Introduction Insulators Types Design Criteria Manufacturing Process Electrical Utility What Does an Insulator Do?

1. A Process review ofA Process review of
Insulators ManufacturingInsulators Manufacturing
andand
Its ApplicationIts Application
Amir MohammadAmir Mohammad
Email-amir225692@gmail.comEmail-amir225692@gmail.com
Abu RoadAbu Road

2. OutlineOutline
 IntroductionIntroduction
 Insulators TypesInsulators Types
 Design CriteriaDesign Criteria
 Manufacturing ProcessManufacturing Process
 Electrical UtilityElectrical Utility

3. IntroductionIntroduction
What Is an InsulatorWhat Is an Insulator??
An insulator is a dam poor conductorAn insulator is a dam poor conductor
AndAnd
An insulator is a mechanical supportAn insulator is a mechanical support..
Primary functionPrimary function––
To Support the “line” mechanicallyTo Support the “line” mechanically
Secondary functionSecondary function––
Electrical Isolation of Conductor with Support orElectrical Isolation of Conductor with Support or
TowersTowers
Outer shells/surfaces are designed to increaseOuter shells/surfaces are designed to increase
leakage distance and strike distance which isleakage distance and strike distance which is
termed as a creep age lengthtermed as a creep age length

4. IntroductionIntroduction
What Does an InsulatorWhat Does an Insulator
DoDo??Maintains an Air GapMaintains an Air Gap
Separates Line from GroundSeparates Line from Ground length of air gaplength of air gap
depends primarily on system voltage, modifieddepends primarily on system voltage, modified
by desired safety margin, contamination, etcby desired safety margin, contamination, etc..
Resists Mechanical StressesResists Mechanical Stresses
““everyday” loads, extreme loadseveryday” loads, extreme loads
Resists Electrical StressesResists Electrical Stresses
system voltage/fields, overvoltages Resistssystem voltage/fields, overvoltages Resists
Environmental Stresses heat, cold, UV,Environmental Stresses heat, cold, UV,
contamination, etccontamination, etc..

5. Insulators TypesInsulators Types
According to Design two basic Insulators areAccording to Design two basic Insulators are
11..Ceramic ( Porcelain ) InsulatorsCeramic ( Porcelain ) Insulators
22..Non Ceramic InsulatorsNon Ceramic Insulators
According to applications three broad categories areAccording to applications three broad categories are::
Distribution lines (thru 69 kVDistribution lines (thru 69 kV((
Transmission lines (69 kV and upTransmission lines (69 kV and up((
Substations (all voltagesSubstations (all voltages((

6. Insulators TypesInsulators Types
DistributionDistribution lineslines
Pin type insulators -mainly porcelain, growing usePin type insulators -mainly porcelain, growing use
of polymeric (HDPE – high density polyethylene),of polymeric (HDPE – high density polyethylene),
Line post insulators – porcelain, polymericLine post insulators – porcelain, polymeric
Dead end insulators – polymeric, porcelain, glassDead end insulators – polymeric, porcelain, glass
Spool insulators – porcelain, polymericSpool insulators – porcelain, polymeric
Strain insulators, polymeric, porcelainStrain insulators, polymeric, porcelain

7. Insulators TypesInsulators Types
Transmission linesTransmission lines
Suspension insulators - new installations mainlySuspension insulators - new installations mainly
NCIs, porcelain and glass now used lessNCIs, porcelain and glass now used less
frequentlyfrequently
Line post insulators – mainly NCIs for new linesLine post insulators – mainly NCIs for new lines
and installations, porcelain much less frequentand installations, porcelain much less frequent
nownow

8. Insulators TypesInsulators Types
SubstationsSubstations
Post insulators – porcelain primarily, NCIsPost insulators – porcelain primarily, NCIs
growing in use at lower voltages (~161 kV andgrowing in use at lower voltages (~161 kV and
belowbelow((
Suspension insulators –NCIs (primarily), ceramicSuspension insulators –NCIs (primarily), ceramic
Cap and Pin insulators – “legacy” typeCap and Pin insulators – “legacy” type

9. Insulators Types - ComparisonInsulators Types - Comparison
CeramicCeramic
Porcelain or toughenedPorcelain or toughened
glassglass
Metal componentsMetal components
fixed with cementfixed with cement
ANSI Standards C29.1ANSI Standards C29.1
through C29.10through C29.10
Non CeramicNon Ceramic
Typically fiberglass rodTypically fiberglass rod
with rubber (EPDM orwith rubber (EPDM or
Silicone) sheath andSilicone) sheath and
weather shedsweather sheds
HDPE line insulatorHDPE line insulator
applicationsapplications
Metal componentsMetal components
normally crimpednormally crimped
ANSI Standards C29.11 –ANSI Standards C29.11 –
C29.19C29.19

