I EC Core Material Test Report Fiberglass Reinforced Plastic (FRP) rods

The Fiberglass Reinforced Plastic (FRP) rod material of the composite suspension insulator product line was evaluated following the requirements of t he IEC 62039 Ed.3-2007 standard. All tests were implemented and evaluated in accordance with the Standard test procedure listed in the IEC 62039 Ed.3-2007. Test samples varying in length were manufactured on the production line to meet the Test Specimen requirements.

Test Title IEC Standard

Resistance to Chemical and Physical Degradation by Water ______ (62039: 3·4 & 62217: 9.4.2) Resistance to Chemical Attack (62039: 3.8 & 61109: 11.2) Glass Transition Temperature (62039: 3.12 & 61006: 7.)

Report Report Numbers

STRI report ______________ _ _____________ T16-2387

EGU report 10368/B/16 lntertek Wilton report IWTN/Wooooo4694RLoo1

It was concluded that the Fiberglass Reinforced Plastic (FRP) rod of the composite suspension insulators met all of the I EC 62039 requirements. A brief summary of the individual reports is provided on the following page.

June 17, 2016 Issue Date Design Engineering Engineering Manager

 

   June 17, 2016       Issue Date   

Material Specifications 

  Manufacturer:   Maclean Power Systems – Newberry    Material Type:   Fiberglass Epoxy Rod   Product Number:   P70585 

Results Summary 

Resistance to Chemical and Physical Degradation of Water   (62039: 3.4) The  test was performed  in  the external accredited  laboratory STRI. The  test was performed  in accordance with IEC 62217: 9.4.2. 

The core material PASSED the requirements given  in IEC 62217: 9.4.2.5 based on the test report T16‐2387 from STRI.  

Resistance to Chemical Attack  (62039: 3.8) The  test was performed  in  the external accredited  laboratory EGU. The  test was performed  in accordance with IEC 61109: 11.2.2 and 62039: 3.8.  

The core material PASSED  the  requirements given  in  IEC 61109:  11.2.3 based on  the  test  report 10368/B/16 from EGU. 

Glass Transition Temperature   (62039: 3.12) The  test was  performed  in  the  external  accredited  laboratory  Intertek Wilton.  The  test was performed in accordance with IEC 61006: 7.7. 

The  core material PASSED  the  requirements given  in  IEC 61006:  7.8 based on  the  test  report IWTN/W000004694RL001 from Intertek Wilton. 

 

   

T16-2387

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Table of Contents Front Page .................................................................................................................................................. 1 Table of Contents ........................................................................................................................................ 21 Test object ........................................................................................................................................... 32 Tests .................................................................................................................................................... 33 Results................................................................................................................................................. 4

3.1 Water immersion test.............................................................................................................. 43.2 Water diffusion test ................................................................................................................. 5

4 Atmospheric conditions ....................................................................................................................... 65 Test circuits ......................................................................................................................................... 7

5.1 Water immersion test: The tan measurement ..................................................................... 75.2 Water diffusion test: The voltage test ..................................................................................... 7

6 Dimension drawings ............................................................................................................................ 87 Photos ............................................................................................................................................... 10

7.1 Water immersion test............................................................................................................ 107.2 Water diffusion test ............................................................................................................... 12

8 Measurement uncertainties ............................................................................................................... 13

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1 Test object

Test object: 9 samples, external diameter 45 mm, cut from the shank of an insulator

Manufacturer: MacLean Power Systems Insulator designation: CS 400 C28L-1675/8400/3500

CS 400 C28L-1675/10500/3500 Catalog Number: S3 6M 6M 119 VXSS 044

S3 6M 6M 119 VX SS 061 Rev. 01 Rev. 02

Test Water immersion test Water diffusion test Test object denomination 6 7 8 20 21 22 23 24 25

2 Tests The tests were performed in the sequence below.

On test objects 6-8: o Water immersion test

o measurement before water immersion test o 50 days in 50°C water immersion o measurement after water immersion test

On test objects 20-25: o Water diffusion test

o 100 hours of boiling o 12 kVrms voltage test

In the water immersion test, three samples were immersed in water at 50°C for 50 days. The samples were placed in a glass container and covered with deionised water. The container was placed in an oven where the temperature was raised to 50 °C and was kept stable throughout the test period. The temperature was measured inside the glass container by means of Thermocouples, type T (copper-constantan). The measured temperature was displayed on a Fluke 51 II Thermometer. Tan was measured before and after the 50 days of water immersion.

