Victor polymer insulator development

Victor polymer insulator development is introduced through design and manufacture distribution class deadend insulators, the adopted raw materials, standards, background and other details.

Victor began development of distribution class polymer insulators in 1997, after an extensive analysis of the needs of the marketplace, the performance history of other manufacturer products, and improvements in designs and materials that have taken place in the past decade.

It was immediately apparent that the single greatest deficiency of the products offered in the marketplace was a lack of uniformity (interchangeability) between insulators manufactured by different suppliers. This situation had arisen due to the lack of existing standards for the products in the era when they were being developed.

The result is a confusing mix of section lengths, electrical values, test protocols, etc. It is left to the user to sort out the necessary characteristics for the system application and to then try and determine what available product comes closest to meeting the application needs.

Since Victor has always been active in the ANSI and NEMA standards making process, we have been deeply involved in the development of standards and proposed standards for polymer insulators.

At present, there is a draft standard (C29.13) covering distribution polymer dead ends, and Victor chose to design the new product line based on the characteristics specified in this proposed standard. We believe that this will become an ANSI Standard by the end of 1999.

We are supplying insulators that may be referenced simply by an ANSI Class Number, assuring the user of interchangeability and of course of guaranteed characteristics.

In supporting the ANSI process in this way, Victor is making sure that the user has a sound basis for selection of product and that interchangeability with products from other manufacturers who design and market product to the standard. This not only makes insulators product selection easier, but provides for the most competitive and available supply.

In addition to the design electrical and mechanical characteristics, the choice of qualification test protocols was analyzed to determine what existing and proposed test standards would offer both Victor and our customers the assurance that the new products were capable of providing years of trouble free service in all operating environments.

The specifications that were selected as the basis for the design and development program were:
ANSI C29.11
ANSI C29.13
IEC 1109

In summary, the underlying philosophy of the development process was to design and manufacture distribution class deadend insulators that complied with all relevant test specifications for these types of products and provided standardized performance characteristics.

Additionally, it was determined early in the development process that the following criteria were fundamental to a successful product and would be followed explicitly:
a) use of proven polymeric materials from nationally recognized suppliers for the housings
b) use of proven fiberglass rod manufactured by nationally recognized suppliers for the load bearing core
c) use of malleable/ductile iron end fittings
d) use of injection molding to form the housings as a continuous sheath
e) use of crimping as the method of attachment of end fittings
f) use of an independent outside laboratory for prototype and design testing

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