The COMPOSITE INSULATORS

Transcription

1 INSUALTOR & ACCESSORIES FACTORY ЗАО АИЗ, Russia OFFICIAL SALES REPRESENTATIVE: UAB VILRIDA, Europe The COMPOSITE INSULATORS Company profile & short insulator brochure 2009

2 THE FACTORY THE INSULATOR & ACCESSORIES FACTORY LTD (ЗАО "АИЗ") was formed in 1999 in the Elektrostal the suburban city of Moscow, after the reorganization of the factories group PROMARMATURA, accumulating its experience in the manufacturing of accessories and insulators for overhead power transmission lines since The key staff experience and technology know how were inherited from the group. Since 2001 the factory opened new glass insulator production line in another suburban Moscow city, the Lytkarino, in the territory of Lytkarino Optical Glass Factory. Since 2004 this production line became the main production line. Since 2003 the production volume rose 7 times compared to the 2000 year level, in spite of a very complicated situation in Russian market and reorganization of RAO "UES of Russia". Annual production capacity level in 2009: 180 tones of accessories per year; 300 tones of polymer insulators per year; 840 tones of glass insulators per year; THE OFFICIAL SALES REPRESENTATIVE Closed Joint Stock Company VILRIDA (UAB VILRIDA ), in European Union Lithuania, is a privately owned company formed in 2004 to supply world class glass and composite insulators, disconnectors, bushings and various custom components, as well as various other equipment and tools for the electrical industry. Since 2004 the UAB VILRIDA is the official sales representative for export markets of the Russian leading glass and composite insulators and their accessories manufacturer INSULATOR AND ACCESSORIES FACTORY LTD (ЗАО АИЗ ). THE CONSTRUCTION BUREAU OF THE FACTORY The factory has a unique construction bureau (CB) for the research and development of new inventions in the armature and insulators. With the help of the bureau, the factory is capable to develop new generation solutions and can implement them to the production in the shortest terms. The work of the CB was highly evaluated by the Russian and foreign specialists: from Iran, Kazakhstan, Syria, 2

3 Vietnam, Serbia, Lithuania, Spain, Portugal, Greece, and Turkey. Thanks to the CB the factory can participate in foreign tenders. For including the new insulators types into the projects, factory created TYPICAL STRINGS for glass and polymer insulators. Clients and project making institutions can obtain the catalogues of typical strings from our factory without limitations. PRODUCTS The current standard production program includes the glass and composite insulators and accessories for: insulation and fixing of overhead electrical transmission line conductors, lighting protection conductors; distribution equipment of electrical stations and substations of DC and AC currents with frequencies up to 1000 Hz and ambient temperature from - 60 to + 50 Сº; railway electrification; districts with various atmospheric pollution level; conditions of cold, hot, humid and tropical climates. Besides standard products the factory produces special types of insulators and armature, which were never produced in Russia before. QUALITY, STANDARDS AND TESTING The products manufactured by INSULATOR AND ACCESSORIES FACTORY LTD have been exhaustively tested and proven. They can be found in service within diverse climactic conditions providing the highest levels of reliability and performance to distribution networks, global electrical utilities and their clients. All insulator types are tested at the accredited high voltage testing laboratory before launching new type production, or after changes in construction or production technology. The production of insulators is carried out with the respect to the newest pioneering technologies and the latest achievements of science in the fields of material science and energetics. Also the developments of national institutions are taken into account (The Construction Bureau of JSC FGC UES (Federal Grid Company of Unified Energy System), The Construction Bureau of Electrosetservice, The RCFSUE VEI, Russia ("The high voltage electrical equipment research centre of The Federal State Unitary enterprise Lenin electrical engineering institute of Russia, Accredited in Russia The factory received the ISO 9001:2000 certificate, issued by National Chamber of Certification Noncoercial Partenreship, Russia( The electro technical parameters of insulators, their types and dimensions completely conform to the requirements of Russian National Standards GOST and the international IEC standards. Insulators are manufactured and tested according national standards of Russian Federation GOST and The International IEC Standards, such as listed below and other: IEC 60 IEC IEC Dimension of ball and socket couplings of string insulator units Locking devices for ball and socket couplings of string insulator units: Dimensions and tests Insulators for overhead lines with a nominal voltage above 1000 V (Parts 1 and 2 as applies) 3

