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Composite Insulators 081208

Composite Insulators 081208

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Published by: Nikitha Chandrashekar on Feb 20, 2012
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05/26/2013

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Bharat Heavy Electricals Limited

Ceramic Business Unit

Industrial Ceramic Products and associated Systems. Bangalore • Insulator Plant (IP). This business unit deals with High Tension Insulators. Industry. processes and applications at • Ceramic Technological Institute (CTI). • Station Post Insulators for Bus bars. Ceramic Business Unit The Ceramic Business Unit (CBU) of BHEL. E l e c t r o S t a t i c Precipitators. Tamilnadu State Electricity Board Nuclear Power Corporation of India Ltd. BHEL has 14 manufacturing plants. 18 regional offices and over 150 project sites spread all over India and abroad. Transmission. Today its “State of the Art” facilities manufacture Polymer insulators that compare with the best in the world.Bharat Heavy Electricals Limited The Company Bharat Heavy Electricals Limited is the largest Engineering and Manufacturing Enterprise of its kind in India. S w i t c h g e a r. Ceramic Wear Resistant liners. It ranks amongst the leading manufacturers of power plant equipment in the world. BHEL make Composite insulators have superior design features that ensure reliability and excellent performance backed by years of expertise in the insulator business. Distribution. etc. Cement. 4 power sector regional centres. Products • High Tension Insulators for Transmission and Distribution lines from 11 kV to 800 kV • Hollow Insulators for Instrument and Power Tr a n s f o r m e r s . Defence and Non-Conventional Energy Systems. 8 service centres. Jagdishpur Advanced Research and Development facilities for Ceramic products. Gujarat Mining Development Corporation Ltd. CBU is headquartered at Bangalore and is supported by: Manufacturing units with “State of the Art” technology for ceramic products and systems at • Electroporcelains Division( EPD). etc. is a Strategic Business Unit for Ceramics and Systems. AREVA T & D Maharashtra State Transmission Company Ltd. . NTPC Ltd. • Industrial Ceramic Products for various applications BHEL – The Pioneer in Insulators BHEL pioneered the development of composite insulators in India in the year 1998 through in-house development efforts. Transportation. It offers a wide spectrum of products and services for core sectors like Power Generation. Hyderabad) Our Esteemed Customers Our Composite Insulators are approved and are in Service with the following customers: Research Development and Standards Organisation (RDSO) of Indian Railways Powergrid Corporation of India Ltd. Steel. support and for Isolators from 11 kV to 400 kV • Composite Insulators for Railway Traction and Transmission applications up to 400 kV • Wear resistant materials for Thermal Power Plant applications. Bangalore ( A Division of Corporate Research & Development. Oil & Gas. Coal Washeries.

The Process Crimping State of Art Microprocessor controlled Crimping machine with Acoustic Crack detection ensures uniform crimping without stress concentration Injection Moulding The Silicone housing is injection moulded over FRP rod in a fully automatic Microprocessor controlled Injection Moulding Machine. .The Manufacturing Shop Modern state-of-art manufacturing facility for production of Silicone composite insulators with complete manufacturing and testing facilities. The housing is bonded securely over the entire length of the FRP rod The Materials Fiber Glass Rod Metal Fittings Silicon Rubber Raw materials (Silicon Rubber. Boron free ECR grade FRP Rod & SGI Castings/Steel Forged Metal Fittings) are sourced from reputed manufacturers after undergoing stringent quality checks.

• • • • Infrared curing of FRP rod to remove moisture Silicone dough procured from reputed manufacturer after complete technical evaluation No binders or fillers are added to dilute the properties of Silicone Metal fittings made of High quality forged steel / Spheroidal Graphite Iron castings.Thicknesss conforming to IEC Interface. .Galvanised Weather Sheds designs for pollutted conditions Interface – Core to Housing. greasy matter and rust.Silicone Overlapping Metal Fitting Double sealing Silicone Housing Manufacturing features unique to BHEL • Weather shed housing overlap at end fittings ensures no moisture penetration. • Segment joining through Lap Jointing to ensure perfect sealing of joints • Ultrasonic cleaning of end fittings after galvanizing to remove moisture.Construction Features Acid Resistant Core rod (ECR Glass) Forged steel Metal Fitting .

