Herramiantas para Evaluar Conductores

Effective December 6, 2006, this report has been made publicly available in
accordance with Section 734.3(b)(3) and published in accordance with Section

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control restrictions and any proprietary licensed material notices embedded in
the document prior to publication.
Long Rod/Suspension Polymer

Insulator Vintage Guide
1012328
Long Rod/Suspension Polymer

Insulator Vintage Guide
1012328
Technical Update, November 2006
EPRI Project Manager

A. Phillips
ELECTRIC POWER RESEARCH INSTITUTE

3420 Hillview Avenue, Palo Alto, California 94304-1338 PO Box 10412, Palo Alto, California 94303-0813 USA
800.313.3774 650.855.2121 askepri@epri.com www.epri.com
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Copyright 2006 Electric Power Research Institute, Inc. All rights reserved.
CITATIONS
This report was prepared by
Electric Power Research Institute (EPRI)
1300 W.T. Harris Blvd.
Charlotte, NC 282622
Principal Investigators
T. Shaw
A. Phillips
This report describes research sponsored by EPRI.
This publication is a corporate document that should be cited in the literature in the following
manner:
Long Rod/Suspension Polymer Insulator Vintage Guide. EPRI, Palo Alto, CA: 2006. 1012328.
iii
ABSTRACT
For over 30 years polymer long rod / suspension insulators have been available and used on
transmission lines. Polymer insulators, also called composite insulators or non-ceramic
insulators (NCI), primary functions are to provide mechanical strength to attach the conductors
to the structures and and to provide electrical insulation between the conductors and the
structure. Initially the use of polymer insulators was limited as utilities had limited experience,
but today the use is more widespread. Consequently more, and different, manufacturers have
entered the market.
With time, manufacturers have made design and manufacturing process changes to their polymer
insulators. These changes have often been related to performance issues or concerns. One of the
challenges that utilities face is determining whether in-service units have any of these design
related performance issues and what action to take. In order to address this issue EPRI has been
tracking design and manufacturing changes of each manufacturer and has compiled the
information into this guide.
This guide describes the make-up and manufacturing processes for each manufacturer and a
timeline of how they have changed. This information will allow utilities to identify the makeup
of the polymer insulators that they have in-service aiding in the identification / evaluation of the
risk that they may pose. The guide also allows utilities to understand the designs of the units that
they are currently purchasing.
This guide will be coordinated with EPRIs Polymer Insulator Failure Database allowing better
queries to be developed and improved failure rate predictions to be made. To date, EPRI has
recorded more than 230 polymer insulator failures in the database.
This guide is envisioned to be a living guide. As new manufacturers come to market and and
design changes occur, EPRI will document the information in future revisions of this guide.
ACKNOWLEDGMENTS
EPRI would like to thank the following people for helping in the creation of this guide.
Bob Gemignani LAPP Insulators, LLC
Eric Smith - LAPP Insulators, LLC
Allen Bernstorf Hubbel Power Systems
Jean-Marie George Sediver S.A.
Bob Hill MacLean Power Systems
Jeff Burnham - NGK-Locke Polymer Insulators, Inc.
Terry Nakachi - NGK-Locke Polymer Insulators, Inc.
vii
TABLE OF CONTENTS
1 Acronyms ................................................................................................................................1-1
2 Introduction .............................................................................................................................2-1
3 LAPP Polypace Insulators ......................................................................................................3-1
Polypace 1 .............................................................................................................................3-2
Polypace 2 .............................................................................................................................3-3
4 LAPP Insulators, LLC..............................................................................................................4-1
Rodurflex................................................................................................................................4-5
Rodurflex................................................................................................................................4-6
Rodurflex................................................................................................................................4-7
5 Hubbell Power System, Inc. - Ohio Brass...............................................................................5-1
Hi*Lite ....................................................................................................................................5-6
Hi*Lite II .................................................................................................................................5-7
Hi*Lite XL ...............................................................................................................................5-8
6 Sediver....................................................................................................................................6-1
Armourlite / Armoursil.............................................................................................................6-4
7 MacLean Power Systems (MPS) Reliable ...........................................................................7-1
Reliable 1 ...............................................................................................................................7-7
Reliable 2 ...............................................................................................................................7-8
Reliable 3 ...............................................................................................................................7-9
Reliable 4 .............................................................................................................................7-10
8 NGK-Locke Polymer Insulators, Inc........................................................................................8-1
SN Design ..............................................................................................................................8-4
SS Design ..............................................................................................................................8-5
SC Design ..............................................................................................................................8-6
SL Design ..............................................................................................................................8-7
9 K-Line Insulators Limited ........................................................................................................9-1
K-Line.....................................................................................................................................9-3
10 Argillon ................................................................................................................................10-1
Argillon .................................................................................................................................10-3
11 Furukawa ............................................................................................................................11-1
Furukawa .............................................................................................................................11-1
ix
1
ACRONYMS
ANSI American National Standards Institute
ECR E-glass, Corrosion Resistant
EPDM - Ethylene Propylene Diene Monomer
EPM Ethylene Propylene Monomer
FRP Fiber Reinforced Plastic
HTV High Temperature Vulcanized
IEC International Electrotechnical Commission
ID Inner Diameter
OD Outer Diameter
RIV Radio Influence Voltage
RTV Room Temperature Vulcanized
SIR SIlicone Rubber
SDD Stress Distribution Disc
SML Specified Mechanical Load
SPC Statistical Process Control
UTS Ultimate Tensile Strength
1-1
2
INTRODUCTION
For over 30 years polymer long rod / suspension insulators have been available and used on transmission lines.
Polymer insulators, also called composite insulators or non-ceramic insulators (NCI), primary functions are to
provide mechanical strength to attach the conductors to the structures and and to provide electrical insulation
between the conductors and the structure. Initially the use of polymer insulators was limited as utilities had
limited experience, but today the use is more widespread. Consequently more, and different, manufacturers
have entered the market.
With time, manufacturers have made design and manufacturing process changes to their polymer insulators.
These changes have often been related to performance issues or concerns. One of the challenges that utilities
face is determining whether in-service units have any of these design related performance issues and what
action to take. In order to address this issue EPRI has been tracking design and manufacturing changes of each
manufacturer and has compiled the information into this guide.
This guide describes the make-up and manufacturing processes for each manufacturer and a timeline of how
they have changed. This information will allow utilities to identify the makeup of the polymer insulators that
they have in-service aiding in the identification / evaluation of the risk that they may pose. The guide also
allows utilities to understand the designs of the units that they are currently purchasing.
This guide will be coordinated with EPRIs Polymer Insulator Failure Database allowing better queries to be
developed and improved failure rate predictions to be made. To date, EPRI has recorded more than 230
polymer insulator failures in the database.
This guide is envisioned to be a living guide. As new manufacturers come to market and design changes occur,
EPRI will document the information in future revisions of this guide. Some information may be missing from
the Guide as information from certain vintages may have been lost over time.
2-1
3
LAPP POLYPACE INSULATORS
Long rod suspension units
Rod
Year Start
Year Stop
1994
Resin Standard
Epoxy
1994
Description
Iron
Year Start
?
Cast iron
Description
EPDM
Year Start
?
Year Stop
1994
Shed Profile
Evenly spaced
uniform smooth
sheds
1994
End Fitting
Seal
No seal
1994
Fiber
Resin
Description
E-glass
Standard
Additional Notes
End Fitting
Material
Manufacturing
Process
Year Stop
Additional Notes
1994
Cast iron, wedge type fittings
1994
Housing
Rubber
Additional Notes
E-field Grading
Description
N/A
End fitting
design
Corona ball
Year Start
?
?
Year Stop
1994
1994
3-1
Additional Notes
End fitting / rubber interface enclosed
with a semi-conductive material
protected by rubber.
Polypace 1
Description: uniform bell shaped sheds, epoxy wedge end fitting
Years of Production: Up to 1994
Live End
Ground End
Live End Dissection
Ground End Dissection
3-2
Polypace 2
Description: uniform bell shaped sheds, epoxy wedge end fitting with corona ball
Years of Production: 1994
Live End
Semi-conductive material
Ground End
Live End Dissection
3-3
4
LAPP INSULATORS, LLC
Rod
Fiber
Resin
Manufacturing
Process
Description
E-glass
Standard
ECR-glass
(Boron-free)
Resin Standard
Epoxy
Hydrolysis
Resistant Epoxy
Vertical
Pultrusion
Year Start
Year Stop
1965
1983
1983
Present
1965
1974
1974
Present
1983
Present
Additional Notes
Lapp is using a low seed content special
ECR glass fiber roving
Vertical pultrusion for suspension.

