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ANSI Silicone Distribution Dead End and Suspension Insulator … · 2005. 4. 7. · Referenced Standards: ANSI C29.11-1989 ANSI C29.12-1997 ANSI C29.13-2000 IEC61109-1992 Date of
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Test Unit: 69kV – 20,000 Lb. Composite Suspension Insulator OEP Part Number: 9710010 Test Type: Prototype, Design and Sample Test Referenced Standards: ANSI C29.11-1989
ANSI C29.12-1997 ANSI C29.13-2000 IEC61109-1992
Date of Test: September 12, 1998 through November 20, 1998 Date Report Was Prepared: December 31, 2003 Report Prepared By: Tom J. Martin
Testing Conclusion: All units tested passed the testing according to all applicable requirements of the referenced standards.
Table of Contents: 1.0 General Unit Design and Specifications 4 2.0 Prototype Tests 4 2.1 Test Unit 4 2.2 Tests On Interfaces and Connections of Metal Fittings 4 2.2.1 Power Frequency Voltage Test 4 2.2.2 Sudden Load Release Test 4 2.2.3 Thermal-Mechanical Test 5 2.2.4 Water PenetrationTest 5 2.2.5 Verification Tests 5 2.2.5.1 Visual Examination 5 2.2.5.2 Steep Front Impulse Voltage Test 5 2.2.5.3 Power Frequency Voltage Test 6 2.3 Core Time-Load Test 6 2.3.1 Test Specimens 6 2.3.2 Determination of Average Failing Load of The Core 6 2.3.3 Core Time Load Test 7 2.4 Housing Tracking and Erosion Test 7 2.5 Core Material Tests 8 2.5.1 Dye Penetration Test 8 2.5.2 Water Diffusion Test 8 2.5.2.1 Prestressing 8 2.5.2.2 Voltage Test 8 3.0 Design Tests 9 3.1 Test Unit 9 3.2 Lightning Impulse Withstand Test (Positive) 9 3.3 Low-Frequency Wet Withstand 9 4.0 Sample Tests 10 4.1 Visual Inspection and Dimensional Verification 10 4.2 Verification of Locking System 10 4.3 Mechanical Load Test 11 4.4 Galvanizing Test 11
1.0 General Unit Design and Specifications See Appendix A 2.0 Prototype Tests
2.1 Test Unit The test unit used for this Prototype Testing was a Composite Suspension insulator design representing the entire class of Silicone Composite Suspension Insulators from 69kV to 230kV. As per the requirement of Clause 7.1.1 of ANSI C29.11-1989, the composite insulator samples used for this Prototype Testing had a metal-to-metal spacing of at least 800mm in length. The actual insulation length of the test units was a minimum of 31.69” (805mm). 2.2 Tests On Interfaces and Connections of Metal Fittings
2.2.1 Power Frequency Voltage Test Three assembled units were randomly selected and subjected to a Power Frequency Voltage Test per Clause 7.1.2 of ANSI C29.11-1989 and Clause 5.1.2 of IEC 61109-1992. The results of this testing are shown in Table 1 below.
Test Conditions: Td = 75.2 °F Tw = 69.8 °F P = 14.674 Psi. Kd = 0.981 Kh = 0.940
Sample Number
Average Value (kV)
Corrected Value (kV)
1 323.9 310.4 2 321.9 308.4 3 329.8 316.0
Table 1
2.2.2 Sudden Load Release Test The three samples from the Power Frequency Voltage Test were subjected to a sudden load release test according to Clause 7.1.3 of ANSI C29.11-1989 and Clause 5.1.3.1 of IEC61109-1992. Each sample was subjected to 30% of the unit’s Specified Mechanical Load (SML) which was then suddenly released. The results of this testing are shown in Table 2 below.
Three samples were subjected to temperature variations under a mechanical load of 11240 Lbs. or A minimum of 50% of the SML Rating according to Clause 7.1.4 of ANSI C29.11-1989 and Clause 5.1.3.2 of IEC61109-1992. The temperature range from cold to hot during each 24 hour cycle was -31 +/- 5 °F to 122 +/- 5 °F. The 24 hour temperature cycles were repeated 4 times per the standard requirements. The initial and final dimensions of the samples are shown in Table 3 below while the results of the testing are shown in Table 4 below.
Samples 1, 2 and 3 from previous tests were immersed in boiling deionized water, containing 0.1 % by weight of Sodium Chloride, for 42 hours per Clause 7.1.5 of ANSI C29.11-1989 and Clause 5.1.3.3 of IEC61109-1992. The samples were then retained in the water while the temperature was lowered to 122 °F. These samples were visually inspected and were found to have no signs of damage. These units were subsequently used for the verification testing in Section 2.2.5.
2.2.5 Verification Tests
2.2.5.1 Visual Examination
Samples 1, 2 and 3 from the Water Penetration test were reexamined for any signs of damage prior to proceeding with testing in Sections 2.2.5.2 and 2.2.5.3. No damage was observed.
2.2.5.2 Steep Front Impulse Voltage Test
The three test samples from the previous tests were fitted with a sharp edged electrode dividing each sample into two equal length sections according to Clause 7.1.6.2 of ANSI C29.11-1989 and Clause 5.1.4.2 of IEC61109-1992. These samples were then subjected to an Impulse Voltage having a rate of rise of at least 1000 kV/µS for 25 positive and negative polarity impulses. The results of this testing are shown in Table 5 below.
The three test samples from previous tests were subjected to a Dry Power Frequency Flashover Voltage Test per Clause 7.1.6.3 of ANSI C29.11-1989 and Clause 5.1.4.3 of IEC 61109-1992. The average value for this test was required to be a minimum of 90% of the initial values determined in Section 2.2.1 of this report. The results of this testing are shown in Table 6 below.
Test Conditions: Td = 53.6 °F Tw = 49.1 °F P = 14.786 Psi.
2.3.1 Test Specimens Six specimens were obtained from a larger group of samples. These specimens were dived into two groups of three for the following test in Sections 2.3.2 and 2.3.3 of this report. 2.3.2 Determination of Average Failing Load of The Core
Three units from Section 2.3.1 above were subjected to an Average Failing Load Test according to Clause 7.2.2 of ANSI C29.11-1989 and Clause 5.2.2.1 of IEC 61109-1992 and. The results of this testing are shown in Table 7 below. These values will be used as base values for Section 2.3.3 of this report.
Three units from Section 2.3.1 above were subjected to a load equal to 60% of the Average Failing Load from Section 2.3.2 and maintained for a period of 96 hours according to Clause 7.2.3 of ANSI C29.11-1989 and Clause 5.2.2.2 of IEC 61109-1992. The results of this testing are shown in Table 8 below.
