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Long Rod Composite Insulator

Product details

Long Rod Composite Insulator

● Improves Reliability (by minimizing interruptions and outages due to vandalism, pole fires, and flashovers in all types of environments)； ● Eliminates or Reduces Maintenance (such as washing and trouble calls) and is compatible with existing plant； ●Service Life (consistent performance over its service life)； ●Life Cycle Cost (savings over porcelain insulators).

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Physical properties of the Long Rod Composite Insulator

The properties and composition of the long rod composite insulators are similar to those specified in article 3 of the standard IEC-61109. The raw material for the insulating material (core and fins) is 100% silicone rubber polymer (Silicon Rubber), prior to the process of adding additives. The carbon content of the finished product does not exceed 20% by weight. Typically long rod polymer insulators consist of a polymer shell, ECR glass fibre rods, metal end joints, corona rings etc.
Shell (sheath and shed)
The sheath is made of HTV type silicone rubber, which protects the core from UV and external media, ensures water tightness and
good performance in contaminated environments. The type of rubber used is completely free of EPDM (ethylene propylene diene propylene). Silicone rubber must be protected against
High temperatures due to partial discharges, arcing and insulator scarring can be achieved by using aluminium trihydrate (ATH) with particle sizes between 4.5 μm and 13 μm. In addition, the resistance to erosion must be 33 kΩ at 6 kV for projects in Peru (Table 1 IEC-60587) and 33 kΩ at 4.5 kV for projects outside Peru (IEC-60587).
They are made of silicone rubber, firmly bonded to the housing or moulded as part of the housing by the HTV vulcanisation process, and are seamless, smooth and free from imperfections. The type of rubber used is completely free of EPDM.
The sheath and skirt of the composite long rod polymer insulator are made from HTV silicone rubber (VMQ - vinyl methyl polysiloxane with filler additives) which does not contain EPDM or other natural rubber. The silicone rubber is of the HTV solid silicone type (high temperature vulcanisation - solid silicone rubber). This type of silicone rubber is solid and is vulcanised at high temperatures (near 200ºC).
Core
ECR glass fibre rods, made from epoxy resin and glass fibre, are free from boron, cracks and air bubbles, acid resistant and therefore not brittle, single piece construction, free from voids, foreign bodies and manufacturing defects.
And the core has high electrical integrity and high resistance to acid corrosion. The epoxy resin is resistant to hydrolysis and the glass fibre reinforcement is resistant to corrosion in order to transfer the mechanical stresses generated by the conductor to the support member and to provide the necessary electrical insulation. The core is the component subjected to mechanical loads and has a minimum tensile strength of 1000Mpa.
End fittings
The end metal fittings are hot dipped galvanised in accordance with ASTM A153 and are made of malleable cast iron or steel and are designed in such a way as to reduce the electrical and mechanical stresses on the outer cover. All metal parts are free from burrs, creases, cracks, fissures, porosity, rough edges or any other defects that could affect the mechanical resistance of the insulator, the good condition of the connections, maintenance operations or cause corona effects. Optimum performance has been observed in the case of an electric field protection ring with an outer cover covering the hardware.
Corona rings
The number of rings will be indicated in the guaranteed technical characteristics; in any case, at the end of the line side, metal rings of sufficient diameter must always be provided to control corona effects, radio interference levels (RIV) and electric field distribution.
Interfaces
The interface between the housing and the core, and between the housing and the external metal hardware, is smooth and free of voids and has a higher shear strength than the housing itself.
Sealing
The complete insulator has a permanent seal at the interface between the end connector and the cover to prevent the ingress of moisture or external materials.

What are the advantages of composite long rod polymer insulators?

Easy maintenance
Whereas porcelain insulators have zero breakdown, zero detection and zero replacement problems, long rod polymer insulators have no such problems. Long rod polymer insulators require little or no maintenance after installation, significantly reducing maintenance costs.

