-15 composite. First, residual thermal stresses have been measured by XRD in aluminum inclusions embedded between the first and second plies of a four-ply 8HS woven graphite/PMR-15 composite. The measurements have been conducted with the composite specimens subjected to four-point bending deformations. Second, viscoelastic computations of interlaminar residual stresses in the composite have been performed using classical laminated plate theory (CLPT) following the manufacturing procedure. Third, the residual strains and stresses in the inclusions have been numerically predicted using the viscoelastic Eshelby model for multiple spherical inclusions. Finally, the interlaminar residual stresses in the composite have been extracted from the XRD strains in the Al inclusions, again using the viscoelastic Eshelby model, and subsequently compared with the residual stresses from the CLPT. It has been shown in this study that the residual interlaminar thermal stresses can be accurately determined not only in unidirectional graphite/polyimide systems as presented in [1] and [2], but also in woven graphite polymer matrix composites.

Comparison of the ±45° Tensile and Iosipescu Shear Tests for Woven Fabric Composite Materials

The mechanical response of a woven eight-harness satin graphite/polyimide composite has been investigated by performing ±45° tensile and Iosipescu shear tests at room temperature. Nonlinear finite element simulations of the tests have been conducted to determine internal stress distributions in the ±45° tensile and Iosipescu fabric specimens as a function of load. In the experimental part of this study, a series of tensile and Iosipescu shear tests have been performed. Acoustic emission techniques have been employed to monitor damage initiation and progression in the composite. The finite element computations have shown that the internal stress distributions in the Iosipescu and tensile fabric specimens are significantly different. In the gage sections of Iosipescu specimens, the state of stress is essentially pure shear, whereas the tensile tests generate biaxial stress conditions. It has been shown in this research that the shear strength of the composite determined from the maximum loads obtained from the Iosipescu shear tests is significantly higher than the shear strength obtained from the ±45° tensile tests. Moreover, the initiation of intralaminar damage in the tensile specimens occurs at much lower loads than in the Iosipescu specimens. It appears that the ±45° tensile test significantly underestimates the shear strength of the composite evaluated from the onset of intralaminar damage and the maximum loads.

An investigation of moisture and leakage currents in GRP composite hollow cylinders

The applicability of using flat composite plates and hollow core composite cylinders for moisture absorption testing of unidirectional glass/polymer composites used in high voltage composite (non-ceramic) insulators was examined. Two main issues were addressed in this work. First, the effect of specimen geometry (cylinders vs. plates) on moisture absorption by the composites was investigated both numerically and experimentally. Both classical Fickian and non-Fickian diffusions were considered. Subsequently, hollow core cylinders made up of ECR (low seed)-glass fibers and epoxy resin were tested for their high voltage properties under controlled moisture diffusion conditions. The specimens were exposed to warm, moist air and their high voltage properties were ascertained using a modified version of the ANSI test (standard C29.11 Section 7.4.2) for water diffusion electrical testing. It was found that the behavior of the hollow core cylinder and flat plate composite specimens subjected to moisture compared reasonably well experimentally and very well numerically. From the high voltage tests, a direct correlation was found between the amount of moisture that had been absorbed by the specimens and the amount of leakage current that was detected. It was shown that using the thin walled composite cylinders leakage currents could be predicted based on the amount of absorbed moisture in the insulator composites. The predictions can be made based on relatively short term moisture data even if the diffusion process in the composites is anomalous in nature with long times required for full saturation. After additional verifications, considering other composite systems, the hollow core cylinder testing under controlled moisture and high voltage conditions could become a screening test for selecting suitable glass/polymer composites for insulator applications.

Discussion on "Can water cause brittle fracture failures of non-ceramic insulators in the absence of electric field" [and reply]

It was postulated by J. Montesinos et al. (see ibid., vol.9, p.236-43, 2002), based on experimental evidence, that brittle fracture failures of composite (non-ceramic) HV insulators could be caused by water and mechanical stresses. It was also claimed therein that the brittle fracture process was more likely to happen with water than acids. This postulation could be of major importance as its ramifications might affect the entire composite insulator technology and, in particular, the usage of glass fiber polymer matrix composites in HV applications. Such an important statement should not be left without an independent verification. Therefore, attempts have been made in this research to initiate this process in unidirectional E-glass/modified polyester and E-glass/vinyl ester composites, used in non-ceramic insulators, by subjecting them to water under four-point bending conditions. This was done to independently verify the main conclusion of J. Montesinos et al. that water may be more damaging to unidirectional E-glass/polymer composites than acids. It has been clearly shown in this work that water, in the absence of electrical field, cannot cause stress corrosion cracking of unidirectional E-glass/polymer composites and thus brittle fracture of composite non-ceramic insulators. Thus the main results of J. Montesinos et al. could not be independently reproduced.