PROCEDURE FOR TESTING & COMMISSIONING OF

INSULATORS
1 PURPOSE:
To have a common practices to accept the manufacturing Quality of the product
and to ensure the Installation quality of the Insulators.
1. SCOPE:
Factory acceptance test at vendor site & Installation at project site.
2. RESPONSIBILITY:
Factory acceptance test by manufacturer & witness by Greenko HO Quality and
Greenko Site Quality for Installation at project site.
3. REFERENCE DOCUMENTS:
IS 5621:1980, IS 2544:1973, IS 731:1971, Approved GTP & Approved Drawings,
IEC 60898-1
4. PROCEDURE:
5.1.
Factory acceptance test:
5.1.1.For hollow Insulators:
5.1.1.1. Type test for Hollow Insulators:
Specification limits should be as per IS 5621: 1980. The hollow insulators shall be
subjected to the following type tests:
5.1.1.1.1.
5.1.1.1.2.
5.1.1.1.3.
5.1.1.1.4.
5.1.1.1.5.

Visual inspection.
Electrical routine test.
Verification of dimensions.
Porosity test.
Temperature cycle test.

Note 1: For certain applications, hollow insulators may have to be submitted to

other tests, for example, internal pressure test 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 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 the type tests, made on not less than three hollow
insulators, identical in all essential details with those to be supplied , are regard
as evidence of compliance.

PROCEDURE FOR TESTING & COMMISSIONING OF

INSULATORS
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.
5.1.1.2. Routine Tests:
Specification limits should be as per IS 5621: 1980
The following shall be carried out as routine tests on every hollow insulator:
5.1.1.2.1.
5.1.1.2.2.
5.1.1.2.3.

Visual inspection.
Electrical routine test.
Verification of important dimensions.

Note: In special cases, the verification of certain dimensions should be a routine

test. In such cases, the relevant drawing of the order should specify which
dimensions are to be verified as a routine test.
5.1.1.3. Acceptance Tests:
Specification limits should be as per IS 5621: 1980
The acceptance tests shall comprise of the following:
5.1.1.3.1.
5.1.1.3.2.
5.1.1.3.3.

Verification of dimensions.
Porosity test.
Temperature cycle test.

The acceptance tests are made on a small number of hollow selected from the
lot after passing the routine tests. The recommended sampling scheme shall be
given In IS 5621: 1980- Appendix A.
5.1.2.For Porcelain post insulator:
Specification limits should be as per IS 2544:1973.
Types of post insulator:
Post insulator and post insulator units are divided into the following two types
according to their construction:
Type A: A post insulator or post insulator unit in which the length of the shortest
puncture path through solid insulating material is at least equal to half the length
of the shortest flashover path through air outside the insulator.
Type B: A post insulator or post insulator unit in which the length of the shortest
puncture path through solid insulating material is less than half the length of the
shortest flashover path through air outside the insulator.

5.1.2.1. Type Test for Porcelain post insulator:

PROCEDURE FOR TESTING & COMMISSIONING OF

INSULATORS
5.1.2.1.1.
5.1.2.1.2.
5.1.2.1.3.
5.1.2.1.4.
5.1.2.1.5.
5.1.2.1.6.
5.1.2.1.7.
5.1.2.1.8.
5.1.2.1.9.
5.1.2.1.10.
5.1.2.1.11.

Visual Examination.
Verification of dimensions.
Visible discharge test.
Impulse voltage withstand test.
Dry power- frequency voltage withstand test.
Wet power-frequency voltage withstand test.
Temperature cycle test.
Test for mechanical Strength.
Puncture test (For insulators Type B only)
Porosity test.
Galvanizing test.

Note 1: for certain insulators, deflection under load may be especially important.
When it is agreed a test for deflection under load is necessary, the test shall be
made.
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 2 post
insulators and post insulator units identical in all essential details with those to
be supplied, are regarded as evidence of compliance.
5.1.2.1.12. The tests should be carried out on two
samples in the order mentioned below:
5.1.2.1.12.1. Test on both Insulator:
5.1.2.1.12.1.1.
Visual Examination.
5.1.2.1.12.1.2.
Verification of dimensions.
5.1.2.1.12.1.3.
Visible discharge test.
5.1.2.1.12.1.4.
Impulse voltage withstand test.
5.1.2.1.12.1.5.
Dry power- frequency voltage withstand
test.
5.1.2.1.12.1.6.
Wet power-frequency voltage withstand
test.
5.1.2.1.12.1.7.
Temperature cycle test.
5.1.2.1.12.2. Test on first insulator:
5.1.2.1.12.2.1.
Test for mechanical Strength.
5.1.2.1.12.2.2.
Porosity test.
5.1.2.1.12.3. Test on second insulator:
5.1.2.1.12.3.1.
Puncture test (For insulators Type B only)
5.1.2.1.12.3.2.
Galvanizing test.

