polymeric station post insulators

Overview

The composite station post insulators are widely applied to disconnector,devices in electric transformer substations, convertor stations and tubular bus-bar and other primary equipment. With so many special advantages, composite station post insulator is increasing its market shares. According to company standard Q/GDW-383 SMART CONVERTOR TECHNOLOGY GUIDE, which is stated by State Grid Corporation of China, “primary equipment should be with high reliability, apply composition material as outer insulation, and suitable for the working environment. 

According to customers requirements, post insulator can be made for voltage of  33kV,  69kV, 132kV, 230KV, 300kV, 400kV, 500kV ... 

Mostly, the plymer post insulators are used to support bus-bars in transformer sub-station yards, support breakers in switchgear, and support capacitor banks etc. These plymer post insulators are generally subjected to bending, torsion and compression forces in service. They may also be installed horizontally, vertically, or underhung some times, and different installations will be accoring to different applications. They can be designs according to IEC, ANSI and other standards or to customer specification, in the factory of GW.

When do we need to replace the porcelain post insulators by composite plymeric station post insulators?

The mechanical heights are the same and electrical performance is comparable to the porcelain ANSI TR Numbers. This means in most cases they are direct replacements, one to one.

For many years substations were constructed using porcelain post insulators. After working so many years, many porcelain post insulators need to be replaced. But the height of many porcelain post insulators used before are different from what we are using today. That make it hard to use new ones to replace the old ones directly.

However, Xiangyang Guowang's composite station post insulators offer a better choice, that is to say we can offer composite station post insulators with appropriate height that can directly replace the old porcelain ones without adjust the bus or switches.

Besides, the composite station post insulators are usually cheaper than the porcelain station insulator. 

Also composite station post insulators can be made to one piece, instead of installed together by several shorter ones.

Structure and process of the composite post insulators

Housing (sheath and sheds)

Sheath and sheds of composite long rod polymer Insulators are made of HTV silicone-rubber (VMQ - Vinyl-Methyl-Polysiloxane, with filler additives) free of EPDM or other natural origin rubbers.Silicone-rubber is HTV solid silicone type (High Temperature Vulcanized – solid silicone rubber).This type of silicone rubber is solid and vulcanizes at a high temperature (near 200ºC).

Core

The ECR fiberglass rod, which produced from epoxy resin and glass fiber, has ability of high electrical integrity & high resistance to acid corrosion. Epoxy resin resistant to hydrolisys reinforced with glass fiber resistant to corrosion in order to transmit the mechanical stresses produced by conductors to the support and provides the necessary electrical insulation.The core is the component to bear mechanical load and has minimum tension strength at 1000Mpa.

Molding Process

compare with compression molding way, injection type insulators molding will make the thickness of insulator's housing more balance, which can get a much higher quality products. Also the injection machine is equipted with cold runner system, which will make the rubber the keep in melting status, during flowing inside the mold.

composite station post insulator structure

Functions

Composite Station post insulators have the advantages of anti-pollution flashover, high strength, light weight, anti-impact, easy for maintenance and project costs saving etc. The composite post insulators are widely applied to:

Advantages

Reference Project

polymeric station post insulators polymeric station post insulators composite post insulator for disconnector
Composite post insulators are applied to Hunan-Hubei soft current exchanging
tower of direct current power transmission system. It works normally and don’t need to be clean which save a lot labor cost.
In the current exchange station of ±800KV ultra high voltage direct current power transmission substation. One piece pole post insulators are used to replace porcelain post insulators which need more than 3 pieces mounted together. Composite post insulators can be applied for disconnectors, switchgears in substation with voltage of 11kV – 500kV. The post can be made in one piece. Or it can be installed together with several pieces

Parameters (IEC 60273)

