BIS 2005

B U R E A U O F I N D I A N S T A N D A R D S
MANAK BHAVAN, 9 BAHADUR SHAH ZAFAR MARG
NEW DELHI 110002
IS : 5621 - 1980
(Reaffirmed 2004)
Edition 2.2
(1987-01)
Price Group 6
Indian Standard
SPECIFICATION FOR
HOLLOW INSULATORS FOR USE IN
ELECTRICAL EQUIPMENT
( First Revision )
(Incorporating Amendment Nos. 1 & 2)
UDC 621.315.62-46 : 621.315.612
IS : 5621 - 1980
BIS 2005
BUREAU OF INDIAN STANDARDS
This publication is protected under the Indian Copyright Act (XIV of 1957) and
reproduction in whole or in part by any means except with written permission of the
publisher shall be deemed to be an infringement of copyright under the said Act.
Indian Standard
SPECIFICATION FOR
HOLLOW INSULATORS FOR USE IN
ELECTRICAL EQUIPMENT
( First Revision )
Electrical Insulators and Accessories Sectional Committee, ETDC 3
Chairman Representing
SHRI L. C. JAIN Central Electricity Authority, New Delhi
Members
DIRECTOR (TRANSMISSION) ( Alternate I to
Shri L. C. Jain )
DEPUTY DIRECTOR (SUBSTATION) ( Alternate II to
Shri L. C. Jain )
SHRI B. C. BANERJEE All India Pottery Manufacturers Association,
Calcutta
SHRI N. K. GUHA ( Alternate )
SHRI CHANDER PARKASH Bengal Potteries Ltd, Calcutta
SHRI S. C. SEN ( Alternate )
SHRI D. S. CHABHAL Directorate General of Technical Development,
New Delhi
SHRI R. T. CHARI Tag Corporation, Madras
SHRI A. GURUPATHAM ( Alternate )
SHRI K. S. CHELLAPPAN Tamil Nadu Electricity Board, Madras
SHRI N. R. SANKARAN ( Alternate )
SHRI A. K. CHOPRA Punjab State Electricity Board, Patiala
SHRI NIRVAIR SINGH ( Alternate )
SHRI A. N. DEB Damodar Valley Corporation, Calcutta
SHRI A. C. BOSE ( Alternate )
DIRECTOR OF RESEARCH (T & D) Maharashtra State Electricity Board, Bombay
D I R E C T O R (TRACTION AND
INSTALLATION)
Research, Designs and Standards Organization
(Ministry of Railways), Lucknow
JOINT DIRECTOR STANDARDS
(TI) ( Alternate )
SHRI H. M. S. LINGAIAH Karnataka Electricity Board, Bangalore
SHRI G. S. MAHAGAONKAR Mysore Porcelains Ltd, Bangalore
SHRI S. K. MUKHERJEE National Test House, Calcutta
SHRI U. S. VERMA ( Alternate )
DR G. M. PHADKE Indian Electrical Manufacturers Association,
Bombay
SHRI P. RAMACHANDRAN ( Alternate )
( Continued on page 2 )
IS : 5621 - 1980
2
( Continued from page 1 )
Members Representing
SHRI J. M. PRANJPAY Directorate General of Posts and Telegraphs,
New Delhi
SHRI T. L. BHATIA ( Alternate )
SHRI P. S. RAMAN NGEF Limited, Bangalore
SHRI E. P. WILFRED ( Alternate )
SHRI R. SUBBA RAO Bharat Heavy Electricals Ltd, Bhopal
SHRI M. L. MITTAL ( Alternate I )
SHRI D. N. NAIDU ( Alternate II )
SHRI M. SANKARALINGAM Directorate General of Supplies & Disposals,
New Delhi
DEPUTY DIRECTOR OF INSPECTION ( Alternate )
SHRI P. K. SAXENA Rural Electrification Corporation Ltd, New Delhi
SHRI G. L. DUA ( Alternate )
SHRI N. S. SEETHURAMON W. S. Insulators of India Ltd, Madras
SHRI V. SRINIVASAN ( Alternate )
SHRI R. D. SHETH Electro Metal Industries, Bombay
SHRI V. VENUGOPALAN ( Alternate )
DR U. S. SINGH High Tension Insulator Factory, Ranchi
SHRI A. D. DUA ( Alternate )
SHRI SURENDRA SINGH U.P. Government Pottery Development Centre,
Khurja
SHRI T. B. L. SRIVASTAVA ( Alternate )
SHRI L. VENKATESUBBU Seshasayee Industries Ltd, Vadalur South Arcot
District
SHRI R. V. ACHUTHAN ( Alternate )
SHRI S. P. SACHDEV,
Director (Elec tech)
Director General, ISI ( Ex-officio Member )
Secretaries
SHRI R. K. MONGA
Deputy Director (Elec tech), ISI
SHRI R. S. SARMA
Assistant Director (Elec tech), ISI
Panel for Dimensions of Bushings, ETDC 3 : P3
Convener
SHRI V. SRINIVASAN W. S. Insulators of India Ltd, Madras
Members
SHRI K. N. JAYARAM Mysore Porcelains Ltd, Bangalore
SHRI S. V. MANERIKAR Crompton Greaves Ltd, Bombay
SHRI M. L. MITTAL Bharat Heavy Electricals Ltd, Bhopal
SHRI S. P. SINGH ( Alternate I )
SHRI B. KRISHNAMURTHY ( Alternate II )
SHRI R. G. PRADHANANI Bharat Bijlee Ltd, Bomaby
SHRI P. RAMACHANDRAN Transformers & Electricals Kerala Ltd, Angamally
South P.O.