4 IEC IEC IEC IEC IEC IEC Radio interference test on high-voltage insulators Artificial pollution tests on high-voltage insulators to be used on a. c. systems Guide for the selection of insulators in respect of polluted conditions Insulators for overhead lines Composite suspension and tension insulators for a. c. systems with a nominal voltage greater than 1000 V Definitions, test methods and acceptance criteria Insulators for overhead lines Composite line post insulators for alternative current with a nominal voltage > 1000 kv. Composite station post insulators for substations with a. c. voltages greater than V up to 245 kv - Definitions, test methods and acceptance criteria IEC Composite strings insulator units for overhead lines with a nominal voltage greater than 1 kv Part 1: Standard strength classes and end fittings. IEC Composite strings insulator units for overhead lines with a nominal voltage greater than 1 kv Part 2: Dimensional and electrical characteristics. SUCCESSFUL PROJECT REFERENCES The factory products are well known in more than 30 countries around the world. Since the very opening, the factory had successfully participated in all major Russian projects for building of new OH lines and reconstruction of old ones. The factory is also very active in foreign tenders. Some of its successful projects for example are: EKIBASTUZ-CENTR, Russia,1150 kv BARNAUL-ITAT, Russia, 750 kv HABAROVSK-HEHZIR, Russia, 500 kv LUK-OIL, Russia, 110 kv GAZPROM-KOGALYM, Russia, 110 kv KHOY-BORDER OF TURKEY, Iran, 400 kv JANDAR-TADMOR, 400 kv, Iran ENERGO NIGERIA, Nigeria, 330 kv WEST QURNA, Iraq, 132 kv MAGRON, HANOY-BORDER, 500 km, 230 kv, Vietnam 110 kv, Ivory coast HARIB-ROCK, Namibia, 132 kv TENGIZCHEVROIL, Kazakhstan, 110 kv KUNDUZ PROVINCE, Afghanistan, 110 kv POWER HOLDING COMPANY OF NIGERIA, 330 kv, Nigeria VILNIUS POWER PLANT, 110 kv, Lithuania RIGAS POWER LINES, Latvia, 110 kv And other 4

5 COMPOSITE MATERIAL ADVANTAGES Polymer materials such as silicone elastomers, hydrocarbon elastomers and epoxy resins are being increasingly used instead of porcelain and glass for outdoor insulation applications such as line insulators, bushings, core insulators, cable terminations, etc., mostly due to the following advantages: light weight = lower construction and transportation costs; vandalism resistance = less gunshot damage; high strength to weight ratio = longer spans/new tower design; hydrophobicity = high performance in polluted areas improved transmission line aesthetics; non explosive housing = improved safety for the staff in the station and for the installation equipment. Unlike porcelain and glass these polymers have low surface free energy which makes the virgin surface (new and without exposure to the environment) of the polymers inherently hydrophobic (water repellent). Hydrophobic surfaces present a higher resistance to leakage current flow than porcelain or glass surfaces (hydrophilic surfaces). They also require higher current and coensurate energy dissipation to initiate the well-known phenomenon of dry band arcing which, ultimately, is responsible for material degradation in the form of tracking and erosion. The lower leakage current and consecutive lower probability of dry band formation require the higher applied voltage to cause flashover. In one word, due to the hydrophobic surface, the polymer materials typically offer much better contamination performance than porcelain and glass. PERFORMANCE BENEFITS Improved Reliability - superior flexibility and strength, which provides high resistance to breakage and improved seismic performance, eliminate damage during transportation, interruptions and outages due to vandalism, and flashovers in all types of environments; are lighter than porcelain or glass but offer an equal or better strength; safe from internal and external overpressure; maintain in 5 times the big static loadings and in 20 times the big dynamic loadings; Eliminates or Reduces Maintenance - low failure rate, low overall mounting and exploitation costs; high resistance to acids, alkalis and ultraviolet radiation; compatible with existing porcelain insulators (connecting sizes and building height fully comply with porcelain insulators to be replaced); improved pollution and hydrophobic properties of silicone rubber provide excellent insulating behavior without the need for washing or greasing even in humid and/ or polluted climates; Improves Power Quality - (lower RI and TVI) Energy Efficiency - reduced losses due to lower leakage currents. Excellent tracking resistance avoids erosion or tracking of the housing material; Safety - a very high level of safety for apparatus, in case of inner over-pressure or external causes; light weight for handling and installation, eliminates catastrophic mechanical failures; Improved Service Life - stable long term operating behavior, 30 years of service time, due to the special composite insulating coating; as demonstrated over many years of outdoor exposure against degradation and deterioration of insulating properties; Life Cycle Cost savings - cost competitive in comparison to conventional insulators. Short process time, hence reduced lead time, a low failure rate combined with low overall operating and 5