Sample Number
Insulation Length (Inches)
60% of Average Failing Load
(Lbs.)
Withstand Time
(Hours) Results 1 96 Passed 2 96 Passed 3
~ 31.69 17394.9 96 Passed
Specification ≥ 31.5 - 96 No Damage Table 8
2.4 Housing Tracking and Erosion Test Two assembled units were subjected to a tracking and erosion test according to Clause 7.3 of ANSI C29.11-1989 and Clause 5.3 of IEC 61109-1992 and. The physical details of the test samples are shown in Table 9 below while the results of the testing are shown in Table 10 below. Test Conditions: Water Flow Rate (kg/m3 x h) = 0.32 – 0.35
Size of Droplets (µm) = 5 - 10 NaCl Content of Water (kg/m3) = 9.5 – 10.0 Fog Chamber Temperature (°C) = 22.0 – 24.0
2.5.1 Dye Penetration Test Ten specimens were cut from a randomly sampled production insulator and tested for dye penetration according to Clause 7.4.1 of ANSI C29.11-1989 and Clause 5.4.1 of IEC 61109-1992. These specimens, measuring 0.944 inches in diameter and 0.394 inches in length were placed upright on a layer of steel balls and a 1% alcohol and fuchsin dye solution was poured into the glass vessel until the dye level was 0.098 inches higher than the surface of the steel balls. The samples remained in the glass vessel for a period of 15 minutes per the standard requirements with no signs of penetration. The details of the samples and the test results are shown in Table 11 below.
Specimen Number
Specimen Length (Inches)
Sample Immersion Time (Minutes) Results
1 0.396 15 No Penetration 2 0.397 15 No Penetration 3 0.398 15 No Penetration 4 0.399 15 No Penetration 5 0.400 15 No Penetration 6 0.386 15 No Penetration 7 0.402 15 No Penetration 8 0.387 15 No Penetration 9 0.398 15 No Penetration
10 0.394 15 No Penetration Specification 0.394 ± 0.02 15 No Penetration
Table 11
2.5.2 Water Diffusion Test
2.5.2.1 Prestressing Six specimens were cut from the same type of production insulator used in the dye penetration testing and tested for water diffusion according to Clause 7.4.2.2 of ANSI C29.11-1989 and Clause 5.4.2.2 of IEC 61109-1992. These specimens, measuring 0.944 inches in diameter and 1.181 inches in length, were boiled in a glass vessel containing deinonized water and 0.1 % by weight of Sodium Chloride, for 100 hours. The specimens were removed from the boiling water and placed in ambient temperature deionized water until cooled. 2.5.2.2 Voltage Test
The specimens from Section 2.5.2.1 above were removed from the deinoized water, dried with filter paper and subjected to a voltage test according to Clause 7.4.2.3 of ANSI C29.11-1989 and Clause 5.4.2.3 of IEC 61109-1992 less than 3 hours after removal from the boiling water. The results of this testing are shown in Table 12 below.
Specification 1.182 ± 0.020 100 12 1 ≤ 1 No Puncture or Flashover
Table 12 3.0 Design Tests
3.1 Test Unit The test unit used for this Design Testing was the Composite Suspension insulator design shown in Appendix A. The unit tested met the requirements of Clause 4.1 of ANSI C29.11-1989 thereby permitting the use of the Prototype Test results detailed above for this unit. 3.2 Lightning Impulse Withstand Test
Three sample Composite Suspension Insulators were subjected to a Lightning Impulse Withstand Test according to Clause 6.1 IEC 61109-1992. The results of this testing are shown in Table 14 below. As the results show, the units withstood the minimum Critical-Impulse Flashover requirement from Table 2 of ANSI C29.13-2000.
Test Conditions: Td = 63.1 °F Tw = 58.1 °F P = 14.88 Psi. Kd = 1.018 Kh = 1.000
Positive Polarity
Sample # Test Wave
(µs) Withstand Test Value
(kV) Corrected Value
(kV) Withstand Time
(Seconds) Results 1 1.15 420.0 15 No Flashover 2 1.15 421.0 15 No Flashover 3 1.15 423.0
Three sample Composite Suspension Insulators were subjected to a Low-Frequency Wet Withstand Test according to Clause 6.2 IEC 61109-1992. The results of this testing are shown in Table 14 below. As the results show, the units withstood the minimum Low-Frequency Wet Flashover specification requirement.
4.1 Visual Inspection and Dimensional Verification Nine samples were taken from the group of units and visually inspected to verify the quality and were measured to verify the actual dimensions against the design dimensions according to Clause 9.2 of ANSI C29.11-1989 and Clause 7.2 of IEC 61109-1992. The quality of the units observed during visual inspection was good. The galvanizing on the end fittings was consistent and the injection molding was good. The results of the dimensional verification are shown in Table 15 below.
1 35.47 82.20 Go No-Go Go No-Go 2 35.55 81.89 Go No-Go Go No-Go 3 35.43 82.68 Go No-Go Go No-Go 4 35.51 82.13 Go No-Go Go No-Go 5 35.39 82.68 Go No-Go Go No-Go 6 35.59 81.89 Go No-Go Go No-Go 7 35.55 81.89 Go No-Go Go No-Go 8 35.43 81.85 Go No-Go Go No-Go 9 35.51 82.09 Go No-Go Go No-Go
Specification 35.31 ± 0.59 ≥ 81.70 Go No-Go Go No-Go Table 15
4.2 Verification of Locking System Locking System Verification testing was conducted on 3 samples taken from the group of units removed from production according to Clause 9.3 of ANSI C29.11-1989 and Clause 7.3 of IEC 61109-1992. The results of this testing are shown in Table 16 below.
Number First Second Third Results At 56Lb. Maximum Load
1 15.63 20.09 22.32 No Uncoupling 2 13.39 17.86 17.86 No Uncoupling 3 26.79 17.86 35.71 No Uncoupling
Specification 5.2 – 56.0 No Uncoupling Table 16
4.3 Mechanical Load Test The 3 samples, used in the previous verification testing, were subjected to mechanical load equivalent to the SML per Clause 9.4 of ANSI C29.11-1989 and Clause 7.4 of IEC 61109-1992. The results of this testing are shown in Table 17 below.
4.4 Galvanizing Test Galvanizing thickness testing was conducted on 3 samples taken from the group of units removed from production according to Clause 9.5 of ANSI C29.11-1989 and Clause 7.5 of IEC 61109-1992. The results of this thickness testing are shown in Table 18 below.