SHRI KURIAKOSE ANTONY ( Alternate )
SHRI P. S. RAMAN NGEF Limited, Bangalore
DR U. S. SINGH High Tension Insulator Factory, Ranchi
SHRI A. D. DUA ( Alternate )
IS : 5621 - 1980
3
Indian Standard
SPECIFICATION FOR
HOLLOW INSULATORS FOR USE IN
ELECTRICAL EQUIPMENT
( First Revision )
0. F O R E W O R D
0.1 This Indian Standard (First Revision) was adopted by the Indian
Standards Institution on 29 October 1980, after the draft finalized by the
Electrical Insulators and Accessories Sectional Committee had been
approved by the Electrotechnical Division Council.
0.2 The object of this standard is to prescribe methods of test and accep-
tance criteria for hollow insulators for use in electrical equipment. This
standard does not specify impulse voltage or power frequency voltage
type tests as the withstand voltages are not characteristics of the hollow
insulator itself, but of the apparatus of which it ultimately forms a part.
0.3 This standard was first issued in 1970 and covered the requirements
of large hollow porcelains only. This revision has been undertaken for
inclusion of the requirements of small hollow insulators in this standard.
0.4 In the preparation of this standard, assistance has been derived from
IEC Publication 233 (1974) Tests of hollow insulators for use in electrical
equipment issued by the International Electrotechnical Commission.
0.5 This edition 2.2 incorporates Amendment No. 1 (July 1983) and
Amendment No. 2 (January 1987). Side bar indicates modification of the
text as the result of incorporation of the amendments.
0.6 For the purpose of deciding whether a particular requirement of this
standard is complied with, the final value, observed or calculated,
expressing the result of a test, shall be rounded off in accordance with
IS : 2-1960*. The number of significant places retained in the rounded
off value should be the same as that of the specified value in this standard.
1. SCOPE
1.1 This standard covers the requirements of insulating shrouds,
weather shields and containers made of ceramic material and applies
before any metal fittings are attached to them. These components are
collectively referred to in this standard as hollow insulators. They are
intended for use in electrical equipment operating on alternating
current at a frequency not greater than 100 Hz or direct current.
*Rules for rounding off numerical values ( revised ).
IS : 5621 - 1980
4
1.1.1 A hollow insulator consists of a single insulating element or of
several parts permanently joined together.
NOTE 1 The hollow insulators covered by this standard consist of hollow bodies, open
from end to end with or without sheds, intended for use in electrical equipment such
as of the following types:
NOTE 2 Hollow insulators are characterized by their shape and the dimensions given
on the relevant drawings.
2. TERMINOLOGY
2.0 For the purpose of this standard, the following definitions shall apply.
2.1 Lot All the hollow insulators of the same type and design manu-
factured under similar conditions of production, offered for acceptance;
a lot may consist of the whole or part of the quantity offered.
2.2 Type Tests Tests carried out to prove conformity with the
specification. These are intended to prove the general qualities and
design of a given type of hollow insulator.
2.3 Acceptance Tests Tests carried out on samples taken from a
lot for the purpose of acceptance of the lot.
2.4 Routine Tests Tests carried out on each hollow insulator to
check requirements which are likely to vary during production.
3. TESTS
3.1 General
3.1.1 Type Tests The hollow insulators shall be subjected to the
following type tests:
NOTE 1 For certain applications, hollow insulators may have to be submitted to
other tests, for example, internal pressure tests or bending tests. Such tests should
always be the subject of agreement between the manufacturer and the purchaser and
will generally be considered as additional tests and not replacements for the normal
a) Instrument transformers,
b) Lightning arresters,
c) Capacitors,
d) Bushings,
e) Cable sealing ends,
f) Circuit-breakers, and
g) Cable sealing boxes.
a) Visual inspection (3.2),
b) Electrical routine test (3.3),
c) Verification of dimensions (3.4),
d) Porosity test (3.5), and
e) Temperature cycle test (3.6).
