Time-Load Testing of Non-Ceramic Insulators

With Fiberglass Core Rod - A 20 Year Summary

R. A. Bernstorf
Hubbell Power Systems - Ohio Brass Co.
Abstract: Time-Load (static fatigue) testing of fiberglass rods used
in non-ceramic insulators (NCIs) has been underway for over 20
years. Data collected over that time frame is reported in this paper
for NCIs manufactured with 16 mm ( 5 / 8 ' ) diameter and 22 mm
(7/8") diameter epoxy fiberglass rods. All of the samples tested
utilized crimped steel end fittings for transference of the applied
tensile load to the fiberglass rod and from the rod to the support
structure. Samples with and without a polymer housing covering
the core rod are included.
The data includes time-load test results under constant load to
failure and residual strength evaluations after the removal of a long-
term time-load.
The results indicate a very flat time-load curve under nominal
conditions. The residual strength tests were unable to quantify any
significant loss in strength as a result of long-term overload
conditions.
Over the course of 20 years, the investigation looked into
looked into the characteristics of 16" and 22 mm rod
insulators. In 1998, the test program was terminated, with
this paper reporting the final test results.
11. TIME-LOAD TESTING
Time-Load testing involves applying a constant load to an
insulator for an extended period of time (typically until it
fails). Unless otherwise noted, that is the means of testing
employed for the included data.
Keywords: Non-ceramic Insulators, Time-load.
I. INTRODUCTION
With the introduction of non-ceramic insulators in the late
60s and early 70s came a growing concern for the long term
strength characteristics of the fiberglass rods used as strength
members, as well as the integrity of the end fitting attachment
methods to that rod. These concerns were a product of the
aerospace industry which had been testing composite
materials and their long-term creep characteristics.
Fig. 1 - Typical outdoor load racks - 16 mm samples.
In an effort to address those concerns, a series of long-term
loading tests (time-load) were undertaken. The goal of the
testing program was the development of an understanding of
the long-term load bearing characteristics of the non-ceramic
insulators.
The non-ceramic insulators evaluated in this test program
utilized either a 15.9 mm (nominal 518 inch) Or 22.3"
(nominal 718 inch) diameter fiberglass rod. For the Purposes
of this paper, the two types will be referenced as 16 mm and
22 mm, respectively. The fiberglass rods were an epoxy
resin system with a E-type unidirectional glass fibers.
Fiberglass rod lengths were at least 20X the diameter in order
to minimize end effects.
End fittings were composed of forged steel. These fittings
were crimped to the fiberglass rod using a rolling crimp,
which proceeded from the innermost point of the end fitting
toward the end. The crimp lengths were 63.5 mm(2.5 in)
and 101.6 mm(4 in) for the 16 mmand 22 mm diameter rod
insulators, respectively.
0-7803-5515-6/99/$10.00 0 1999 IEEE
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The minimum ultimate tensile strength load ratings for the
insulators were 89 kN for the 16 mm rod and 222 kN for the
22 mm rod. The recommended maximum loadings for these
insulators were 44 kN and 11 1 kN for the 16 mm and 22 mm
rod insulators, respectively.
Samples were tested in load frames located both indoors
Samples without weathersheds were only and outdoors.
tested indoors (see fig. 1)
The load frames used lever arms to apply a load to the
insulator. All loads were established by inserting a load cell
(originally hydraulic, later electronic) and measuring the load
during three applications. The error listed for the data
represents the range. Pivot points within the load frames
were lubricated with a high pressure lubricant.
The date and time of loading was recorded exactly. For
newly loaded samples, conditions were checked daily. As
time went by, the samples were checked less frequently.
Sample failure was indicated by mechanical failure and noted
by the load bucket at the free end of the moment arm resting
on the floor. Time to failure was established as an average
time (between checks) and a range.
The data displayed large variations in time to failure as a
function of load. To make sense of the data, it was plotted as
a log-log graph (see fig. 2). The 16 mm rod diameter data
was also analyzed using Chi-Squared analysis. The analysis
was performed in the statistical mode using a logarithmic
equation as shown on the face of the graph. Assumed errors
were 3% for all data.
16" ROD - TIME LOAD DATA
course of the test for the 5/ 8 samples. All of these tests were
performed with the insulator in a vertical position. The solid
line represents the equation derived using the Chi-squared
analysis. Since the samples which did not fail are included,
the curve will be somewhat pessimistic. Had those units been
permitted to remain on test until failure, the curve would
have demonstrated less slope.
With the data for the samples which did not fail removed,
the graph shown in Fig. 3 results.
16" TIME-LOAD FAILURES
o m 1 Owool o w 0 1 owl 001 0 1 I IO I W
,,ME, YE, , , , s Ln(Y)=-O OOor88'Ln(X)+4 414
ChiA2=0 000416
Fig. 3 - Time-load data including only failures.
It should be noted that more than 95% of the samples
which failed during the test sustained a rod failure. The
remainder sustained crimp slips (the crimped fitting slides
from the rod) or hardware failures (the metallic coupling
zone fails).