Horizontal for line post.
End Fitting
Material
Manufacturing
Process
Description
Iron
Year Start
1965
Year Stop
Additional Notes
1985
Cast iron, wedge type fittings
Forged steel, crimp type fittings, cast
Present iron for some applications with
SML<160kN (36 lbs)
Steel
1985
Cast iron
Forged (cast
iron)
1965
1985
1985
Present
Description
Cast
Machine Bore
Year Start
1965
1985
Cast socket fittings used for

SML<160kN (36 lbs)
Crimping
Bore
Preparation
Year Stop
Additional Notes
1985
Epoxy wedge type fittings
Present Crimp type fittings
4-1
N/A
Calibration
Force
Distribution
1965
1985
Force controlled
1985
Present
N/A
Linear
1965
1985
1985
Present
F(s) controlled, integrated statistical

process control, data record of each
crimping
F(s) is the force applied as a function of
the die travel distance.
Housing
Rubber
Molding
Process
Description
Year Start
Silicone Rubber
1965
(RTV)
Silicone Rubber
1979
(HTV)
RTV silicone
rubber / Casting
Extruded HTV
silicone rubber
Year Stop
1979
Present
1965
1979
1979
Present
1965
1979
1979
Present
Generation I
1965
1974
Generation II
1974
1982
Generation III
1982
Present
Cast silicone
rubber RTV to
rod
Application to Sheath extruded
the Rod
to rod then
sheds attached
with cross
linking paste
Additional Notes
Rod and Fitting