IS : 5621 - 1980
5
tests listed above. Although the scope of this standard is limited to hollow insulators
before the metal fittings are attached, these special tests may have to be done after the
attachment of the metal fittings. Attention is drawn to the risk that excessive loads in
these special tests may adversely affect the performance of insulators in service. In
general, routine test loads should not exceed 70 percent of the minimum failing load.
NOTE 2 Type tests are normally made once and unless otherwise agreed to, test
certificate giving the results of type tests, made on not less than three hollow
insulator, identical in all essential details with those to be supplied, are regarded as
evidence of compliance.
NOTE 3 Type tests shall be made and certified by the manufacturer or by an agreed
independent authority.
NOTE 4 Type tests shall be made on the hollow insulator that has passed the
routine tests.
3.1.2 Acceptance Tests The acceptance tests shall comprise of the
following:
3.1.2.1 The acceptance tests are made on a small number of hollow
insulators selected from the lot after passing the routine tests. The
recommended sampling scheme shall be as given in Appendix A.
3.1.3 Routine Tests The following shall be carried out as routine
tests on every hollow insulator:
NOTE In special cases, the verification of certain dimensions should be a routine
test. In such cases, the relevant drawing or the order should specify which.
dimensions are to be verified as a routine test.
3.2 Visual Inspection
3.2.1 The glaze shall be smooth and free from any faults prejudicial to
satisfactory performance in service. The colour shall be as specified on
the drawing, but small variations in colour shall be permitted and
shall not constitute cause for rejection.
3.2.2 Glazed and unglazed areas shall be in accordance with the drawing.
3.2.3 In general, glaze faults which affect only the appearance of a
hollow insulator shall be permitted on the parts visible in service, if:
a) Verification of dimensions (3.4),
b) Porosity test (3.5), and
c) Temperature cycle test (3.6).
a) Visual inspection (3.2),
b) Electrical routine test (3.3), and
c) Verification of important dimensions (3.4) ( see Note ).
a)
their total surface area is less than: mm
2
,
b)
the area of a single glaze fault is less than: mm
2
100
D . L
1 000
-------------- - +
50
D . L
10 000
------------------ +
IS : 5621 - 1980
6
where
3.2.4 The total area of glaze fault permitted by the formula given above
may not be acceptable if the faults are concentrated in groups which
unduly affect the appearance. In such cases, high resistance coating may
be applied to the insulator to restore its appearance. The coated hollow
insulators may be accepted if it withstands the electrical routine test (3.3)
satisfactorily.
3.2.5 For certain hollow insulators, it may be specified at the time of
ordering or on the drawing that glaze faults on the surfaces not visible
in service shall be in accordance with special requirements or,
alternatively, that the above requirements for external surfaces shall
apply also to internal surfaces. In the latter case, D shall be taken as
the greatest inside diameter of the hollow insulator (expressed in
millimetres).
3.3 Electrical Routine Test
3.3.1 This test is intended to verify the soundness of the wall of the hollow
insulator by means of a voltage applied between internal and external
electrodes.
3.3.2 The internal electrode shall be one of the following types:
Water, filling the hollow insulator, bottom end of which has been
closed;
or
A conductor applied to the internal profile.
3.3.3 The external electrode may consist of ribbons of damp cloth or
any other conductor (chains, wires, etc) placed on the external wall as
considered necessary and particularly at any joints made during
manufacture.
3.3.4 An alternating voltage with a frequency in the range of 15 Hz to
100 Hz shall be applied between the internal and external electrodes.
Its value shall be equal to 1.5 kV rms per millimetre of wall thickness
of the hollow insulator at its thinnest point, with a minimum of 35 kV.
This voltage shall be maintained for 5 minutes.
3.3.5 For small hollow insulators, the minimum voltage of 35 kV may not
always be applicable because of flashover. In such cases, the highest
practicable voltage shall be applied.
3.3.6 Any insulator which punctures during the test shall be eliminated.
NOTE When a hollow insulator does not contain any joints made before or after
firing, for example, when it is manufactured solely by extrusion, the electrical routine
test may be eliminated by agreement between the manufacturer and the purchaser.
D = greatest external diameter over the sheds, and
L = height of the hollow insulator (each expressed in millimetres).
IS : 5621 - 1980
7
3.4 Verification of Dimensions
3.4.1 The dimensions shall conform with the values indicated on the
drawing.