The general suspension porcelain insulators are of internal glued construction with steel feet embedded in the porcelain ball head. Therefore, at operating voltage, the electric field strength is most concentrated at the steel feet. The adhesive is used for the internal glue. Due to the different thermal expansion coefficients of the porcelain foot and the cemented steel foot, when the porcelain insulator is subjected to hot and cold changes, the difference in thermal expansion coefficients of the components will subject the porcelain parts to large compressive and shear stresses. Stress, so the porcelain parts are prone to cracking or easy to break through and become zero value insulators. Long rod polymer insulators are mechanically non-breakdown structures and do not have a zero value problem.
Excellent fouling resistance
The good flicker resistance of composite long rod polymer insulators is an important reason for their rapid development. Fouling flash caused by contamination of the insulator surface is a major threat to the safe operation of the power grid and a decisive factor in the selection of insulators for transmission lines. The surface of porcelain insulators is a high-energy surface and forms a continuous water film when wetted by water. At the same time, it is contaminated and prone to fouling and flashing. Therefore, manual cleaning or the application of silicone rubber paint should be used in daily operations.

According to statistics, two mega fouling flashes have occurred in China's Henan power grid in the last two decades. In the large-scale fouling flash accidents in 1990 and 2001, porcelain insulators flashed 104 times, accounting for 67%; glass insulators flashed 50 times, accounting for 32%; and composite long rod polymer insulators flashed only 1 time due to ice cover, accounting for 1%.

The composite long rod polymer insulator is made up of silicone rubber, with a low energy surface on the skirt and sheath, which has good hydrophobic and hydrophobic migration properties. Even in wet and dirty environments, the composite insulator shed surfaces do not form a continuous film of water, but only droplets of water independent of each other, making the composite insulator highly resistant to contamination. Although the hydrophobicity of composite insulators deteriorates after a certain period of operation, their resistance to pollution is still high compared to porcelain insulators.
Mechanical behaviour
The axial tensile strength of glass fibre mandrels for composite insulators is high, generally above 600 MPa, and the latest ECR acid-resistant mandrels have a tensile strength of over 1000 MPa, which is 5-10 times the strength of high-quality carbon steel. However, the mass per unit length of mandrel material is much lighter than both porcelain and steel. Composite long rod polymer insulators can be manufactured to be very strong and lightweight.
Ageing resistance
With nearly 100 years of operational experience, porcelain insulators are highly resistant to ageing. Long after being put into operation, ageing replacement is negligible if zero damage occurs. Composite long rod polymer insulators are organic material insulators. The organic material within the umbrella sheath will age and deteriorate during operation due to atmospheric, high and low temperature, ultraviolet light and strong electric fields, resulting in poor insulating properties of the composite insulator. This reduces the service life of the composite insulator. However, from current operating experience, the service life of composite long rod polymer insulators can generally reach more than 10 years.
Economic performance
According to relevant calculations, the use of composite long rod polymer insulators is more economical than porcelain insulators for both new and old line renewals, the late operation and maintenance workload of composite insulators is low and zero value testing is not required.
Colours and markings
Composite insulators are available in grey, red or as per customer requirements. Each insulator must be clearly and permanently marked on the metal terminals with the following information.

Manufacturer - Xiangyang Guowang Composite Insulator Co Ltd or TONLY
Year of manufacture
Model
Guaranteed and/or conventional mechanical load
These markings are indelible and resistant to exposure to the elements.

● Application: Used on surge arrester, circuit breaker, capacitor, instrument transformer, power transformer, cable termination & GIS, etc;

● Color: Red, Brown, Gray or Customer's requirement;

● Applicable Standard: IEC, GB, BS, ANSI, AS or Customer's requirement;

● Excellent mechanical and electrical properties,

●Hydrophobic properties of the silicone rubber insulation cover ensure high resistance to dirt and self-cleaning properties;

●Lower risk of mechanical damage during transport, assembly and operation;

●Resistance to UV radiation, ozone, moisture;

●Shock and impact resistance – suitable for use in areas of seismic activity;

●Capable of carrying specific torsional loads.

You can find more details about our composite long rod insulators here.

