Enhancing Insulator Performance Using Field Reduction Electrodes:Simulation Analysis and Experimental Investigation of HV Disc Insulators

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Ramesh, K. Karunanithi, R. Sreedhar, S. Vinoth John Prakash, and 1 more This is a preprint; it has not been peer reviewed by a journal. https://doi.org/ 10.21203/rs.3.rs-6400499/v1 This work is licensed under a CC BY 4.0 License Status: Posted Version 1 posted You are reading this latest preprint version Abstract The insulator is a pivotal element in the electrical transmission system. It is also used in all electrical and electronic equipment to prevent electric current from passing through itself. In transmission lines, it separates the electric conductor from the overhead towers. To improve the performance of insulators, surface flashover should be reduced using a field reduction electrode. The objective of the present work is to minimize insulator flashover caused by faults or external factors at an early stage. In this study, a comparative analysis of the performance of High-Voltage (HV) disc insulator strings made of porcelain and polymer, with and without a Field Reduction Electrode (FRE), was conducted. Based on theoretical and practical values, it is evident that the withstand capacity, flashover resistance, and lifespan of the insulator can be enhanced by the proposed FRE methodology. The software simulation and characteristic study were conducted using ANSYS software also the effectiveness of the design structure was experimentally verified. ANSYS Field Reduction Electrode insulator porcelain polymer withstand voltage Figures Figure 1 Figure 2 Figure 3 Figure 4 Figure 5 Figure 6 Figure 7 Figure 8 Figure 9 Figure 10 Figure 11 Figure 12 Figure 13 Figure 14 I. INTRODUCTION In recent years, the need for electrical power supply generation and distribution is increasing drastically. Due to this, both generation and distribution sectors also to be modernized according to current trend. Considering future demand, the technological development is exclusively important in insulator design for safety purpose. To ensure the security of high-voltage transmission lines, proper protection of insulators is essential. The primary purpose of an insulator is to electrically isolate equipment or machinery from other charged or uncharged metal parts. Insulating materials should be employed in electrical systems to prevent the unwanted flow of current to the ground from their supporting points. These materials play a significant role in electrical systems by providing electrical isolation [1]. Electrical insulation offers a highly resistive path through which almost no current flows. In transmission and distribution systems, overhead conductors are typically supported by towers or poles, both of which are properly grounded. Insulators are essential components in electrical systems and are designed to withstand cantilever or tension loading. They serve as barriers between live conductors and overhead towers. Various types of insulators are available, including suspension, string, pin, post, stay, and shackle insulators, all of which are designed to prevent the flow of electric current from the conductor to the tower [2–3]. Insulators can fail due to excessive electrical, mechanical, and field stress or due to environmental chemical reactions on their surface. Common signs of failure include flashover between metal parts on both sides of the insulator, partial discharges, treeing, tracking, punctures, and cracking. Some of the main causes of insulation failure include: Aging Excessive heat and moisture Chemical deterioration due to heat, moisture, and dirt Mechanical vibrations Sunlight exposure Voltage stresses The primary purpose of insulation is to prevent the flow of electrical current between points of different potentials within an electrical system. Insulation failure is one of the most common causes of electrical equipment malfunctions and power supply failure [4]. The failure in insulators causes mainly due to the sudden raise in flashover voltage. The insulating material should be properly tested to overcome this type of failures [5]. The effect of flashover voltage on transmission line insulators are examined and reviewed in [6]. This study reveals that the surface flashover voltage must be minimized to reduce the insulation failure. The key objective of the proposed work is to enhance the performance of porcelain and polymer insulators using a novel technique called the field reduction method. By applying a Field Reduction Electrode (FRE), the surface flashover resistance can be improved, leading to an extended lifespan of the insulator [7]. II. TYPES OF INSULATORS Insulators used in HVAC / HVDC transmission are currently designed using glass, porcelain, or composite polymer materials. While discussing about the types of insulators, it is essential to evaluate its performance under various environmental conditions [8-9]. The design of insulator using different manufacturing materials are discussed as follows. A. Porcelain insulator Porcelain (ceramic ware) is made from alumina, china-clay, quartz, feldspar, and is coated to repel water and other dust particles. It is designed using ceramic ware concentrated with aluminum oxide are employed in applications where excess mechanical robustness is a key requirement. It has an insulating capability of approximately 4–10 kV/mm. Recently, affordable micro additives are employed to design procelain insulators [10] which will reduce overall cost of the insulators. The nanotextured superhydrophobic coated porcelain insulators are designed and tested in [11] which acknowledges that there is a need to design a self-sustained, low-cost insulator for HV applications. In [12], the authors analyzed electric potential and leakage current of procelain insulators under various environmental conditions. The test results prove that, the procelain type insulators withstand for high electric field with very minimal leakage current. The model of procelain disc insulator is displayed in Fig. 1. B. Polymer insulator Polymer insulators are made of silicone rubber and composite materials with a smooth glazed surface for improved performance. Silicone rubber sheds provide excellent hydrophobic properties, strong resistance to aging, tracking, and erosion. They also offer high mechanical strength and good flexibility. The sustainability of polymer insulator in electric field is disclosed in [13]. For voltages exceeding 33 kV, suspension-type insulators are commonly used. These insulators consist of multiple glass or ceramic discs coupled in series by metal links, forming a string. The main cause of insulation failure in polymer-based insulator is uneven voltage stress. This will enhance the aging effect of insulators drastically [14]. By the employment of proper design structure, the aging effect can be diminished well. The model of polymer disc insulator is displayed in Fig. 2. III. DESIGN METHODOLOGY There are various methods of insulator design existing in current scenario. One of the common and effective methodology in the insulator design is based on the differential equations [5]. The differntial equations of the electric field can be solved using the two methods. 