3.4.2 Unless otherwise specified, the tolerance on each dimension shall
be:
(0.04 d + 1.5) mm, where d is equal to or less than 300
(0.025 d + 6) mm, where d is greater than 300
d being the value expressed in millimetres, on the drawing for the
dimension concerned.
NOTE If a minimum creepage distance is specified on the drawing, it should be
considered as the minimum value to be obtained in measurements on the insulators.
If the creepage distance is specified as a nominal value, the negative tolerance stated
above will apply.
3.4.3 The tolerances on diameter of upper and lowest ends, wall
thickness and ground portion are given in Appendix B. The
permissible limits of out of roundness of inside and outside diameters
(also known as ovality), camber, tilt of shed and sand band, lean and
parallelism of ground surfaces and finish are also given in Appendix B.
3.5 Porosity Test
3.5.1 Verification of the absence of porosity shall be carried out:
3.5.2 The pieces used for the porosity test shall be representative of the
batch of hollow insulators and their minimum dimensions shall
approximate to the thickness defined in Table 1.
3.5.3 The test pieces shall be broken into fragments which shall be
immersed in a 1 percent alcohol solution of fuchsin (1 g fuchsin in 100 g
methylated spirit). The solution shall be maintained at a pressure not less
than 15 10
6
N/m
2
during a time such that the product of the test
duration in hours and the test pressure in newtons per square metre is
not less than 180 10
6
.
3.5.4 The fragments shall then be removed from the solution, washed,
dried and again broken.
3.5.5 Examination with the naked eye of the freshly broken surfaces shall
not reveal any dye penetration. Penetration into small cracks formed
during the initial breaking of the test specimen shall be neglected.
a) on control blocks of the same ceramic composition as the hollow
insulator, fired adjacent to it, in the position considered by the
manufacturer to be the region of minimum temperature;
b) or by agreement between manufacturer and purchaser on pieces
of representative thickness cut from the hollow insulator during
grinding; and
c) or on pieces from a hollow insulator of the same batch rejected
for other reasons or broken during test.
IS : 5621 - 1980
8
3.6 Temperature Cycle Test
3.6.1 The hollow insulator initially at ambient temperature shall be
quickly immersed, without being placed in an intermediate container,
in a water-bath maintained at a temperature tC above that of the cold
water and shall remain submerged for a period of 15 + 0.7 m minutes
with a maximum of 30 minutes ( m being the mass of the hollow
insulator in kilograms ). It shall then be withdrawn and quickly
immersed in the bath of cold water where it shall remain submerged
for the same number of minutes.
3.6.2 This heating and cooling cycle shall be performed three times in
succession. The time taken to transfer from one bath to another shall be
as short as possible.
3.6.3 The temperature difference t is given in Table 1 as a function of the
dimensions of the hollow insulator. This temperature difference may be
marked on the drawing.
3.6.4 Alternative Test for Large Hollow Insulators
3.6.4.1 For hollow insulators having a height greater than 1 200 mm, the
following method of test may, by agreement between the manufacturer
and the purchaser, be used instead of the method of test described above.
3.6.4.2 The temperature of the hollow insulator shall be raised slowly by
any convenient means (circulation of heated air or water, infra red
TABLE 1 TEMPERATURE DIFFERENCE FOR TEMPERATURE CYCLE TEST
TEMPERATURE DIFFERENCE tC FOR THICKNESS mm
D
2
L mm
3
10
6
23 23< 26 26< 32 32< 36 36< 43 43<
(1) (2) (3) (4) (5) (6) (7)
D
2
L164 60 55 50 45 40 35
164<D
2
L410 55 55 50 45 40 35
410<D
2
L655 50 50 50 45 40 35
655<D
2
L900 45 45 45 45 40 35
900<D
2
L1 150 40 40 40 40 40 35
1 150<D
2
L2 000 35 35 35 35 35 35
D
2
L>2 000 Subject to agreement between the manufacturer and the purchaser.
D = the greatest external diameter over the sheds of the hollow insulator, expressed
in millimetres.
L = the height of the hollow insulator, expressed in millimetres.
= the greatest thickness of material defined as the diameter, expressed in milli-
metres, of the largest circle which can be inscribed in the outline of a section
through the axis of the hollow insulator ( see Fig. 1 ).
NOTE The temperature differences in Table 1 apply to insulators of parallel or tapered
internal shape which allow free access of water to the interior on immersion. Insulators
are considered not to offer free access of water if the smallest internal diameter is less
than 0.25 times the largest internal diameter. In such cases, the value of t shall be
agreed between the manufacturer and the purchaser.

IS : 5621 - 1980
9
radiation, etc) to a value tC higher than that of the cold water which is
later used to spray it with artificial rain. This temperature shall be
maintained for 15 minutes.