Technical Refemrence Number Model BIL Rating kV Power Frequency Withstand Wet Height mm Leakage Distance mm Bolt Circle mm Cantilever Strength kN Torsional Strength N·M
top base
C2-325 GW-325-CT6 325 140 770 2150 127 127 6 2000
C4-325
C6-325 GW-325-CT8 1950 127 127 8 3000
C8-325
C10-325 GW-325-CT12.5 1800 127 127 12.5 4000
C12.5-325
C16-325 GW-325-CT16 2000 127 225 16 5000
C20-325 GW-325-CT20 2000 127 254 20 6000
C2-450 GW-450-CT5 450 185 1020 3000 127 127 5 1800
C4-450 GW-450-CT8 2800 127 127/178 8 2500
C6-450 GW-450-CT10-1 2700 127 127/178 10 3500
C8-450 GW-450-CT10-2 2700 127 127/200 10 4000
C10-450 GW-450-CT10-3 2700 127 127/225 10 4000
C12.5-450 GW-450-CT12.5 2950 127 225 12.5 6000
C16-450 GW-450-CT16 2950 127 254 16 6000
C20-450 GW-450-CT20 2950 127 254 20 6000
C2-550 GW-550-CT6-1 550 230 1220 3600 127 127 6 2000
C4-550 GW-550-CT6-2 3600 127 127/178 6 3000
C6-550 GW-550-CT8-1 3350 127 127/200 8 4000
C8-550 GW-550-CT8-2 3350 127 127/200 8 4000
C10-550 GW-550-CT10 3350 127 127/225 10 4000
C12.5-550 GW-550-CT12.5 3750 127 254 12.5 6000
C16-550 GW-550-CT16 3750 127 254 16 6000
C20-550 GW-550-CT20 3750 127 275 20 6000
C2-650 GW-650-CT6-1 650 275 1500 4600 127 127/178 6 2000
C4-650 GW-650-CT6-2 4600 127 127/200 6 3000
C6-650 GW-650-CT6-3 4600 127 127/200 6 3000
C8-650 GW-650-CT8 4800 127/225 127/225 8 4000
C10-650 GW-650-CT10 4800 127/225 254 10 4000
C12.5-650 GW-650-CT12.5 4800 127/225 254 12.5 6000
C16-650 GW-650-CT16 4650 225 275 16 6000
C20-650 GW-650-CT20 4700 225 300 20 6000
C2-750 GW-750-CT4-1 750 325 1700 5100 127 127/178 4 2000
C4-750 GW-750-CT4-2 5100 127 127/200 4 3000
C6-750 GW-750-CT6 4800 127/225 127/225 6 3000
C8-750 GW-750-CT8 5300 127/225 127/225 8 4000
C10-750 GW-750-CT10 5300 127/225 254 10 4000
C12.5-750 GW-750-CT12.5 5200 127/225 254 12.5 6000
C16-750 GW-750-CT16 5200 225/254 275 16 6000
C20-750 GW-750-CT20 5200 225/254 300 20 6000
C4-850 GW-850-CT4 850 360 1900 5800 127 200 4 3000
C6-850 GW-850-CT6 5500 127/225 225 6 3000
C8-850 GW-850-CT8 6000 127/225 254 8 4000
C10-850 GW-850-CT10 6000 127/225 254 10 4000
C12.5-850 GW-850-CT12.5 6000 127/225/254 254 12.5 6000
C16-850 GW-850-CT16 6000 225/254 275 16 6000
C20-850 GW-850-CT20 6000 225/254 300 20 6000
C4-950 GW-950-CT4 950 395 2100 6200 127 200 4 3000
C6-950 GW-950-CT6 6900 127/225 225 6 3000
C8-950 GW-950-CT8 6900 127/225 254 8 4000
C10-950 GW-950-CT10 6900 127/225 254 10 4000
C12.5-950 GW-950-CT12.5 6900 127/225/254 275 12.5 6000
C16-950 GW-950-CT16 6700 225/254 300 16 6000
C20-950 GW-950-CT20 6700 225/254 325 20 6000
C4-1050 GW-1050-CT4 1050 460 2300 6900 127 200 4 3000
C6-1050 GW-1050-CT6 7700 127/225 225 6 3000
C8-1050 GW-1050-CT8 7700 127/225 254 8 4000
C10-1050 GW-1050-CT10 7700 127/225 275 10 4000
C12.5-1050 GW-1050-CT12.5 7700 127/225/254 275 12.5 6000
C16-1050 GW-1050-CT16 7600 225/254 300 16 6000
C20-1050 GW-1050-CT20 7600 225/254 325 20 6000
C4-1175 GW-1175-CT4 1175   2650 8050 127/225 225 4 3000
C6-1175 GW-1175-CT6 9000 127/225 254 6 3000
C8-1175 GW-1175-CT8 9000 127/225 254 8 4000
C10-1175 GW-1175-CT10 9000 127/225 275 10 4000
C12.5-1175 GW-1175-CT12.5 8900 127/225/254 300 12.5 6000
C16-1175 GW-1175-CT16 8900 225/254 325 16 6000
C20-1175 GW-1175-CT20 8900 225/254 356 20 6000
