The 20th International Symposium on High Voltage Engineering, Buenos Aires, Argentina, August 27 – September 01, 2017
FIELD FAILED ANALYSIS OF DECAY-LIKE FRACTURE OF
COMPOSITE INSULATORS
Liang Xidong 1*, Bao Weining 1, Gao Yanfeng 2, Wang Jiafu 3, He Zilan 4 and Luo Bing 4
1 Department of Electrical Engineering, Tsinghua University, Beijing, 100084, China
2 State Grid Jibei Electric Power Co. Ltd. Research Institute, North China Electric Power
Research Institute Co. Ltd., Beijing, 100045, China
3 National Institute of Metrology, Beijing, 100029, China
4 Electric Power Research Institute, CSG, Guangzhou, 510080, China
*Email: lxd-dea@[Link]
Abstract: In recent year, a new kind of abnormal fracture phenomenon of composite
insulators, which was different from brittle fracture and normal fracture, occurred in high
voltage transmission lines in several countries. According to the general features of the
fracture spot, this type of failure was named decay-like fracture of composite insulators. In
this paper, the main macroscopic features of decay-like fractured composite insulators
were summarized by analysing some field failed composite insulators. From macroscopic
inspections, the fracture spot became crisp and looked like decayed wood, and the
interface between silicone rubber sheath and Fibre Reinforced Plastic (FRP) core rod
near the fracture spot degraded obviously. In addition, horizontal electro-erosion puncture
holes occurred in the sheath of fractured insulators. Scanning Electron Microscope (SEM),
Fourier Transform Infrared (FTIR) Spectroscopy and Thermal Gravimetric Analysis (TGA)
methods were utilized to explain the microscopic physicochemical characteristics of
decay-like fracture of composite insulators. Ion-exchange and hydrolysis in the glass fibre
three-dimensional network structure caused the fracture of glass fibre. The abundance
changes of functional groups in epoxy resin matrix in the decay-like fractured FRP rod
indicated that epoxy resin matrix was degraded by discharge and current, and
degradation in the external region of fractured FRP rod was more serious than that in the
interior region. Some broken glass fibres were separated from eroded epoxy resin matrix
and many bubbles and air holes still remained on the glass fibre. Furthermore, features
comparisons between decay-like fracture and brittle fracture were discussed in depth.
1 INTRODUCTION fracture of composite insulators, in contrast with
normal fracture. Brittle fracture, as the most
Composite insulators are widely used in electrical familiar fracture type of abnormal fracture, had
engineering transmission lines due to the received widely attention by researchers and
advantages of excellent pollution resistance, light productive work had been done to investigate the
weight, high mechanical strength and installation characteristic, mechanism, influencing factors and
convenience in maintenance [1]. By 2014, there preventive measurements of it. The most
are more than 7.1 million composite insulators prominent feature of brittle fracture was that there
units operated on transmission lines of 110 kV or were one or more smooth, clean and planar
higher in China [2]. surfaces, mostly perpendicular to the core axis,
giving the rod the appearance of being cut [3].
Composite insulator is composed of silicone rubber
sheath and Fibre Reinforced Plastic (FRP) core In recent years, a new kind of abnormal fracture
rod. Among them, FRP core rod, which is made of phenomena of composite insulators, which was
glass fibre and epoxy resin matrix, is the structural different from brittle fracture and normal fracture,
unit to support the internal insulation and occurred in several countries [4-8]. Some basic
mechanical loads of composite insulator. When information of field failed decay-like fractured
mechanical loads subjected to the composite composite insulators was shown in Table 1.
insulators were too high to withstand, FRP rod
would fracture, with one or more irregular fracture In this type of fracture, the spot of FRP core rod
surfaces and crumbling glass fibres appearing. became crisp and looked like decayed wood. Thus,
These phenomena were named normal fracture of it was named decay-like fracture of composite
composite insulators. insulators [4]. As more and more decay-like
fractured composite insulators were found, this
Since 1970s, hundreds of composite insulators fracture type should be treated as another
failed after only a relatively short time in service on abnormal mechanical failure of composite
a fraction of specified mechanical load, and this insulators juxtaposed with brittle fracture. Since
type of mechanical failure was so called abnormal that the fracture of composite insulators could
result in serious electrical accidents, it is of great investigate the features and mechanisms of decay-
scientific significance and engineering value to like fracture of composite insulators.