5.1.2.2. Acceptance Test for Porcelain post insulator:

The test samples after having withstood the routine tests shall be subjected to
the following acceptance tests in the order indicated below:

PROCEDURE FOR TESTING & COMMISSIONING OF

INSULATORS
5.1.2.2.1.
Verification of dimensions.
5.1.2.2.2.
Temperature cycle test.
5.1.2.2.3.
Mechanical strength test.
5.1.2.2.4.
Puncture test.
5.1.2.2.5.
Porosity test.
5.1.2.2.6.
Galvanizing test.
5.1.2.3. Routine test for Porcelain post insulator:
The following shall be carried out as routine tests on each post insulator or post
insulator unit:
5.1.2.3.1.
Visual examination.
5.1.2.3.2.
Routine electrical test.
5.1.2.3.3.
Routine mechanical test.
5.1.3.For Porcelain insulator:
Specification limits should be as per IS 731:1971.
5.1.3.1. Type test for porcelain insulators:
The following tests shall constitute the type tests:
5.1.3.1.1.
Visual examination.
5.1.3.1.2.
Verification of dimensions.
5.1.3.1.3.
Visible discharge test.
5.1.3.1.4.
Impulse voltage withstand test.
5.1.3.1.5.
Wet power-frequency voltage withstand test.
5.1.3.1.6.
Temperature cycle test.
5.1.3.1.7.
Electro-mechanical failing load test (for string
insulator units, Type B only).
5.1.3.1.8.
Mechanical failing load test (for string insulator
units of Type A and those of Type B to which
electromechanical failing load test is not applicable and
for rigid insulators only).
5.1.3.1.9.
24 hours mechanical strength test (for string
insulators only when specified by the purchaser).
5.1.3.1.10.
Puncture test (for insulators, Type B only).
5.1.3.1.11.
Porosity test.
5.1.3.1.12.
Galvanizing test.
NOTE 1 A radio interference test is under consideration.
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 two
insulators identical in all essential details with those to be supplied, are regarded
as evidence of compliance. The tests should be carried out on two samples in the
order mentioned below:
5.1.3.1.13. The tests should be carried out on two
samples in the order mentioned below:
5.1.3.1.13.1. Tests on both insulators:
5.1.3.1.13.1.1. Visual examination.
5.1.3.1.13.1.2. Verification of dimensions.

PROCEDURE FOR TESTING & COMMISSIONING OF

INSULATORS
5.1.3.1.13.1.3.
5.1.3.1.13.1.4.
5.1.3.1.13.1.5.
test.
5.1.3.1.13.1.6.

Visible discharge test.

Impulse voltage withstand test.
Wet power frequency withstand
Temperature cycle test.

5.1.3.1.13.2. Tests on first insulator:

5.1.3.1.13.2.1. Twenty-four hour mechanical
strength test (for string insulators only
when specified by the Greenko)
5.1.3.1.13.2.2. Electromechanical failing load test
(for string insulator units Type B only)
5.1.3.1.13.2.3. Mechanical failing load test (for
string insulator units Type A and for rigid
insulators only)
5.1.3.1.13.2.4. Porosity test.
5.1.3.1.13.3. Tests on second insulator:
5.1.3.1.13.2.1. Puncture test (for insulator units,
Type B only).
5.1.3.1.13.2.2. Galvanizing test.
5.1.3.2. Acceptance tests for porcelain insulator:
The test samples shall be subjected to the following acceptance tests in the
order indicated below:
5.1.3.2.1.
Verification of dimensions.
5.1.3.2.2.
Temperature cycle test.
5.1.3.2.3.
Twenty four hours mechanical strength test (for
string insulator units only when specified by the
purchaser).
5.1.3.2.4.
Electro-mechanical failing load test (for string
insulator units Type B only).
5.1.3.2.5.
Mechanical failing load test (for string insulator
units Type A and for rigid insulators only).
5.1.3.2.6.
Puncture test (for string insulator units, Type B
only).
5.1.3.2.7.
Porosity test.
5.1.3.2.8.
Galvanizing test.
5.1.3.3. Routine Tests for porcelain insulators:
The following tests shall be carried out as routine tests:
5.1.3.3.1.
Visual examination.
5.1.3.3.2.
Mechanical routine test (for string insulator units
only).
5.1.3.3.3.
Electrical routine test (for Type B string
insulators and rigid insulators.
NOTE Attention is drawn to the fact that ultrasonic tests may be used on Type
A insulator to detect internal flaws and cracks. Experience is necessary to
interpret results of ultrasonic tests and, therefore, precis forms of tests cannot
yet be adopted as standard.

PROCEDURE FOR TESTING & COMMISSIONING OF

INSULATORS
5.2.

Installation & Commissioning of insulator:

Generally there is no separate Installation & commissioning guidelines for

insulator. Installation and commissioning as per Vendor or Greenko- Inspection
and test plan and observation will be recorded on Check list for erection of
equipments that has a insulator as a part.
5. RECORDS:
5.1.Material Quality Inspection report
5.2.Incoming Inspection report
5.3.Erection Checklist of Insulator -

F-CO-QA06-01.
F-CO-QA06-02.
F-CO-QA-20-01.