Primers/Gel
4-2
Assembly and vulcanization of premanufactured injection molded sheds
No sealing, no primers
RTV sealing, RTV condensation
crosslink based primers
Methoxysiloxane primers with cross
linking groups for silicone rubber sleeve
and sheds. All rubber to rubber and
rubber to FRP rod interfaces are
chemically bonded.
Evenly spaced
uniform smooth
sheds
Evenly spaced
alternating
Shed Profile smooth sheds
Ribbed
underside sheds
Flat (extreme
aerodynamic,
desert) sheds
Minimum
Sheath
Thickness
End Fitting
Seal
1979
Present
1981
Present
1993
Present
Alternating and uniform
2006
Present
Alternating and uniform
0.5mm
1965
1979
3mm
1979
Present
No seal
RTV seal
1965
1974
1974
1982
Metastable
sealant
1982
Present
No sealing on Generation I design

RTV on Generation II design
Gap between rod and metal end fitting
filled with Metastable sealant for
Generation III design
E-field Grading
End fitting
design
Description
Enlarged end
fitting
161 kV
230 kV
345 kV
500 kV
765 kV
Year Stop
1985
2006
2006
modification
System Voltage
161 kV
230 kV
345 kV
Year Start
2006
Present
Additional Notes
Modified to for use at 161kV without
corona ring, to control RIV, and avoid
water accumulation.
Corona ring design

Ground End
1972 to 1976
6.4 ring
None
7.8 ring
None
13.8 ring
None
1976 to 2004
6.4 ring
None
7.8 ring
None
13.8 ring
None
17.7 ring
7.8 ring
Special cases
Line End
4-3
Additional Notes
2004 to Present
161 kV
None
None
230 kV
345 kV
500 kV
765 kV
7.8 ring
13.8 ring
17.7 ring
Grading accomplished with

modification of the end fitting.
None
None
7.8 ring
Special cases
Manufactured Designs
Description
Rodurflex Generation I
Rodurflex Generation II
Rodurflex Generation III
Year Start
1965
1979
1982
Year Stop
1979
1982
Present
Additional Notes
Catalog Number
1975 - 1995
Example: 75K1234
K
75
Year the design was
created
CS2
SML (lbs)
CS2: 25k
CS3: 30k
CS5: 50k
CS7: 100k
041
Section length
(inches)
Komposite, German word for

polymer product line
1234
Sequential number reset at the
beginning of each year
1995 Present
Example: CS2-041-YB-074-A
YB
074
Tower / line end
Creepage Distance
fitting
(inches)
Y: Y-clevis
S: Socket
E: Oval Eye
C: Clevis
T: Tongue
B: Ball
4-4
A
Corona ring
A: None
B: Line end
only
C: Both ends
Rodurflex
Description: uniform shed diameters with ribbed undersides ( also available with smooth
undersides)
Years of Production: 1993 2006
Live End ribbed sheds shown
Ground End ribbed sheds shown
Live End Dissection
4-5
Rodurflex
Description: alternating sheds diameters with ribbed undersides ( also available with smooth
undersides)
Years of Production: 1993 - 2006
Live End
Ground End
Live End Dissection
4-6
Rodurflex
Description: uniform sheds diameters with ribbed undersides (also available with smooth
undersides and alternating shed diameters)
Years of Production: 2006 - Present
Live End
Ground End
Live End Dissection
4-7
5
HUBBELL POWER SYSTEM, INC. - OHIO BRASS
Rod
Description
Year Start
Year Stop
Additional Notes
Typically multi-end drawn.
Currently used if ECR glass is
E-glass
1977
Present
unavailable.
Fiber
Typically direct drawn.
ECR glass
1991
Present
Currently used 99% of time.
Note: There are no markings to indicate which type of glass was used.
Multi-end drawn fibers: Spools are made of multiple fibers. The groups of fibers from each spool
collected to assemble the rod.
Direct drawn fibers: Spools are made of single fibers. Individual fibers from each spool are
collected to assemble the rod.
Resin
Epoxy
Vinyl ester
1977
1986
Present
Present
Manufacturing
Process
Molded
Pultrusion
1977
1986
1986
Present
End Fitting
Material
Description
Steel or ductile
iron
Manufacturing
Forged or cast
Process
Year Start
Year Stop
1977
Present
1977
Present
Additional Notes
Crimping
Bore
Preparation
Description
Year Start
Year Stop
Machine Bore
1977
Present
5-1
Additional Notes
Pressure control
crimping
1977
1990
Fitting OD is
machined to
size.
1991
Present
1977
1990
1991
Present
Calibration
Graded by the
shape of the
crimp dies.
Force
Distribution
Graded by
shape of the end
fitting
Pressure control crimping was used with

independently floating crimp shoes.
Each fitting type was tested for
appropriate pressure setting before
production runs were initiated.
Crimping is crush controlled. OD/ID
controlled with tight tolerances on
hardness to control yield characteristics.
Settings are made by UTS for each
fitting type crimped.
Housing
Rubber
Molding
Process
Description
Year Start
EPM
1977
EPM/SIR Alloy
1986
EPDM/SIR Alloy
1991
Injection
Molding
Injection
Molding
Year Stop
1986
1990
Present
1977
1990
1991
Present
Single sheds
1977
1990
Multiple shed
sections
1991
Present
Gel interface
1977
Present
Application to
the Rod
Rod and Fitting