Test Unit: 115kV – 20,000 Lb. Composite Suspension Insulator OEP Part Number: 9710013 Test Type: Prototype, Design and Sample Test Referenced Standards: ANSI C29.11-1989
ANSI C29.12-1997 ANSI C29.13-2000 IEC61109-1992
Date of Test: September 12, 1998 through November 20, 1998 Date Report Was Prepared: January 2, 2004 Report Prepared By: Tom J. Martin
Testing Conclusion: All units tested passed the testing according to all applicable requirements of the referenced standards.
Table of Contents: 1.0 General Unit Design and Specifications 4 2.0 Prototype Tests 4 2.1 Test Unit 4 2.2 Tests On Interfaces and Connections of Metal Fittings 4 2.2.1 Power Frequency Voltage Test 4 2.2.2 Sudden Load Release Test 4 2.2.3 Thermal-Mechanical Test 5 2.2.4 Water PenetrationTest 5 2.2.5 Verification Tests 5 2.2.5.1 Visual Examination 5 2.2.5.2 Steep Front Impulse Voltage Test 5 2.2.5.3 Power Frequency Voltage Test 6 2.3 Core Time-Load Test 6 2.3.1 Test Specimens 6 2.3.2 Determination of Average Failing Load of The Core 6 2.3.3 Core Time Load Test 7 2.4 Housing Tracking and Erosion Test 7 2.5 Core Material Tests 8 2.5.1 Dye Penetration Test 8 2.5.2 Water Diffusion Test 8 2.5.2.1 Prestressing 8 2.5.2.2 Voltage Test 8 3.0 Design Tests 9 3.1 Test Unit 9 3.2 Lightning Impulse Withstand Test (Positive) 9 3.3 Low-Frequency Wet Withstand 9 4.0 Sample Tests 10 4.1 Visual Inspection and Dimensional Verification 10 4.2 Verification of Locking System 10 4.3 Mechanical Load Test 11 4.4 Galvanizing Test 11
1.0 General Unit Design and Specifications See Appendix A 2.0 Prototype Tests
2.1 Test Unit The test unit used for this Prototype Testing was a Composite Suspension insulator design representing the entire class of Silicone Composite Suspension Insulators from 69kV to 230kV. As per the requirement of Clause 7.1.1 of ANSI C29.11-1989, the composite insulator samples used for this Prototype Testing had a metal-to-metal spacing of at least 800mm in length. The actual insulation length of the test units was a minimum of 31.69” (805mm). 2.2 Tests On Interfaces and Connections of Metal Fittings
2.2.1 Power Frequency Voltage Test Three assembled units were randomly selected and subjected to a Power Frequency Voltage Test per Clause 7.1.2 of ANSI C29.11-1989 and Clause 5.1.2 of IEC 61109-1992. The results of this testing are shown in Table 1 below.
Test Conditions: Td = 75.2 °F Tw = 69.8 °F P = 14.674 Psi. Kd = 0.981 Kh = 0.940
Sample Number
Average Value (kV)
Corrected Value (kV)
1 323.9 310.4 2 321.9 308.4 3 329.8 316.0
Table 1
2.2.2 Sudden Load Release Test The three samples from the Power Frequency Voltage Test were subjected to a sudden load release test according to Clause 7.1.3 of ANSI C29.11-1989 and Clause 5.1.3.1 of IEC61109-1992. Each sample was subjected to 30% of the unit’s Specified Mechanical Load (SML) which was then suddenly released. The results of this testing are shown in Table 2 below.
Three samples were subjected to temperature variations under a mechanical load of 11240 Lbs. or A minimum of 50% of the SML Rating according to Clause 7.1.4 of ANSI C29.11-1989 and Clause 5.1.3.2 of IEC61109-1992. The temperature range from cold to hot during each 24 hour cycle was -31 +/- 5 °F to 122 +/- 5 °F. The 24 hour temperature cycles were repeated 4 times per the standard requirements. The initial and final dimensions of the samples are shown in Table 3 below while the results of the testing are shown in Table 4 below.
Samples 1, 2 and 3 from previous tests were immersed in boiling deionized water, containing 0.1 % by weight of Sodium Chloride, for 42 hours per Clause 7.1.5 of ANSI C29.11-1989 and Clause 5.1.3.3 of IEC61109-1992. The samples were then retained in the water while the temperature was lowered to 122 °F. These samples were visually inspected and were found to have no signs of damage. These units were subsequently used for the verification testing in Section 2.2.5.
2.2.5 Verification Tests
2.2.5.1 Visual Examination
Samples 1, 2 and 3 from the Water Penetration test were reexamined for any signs of damage prior to proceeding with testing in Sections 2.2.5.2 and 2.2.5.3. No damage was observed.
2.2.5.2 Steep Front Impulse Voltage Test
The three test samples from the previous tests were fitted with a sharp edged electrode dividing each sample into two equal length sections according to Clause 7.1.6.2 of ANSI C29.11-1989 and Clause 5.1.4.2 of IEC61109-1992. These samples were then subjected to an Impulse Voltage having a rate of rise of at least 1000 kV/µS for 25 positive and negative polarity impulses. The results of this testing are shown in Table 5 below.
The three test samples from previous tests were subjected to a Dry Power Frequency Flashover Voltage Test per Clause 7.1.6.3 of ANSI C29.11-1989 and Clause 5.1.4.3 of IEC 61109-1992. The average value for this test was required to be a minimum of 90% of the initial values determined in Section 2.2.1 of this report. The results of this testing are shown in Table 6 below.
Test Conditions: Td = 53.6 °F Tw = 49.1 °F P = 14.786 Psi.
2.3.1 Test Specimens Six specimens were obtained from a larger group of samples. These specimens were dived into two groups of three for the following test in Sections 2.3.2 and 2.3.3 of this report. 2.3.2 Determination of Average Failing Load of The Core
Three units from Section 2.3.1 above were subjected to an Average Failing Load Test according to Clause 7.2.2 of ANSI C29.11-1989 and Clause 5.2.2.1 of IEC 61109-1992 and. The results of this testing are shown in Table 7 below. These values will be used as base values for Section 2.3.3 of this report.
Three units from Section 2.3.1 above were subjected to a load equal to 60% of the Average Failing Load from Section 2.3.2 and maintained for a period of 96 hours according to Clause 7.2.3 of ANSI C29.11-1989 and Clause 5.2.2.2 of IEC 61109-1992. The results of this testing are shown in Table 8 below.
Sample Number
Insulation Length (Inches)
60% of Average Failing Load
(Lbs.)
