Disc Suspension Insulators

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High Reliability

High reliability is achieved by long-term experience and accumulation of technology.

Selected High Quality Raw Material
High strength porcelain insulators require not only higher amount of alumina but also

  • Management of mining site
  • Sufficient technology of material analysis
  • Strict incoming inspection - Use only selected material
  • Fine and uniform distribution of particles

Optimum Design Engineering
Straight head design with less stress concentration
X-3s >= M&E rating with stable mechanical strength (X: average, s: standard deviation in M&E test*) Light weight and compact design

Advanced Manufacturing Technology

  • Automated mass production system
  • Uniform quality by continuous firing and production control
  • Control of porcelain thermal expansion
  • Forming without material damage
  • Accurate assembling without stress concentration

Strict Quality Control
In addition to ISO 9001 certified,

  • Routine hydraulic pressure test developed by NGK - Effective elimination of manufacturing defects
  • Total quality activities of preventive maintenance
  • Hydraulic Pressure Test

Excellent Long-Term Performance
Long-Term Performance Evaluation
Thermal-Mechanical (T&M) performance test as per IEC 60383-1 or ANSI C29.2 is to evaluate long-term reliability of insulators.
As these standards specify minimum requirements only, all NGK insulators have been confirmed to pass modified T&M test.

Acceptance Criteria for T&M Test
To exclude poor quality insulators, M&E test results before and after T&M test are:

  • No change in strength
  • No change in fracture pattern
  • No electrical puncture or no shatter
  • R-3s>Specified M&E failing load

Zinc Sleeve
Contaminated and wet insulators display a biased leakage current having DC component. This DC component causes electrolytic corrosion and reduction of pin diameter.

Pin Corrosion of suspension (disc) insulator

  • Resultant reduction of mechanical strength
  • Breakage of ceramic body due to expansion of pin

Ninija supplies well developed Zinc Sleeve to prevent pin corrosion.

  • Galvanically positive
  • Large potential difference from iron
  • Sacrificial electrode at cement boundary
  • Bonded area of sleeve: Min. 80% of sleeve/pin interfacial area to prevent corona discharges
  • Purity of zinc >- 99.8% to prevent granular corrosion

Test & Standard

NGK suspension (disc) insulators meet the requirements and tests of the following standards.

IEC Standard and Technical Report

60060-1 High-voltage test techniques, Part 1: General definitions and test requirements
60120 Dimensions of ball and socket coupling of string insulator units
60305 Characteristics of insulator units of the cap and pin type
60383-1 Insulator units - Definitions, test methods and acceptance criteria
60383-2 Insulator strings - Definitions, test methods and acceptance criteria
60437 Radio interference test on high-voltage insulators
60471 Dimensions of clevis and tongue coupling of string insulator units
60507 Artificial pollution tests on high-voltage insulators to be used on a.c. systems
60575 Thermal-mechanical performance test
60797 Residual strength of string insulator units
60815 Guide for the selection of insulators in respect of polluted conditions
61211 Puncture testing
61245 Artificial pollution tests on high-voltage insulators to be used on d.c. systems
61325 Insulator units for d.c. systems - Definitions, test methods and acceptance criteria

ANSI Standard

C29.1 Electrical power insulators - test methods
C29.2 Wet-process porcelain and toughened glass - suspension type

CAN/CSA Standard

C411.1 AC suspension insulators

EHV & UHV Service Experiences

Transmission lines with higher system-voltage carry greater power flow. They serve the role of trunk feeder in the delivery of power. Instability in EHV and UHV line operation may cause great negative impact on the entire power system.

Thus, insulators for EHV and UHV transmission lines require not only endurance against higher electrical and mechanical stress but must also ensure uniformly high quality to maintain the reliability of system operation.

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Insulators are essential to the safe and stable distribution of electricity generated at power plants. Suspension insulators support transmission lines on steel towers, isolating the lines from the tower. They play a key role in the safe supply of electricity.

Based on the transmission voltage and usage environment, suspension insulators are used in configurations of two or more.

