composite insulators 081208

Ceramic Business Unit

Bharat HeavyElectricals Limited

The Company

Ceramic Business Unit

Products

Bharat Heavy Electricals Limited is the largest Engineering

and Manufacturing Enterprise of its kind in India. It ranks

amongst the leading manufacturers of power plant

equipment in the world.

BHEL has 14 manufacturing plants, 4 power sector

regional centres, 8 service centres, 18 regional offices and

over 150 project sites spread all over India and abroad. It

offers a wide spectrum of products and services for core

sectors like Power Generation, Transmission,

Distribution, Industry, Transportation, Oil & Gas, Defence

and Non-Conventional Energy Systems.

The Ceramic Business Unit (CBU) of BHEL, is a Strategic

Business Unit for Ceramics and Systems. This business

unit deals with High Tension Insulators, Ceramic Wear

Resistant liners, Industrial Ceramic Products and

associated Systems. 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), Bangalore

• Insulator Plant (IP), Jagdishpur

Advanced Research and Development facilities

for Ceramic products, processes and

applications at

• Ceramic Technological Institute (CTI), Bangalore

( A Division of Corporate Research & Development,

Hyderabad)

• High Tension Insulators for Transmission and

Distribution lines from 11 kV to 800 kV

• Hollow Insulators for Instrument and Power

Trans formers , Swi tchgear, E lec t ro S ta t i c

Precipitators, etc.

Bharat Heavy Electricals Limited

• Station Post Insulators for Bus bars, 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, Steel, Coal Washeries, Cement, etc.

• Industrial Ceramic Products for various applications

BHEL pioneered the development of composite

insulators in India in the year 1998 through in-house

development efforts. Today its “State of the Art” facilities

manufacture Polymer insulators that compare with the

best 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.

BHEL – The Pioneer in

Insulators

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.

NTPC Ltd.

Tamilnadu State Electricity Board

Nuclear Power Corporation of India Ltd.

Gujarat Mining Development

Corporation Ltd.

AREVA T & D

Maharashtra State Transmission Company Ltd.

The Process

State of Art Microprocessor controlled Crimping machine

with Acoustic Crack detection ensures uniform crimping

without stress concentration

Crimping

The Silicone housing is injection moulded over FRP rod in a

fully automatic Microprocessor controlled Injection

Moulding Machine. The housing is bonded securely over the

entire length of the FRP rod

Injection Moulding

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.

The Materials

Fiber Glass Rod Metal Fittings Silicon Rubber

Modern state-of-art manufacturing facility for production of

Silicone composite insulators with complete manufacturing

and testing facilities.

The Manufacturing Shop

Construction Features

Acid Resistant Core rod (ECR Glass)

Forged steel Metal Fitting - Galvanised

Weather Sheds designs for pollutted conditions

Interface – Core to Housing- Thicknesss conforming to IEC

Interface- Silicone Overlapping Metal Fitting

Double sealing Silicone Housing

Manufacturing features unique to BHEL

• 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.

• 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, greasy matter and rust.

BHEL polymer insulators have successfully undergone

stringent design tests in conformance to IEC 61109

Annexure C1, at world renowned laboratories at

KEMA, Holland

Rheology Tensile testing Die Penetration Test

Quality & ReliabilityBHEL’s Composite insulators undergo rigorous design tests, type tests , routine tests and acceptance tests in conformance to IEC 61109 and IEC 62217.

BHEL has facilities to carry out all the required tests for incoming materials such as Silicone, FRP rods and metal end fittings. 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 , Water absorption, density, BD voltage tests on FRP rods

e) Tensile, microstructure, galvanisation tests on metal end fittings.

BHEL Polymer insulators undergo various routine tests

and acceptance tests in conformance to IEC standards as

well as Customer specific test requirements

1. Routine Electrical test

2. Mechanical Strength test

3. Thermal Mechanical Performance Test

Hydrophobicity test

BHEL insulators successfully undergone5000 Hrs Accelerated Aging Test at KEMA,Holland as per IEC 62217

• Superior Handling of Mechanical Shock Loads hence

convenient to handle, transport and erect.

• 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

o• Wide range of service Temperatures (from –50 C to o100 C)

• Interchangeability – can easily replace existing Porcelain

insulators

• Better Aesthetics

Advantages of Silicone based Composite Insulators

Silicone Composite Insulators Vs Porcelain Insulators

W e i g h t r a t i o

between Porcelain

I n s u l a t o r a n d

composite long rod

i n s u l a t o r s f o r

t r a n s m i s s i o n

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

wayWeight ratio Porcelain to Silicone Composite

insulator for Railway Traction applications is 3:1

1. Sketch is indicative only.2. Specific creepage distance from 16 mm / kV to 40 mm / kV3. Length ranges from 285 mm to 4080 mm4. Specified mechanical loads from

a. 45 KN to 120 KN for 33 KV to 132 KV. b. 70 KN to 160 KN for 220 KV. c. 120 KN to 160 KN for 400 KV.