1. Domain Based Methods 2. Boundary Based Methods 1. Domain based methods It is further classified in to two different methods as follows. A. Finite Difference Method (FDM) FDM is a numerical based design methodology, which is employed to deduce differential equations. It involves discretizing continuous equations, converting them into a system of algebraic equations. In this method, linear equations can transform into nonlinear systems depending on the problem's complexity. B. Finite Element Method (FEM) Finite element analysis (FEA) is a computerized method used to predict how a product responds to real-world forces, vibrations, heat, fluid flow, and other physical effects. It helps determine whether a product will fail, wear out, or perform as intended. 2. Boundary based methods It is further classified in to three different methods as follows. A. Boundary Element Method (BEM) The BEM utilizes the boundary conditions given by the manufacturer to determine boundary values, rather than solving for results throughout the entire space. It is a numerical computational technique used to solve electromagnetic and electrostatic field problems, especially in complex geometries. BEM is effective in evaluating the electric field distribution along the surface of insulators, particularly near the triple junction (air, insulator, and metal interface), where field enhancement can lead to corona or surface flashover. Since BEM requires discretization only on the boundary surfaces (not the entire volume), it is especially efficient for problems involving large open spaces, such as outdoor high voltage equipment. It helps in optimizing the shape and shed profile of disc insulators to ensure uniform electric field distribution, which improves performance and extends lifespan by minimizing local discharges. B. Charge Simulation Method (CSM) In CSM, the magnitude of charges is estimated so that their combined effect satisfies the boundary conditions exactly at selected points on the boundary. For this reason, CSM is also referred to as a Point Matching Method. Due to several disadvantages associated with both the Discrete Boundary Method (DBM) and Charge Simulation Method (CSM), we are transitioning to an advanced approach known as SCSM (Simplified Charge Simulation Method). Fig. 3 displays the simulation contour of charge particles spread over the insulator using CSM method. C. Surface Charge Simulation Method (SCSM) SCSM is advantageous because it can effectively handle both two-dimensional (2D) and three-dimensional (3D) electric field distributions with asymmetrical boundary conditions (such as irregular electrode configurations). Unlike other methods, it provides high accuracy in modelling the behaviour of electric fields in complex geometries. Additionally, SCSM is highly suitable for analysing insulating materials with different permitivities. In high-voltage applications, insulators with varying dielectric constants are commonly used. This method allows for precise computation of electric fields across such heterogeneous materials, ensuring a better understanding of insulation performance and potential failure points. In this technique, the actual charge distribution within a system is approximated using a large number of discrete accumulated or surface charges. These simulated charges help replicate the real electric field behavior, allowing engineers to analyze and optimize electrical insulation and field distribution. IV. 3D MODELING AND SIMULATION The 3D models of disc insulators are created using ANSYS software to analyze the electric field distribution. ANSYS can simulate electromagnetic performance and evaluate critical factors such as temperature, vibration, and mechanical effects. Since hardware testing carries inherent risks, initial analysis was conducted solely through software simulations to gain insights before real-world implementation. This makes ANSYS an essential tool for evaluating insulator performance and optimizing designs. 1. Modeling Process Using SolidWorks and ANSYS The insulator designs were first modeled using SolidWorks, a solid modeling computer-aided design (CAD) and computer-aided engineering (CAE) software that runs on Microsoft Windows. For this study, insulator strings for both porcelain and polymer insulators (66 kV) were designed. A. Porcelain Insulator Analysis The first step was to model a 6-disc porcelain insulator string in SolidWorks as shown in Fig. 4. This model was then imported into ANSYS, where the following steps were performed: Meshing the model Applying voltage Evaluating the electric field distribution and temperature effects After simulation, ANSYS displayed the response through color variations, indicating areas of higher field stress. The results showed that the pin at the first disc (which connects directly to the live conductor) experienced the highest field stress. This phenomenon increases the risk of surface flashover, which must be mitigated. Fig. 5 illustrates the high field stress on the pin of the porcelain insulator. B. Polymer Insulator Analysis Next, the polymer insulator was modeled using the same process in SolidWorks and imported into ANSYS. Fig. 6 shows the 5-string polymer insulator model (66 kV) used in the study. Similar to the porcelain insulator, the polymer model underwent the following steps: Meshing Voltage application Electric field analysis The simulation results showed that the pin region of the polymer insulator string also suffered from severe field stress, as illustrated in Fig. 7. This issue, like in porcelain insulators, needed to be addressed to prevent flashover. The software simulations revealed that the pin directly connected to the live conductor experienced the highest field stress in both porcelain and polymer insulators. To mitigate this effect, a Field Reduction Electrode (FRE) is introduced at the pin of the first insulator. V. IMPACT OF FIELD REDUCTION ELECTRODE The primary objective of incorporating a Field Reduction Electrode (FRE) is to enhance surface flashover performance and reduce high field stress in the pin region of the insulator. To achieve this, the FRE must possess specific characteristics, including: High electrical conductivity Low resistivity Ability to modify the original surface of the pin, effectively transforming it into a field reduction electrode A. Selection of an Optimal FRE Material Significant effort was dedicated to identifying suitable materials for the FRE. After conducting numerous tests on various samples, the optimal field reduction electrode (FRE) material was identified as a combination of ferrous sulfate (FeSO₄) and copper sulfate (CuSO₄). This selection was based on their high electrical conductivity when mixed together as a solution, making them effective in reducing field stress and improving insulator performance. The first layer of the Field Reduction Electrode (FRE) was formed using ferrous sulfate (FeSO₄) shown in Fig. 8, which was dissolved in boiled distilled water (H₂O). After the solution settled, the second layer was applied using copper sulfate (CuSO₄) as shown in Fig. 9, creating a conductive coating for effective field stress reduction. The second layer of the Field Reduction Electrode (FRE) was