Table 1: Field failed decay-like fractured composite insulators
Failing Failing In-service Manufac Distance between fracture
Voltage Reference
time Place year/year turers* spot and high voltage end**
1 1998.02 Shanghai 500kV 4.2 A 6 sheds Wang Jiafu [4]
2 2008.05 Shandong 500kV 7.0 B 7 sheds Wang Jiafu [4]
3 2008.11 Guangdong 500kV ~7.0 C 5 sheds Wang Jiafu [4]
4 2010.06 Jiangsu 500kV 9.0 B 30 cm Liu Yang [5]
5 2010.09 China 500kV 12.0 B 2 - 3 sheds Wang Shaohua [6]
6 2010.11 Guangdong 500kV ~12.0 C 8 sheds Wang Jiafu [4]
7 2010.11 Guangxi 500kV 5.0 C 7 sheds Wang Jiafu [4]
8 2011.02 Shandong 500kV 10.0 B Not clear Wang Jiafu [4]
9 2011.05 Shandong 500kV 10.0 B Not clear Wang Jiafu [4]
10 2011.08 Shandong 500kV 7.0 B 3 sheds Wang Jiafu [4]
11 2013.10 Henan 500kV 10.0 --- 1 shed Lu Ming [7]
Isaias Ramirez-
12 2011.01 Mexico 400kV 7.0 --- ---
Vazquez [8]
13 2012.04 Korea 765kV ~7.0 B 7 sheds Wang Jiafu [4]
* A, B and C represent three different manufactures; Manufacturers of Insulator 11 and 12 was unclear.
** Insulator 8 and 9 fractured near high voltage ends, but the distance between the fracture spots and the
high voltage ends was not clearly reported; Insulator 12 fracture spot was not clearly reported.
In this paper, by analysing the features of some fracture surfaces. The colour of the fracture
field failed composite insulators, the main surface turned to brown and white. Fracture
macroscopic morphology of decay-like fractured surfaces of some field fractured composite
composite insulators were summarized. Then, insulators were shown in Figure 1.
Scanning Electron Microscope (SEM), Fourier
Transform Infrared (FTIR) Spectroscopy and
Thermal Gravimetric Analysis (TGA) methods were
utilized to explain the microscopic physicochemical
features of decay-like fracture of composite
insulators. Furthermore, features differences of
decay-like fracture and brittle fracture were
discussed. (a) In Shandong, 2008 (b) In Guangxi, 2010
2 MACROSCOPIC FEATURES
In this paper, some field failed decay-like fractured
composite insulators was investigated, and the
macroscopic features could be divided into four
parts, fracture surface, silicone rubber sheath, FRP (c) In Mexico, 2011 (d) In Korea, 2012
core rod and sheath-core interface. Detailed
descriptions of decay-like fracture were Figure 1: Fracture surfaces of field failed decay-
demonstrated, as follow. The sheds of the like fractured composite insulators.
fractured insulators were numbered as #1, #2, #3,
etc. from the high voltage end to the grounded end. 2.2 Silicone rubber sheath
2.1 Fracture surface In the decay-like fractured insulator, there were
several horizontal electro-erosion puncture holes in
According to the field failed decay-like fractured the sheath, some actual puncture holes images
composite insulators, the fracture surfaces were shown in Figure 2. When silicone rubber sheath
not orderly, in contrast with smooth, clean and was dissected, it was confirmed that the holes
planar surface of brittle fracture. At the fracture reached the FRP core rod. Moreover, the diameter
spots, fluffy and powdery fragments appeared on of the holes increased when they were near the
the surfaces of the fractured FRP core rods. No rod. It was assumed that the puncture holes were
long glass fibres were remained outside the
initiated from the sheath-core interface and and the sheath could be removed from the rod
developed outwards. easily. Whereas, in the area far from the fracture
spot, the adhesion strength between core rod and
sheath kept high enough.
3 MICROSCOPIC FEATURES
In order to receive a more comprehensive
understanding of decay-like fractured composite
insulators, some physicochemical analysis
methods were utilized to investigate microscopic
(a) In Shandong, 2008 (b) In Guangxi, 2010 morphology and chemical contents of a fractured
composite insulator, which was field failed in
Shandong, 2008. The sampling spots were 10 cm
far from the fracture spot, and an intact composite
insulator, which was produced, installed and
operated simultaneously with the fractured one,
was used as the comparative results. Furthermore,
interior region and external region of the FRP rod,
(c) In Guangdong, 2010 (d) In Henan, 2013 which was next to the sheath-core interface, were
separated and compared in this paper.
Figure 2: Horizontal electro-erosion puncture
holes in silicone rubber sheath of field failed decay- 3.1 Glass fibre ion-exchange and hydrolysis
like fractured composite insulators.
