Insulation and Components

Hollow composite insulators 72-1,200 kV

Design for reliable performance
A century of innovation

ABB develops and manufactures power composites – high

performance insulating components made of fiber composite
materials for power and high voltage applications. Our mission
is to produce world-class, cost-efficient products for customers
all over the world.
ABB’s composite business is located in Piteå in the north
of Sweden. The company was founded by pioneers in the
Swedish polymer industry, and production of electrical
insulating material started in 1918. The present location was
established in 1967. The core expertise of the company
is knowledge of the electrical, mechanical and physical
properties of composite materials, and in the ability to
engineer unique insulation solutions for customers. The main
products are filament-wound products, breaker components
and hollow composite insulators.

2 A century of innovation | Insulation and Components Insulation and Components | A century of innovation 3
ABB Composite Insulator Technology
Developing various types of composite insulators for the most
demanding applications known today requires not only in-depth
material and design know-how, it also requires an absolute
understanding of the production process. ABB is knowledgeable
of the requirements for high voltage applications and the
essence of being a reliable business partner with the highest
quality standards.
ABB currently provides hollow composite insulators rang-
ing from 72 kV up to 1,200 kV AC and 1,100 kV DC, and in
lengths up to over 15 meters. ABB’s product range is wide
with more than 300 different composite insulators in
production. Each composite insulator design is tailor-made
to the customer’s requirements. By choosing ABB composite
insulators, excellent perfomance and reliability can be assured
for the lifetime of your equipment.
In-house production of one-piece fiberglass composite
tubes
The load-bearing insulator tubes are made of electrical grade
fiberglass, reinforced with epoxy resin using a wet filament
winding technique. Continuous fibers are impregnated in a
bath of epoxy resin and then wound at a controlled pre-stress
onto the mandrel. Precise and defined winding of the fiber
onto the mandrel ensures uniform laminates of the highest
quality.
4 ABB Composite Insulator Technology | Insulation and Components
The tubes are cured on continuously rotating mandrels in
ovens with a precisely controlled temperature profile to ensure
fully cured tubes with excellent quality. The whole process
ensures high grade insulator tubes with low manufacturing
tolerances and superb mechanical and dielectrical properties.
All ABB insulator tubes are made in-house and as one
continuous piece. The alternative would be to join tube
segments into a full length tube but the ABB design
philosophy is to avoid such possible weak spots. Until
relatively recently, the maximum length of one-piece
composite insulators available on the market was about 6 m.
This limitation has been set aside by ABB pushing it up to
over 15 m.
Today ABB manufactures the worlds largest on-piece
insulators.
One piece tailored glass fiber composite tube
Best mechanical and dielectrical performance
High-strength aluminum end fittings
Strong, gas-tight and leak-proof joint
Insulators of the conical/tapered type offer great advantages
in many applications. Cost-efficient design with less material,
lower weight and gas volume reduction for SF6-filled products
are just some of benefits of tapered insulators.
The composite insulators are designed according to the
mechanical requirements of our customers to manage both
bending forces and the inner pressures to which the insulators
are subjected during their service lives. An inner layer of poly-
ester liner is normally used. This is a requirement for insulators
used in gas-insulated circuit breaker applications to be able
to withstand the decomposition products of the insulation gas
SF6.
High temperature vulcanized (HTV) silicone
rubber with high amount of aluminum trihydrate
(ATH) filler
Improved tracking and erosion performance and
best long term performance
Seamless helical extrusion process for a
continuous outer silicone housing
No mold lines where dirt or salt can accumulate
Optimized shed profiles with large shed tip
radius and high protective creepage distance
Lowest possible leakage currents and electrical field
High strength flange design
The fiberglass tubes are fitted into high strength and high
resistant aluminum alloy casted flanges using a special
process, which results in a combined shrink fit and adhesive
bond. The result is an extremely strong, gas-tight and leak-
proof joint. Anodized flange solutions are available for extreme
environments and special applications.
Insulation and Components | ABB Composite Insulator Technology 5