applied using copper sulfate (CuSO₄). The coated surface was then left to dry for 12 hours. After this settling period, the Field Reduction Electrode (FRE) was successfully formed. VI. HARDWARE OUTCOMES The testing was carried on both polymer and porcelain insulator of 66 kV. For porcelain 6 no’s of 11kV-11kN porcelain discs with and without the field reduction electrode (FRE). And for polymer, 2 no’s of 33kV strings with and without field reduction electrode (FRE). The power frequency dry and wet withstand test was conducted on the both samples ie., porcelain and polymer insulators. This test gives the results as how much it can withstand the applying voltage by its own during dry and wet conditions. The dry condition is the normal condition of outdoor steady state temperature and pressure. For the wet condition, the compressor setup was made to spray the diluted water on the specimen which was hanged on crane. The designed insulator is shown in Fig. 10. A. Porcelain outcomes At first the 6 porcelain discs without field reduction electrode (FRE) string was made to undergo power frequency dry test and the test results (A1) were noted down. And it engaged to power frequency wet test and the test results (B1) were noted down. Similarly, the field reduction electrode (FRE) was included and test was conducted on both dry and wet condition and the test results (A1), (B2) were noted down and displayed in Table 1. The flashover test conducted on designed procelain insulator is displayed in Fig. 11. Table 1: Performance of procelain insulator Porcelain Insulator Without Field Reduction Electrode With Field Reduction Electrode Dry 301.3 350.6 Wet 242.2 272.1 The outcomes of the withstand test conducted on the procelain insulator is graphically represented in Fig. 12. This graphical representation proposed the difference between the with and without field reduction electrode and conclude that, the field reduction electrode equipped insulator has the higher improvement than normal sample. B. Polymer outcomes The string test conducted on designed polymer insulator is given in Fig. 13. At first, two 33kV polymer insulators without field reduction electrode (FRE) string was made to undergo power frequency dry test and the test results(C1) were noted down. And it engaged to power frequency wet test and the test results (D1) were noted down. Similarly, the field reduction electrode (FRE) was included and test was conducted on both dry and wet condition and the test results (C2), (D2) were noted down and displayed in Table 2. The outcomes of the withstand test conducted on the polymer insulator is graphically represented in Fig. 14. Table 2: Performance of polymer insulator Polymer insulator Without Field Reduction Electrode With Field Reduction Electrode Dry 290.2 297.6 Wet 263 272.6 This graphical representation proposed the difference between the with and without field reduction electrode and conclude that, the field reduction electrode equipped insulator has the higher improvement than normal sample. It explains the performance of the field reduction electrode equipped in the insulator. This comparison shows the improvement of the surface flashover performance and debit the field stress accumulated near the pin. The FRE made its function properly as the result, the withstand voltage of the FRE equipped insulator was higher than the normal insulator in which don’t have the field reduction electrode. VII. CONCLUSION The present study successfully demonstrates the effectiveness of the Field Reduction Electrode (FRE) in enhancing the surface flashover performance of high-voltage porcelain and polymer insulators. Through software simulations using ANSYS and experimental validation, it was observed that the pin region of both insulator types experiences significant field stress, leading to flashover. To mitigate this effect, an FRE coating comprising ferrous sulfate (FeSO₄) and copper sulfate (CuSO₄) was developed and applied. The results from both simulation and hardware testing indicate that insulators equipped with an FRE exhibit higher withstand voltage under both dry and wet conditions compared to those without FRE. The application of FRE effectively redistributes electric field stress, reducing the likelihood of flashover and significantly improving the insulation performance and lifespan of the insulators. This study provides a practical and cost-effective solution for improving the reliability of high-voltage transmission networks, ensuring greater operational efficiency and enhanced power system safety. Future research could focus on optimizing FRE materials and expanding its application to higher voltage levels and different insulator configurations. Declarations Author Contribution Author 1 (Dr.S.Ramesh): Conceptualization of the study, methodology development, supervision, and final manuscript review.Author 2 (Dr.K.Karunanithi): Conducted simulation studies using ANSYS, data analysis, and contributed to manuscript writing.Author 3 (Mr.R.Sreedhar): Led the experimental investigation, setup testing environment, collected and interpreted experimental data.Author 4 (Dr. S.Vinoth John Prakash): Literature review, assisted in comparative performance analysis of porcelain and polymer insulators, and contributed to result discussion.Author 5 (Dr.P.Rajakumar): Drafted the initial manuscript, handled figures and tables, and assisted in revisions and formatting for journal submission.All authors have read and approved the final manuscript and agree to be accountable for all aspects of the work. Acknowledgement Nil References Ogbonna, V. E., A. P. I. Popoola, O. M. Popoola, and S. O. Adeosun. 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Haque, SK Manirul, Jorge Alfredo Ardila-Rey, Yunusa Umar, Abdullahi Abubakar Mas’ ud, Firdaus Muhammad-Sukki, Binta Hadi Jume, Habibur Rahman, and Nurul Aini Bani. "Application and suitability of polymeric materials as insulators in electrical equipment." Energies 14, no. 10 (2021): 2758. Y. Liu, S. Chen, and X. He, "Aging performance of polymeric insulators under high voltage stress," in Proc. IEEE Electrical Insulation Conf., 2019, pp. 89-93. Additional Declarations No competing interests reported. Cite Share Download PDF Status: Posted Version 1 posted You are reading this latest preprint version Research Square lets you share your work early, gain feedback from the community, and start making changes to your manuscript prior to peer review in a journal. As a division of Research Square Company, we’re committed to making research communication faster, fairer, and more useful. We do this by developing innovative software and high quality services for the global research community. Our growing team is made up of researchers and industry professionals working together to solve the most critical problems facing scientific publishing. Also discoverable on Platform About Our Team In Review Editorial Policies Advisory Board Help Center Resources Author Services Accessibility API Access RSS feed Manage Cookie Preferences © Research Square 2026 | ISSN 2693-5015 (online) Privacy Policy Terms of Service Do Not Sell My Personal Information {"props":{"pageProps":{"initialData":{"identity":"rs-6400499","acceptedTermsAndConditions":true,"allowDirectSubmit":true,"archivedVersions":[],"articleType":"Research Article","associatedPublications":[],"authors":[{"id":484632121,"identity":"32e4b23b-a00c-4625-b73f-1b3fb0cec134","order_by":0,"name":"S. 