3.6.4.3 The hollow insulator shall then be immediately sprayed with
artificial rain at an intensity of about 3 mm per minute and this
spraying shall continue for 15 minutes.
3.6.4.4 This heating and cooling cycle shall be performed three times
in succession. The temperature difference t is given in Table 2 as a
function of the wall thickness as defined above.
3.6.5 The volume of water contained in the baths for tests above shall
be sufficiently great for the immersion of the insulator not to cause a
variation of more than 5C in the temperature of the water.
3.6.6 After the three cycles, the hollow insulator shall show no cracks
or damage to the glaze or other faults causing a deterioration in its
electrical or mechanical properties.
3.6.7 The absence, of such deterioration is considered verified if the
hollow insulator passes the electrical routine test described in 3.3.
FIG. 1 ILLUSTRATION FOR THICKNESS
TABLE 2 TEMPERATURE DIFFERENCE FOR TEMPERATURE
CYCLE TEST ON LARGE HOLLOW INSULATORS
THICKNESS TEMPERATURE DIFFERENCE tC
(1) (2)
30 70
>30 50
IS : 5621 - 1980
10
3.6.8 A hollow insulator which has successfully passed the temperature
cycle test may be supplied with the rest of the lot for normal service.
4. Clause deleted
A P P E N D I X A
( Clause 3.1.2 )
RECOMMENDED SAMPLING PROCEDURE FOR
ACCEPTANCE PURPOSE
A-1 SELECTION OF SAMPLES
A-1.1 The hollow insulators shall be selected at random from the lot
and in order to ensure the randomness of selection, procedures given
in IS : 4905-1968* shall be followed.
A-2. CRITERION FOR CONFORMITY
A-2.1 The number of hollow insulators to be selected at random in the
first stage shall be in accordance with col 1 and 3 of Table 3. Each of
the selected hollow insulators shall be tested for the acceptance tests.
If a hollow insulator fails in any one of the acceptance tests, it shall be
termed as defective. The lot shall be declared as accepted if the
number of defectives found in the sample is less than or equal to the
acceptance number ( see col 5 ) and shall be rejected if it is greater than
or equal to the rejection number ( see col 6 ). In case the number of
defectives lies between the acceptance number and rejection number,
the second sample of the same size shall be chosen at random and
tested. If the number of defectives found in the combined samples is
greater than or equal to the rejection number, the lot shall be rejected;
otherwise the lot shall be accepted.
*Methods for random sampling.
TABLE 3 SCALE OF SAMPLING AND PERMISSIBLE
NUMBER OF DEFECTIVES
LOT SIZE STAGE SAMPLE
SIZE
CUMULATIVE
SAMPLE SIZE
ACCEPTANCE
NUMBER
REJECTION
NUMBER
(1) (2) (3) (4) (5) (6)
2 to 100 First
Second
2
2
2
4
0
1
2
2
101 to 300 First
Second
3
3
3
6
0
1
2
2
301 to 500 First
Second
5
5
5
10
0
1
2
2
501 and above First
Second
8
8
8
16
0
1
2
2
IS : 5621 - 1980
11
A P P E N D I X B
( Clause 3.4.3 )
TOLERANCES AND PERMISSIBLE LIMITS OF CERTAIN
DIMENSIONAL CHARACTERISTICS OF HOLLOW
INSULATORS
B-1. GENERAL
B-1.1 The general tolerance formula on dimensions is given in 3.4.2 of
this standard. However, this formula may not be applicable to
dimensions like diameter of upper and lower ends, wall thickness and
ground portion and also does not cover permissible limits of out of
roundness of inside and outside diameters (also known as ovality),
camber, tilt of shed and sand band, lean and parallelism of ground
surfaces and finish. The tolerances and permissible limits for these
dimensional characteristics are covered in B-2 to B-8.
B-2. TOLERANCES ON DIAMETER OF UPPER AND LOWER
ENDS
B-2.1 Tolerances on diameter of upper and lower ends of hollow
insulators shall be as specified in Table 4 and Fig. 2.
TABLE 4 TOLERANCES ON DIAMETER OF UPPER AND LOWER ENDS
NOMINAL DIAMETER
( D, d & )
TOLERANCE
(1) (2)
mm mm
0 to 50 2.0
Above 50 and up to 75 2.5
,, 75 ,, 100 3.0
,, 100 ,, 125 3.5
,, 125 ,, 150 4.0
,, 150 ,, 175 4.5
,, 175 ,, 200 5.0
,, 200 ,, 250 5.5
,, 250 ,, 300 6.0
,, 300 ,, 350 7.0
,, 350 ,, 400 8.0
,, 400 ,, 500 9.0
,, 500 ,, 600 11.0
,, 600 ,, 700 13.0
,, 700 ,, 800 15.0
,, 800 ,, 900 17.0
,, 900 ,, 1 000 19.0
,, 1 000 2 percent
NOTE The general tolerances given in 3.4.2 of this standard shall be applicable
unless tolerances given in this table are indicated on the drawing.