Withstand Time
(Hours) Results 1 96 Passed 2 96 Passed 3
~ 31.69 17394.9 96 Passed
Specification ≥ 31.5 - 96 No Damage Table 8
2.4 Housing Tracking and Erosion Test Two assembled units were subjected to a tracking and erosion test according to Clause 7.3 of ANSI C29.11-1989 and Clause 5.3 of IEC 61109-1992 and. The physical details of the test samples are shown in Table 9 below while the results of the testing are shown in Table 10 below. Test Conditions: Water Flow Rate (kg/m3 x h) = 0.32 – 0.35
Size of Droplets (µm) = 5 - 10 NaCl Content of Water (kg/m3) = 9.5 – 10.0 Fog Chamber Temperature (°C) = 22.0 – 24.0
2.5.1 Dye Penetration Test Ten specimens were cut from a randomly sampled production insulator and tested for dye penetration according to Clause 7.4.1 of ANSI C29.11-1989 and Clause 5.4.1 of IEC 61109-1992. These specimens, measuring 0.944 inches in diameter and 0.394 inches in length were placed upright on a layer of steel balls and a 1% alcohol and fuchsin dye solution was poured into the glass vessel until the dye level was 0.098 inches higher than the surface of the steel balls. The samples remained in the glass vessel for a period of 15 minutes per the standard requirements with no signs of penetration. The details of the samples and the test results are shown in Table 11 below.
Specimen Number
Specimen Length (Inches)
Sample Immersion Time (Minutes) Results
1 0.396 15 No Penetration 2 0.397 15 No Penetration 3 0.398 15 No Penetration 4 0.399 15 No Penetration 5 0.400 15 No Penetration 6 0.386 15 No Penetration 7 0.402 15 No Penetration 8 0.387 15 No Penetration 9 0.398 15 No Penetration
10 0.394 15 No Penetration Specification 0.394 ± 0.02 15 No Penetration
Table 11
2.5.2 Water Diffusion Test
2.5.2.1 Prestressing Six specimens were cut from the same type of production insulator used in the dye penetration testing and tested for water diffusion according to Clause 7.4.2.2 of ANSI C29.11-1989 and Clause 5.4.2.2 of IEC 61109-1992. These specimens, measuring 0.944 inches in diameter and 1.181 inches in length, were boiled in a glass vessel containing deinonized water and 0.1 % by weight of Sodium Chloride, for 100 hours. The specimens were removed from the boiling water and placed in ambient temperature deionized water until cooled. 2.5.2.2 Voltage Test
The specimens from Section 2.5.2.1 above were removed from the deinoized water, dried with filter paper and subjected to a voltage test according to Clause 7.4.2.3 of ANSI C29.11-1989 and Clause 5.4.2.3 of IEC 61109-1992 less than 3 hours after removal from the boiling water. The results of this testing are shown in Table 12 below.
Specification 1.182 ± 0.020 100 12 1 ≤ 1 No Puncture or Flashover
Table 12 3.0 Design Tests
3.1 Test Unit The test unit used for this Design Testing was the Composite Suspension insulator design shown in Appendix A. The unit tested met the requirements of Clause 4.1 of ANSI C29.11-1989 thereby permitting the use of the Prototype Test results detailed above for this unit. 3.2 Lightning Impulse Withstand Test
Three sample Composite Suspension Insulators were subjected to a Lightning Impulse Withstand Test according to Clause 6.1 IEC 61109-1992. The results of this testing are shown in Table 14 below. As the results show, the units withstood the minimum Critical-Impulse Flashover requirement.
Test Conditions: Td = 63.1 °F Tw = 58.1 °F P = 14.88 Psi. Kd = 1.018 Kh = 1.000
Positive Polarity
Sample # Test Wave
(µs) Withstand Test Value
(kV) Corrected Value
(kV) Withstand Time
(Seconds) Results 1 1.15 571.0 15 No Flashover 2 1.15 573.0 15 No Flashover 3 1.15 571.0
Three sample Composite Suspension Insulators were subjected to a Low-Frequency Wet Withstand Test according to Clause 6.2 IEC 61109-1992. The results of this testing are shown in Table 14 below. As the results show, the units withstood the minimum Low-Frequency Wet Flashover specification requirement.
4.1 Visual Inspection and Dimensional Verification Nine samples were taken from the group of units and visually inspected to verify the quality and were measured to verify the actual dimensions against the design dimensions according to Clause 9.2 of ANSI C29.11-1989 and Clause 7.2 of IEC 61109-1992. The quality of the units observed during visual inspection was good. The galvanizing on the end fittings was consistent and the injection molding was good. The results of the dimensional verification are shown in Table 15 below.
1 48.82 114.57 Go No-Go Go No-Go 2 48.62 114.76 Go No-Go Go No-Go 3 48.74 114.76 Go No-Go Go No-Go 4 48.82 114.96 Go No-Go Go No-Go 5 48.62 114.76 Go No-Go Go No-Go 6 48.82 114.88 Go No-Go Go No-Go 7 48.82 114.65 Go No-Go Go No-Go 8 48.82 114.96 Go No-Go Go No-Go 9 48.62 114.37 Go No-Go Go No-Go
Specification 48.26 ± 0.59 ≥ 113.19 Go No-Go Go No-Go Table 15
4.2 Verification of Locking System Locking System Verification testing was conducted on 3 samples taken from the group of units removed from production according to Clause 9.3 of ANSI C29.11-1989 and Clause 7.3 of IEC 61109-1992. The results of this testing are shown in Table 16 below.
Number First Second Third Results At 56Lb. Maximum Load
1 17.86 8.93 22.32 No Uncoupling 2 13.39 29.02 24.55 No Uncoupling 3 15.63 24.55 17.86 No Uncoupling
Specification 5.2 – 56.0 No Uncoupling Table 16
4.3 Mechanical Load Test The 3 samples, used in the previous verification testing, were subjected to mechanical load equivalent to the SML per Clause 9.4 of ANSI C29.11-1989 and Clause 7.4 of IEC 61109-1992. The results of this testing are shown in Table 17 below.
4.4 Galvanizing Test Galvanizing thickness testing was conducted on 3 samples taken from the group of units removed from production according to Clause 9.5 of ANSI C29.11-1989 and Clause 7.5 of IEC 61109-1992. The results of this thickness testing are shown in Table 18 below.
Thickness Values of Socket End Fitting (Mils)
Thickness Values of Ball End Fitting (Mils) Sample
Test Unit: 230kV – 20,000 Lb. Composite Suspension Insulator PBI Part Number: 9710017 Test Type: Prototype, Design and Sample Test Referenced Standards: ANSI C29.11-1989
ANSI C29.12-1997 ANSI C29.13-2000 IEC61109-1992
Date of Test: September 12, 1998 through November 20, 1998 Date Report Was Prepared: January 2, 2004 Report Prepared By: Tom J. Martin
Testing Conclusion: All units tested passed the testing according to all applicable requirements of the referenced standards.