5. For specific requirement, contact: CBU / Marketing, Malleshwaram, Bangalore....560012

TONGUE & CLEVIS TYPE BALL & SOCKET TYPE

TECHNICAL PARTICULARS OF COMPOSITE LONG ROD INSULATORS

Our Range of Composite Insulators LONG ROD

Shed Diameter (Big / Small)

Unit Spacing

Creepage Distance

Arcover Distance

Electro-Mechanical Min. 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

142 or 132/112

285

320

140

45

16

35

40

75

9

1.0

142 or 132/112

375

370

160

120

20

45

50

90

9

1.5

142 or 132/112

325

900

340

70/90

16

75

85

170

27

4.0

142 or 132/112

375

1110

360

120

20

85

95

170

27

4.5

11 kV 11 kV 33 kV 33 kV

1.

2.

3.

4.

5.

6.

7.

8.

9.

10.

11.

UnitParameter

1 Sketch is indicative only.2 BHEL Manufacture & supply

a Specific creepage distance from 16mm/kv to 40mm/kvb Height ranges from 285mm to4080mmc Specified mehanical load require from

120KN to 160KN for 400KV. 45KN to 120KN for 33KV to 132KV. 70KN to 160KN for 220KV.

3. For specific requirement, contact: CBU / MARKETING, Malleshwaram, Bangalore....560012



Shed Diameter (Big / Small)

Unit Spacing

Creepage Distance

Arcover Distance







Weight of Unit

mm

mm

mm

mm

kN

mm

kV

kV

kVP

kV

kg

142 or 132/112

770

2250

560

70/90

16

140

150

325

53

4.8

142 or 132/112

870

2250

560

120

20

140

150

325

53

5.5

66 kV 66 kV

1.

2.

3.

4.

5.

6.

7.

8.

9.

10.

11.

UnitParameter



Shed Diameter (Big/Small)

Unit Spacing

Creepage Distance

Arcover Distance







Weight of Unit (approx.)

mm

mm

mm

mm

kN

mm

kV

kV

kVP

kV

kg

142 or 132/112

1460

3870

1175

70/90

16

185

200

450

88

6.0

142 or 132/112

1460

3870

1175

120

20

185

200

450

88

6.8

142 or 132/112

1450

4300

1210

70/90

16

275

325

650

105

7.5

142 or 132/112

1460

4300

1210

120

20

290

335

650

105

8.0

110 kV 110 kV 132 kV 132 kV

1.

2.

3.

4.

5.

6.

7.

8.

9.

10.

11.

UnitParameter







Our Range of Composite InsulatorsLONG ROD


Shed diameter (Big/small)

Unit Spacing

Creepage Distance

Arcover Distance







Weight of unit (approx)

mm

mm

mm

mm

kN

mm

kV

kV

kVP

kV

Kg

142 or 132/112

2610

8000

2300

70/90

16

500

575

1080

154

11.5

142 or 132/112

2610

8000

2300

120

20

500

575

1080

154

12.2

142 or 132/112

3335

10500

3050

120

20

680

720

1550

305

18.5

142 or 132/112

3910

13020

3400

160

20

680

720

1550

305

21

220 kV 220 kV 400 kV 400 kV

1.

2.

3.

4.

5.

6.

7.

8.

9.

10.

11.

UnitParameter

Railway Traction for Standard and Polluted applications

TECHNICAL PARTICULARS OF COMPOSITE RAILWAY TRACTION INSULATORS

STAY ARM BRACKET 9-TONNE

Shed Diameter

Unit Spacing

Creepage Distance

Arcover Distance

Bending Strength


PF-WET Withstand Voltage (horizontally)

PF-WET Withstand Voltage (vertically)

DRY-Lightning Impulse Withstand Voltage positive

DRY-Lightning Impulse Withstand Voltage negative


Weight of Unit (approx.)

mm

mm

mm

mm

kgfm

kgf

kV

kV

kVP

kVP

kV

kg

185/145

489

1050

390

200

7000

125

100

240

260

35

4.4

185/145

555

1050

390

200

7000

125

100

240

260

35

5.0

185/145

540

1050

390

210

11000

125

100

240

260

35

5.4

Stayarm Insulator Bracket Insulator 9-tonne Insulator

1.

2.

3.

4.

5.

6.

7.

8.

9.

10.

11.

12.

Sketch is indicative only.

UnitParameter



(A Government of India undertaking)

Registered and Corporate OfficeBHEL House, Siri Fort, New Delhi - 110 049.Tel: 011-2600 1010 Fax: 011-2649 3021

www.bhel.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.

For enquiries please contact:

(A Government of India Undertaking)

Ceramic Business UnitProf. C.N.R. Rao Circle,Opp. Indian Institute of ScienceMalleswaram, Bangalore-560 012 (India)Ph: 080-23442988, 22182247 Fax: 080-23560741, 23344231

www.bhelceramics.com

composite insulators 081208

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