10. County’s service ExperienceCounty’s service Experience
 The main problemThe main problem
cause a worry forcause a worry for
NCI Insulators isNCI Insulators is
the bird attacksthe bird attacks
which eat part ofwhich eat part of
the insulator andthe insulator and
render it uselessrender it useless

11. Design Criteria - ElectricalDesign Criteria - Electrical
Dry Arcing Distance –Dry Arcing Distance –
(Strike Distance) –(Strike Distance) –
“The shortest“The shortest
distance through thedistance through the
surrounding mediumsurrounding medium
between terminalbetween terminal
electrodeselectrodes……

12. Design Criteria – Leakage DistanceDesign Criteria – Leakage Distance
What is LeakageWhat is Leakage
DistanceDistance??
““The sum of theThe sum of the
shortest distancesshortest distances
measured alongmeasured along
the insulatingthe insulating
surfaces betweensurfaces between
the conductivethe conductive
parts, asparts, as
arranged for dryarranged for dry
flashover testflashover test

13. Design Criteria – MechanicalDesign Criteria – Mechanical

14. Manufacturing - ProcessManufacturing - Process

15. Slurry PreparationSlurry Preparation
Ball MillBall Mill BlungerBlunger

16. Filter PressingFilter Pressing

17. ExtrusionExtrusion

18. Turning - FinishingTurning - Finishing

19. DryingDrying

20. Dry Finishing / GlazingDry Finishing / Glazing

21. Kiln FiringKiln Firing

22. Cutting And GrindingCutting And Grinding

23. AssemblyAssembly

24. Testing – Bending ( MechanicalTesting – Bending ( Mechanical((

25. Testing – Tensile ( MechanicalTesting – Tensile ( Mechanical((

26. Testing – Beam Load ( MechanicalTesting – Beam Load ( Mechanical((

27. Testing – Vibration ( MechanicalTesting – Vibration ( Mechanical((

28. Testing – Compression( MechanicalTesting – Compression( Mechanical((

29. Testing - StructuralTesting - Structural
Ultra Sonic Flaw DetectionUltra Sonic Flaw Detection

30. Testing - ElectricalTesting - Electrical
H V Step Up Transformers Set H V Measurement By Potential Dividers

31. Electrical - UtilityElectrical - Utility

32. 3333kV Electrical Switch YardkV Electrical Switch Yard

33. Electrical 415 V LT DistributionElectrical 415 V LT Distribution

34. APFC – Panel ( Maintains 0.999APFC – Panel ( Maintains 0.999((

35. Synchronization – Dark LampSynchronization – Dark Lamp

36. Standby D.G. Sets 1000 KVAStandby D.G. Sets 1000 KVA

37. Sl. RAW MATERIALS MIL 082
1 HI ALUMINA 25.7
2 FELDSPAR PINK 13.4
3 FELDSPAR WHITE 12.9
4 NC-II CLAY 5.9
5 DM CLAY 8.9
6 BGP CLAY 3.0
7 HYMOD KC Ball Clay 12.9
8 TGH CLAY 5.9
9 A-7 CLAY 6.4
10
FIRED PORCELAIN
POWDER 5.0
11 STEATITE (TALC) 0.0
Total 100.0
Insulators – Body CompositionInsulators – Body Composition

38. Glaze - CompositionGlaze - Composition
Material Composition Composition
BROWN GREY
1QUARTZ 35.0 42.0
2FELDSPAR PINK 20.0 20.0
3DM CLAY 3.0
4HYMOD KC 3.0
5CALC. CHINA CLAY 13.2
6WOLLASTONITE 9.0
7BENTONITE 1.0
8TALC (STEATITE) 2.0
9BAGESHPUR CLAY 7.0
10DOLOMITE 2.0 5.0
11CALCITE 10.3
12BARIUM CARBONATE 2.0 2.5
13HI-ALUMINA 2.5
14ZINC OXIDE 2.0
15ZIRCONIUM SILICATE 7.5
16MANGANEESECARBONATE 7.4
17FERRIC OXIDE 1.0
18CROMIUM OXIDE 1.0
19G-2 STAIN LATEST 0.8
20CMC 0.4 0.4
21SANTOBRITE 0.04 0.04
TOTAL 100.0 100.0