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9","display":"","copyAsset":false,"role":"figure","size":339077,"visible":true,"origin":"","legend":"\u003cp\u003eCopper Sulphate Salt\u003c/p\u003e","description":"","filename":"9.png","url":"https://assets-eu.researchsquare.com/files/rs-6400499/v1/356d224297708a1a428a3319.png"},{"id":86675528,"identity":"9a4b0019-fdae-472a-87cc-bd5a2c8e1017","added_by":"auto","created_at":"2025-07-14 12:00:30","extension":"png","order_by":10,"title":"Figure 10","display":"","copyAsset":false,"role":"figure","size":380480,"visible":true,"origin":"","legend":"\u003cp\u003eField Electrode was Equipped\u003c/p\u003e","description":"","filename":"10.png","url":"https://assets-eu.researchsquare.com/files/rs-6400499/v1/10539b50d3d6bfcf66e9424f.png"},{"id":86673019,"identity":"ce651294-1c1e-4320-9f6b-38b4b668a023","added_by":"auto","created_at":"2025-07-14 11:44:30","extension":"png","order_by":11,"title":"Figure 11","display":"","copyAsset":false,"role":"figure","size":236064,"visible":true,"origin":"","legend":"\u003cp\u003ePorcelain Insulator Flashover\u003c/p\u003e","description":"","filename":"11.png","url":"https://assets-eu.researchsquare.com/files/rs-6400499/v1/869e488d950ed0ffd4fb58be.png"},{"id":86674241,"identity":"0a7948ea-685d-4c9c-ac3e-30c3ed0530d6","added_by":"auto","created_at":"2025-07-14 11:52:30","extension":"png","order_by":12,"title":"Figure 12","display":"","copyAsset":false,"role":"figure","size":40721,"visible":true,"origin":"","legend":"\u003cp\u003eporcelain withstand test outcomes\u003c/p\u003e","description":"","filename":"12.png","url":"https://assets-eu.researchsquare.com/files/rs-6400499/v1/ca314e472e736b84d4a30ddd.png"},{"id":86673024,"identity":"3cc15d68-8aec-43f1-9674-a0f583de9411","added_by":"auto","created_at":"2025-07-14 11:44:31","extension":"png","order_by":13,"title":"Figure 13","display":"","copyAsset":false,"role":"figure","size":354726,"visible":true,"origin":"","legend":"\u003cp\u003ePolymer String Testing\u003c/p\u003e","description":"","filename":"13.png","url":"https://assets-eu.researchsquare.com/files/rs-6400499/v1/f2a315aa88f4437317bfde9a.png"},{"id":86673033,"identity":"d9ebbda5-99a7-41ff-aa0c-f6352c28d4a8","added_by":"auto","created_at":"2025-07-14 11:44:31","extension":"png","order_by":14,"title":"Figure 14","display":"","copyAsset":false,"role":"figure","size":36626,"visible":true,"origin":"","legend":"\u003cp\u003ePolymer Withstand Test Outcomes\u003c/p\u003e","description":"","filename":"14.png","url":"https://assets-eu.researchsquare.com/files/rs-6400499/v1/d03e2a4be06e6058da0b723e.png"},{"id":88362901,"identity":"77fba424-2d49-4ca8-b637-8a5cc4f84f90","added_by":"auto","created_at":"2025-08-05 16:46:45","extension":"pdf","order_by":0,"title":"","display":"","copyAsset":false,"role":"manuscript-pdf","size":3931108,"visible":true,"origin":"","legend":"","description":"","filename":"manuscript.pdf","url":"https://assets-eu.researchsquare.com/files/rs-6400499/v1/536b89d6-a608-49d5-a146-bfb06f36c5c9.pdf"}],"financialInterests":"No competing interests reported.","formattedTitle":"Enhancing Insulator Performance Using Field Reduction Electrodes:Simulation Analysis and Experimental Investigation of HV Disc Insulators","fulltext":[{"header":"I.\tINTRODUCTION ","content":"\u003cp\u003eIn recent years, the need for electrical power supply generation and distribution is increasing drastically. Due to this, both generation and distribution sectors also to be modernized according to current trend. Considering future demand, the technological development is exclusively important in insulator design for safety purpose. To ensure the security of high-voltage transmission lines, proper protection of insulators is essential. The primary purpose of an insulator is to electrically isolate equipment or machinery from other charged or uncharged metal parts.\u003c/p\u003e\u003cp\u003eInsulating materials should be employed in electrical systems to prevent the unwanted flow of current to the ground from their supporting points. These materials play a significant role in electrical systems by providing electrical isolation [1]. Electrical insulation offers a highly resistive path through which almost no current flows. In transmission and distribution systems, overhead conductors are typically supported by towers or poles, both of which are properly grounded.\u003c/p\u003e\u003cp\u003eInsulators are essential components in electrical systems and are designed to withstand cantilever or tension loading. They serve as barriers between live conductors and overhead towers. Various types of insulators are available, including suspension, string, pin, post, stay, and shackle insulators, all of which are designed to prevent the flow of electric current from the conductor to the tower [2\u0026ndash;3].\u003c/p\u003e\u003cp\u003eInsulators can fail due to excessive electrical, mechanical, and field stress or due to environmental chemical reactions on their surface. Common signs of failure include flashover between metal parts on both sides of the insulator, partial discharges, treeing, tracking, punctures, and cracking.\u003c/p\u003e\u003cp\u003eSome of the main causes of insulation failure include:\u003c/p\u003e\u003cp\u003e\u003cul\u003e\u003cli\u003e\u003cp\u003eAging\u003c/p\u003e\u003c/li\u003e\u003cli\u003e\u003cp\u003eExcessive heat and moisture\u003c/p\u003e\u003c/li\u003e\u003cli\u003e\u003cp\u003eChemical deterioration due to heat, moisture, and dirt\u003c/p\u003e\u003c/li\u003e\u003cli\u003e\u003cp\u003eMechanical vibrations\u003c/p\u003e\u003c/li\u003e\u003cli\u003e\u003cp\u003eSunlight exposure\u003c/p\u003e\u003c/li\u003e\u003cli\u003e\u003cp\u003eVoltage stresses\u003c/p\u003e\u003c/li\u003e\u003c/ul\u003e\u003c/p\u003e\u003cp\u003eThe primary purpose of insulation is to prevent the flow of electrical current between points of different potentials within an electrical system. Insulation failure is one of the most common causes of electrical equipment malfunctions and power supply failure [4].\u003c/p\u003e\u003cp\u003eThe failure in insulators causes mainly due to the sudden raise in flashover voltage. The insulating material should be properly tested to overcome this type of failures [5]. The effect of flashover voltage on transmission line insulators are examined and reviewed in [6]. This study reveals that the surface flashover voltage must be minimized to reduce the insulation failure.\u003c/p\u003e\u003cp\u003eThe key objective of the proposed work is to enhance the performance of porcelain and polymer insulators using a novel technique called the field reduction method. By applying a Field Reduction Electrode (FRE), the surface flashover resistance can be improved, leading to an extended lifespan of the insulator [7].\u003c/p\u003e"},{"header":"II. TYPES OF INSULATORS ","content":"\u003cp\u003eInsulators used in HVAC / HVDC transmission are currently designed using glass, porcelain, or composite polymer materials. While discussing about the types of insulators, it is essential to evaluate its performance under various environmental conditions [8-9]. The design of insulator using different manufacturing materials are discussed as follows.