Primers/Gel
5-2
Additional Notes
Single shed sections

Multiple shed sections
Slipped on core with grease interface.
Compression between individual shed
together with internal grease provides
seal.
Multiple shed sections slipped on core
with grease interface
Multiple shed sections clipped together
with a compression seal together with
an external clip.
Even shed
spacing.
Shed Profile
Minimum
Sheath
Thickness
End Fitting
Seal
1977
1990
Sheds have top hat shape
Multiple Shed
Section Design
Medium
Creepage
1991
Present
Sections are 6 inches (maximum) or

every 4 sheds. Some sheath sections
have a larger diameter and a slightly
larger shed spacing. For all intents and
purposes these are evenly spaced
Multiple Shed
Section Design
Long
Creepage
1996
Present
For long creepage distance

requirements, alternating sheds with
larger diameters are available.
5mm
1977
Present
Compression
1977
1990
Compression
seal with set
screw
1991
1998
Grease aids in end fitting seal

Compression seal between rubber and
end fitting.
Aluminum ring clips on rubber & held
onto metal end fitting by set screw
Compression
Set screw mounts in groove on end
seal with set
1998
Present
fitting to minimize handling damage.
screw
The torque on the set screw is specified by the manufacturer to 40-45 in-lb.
E-field Grading
Description
No grading
design into the
end fitting
End fitting
design
Year Start
Year Stop
1977
1986
Stress
distribution disc
1986
1990
Hi*Lite XL:
Aluminum ring
1991
Present
5-3
Additional Notes
Stress distribution disc (mushroom

shape) crimped in place on every
bottom end fitting. Plus external rings.
Aluminum ring with set screw provides
localized grading. Plus external rings.
Corona ring design

System Voltage
Line end
Ground end
The Hi*Lite catalog (catalog 79, published 1978) did not mention rings. Catalog 89
(published 1981) includes the following recommendations
230 kV and below
None
None
345 kV
12 ring
None
500 kV
12 ring
8 ring
735/765 kV
15 ring
8 ring
Catalog 99 (published 1987) listed the following
25k/50k
80k/160k
25k/50k
None
8/12 ring
None
None
8/12 ring
None
12 ring
12ring
None
12 ring
12ring
8 ring
15 ring
15 ring
8 ring
<230 kV
230 kV
345 kV
500 kV
765 kV
80k/160k
None
None
None
8/12 ring
15 ring
230 kV
345 kV
500 kV
Catalog 101 (published 1991) listed the following

8 ring
12 ring
15 ring
None
None
8 ring
230 kV
345 kV
500 kV
Catalog 26 (published 2000) detailed the following:

8 ring
12 ring
15 ring
None
None
8 ring
230 kV
345 kV
500 kV
Catalog 26 (published 2006) details the following

8 ring
12 ring
15 ring
None
None
8 ring
Description
Hi*Lite
Hi*Lite II
Hi*Lite XL
Year Start
1976
1986
1991
Year Stop
1986
1990
Present
Additional Notes
Manufacturing Locations
Location
Mansfield, OH
Aiken, SC
Year Start
1977
1984
Year Stop
1984
Present
5-4
Additional Notes
Catalog Number
Up to 1990
Example: 234 - 3001
234
Hubbell internal reference
51
Hi*Lite
XL
1
Strength
1: 25k
SML
5: 30k
SML
3: 50k
SML
0
Construction
0: Standard
hardware / 0
sheds added
1: Dull
hardware* / 0
sheds added
2: Standard
hardware / 2
sheds added
3: Dull
hardware* / 2
sheds added
3001
End fittings
3001 Eye / ball
3002 Eye / eye
3003 Ball / ball
3004 Eye / rotated eye
1990 - Present
Example: 511012-1201
12
Weathershed
configuration
Number of sheds equal
this number times four,
plus any added sheds
listed in the construction
digit.
1
Labeling
1: English
2: Metric
3: English
w/ SDD
4: Metric
w/ SDD
2
Ground
end
fittings
0: Chain
eye
1: ANSI
ball
2:
Y=clevis
3: ANSI
socket
4: ANSI
straight
clevis
01
Line end
fittings
00: Chain
eye
01: ANSI
ball
02: Yclevis
03: ANSI
socket
04: ANSI
straight
clevis
* Dull refers to hardware that does not easily reflect light
Serial Number
88
Year of manufacture
Up to 1990
Example: 881-012345
1
Manufacturing line
012345
Serial number
1990 to Present
Example: 98123 or 12398
98
Year of manufacture
123
Day of year
Or
123
98
Day of year
Year of manufacture
Housings are stamped with year and month. A circle with a two digit year within. The dots around
the circle indicate the month.
5-5
Hi*Lite
Description: Individual top hat shaped sheds compressed onto the rod. Sheds are not bonded to
the rod
Years in Production: 1976 1986
Live End
Ground End
Live End Dissection
5-6
Hi*Lite II
Description: Individual top hat shaped sheds compressed onto the rod. Sheds are not bonded to
the rod. A stress distribution disc was added to help with grading.
Live End
Ground End
Live End Dissection
5-7
Hi*Lite XL
Description: Multi-shed sections floating on the rod and held in place at the end fittings.
Live End
Ground End
Live End Dissection
Joint Section
Joint Section Dissection
5-8
6
SEDIVER
Rod
Type
E-Glass
Acid resistant
glass
Year Start
Mid 1970s
Year Stop
Present
1996
Present
Resin
Epoxy
Mid 1970s
Present
Manufacturing
Process
Outsourced
Pultrusion
Mid 1970s
1980
1980
Present
Fiber
Additional Notes
Both Types of glass are being offered
Hardener formulation changed in 2000
End Fitting
Material
Type
Year Start
Malleable Steel Mid 1970s
Ductile Iron
Mid 1970s
Manufacturing Forged (Steel)