100
3
2
s
9
U1
Y
0
2
-
4
10
0000001 000001 00001 0001 001 0 1 1 10 100
EUPSED TIME. YEARS
WO=- 000839*Ln(X)+4 3948
Ch1"2=00213
Fig. 4 - Outdoor load racks for 22 mm rod samples.
Fig. 2 - Time-load data including samples which did not fail.
This graph includes all of the data obtained, including the
time to removal for samples which did not fail during the
The test program for the 22 mm insulators was performed
in a similar manner. In this instance, all of the insulators
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were tested in frames which placed the insulators in a
horizontal position (see fig. 4). All of the tests were
performed outdoors, requiring the use of full insulators.
The data for the 22 mm samples was not run through the
Chi-squared analysis. However, the data is plotted in fig. 5.
22 mm Rod Time-Load Data
10
OOWOl o w 0 1 ow1 001 0 1 1 10
Elapsed Ti m. Yean
Fig. 5 - Time-load data including samples which did not fail.
111. ULTIMATE AND RESIDUAL STRENGTH
The time-load results indicate the ability of the insulator to
sustain a fixed load for a period of time. But that load is
typically well above the loads which would be expected in
the field. The primary concern of most users involves the
residual strength in the design resulting from the insulator's
service history.
Before the time-load tests were begun, control samples
were prepared. These insulators were tested in tension to
determine the ultimate tensile strength. When the test
program was established, every third insulator manufactured
was tested to ascertain the characteristic tensile strength of
the batch. Since no test protocol existed, the load was
applied at a relatively uniform rate until failure occurred. A
typical example of the loading profile (see fig. 6) and the
initial data collected for all of the samples is shown in Fig. 7.
After the termination of the time-load tests, the unfailed
samples which were removed from the loading racks were
subjected to the same ultimate tensile strength test. Those
results are shown in Fig. 8 for the 16 mm test samples.
1m
i m
80
4 60
I
;
40
20
0
1998 - UTS - Time-Load Sample
0 5 4 0 1 5 2 0 2 5 3 0 3 5 4 0 4 5
El.pr.d Thu.
Fig. 6 -Typical Ultimate Tensile Strength load profile.
16mm -CONTROL SAMPLES - UTS
1E-07 O.OOWO1 O.OOW1 0.0001 0.001 0.01 0.1 1
EIAPSED TIME. YEARS
Fig. 7 - Control Samples UTS data.
The data was analyzed using a student's t-test [l]. For the
analysis, a two-tailed distribution was assumed. Details
follow:
1977: Average(l9) =124.25
1998: Average(l1) =120.95
P(T,n) =0.837
o =9.63
o =7.48
2( 1 -P) =.326
The analysis indicates a 32.6% probability that the two
groups of data are from the same general population. That
probability is substantial enough to make doubtful any
supposition that the insulators sustained a measurable loss in
strength as a result of the time under load.
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16mm RODS - UTS SAMPLES - BEFORE AND AFTER
I
V. CONCLUSIONS
The data collected over 20 years indicates that non-ceramic
insulators exhibit very stable time-load characteristics.
p ; ~ Extrapolations based upon the existing data indicate that the
2-to-1 safety factor applied to this type of insulator, if
properly followed, provides sufficient margin to assure
appropriate long term service.
.S"Z
A comparison of ultimate strength data collected at the
start of the test program with that collected after 20 years of
ODOOOOOI ooowo, Oo wo l oow1 ow1 001 0 1
ELIPSEDIIHE,IEIR~ . 1977 DATi. CONTROLS testing indicates no significant reduction in strength.
SERIES 2 - 1998 DATA - POST LOAD
Fig. 8 - Control samples and post test UTS data
VI. REFERENCES
IV. DISCUSSION
The data collected over 20 years of testing indicates that
the time-load strength reduction for non-ceramic insulators is
minimal. The 2-to-I safety margin normally used for these
insulators is sufficient to permit the insulator to be operated
without fear of failure for any reasonable service life.
The ultimate strength data collected before and after the
time-load test indicates no substantial loss of strength
resulting from the loading. However, since insulators do fail
during time-load testing, there must be strength loss. The
strength loss may be so gradual that it cannot be precisely
determined or it may be non-linear. In either case, the data
implies that evaluations of tensile strength for insulators
removed from service may not be an indicator of their
condition.
[l ] S . L. Meyer, Data Analysis for Scientists and
Engineers, J ohn Wiley and Sons, 1975, pp. 279-
282.
VII. BIOGRAPHIES
R. Allen Bernstorf graduated with a B.A. from Gettysburg
College and an M.S. in physics from the University of Akron.
In his current position as principal engineer, insulators, he is
responsible for the testing and application of insulator
products. He is a member of the IEEE and is active in the
IEEEPES, the ANSI C-29 Committee, the CSA C411
Committee and NEMA HVITC.
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