\u003c/p\u003e\n\u003ch2\u003e\u003cstrong\u003eA. Porcelain insulator\u003c/strong\u003e\u003c/h2\u003e\n\u003cp\u003ePorcelain (ceramic ware) is made from alumina, china-clay, quartz, feldspar, and is coated to repel water and other dust particles. It is designed using ceramic ware concentrated with aluminum oxide are employed in applications where excess mechanical robustness is a key requirement. It has an insulating capability of approximately 4\u0026ndash;10 kV/mm.\u003c/p\u003e\n\u003cp\u003eRecently, affordable micro additives are employed to design procelain insulators [10] which will reduce overall cost of the insulators. \u0026nbsp;The nanotextured superhydrophobic coated porcelain insulators are designed and tested in [11] which acknowledges that there is a need to design a self-sustained, low-cost insulator for HV applications. \u0026nbsp;In [12], the authors analyzed electric potential and leakage current of procelain insulators under various environmental conditions. The test results prove that, the procelain type insulators withstand for high electric field with very minimal leakage current. The model of procelain disc insulator is displayed in Fig. 1.\u003c/p\u003e\n\u003ch2\u003eB. \u003cstrong\u003ePolymer insulator\u003c/strong\u003e\u003c/h2\u003e\n\u003cp\u003ePolymer insulators are made of silicone rubber and composite materials with a smooth glazed surface for improved performance. Silicone rubber sheds provide excellent hydrophobic properties, strong resistance to aging, tracking, and erosion. They also offer high mechanical strength and good flexibility. The sustainability of polymer insulator in electric field is disclosed in [13].\u0026nbsp;\u003c/p\u003e\n\u003cp\u003eFor voltages exceeding 33 kV, suspension-type insulators are commonly used. These insulators consist of multiple glass or ceramic discs coupled in series by metal links, forming a string. The main cause of insulation failure in polymer-based insulator is uneven voltage stress. This will enhance the aging effect of insulators drastically [14]. By the employment of proper design structure, the aging effect can be diminished well. The model of polymer disc insulator is displayed in Fig. 2.\u003c/p\u003e"},{"header":"III. DESIGN METHODOLOGY ","content":"\u003cp\u003eThere are various methods of insulator design existing in current scenario. One of the common and effective methodology in the insulator design is based on the differential equations [5]. The differntial equations of the electric field can be solved using the two methods.\u0026nbsp;\u003c/p\u003e\n\u003cp\u003e\u0026nbsp; \u0026nbsp; \u0026nbsp;1. Domain Based Methods\u003c/p\u003e\n\u003cp\u003e\u0026nbsp; \u0026nbsp; \u0026nbsp;2. Boundary Based Methods\u003c/p\u003e\n\u003cp\u003e\u003cstrong\u003e\u003cem\u003e1. Domain based methods\u003c/em\u003e\u003c/strong\u003e\u003c/p\u003e\n\u003cp\u003eIt is further classified in to two different methods as follows.\u0026nbsp;\u003c/p\u003e\n\u003cp\u003e\u003cstrong\u003eA. Finite Difference Method (FDM)\u003c/strong\u003e\u003c/p\u003e\n\u003cp\u003eFDM is a numerical based design methodology, which is employed to deduce differential equations. It involves discretizing continuous equations, converting them into a system of algebraic equations. In this method, linear equations can transform into nonlinear systems depending on the problem\u0026apos;s complexity.\u003c/p\u003e\n\u003cp\u003e\u003cstrong\u003eB. Finite Element Method (FEM)\u003c/strong\u003e\u003c/p\u003e\n\u003cp\u003eFinite element analysis (FEA) is a computerized method used to predict how a product responds to real-world forces, vibrations, heat, fluid flow, and other physical effects. It helps determine whether a product will fail, wear out, or perform as intended.\u003c/p\u003e\n\u003cp\u003e\u003cstrong\u003e\u003cem\u003e2. Boundary based methods\u003c/em\u003e\u003c/strong\u003e\u003c/p\u003e\n\u003cp\u003eIt is further classified in to three different methods as follows.\u003c/p\u003e\n\u003cp\u003e\u003cstrong\u003eA. Boundary Element Method (BEM)\u003c/strong\u003e\u003c/p\u003e\n\u003cp\u003eThe BEM utilizes the boundary conditions given by the manufacturer to determine boundary values, rather than solving for results throughout the entire space. It is a numerical computational technique used to solve electromagnetic and electrostatic field problems, especially in complex geometries.\u0026nbsp;\u003c/p\u003e\n\u003cp\u003eBEM is effective in evaluating the electric field distribution along the surface of insulators, particularly near the triple junction (air, insulator, and metal interface), where field enhancement can lead to corona or surface flashover.\u003cbr\u003e\u0026nbsp;Since BEM requires discretization only on the boundary surfaces (not the entire volume), it is especially efficient for problems involving large open spaces, such as outdoor high voltage equipment. It helps in optimizing the shape and shed profile of disc insulators to ensure uniform electric field distribution, which improves performance and extends lifespan by minimizing local discharges.\u003c/p\u003e\n\u003cp\u003e\u003cstrong\u003eB. Charge Simulation Method (CSM)\u003c/strong\u003e\u003c/p\u003e\n\u003cp\u003eIn CSM, the magnitude of charges is estimated so that their combined effect satisfies the boundary conditions exactly at selected points on the boundary. For this reason, CSM is also referred to as a Point Matching Method.\u003c/p\u003e\n\u003cp\u003eDue to several disadvantages associated with both the Discrete Boundary Method (DBM) and Charge Simulation Method (CSM), we are transitioning to an advanced approach known as SCSM (Simplified Charge Simulation Method). Fig. 3 displays the simulation contour of charge particles spread over the insulator using CSM method.\u003c/p\u003e\n\u003cp\u003e\u003cstrong\u003eC. Surface Charge Simulation Method (SCSM)\u003c/strong\u003e\u003c/p\u003e\n\u003cp\u003eSCSM is advantageous because it can effectively handle both two-dimensional (2D) and three-dimensional (3D) electric field distributions with asymmetrical boundary conditions (such as irregular electrode configurations). Unlike other methods, it provides high accuracy in modelling the behaviour of electric fields in complex geometries.\u003c/p\u003e\n\u003cp\u003eAdditionally, SCSM is highly suitable for analysing insulating materials with different permitivities. In high-voltage applications, insulators with varying dielectric constants are commonly used. This method allows for precise computation of electric fields across such heterogeneous materials, ensuring a better understanding of insulation performance and potential failure points.\u003c/p\u003e\n\u003cp\u003eIn this technique, the actual charge distribution within a system is approximated using a large number of discrete accumulated or surface charges. These simulated charges help replicate the real electric field behavior, allowing engineers to analyze and optimize electrical insulation and field distribution.