Process
Cast (Iron)
Mid 1970s
Mid 1970s
Year Stop
Present
Present
Present
Present
6-1
Additional Notes
Crimping
Description
N/A
Machine Bore
Year Start
Mid 1970s
1984
Year Stop
1984
Present
Accelerometer
Acoustic
Detection
1987
1998
Calibration
1998
Present
Mid 70s
1985
Assembly technology of fittings with

cone
1985
1992
Crimping
Force
Distribution
Resin wedge
cone
Compression
with elongation
Compression
crimping
Linear with
compressive
radial
application
1991
Present
Crimping
1998
Present
Crimping
Bore
Preparation
Additional Notes
Housing
Rubber
Molding
Process
Type
Year Start
Year Stop
EPDM
Mid 70s
Present
SIR-HTV
1990
Present
1984
Present
1992
2000
Mid 70s
1984-86
One Shot
Molding or
multishot
1984
Present
EPDM
Silicone
Mid 70s
1990
Present
Present
High pressure
Injection
Molding
Dielectric
Spacers
Extruded sheath
with shed
assembly
Application to
the Rod
Rod and Fitting

Primers/Gel
6-2
Additional Notes
Minor evolutions on color in 1986 (black
to grey)
Evolution in 2000
In both cases, the primer is sprayed on

the insert (rod + fittings already crimped)
Shed Profile
Short Creepage
Medium
Creepage
Mid 70s
Present
Mid 70s
Present
Long Creepage
Mid 70s
Present
3mm
Mid 70s
Present
Assembly
technology with
rubber seal
being vulcanized
in autoclave
oven
Mid 70s
1984
First technology
Present
Direct Bonding between rubber and

metal end fitting
End fitting partially embedded in
housing
Minimum
Sheath
Thickness
End Fitting
Seal
Direct bond to
end fitting
1984
Evenly distributed sheds at constant

spacing
Alternating Sheds (different profiles from
long to short creepage requirements).
No under ribs.
E-field Grading
End fitting
design
Description
Enlarged collar
radius
System Voltage
200 345 kV
400 kV
500kV
765 kV
Year Start
Year Stop
1984
Present
Additional Notes
End fitting with enlarged collar radius
partially embedded under first shed
Corona ring design

Line end
Ground end
1980s 1990
11 ring
15 ring
15 ring
Additional Notes
Recommendation began
in 1970s
16 ring
1990 2000
200 345 kV
400 kV
500kV
765 kV
11 ring
15 ring
15 ring
16 ring
Attachment method
changed
2000 Present
200 345 kV
400 kV
500kV
765 kV
11 ring
15 ring
15 ring
16 ring
None
None
11 ring
16 ring
6-3
Shape changed
Description
Armourlite
Armoursil
Year Start
1985
1990
Year Stop
Present
Present
Additional Notes
Armourlite / Armoursil
Description: Short creepage distance. Weathershed molded onto the end fitting.
Years of Production: 1985 / 1990 Present
Live End
Ground End
Live End Dissection
6-4
Description: Medium creepage distance. Weathershed molded onto the end fitting.
Live End
Ground End
Live End Dissection
6-5
Description: Long creepage distance. Weathershed is molded onto the end fittings.
Live End
Ground End
Live End Dissection
6-6
7
MACLEAN POWER SYSTEMS (MPS) RELIABLE
Rod
Fiber
Resin
Manufacturing
Process
Type
E-glass and
ECR
E-glass
Year Start
Year Stop
1978
~1987
~1987
1999
Boron free
1999
Present
Epoxy
1978
Late 1980s
Vinyl Ester
Late 1980s
1997
Epoxy
1997
Present
Pultrusion
Pultrusion
1978
1997
1997
Present
Type
Ductile Iron
Steel
Year Start
1978
1994
Year Stop
~1994
Present
Cast
Forged
1978
1994
~1994
Present
Additional Notes
Some ECR imported from Rosenthal
during this period
Boron free glass is an attribute for of
corrosion resistant glass.
Some epoxy used during this period, but
primarily vinyl ester
Externally sourced
MPS manufactured
End Fitting
Material
Manufacturing
Process
7-1
Additional Notes
Crimping
Bore
Preparation
Description
N/A
Machine Bore /
Surface
Finished
See Additional
Notes
Calibration
Force
Distribution
Year Start
1978
Year Stop
1987
1987
Present
Additional Notes
Epoxy wedge design
Crimped end fitting designs started in
1987
Wedge style attachment method used