In the diffusion test, six samples were boiled in a glass container for 100 hours in deionised water with 0.1 % NaCl by weight. The samples were prepared according to the standard. After 100 hours the samples were immediately placed in a glass bowl of ambient temperature tap water for 30 minutes. The voltage test was carried out within an hour after the boiling was stopped.

The voltage test in the water diffusion test in the water immersion test is covered by the STRI accreditation. The instrument used for current measurement during the voltage test and the temperature measurement during the water immersion test was traceable calibrated but is not included in the STRI accreditation.

Measurement uncertainties are included in clause 8.

T16-2387

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3 Results

3.1 Water immersion test The water immersion test was carried out on three samples; no 6, 7 and 8. The loss factor was measured before and after the water immersion. The results are presented in Table 1 and Table 2 respectively.

Acceptance criteria according to standard: < 20 % after 50 days of water immersion at 50 °C

Table 1. Results from water immersion test.

Test specimen No.

Test voltage (kVrms) (%)

6 5.0 2.6 7 5.0 3.1 8 5.0 3.0

Table 2. Results from water immersion test.

Test specimen No.

Test voltage (kVrms) (%)

6 5.4 11.5 7 5.2 10.9 8 5.2 11.2

The test object fulfilled the requirements in accordance with the standard.

Result: Tan were less than 0.2 after the 50 days immersion test.

T16-2387

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3.2 Water diffusion test The water diffusion test was carried out on six samples, no. 20-25. The voltage test was carried out after the 100 hours of boiling. The voltage was raised by approximately 1 kV/second up to 12 kVrms and kept there for one minute. Each sample was tested separately. The results are presented in Table 3.

Acceptance criteria according to standard: Maximum 1mArms leakage current No puncture or flashover

Table 3. Results from voltage test.

Test specimen No.

Test voltage (kVrms)

Time (minutes)

Measured current (mA)

20 12.3 1 0.40 21 12.1 1 0.36 22 12.1 1 0.37 23 12.2 1 0.38 24 12.0 1 0.36 25 12.2 1 0.36

The test object fulfilled the requirements in accordance with the standards/specifications.

Result: The leakage currents were less than 1 mA. No puncture or flashover occurred.

T16-2387

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4 Atmospheric conditions

The atmospheric conditions during the test: t=21°C b=993 mbar h=2.74 g/m3

The atmospheric conditions during the test: t=25°C b=1004 mbar h=10.33 g/m3

12 kV voltage test The atmospheric conditions during the test: t=22°C b=1003 mbar h=3.29 g/m3

T16-2387

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5 Test circuits 5.1 Water immersion test: The tan measurement

Equipment: Presco Capacitance & -3MOD, T-054 Standard capacitor, Hartmann & Braun, 200 kV Test transformer, Ferranti, 50kV Regulator 0-450 V, 19.4 A, STRI no. 000476 Fluke 73, E-F655 and Fluke 87 E-F385 (measurement of regulator voltage)

5.2 Water diffusion test: The voltage test

Equipment: Test transformer, 30 kV Presco Capacitance & -3MOD, T-054 Standard capacitor, Hartmann & Braun, 200 kV Flashover protection T-F27 and shunt T-S30

Standardcapacitor

Connectionbox

Testsetup

Capacitance & tanmeasuring bridge

V

Test setup

ProtectionCapacitance &

measuring bridge

Standardcapacitor

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6 Dimension drawings

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T16-2387

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7 Photos 7.1 Water immersion test

The test set up for the 50 days of 50 °C water immersion test is presented in Figure 1. The test set-up for the voltage test in the immersion test is presented in Figure 2.

Figure 1. Test set-up for the water immersion test.

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Figure 2. Test set-up for the tan measurement in the water diffusion test.

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7.2 Water diffusion test The test set up for the voltage test in the water diffusion test is presented in Figure 3.

Figure 3. Test set up for the voltage test in the water diffusion test.

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8 Measurement uncertainties The coverage factor k is equal to 2, which implies a confidence interval B equal to 95%.