\u003c/p\u003e"},{"header":"IV. 3D MODELING AND SIMULATION","content":"\u003cp\u003eThe 3D models of disc insulators are created using ANSYS software to analyze the electric field distribution. ANSYS can simulate electromagnetic performance and evaluate critical factors such as temperature, vibration, and mechanical effects.\u003c/p\u003e\n\u003cp\u003eSince hardware testing carries inherent risks, initial analysis was conducted solely through software simulations to gain insights before real-world implementation. This makes ANSYS an essential tool for evaluating insulator performance and optimizing designs.\u003c/p\u003e\n\u003cp\u003e\u003cstrong\u003e1. Modeling Process Using SolidWorks and ANSYS\u003c/strong\u003e\u003c/p\u003e\n\u003cp\u003eThe insulator designs were first modeled using SolidWorks, a solid modeling computer-aided design (CAD) and computer-aided engineering (CAE) software that runs on Microsoft Windows. For this study, insulator strings for both porcelain and polymer insulators (66 kV) were designed.\u003c/p\u003e\n\u003cp\u003e\u003cstrong\u003eA. Porcelain Insulator Analysis\u003c/strong\u003e\u003c/p\u003e\n\u003cp\u003eThe first step was to model a 6-disc porcelain insulator string in SolidWorks as shown in Fig. 4. This model was then imported into ANSYS, where the following steps were performed:\u003c/p\u003e\n\u003cul\u003e\n \u003cli\u003eMeshing the model\u003c/li\u003e\n \u003cli\u003eApplying voltage\u003c/li\u003e\n \u003cli\u003eEvaluating the electric field distribution and temperature effects\u003c/li\u003e\n\u003c/ul\u003e\n\u003cp\u003eAfter simulation, ANSYS displayed the response through color variations, indicating areas of higher field stress. The results showed that the pin at the first disc (which connects directly to the live conductor) experienced the highest field stress. This phenomenon increases the risk of surface flashover, which must be mitigated. Fig. 5 illustrates the high field stress on the pin of the porcelain insulator.\u003c/p\u003e\n\u003cp\u003e\u003cstrong\u003eB. Polymer Insulator Analysis\u003c/strong\u003e\u003c/p\u003e\n\u003cp\u003eNext, the polymer insulator was modeled using the same process in SolidWorks and imported into ANSYS. Fig. 6 shows the 5-string polymer insulator model (66 kV) used in the study.\u003c/p\u003e\n\u003cp\u003eSimilar to the porcelain insulator, the polymer model underwent the following steps:\u003c/p\u003e\n\u003cul\u003e\n \u003cli\u003eMeshing\u003c/li\u003e\n \u003cli\u003eVoltage application\u003c/li\u003e\n \u003cli\u003eElectric field analysis\u003c/li\u003e\n\u003c/ul\u003e\n\u003cp\u003eThe simulation results showed that the pin region of the polymer insulator string also suffered from severe field stress, as illustrated in Fig. 7. This issue, like in porcelain insulators, needed to be addressed to prevent flashover. The software simulations revealed that the pin directly connected to the live conductor experienced the highest field stress in both porcelain and polymer insulators. To mitigate this effect, a Field Reduction Electrode (FRE) is introduced at the pin of the first insulator.\u003c/p\u003e"},{"header":"V. IMPACT OF FIELD REDUCTION ELECTRODE","content":"\u003cp\u003eThe primary objective of incorporating a Field Reduction Electrode (FRE) is to enhance surface flashover performance and reduce high field stress in the pin region of the insulator.\u003c/p\u003e\n\u003cp\u003eTo achieve this, the FRE must possess specific characteristics, including:\u003c/p\u003e\n\u003cul type=\"disc\"\u003e\n \u003cli\u003eHigh electrical conductivity\u003c/li\u003e\n \u003cli\u003eLow resistivity\u003c/li\u003e\n \u003cli\u003eAbility to modify the original surface of the pin, effectively transforming it into a field reduction electrode\u003c/li\u003e\n\u003c/ul\u003e\n\u003cp\u003e\u003cstrong\u003e\u003cem\u003eA. Selection of an Optimal FRE Material\u003c/em\u003e\u003c/strong\u003e\u003c/p\u003e\n\u003cp\u003eSignificant effort was dedicated to identifying suitable materials for the FRE. After conducting numerous tests on various samples, the optimal field reduction electrode (FRE) material was identified as a combination of ferrous sulfate (FeSO₄) and copper sulfate (CuSO₄).\u003c/p\u003e\n\u003cp\u003eThis selection was based on their high electrical conductivity when mixed together as a solution, making them effective in reducing field stress and improving insulator performance.\u003c/p\u003e\n\u003cp\u003eThe first layer of the Field Reduction Electrode (FRE) was formed using ferrous sulfate (FeSO₄) shown in Fig. 8, which was dissolved in boiled distilled water (H₂O). After the solution settled, the second layer was applied using copper sulfate (CuSO₄) as shown in Fig. 9, creating a conductive coating for effective field stress reduction.\u003c/p\u003e\n\u003cp\u003eThe second layer of the Field Reduction Electrode (FRE) was applied using copper sulfate (CuSO₄). The coated surface was then left to dry for 12 hours. After this settling period, the Field Reduction Electrode (FRE) was successfully formed.\u003c/p\u003e"},{"header":"VI. HARDWARE OUTCOMES","content":"\u003cp\u003eThe testing was carried on both polymer and porcelain insulator of 66 kV. For porcelain 6 no\u0026rsquo;s of 11kV-11kN porcelain discs with and without the field reduction electrode (FRE). And for polymer, 2 no\u0026rsquo;s of 33kV strings with and without field reduction electrode (FRE). The power frequency dry and wet withstand test was conducted on the both samples ie., porcelain and polymer insulators.\u003c/p\u003e\n\u003cp\u003eThis test gives the results as how much it can withstand the applying voltage by its own during dry and wet conditions. The dry condition is the normal condition of outdoor steady state temperature and pressure. For the wet condition, the compressor setup was made to spray the diluted water on the specimen which was hanged on crane. The designed insulator is shown in Fig. 10.\u003c/p\u003e\n\u003cp\u003e\u003cstrong\u003e\u003cem\u003eA. Porcelain outcomes\u003c/em\u003e\u003c/strong\u003e\u003c/p\u003e\n\u003cp\u003e\u003cem\u003e\u0026nbsp;\u003c/em\u003eAt first the 6 porcelain discs without field reduction electrode (FRE) string was made to undergo power frequency dry test and the test results (A1) were noted down. And it engaged to power frequency wet test and the test results (B1) were noted down. Similarly, the field reduction electrode (FRE) was included and test was conducted on both dry and wet condition and the test results (A1), (B2) were noted down and displayed in Table 1. The flashover test conducted on designed procelain insulator is displayed in Fig. 11.