1987/1994 prior to introduction of crimping in
1987/1994.
1978
Design, process
and statistical 1987/1994
control
Present
Crimping of 16mm started in 1987, other

sizes started in 1994
Wedge style attachment method used

1987/1994 prior to introduction of crimping in
1987/1994
Crimping of 16mm started in 1987, other
Present
sizes started in 1994
See Additional
Notes
1978
Linear
1987/1994
Type
Year Start
Year Stop
SIR
1978
Present
Housing
Rubber
Molding
Process
See Application to Rod

Extruded and
high temp
vulcanized to
rod
1978
Present
Primer applied
Rod and Fitting
to rod prior to
Primers/Gel
extrusion
1978
Present
Application to
the Rod
Additional Notes
1978-1984: imported from Rosenthal
1984: domestic production
7-2
Sheath extruded and HTV vulcanized

onto Rod. Sheds then attached to
sheath with SIR cross-linking paste and
HTV vulcanized.
Shed Profile
Minimum
Sheath
Thickness
Short Creepage
Medium
Creepage
Long Creepage
Short Creepage
(Stacked Shed)
Medium
Creepage
(Stacked Shed)
Long Creepage
(Stacked Shed)
3mm
1.5mm
3mm
Clear gel-type
sealant
Gray RTV
sealant
End Fitting
Seal
1978
2002
1978
2002
1978
2002
2002
Present
2002
Present
2002
Present
1978
1987
1994
1987
1993
Present
1982
1992
1992
1997
Stacked sheds (closely spaced) at

energized and grounded ends. Other
sheds evenly spaced. Sheds available
in alternating diameters or same
diameter.
Compression seal made by controlled

pressure of rod into end fitting during
crimping process
Compression
Seal
Metal end fitting
machined for
smooth surface
Sheath cut at
angle
Internal and
External Sealant
Applied
Sheds available in alternating diameters

or same diameters. Shed design
evolutions in this timeframe
1997
Present
E-field Grading
End fitting
design
Description
Year Start
Cast ductile iron
1978
fittings
Forged steel
1994
fittings
Year Stop
1994
Present
7-3
Additional Notes
Rosenthal design
Enlarged rounded end fitting to control
local E-field.
System Voltage
200-230 kV
300-400 kV
500kV
765 kV
200-230 kV
300-400 kV
500kV
765 kV
200-230 kV
300-400 kV
500kV
765 kV
Corona ring design

Line end
Ground end
1978 1994
6 ring
None
11 ring
None
16 ring
6 ring
16 ring
11 ring
1994 2001
8 ring
None
12 ring
None
17 ring
8 ring
17 ring
12 ring
2001 Present
8 ring
None
12 ring
None
17 ring
8 ring
17 ring
12 ring
7-4
Additional Notes
2-piece closed ring
designs
Open design rings

single clamp
Open design ringsdouble clamp
Description
Reliable 1
Reliable 2
Reliable 3
Reliable 4
Year Start
1978
1987
1994
2002
Year Stop
1987
1994
2002
Present
Additional Notes
Manufacturing Locations of Suspension Insulators

Location
Franklin Park, IL
York, SC
Guangzhou, China
Year Start
1980
2002
2003
Year Stop
Present
Present
Present
Additional Notes
For domestic China market
Catalog Number
S
C:
compression
S: wedge style
1
1: 16
mm
2: 24
mm
3: 36
mm
Up to 1994
Example: S148072XYZ
4
8
072
End Fitting
Section Length
Type
(Inches)
4: Y-clevis
5: Tongue
6: Clevis
7: Socket
8: Ball
9: Eye
7-5
X
Rubber
color
Y
Leakage
Z
Special
Features
S1
Insulator Type
(SML)
1: 16 mm (25k
SML)
2: 24 mm (50k
SML)
4: 32 mm (80k
SML)
5: 18 mm (30k
SML)
6: 18 mm (36k
SML)
4
8
End Fitting
Type
4: Y-clevis
5: Tongue
6: Clevis
7: Socket
8: Ball
9: Eye
1994 Present
Example: S148072VAXY
072
V
Section Length
Leakage
(Inches)
Code
A
Corona Rings
Tower Line
A None
8
B None
12
C None
17
D
8
8
E
12
12
F
17
17
G
8
12
H
12
17
V
8
17
X None None
XY
MPS Internal
Use
Serial Number
94
Year of manufacture
Up to 1994
Example: 94A123
A
1
Month of
manufacture
(e.g. A:
January)
123
Manufacturing Run Number
2
Manufacturing Run Number
1994 Present
Example: 123298
2
Quarter year of
manufacture
7-6
98
Year of manufacture
Reliable 1
Description: Epoxy wedge end fitting with cup shape design. Long creepage distance shown.
Live End
Ground End
Live End Dissection
7-7
Reliable 2
Description: Crimped end fitting with cup shape design. Short creepage distance shown.
Years of Production: 1987-1994
Live End
Ground End
7-8
Reliable 3
Description: Crimped end fitting. Medium creepage distance shown.
Live End
Ground End
Live End Dissection
7-9
Reliable 4
Description: Stacked shed design. Long creepage distance shown.
Years of Production: 2002 Present
Live End
Ground End
Live End Dissection
7-10
8
NGK-LOCKE POLYMER INSULATORS, INC.
Note: Full scale manufacturing began in 1993. Some dates presented reflect when design changes were
finalized before 1993.
Rod
Fiber
Resin
Description
E-glass
Year Start
1990
Year Stop
Present
Boron free
2000
Present
Epoxy
1990
Present
1990
Present
2000
Present
Pultrusion Eglass
Manufacturing
Process
Pultrusion ECR
Additional Notes
Boron free glass is an attribute for of
corrosion resistant glass.
End Fitting
Material
Description
Steel or Iron
Manufacturing
Forged or cast
Process
Year Start
1980
Year Stop
Present
1980
Present
Additional Notes
Crimping
Description
Year Start
Year Stop
Bore
Preparation
Machine Bore
1980
Present
Calibration
Acoustic
Detection
1998
Present
Force
Distribution
Graded
Linear(Pressure
Controlled multistep crimping)
1980s
Present
8-1
Additional Notes
Housing
SIR
1990
Present
Silan added
1997
Present
Molding
Process
Compression
molding
1990
Present
Application to
the Rod
One Piece
Molding
1990
Present
1990
Present
Plane Sheds
1990
Present
Alternating
Sheds
1998
Present
Minimum
Sheath
Thickness
3mm
1990
Present
End Fitting
Seal
Built-in double
O-ring with
silicone sealant
1980
Present
Rubber
Rod and Fitting