6 maintenance costs (savings over porcelain insulators). The price of insulator is lower than the price porcelain due to small densities of polymers and smaller quantity of raw material; The design flexibility - allows for adaptation to suit specific needs, such as changes in creepage distance independent of insulator length, and aerodynamic profile; Ecologic advantages- in comparison to glass and porcelain insulators. PORCELAIN AND GLASS REPLACEMENT PROGRAM The factory established The Porcelain and Glass Replacement Program and is seriously working on the complete replacement of all existing porcelain and glass types and classes of insulators into the polymer composite based products. The program has already resulted in development of such types as: Station post polymer insulators up to 220 кv; bus bar polymer insulators up to 220 kv; polymer long rod insulator for up to 550 кv; polymer railway insulators of all types, station post-pin type (having no analogues); first in Russia pin core rod line for 10 and 20 кv (for replacement for porcelain); line post insulators up to 220 kv; bushing insulators for kv voltages and currents up to 4000A; polymer bushings for the replacement of oil type of up to 220 кv, digital optical fibre current transformers with accuracy class 0.02S, i.e. 10 times better existing ones, digital voltage transformers, united with current transformers for the needs of automated computer aided power and energy measurement system, polymer surge arresters up to 330кV, suspension polymer disc insulators, and other. 6

7 COMPOSITE INSULATOR GENERAL DESIGN ECR ROD high temperature non alkaline acid-resistant rod produced from E type fibre glass, supplied by companies Fiberglass (Germany) or AO Bijskij savod stekloplastikov (Russia). The combination of a hydrolysis resistant epoxy resin with acid resistant glass fibers (ECR glass) is a safe assurance against brittle fracture. The high quality monolithic reinforced fiber glass core rod is specially developed for electrical and mechanical applications, more than 50% glass fibers in cross section. The high strength monolithic core rods manufactured using the cyclo aliphatic epoxy resins are used. These resins are highly resistant to severe atmosphere conditions, ozone, sun radiation, acids, electrical discharge and tracking. They protect core rod from any breakage, ensure stable insulator operating behaviour at extreme conditions, even when the protective silicone coating is faulty or damaged or is at all absent. The core rods are made from reinforced fiber glass material by the method of pultrusion. This process is based on pulling the glass fiber threads coated with the special epoxy resin (roving) through the heated die of the necessary diameter. Only the E type non-alkaline glass roving for core rods is used in order to enhance the resistance to alkaline and aggressive environments. Unlike pipes filled by foam, the insulators with the monolithic core rod are protected from inner discharge generation of and puncture; they are protected from current leakages along inner surfaces and walls because they are free from condensation, present in hollow pipes. HOUSING AND SHEDS made from special silicone for high voltage insulators, hardening at high temperature (ºC), supplied by well known companies such as Dow Corning, Wacker, General Electric or other. Housing manufactured with silicon alloy rubber conforms to IEC standard requirement - exhibit long-term hydrophobic properties, high mechanical strength, excellent corona resistance low permeability to moisture and the highest grade of tracking and corrosion resistance, coating thickness >=5. END FITTINGS produced by the method of hot punching, which