\u003c/p\u003e\n\u003cp\u003e\u003cstrong\u003eTable 1: Performance of procelain insulator\u003c/strong\u003e\u003c/p\u003e\n\u003ctable border=\"1\" cellspacing=\"0\" cellpadding=\"0\" width=\"312\"\u003e\n \u003ctbody\u003e\n \u003ctr\u003e\n \u003ctd style=\"width: 85px;\"\u003e\n \u003cp\u003e\u003cstrong\u003ePorcelain Insulator\u003c/strong\u003e\u003c/p\u003e\n \u003c/td\u003e\n \u003ctd style=\"width: 104px;\"\u003e\n \u003cp\u003e\u003cstrong\u003eWithout Field Reduction Electrode\u003c/strong\u003e\u003c/p\u003e\n \u003c/td\u003e\n \u003ctd style=\"width: 123px;\"\u003e\n \u003cp\u003e\u003cstrong\u003eWith Field Reduction Electrode\u003c/strong\u003e\u003c/p\u003e\n \u003c/td\u003e\n \u003c/tr\u003e\n \u003ctr\u003e\n \u003ctd style=\"width: 85px;\"\u003e\n \u003cp\u003eDry\u003c/p\u003e\n \u003c/td\u003e\n \u003ctd style=\"width: 104px;\"\u003e\n \u003cp\u003e301.3\u003c/p\u003e\n \u003c/td\u003e\n \u003ctd style=\"width: 123px;\"\u003e\n \u003cp\u003e350.6\u003c/p\u003e\n \u003c/td\u003e\n \u003c/tr\u003e\n \u003ctr\u003e\n \u003ctd style=\"width: 85px;\"\u003e\n \u003cp\u003eWet\u003c/p\u003e\n \u003c/td\u003e\n \u003ctd style=\"width: 104px;\"\u003e\n \u003cp\u003e242.2\u003c/p\u003e\n \u003c/td\u003e\n \u003ctd style=\"width: 123px;\"\u003e\n \u003cp\u003e272.1\u003c/p\u003e\n \u003c/td\u003e\n \u003c/tr\u003e\n \u003c/tbody\u003e\n\u003c/table\u003e\n\u003cp\u003eThe outcomes of the withstand test conducted on the procelain insulator is graphically represented in Fig. 12. This graphical representation proposed the difference between the with and without field reduction electrode and conclude that, the field reduction electrode equipped insulator has the higher improvement than normal sample.\u003c/p\u003e\n\u003cp\u003e\u003cstrong\u003e\u003cem\u003eB. Polymer outcomes\u003c/em\u003e\u003c/strong\u003e\u003c/p\u003e\n\u003cp\u003eThe string test conducted on designed polymer insulator is given in Fig. 13. At first, two 33kV polymer insulators without field reduction electrode (FRE) string was made to undergo power frequency dry test and the test results(C1) were noted down. And it engaged to power frequency wet test and the test results (D1) were noted down. Similarly, the field reduction electrode (FRE) was included and test was conducted on both dry and wet condition and the test results (C2), (D2) were noted down and displayed in Table 2. The outcomes of the withstand test conducted on the polymer insulator is graphically represented in Fig. 14.\u003c/p\u003e\n\u003cp\u003e\u003cstrong\u003eTable 2: Performance of polymer insulator\u003c/strong\u003e\u003c/p\u003e\n\u003ctable border=\"1\" cellspacing=\"0\" cellpadding=\"0\"\u003e\n \u003ctbody\u003e\n \u003ctr\u003e\n \u003ctd style=\"width: 113px;\"\u003e\n \u003cp\u003e\u003cstrong\u003ePolymer insulator\u003c/strong\u003e\u003c/p\u003e\n \u003c/td\u003e\n \u003ctd style=\"width: 113px;\"\u003e\n \u003cp\u003e\u003cstrong\u003eWithout Field Reduction Electrode\u003c/strong\u003e\u003c/p\u003e\n \u003c/td\u003e\n \u003ctd style=\"width: 113px;\"\u003e\n \u003cp\u003e\u003cstrong\u003eWith Field Reduction Electrode\u003c/strong\u003e\u003c/p\u003e\n \u003c/td\u003e\n \u003c/tr\u003e\n \u003ctr\u003e\n \u003ctd style=\"width: 113px;\"\u003e\n \u003cp\u003eDry\u003c/p\u003e\n \u003c/td\u003e\n \u003ctd style=\"width: 113px;\"\u003e\n \u003cp\u003e290.2\u003c/p\u003e\n \u003c/td\u003e\n \u003ctd style=\"width: 113px;\"\u003e\n \u003cp\u003e297.6\u003c/p\u003e\n \u003c/td\u003e\n \u003c/tr\u003e\n \u003ctr\u003e\n \u003ctd style=\"width: 113px;\"\u003e\n \u003cp\u003eWet\u003c/p\u003e\n \u003c/td\u003e\n \u003ctd style=\"width: 113px;\"\u003e\n \u003cp\u003e263\u003c/p\u003e\n \u003c/td\u003e\n \u003ctd style=\"width: 113px;\"\u003e\n \u003cp\u003e272.6\u003c/p\u003e\n \u003c/td\u003e\n \u003c/tr\u003e\n \u003c/tbody\u003e\n\u003c/table\u003e\n\u003cp\u003eThis graphical representation proposed the difference between the with and without field reduction electrode and conclude that, the field reduction electrode equipped insulator has the higher improvement than normal sample.\u003c/p\u003e\n\u003cp\u003eIt explains the performance of the field reduction electrode equipped in the insulator. This comparison shows the improvement of the surface flashover performance and debit the field stress accumulated near the pin. The FRE made its function properly as the result, the withstand voltage of the FRE equipped insulator was higher than the normal insulator in which don\u0026rsquo;t have the field reduction electrode. \u0026nbsp;\u0026nbsp;\u003c/p\u003e"},{"header":"VII. CONCLUSION","content":"\u003cp\u003eThe present study successfully demonstrates the effectiveness of the Field Reduction Electrode (FRE) in enhancing the surface flashover performance of high-voltage porcelain and polymer insulators. Through software simulations using ANSYS and experimental validation, it was observed that the pin region of both insulator types experiences significant field stress, leading to flashover. To mitigate this effect, an FRE coating comprising ferrous sulfate (FeSO₄) and copper sulfate (CuSO₄) was developed and applied. The results from both simulation and hardware testing indicate that insulators equipped with an FRE exhibit higher withstand voltage under both dry and wet conditions compared to those without FRE.\u003c/p\u003e\u003cp\u003eThe application of FRE effectively redistributes electric field stress, reducing the likelihood of flashover and significantly improving the insulation performance and lifespan of the insulators. This study provides a practical and cost-effective solution for improving the reliability of high-voltage transmission networks, ensuring greater operational efficiency and enhanced power system safety. Future research could focus on optimizing FRE materials and expanding its application to higher voltage levels and different insulator configurations.\u003c/p\u003e"},{"header":"Declarations","content":"\u003ch2\u003eAuthor Contribution\u003c/h2\u003e\u003cp\u003eAuthor 1 (Dr.S.Ramesh): Conceptualization of the study, methodology development, supervision, and final manuscript review.Author 2 (Dr.K.Karunanithi): Conducted simulation studies using ANSYS, data analysis, and contributed to manuscript writing.Author 3 (Mr.R.Sreedhar): Led the experimental investigation, setup testing environment, collected and interpreted experimental data.Author 4 (Dr. S.Vinoth John Prakash): Literature review, assisted in comparative performance analysis of porcelain and polymer insulators, and contributed to result discussion.Author 5 (Dr.P.Rajakumar): Drafted the initial manuscript, handled figures and tables, and assisted in revisions and formatting for journal submission.All authors have read and approved the final manuscript and agree to be accountable for all aspects of the work.\u003c/p\u003e\u003ch2\u003eAcknowledgement\u003c/h2\u003e\u003cp\u003eNil\u003c/p\u003e"},{"header":"References","content":"\u003col\u003e\n \u003cli\u003eOgbonna, V. E., A. P. I. Popoola, O. M. Popoola, and S. O. Adeosun. \u0026quot;A review on corrosion, mechanical, and electrical properties of glass fiber-reinforced epoxy composites for high-voltage insulator core rod applications: challenges and recommendations.\u0026quot; \u003cem\u003ePolymer Bulletin\u003c/em\u003e 79, no. 9 (2022): 6857-6884.\u003c/li\u003e\n \u003cli\u003eSaleem, Muhammad Zaheer, and Mohammad Akbar. \u0026quot;Review of the performance of high-voltage composite insulators.\u0026quot; \u003cem\u003ePolymers\u003c/em\u003e 14, no. 3 (2022): 431.\u003c/li\u003e\n \u003cli\u003eAli, Arfan, Abdul Rauf Bhatti, Akhtar Rasool, Fazal Ur Rehman, Muhammad Amjad Khan, Ahmed Ali, and Abdulkerim Sherefa. \u0026quot;Performance analysis of high voltage disc insulators with different profiles in clean and polluted environments using flashover, withstand voltage tests and finite element analysis.