C4-1300 GW-1300-CT4 1300   2900 10000 127/225 225 4 3000
C6-1300 GW-1300-CT6 10000 127/225 254 6 3000
C8-1300 GW-1300-CT8 10000 127/225 275 8 4000
C10-1300 GW-1300-CT10 10000 127/254 275 10 4000
C12.5-1300 GW-1300-CT12.5 9850 127/225/254 300 12.5 6000
C16-1300 GW-1300-CT16 9750 225/254 325 16 6000
C20-1300 GW-1300-CT20 9750 225/254 356 20 6000
C4-1425 GW-1425-CT4 1425   3150 11000 127/225 225 4 3000
C6-1425 GW-1425-CT6 11000 127/225 254 6 3000
C8-1425 GW-1425-CT8 11000 127/225 275 8 4000
C10-1425 GW-1425-CT10 11000 127/225 300 10 4000
C12.5-1425 GW-1425-CT12.5 10850 127/225/254 325 12.5 6000
C16-1425 GW-1425-CT16 10750 225/254 356 16 6000
C20-1425 GW-1425-CT20 10600 225/254 356 20 6000
C4-1550 GW-1550-CT4 1550   3350 11700 127/225 225 4 3000
C6-1550 GW-1550-CT6 11700 127/225 254 6 3000
C8-1550 GW-1550-CT8 11700 127/225 275 8 4000
C10-1550 GW-1550-CT10 11600 127/225 300 10 4000
C12.5-1550 GW-1550-CT12.5 11600 127/225/254 325 12.5 6000
C16-1550 GW-1550-CT16 11600 225/254 356 16 6000
C20-1550 GW-1550-CT20 11400 225/254 356 20 6000
C4-1675 GW-1675-CT4 1675   3650 13000 127/225 254 4 3000
C6-1675 GW-1675-CT6 13000 127/225 275 6 3000
C8-1675 GW-1675-CT8 13000 127/225 300 8 4000
C10-1675 GW-1675-CT10 12800 127/225 300 10 4000
C12.5-1675 GW-1675-CT12.5 12800 225/254 325 12.5 6000
C16-1675 GW-1675-CT16 12650 225/254 356 16 6000
C4-1800 GW-1800-CT4 1800   4000 14200 225/254 254 4 3000
C6-1800 GW-1800-CT6 14200 225/254 275 6 3000
C8-1800 GW-1800-CT8 14200 225/254 300 8 4000
C10-1800 GW-1800-CT10 14200 225/254 325 10 4000
C12.5-1800 GW-1800-CT12.5 14000 225/254 356 12.5 6000
C16-1800 GW-1800-CT16 13850 225/254 356 16 6000
C4-1950 GW-1950-CT4 1950   4400 15650 225/254 254 4 3000
C6-1950 GW-1950-CT6 15650 225/254 275 6 3000
C8-1950 GW-1950-CT8 15450 225/254 300 8 4000
C10-1950 GW-1950-CT10 15350 225/254 325 10 4000
C12.5-1950 GW-1950-CT12.5 15350 225/254 356 12.5 6000
C4-2100 GW-2100-CT4 2100   4700 16400 225/254 254 4 3000
C6-2100 GW-2100-CT6 16400 225/254 275 6 3000
C8-2100 GW-2100-CT8 16400 225/254 300 8 4000
C10-2100 GW-2100-CT10 16400 225/254 325 10 4000
C12.5-2100 GW-2100-CT12.5 16400 225/254 356 12.5 6000
C4-2250 GW-2250-CT4 2250   5000 17800 225/254 254 4 3000
C6-2250 GW-2250-CT6 17800 225/254 300 6 3000
C8-2250 GW-2250-CT8 17800 225/254 325 8 4000
C10-2250 GW-2250-CT10 17800 225/254 356 10 4000
C12.5-2250 GW-2250-CT12.5 17800 225/254 356 12.5 6000
C4-2400 GW-2400-CT4 2400   5300 19100 225/254 254 4 3000
C6-2400 GW-2400-CT6 19100 225/254 300 6 3000
C8-2400 GW-2400-CT8 19100 225/254 325 8 4000
C10-2400 GW-2400-CT10 18900 225/254 356 10 4000
C12.5-2400 GW-2400-CT12.5 18900 225/254 356 12.5 6000
C4-2550 GW-2550-CT4 2550   5700 20500 225/254 275 4 3000
C6-2550 GW-2550-CT6 20500 225/254 300 6 3000
C8-2550 GW-2550-CT8 20500 225/254 325 8 4000
C10-2550 GW-2550-CT10 20500 225/254 356 10 4000

FAQ

What is BIL for post insulator?

Insulation levels are designed to , rather than only normal operating voltages. Since the insulation lines and equipment is protected by surge arresters draining the surges rapidly before the insulation is damaged, the arrester must operate below the minimum insulation level that must withstand the surges.