Hollow core insulator Composite Technology

Hollow core insulator Composite Technology also called silicone technology, includes silicone Design, Conception & Tests, insulator Design and Testing, process, mechanically, electrically, cut away, quality and standards.

Hollow core insulator

Hollow core insulator Composite Technology:
Composite Technology: Design, Conception & Tests
Insulators- Design and Testing:
Our insulators are designed to perform mechanically, electrically and environmentally according to the specified requirements for their entire life span.
In order to assure the best long-term performance, our R&D department has developed special computer simulation of all stresses the insulators may experience during their life depending on the specific application.
Step 1: Filament Winding of HCI's
Step 2: Cured FRP Tube
Step 3: FRP Tube machining
Step 4: Flange, preparation and cleaning
Step 5: Collar to tub assembly
Step 6: Silicone extrusion...
Step 6: Silicone extrusion follow- The silicone is applied in a spiral over tubes of various shapes.
Step 7: Water rangling ? -- Water follows the shed angle during wet electrical tests.

Hollow core insulator mechanically:
The insulators are designed to withstand the maximum design stresses without affecting the long-term mechanical performance, basically by assuring that the maximum expected loads are below the damage limit of FRP Tubes and elastic limit of fittings. The basic design is made based on traditional methods of material resistance then verified by finite element analysis.
By request, we perform computer stress analysis under seismic or short circuit conditions.

Hollow core insulator electrically:
The final electrical performance is guaranteed by the OEM.
The insulator housing expected electrical characteristics are typically based on geometrical factors.
The final design of our insulators has to meet our own criterial for long term electrical and material performance, such as E-Field limits.
By request we perform Computer calculation of E-Field stress with Electro software.

Hollow core insulator Composite Technology:
Cut Away
Quality and Standards
Hollow core insulators are designed according to a selection of IEC and NEMA Standards to assure long-term performance under normal (1) and proper (2) use.
(1) The function and the stresses are determined by the OEM and End-User specifications and meet applicable clauses of current composite insulator standards including IEC 60815, IEC 61109, IEC 61462, ISPESL AND IEEE 693 seismic Standard. The insulators intended for GIS and dead tank application are also temperature cycle tested as per NEMA SG4 Standards (pressure vessel)
(2) According to handling, installation and maintenance recommendations issued by the insulator manufacturer and the OEM.
IEC 61109 (Composite insulators)
IEC 61462 (Composite hollowcore)
IEEE 693 (Seismic)
NEMA SG4 (Pressure & Temperature cycling Fatique test)
ISPESL Qualification
ANSI C29.9 & IEC168 (Support Standards)

Hollow core insulator Advantages:
Higher Mechanical Strength
FRP tubes in composite insulators are more resistant to bending motion
Light weight
FRP Tube and Silicone rubber housing are non-brittle elastomeric materials
Failure mode is by delamination of the tube without destructive fragments
High Temperature Resistance
High permanent working temperature of Apparatus
Stable behavior at extreme climatic conditions -50 / +110°C
Higher Electrical Strength
Hydrophobicity-- Control of leakage currents
Excellent performance under heavy pollution
Custom design with Profiles designed for any environmental condition (class I to IV, IEC 815)

Hollow core insulator Key Features:
FRP (Fiberglass reinforced polymer) Tube with Wet filament winding process
Custom Design (fibers angle and wall thickness) for Performance optimization (Stiffness versus internal pressure performance)
"E" Glass corrosion resistant fibers
High temperature resin and assembly glue
Permanent bonding assured by a primer between tub, fittings and weather-sheds
Gas tightness
Protective liner PE against SF6 decay products
HTV Silicone
Patented extrusion process
Patented fittings assembly method
Savings: Polymer vs. BIL --7 years no washing.

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