Primer coating
Primers/Gel
Shed Profile
Silan was added to the filler compound

in SIR
Used for short and medium creepage

distance.
Used for medium, long, and extra long
creepage distance.
End fitting is compressed onto O-ring in

crimping process
E-field Grading
End fitting
design
Description
Additional
grading rings
System Voltage
161 kV
230 kV
345 kV
500 kV
765 kV
Year Start
Year Stop
1980
Present
Additional Notes
Grading provided by attached grading
rings and rounded edges on fitting.
Corona ring design

Ground End
1998 to 2004
4 ring
None
8 or 9.5 ring**
None
11 or 13 ring**
4 ring
15 ring
8, 9.5, or 11 ring**
N/A
N/A
Line End
8-2
Additional Notes
2004 to Present
161 kV
4 ring
None
230 kV
8 or 9.5 ring**
None
345 kV
11 or 13 ring**
4 ring
500 kV
15 ring
8, 9.5, or 11 ring**
765 kV
16 ring
11 ring
** Ring size selection is based on shed diameter
Note: In 2005, the 8 corona ring was modified where the ring meets the rubber. The radius of the
edge was increased to improve the E-field performance.
Catalog Number
25
SML
(x1000lbs)
1
Core
Diameter
1: 16 mm
2: 22 or 24
mm
3: 32 mm
1993 Present
Example: 251-SS310-SJ-08
SS
31
0
Shed Shape
SC: Compact
SS / SN:
Standard
SL: Longer
leakage
SE: Extra
long leakage
Number of
sheds
Design
variation
SJ
08
End fittings,
tower / line
E: Oval eye
Y: Y-clevis
C: Clevis
T: Tongue
S: Socket
J : Ball (ANSI
J)
K: Ball (ANSI
K)
Grading Ring,
tower / line
0: None
4: 4 disc
8: 8 ring
9: 9.5 ring
1: 11 ring
5: 15 ring
Serial Number
1
Crimping machine
number
95
Year of
Manufacture
1993 Present
1-95-233-157
23
3
Physical
Date number (e.g. 1:
week
Mon)
8-3
157
Serial number of
day
SN Design
Description: Standard shed design: SN is for 80 kip designs only.
Live End
Ground End
Live End Dissection
8-4
SS Design
Description: Standard shed design: SS
Live End
Ground End
Live End Dissection
8-5
SC Design
Description: Compact design: SC
Live End
Ground End
Live End Dissection
8-6
SL Design
Description: Longer leakage design: SL
Live End
Ground End
Live End Dissection
8-7
9
K-LINE INSULATORS LIMITED
Rod
Description
E-glass
ECR
Year Start
1983
1983
Year Stop
Present
Present
Resin
Epoxy
1999
Present
Manufacturing
Process
Pultrusion
1983
Present
Fiber
Additional Notes
End Fitting
Description
Steel
Year Start
1983
Year Stop
Present
Forged
1983
Present
Year Start
Year Stop
Bore
Preparation
Description
Precision
Machine Bore
1983
Present
Calibration
N/A
Force
Distribution
Linear
1983
Present
Material
Manufacturing
Process
Additional Notes
Crimping
Housing
Rubber
SIR
1985
Present
Molding
Process
Injection
Molding
1983
Present
Application to One shot / Step

molding
the Rod
1983
9-1
Additional Notes
Rod and Fitting

Primers/Gel
Shed Profile
Medium
Creepage
Long Creepage
1986
Present
1992
Present
3mm
1983
Present
1983
Present
Minimum
Sheath
Thickness
End Fitting
Seal
Compression
seal
Compression seal between rubber and

metal end fitting
E-field Grading
End fitting
design
Description
Year Start
Year Stop
Pressed on ring
1986
Present
System Voltage
Line End
< 161 kV
161 230 kV
3.25 disc
8.25 ring
< 161 kV
161 230 kV
345 kV
3.25 disc
8.25 ring
8.25 ring
Additional Notes
Grading provided by attached grading
rings and rounded edges on fitting.
Corona ring design