BHEL has facilities to carry out all the required tests for incoming materials such as Silicone. Holland as per IEC 62217 . Rheology Tensile testing Die Penetration Test BHEL polymer insulators have successfully undergone stringent design tests in conformance to IEC 61109 Annexure C1. Routine Electrical test 2. routine tests and acceptance tests in conformance to IEC 61109 and IEC 62217. microstructure. BD voltage tests on FRP rods e) Tensile. type tests . Water absorption. Mechanical Strength test 3. Some of them are a) Rheological characteristics of Silicone compound to determine curing characteristics b) Specific gravity and shore hardness after curing of Silicone c) Tensile and tear strength of Silicone compound d) Die penetration . FRP rods and metal end fittings. at world renowned laboratories at KEMA. Thermal Mechanical Performance Test BHEL insulators successfully undergone 5000 Hrs Accelerated Aging Test at KEMA. galvanisation tests on metal end fittings. Holland Hydrophobicity test BHEL Polymer insulators undergo various routine tests and acceptance tests in conformance to IEC standards as well as Customer specific test requirements 1.Quality & Reliability BHEL’s Composite insulators undergo rigorous design tests. density.

• Low weight ( < 80 % of conventional porcelain) – easy handling • Resistance to Vandal Damage • Superior Dielectric Strength • High Power arc resistance due to high thermal Withstand ability • Excellent Pollution Performance (Durable & Regenerative Hydrophobicity) • Flame resistant • Shatter resistance • Aerofoil design offering minimum Wind Resistance • Low Leakage current and Power loss due to its high surface resistivity Regenerative Hydrophobicity • Wide range of service Temperatures (from –50oC to 100oC) • Interchangeability – can easily replace existing Porcelain insulators • Better Aesthetics Silicone Composite Insulators Vs Porcelain Insulators We i g ht r a t i o between Porcelain Insulator and composite long rod insulators for transmission applications is more than 10:1 making c o m p o s i t e insulators an ideal insulator for lines with limited right of way Weight ratio Porcelain to Silicone Composite insulator for Railway Traction applications is 3:1 .Advantages of Silicone based Composite Insulators • Superior Handling of Mechanical Shock Loads hence convenient to handle. transport and erect.

Specific creepage distance from 16 mm / kV to 40 mm / kV 3. Length ranges from 285 mm to 4080 mm 4. Weight of Unit mm mm mm mm kN mm kV kV kVP kV kg 1. PF-WET Withstand Voltage 8. Coupling Designation 7. PF-DRY Withstand Voltage 9. Specified mechanical loads from a.. Shed Diameter (Big / Small) 2. b. Bangalore. Visible Discharge Test Voltage 11.0 33 kV 142 or 132/112 375 1110 360 120 20 85 95 170 27 4. 5. Failing load 6.5 1. Electro-Mechanical Min.. 45 KN to 120 KN for 33 KV to 132 KV.560012 . DRY-Lightning Impulse Withstand Voltage 10. 2. 120 KN to 160 KN for 400 KV. Unit Spacing 3.0 11 kV 142 or 132/112 375 370 160 120 20 45 50 90 9 1. Malleshwaram. Arcover Distance 5. 70 KN to 160 KN for 220 KV. c.5 33 kV 142 or 132/112 325 900 340 70/90 16 75 85 170 27 4.. For specific requirement. Creepage Distance 4.Our Range of Composite Insulators LONG ROD TECHNICAL PARTICULARS OF COMPOSITE LONG ROD INSULATORS TONGUE & CLEVIS TYPE BALL & SOCKET TYPE Parameter Unit 11 kV 142 or 132/112 285 320 140 45 16 35 40 75 9 1. Sketch is indicative only. contact: CBU / Marketing.

Bangalore. contact: CBU / MARKETING. 5.Our Range of Composite Insulators LONG ROD TECHNICAL PARTICULARS OF COMPOSITE LONG ROD INSULATORS Parameter Unit 66 kV 142 or 132/112 770 2250 560 70/90 16 140 150 325 53 4. 7.. Malleshwaram. Shed Diameter (Big / Small) Unit Spacing Creepage Distance Arcover Distance Electro-Mechanical Min. 10. 11. 4. 3.560012 . 2 BHEL Manufacture & supply a Specific creepage distance from 16mm/kv to 40mm/kv b Height ranges from 285mm to4080mm c Specified mehanical load require from 120KN to 160KN for 400KV. 9. Failing load Coupling Designation PF-WET Withstand Voltage PF-DRY Withstand Voltage DRY-Lightning Impulse Withstand Voltage Visible Discharge Test Voltage Weight of Unit mm mm mm mm kN mm kV kV kVP kV kg 1 Sketch is indicative only.5 1.8 66 kV 142 or 132/112 870 2250 560 120 20 140 150 325 53 5. 8.. 3. For specific requirement.. 6. 45KN to 120KN for 33KV to 132KV. 2. 70KN to 160KN for 220KV.

