Enhancing the Performance Consistency of Porcelain Insulators by Understanding Failure Modes: Case Study Approach

Abstract: World over, 40% of insulators used in transmission and distribution segment of power are the composite insulators made from polymeric compound. These insulators are very light in weight, almost 1/5th of conventional porcelain or glass insulators and cost almost 25% of the conventional insulators. Thus, they clearly have technical advantage over porcelain insulators because of their hydrophobic property. This feature enables them to withstand very high pollution levels. In tune with the global demand for pollution control, the demand for these composite insulators are increasing simply because, the high pollution causes frequent flashover and disrupt the power supply. The low cost of composite insulators reduces the project cost thus threatening the demand for conventional porcelain insulators. This is affecting their market share in business. A case study has been undertaken to study the Global Insulators Ltd., Dhanbad in India with an intent to, probe into use of composite insulators, which have not been time tested for their sustenance in the face of their frequent failures, despite their enhanced hydrophobic property. The study is intended to find a reprieve for demand of the conventional porcelain insulators through root cause analysis of failure and suggest ways to enhance their di-electric properties to increase their life. In order to safe guard the business interest of the manufacturer; the name has been changed along with altered data values without affecting the outcome for the results.

Keywords: Composite, Insulators, di-electric, root cause, hydrophobic.