IS : 5621 - 1980
12
B-3. PERMISSIBLE LIMITS OF OUT-OF-ROUNDNESS OF
INSIDE AND OUTSIDE DIAMETERS
B-3.1 Permissible limits on out-of-roundness of inside and outside
diameters [also known as ovality] shall be in accordance with Table 5
and Fig. 3.
All dimensions in millimetres.
FIG. 2 TOLERANCE ON DIAMETER OF UPPER AND LOWER ENDS
FIG. 3 OUT-OF ROUNDNESS OF INSIDE AND OUTSIDE DIAMETERS ( a b )
IS : 5621 - 1980
13
.
B-4. CAMBER
B-4.1 The camber of a hollow insulator is defined as the maximum
distance between the theoretical, straight, axis A-A of the piece as
shown on the drawing and the actual, deformed, axis of the insulator
(locus of the centres of transverse cross sections).
B-4.1.1 One method of measuring the camber is as follows:
The hollow insulator is mounted so that it may be rotated about an
axis passing through the centres of the end faces or as close as possible
to these centres. The insulator is then rotated through a complete
revolution and the distance from the outer surface of the wall to a
reference plane parallel to the axis of rotation is measured at various
points along the length of the piece. At each point, the difference
X
max
- X
min
resulting from a rotation of 180 is determined.
The camber is then given by the maximum value of: ( X
max
- X
min
).
The camber way conveniently be measured in this way while the
hollow insulator is being ground.
TABLE 5 PERMISSIBLE LIMITS OF OUT-OF-ROUNDNESS
OF INSIDE AND OUTSIDE DIAMETER
( Clause B-3.1 )
NOMINAL DIAMETER
D & d
OUT-OF-ROUNDNESS
( a b )
(1) (2)
mm mm
0 to 50 2.0
Above 50 and up to 75 2.5
,, 75 ,, 100 3.0
,, 100 ,, 125 3.5
,, 125 ,, 150 4.0
,, 150 ,, 175 4.5
,, 175 ,, 200 5.0
,, 200 ,, 250 5.5
,, 250 ,, 300 6.0
,, 300 ,, 350 7.0
,, 350 ,, 400 8.0
,, 400 ,, 500 9.0
,, 500 ,, 600 11.0
,, 600 ,, 700 13.0
,, 700 ,, 800 15.0
,, 800 ,, 900 17.0
,, 900 ,, 1 000 19.0
,, 1 000 2 percent
IS : 5621 - 1980
14
B-4.1.2 Alternatively, the camber may be checked by internal gauges:
Since a hollow insulator may have a camber up to 0.8 percent of
its length, it follows ( see Fig. 4 ) that the angle between the
perpendicular to the deformed axis and the end face after grinding may
be up to 0.032 radians. Thus, the sheds at the ends of the insulator may
be inclined at this angle and the distance H between the end shed and
the ground face of the insulator will vary round the periphery. The
minimum allowable dimension H may be shown on the drawing, taking
into account the dimensions of fittings which are to be attached to the
insulator. To verify the dimension H, H
max
and H
min
shall be measured.
The position of the end shed complies with the drawing if the average
value of H, that is H
max
+ H
min
is within the general tolerances or
any special tolerances on dimension H shown on the drawing. In
addition, the inclination of the end shed shall not be such that
H
max
H
min
exceeds 0.032 D + 3 mm, where D is the nominal
diameter of the end shed, express in millimetres. Similar considera-
tions apply to the length of sandglazing and to the height h of a
flange at the end of an insulator where the face AB is not ground and
the end face is ground ( see Fig. 5 ).
B-4.2 Camber ( in Fig. 4) It shall not be greater than the value
specified in Table 6 and Fig. 4.
FIG. 4 ILLUSTRATION FOR CAMBER
IS : 5621 - 1980
15
B-4.3 The permissible value for the camber shall be subject to special
agreement between the manufacturer and the purchaser if the ratio of
height to greatest inside diameter of hollow insulator is equal to or
greater than 6, or if the shape of the hollow insulator leads to a special
difficulty.
B-4.4 A gauge rod of diameter A as shown in Fig. 6 shall be passed
through the bore of the porcelain and rod should pass freely.