Table of Contents: 1.0 General Unit Design and Specifications 4 2.0 Prototype Tests 4 2.1 Test Unit 4 2.2 Tests On Interfaces and Connections of Metal Fittings 4 2.2.1 Power Frequency Voltage Test 4 2.2.2 Sudden Load Release Test 4 2.2.3 Thermal-Mechanical Test 5 2.2.4 Water PenetrationTest 5 2.2.5 Verification Tests 5 2.2.5.1 Visual Examination 5 2.2.5.2 Steep Front Impulse Voltage Test 5 2.2.5.3 Power Frequency Voltage Test 6 2.3 Core Time-Load Test 6 2.3.1 Test Specimens 6 2.3.2 Determination of Average Failing Load of The Core 6 2.3.3 Core Time Load Test 7 2.4 Housing Tracking and Erosion Test 7 2.5 Core Material Tests 8 2.5.1 Dye Penetration Test 8 2.5.2 Water Diffusion Test 8 2.5.2.1 Prestressing 8 2.5.2.2 Voltage Test 8 3.0 Design Tests 9 3.1 Test Unit 9 3.2 Lightning Impulse Withstand Test (Positive) 9 3.3 Low-Frequency Wet Withstand 9 4.0 Sample Tests 10 4.1 Visual Inspection and Dimensional Verification 10 4.2 Verification of Locking System 10 4.3 Mechanical Load Test 11 4.4 Galvanizing Test 11
1.0 General Unit Design and Specifications See Appendix A 2.0 Prototype Tests
2.1 Test Unit The test unit used for this Prototype Testing was a Composite Suspension insulator design representing the entire class of Silicone Composite Suspension Insulators from 69kV to 230kV. As per the requirement of Clause 7.1.1 of ANSI C29.11-1989, the composite insulator samples used for this Prototype Testing had a metal-to-metal spacing of at least 800mm in length. The actual insulation length of the test units was a minimum of 31.69” (805mm). 2.2 Tests On Interfaces and Connections of Metal Fittings
2.2.1 Power Frequency Voltage Test Three assembled units were randomly selected and subjected to a Power Frequency Voltage Test per Clause 7.1.2 of ANSI C29.11-1989 and Clause 5.1.2 of IEC 61109-1992. The results of this testing are shown in Table 1 below.
Test Conditions: Td = 75.2 °F Tw = 69.8 °F P = 14.674 Psi. Kd = 0.981 Kh = 0.940
Sample Number
Average Value (kV)
Corrected Value (kV)
1 323.9 310.4 2 321.9 308.4 3 329.8 316.0
Table 1
2.2.2 Sudden Load Release Test The three samples from the Power Frequency Voltage Test were subjected to a sudden load release test according to Clause 7.1.3 of ANSI C29.11-1989 and Clause 5.1.3.1 of IEC61109-1992. Each sample was subjected to 30% of the unit’s Specified Mechanical Load (SML) which was then suddenly released. The results of this testing are shown in Table 2 below.
Three samples were subjected to temperature variations under a mechanical load of 11240 Lbs. or A minimum of 50% of the SML Rating according to Clause 7.1.4 of ANSI C29.11-1989 and Clause 5.1.3.2 of IEC61109-1992. The temperature range from cold to hot during each 24 hour cycle was -31 +/- 5 °F to 122 +/- 5 °F. The 24 hour temperature cycles were repeated 4 times per the standard requirements. The initial and final dimensions of the samples are shown in Table 3 below while the results of the testing are shown in Table 4 below.
Samples 1, 2 and 3 from previous tests were immersed in boiling deionized water, containing 0.1 % by weight of Sodium Chloride, for 42 hours per Clause 7.1.5 of ANSI C29.11-1989 and Clause 5.1.3.3 of IEC61109-1992. The samples were then retained in the water while the temperature was lowered to 122 °F. These samples were visually inspected and were found to have no signs of damage. These units were subsequently used for the verification testing in Section 2.2.5.
2.2.5 Verification Tests
2.2.5.1 Visual Examination
Samples 1, 2 and 3 from the Water Penetration test were reexamined for any signs of damage prior to proceeding with testing in Sections 2.2.5.2 and 2.2.5.3. No damage was observed.
2.2.5.2 Steep Front Impulse Voltage Test
The three test samples from the previous tests were fitted with a sharp edged electrode dividing each sample into two equal length sections according to Clause 7.1.6.2 of ANSI C29.11-1989 and Clause 5.1.4.2 of IEC61109-1992. These samples were then subjected to an Impulse Voltage having a rate of rise of at least 1000 kV/µS for 25 positive and negative polarity impulses. The results of this testing are shown in Table 5 below.
The three test samples from previous tests were subjected to a Dry Power Frequency Flashover Voltage Test per Clause 7.1.6.3 of ANSI C29.11-1989 and Clause 5.1.4.3 of IEC 61109-1992. The average value for this test was required to be a minimum of 90% of the initial values determined in Section 2.2.1 of this report. The results of this testing are shown in Table 6 below.
Test Conditions: Td = 53.6 °F Tw = 49.1 °F P = 14.786 Psi.
2.3.1 Test Specimens Six specimens were obtained from a larger group of samples. These specimens were dived into two groups of three for the following test in Sections 2.3.2 and 2.3.3 of this report. 2.3.2 Determination of Average Failing Load of The Core
Three units from Section 2.3.1 above were subjected to an Average Failing Load Test according to Clause 7.2.2 of ANSI C29.11-1989 and Clause 5.2.2.1 of IEC 61109-1992 and. The results of this testing are shown in Table 7 below. These values will be used as base values for Section 2.3.3 of this report.
Three units from Section 2.3.1 above were subjected to a load equal to 60% of the Average Failing Load from Section 2.3.2 and maintained for a period of 96 hours according to Clause 7.2.3 of ANSI C29.11-1989 and Clause 5.2.2.2 of IEC 61109-1992. The results of this testing are shown in Table 8 below.
Sample Number
Insulation Length (Inches)
60% of Average Failing Load
(Lbs.)