Table 4: Measurement uncertainty of the equipment used in the test Type Measurement uncertainty IEC-requirement AC 2.9 % 3 % Cap 0.2 % - Tan 2.2 % of reading -

Table 5: Measurement uncertainty of secondary measuring systems Type Measurement uncertainty IEC-requirement Temperature air 1.6 0.3°C) 1°C Relative air humidity 2.9 % of reading See notePressure air 0.19 1.9 hPa) 2 hPa

Note: The IEC-requirement is 1 g/m3.

TEST REPORT No.:10368/B/16

TEST REPORT No.: 10368/B/16

TEST OBJECT:

MPS CATALOG No.:

TYPE.:

MANUFACTURER:

DATE OF DELIVERY:

TEST STANDARDS:

TESTS WITNESSED BY:

ANNEX:

TABLE OF CONTENTS

1 LIST OF SYMBOLS.................................................................................................................... 4

2 TESTS PERFORMED.................................................................................................................. 5

2.1 Verification of dimension......................................................................................................5

2.1.1 Test procedure................................................................................................................5

2.1.2 Test results .....................................................................................................................6

2.1 Galvanizing test .....................................................................................................................7

2.1.1 Test procedure................................................................................................................7

2.1.2 Test results .....................................................................................................................7

2.2 Dry lightning impulse voltage test ........................................................................................8

2.2.1 Test procedure................................................................................................................8

2.2.2 Test results .....................................................................................................................9

2.3 Wet switching impulse voltage test.....................................................................................10

2.3.1 Test procedure..............................................................................................................10

2.3.2 Test results ...................................................................................................................11

2.4 Wet power-frequency withstand voltage test ......................................................................12

2.4.1 Test procedure..............................................................................................................12

2.4.2 Test results ...................................................................................................................13

2.5 Damage limit proof test and test of tightness of the interface between end fittings and insulator housing ............................................................................................................................14

2.5.1 Test specimens .............................................................................................................14

2.5.2 Performance of the test ................................................................................................14

2.5.3 Test results ...................................................................................................................15

2.6 Damage limit proof test and test of tightness of the interface between end fittings and insulator housing – resistance to chemical attack ..........................................................................16

2.6.1 Test specimen...............................................................................................................16

2.6.2 Test sample No. 5 with acid test ..................................................................................16

2.6.3 Performance of the test ................................................................................................16

2.6.4 Test result .....................................................................................................................16

3 UNCERTAINTY OF MEASUREMENTS ................................................................................ 17

4 PRODUCT DRAWING ............................................................................................................. 18

5 GRAPHS AND RECORDS ...................................................................................................... 20

6 TEST SETUP PHOTOS............................................................................................................. 25

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1 LIST OF SYMBOLS

All measured voltages are corrected for the standard reference atmosphere according to IEC 60060-1, clauses 4.3 and 4.4.2.

All measured data including values of atmospheric conditions are given in the following tables where:p air pressure (kPa),t air temperature (°C),RH relative humidity (%),

k1 air density correction factor,k2 humidity correction factor,Kt atmospheric correction factor,

U50LI 50% dry lightning impulse flashover voltage (kV), corresponding to the standard reference atmosphere,

U10LI 10% dry lightning impulse flashover voltage (kV), corresponding to the standard reference atmosphere,

U50SI 50% wet switching impulse flashover voltage (kV), corresponding to the standard reference atmosphere,

U10SI 10% wet switching impulse flashover voltage (kV), corresponding to the standard reference atmosphere,

UF wet power-frequency flashover voltage (kV), corresponding to the standard reference atmosphere,

UMW maximum wet power-frequency withstand voltage (kV), corresponding to standard reference atmosphere,

r.i. average value of the measured rainfall intensity (mm/min): - v.c. - vertical component, - h.c. - horizontal component,

Conductivity water conductivity (µS/cm).

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2.6 Damage limit proof test and test of tightness of the interface between end fittings and insulator housing – resistance to chemical attackTest was carried out according to IEC 61109, clause 11.2 and IEC/TR 62039, clause 3.8.