gives additional strength to the metal. The end fittings are crimped by special press Finn-Power with round dies by even crimping force from all sides. The crimping force is 3500 kn. First of all the metal bushings are crimped at area where the end fitting is going to be crimped on to the electro insulating body. The bushings are crimped by round dies which evenly surround rod diameter from all sides. The strain control and acoustic inspection is carried out. After that the end fittings are fixed to the bushings. In this way the end fitting fixing process can not damage insulator integrity or its hermetical properties. INTER-JUNCTION HOUSING/END FITTING - The hydrophobic and anti-leakage characteristics at the junction of housing and end fitting is achieved through the labyrinth configuration of the internal part of the end fitting in which the silicone is included during crimping - method adopted from Japanese company NGK. CORONA RINGS the triple junction (fitting/housing/core rod) is screened from electrical field by corona rings. Corona rings produced from aluminium alloy by the method of high precision moulding under pressure. The corona rings have the necessary round and completely smooth configuration. 7

8 PRODUCTION PROCESS INJECTION MOULDING for 110 kv insulators. A single shot moulding process is used - the rod is positioned between two halves of a parted mould and the housing (including the sheds at the same time) material is injected into the mould. Due to heating, the vulcanising process starts to crosslink the housing materials as well as the bond between housing and the rod surface. When a stale state of housing material is reached, the mould is opened and insulating body is taken out. The silicone is one piece high pressure (>=85 kg / cm2) injection molded and chemically bonded to the core rod, ensures that the interface between the rubber and rod is impenetrable against moisture ingress. Secondary vulcanization is carried out. The fittings are crimped directly onto the rod by a special process, which develops a high percentage of the rod s inherent tensile strength. MODULAR SYSTEM - for 220 kv insulators. The ECR rod, using extrusion technology, is coated with a seamless sheath of high-temperature vulcanized (HTV) silicone rubber, ensuring optimum adhesion and perfect rod hermetization. No longitudinal moulding line is formed during the extrusion. The separately pre moulded sheds are pushed onto the pre-cut type fibreglass rod. The sheds have special form enabling their inter linkage. Everything is vulcanised together at elevated temperatures (HVT high temperature vulcanisation). This stage creates a durable high-strength bond between the sheds and the rod sheath. The sheds are made from strengthened silicone resin containing high percentage of anti erosion and anti tracking substances (mainly finely grounded mineral materials having high abrasive properties). The sheds are produced by the means of punching the technology that combines all of the advantage from the machine hermetical casting technology, provides resistance to tracking and results in no moulding line. The metal hardware is mounted on the coated rod by a crimping process which ensures that no damage is done to the insulator integrity and hermetic properties. The triple junction (fitting/housing/core rod) is screened from electrical field by corona rings. The design and manufacturing method results in no moulding line along the insulator spank between the sheds. The sheds themselves show the moulding line at the outer periphery of the sheds. These moulding lines are arranged perpendicular to the main direction of the electrical field. No longitudinal moulding line is formed. 8