High temperature vulcanized silicone rubber for best
long-term performance
ABB uses only high quality, high temperature vulcanized (HTV)
silicone rubber to ensure the highest possible durability of
sheds, as well as outstanding tracking and erosion resistance.
Using only hard-wearing HTV silicone rubber also ensures
superior performance in sandstorm areas and minimization
of damages during transportation and handling. The material
also exhibits stable behavior under extreme climate conditions
(-60°C to +110°C).
A high filler content of aluminum trihydrate (ATH) is used
to achieve superb tracking and erosion behavior. It is well
documented that HTV silicone rubber enriched with ATH filler
outperforms low viscosity silicone rubbers, such as liquid
silicone rubber (LSR), regarding long-term performance.
Extensive research and development (R&D) has been
invested in our material to find the optimum balance between
hydrophobic properties and tracking/erosion resistance. The
superior silicone material used by ABB involves an ATH level
of more than 45 percent in weight. The resulting material
fulfils tracking class 1A4.5 (as per IEC TR 62039) with a
hydrophobicity transfer recovery of less than 24 h. Pollution
performance is verified in both laboratory and field testing.
6 ABB Composite Insulator Technology | Insulation and Components
Seamless helical extrusion process for continuous outer
silicone housing
Our fiberglass tubes are equipped with HTV silicone rubber
weather sheds using a void-free helical extrusion process.
ABB has developed a unique patented method of extruding
the sheds with a helical pattern. This method ensures the best
possible interface between the silicone and the tube.
The silicone rubber sheds are chemically bonded to the tube,
thus allowing no moisture or contamination to enter. The result
is a seamless silicone coating with no molding lines. Even
the longest insulators (more than 15 m) are manufactured in
one step, resulting in continuous silicone housings without
molding lines (where dirt and salt can accumulate) or other
potential weak joints.
The flexibility of this method also ensures that any specific
customer dimensions (diameter, length or shape) can be met
with even the most stringent creepage distance requirements.
The cost of tooling is low compared to other methods, which
makes our process highly suitable for optimizing the design to
our customers’ needs in a cost-efficient way.
1 2
1. Large shed tip for minimized electrical field 2. Optimized shed profile with high protective creepage distance
Optimized shed profiles with large shed tip radius and
high protective creepage distance
Major development efforts have been carried out to achieve
our optimized shed profiles. ABB primarily offers shed profiles
using alternating long and short sheds, which ensure wet
performance and self-cleaning properties. Both the bottom
surface and top surface of the sheds are angled. This ensures
optimal creepage distance and protected areas, resulting in
the lowest possible leakage currents, even in severe
environments.
The upper inclination angle is ≥15°, which is more than the
minimum requirement in IEC 61805-3. A steep angle causes
water to roll off outside the underlying sheds instead of creat-
ing long pendant drops, which could trigger flashover.
≥ 15°
≥ 8°
R ≥ 2,5
The under inclination angle is ≥ 8° so as to obtain an optimum
balance between protected creepage distance, water roll-
off from the sheds’ undersides and natural cleaning. Sheds
with under inclination angles have high protected creepage
distances, which is very beneficial. In coastal and industrial
environments, the protected creepage distances prevent the
whole surface from being covered with liquid electrolytes.
Insulators with protected creepage distances also maintain
their initial surface hydrophobicity for a much longer time in
fog conditions.
The tip of each shed is well-rounded with a radius of ≥ 2.5
mm to minimize the electrical field and the risk of flashover.
Another feature of the ABB shed profile is the drip edge at the
shed tip. This feature ensures water roll-off and increases the
tear strength of the shed.
All of ABB’s standard shed profiles comply with IEC 60815-3.
Special shed profiles fulfilling requirements for UHVDC (800
kV DC and 1,100 kV DC) are also available.
Insulation and Components | ABB Composite Insulator Technology 7
Advantages of the technology
Silicone rubber is the fastest-growing, most dominant polymeric
insulation material for high voltage products. Composite
insulators with silicone rubber offer significant benefits as
compared to the former porcelain technology.
Composite insulators were first introduced more than 30
years ago, and the use of hollow composite insulators on
high voltage apparatuses is now well accepted. Composite
insulators are proven in the field and are direct replacements
for porcelain insulators used in high voltage applications.
Increased safety, light weight and superior pollution and
insulation performance are some of the reasons customer
choose composite insulators. The following benefits
are taken under consideration when OEMs and utilities
worldwide choose composite insulators for their high voltage