2.6.1 Test specimenTest was carried out according to IEC 61109, clause11.2 and IEC/TR 62039 clause 3.8. The test was performed on shorter special test samples acc. IEC 61109, clause 11.2.1, test samples were without sheds (see Figure 2). The production process, coupling size and all dimensions, except length, are same. The test result is applicable to composite insulator CS 400 C28L-1675/8400/3500. The one insulator was examined visually.

Test resultsInsulators were without damage

2.6.2 Test sample No. 5 with acid test

The middle part of core (without housing) with the length of at least 150 mm was smoothed by means of fine abrasive cloth (grain size 180). The acid container was arranged surrounding smoothed core surface in such a way that the liquid can simply be poured into the container and no acid comes into contact with end fittings.The size of acid container was adapted in such a way that the FRP core is surrounded of a liquid thickness not less than 1 cm and a liquid level not less than 4 cm. The container was preventvapouring of the liquid more than 5 % of its volume during the test period.

Immediately after the load application, nitric acid of a concentration of 1 n (1 n = 63 g of HNO3plus 973 g of H2O) was poured into an acid container.

Test samples No. 5 with container with acid test is shown in Figure 9.

2.6.3 Performance of the test

Test date: from 2016-02-18 till 2016-02-22Test was carried out according to IEC 61109, clause 11.2.2 and IEC/TR 62039.This test was performed on insulators No. 5.

a) test specimens with container with acid was subjected to a tensile load applied between couplings. The tensile load was increased rapidly but smoothly, from zero up to 350 kN (70 % of SML 500 kN) and then maintained at this value for 96 hours. Test samples No. 5, during tensile load test is shown in Figure 8 and 9. Picture of test sample No. 4, after tensile load test are shown in Figure 10.

Record of measured 96 hours mechanical test is given in Graph 7.

Testing and measuring equipment:hydraulic loading machine LabTest 5.600SP1, serial No. 15/12

2.6.4 Test resultConclusion: No visual surface deterioration of the core recorded on insulator No. 5.

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3 UNCERTAINTY OF MEASUREMENTS

QUANTITY UNCERTAINTY(k=2)

Lightning impulse voltageUmT1T2

1,6 %5,1 %4,0 %

Switching impulse voltageUmT1T2

2,5 %4,2 %4,0 %

Power-frequency voltage 1,7 %Mechanical load 1,0 %

Atmospheric pressure 0,04 kPaAir temperature 0,7 °C

Relative humidity 5,3 %Time 0,7 %

Conductivity (0,1 S/cm – 1000 mS/cm) 1,0 %Rainfall intensity 10,0 %

Measuring galvanizing (0 - 2000 µm) 6,7 %Water level with angle gauge 0,2°

Length – slide gauge - (0,2 – 300 mm) 120 mLength – slide gauge - (0,2 – 500 mm) 123 m

Length – yard stick (1 – 5000 mm) 630 mLength – yard stick (1 – 7500 mm) 630 m

The reported expanded uncertainty of measurement is stated as the standard uncertainty of measurement multiplied by the coverage factor k = 2, which for a Normal (Gaussian) distribution corresponds to a coverage probability of approximately 95 %.

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4 PRODUCT DRAWING

Figure 1Composite insulator CS 400 C28L-1675/8400/3500

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Figure 2Composite insulator, drawing No. F081661

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Graph 7Composite insulator, drawing No. F081661,

record of 96 hours mechanical loading test, samples No. 4 and 5 (acid test)

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Figure 7Composite insulator, drawing No. F081661,

after dye penetration test, sample No. 3

Figure 8Composite insulator, drawing No. F081661,

during verification of the 96 hours mechanical load test, test samples No. 4 and 5 (acid test)

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Figure 9Composite insulator, drawing No. F081661,test sample No. 5 with container with acid

Figure 10Composite insulator, drawing No. F081661,

test sample No. 5 after 96h mechanical load test

- end of test report -

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Report No: IWTN/W000004694RL001

Page 1 of 5

Work reported in this document is outside the scope of the UKAS ISO 17025 accreditation for UKAS Laboratory No. 0967.

Test Report

DMA Evaluation of a FRP

Test Report : IWTN/W000004694RL001

Prepared for : Michal Novotny

EGU HV Laboratory a.s.