Withstand Time
(Hours) Results 1 96 Passed 2 96 Passed 3
~ 31.69 17394.9 96 Passed
Specification ≥ 31.5 - 96 No Damage Table 8
2.4 Housing Tracking and Erosion Test Two assembled units were subjected to a tracking and erosion test according to Clause 7.3 of ANSI C29.11-1989 and Clause 5.3 of IEC 61109-1992 and. The physical details of the test samples are shown in Table 9 below while the results of the testing are shown in Table 10 below. Test Conditions: Water Flow Rate (kg/m3 x h) = 0.32 – 0.35
Size of Droplets (µm) = 5 - 10 NaCl Content of Water (kg/m3) = 9.5 – 10.0 Fog Chamber Temperature (°C) = 22.0 – 24.0
2.5.1 Dye Penetration Test Ten specimens were cut from a randomly sampled production insulator and tested for dye penetration according to Clause 7.4.1 of ANSI C29.11-1989 and Clause 5.4.1 of IEC 61109-1992. These specimens, measuring 0.944 inches in diameter and 0.394 inches in length were placed upright on a layer of steel balls and a 1% alcohol and fuchsin dye solution was poured into the glass vessel until the dye level was 0.098 inches higher than the surface of the steel balls. The samples remained in the glass vessel for a period of 15 minutes per the standard requirements with no signs of penetration. The details of the samples and the test results are shown in Table 11 below.
Specimen Number
Specimen Length (Inches)
Sample Immersion Time (Minutes) Results
1 0.396 15 No Penetration 2 0.397 15 No Penetration 3 0.398 15 No Penetration 4 0.399 15 No Penetration 5 0.400 15 No Penetration 6 0.386 15 No Penetration 7 0.402 15 No Penetration 8 0.387 15 No Penetration 9 0.398 15 No Penetration
10 0.394 15 No Penetration Specification 0.394 ± 0.02 15 No Penetration
Table 11
2.5.2 Water Diffusion Test
2.5.2.1 Prestressing Six specimens were cut from the same type of production insulator used in the dye penetration testing and tested for water diffusion according to Clause 7.4.2.2 of ANSI C29.11-1989 and Clause 5.4.2.2 of IEC 61109-1992. These specimens, measuring 0.944 inches in diameter and 1.181 inches in length, were boiled in a glass vessel containing deinonized water and 0.1 % by weight of Sodium Chloride, for 100 hours. The specimens were removed from the boiling water and placed in ambient temperature deionized water until cooled. 2.5.2.2 Voltage Test
The specimens from Section 2.5.2.1 above were removed from the deinoized water, dried with filter paper and subjected to a voltage test according to Clause 7.4.2.3 of ANSI C29.11-1989 and Clause 5.4.2.3 of IEC 61109-1992 less than 3 hours after removal from the boiling water. The results of this testing are shown in Table 12 below.
Specification 1.182 ± 0.020 100 12 1 ≤ 1 No Puncture or Flashover
Table 12 3.0 Design Tests
3.1 Test Unit The test unit used for this Design Testing was the Composite Suspension insulator design shown in Appendix A. The unit tested met the requirements of Clause 4.1 of ANSI C29.11-1989 thereby permitting the use of the Prototype Test results detailed above for this unit. 3.2 Lightning Impulse Withstand Test
Three sample Composite Suspension Insulators were subjected to a Lightning Impulse Withstand Test according to Clause 6.1 IEC 61109-1992. The results of this testing are shown in Table 14 below. As the results show, the units withstood the minimum Critical-Impulse Flashover requirement.
Test Conditions: Td = 63.1 °F Tw = 58.1 °F P = 14.88 Psi. Kd = 1.018 Kh = 1.000
Positive Polarity
Sample # Test Wave
(µs) Withstand Test Value
(kV) Corrected Value
(kV) Withstand Time
(Seconds) Results 1 1.15 1021.0 15 No Flashover 2 1.15 1023.0 15 No Flashover 3 1.15 1024.0
Three sample Composite Suspension Insulators were subjected to a Low-Frequency Wet Withstand Test according to Clause 6.2 IEC 61109-1992. The results of this testing are shown in Table 14 below. As the results show, the units withstood the minimum Low-Frequency Wet Flashover specification requirement.
4.1 Visual Inspection and Dimensional Verification Nine samples were taken from the group of units and visually inspected to verify the quality and were measured to verify the actual dimensions against the design dimensions according to Clause 9.2 of ANSI C29.11-1989 and Clause 7.2 of IEC 61109-1992. The quality of the units observed during visual inspection was good. The galvanizing on the end fittings was consistent and the injection molding was good. The results of the dimensional verification are shown in Table 15 below.
1 84.33 220.47 Go No-Go Go No-Go 2 84.25 222.44 Go No-Go Go No-Go 3 84.45 220.47 Go No-Go Go No-Go 4 84.17 223.62 Go No-Go Go No-Go 5 84.25 224.41 Go No-Go Go No-Go 6 84.25 220.47 Go No-Go Go No-Go 7 84.06 223.62 Go No-Go Go No-Go 8 84.25 222.44 Go No-Go Go No-Go 9 84.17 220.47 Go No-Go Go No-Go
Specification 84.44 ± 1.18 ≥ 193.22 Go No-Go Go No-Go Table 15
4.2 Verification of Locking System Locking System Verification testing was conducted on 3 samples taken from the group of units removed from production according to Clause 9.3 of ANSI C29.11-1989 and Clause 7.3 of IEC 61109-1992. The results of this testing are shown in Table 16 below.
Number First Second Third Results At 56Lb. Maximum Load
1 31.25 20.09 22.32 No Uncoupling 2 17.86 26.79 26.79 No Uncoupling 3 26.79 40.18 20.09 No Uncoupling
Specification 5.2 – 56.0 No Uncoupling Table 16
4.3 Mechanical Load Test The 3 samples, used in the previous verification testing, were subjected to mechanical load equivalent to the SML per Clause 9.4 of ANSI C29.11-1989 and Clause 7.4 of IEC 61109-1992. The results of this testing are shown in Table 17 below.
4.4 Galvanizing Test Galvanizing thickness testing was conducted on 3 samples taken from the group of units removed from production according to Clause 9.5 of ANSI C29.11-1989 and Clause 7.5 of IEC 61109-1992. The results of this thickness testing are shown in Table 18 below.
Thickness Values of Socket End Fitting (Mils)
Thickness Values of Ball End Fitting (Mils) Sample
Test Unit: 500kV – 36,000 Lb. Composite Suspension Insulator PBI Part Number: 9710019 Test Type: Prototype, Design and Sample Test Referenced Standards: ANSI C29.11-1989
ANSI C29.12-1997 ANSI C29.13-2000 IEC61109-1992
Date of Test: September 12, 1998 through November 20, 1998 Date Report Was Prepared: January 2, 2004 Report Prepared By: Tom J. Martin
Testing Conclusion: All units tested passed the testing according to all applicable requirements of the referenced standards.