Ground End
1985 - 2005
None
None
2005 to Present
None
None
Additional Notes
Factory assembled Al disc
Field assembled Al ring
Factory assembled Al disc
Field assembled Al ring
Field assembled
Catalog Number
KL
115
BS
28
Company ID
Voltage class
Leakage specification
End fitting type

BS: ANSI ball / socket
BY: ANSI ball / Y-clevis
BE: ANSI ball / oval eye
EE: Oval eye / oval eye
CT: Clevis / tongue
Number of sheds
9-2
K-Line
Description: Standard shed profile with small grading ring
Live End
Ground End
Live End Dissection
9-3
10
ARGILLON
Rod
Description
Boron Free
(70%)
Year Start
Year Stop
1997
Present
Resin
Epoxy (30%)
1997
Present
Manufacturing
Process
Pultrusion
1997
Present
Fiber
Additional Notes
Corrosive Resistant Advantex
End Fitting
Material
Manufacturing
Process
Description
Steel
Year Start
1997
Year Stop
Present
Forged
1997
Present
Additional Notes
Crimping
Description
Year Start
Year Stop
Bore
Preparation
Machined Bore
1997
Present
Calibration
Acoustic
Detection
1997
Present
Force
Distribution
Linear
1997
Present
10-1
Additional Notes
8 face crimping dye. High strength units

(>120 to 360 kN) two step crimping with
no overlap and 5mm groove between
the 2 crimp positions.
Housing
Rubber
Liquid SIR
1997
Present
Molding
Process
Injection
Molding
1997
Present
Application to
the Rod
One shot
molding
Multi-shot
molding
1997
Present
For voltages up to 245kV
1997
Present
For voltages greater than 245kV
Rod and Fitting

Primers/Gel
Proprietary
1997
Present
1997
Present
Shed Profile
Even spaced
sheds
Alternating
sheds
1997
Present
1997
Present
Minimum
Sheath
Thickness
> 3 mm
Direct bonding
End Fitting
Seal
Mechanical
protection
1997
Present
Present
1998
Direct bonding between rubber and

metal end fitting using a special primer
Mechanical protection of the triple point
(silicone metal air) using a pressed
on ring
E-field Grading
End fitting
design
Corona ring
design
Description
Year Start
Year Stop
Standard
1997
Present
Steel ring
1998
Present
Description
Year Start
Year Stop
Additional
grading ring
1998
Present
10-2
Additional Notes
Steel ring press fitted onto end fitting for
voltage levels up to 123 kV for higher
voltage levels additional grading rings
System Voltage
Level
161kV and
above
Additional Notes
Argillon
Description: Standard shed profile
Live End
Ground End
Live End Dissection
10-3
11
FURUKAWA
Furukawa
Description: Standard shed profile
Live End
Ground End
Live End Dissection
11-1
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Herramiantas para Evaluar Conductores

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Effective December 6, 2006, this report has been made publicly available in

accordance with Section 734.3(b)(3) and published in accordance with Section

Long Rod/Suspension Polymer

Long Rod/Suspension Polymer

EPRI Project Manager

ELECTRIC POWER RESEARCH INSTITUTE

DISCLAIMER OF WARRANTIES AND LIMITATION OF LIABILITIES

Live End Dissection

Ground End Dissection

Live End Dissection

Ground End Dissection

Vertical pultrusion for suspension.

Cast socket fittings used for

F(s) controlled, integrated statistical

Rod and Fitting

Assembly and vulcanization of premanufactured injection molded sheds

Alternating and uniform

Alternating and uniform

No sealing on Generation I design

Corona ring design

Grading accomplished with

Komposite, German word for

Live End ribbed sheds shown

Ground End ribbed sheds shown

Live End Dissection

Ground End Dissection

Live End Dissection

Ground End Dissection

Live End Dissection

Ground End Dissection

Pressure control crimping was used with

Rod and Fitting

Single shed sections

Sheds have top hat shape

Sections are 6 inches (maximum) or

For long creepage distance

Grease aids in end fitting seal

Stress distribution disc (mushroom

Corona ring design

Catalog 101 (published 1991) listed the following

Catalog 26 (published 2000) detailed the following:

Catalog 26 (published 2006) details the following

* Dull refers to hardware that does not easily reflect light

Live End Dissection

Ground End Dissection

Live End Dissection

Ground End Dissection

Live End Dissection

Ground End Dissection

Joint Section Dissection

Manufacturing Forged (Steel)

Assembly technology of fittings with

Rod and Fitting

In both cases, the primer is sprayed on

Direct Bonding between rubber and

Evenly distributed sheds at constant

Corona ring design

Live End Dissection

Ground End Dissection

Live End Dissection

Ground End Dissection

Live End Dissection

Ground End Dissection