Epoxy is used widely in high voltage outdoor insulator because of its light weight (this avoids the need to use heavy cranes for their handling and installation and this reduces cost), easy handling, easy blending with additives, and having hydrophobicity. This paper focuses on improving epoxy electrical characteristics (flashover voltage) for high voltage outdoor insulator by adding silica filler. Composite of epoxy with silica filler: silica is prepared with 0 %, 10 %, 20 %, 30 % and 40 % weight percentages concentration. The flashover voltage (FOV) is tested under various environmental conditions with different samples lengths. Grey wolf optimizer (GWO) is developed to predict the best optimal value of flashover voltage under various environmental conditions using laboratory measurements of flashover voltage. The obtained results from GWO are compared with experimental measured data. Results showed an improvement with silica concentration at different samples lengths in flashover voltage for composite samples over epoxy without any additions. A comparison between three different conditions showed higher flashover voltage for samples in dry condition than that of samples in (wet, salt wet) conditions.
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