Table of Contents: 1.0 General Unit Design and Specifications 4 2.0 Prototype Tests 4 2.1 Test Unit 4 2.2 Tests On Interfaces and Connections of Metal Fittings 4 2.2.1 Power Frequency Voltage Test 4 2.2.2 Sudden Load Release Test 4 2.2.3 Thermal-Mechanical Test 5 2.2.4 Water PenetrationTest 5 2.2.5 Verification Tests 5 2.2.5.1 Visual Examination 5 2.2.5.2 Steep Front Impulse Voltage Test 5 2.2.5.3 Power Frequency Voltage Test 6 2.3 Core Time-Load Test 6 2.3.1 Test Specimens 6 2.3.2 Determination of Average Failing Load of The Core 6 2.3.3 Core Time Load Test 7 2.4 Housing Tracking and Erosion Test 7 2.5 Core Material Tests 8 2.5.1 Dye Penetration Test 8 2.5.2 Water Diffusion Test 8 2.5.2.1 Prestressing 8 2.5.2.2 Voltage Test 8 3.0 Design Tests 9 3.1 Test Unit 9 3.2 Lightning Impulse Withstand Test (Positive) 9 3.3 Low-Frequency Wet Withstand 9 3.4 Wet Switching Impulse Withstand 10 4.0 Sample Tests 10 4.1 Visual Inspection and Dimensional Verification 10 4.2 Verification of Locking System 10 4.3 Mechanical Load Test 11 4.4 Galvanizing Test 11
1.0 General Unit Design and Specifications See Appendix A 2.0 Prototype Tests
2.1 Test Unit The test unit used for this Prototype Testing was a Composite Suspension insulator design representing the entire class of 500kV Silicone Composite Suspension Insulators. As per the requirement of Clause 7.1.1 of ANSI C29.11-1989, the composite insulator samples used for this Prototype Testing had a metal-to-metal spacing of at least 800mm in length. The actual insulation length of the test units was a minimum of 31.69” (820mm). 2.2 Tests On Interfaces and Connections of Metal Fittings
2.2.1 Power Frequency Voltage Test Three assembled units were randomly selected and subjected to a Power Frequency Voltage Test per Clause 7.1.2 of ANSI C29.11-1989 and Clause 5.1.2 of IEC 61109-1992. The results of this testing are shown in Table 1 below.
Test Conditions: Td = 71.6 °F Tw = 68.9 °F P = 14.713 Psi. Kd = 0.981 Kh = 0.940
Sample Number
Average Value (kV)
Corrected Value (kV)
1 349.0 335.4 2 347.0 333.5 3 346.0 332.5
Table 1
2.2.2 Sudden Load Release Test The three samples from the Power Frequency Voltage Test were subjected to a sudden load release test according to Clause 7.1.3 of ANSI C29.11-1989 and Clause 5.1.3.1 of IEC61109-1992. Each sample was subjected to 30% of the unit’s Specified Mechanical Load (SML) which was then suddenly released. The results of this testing are shown in Table 2 below.
Three samples were subjected to temperature variations under a mechanical load of 11240 Lbs. or A minimum of 50% of the SML Rating according to Clause 7.1.4 of ANSI C29.11-1989 and Clause 5.1.3.2 of IEC61109-1992. The temperature range from cold to hot during each 24 hour cycle was -31 +/- 5 °F to 122 +/- 5 °F. The 24 hour temperature cycles were repeated 4 times per the standard requirements. The initial and final dimensions of the samples are shown in Table 3 below while the results of the testing are shown in Table 4 below.
Samples 1, 2 and 3 from previous tests were immersed in boiling deionized water, containing 0.1 % by weight of Sodium Chloride, for 42 hours per Clause 7.1.5 of ANSI C29.11-1989 and Clause 5.1.3.3 of IEC61109-1992. The samples were then retained in the water while the temperature was lowered to 122 °F. These samples were visually inspected and were found to have no signs of damage. These units were subsequently used for the verification testing in Section 2.2.5.
2.2.5 Verification Tests
2.2.5.1 Visual Examination
Samples 1, 2 and 3 from the Water Penetration test were reexamined for any signs of damage prior to proceeding with testing in Sections 2.2.5.2 and 2.2.5.3. No damage was observed.
2.2.5.2 Steep Front Impulse Voltage Test
The three test samples from the previous tests were fitted with a sharp edged electrode dividing each sample into two equal length sections according to Clause 7.1.6.2 of ANSI C29.11-1989 and Clause 5.1.4.2 of IEC61109-1992. These samples were then subjected to an Impulse Voltage having a rate of rise of at least 1000 kV/µS for 25 positive and negative polarity impulses. The results of this testing are shown in Table 5 below.
The three test samples from previous tests were subjected to a Dry Power Frequency Flashover Voltage Test per Clause 7.1.6.3 of ANSI C29.11-1989 and Clause 5.1.4.3 of IEC 61109-1992. The average value for this test was required to be a minimum of 90% of the initial values determined in Section 2.2.1 of this report. The results of this testing are shown in Table 6 below.
Test Conditions: Td = 78.8 °F Tw = 73.4 °F P = 14.728 Psi.
2.3.1 Test Specimens Six specimens were obtained from a larger group of samples. These specimens were dived into two groups of three for the following test in Sections 2.3.2 and 2.3.3 of this report. 2.3.2 Determination of Average Failing Load of The Core
Three units from Section 2.3.1 above were subjected to an Average Failing Load Test according to Clause 7.2.2 of ANSI C29.11-1989 and Clause 5.2.2.1 of IEC 61109-1992 and. The results of this testing are shown in Table 7 below. These values will be used as base values for Section 2.3.3 of this report.
Three units from Section 2.3.1 above were subjected to a load equal to 70% of the Specified Mechanical Load Section 2.3.2 and maintained for a period of 96 hours according to Clause 7.2.3 of ANSI C29.11-1989 and Clause 5.2.2.2 of IEC 61109-1992. The results of this testing are shown in Table 8 below.
Sample Number
Insulation Length (Inches)
60% of Average Failing Load
(Lbs.)
Withstand Time
(Hours) Results 1 96 Passed 2 96 Passed 3
~ 32.09 25179.9 96 Passed
Specification ≥ 31.5 - 96 No Damage Table 8
2.4 Housing Tracking and Erosion Test Two assembled units were subjected to a tracking and erosion test according to Clause 7.3 of ANSI C29.11-1989 and Clause 5.3 of IEC 61109-1992 and. The physical details of the test samples are shown in Table 9 below while the results of the testing are shown in Table 10 below. Test Conditions: Water Flow Rate (kg/m3 x h) = 0.32 – 0.35
Size of Droplets (µm) = 5 - 10 NaCl Content of Water (kg/m3) = 9.5 – 10.0 Fog Chamber Temperature (°C) = 22.0 – 24.0
2.5.1 Dye Penetration Test Ten specimens were cut from a randomly sampled production insulator and tested for dye penetration according to Clause 7.4.1 of ANSI C29.11-1989 and Clause 5.4.1 of IEC 61109-1992. These specimens, measuring 0.944 inches in diameter and 0.394 inches in length were placed upright on a layer of steel balls and a 1% alcohol and fuchsin dye solution was poured into the glass vessel until the dye level was 0.098 inches higher than the surface of the steel balls. The samples remained in the glass vessel for a period of 15 minutes per the standard requirements with no signs of penetration. The details of the samples and the test results are shown in Table 11 below.