9 СOMPOSITE INSULATORS FOR OVERHEAD POWER TRANSMISSION LINES And STATION POST INSULATORS CS TYPE - TENSION / SUSPENSION FOR KV FOR OVERHEAD LINES International type Type of insulator Composite silicone Insulators for overhead power transmission lines Russian type Ultimate Mech. Strength, kn Shed diamete r, Spacing, Creepage distance, Metal fitting dimensions, IEC60 Weight Kg CS70 #16#16 230/900 LK70/ ,8 CS70 #16#16 570/2640 LK70/ ,65 CS70 #16# /4800 LK70/ ,6 CS70 #16# /6700 LK70/ ,7 CS160 #20# /4680 LK160/ ,1 CS160 #20# /7200 LK160/ ,4 CS160 #20# /9500 LK160/ ,0 CS300 #24# /6850 LK300/ ,5 CS300 #24# /9130 LK300/ ,8 CS300#24# /11100 LK300/ / ,8 CS600 #32# /7200 LK600/ / ,2 FSK 70/27, ,8 9

10 Designation of composite tension and suspension type insulators are according to IEC 61109, EN Composite tension and suspension type of insulators are designated by letter CS followed by a number indicating the specified mechanical load (SML) in kilonewtons (kn). The letter B,S, T, C, Y or E or a combination thereof which follows specifies a ball, socket, tongue, clevis, Y-clevis or eye coupling. The following figures specify the size of the coupling. When a combination of couplings is used, the first letter shall always express the coupling of the upper end of the insulator. The following two numbers separated by a solidus indicate the standard lightning impulse withstand voltage and the minimum creepage distance. Insulator having normal profile NOTE: Letter "#" accordance any letter B,S,T,Y,E according to IEC Example: CS70 E16B16 230/900 - composite silicon insulator 70kN, upper end fitting Eye (letter E)- 16, down Ball (letter B)-16, lighting impulse 230kV, creepage distance

11 ISOSIL OCK TYPE - STATION POST COMPOSITE INSULATORS FOR SUBSTATIONS The connecting sizes and building height fully comply with porcelain insulator types to be replaced. The price of composite insulator is lower than the price porcelain due to small densities of polymers and smaller quantity of raw material. International type Porcelain analogue type Minimum failing bending loading, kn Core diameter, Spacing, Creepage distance, Rated voltage, kv Impulse voltage, kv ISOSIL OCK-4-35 C ISOSIL OCK C ISOSIL OCK C ISOSIL OCK A C ISOSIL OCK B C ISOSIL OCK C C ISOSIL OCK A C ISOSIL OCK A C ISOSIL OCK B C ISOSIL OCK A C ISOSIL OCK A C ISOSIL OCK B C MONOLITHICALLY CASTED ALUMINIUM FLANGE Only monolithic flanges casted from high strength aluminium alloy or cast iron are used. Unlike welded armature, the monolithic flanges eliminate breakage at extreme temperatures, where welded seams undergo high tensions caused by the welding process usually leading to the flange breakage along the weld seam. The flange construction has additional sheds enhancing the stiffness; sheds are designed by a special hard body modelling technique. In the case of cast iron, the flanges are hot-dip galvanized or coated with Zink by the method of thermal diffusion at 85 mkm iersion. The surface layers of steel are saturated with Zink. This ensures the corrosion protection for a period over 30 years. The monolithic properties of 11

12 l OFFICIAL SALES REPRESENTATIVE: VILRIDA LTD the thermal diffusion coating prevent surface layers from chipping off during the compression of end fittings on to the core rod, and provides 3 times better protection than Zink coating by galvanization and 1.5 times better protection than iersion Zink solution. Insulators with the aluminium flanges are lighter in weight and are handier for mounting. The necessity to use only monolithic flanges is suggested by the experience of design, production and exploitation in overhead lines, especially at the extreme weather conditions at the Far North and South deserted / tropical conditions. А d2 4 holes Draw. 1 А Б D D1 А d Draw. 2 the rest in Draw. 1 Б d1 l1 L1 Н L l1 L1 Dp А Draw. 3 the rest in Draw. 1 Б Б d3 4 holes 12

