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The influences of the pollution layer parameters including; conductivity, position and length on the performance of high-voltage cylindrical insulator were investigated. Parameters effects and their interactions have been assessed and determined using the variance statistical technique and the relation between parameters and the flashover voltage, maximum electric field and the breakdown strength is modeled by the response surface methodology (RMS). The 3D model from Comsol Multiphysics was used for modeling and the FEM method was utilized for simulations. The findings demonstrate that the flashover voltage of the non-uniformly contaminated surface is primarily affected by the pollution layer length. Simulation results show that the intensity of the electric field rises with the increasing in length of pollution layer and its position. It was noted that the experimental tests in laboratory for non-uniform contamination are in strong alignment with simulation studies. The results of this analysis should expand our understanding about the performance of outdoor insulators under specific contaminated conditions. The knowledge gathered can be used to enhance the configuration of insulators used in contaminated regions and it is believed that the current study has resulted methodology to estimate reliably and realistically the pollution performance of cylindrical porcelain insulators. [ABSTRACT FROM AUTHOR]

• Modelling of three-dimensional model of a 220 kV composite insulator and its associated corona ring using COMSOL software. • Investigating the relationship between corona ring design variables and electric field strength. • Bat Algorithm is an innovative method to reduce electric field intensity in critical areas of composite insulators. • Combining Experimental Design Methodology and Bat algorithm can be a powerful tool for optimizing corona ring design. • Achieving a significant decrease in maximum electric field strength. The distribution of the electric field plays a crucial role in evaluating the effectiveness of composite insulators. This research presents an innovative approach for optimizing the design of corona rings, aiming to decrease the electric field intensity in critical areas to satisfactory levels. The investigation examined the correlation among corona ring design variables and the intensity of the electric field close to the energized-end fitting in a 220 kV composite insulator equipped with a corona ring. Using design of experiment methods, the impact of three corona ring design parameters – corona ring diameter (R), ring tube diameter (Dr), and corona ring height (H) – was assessed. A novel nonlinear mathematical objective function was formulated, connecting the electric field magnitude to the structural parameters of the corona ring. Subsequently, the Bat algorithm, a bio-inspired optimization technique, was employed to enhance the initial corona ring design and mitigate the electric field intensity. Finally, the Finite Element Method (FEM) was utilized to simulate and evaluate the voltage distribution and electric field stress. The optimization process resulted in a substantial decrease in the highest electric field magnitude, by 58.6 % compared to the insulator with the threshold value, and 75 % when devoid of a corona ring. Additionally, the research highlighted the significant influence of ring tube thickness on the distribution of the electric field. The combination of experimental design and the Bat algorithm proved to be a powerful tool for optimizing the design of corona rings on transmission line composite insulators, providing precise solutions for optimizing corona discharge problems and enhancing the reliability of power transmission systems. [ABSTRACT FROM AUTHOR]