Specimen Number
Specimen Length (Inches)
Sample Immersion Time (Minutes) Results
1 0.402 15 No Penetration 2 0.402 15 No Penetration 3 0.400 15 No Penetration 4 0.400 15 No Penetration 5 0.406 15 No Penetration 6 0.402 15 No Penetration 7 0.401 15 No Penetration 8 0.402 15 No Penetration 9 0.403 15 No Penetration
10 0.405 15 No Penetration Specification 0.394 ± 0.02 15 No Penetration
Table 11
2.5.2 Water Diffusion Test
2.5.2.1 Prestressing Six specimens were cut from the same type of production insulator used in the dye penetration testing and tested for water diffusion according to Clause 7.4.2.2 of ANSI C29.11-1989 and Clause 5.4.2.2 of IEC 61109-1992. These specimens, measuring 0.944 inches in diameter and 1.181 inches in length, were boiled in a glass vessel containing deinonized water and 0.1 % by weight of Sodium Chloride, for 100 hours. The specimens were removed from the boiling water and placed in ambient temperature deionized water until cooled. 2.5.2.2 Voltage Test
The specimens from Section 2.5.2.1 above were removed from the deinoized water, dried with filter paper and subjected to a voltage test according to Clause 7.4.2.3 of ANSI C29.11-1989 and Clause 5.4.2.3 of IEC 61109-1992 less than 3 hours after removal from the boiling water. The results of this testing are shown in Table 12 below.
Specification 1.182 ± 0.020 100 12 1 ≤ 1 No Puncture or Flashover
Table 12 3.0 Design Tests
3.1 Test Unit The test unit used for this Design Testing was the Composite Suspension insulator design shown in Appendix A. The unit tested met the requirements of Clause 4.1 of ANSI C29.11-1989 thereby permitting the use of the Prototype Test results detailed above for this unit. 3.2 Lightning Impulse Withstand Test
Three sample Composite Suspension Insulators were subjected to a Lightning Impulse Withstand Test according to Clause 6.1 IEC 61109-1992. The results of this testing are shown in Table 14 below. As the results show, the units withstood the minimum Critical-Impulse Flashover requirement.
Test Conditions: Td = 69.8 °F Tw = 62.60 °F P = 14.734 Psi. Kd = 1.018 Kh = 1.000
Positive Polarity
Sample # Test Wave
(µs) Withstand Test Value
(kV) Corrected Value
(kV) Withstand Time
(Seconds) Results 1 1.15 2062.0 15 No Flashover 2 1.15 2062.0 15 No Flashover 3 1.15 2062.0
Three sample Composite Suspension Insulators were subjected to a Low-Frequency Wet Withstand Test according to Clause 6.2 IEC 61109-1992. The results of this testing are shown in Table 14 below. As the results show, the units withstood the minimum Low-Frequency Wet Flashover specification requirement.
3.4 Wet Switching Impulse Withstand Test Three samples were subjected to a Wet Switching Impulse Withstand Voltage Test per Clause 6.3 of IEC 61109-1992 and ANSI C29.11-1989 and Clause 8.3 of ANSI C29.11-1989. The results of this testing are shown in Table 15 below.
Test Conditions: Td = 70.0 °F Tw = 64.6 °F P = 14.728 Psi. Kd = 1.00
Rain Water Resistivity: ρ20.0 = 104.0 Ω.m
Rain Rate: 1.4 mm/min (Horizontal and Vertical)
Sample Number
Test Wave (µS)
Corrected Value (kV)
Withstand Test Value
(kV)
Withstand Time (Sec) Results
1 1240.0 15 Passed 2 1240.0 15 Passed 3
260/2400 1240.0 1240.0 15 Passed
Specification 250 ± 20% / 2500 ± 60%
Sample should withstand 1240 kV ± 3% for 15 cycles with no flashovers.
Table 15 4.0 Sample Tests
4.1 Visual Inspection and Dimensional Verification Nine samples were taken from the group of units and visually inspected to verify the quality and were measured to verify the actual dimensions against the design dimensions according to Clause 9.2 of ANSI C29.11-1989 and Clause 7.2 of IEC 61109-1992. The quality of the units observed during visual inspection was good. The galvanizing on the end fittings was consistent and the injection molding was good. The results of the dimensional verification are shown in Table 16 below.
1 175.20 496.06 Go No-Go Go No-Go 2 175.31 496.46 Go No-Go Go No-Go 3 175.39 496.46 Go No-Go Go No-Go 4 175.20 496.06 Go No-Go Go No-Go 5 175.59 496.85 Go No-Go Go No-Go 6 175.20 496.06 Go No-Go Go No-Go 7 175.39 496.46 Go No-Go Go No-Go 8 175.28 496.06 Go No-Go Go No-Go 9 175.20 496.06 Go No-Go Go No-Go
Specification 175.20 ± 1.97 ≥ 433.07 Go No-Go Go No-Go Table 16
4.2 Verification of Locking System Locking System Verification testing was conducted on 3 samples taken from the group of units removed from production according to Clause 9.3 of ANSI C29.11-1989 and Clause 7.3 of IEC 61109-1992. The results of this testing are shown in Table 17 below.
Moving Load (Lbs.) Sample Number First Second Third
Results At 56Lb. Maximum Load
1 24.55 26.79 35.71 No Uncoupling 2 40.18 40.18 33.48 No Uncoupling 3 22.32 42.41 40.18 No Uncoupling
Specification 5.2 – 56.0 No Uncoupling Table 17
4.3 Mechanical Load Test The three samples, used in the previous verification testing, were subjected to mechanical load equivalent to the SML per Clause 9.4 of ANSI C29.11-1989 and Clause 7.4 of IEC 61109-1992. The results of this testing are shown in Table 18 below.
4.4 Galvanizing Test Galvanizing thickness testing was conducted on 3 samples taken from the group of units removed from production according to Clause 9.5 of ANSI C29.11-1989 and Clause 7.5 of IEC 61109-1992. The results of this thickness testing are shown in Table 19 below.