applications.
Explosion-proof for maximum safety
In the event of an internal fault/inner overpressure or external
influence/vandalism, a porcelain insulator will exhibit violent
failure (explosion) with dangerous fragments ejected at high
speed.
The failure mode of a composite insulator is delamination/
puncture without the launch of destructive fragments.
The insulator maintains load carrying capacity and will not
break down like a porcelain insulator. There is no damage
to surrounding equipment and no danger to people in the
vicinity. This ensures maximum safety for both personnel and
substation equipment.
Shatter test of live tank circuit breaker with porcelain insulator (high speed camera, 16 ms sequence)
8 Advantages of technology | Insulation and Components
Composite insulators offer outstanding safety in the event of:
−− Internal faults/inner overpressures in the equipment
−− External influences, eg, during transportation, installation
and maintenance
−− Environmental influences, eg, earthquakes, landslides,
tornadoes
−− Vandalism, eg, rock throwing, shooting
Non-brittle material with reduced risk of handling
damages
Since composite insulators are non-brittle and resistant to
shock, the risk of damage to the equipment during transport,
installation and service is reduced. If, however, minor shed
damage occurs, it can be easily repaired in the field. This is
not the case with porcelain insulators.
Leakage current control due to hydrophobicity
Composite insulators with silicone rubber sheds have the
added benefit of being hydrophobic, a term meaning “fears
water.” This characteristic helps break up water films and
creates separate droplets, which reduces leakage current
along the insulator surface, prevents flashover and elevates
the voltage withstand capability under wet and highly
contaminated conditions. The low leakage current also
minimizes discharge activity on the surface and erosion.
Hydrophobicity functions as a self-cleaning property that
extends service life and lowers substation maintenance costs.
The mechanism behind the hydrophobicity of silicone rubber
is the diffusion of low molecular weight (LMW) silicone from
Maintenance-free and outstanding pollution performance
HTV silicone rubber has the ability to transfer its water-
the bulk of the material to the surface. LMW silicone forms a repellent properties into the pollution layers that cover the
layer on the surface that is hydrophobic (non-wetting). surface. This eliminates the need for maintenance or cleaning
of the high voltage apparatuses in polluted environments.
This layer is extremely thin, only a few molecular layers, and
is distributed over the entire surface, thus forming a hydro-
Expensive solutions normally used for porcelain, such as
cleaning, greasing or coating, can be avoided.
phobic layer. The LMW silicones diffuse to the surface over
the entire life of the insulator; however, the loss of material UV stability
is negligible and does not impair other insulation properties. HTV silicone rubber is ultraviolet (UV) and ozone resistant.
Another benefit of silicone is its capability to encapsulate Natural UV radiation from the sun has wavelengths of over
contaminated particles. 300 nanometers. Shorter and more energetic wavelengths
are filtered out in the atmosphere. Silicone has its maximum
Leakage current over time at salt fog test absorption below this wavelength, which ensures superior
stability against UV radiation.
1 Porcelain
Leakage current, A
Silicone Absorption max of SiO2 bond
0,1
Solar radation, UV
0,01
0,001
0,2 0,4 0,6 0,8 1
Time, hours
Excellent insulation for reduced creepage requirements 290 300 400
Composite insulators have excellent insulation properties Wavelength, nm
and outstanding contamination performance due to the
silicone rubber. Published field studies show that it is possible Additional advantages
to reduce the required creepage distance by at least one Other advantages of composite insulators are short and
pollution level when composite insulators are chosen over reliable delivery times, best possible strength-to-weight ratio,
porcelain. the option of reducing gas volumes on SF6 breaker bushings
with conical insulators compared to cylindrical designs, proven
Flashover resistance aging resistance and high inherent fire resistance.
The efficient suppression of leakage currents means that the
risk of flashover is reduced compared to porcelain insulators.
Outstanding seismic performance provides safety and
reliability
The low weight and the shock-proof design of composite
insulators compared to porcelain offer advantages in terms
of earthquake resistance capability. No shock absorbers or
special designs are required in seismic areas.
Low weight for cost savings
Composite insulators are much lighter and provide higher
performance than porcelain insulators. This leads to a drastic
reduction in the use of the other materials that make up high
voltage electrical substations, such as foundation materials
and bearing structures. The installation phase is also easier
due to the reduced need for heavy installation equipment.
Insulation and Components | Advantages of technology 9
Evaluating a great concept