\u0026quot; \u003cem\u003eScientific reports\u003c/em\u003e 14, no. 1 (2024): 20299.\u003c/li\u003e\n \u003cli\u003eArora, Ravindra, and Wolfgang Mosch. \u003cem\u003eHigh voltage and electrical insulation engineering\u003c/em\u003e. John Wiley \u0026amp; Sons, 2022.\u003c/li\u003e\n \u003cli\u003ePeratchiammal, M., N. B. Prakash, M. Murugappan, B. Vigneshwaran, and M. Bakrutheen. \u0026quot;Statistical Reliability Analysis on Flashover Characteristics of Ceramic Disc Insulator and Polymeric Insulators.\u0026quot; \u003cem\u003eArabian Journal for Science and Engineering\u003c/em\u003e 47, no. 11 (2022): 14627-14639.\u003c/li\u003e\n \u003cli\u003eSalem, Ali Ahmed, Kwan Yiew Lau, Wan Rahiman, Zulkurnain Abdul-Malek, Samir Ahmed Al-Gailani, Nabil Mohammed, Rahisham Abd Rahman, and Salem Mgammal Al-Ameri. \u0026quot;Pollution flashover voltage of transmission line insulators: Systematic review of experimental works.\u0026quot; \u003cem\u003eIEEE Access\u003c/em\u003e 10 (2022): 10416-10444.\u003c/li\u003e\n \u003cli\u003eS. Karmakar and S. Mitra, \u0026quot;Enhancement of insulation performance using optimized field reduction electrodes,\u0026quot; IEEE Transactions on Dielectrics and Electrical Insulation, vol. 29, no. 1, pp. 54-63, Feb. 2022.\u003c/li\u003e\n \u003cli\u003eX. Liang, Y. Gao, Z. Li, and H. Wang, \u0026quot;Surface flashover characteristics of silicone rubber insulators under different pollution conditions,\u0026quot; IEEE Transactions on Dielectrics and Electrical Insulation, vol. 27, no. 4, pp. 1245-1252, Aug. 2020.\u003c/li\u003e\n \u003cli\u003eG. Chen, M. Fu, Z. Liu, and B. Li, \u0026quot;A study on the flashover characteristics of insulators with coatings for field stress control,\u0026quot; in Proc. IEEE Int. Conf. High Voltage Eng. Appl., 2018, pp. 147-150.\u003c/li\u003e\n \u003cli\u003eKaraman, Hesham S., Sherif MM Sherif, S. M. A. El-Gamal, Naser Abdel-Rahim, and M. A. Abd-Allah. \u0026quot;Performance enhancing of porcelain insulators using low cost micro additives.\u0026quot; \u003cem\u003eAin Shams Engineering Journal\u003c/em\u003e 15, no. 4 (2024): 102622.\u003c/li\u003e\n \u003cli\u003eAllahdini, Anahita, Gelareh Momen, Fr\u0026eacute;d\u0026eacute;rick Munger, Stephan Brettschneider, Issouf Fofana, and Reza Jafari. \u0026quot;Performance of a nanotextured superhydrophobic coating developed for high-voltage outdoor porcelain insulators.\u0026quot; \u003cem\u003eColloids and Surfaces A: Physicochemical and Engineering Aspects\u003c/em\u003e 649 (2022): 129461.\u003c/li\u003e\n \u003cli\u003eKhan, Sana, Shahid Alam, and Muhammad Zaheer Saleem. \u0026quot;Analysis of electric field and leakage current of glass and porcelain insulators under clean and polluted conditions: A comparative study of three profiles.\u0026quot; \u003cem\u003eElectric Power Systems Research\u003c/em\u003e 239 (2025): 111283.\u003c/li\u003e\n \u003cli\u003eHaque, SK Manirul, Jorge Alfredo Ardila-Rey, Yunusa Umar, Abdullahi Abubakar Mas\u0026rsquo; ud, Firdaus Muhammad-Sukki, Binta Hadi Jume, Habibur Rahman, and Nurul Aini Bani. \u0026quot;Application and suitability of polymeric materials as insulators in electrical equipment.\u0026quot; \u003cem\u003eEnergies\u003c/em\u003e 14, no. 10 (2021): 2758.\u003c/li\u003e\n \u003cli\u003eY. Liu, S. Chen, and X. He, \u0026quot;Aging performance of polymeric insulators under high voltage stress,\u0026quot; in Proc. IEEE Electrical Insulation Conf., 2019, pp. 89-93.\u003c/li\u003e\n\u003c/ol\u003e"}],"fulltextSource":"","fullText":"","funders":[],"hasAdminPriorityOnWorkflow":false,"hasManuscriptDocX":true,"hasOptedInToPreprint":true,"hasPassedJournalQc":"","hasAnyPriority":false,"hideJournal":true,"highlight":"","institution":"","isAcceptedByJournal":false,"isAuthorSuppliedPdf":false,"isDeskRejected":"","isHiddenFromSearch":false,"isInQc":false,"isInWorkflow":false,"isPdf":false,"isPdfUpToDate":true,"isWithdrawnOrRetracted":false,"journal":{"display":true,"email":"[email protected]","identity":"researchsquare","isNatureJournal":false,"hasQc":true,"allowDirectSubmit":true,"externalIdentity":"","sideBox":"","snPcode":"","submissionUrl":"/submission","title":"Research Square","twitterHandle":"researchsquare","acdcEnabled":true,"dfaEnabled":false,"editorialSystem":"","reportingPortfolio":"","inReviewEnabled":false,"inReviewRevisionsEnabled":true},"keywords":"ANSYS, Field Reduction Electrode, insulator, porcelain, polymer, withstand voltage","lastPublishedDoi":"10.21203/rs.3.rs-6400499/v1","lastPublishedDoiUrl":"https://doi.org/10.21203/rs.3.rs-6400499/v1","license":{"name":"CC BY 4.0","url":"https://creativecommons.org/licenses/by/4.0/"},"manuscriptAbstract":"\u003cp\u003eThe insulator is a pivotal element in the electrical transmission system. It is also used in all electrical and electronic equipment to prevent electric current from passing through itself. In transmission lines, it separates the electric conductor from the overhead towers. To improve the performance of insulators, surface flashover should be reduced using a field reduction electrode. The objective of the present work is to minimize insulator flashover caused by faults or external factors at an early stage. In this study, a comparative analysis of the performance of High-Voltage (HV) disc insulator strings made of porcelain and polymer, with and without a Field Reduction Electrode (FRE), was conducted. Based on theoretical and practical values, it is evident that the withstand capacity, flashover resistance, and lifespan of the insulator can be enhanced by the proposed FRE methodology. The software simulation and characteristic study were conducted using ANSYS software also the effectiveness of the design structure was experimentally verified.\u003c/p\u003e","manuscriptTitle":"Enhancing Insulator Performance Using Field Reduction Electrodes:Simulation Analysis and Experimental Investigation of HV Disc Insulators","msid":"","msnumber":"","nonDraftVersions":[{"code":1,"date":"2025-07-14 11:44:25","doi":"10.21203/rs.3.rs-6400499/v1","editorialEvents":[{"type":"communityComments","content":0}],"status":"published","journal":{"display":true,"email":"[email protected]","identity":"researchsquare","isNatureJournal":false,"hasQc":true,"allowDirectSubmit":true,"externalIdentity":"","sideBox":"","snPcode":"","submissionUrl":"/submission","title":"Research Square","twitterHandle":"researchsquare","acdcEnabled":true,"dfaEnabled":false,"editorialSystem":"","reportingPortfolio":"","inReviewEnabled":false,"inReviewRevisionsEnabled":true}}],"origin":"","ownerIdentity":"dbc03365-838a-4912-9b48-81faa94b95ad","owner":[],"postedDate":"July 14th, 2025","published":true,"recentEditorialEvents":[],"rejectedJournal":[],"revision":"","amendment":"","status":"posted","subjectAreas":[],"tags":[],"updatedAt":"2025-08-05T16:38:35+00:00","versionOfRecord":[],"versionCreatedAt":"2025-07-14 11:44:25","video":"","vorDoi":"","vorDoiUrl":"","workflowStages":[]},"version":"v1","identity":"rs-6400499","journalConfig":"researchsquare"},"__N_SSP":true},"page":"/article/[identity]/[[...version]]","query":{"redirect":"/article/rs-6400499","identity":"rs-6400499","version":["v1"]},"buildId":"8U1c8b4HqxoKbykW_rLl7","isFallback":false,"isExperimentalCompile":false,"dynamicIds":[84888],"gssp":true,"scriptLoader":[]}