Shed Diameter (Big/Small) Unit Spacing Creepage Distance Arcover Distance Electro-Mechanical Min.0 DRY-Lightning Impulse Withstand Voltage kVP 10.. contact: CBU / Marketing.0 110 kV 142 or 132/112 1460 3870 1175 120 20 185 200 450 88 6. 6.5 1460 4300 1210 120 20 290 335 650 105 8. 9. c.. 70 KN to 160 KN for 220 KV. 2. 7. Sketch is indicative only.) 1. Malleshwaram. Length ranges from 285 mm to 4080 mm 4. 4. Specified mechanical loads from a. Bangalore. 120 KN to 160 KN for 400 KV. 8.560012 . Specific creepage distance from 16 mm / kV to 40 mm / kV 3. 3. Failing load Coupling Designation PF-WET Withstand Voltage PF-DRY Withstand Voltage mm mm mm mm kN mm kV kV kV kg 1450 4300 1210 70/90 16 275 325 650 105 7.Our Range of Composite Insulators LONG ROD TECHNICAL PARTICULARS OF COMPOSITE LONG ROD INSULATORS Parameter Unit 110 kV 142 or 132/112 1460 3870 1175 70/90 16 185 200 450 88 6. 2.8 132 kV 142 or 132/112 132 kV 142 or 132/112 1. Weight of Unit (approx. b. 5. Visible Discharge Test Voltage 11. 5. For specific requirement. 45 KN to 120 KN for 33 KV to 132 KV..

70 KN to 160 KN for 220 KV.. Sketch is indicative only. Visible Discharge Test Voltage 11.. Specific creepage distance from 16 mm / kV to 40 mm / kV 3. 4.2 400 kV 3335 10500 3050 120 20 680 720 1550 305 18. Specified mechanical loads from a. 45 KN to 120 KN for 33 KV to 132 KV. 7.5 220 kV 2610 8000 2300 120 20 500 575 1080 154 12. Shed diameter (Big/small) Unit Spacing Creepage Distance Arcover Distance Electro-Mechanical Min. Weight of unit (approx) 1. 9.560012 . 6. 5. 2.. 5.5 400 kV 3910 13020 3400 160 20 680 720 1550 305 21 1. 8. Malleshwaram. 2. 120 KN to 160 KN for 400 KV.Our Range of Composite Insulators LONG ROD TECHNICAL PARTICULARS OF COMPOSITE LONG ROD INSULATORS Parameter Unit 220 kV 142 or 132/112 2610 8000 2300 70/90 16 500 575 1080 154 11. Length ranges from 285 mm to 4080 mm 4. Failing load Coupling Designation PF-WET Withstand Voltage PF-DRY Withstand Voltage DRY-Lightning Impulse Withstand Voltage mm mm mm mm kN mm kV kV kVP kV Kg 142 or 132/112 142 or 132/112 142 or 132/112 10. b. 3. c. For specific requirement. contact: CBU / Marketing. Bangalore.

) mm mm mm mm kgfm kgf kV kV kVP kVP kV kg 185/145 489 1050 390 200 7000 125 100 240 260 35 4. 9. 5. 3. 11.4 185/145 555 1050 390 200 7000 125 100 240 260 35 5. Shed Diameter Unit Spacing Creepage Distance Arcover Distance Bending Strength Electro-Mechanical Min. 6. 4. 8.4 Sketch is indicative only. . 2.0 185/145 540 1050 390 210 11000 125 100 240 260 35 5.Railway Traction for Standard and Polluted applications TECHNICAL PARTICULARS OF COMPOSITE RAILWAY TRACTION INSULATORS STAY ARM Parameter BRACKET Unit Stayarm Insulator 9-TONNE Bracket Insulator 9-tonne Insulator 1. 10. 7. 12. Failing load PF-WET Withstand Voltage (horizontally) PF-WET Withstand Voltage (vertically) DRY-Lightning Impulse Withstand Voltage positive DRY-Lightning Impulse Withstand Voltage negative Visible Discharge Test Voltage Weight of Unit (approx.

For enquiries please contact: Bharat Heavy Electricals Limited (A Government of India Undertaking) Ceramic Business Unit Prof. Rao Circle.R. New Delhi .bhelceramics.bhel.110 049. Siri Fort.com .N. 23344231 www. Bangalore-560 012 (India) Ph: 080-23442988.Bharat Heavy Electricals Limited (A Government of India undertaking) Registered and Corporate Office BHEL House. C.com Efforts are constantly being made to improve the product design and hence the products supplied may differ in minor details from that given in the catalogue. 22182247 Fax: 080-23560741. Opp. Tel: 011-2600 1010 Fax: 011-2649 3021 www. Indian Institute of Science Malleswaram.

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