Subjecting the products to extensive testing well beyond the

requirements of applicable standards, such as in long-term field
tests and extreme voltage stress, has confirmed the outstanding
performance of ABB composite insulators in all types of high
voltage and ultra high voltage applications. More than 100,000
insulators are installed around the globe, representing all types
of environments.

ABB composite insulators are thoroughly tested Aging withstand, electrical and mechanical erosion resistance, Field tests Examples of long-term field tests
to international standards and higher. They have and UV stability have been fully verified. Natural pollution tests Numerous long-term field tests of ABB composite insulators Place Type Duration
demonstrated excellent performance under all climates are continually performed at test stations in both marine and have been performed. Dungeness, UK Costal, very heavy pollution 4 years
and harsh conditions, such as coastal, desert and desert climates. Guangzhou, CN 500 kV DC 1 year
industrial environments. Test installations around the world have been made to gain Ludvika, SE 800 kV DC 4 years
Testing is also performed at low ambient temperatures, information on long-term behavior and insulation performance Koeberg, ZA Extreme pollution 1 year
Service experience worldwide down to -60˚C. The composite insulators comply fully with in different environments. The test stations represent all
Since 1985, when the first ABB high voltage equipment with the requirements specified by the IEC. The insulators have possible climates – arctic, coastal, subtropical and desert
silicone rubber sheds were installed, ABB has delivered a undergone vandalism tests; a circuit breaker with composite areas – as well environments at high altitudes and with
vast number of high voltage apparatuses equipped with insulators has even been subjected to gunfire to show that extreme pollution and strong UV light.
composite insulators. They have been installed in all types of this kind of damage does not cause complete breakdown or
environments, from marine and desert regions to areas with explosion that could injure personnel or damage surrounding
heavy industrial pollution. equipment.

The performance of ABB composite insulators in installations Examples of performed tests

with extreme environmental conditions has been studied in High and low temperature -60°C and +110°C
detail, and the results have been published at a number of Dielectric
conferences and in well-known journals. The observations UV radiation
show excellent performance with insignificant changes in Accelerated aging
material properties.The HTV silicone material has proven its 5,000 hour multi-stress cycling
outstanding performance at test stations in severe climates 1,000 hour salt fog
and commercial installations all over the world. Mechanical strength
Overpressure
More than 100,000 ABB composite insulators are installed in Seismic
over 70 countries worldwide. The service history is excellent Shatter
with no reports of flashovers, premature ageing or other major Pressure cycling, -40°C and +100°C
faults.

Extensive testing beyond standards

ABB composite insulators have been subjected to extensive
testing to ensure high quality and to verify their mechanical
and electrical properties under all environmental conditions.

10 Evaluating a great concept | Insulation and Components Insulation and Components | Evaluating a great concept 11
Ultra high voltages and ultra high voltage direct current The development of 1,100 kV composite insulators addresses
Insulators are key components for transmission at several technology challenges, including sheer size and scale,
higher voltages. ABB is pioneering the development and electrical insulation and thermal performance parameters.
manufacturing of hollow core composite insulators for ultra The successful testing at 1,100 kV UHVDC verifies ABB
high voltage (UHV) and ultra high voltage direct current composite insulators’ excellent performance.
(UHVDC) applications. The field tests together with our
extensive deliveries for UHV and UHVDC applications is
a verification of the ABB composite insulators’ excellent
insulation properties, the durability of the design and long-
term performance.

The world`s first 800 kV DC transmission system, Xiangjiaba-

Shanghai, was put into commercial operation by ABB in 2010.
It has a capacity of 6,400 MW, and at just over 2,000 km, is
the longest power link of its kind in operation. ABB composite Design, type and routine tests This ensures the highest level of quality and long-term
insulator technology is used for all main high voltage equip- ABB composite insulators are designed, type and routine performance for the insulators. In addition, ABB has a
ment (transformer bushings, wall bushings, live tank circuit tested in accordance with IEC 61462 and other regional fully equipped laboratory for material analysis. Electrical,
breakers, instrument transformers as well as voltage dividers). standards. All requirements of IEC 62217 and IEC 60815 are mechanical and physical properties are measured and
fulfilled. documented on a routine basis to ensure all important
UHVDC at 1,100 kV is the next step. ABB has successfully material properties.
developed and tested the first 1,100 kV UHVDC converter ABB has invested in sophisticated equipment for routine
transformer with ABB composite insulator technology, testing, and our testing goes beyond the IEC requirements.
breaking the record for the highest DC voltage ever achieved. Routine testing includes cantilever bending tests, pressure
tests and quantitative gas tightness measurements.