EGU-HV Laboratory a.s. Podnikatelska 267 190 11 Praha 9 Czech Republic

Prepared by: Andrew Broadhurst Senior Experimental Scientist Intertek Wilton Room N117 ITS Testing Services (UK) Ltd The Wilton Centre Redcar TS10 4RF Telephone: 01642 435718 Fax: 01642 435777 Email: andrew.broadhurst@intertek.com

Report No: IWTN/W000004694RL001

Page 2 of 5

Work reported in this document is outside the scope of the UKAS ISO 17025 accreditation for UKAS Laboratory No. 0967.

Samples Submitted Intertek Sample Reference Sample Description Customer Identifier

IWTN/W000004694-1 FRP FRP

Description of Work Required Tg by tan delta peak - IEC 61006 Calibrations The temperatures were calibrated at 2°C/minute with a two point calibration. Phenyl Salicylate (TARM9/3) and Tin (TARM 2/3) reference materials were used. An Indium sample (TARM 1/7) was run to check the calibration, this had an onset of 154.98°C compared to the reference 156.6°C. The tabulated data has been corrected by adding 1.6°C to the computer generated results. The file number is ind6011. The modulus was calibrated using the TA Instruments calibration routine. Experimental Three specimens were machined to size and then subjected to the following test in a TA Instruments DMA. The samples were heated between 20°C and 250°C at a rate of 2°C/minute on a TA Q800 DMA using the single cantilever clamps. A frequency of 1Hz and strain of 0.09% were used. Samples were run in still air The TA Instruments Q800 DMA is not covered by our UKAS spec

TEST REPORT

Report Number: IWTN/W000004694RL001

Chit Number: ITWI-00000013308

Receipt Date: 27/04/2016

Lab Book Reference:

File Reference Location: L:\Thermal\DATA\Backup\TA Instruments\2016data

Number of Samples: 1

Method Reference: Non UKAS (IEC 61006 method DMA)

Report No: IWTN/W000004694RL001

Page 3 of 5

Work reported in this document is outside the scope of the UKAS ISO 17025 accreditation for UKAS Laboratory No. 0967.

Results

Sample ID E’ onset °C

Tan δ peak °C

E’’ peak °C

File

FRP (1) 96 143 125 xd6027

FRP (2) 97 143 126 xd6028

FRP (3) 94 151 125 xd6029

Above data has been corrected by adding 1.6°C to the computer generated results

Definitions

The following shorthand symbols have been used in the tabulated results section E’ onset : The onset of a fall in Storage Modulus

Tan δ peak : The peak of the mechanical dissipation factor

E’’ peak : The peak of the Loss Modulus Interpretations

BS EN 61006 states that the Tg should be quoted as the mean value of the dissipation factor peak (tan delta) at 1Hz. The mean tan delta peak for the three runs is 145.5°C, which is higher that the 95°C specified in the supplied specification sheet. Report Authorisation

Andrew Broadhurst

Senior Experimental Scientist Date: 27/04/2016

Intertek Wilton welcomes feedback on all aspects of the service provided to you. Please email any comments that you have to wilton.feedback@intertek.com

Report No: IWTN/W000004694RL001

Page 4 of 5

Work reported in this document is outside the scope of the UKAS ISO 17025 accreditation for UKAS Laboratory No. 0967.

94.75°C

123.85°C

141.13°C

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DMAFile: C:\TA\Data\DMA\2016data\xd6027.001Operator: AB/PLRun Date: 27-Apr-2016 12:11Instrument: DMA Q800 V7.5 Build 127

Universal V4.5A TA Instruments

94.98°C

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DMAFile: C:\TA\Data\DMA\2016data\xd6028.001Operator: AB/PLRun Date: 27-Apr-2016 13:50Instrument: DMA Q800 V7.5 Build 127

Universal V4.5A TA Instruments

Report No: IWTN/W000004694RL001

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Work reported in this document is outside the scope of the UKAS ISO 17025 accreditation for UKAS Laboratory No. 0967.

91.98°C

123.08°C

149.58°C

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Sample: FRP (3)Size: 17.3000 x 10.9300 x 2.7100 mmMethod: FRP at 2°C/min

DMAFile: C:\TA\Data\DMA\2016data\xd6029.001Operator: AB/PLRun Date: 27-Apr-2016 15:27Instrument: DMA Q800 V7.5 Build 127

Universal V4.5A TA Instruments