13 TYPE ISOSIL OLK - LINE POST COMPOSITE INSULATORS International type Porcelain analogue type Minimum failing bending loading,kn Core diameter, Spacing, Creepage distance, Rated voltage, kv Impulse voltage, kv ISOSIL OLK VHD ISOSIL OLK VHD ISOSIL OLK-4-35-A ISOSIL OLK-4-35-B ISOSIL OLK-4-35-C O-post; L-linear; K- material of protective environment, silicone rubber; Value of the mechanical failing load at bending, kn (12.5kN); and after a dash a class of a voltage, kv; And, etc. - an index of updating of insulator, types end fittings. 13

14 ISOSIL SHPU TYPE - LINE POST PIN COMPOSITE INSULATORS International Trade Mark Silicone Insulator Mark porcelain analog Minimum failing bending loading,kn Core diameter, Height, Creep age distan ce, Rated voltage, kv Impulse voltage, kv ISOSIL SHPU-10 VHD , ISOSIL SHPU-20 VHD , ISOSIL SHPU-35 VHD ,

15 TYPE SHOP - BUS BAR POST INSULATORS Parameter Nominal voltage, кv SHOP-35 SHOP- 110 SHOP- 150 SHOP- 220 SHOP -330 SHOP Maximum working voltage, кv Testing voltage of full lighting impulse, кv 40, Maximum value of nominal shortterm withstand current ( electrodynamic resistance),ка 31, ,5 40 Permissible conductor tension in horisontal position for conductor fixing, N Creepage distance of outer insulation, not less than, см H Ø18 Б 8 отв. Ø340 Ø300 Б 15

16 TYPE ONSHP STATION POST PIN COMPOSITE INSULATOR Parameter Nominal voltage, кv ONSHP ONSHP ONSHP ONSHP Maximum working voltage, кv ,5 40,5 Testing voltage of full lightning impulse, not less, kv Failing load,кn Creepage distance, Outdated types to be replaced ONSH УХЛ1, OSHN ONSH УХЛ1, OSHN ONSH-35-20, OSHN ONSH-35-20, OSHN

17 TYPE IPPU BUSHING COMPOSITE INSULATOR М Paramater IPPU-10/ А4 IPPU-20/ ,5-А4 IPPU-20/ ,5-А4 IPPU-35/400-7,5-А4 IPPU-35/630-7,5-А4 IPPU-35/630-7,5-А4 IPPU-35/1000-7,5-А4 IPPU-35/1600-7,5-А4 Nominal voltage, кv Maximum working voltage,кv ,5 40,5 40,5 40,5 40,5 Testing voltage of full lightning impulse, not less than, кv Maximum peak of short term withstand current,ка ,0 16,0 16,0 16,0 16,0 Failing load, кn 30 12,5 12,5 7,5 7,5 7,5 7,5 7,5 Creepage distance,

18 COMPOSITE INSULATORS FOR RAILWAY CONTACT NETWORK TYPE FSPK Paramater 25/1,1-3/0,6 25/0,95 25/1.1 FSPK-70- FSPK- FSPK-- FSPK-- FSPK-- 25/1.5 Nominal voltage, kv 3,0 Testing voltage of full lightning impulse, not less than, kv Testing voltage of industrial frequency, kv Failing load, kn Creepage distance,

19 TYPE NSPK Paramater NSPK-70- NSPK-- NSPK-- NSPK-- 3/0,6 3/0,6 25/1,1 25/1,5 Nominal voltage, kv 3,0 3,0 Testing voltage of full lightning impulse, not less than, kv Testing voltage of industrial frequency, kv Failing load, kn 70 Creepage distance,

20 TYPE PSPK Paramater PSPK-70-3/0,6 PSPK-70-25/0,95 PSPK-70-25/1.1 PSPK-70-25/1.5 PSPK--3/0.6 PSPK--25/0.95 PSPK--25/1.1 PSPK--25/1.5 Nominal voltage, kv 3,0 3,0 Testing voltage of full lightning impulse, not less than, kv Testing voltage of industrial frequency, kv Failing load, kn Creepage distance,