12 Evaluating a great concept | Insulation and Components Insulation and Components | Evaluating a great concept 13
Application examples

1. Wall bushing 800 kV DC 2. Compact transmission line post insulator 275 kV 3. Wall bushing 1,100 kV DC 4. Live tank circuit breaker 550 kV 9. By pass switch 1,100 kV 10. UHVDC station post insulator and voltage divider 800 kV DC 11. Composite station post insulator 145 kV
5. Coupling Capacitor 1,100 kV DC 6. Surge arrester 420 kV 7. Outdoor instrument transformer 550 kV 8. Dead tank circuit breaker 145 kV 12. Cable termination 300 kV 13. Dead tank circuit breaker 800 kV 14. Transformer bushing 800 kV DC
1 2 9 10

3 4 5 11 12

6 7 13 14

14 Application examples | Insulation and Components Insulation and Components | Application examples 15
Design guide

Lmax
ABB offers a wide range of composites with more than 300 different insulator types in production. Together with
flexible production methods, ABB can deliver composite insulators that will meet and exceed your requirements.

This design guide makes it is easy to choose a composite insulator that meets your requirements. If none of our standard D1
designs match your needs, other designs can be easily developed on request.

The easiest way to design an insulator is as follows:

1) Specify the inner diameter and length of the tube from the diameter set table
Inner diameter
2) Choose a shed design and creepage factor 82 130 150 160 180 210 260 311 335 358 375 420 450 470 486 575
D1 [mm]
3) Choose flanges to match your installation preferences
Maximum length
2300 3200 3200 3200 4350 4300 10000 5000 4300 5000 4000 4300 3800 3800 9100 3800
Lmax [mm]
Fiberglass tubes
ABB can offer composite insulators with cylindrical, conical and combinations of cylindrical and conical sections. Lengths
over 15 m can be manufactured as a single tube without adhesive joints. All tubes are customized (wall thickness and winding
angles) to meet customers’ mechanical requirements (pressure and bending). Shed profiles
The required creepage distance for your apparatus will determine which shed profile is suitable for your design and that will
L max meet your requirements. ABB offers a wide range of standard shed profiles, see table below. Standard shed profiles from ABB
comply with IEC 60815-3. Other shed profiles can be arranged quickly and cost-efficiently on request. Extreme creepage
requirements (> 50 mm/kV) can also be arranged.

D1 D2

S [mm] P [mm] P 1 [mm] Cf, Creepage factor R S

R
L1 L3 50 32 - 2.25 8,5
L2
55 27 27 2.65 2,5
55 55 25 3.55 2,5
Inner diameter 1 Inner diameter 2 Length 1 Length 2 Length 3 Maximum length 55 60 30 3.87 2,5
D1 [mm] D 2 [mm] L 1 [mm] L 2 [mm] L 3 [mm] Lmax [mm] 55 60 40 4.21 2,5
P
200 100 300 898 100 1298 70 75 55 4.25 2,5
250 219 680 855 470 2005 60 70 50 4.49 2,5 P1
260 180 7330 3500 1340 12170 60 70 50 4.51 3
270 130 300 1100 500 1900 55 65 48 4.61 2,5
270 130 460 1100 450 2010 63 78 58 4.8 2,5
270 130 380 1270 160 1810 49 63 46 4.89 2,5
296 219 770 1595 700 3065 55 73 56 5.1 2,5
321 120 770 1970 190 2930
326 219 780 1965 700 3445 To estimate the creepage distance from the shed profiles’ creepage factor, the following equation can be used:
330 210 150 1310 680 2140
330 210 150 630 190 970 Cd = Cf × ( ad - 300 ) + 300
355 130 750 1776 420 2946
394 286 990 2300 990 4280 where:
400 260 2050 6000 2050 10100 Cd = Creepage distance*
402 205 580 1570 750 2900 a d = Arcing distance**
450 210 1450 700 2000 4150 C f = Creepage factor
486 385 1860 1615 2090 5565
486 124 1420 2940 350 4710
500 311 1400 1800 1100 4300
517 245 3170 2515 730 6415
550 400 2700 625 3250 6575
630 480 1950 1100 3200 6250 Explanatory text from IEC 61462