B-4.4.1 The diameter A shall be determined by the following relation
in case when centering with the porcelain axis is required:
A = ( D d ) 2
B-4.4.2 In case when centering is not required, diameter A shall be
determined by the following relationship:
A = ( D d )
where
A = diameter of gauge rod,
FIG. 5 ILLUSTRATION OF CAMBER IN CASE OF SANDGLAZING
FIG. 6 GAUGING ROD FOR CAMBER
IS : 5621 - 1980
16
D = diameter of bore,
= camber, and
d = (0.04 d + 1.5) mm where d is equal to or less than 300 mm
( see also 3.4.2).
TABLE 6 CAMBER
( Clause B-4.2 )
NOMINAL HEIGHT
L
CAMBER,
(1) (2) (3) (4)
mm mm mm mm
0 to 50 1.0 1.0 1.5
Above 50 and up to 70 1.2 1.2 1.5
,, 70 ,, 100 1.5 1.5 2.0
,, 100 ,, 200 2.0 2.0 3.0
,, 200 ,, 300 3.0 3.0 4.0
,, 300 ,, 400 4.0 4.0 5.0
,, 400 ,, 500 4.0 4.5 6.0
,, 500 ,, 600 4.5 5.0 6.5
,, 600 ,, 700 5.0 6.0 7.0
,, 700 ,, 800 5.0 6.0 8.0
,, 800 ,, 900 5.5 7.0 9.0
,, 900 ,, 1 000 5.5 7.0 9.0
,, 1 000 ,, 1 100 6.0 8.0 10.0
,, 1 100 ,, 1 200 6.0 8.0 10.0
,, 1 200 ,, 1 300 7.0 9.0 11.0
,, 1 300 ,, 1 400 8.0 10.0 12.0
,, 1 400 ,, 1 500 9.0 11.0 13.0
,, 1 500 ,, 1 800 10.0 12.0 14.0
,, 1 800 ,, 2 100 11.0 13.0 15.0
,, 2 100 ,, 2 400 12.0 14.0 16.0
,, 2 400 ,, 2 700 13.0 15.0 17.0
,, 2 700 ,, 3 000 18.0
,, 3 000 ,, 3 500 20.0
,, 3 500 ,, 4 000 22.0
,, 4 000 ,, 4 500 24.0
,, 4 500 0.8 percent
*NOTE Use B
1
or B
2
whichever is greater.

L
B
1
*
or B
2
--------------------------- 2 2
L
B
1
*
or B
2
---------------------------- 3 < 3
L
B
1
*
or B
2
--------------------------- 6 <
IS : 5621 - 1980
17
B-5. TOLERANCES ON WALL THICKNESS
B-5.1 Tolerances on wall thickness and differential of wall thickness [ a
and ( t
1
t
2
) in Fig. 7 ] shall be in accordance with Table 7 and Fig. 7.
TABLE 7 TOLERANCES ON WALL THICKNESS
NOMINAL WALL THICKNESS TOLERANCES ON WALL
THICKNESS (SEE NOTE 2 BELOW)
DIFFERENTIAL OF WALL
THICKNESS, ( t
1
t
2
)
(1) (2) (3)
mm mm mm
0 to 10 + a
1.5
1.5
Above 10 and up to 15 + a
2.0
2.0
,, 15 ,, 20 + a
3.0
2.5
,, 20 ,, 25 + a
3.5
3.0
,, 25 ,, 30 + a
4.0
3.5
,, 30 ,, 40 + a
4.5
4.0
,, 40 ,, 55 + a
5.0
4.5
,, 55 ,, 70 + a
6.0
5.0
NOTE 1 These tolerances shall not be applied to ground wall.
NOTE 2 Plus side tolerance a on all thickness shall be determined by following
equation:
x, y are diameter tolerances on diameter D and d respectively (Fig. 7).
FIG. 7 TOLERANCE OF WALL THICKNESS
a
x y +
2
------------ =
IS : 5621 - 1980
18
B-6. TILT OF SHED AND SAND BAND
B-6.1 Tilt of shed and sand band shown in Fig. 8 shall not be greater than
the value specified in Table 8 and Fig. 8. These shall be determined by
the following relations:
B-6.2 Tilt of Clamping Part The tilt of clamping part is given
in Fig. 9. The limit of tilt of clamping part shall have the same limits
as for tilt of shed and sand band.
Tilt of shed = h
1
Max h
2
Min
or h
1
Max h
2
Min
Tilt of sand band = r
1
Max r
2
Min
or r
1
Max r
2
Min
FIG. 8 TILT OF SHED AND SAND BAND
IS : 5621 - 1980
19
B-7. TOLERANCES ON GROUND PORTION
B-7.1 Porcelain body may be ground within a tolerance whose minimum
is indicated in Table 9, when specially requested by purchaser. Special
attention shall be drawn to the fact that grinding affects tolerances of
inter-relating portions as illustrated in B-7.2, B-7.3 and Fig. 10.