Epoxy resin prepolymers, along with curing agent
2.3 FRP core rod
and coupling agent added during curing process,
contained a variety of organic functional bands,
Along the insulators from high voltage end to the which made the FRP rod with rich infrared
grounded end, different appearances of the core spectrum features. Table 2 summarized some
rods were observed, as shown in Figure 3. The possibly observed characteristic absorption peaks
core rod surface from the high voltage end to the and its corresponding functional bands by FTIR in
fracture spot were degraded most seriously. Glass the composite insulator FRP rod. In this paper,
fibres were separated and broken, and a number Nicolet 6700 FTIR instrument was used to analyse
of fragments were adhered to the core surface. the infrared spectrum of FRP rod in decay-like
When observed from the fracture spot to the fractured composite insulator using KBr disc
grounded end, less fragments appeared on the technique. The spectrum of external region of
surface of the core rod. Then, in the area far from decay-like fractured FRP was shown in Figure 4.
fracture spot, the core surface turned to normal
status. Table 2: Characteristic FTIR absorption peaks
and corresponding functional bands for FRP [9]
Wavenumber(cm-1) Functional Bands
3700-3200 Hydroxyl
2920-2970 C-H in methyl
1736 C=O in ester
(a)between sheds #1 & (b) between sheds #7
1630 C=O in amide
#4 (high voltage end) & #8 (fracture spot)
1608 Aromatic structure
1508 Aromatic structure
1458 C-H in aliphatic
1182 C-C in aliphatic
(c) between sheds #10 & (d) near shed #17 (far
#13 (near fracture spot) from fracture spot) 1038 C-O-C in aliphatic
Figure 3: FRP core rod surface along the 831 Aromatic structure
composite from high voltage end to grounded end 480 Si-O
of the field failed decay-like fractured insulator.
2.4 Sheath-core interface
The adhesion strength between FRP core rod and
sheath was weak in the area near the fracture spot,
content of epoxy resin matrix in fractured FRP rod
was less than that in intact FRP rod.
In addition, more evidences was obtained by FTIR
spectrum in Figure 4. The abundance of the
absorption peak at 2970 - 2920 cm-1, 1608 cm-1,
1508 cm-1, 1451 cm-1, 1182 cm-1 and 1038 cm-1 in
the FTIR spectrum in decay-like fractured FRP rod
was obviously less than that in intact one, which
indicated the decrease of methyl, aromatic
structure and aliphatic groups, that were functional
bands in epoxy resin matrix, in decay-like fractured
FRP rod. These results proved the degradation
and deterioration of epoxy resin matrix in fractured
FRP rod.
Figure 4: FTIR spectrum of external region of FRP
rod in decay-like fractured composite insulator
The abundance of the absorption peak at 480 cm -1
in the FTIR spectrum in decay-like fractured FRP
rod was obviously less than that that in intact one.
It was assumed metal ions in glass fibre structure
was exchanged by hydrogen ions and Si-O bonds
was hydrolysed. Excessive hydrogen ions in FRP
rod inferred to partial discharge inside the
composite insulators.
The relevant evidences were observed from the
new absorption peaks at 1384 cm -1 and 1630 cm-1
in the FTIR spectrum of decay-like fractured FRP
rod, which indicated the presence of nitrate ion and
amide on the surface originated under the common Figure 5: TGA curve of decay-like fractured and
action of damp condition and partial discharge in intact FRP rod
high field strength area.
Regional nuances of decay-like fracture was
3.2 Epoxy resin content shown in the illustration in Figure 5. Within the
temperature of 50 - 150 ℃, the weight loss of the
TGA method, a direct measurement for chemical external region of FRP rod was larger than that of
composition, was used to analyse the contents of the interior region, which indicated that moisture
glass fibre and epoxy resin matrix in FRP material penetrated in the external region was more than
[10]. At the temperature of less than 800 ℃, the that in the interior region. Whereas, after epoxy
weight loss process of FRP rod was caused by the resin matrix was decomposed at the temperature
decomposition of the epoxy resin matrix. Thus, the more than 480 ℃ , weight loss of the external
remaining weight up to 800 ℃ was on behalf of the region was less than that of the interior region. It
component of glass fibre. In this paper, Mettler was concluded that content of epoxy resin matrix in
Toledo TGA/DSCI instrument was carried out to external region was less than that in interior region.
analyse the TGA curve of FRP rod samples within Thus, epoxy resin matrix was supposed to be
the temperature range of 50 - 800 ℃. The heating eroded in decay-like fractured FRP rod and the
rate was 10 ℃/min and nitrogen was used as the degradation in the external region was more
shielding gas. serious than that in the interior region.