740 580 3550 1000 5650 10200 */ Creepage distance

Shortest distance or the sum of the shortest distances along the surface on an insulator between two conductive parts which normally have the operating voltage between them
983 725 5240 2448 3500 11188
**/ Arcing distance
983 725 3120 2448 6700 12268 Shortest distance in the air external to the insulator between the metallic parts which normally have the operating voltage between them

16 Design guide | Insulation and Components Insulation and Components | Design guide 17
Flanges Tube Fittings
The flange design is critical for the fit of the insulator on the apparatus to which it will be attached. ABB offers a wide range of D1 NH DBC DH DO
standard flange designs. If none of the standard flanges meets your requirements, other designs are available on request. [mm] [pcs] [mm] [mm] [mm]
225 M16 267
4
326 16 356
14 356
356
6 326 16
362
18 362
180
310
D BC D1 Do 275 18
319
280 15 310
8
300 18 344
325 18 365
330 18 365
4 182,5 M8 250
200 289 M12 375
8
DH × NH 361 15 393
160 M8 245
225 M16 273
Tube Fittings 286 15 ¤255
4
D1 NH DBC DH DO 296 M8 312
[mm] [pcs] [mm] [mm] [mm] 350 14 380
82 4/4 122 / 130 M8 / M10 160 360 14 390
100 6 213 M12 254 6 360 14 390
210
120 8 270 15 300 325 18 369
123 8 232 M12 260 8 326 M10 346
135 M8 165 356 18 400
171,5 M8 185 10 326 14 390
225 18 270 6/6 362 14 / 18 400
4
260 15 230 220 M10 278
16
15 ¤255 274 11 330
130 286
19 ¤255 219 6 308 M10 333
6 185 16 225 245 16 360 14 395
215 12 242 250 12 457 15 490
8
232 M12 260 406 14 315
4
12 155 M10 213 406 14 436
286 19 ¤255 6 406 14 436
4
318 18 363,5 M16 365
260 330
290 14 325 8 18 365
150 6
326 14 356 375 18 420
280 15 310 12 406 15 436
8
330 18 365 16 270 M10 327
4 160 M8 200 8 450 19 480
160 195 270 12 390 M12 420
12 180 M10
237 16 450 16 480
¤ = non-circular flange, square 286 6 389 M10 455
296 12 502 15 532
4 160 M8 365
310
24 327 M12 388
¤ = non-circular flange, square Continued on next page

18 Design guide | Insulation and Components Insulation and Components | Design guide 19
 Tube Fittings Material properties
D1 NH DBC DH DO Only the highest quality materials from well-known suppliers are used in products.
[mm] [pcs] [mm] [mm] [mm]
6 456 14 486 Material specifications, fiberglass tubes
360 M12 390 Composite tubes, filament-wound with fiberglass roving impregnated with epoxy resin. The inner surface is coated with non-
8
311 456 14 486 woven polyester. The table below shows typical properties for a tube with a 38° winding angle.
395 M12 430
16
520 22 600 Properties Unit Typical value Test method
320 8 500 19 536
326 12 527 15 560 Winding angle Degree 38
8 360 M12 390 Density g/cm 3 2 ISO 1183
335
16 450 16 480 Glass content % weight 75 ISO 1172
4 160 M8 415
358
24 380 M12 441 Interlaminar shear strength*, ILSS MPa EN 2377
4 425 M10 543 RT 40
375
16 570 14 614 110°C 28
385 16 555 M12 580 140°C 12
394 24 605 15 635
530 14 565 Flexural strength MPa 250 ISO 178
12
400 600 22 645 Flexural modulus GPa 16 ISO 178
16 550 14 587 Compressive strength, axial MPa 200 ISO 604
8 360 M12 466 Dielectric strength, tangential, oil. 90°C kV/mm min 3.6 IEC 60243
420 20 480 M12 523 Dielectric strength, axial oil. 90°C kV/mm min 3.6 IEC 60243
30 509 8 560 Partial discharge at 3.6 kV/mm pC <10 ABB 309-01
450 15 558 M10 573 Tracking index**, CTI >600 IEC 60112
480 20 610 18 645 Dielectric constant, RT 5.75 IEC 60250
16 700 18 740 Dissipation factor, RT 0.0047 IEC 60250
485
30 605 14 640
8 600 18 640 Volume resistivity ohm IEC 60093
500
12 675 18 715 3 000 V 2x1,014
517 24 656 18 697 5 000 V 3x1,014
550 16 680 18 720
581 24 710 18 745 Surface resistivity ohm IEC 60093
630 30 780 26 830 Outside 3 000 V 2x1,016
720 24 880 18 920 Outside 5 000 V 2x1,016
740 32 890 26 940
970 32 1130 26 1180 Surface resistivity ohm IEC 60093
Inside 3 000 V 8x1,016
Inside 5 000 V 8x1,016