B-7.2 Tolerances r and s ( see Fig. 10A ) shall be determined by using
the following equations:
where
NOTE Tilt of clamping part S
1
Max S
2
Min or
S
1
Max S
2
Min
FIG. 9 TILT OF CLAMPING PART
r =
s =
( a + b ) = X H (Divide X h into a and b properly.)
r and s = tolerances of R and S respectively but minimum 2 mm,
and = tilts of R and S respectively,
X = general tolerance of H, and
h = required tolerances of H.
a

2
--- +
b

2
--- +
IS : 5621 - 1980
20

TABLE 8 TILT OF SHED AND SAND BAND
( Clause B-6.1, Fig. 8 )
NOMINAL SHED DIAMETER,
, , D or D
TILT OF SHED AND
SAND BAND
(1) (2)
mm mm
0 to 100 4.0
Above 100 and up to 200 5.0
,, 200 ,, 250 6.0
,, 250 ,, 300 7.0
,, 300 ,, 350 8.0
,, 350 ,, 400 8.0
,, 400 ,, 450 9.0
,, 450 ,, 500 10.0
,, 500 ,, 525 11.0
,, 525 ,, 550 12.0
,, 550 ,, 575 13.0
,, 575 ,, 600 14.0
,, 600 ,, 700 15.0
,, 700 ,, 800 16.0
,, 800 ,, 900 17.0
,, 900 ,, 1 000 18.0
,, 1 000 ,, 1 200 19.0
TABLE 9 TOLERANCES ON GROUND PORTION
( Clause B-7.1 )
NOMINAL DIMENSIONS TOLERANCE
(1) (2)
mm mm
0 to 100 0.2
Above 100 and up to 250 0.5
,, 250 ,, 500 1.0
,, 500 ,, 1 000 1.5
,, 1 000 ,, 2 500 2.0
,, 2 500 3.0
IS : 5621 - 1980
21
B-7.3 Tolerances a, b, r and s ( see Fig. 10B ) shall be determined by
using the following equation:
where
B-8. FINISH OF GROUND SURFACES
B-8.1 Finish of ground surfaces shall be as specified in Table 10 and
Fig. 10.
FIG. 10 TOLERANCES OF GROUND PORTION
r =
s =
a + b h
r and s = tolerances of R and S respectively but minimum 2 mm,
and = tilts of R and S respectively,

1
and
2
= general tolerances of A and B,
a and b = tolerances of A and B respectively,
h = required tolerances of H.

1
a ( )

2
--- +

2
b ( )

2
--- +
IS : 5621 - 1980
22
B-8.2 Parallelism and lean of ground portions shall not be greater than
the value specified in Table 11 and Fig. 11.
TABLE 10 FINISH OF GROUND SURFACE
( Clause B-8.1, Fig. 10 )
FINISH OF GROUND SURFACES APPLICATION
Marking Surface Finish
(1) (2) (3)
V Roughness height 25 micron PVA Max Oil-tight sealing portion and general
purpose
VV Roughness height 12 micron PVA, Max Specially air-tight sealing portion
Waviness height 25 micron PVA, Max
VVV Roughness height 3 micron Specially required portion
Waviness height 8 micron PVA, Max
TABLE 11 FINISH OF GROUND SURFACES
( Clause B-8.2, Fig. 11 )
NOMINAL HEIGHT, H LEAN, a PARALLELISM, b
( See Also Note )
(1) (2) (3)
mm mm mm
0 to 200 0.5 0.4
Above 200 and up to 300 0.8 0.4
,, 300 ,, 400 1.0 0.4
,, 400 ,, 500 1.3 0.4
,, 500 ,, 600 1.5 0.4
,, 600 ,, 700 1.8 0.4
,, 700 ,, 800 2.0 0.4
,, 800 ,, 900 2.3 0.4
,, 900 ,, 1 500 2.5 0.4
,, 1 500 ,, 2 800 3.0 0.4
,, 2 800 ,, 4.0 0.4
NOTE When special parallelism value below 0.4 mm is required, it shall be subject
so agreement between the manufacturers and the purchasers.

IS : 5621 - 1980
23
FIG. 11 PARALLELISM AND LEAN OF GROUND PORTIONS
Bureau of Indian Standards
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Review of Indian Standards
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amendments or edition by referring to the latest issue of BIS Catalogue and Standards : Monthly
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This Indian Standard has been developed by Technical Committee : ETDC 3
Amendments Issued Since Publication
Amend No. Date of Issue
Amd. No. 1 July 1983
Amd. No. 2 January 1987
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