Specification

Rated System Voltage (kV)	Type	Section Length (mm)	Arcing Distance (mm)	Creepage Distance (mm)	Coupling Size	Specified Mechanical Load (kN)	Lightning Impulse Withstand Voltage (kV)	Power Frequency Withstand Voltage (kV)
Rated System Voltage (kV)	Type	Section Length (mm)	Arcing Distance (mm)	Creepage Distance (mm)	Coupling Size	Specified Mechanical Load (kN)	Lightning Impulse Withstand Voltage (kV)	Dry	Wet
10	FXBW—10/70	310	160	350	16	70	75	42	38
35	FXBW—35/70	670	505	810	16	70	230	106	95
66	FXBW—66/70	870	765	1920	16	70	410	230	185
66	FXBW—66/120	870	745	1920	16	120	410	230	185
110	FXBW—110/70	1240	1220	3520	16	70	550	285	230
110	FXBW—110/120	1240	1220	3520	16	120	550	285	230
110	FXBW—110/160	1340	1180	3520	20	160	550	285	230
220	FXBW—220/120	2240	2220	7040	16	120	1000	440	395
220	FXBW—220/160	2240	2200	7040	20	160	1000	440	395
220	FXBW—220/210	2240	2200	7040	16	120	1000	440	395
330	FXBW—330/120	2930	3050	10560	16	120	1425	630	570
330	FXBW—330/160	2930	3050	10560	20	160	1425	630	570
330	FXBW—330/210	2930	3050	10560	20	210	1425	630	570
500	FXBW—500/120	4050	4600	16000	16	120	2050	820	740
500	FXBW—500/160	4050	4600	16000	20	160	2050	820	740
500	FXBW—500/210	4050	4600	16000	20	210	2050	820	740
500	FXBW—500/300	4450	4500	16000	24	300	2050	820	740
500	FXBW—500/420	4450	4500	16000	28	420	2050	820	740
750	FXBW—750/120	7150	6750	23500	16	120	2700	1160	1050
750	FXBW—750/210	7150	6750	23500	20	210	2700	1160	1050
750	FXBW—750/300	7150	6750	23500	24	300	2700	1160	1050
750	FXBW—750/420	7150	6750	23500	28	420	2700	1160	1050
750	FXBW—750/550	7150	6550	23500	32	550	2700	1160	1050
1000	FXBW—1000/210	9000/9750^a	8500	≥32000	20	210	3200	1440	1300
1000	FXBW—1000/300	9000/9750^a	8500	≥32000	24	300	3200	1440	1300
1000	FXBW—1000/420	9000/9750^a	8500	≥32000	28	420	3200	1440	1300
1000	FXBW—1000/550	9000/9750^a	8300	≥32000	32	550	3200	1440	1300
±400	FXBZ—±400/160—G	8000	7500	28030	20	160	2800	830	750
±400	FXBZ—±400/210—G	8000	7500	28030	20	210	2800	830	750
±400	FXBZ—±400/300—G	8000	7500	28030	24	300	2800	830	750
±500	FXBZ—±500/120	6800	6400	22800	16	120	2550	660	600
±500	FXBZ—±500/160	6800	6400	22800	20	160	2550	660	600
±500	FXBZ—±500/210	6800	6400	22800	20	210	2550	660	600
±500	FXBZ—±500/300	6800	6400	22800	24	300	2550	660	600
±500	FXBZ—±500/420	6800	6400	22800	28	420	2550	660	600
±660	FXBZ—±660/160	9200	8700	38400	20	160	2800	830	750
±660	FXBZ—±660/210	9200	8700	38400	20	210	2800	830	750
±660	FXBZ—±660/300	9200	8700	38400	24	300	2800	830	750
±660	FXBZ—±660/420	9200	8700	38400	28	420	2800	830	750
±800	FXBZ—±800/160	10600	10000	36300	20	160	3600	1000	900
±800	FXBZ—±800/210	11500	10900	45430	20	210	3600	1000	900
±800	FXBZ—±800/240	10600	10000	36300	20	240	3600	1000	900
±800	FXBZ—±800/300	10600	10000	36300	24	300	3600	1000	900
±800	FXBZ—±800/420	10600	10000	36300	28	420	3600	1000	900
±800	FXBZ—±800/550	10600	10000	36300	32	550	3600	1000	900
±1100	FXBZ—±1100/160	12300	11600	47355	6	160	4500	1280	1150
±1100	FXBZ—±1100/210	12300	11600	47355	30	210	4500	1280	1150
±1100	FXBZ—±1100/300	12300	11600	47355	34	300	4500	1280	1150
±1100	FXBZ—±1100/420	12300	11600	47355	40	420	4500	1280	1150
±1100	FXBZ—±1100/550	12300	11600	47355	42	550	4500	1280	1150
±1100	FXBZ—±1100/1000	12300	11600	47355	50	1000	4500	1280	1150
Order Information: ① Pollution level; ② Voltage grade; ③ Mechanical load; ④ Insulation distance; ⑤ Creepage distance; ⑥ Section length; ⑦Coupling type Ps. Different design could be supplied as customer requirements

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