Water absorption, RT mg 7.5 ISO R 62

Glass transition temp. °C min 130 ISO 11357-2
Temperature index °C 160 IEC 60216

*/ Interlaminar shear strength-tangential

**/ Criteria 50 % reduction of flexural strength after 20,000 h, plan laminate fiber directional

20 Design guide | Insulation and Components Insulation and Components | Design guide 21
 Customer request form

Please use this request form to specify your ABB composite insulator
Material specifications, high temperature vulcanized silicone rubber
Platina curing, solid high temperature vulcanized (HTV) silicone rubber based on polydimethylsiloxane (PDMS) with aluminum Company:
trihydrate (ATH) filler. Contact person: Phone no:
Type of apparatus:
Properties Unit Specific value Test method Annual quantity: Batch size:
Insulating medium:
Vulcanized rubber Service temperature range: to °C
Silicone (polydimethylsiloxane, PDMS) content > 33%
Aluminum trihydrate (ATH) filler content > 45% Mechanical requirements acc. IEC 61462
Tracking and erosion resistance 4.5 kV in class 1A IEC 60587 Max. mechanical load, MML: kN
Recovery of hydrophobicity WC 1-3 within 24 hours IEC TS 62073 Max. deflection at MML: mm
Color ANSI 70 5.0BG 7.0/0.4 Max. service pressure, MSP: MPa
Tensile strength, RT MPa min. 3.0 ASTM D412
Elongation at break, tensile % min. 170 ASTM D412 Electrical requirements
Hardness Shore A 65-75 ASTM D2204 Min. arcing distance: mm
Tear strength kN/m min. 15 ASTM D 624B Min. creepage distance: mm
Dielectric strength, 1 mm sheet, RT_I_ kV/mm 23 IEC 60243
L1 L2
Tracking resistance 1A4.5 IEC 60587
Dielectric constant 100 Hz, RT 3.7 IEC 60250
Dissipation factor 50 Hz, RT 0.017 IEC 60250
Volyme resistivity Ωcm 2.0x10 14 IEC 60093
D1
D2 D o DBC

Material specifications, aluminum alloys DH x NH

L
Alloy description Numeric short Material Tensile Yield Elongation Brinell
Material
(DIN EN 1706) symbol number strength strength at break hardness Dimensions
designation
Chemical symbol Numeric (DIN 1725-2) (DIN 1725-2) Rm (MPa) Rp 0.2 (MPa) A5 % HBS If it is possible, please give us dimension limits (max. and min.)
GK-AlSi7Mg EN AC-AlSi7Mg0.3 EN AC-42100-T6 G-AlSi7Mg 3.2371 290 210 4 90
GK-AlSi10Mg EN AC-AlSi10Mg(a) EN AC-43000-T6 G-AlSi10Mg 3.2581 260 220 1 90 Cylindrical Max. Min.
EN AC-AlSi10Mg(b) EN AC-43100-T6 260 220 1 90 Length of insulator, L: mm mm
Inner diameter, D1: mm mm

Conical Max. Min.

Length of insulator, L: mm mm
L1: mm mm
L 2: mm mm
Inner diameter 1, D 1: mm mm
Inner diameter 2, D 2: mm mm

Flange design
Top flange Bottom flange
Outer diameter, Do: mm mm
Hole dimension, D h: mm mm
Bolt circle diameter, DBC: mm mm
Number of holes, NH: pcs pcs

Additional information:

22 Design guide | Insulation and Components

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Note
1ZSP000001 revision B, 2013-06
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