TGA curves of the decay-like fractured and intact 3.3 Glass fibre and epoxy resin morphology
FRP rod were shown in Figure 5. At the
temperature less than 150 ℃, the weight loss of In this paper, FEI Quanta 2000 FEG SEM
fractured and intact FRP rod was mainly caused by instrument was utilized to analyse microscopic
the evaporation of moisture penetrated and morphology of the fracture spot side-section of
remained in the pre-processing. At the temperature FRP rod (see Figure 6) and cross-section of FRP
more than 480 ℃, the epoxy resin matrix had been fragments (see Figure 7) in decay-like fractured
decomposed completely, and the remaining mass composite insulator. The glass fibre fragments
represented the content of glass fibre. Obviously, were adhered to the FRP rod surface 10cm far
from the fracture spot.
resin matrix. A number of bubbles and air holes
appeared on the residual epoxy resin matrix, as
shown in Figure 6(d). It was assumed that epoxy
resin matrix was soften, melt and evaporated at
first, mainly causing the bubbles on the epoxy resin
matrix. Then, bubbles broke open and air holes
was retained. These results also verified the
decrease of epoxy resin content in decay-like
fractured FRP rod. It was noted that degradation of
epoxy resin matrix by discharge and current was
one of the main features of decay-like fracture.
As shown in Figure 7, viewing direction parallel to
the glass fibre axis, the mesoscopic fracture spot
section of tens of glass fibres was not orderly,
whereas the cross-section of a single glass fibre
was orderly, caused by stress corrosion under the
common action of ion-exchange and mechanical
stress. Besides, it was observed that epoxy resin
Figure 6: Fracture spot side-section morphology of and glass fibre was separated and fibre-resin
FRP core rod in decay-like fractured composite interface was failed.
insulator
4 COMPARISONS BETWEEN DECAY-LIKE
FRACTURE AND BRITTLE FRACTURE
According to the investigation of field decay-like
fractured composite insulators, we summarized the
main macroscopic and microscopic features of
decay-like fracture, and gave a comprehensive
comparison with brittle fracture, as shown in Table
3. It was clear that decay-like fracture of composite
insulators was a new type of abnormal fracture,
which was totally different from brittle fracture.
From macroscopic morphology, the main feature of
decay-like fracture was the crisp and decay-like
fracture spot, in contrast to the smooth surface of
brittle fracture. Moreover, a number of puncture
holes near the high voltage end was another
distinctive feature.
From microscopic morphology, the main feature of
Figure 7: Fracture spot cross-section morphology decay-like fracture was the degradation and
of FRP fragments in decay-like fractured erosion of FRP core rod by electrical damage [11].
composite insulator Many bubbles and air holes remained on the
broken glass fibre reflected the deterioration
As shown in Figure 6, viewing direction process of epoxy resin matrix soften, melt and
perpendicular to the glass fibre axis, some broken evaporated, causing decrease of epoxy resin
glass fibres were separated from eroded epoxy content.
Table 3: Comparisons between decay-like fracture and brittle fracture
Decay-like fracture Brittle fracture
(1) Fluffy and powdery fragments One or more smooth, clean and planar planes
appeared on the surface of fractured perpendicular to the core axis covered more than
Fracture spot
FRP core rods. half of the fracture surface.
(2) Fractured surface was not orderly.
Many puncture holes near high voltage
Macroscopic Sheath Most were broken, but some were still good.
end.
features
FRP core rods became crisp and
FRP core rod No significant change.
looked like decayed wood.
Sheath-core interface near the fracture
Sheath-core interface
spot degraded obviously, but some still Most had a weak sheath-core interface.
adhesion
good near the grounded end.
(1) The mesoscopic fracture spot
section of tens of glass fibres was not
Mirror, mist, and hackle zones on the fracture
orderly, whereas the cross-section of a
Glass fibre morphology surfaces of individual E-glass fibres were formed
single glass fibre was orderly.
[12].
(2) Broken glass fibres were separated
with epoxy resin.
No significant resin decomposition present
Many bubbles and air holes appeared between the glass fibres when failure occurs inside
Microscopic Epoxy resin morphology
on the eroded epoxy resin matrix. the fitting, while severe resin decomposition were
features observed when failures above the hardware. [13]
Content of epoxy resin decreased
Epoxy resin content No research mentioned.
compared with intact FRP rod.
Longitudinal debonding between fibres and resin
was apparent in many of the fracture faces, and
Interface between epoxy The failure of interface was observed
transverse sections of the rod some 50 mm away
resin and glass fibre near the single broken glass fibre.
from the fracture face showed that debonding
occurred over considerable distances. [14]
5 CONCLUSIONS Insulator FRP Rod and the Coping Strategy”,
East China Electric Power, Vol. 39, No. 3, pp.
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microscopic features of decay-like fractured [6] S. Wang, Z. Ye and S. Luo, “Fracture
composite insulators were summarized by Mechanism and Detection Method of 500 kV
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[10] CR Moon, BR Bang, WJ Choi, GH Kang and
This study was supported by Electric Power SY Park, “A technique for determining fibre
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[11] S. J. Harris, B. Nobel, M. J. Owen,
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