Ninija supplies wide range of Suspension (Disc) Insulators have been field successfully tested by many electrical insulation company and in particular have a majority in EHV, UHV and HVDC transmission lines.

Available for any voltage and contamination level by changing number of insulators

  • Mechanical strength up to 530kN
  • High reliability through accumulated technology
  • Excellent long-term performance

High Reliability

High reliability is achieved by long-term experience and accumulation of technology.

Selected High Quality Raw Material
High strength porcelain insulators require not only higher amount of alumina but also

  • Management of mining site
  • Sufficient technology of material analysis
  • Strict incoming inspection – Use only selected material
  • Fine and uniform distribution of particles

Optimum Design Engineering
Straight head design with less stress concentration
X-3s >= M&E rating with stable mechanical strength (X: average, s: standard deviation in M&E test*) Light weight and compact design

Advanced Manufacturing Technology

  • Automated mass production system
  • Uniform quality by continuous firing and production control
  • Control of porcelain thermal expansion
  • Forming without material damage
  • Accurate assembling without stress concentration

Strict Quality Control
In addition to ISO 9001 certified,

  • Routine hydraulic pressure test developed by NGK – Effective elimination of manufacturing defects
  • Total quality activities of preventive maintenance
  • Hydraulic Pressure Test

Excellent Long-Term Performance
Long-Term Performance Evaluation
Thermal-Mechanical (T&M) performance test as per IEC 60383-1 or ANSI C29.2 is to evaluate long-term reliability of insulators.
As these standards specify minimum requirements only, all NGK insulators have been confirmed to pass modified T&M test.

Acceptance Criteria for T&M Test
To exclude poor quality insulators, M&E test results before and after T&M test are:

  • No change in strength
  • No change in fracture pattern
  • No electrical puncture or no shatter
  • R-3s>Specified M&E failing load

Zinc Sleeve
Contaminated and wet insulators display a biased leakage current having DC component. This DC component causes electrolytic corrosion and reduction of pin diameter.

Pin Corrosion of suspension (disc) insulator

  • Resultant reduction of mechanical strength
  • Breakage of ceramic body due to expansion of pin

Ninija supplies well developed Zinc Sleeve to prevent pin corrosion.

  • Galvanically positive
  • Large potential difference from iron
  • Sacrificial electrode at cement boundary
  • Bonded area of sleeve: Min. 80% of sleeve/pin interfacial area to prevent corona discharges
  • Purity of zinc >- 99.8% to prevent granular corrosion

Test & Standard

NGK suspension (disc) insulators meet the requirements and tests of the following standards.

IEC Standard and Technical Report

60060-1 High-voltage test techniques, Part 1: General definitions and test requirements
60120 Dimensions of ball and socket coupling of string insulator units
60305 Characteristics of insulator units of the cap and pin type
60383-1 Insulator units – Definitions, test methods and acceptance criteria
60383-2 Insulator strings – Definitions, test methods and acceptance criteria
60437 Radio interference test on high-voltage insulators
60471 Dimensions of clevis and tongue coupling of string insulator units
60507 Artificial pollution tests on high-voltage insulators to be used on a.c. systems
60575 Thermal-mechanical performance test
60797 Residual strength of string insulator units
60815 Guide for the selection of insulators in respect of polluted conditions
61211 Puncture testing
61245 Artificial pollution tests on high-voltage insulators to be used on d.c. systems
61325 Insulator units for d.c. systems – Definitions, test methods and acceptance criteria

ANSI Standard

C29.1 Electrical power insulators – test methods
C29.2 Wet-process porcelain and toughened glass – suspension type

CAN/CSA Standard

C411.1 AC suspension insulators

EHV & UHV Service Experiences

Transmission lines with higher system-voltage carry greater power flow. They serve the role of trunk feeder in the delivery of power. Instability in EHV and UHV line operation may cause great negative impact on the entire power system.

Thus, insulators for EHV and UHV transmission lines require not only endurance against higher electrical and mechanical stress but must also ensure uniformly high quality to maintain the reliability of system operation.

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