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3FL Silicone Long Rod Insulators for Transmission Lines 69500 kVStrong performance reliable service

3FL silicone long rod insulators performance meets durability

Core

The core rod is a boron-free, corrosion-re-sistant ECR2 glass-fiber-reinforced plastic rod (FRP rod). Due to the extremely high hydrolysis and acid resistance of the FRP rod the risk of so-called brittle fracture is eliminated for 3FL insulators.

End fittings

The end fittings, made of hot-dip galva-nized forged steel or ductile cast iron, are directly attached to the FRP core rod by a circumferential crimping process. Each crimping process is stringently monitored with a special control system. A complete range of end fittings according to the lat-est IEC and ANSI standards is available with 25, 30, 36 and 50 klbs of SML3. The 3FL is 100% exchangeable and compatible with existing insulators and line hardware of all types.

The special design of the end fitting in the junction minimizes the electrical field strength and partial discharge inside the junction zone as well as on the silicone housing surface, by utilizing an integrated grading ring. This prevents corrosion of the insulating material and eliminates the risk of subsequent failure of the insulator.

3FL HTV silicone rubber housing for best pollution performances

The excellent pollution layer characteristics of the HTV silicone rubber ensure maxi-mum reliability of the 3FL insulator, even under extreme service conditions. The high hydrophobicity of silicone rubber pre-vents the formation of conductive film on its surface. Even the most severe ambient conditions, such as salt fog in coastal re-gions or dust-laden air in industrial areas, cannot impair the intrinsic hydrophobicity of the HTV silicone rubber. Surface cur-rents and discharges are ruled out. Neither water nor dirt on the housing surface can cause insulator flashovers a significant factor for insulator performance.

Siemens quality

According to long-established Siemens tra-dition and experience in producing high-voltage equipment for more than a century, each production step for the 3FL begin-ning with numerous incoming raw material inspections, through the assembly of the individual components, to routine tests of the finished product is rigorously moni-tored and controlled.

Good reasons to use 3FL

The new Siemens silicone long rod in-sulators (type 3FL) combine the highest levels of electrical insulation and mechani-cal tensile strength with a compact, light-weight design. Thanks to their superior de-sign and minimized weight, 3FL long rod insulators are especially suited for over-head compact-line applications where low tower design and short line spans are re-quired. They are also more economical to transport and install.

Design

The 3FL insulator has a one-piece HTV1 silicone rubber housing made by a high-pressure injection molding process. The HTV silicone is directly molded onto the core rod by overlapping the triple junction point and part of the metal end fittings. The design ensures a total enclosure of the most sensitive part of a silicone insulator the junction zone (metal end fitting/FRP rod/silicone housing), where the highest electrical field strength is usually concen-trated. This overlapping system eliminates any possibility of moisture ingress.

3FL long rod insulators can be used either as suspension or tension insulators 3FL a superior design to meet the highest requirements

HTV silicone rubber for best pollution performances

Brittle-fracture-resistantECR-glass FRP rod

One-piece HTV silicone rubber housing

Junction point: FRP rod/metal fitting/silicone (triple point) completely embedded in the silicone housing

Integrated grading ring reduces the electric field inside and outside the junction zone

Junction zone

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Product standards

ANSI C29.11 Tests for Composite Suspension Insulation for Overhead Transmission Lines

ANSI C29.12 Insulators Composites Suspension Type

ANSI C29.1 Test Methods for Electrical Power Insulators

ANSI C29.2 Insulators Wet-process Porcelain and Toughened Glass Suspension Type

Standards and tests

All 3FL long rod insulators are designed and completely tested in compliance with the latest ANSI C29.11 and ANSI C29.12 standards for composite suspension insulators.

Each Siemens 3FL insulator that leaves the factory is routinely tested with a corre-sponding mechanical tensile test load of at least 50 percent of the defined SML load for at least ten seconds.

1HTV: High-temperature vulcanizing2ECR glass: Electrical- and corrosion-resistant glass3SML: Specified mechanical load4RIV: Radio interference voltage

Maximized service life

Minimized electrical field strength

After numerous electrical calculations re-garding E-field distribution along the insu-lator, and the connection zone on the high-voltage side in particular, the design of the 3FL insulator was optimized for maximum reduction of electrical field stress, reduced corona effect, and mini-mized RIV4 value. Two design keys ensure improved life expectancy by reducing elec-trical field stress in the triple point and on the silicone surface:

The spherical-shaped rim of the end fit-ting inside the housing homogenizes the E-field distribution on the high-volt-age side of the 3FL insulator with an in-tegrated grading ring up to 170 kV.

The overmolded design system and the silicone housing shape at the connec-tion zone reduce the electrical field strength inside the housing, at the inner triple point in particular, as well as on the silicone surface directly. This by displacing the higher electrical field strength outside the housing (i.e. to the surrounding air area), and by taking ad-vantage of the higher silicone relative permittivity.

In this way, 3FL insulators can be applied on 170 kV systems without the need for additional grading/corona rings.

No moisture ingress

The one-piece housing of the 3FL insula-tors, i.e. weathersheds and core rod sheath (coating) is one-piece, and has only one in-ternal interface throughout the whole in-sulator, namely the boundary interface be-tween the housing and the FRP core rod. This design eliminates all internal inter-faces between weathersheds and the core rod coating. These kinds of longitudinal interfaces are normally very sensitive to tangential electrical field stress, which in worst case scenarios can easily lead to ero-sion damage of the polymer interfaces. In particular leading to erosion of the bond-ing between sheds and rod sheath, and thus damage to the insulator housing.

Furthermore, the junction point in the con-nection zone, where all three elements (FRP rod, metal end fitting, and silicone housing) meet each other, is absolutely water- and air-tight sealed during manu-facturing by using an overmolding hous-ing system. It totally encloses this junction point with the HTV silicone rubber of the housing itself. The highest bonding strength of the one-piece HTV silicone housing to the FRP core rod combined with the overmolding design system prevent moisture ingress at the connection zone of the insulator.

Housing (HTV SiR)

FRP rod

Connection zone

End fitting

3FL

E-field distribution (%/mm) in silicone housing and in FRP core rod at 3FL insulator high-voltage end

E-field distribution (%/mm) at 3FL insulator high-voltage end

Silicone surface

Inner triple point

Spherical-shaped rim

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All types of end fittings in accordance with ANSI C29.12 and ANSI C29.2 are available with 25, 30, 36 and 50 klbs. In addition, all end fitting types according to IEC 61466-1

End fittings

Corona ring

Recommended corona rings (diameter in inch [mm]) by line voltage

Line voltage kV

Ground end (top end fitting)

Line end (conductor end fitting)

170 kV None None

245 kV None 8.3 ( 210)

300 kV None 13 ( 330)

362 kV None 13 ( 330)

420 kV 8.3 ( 210) 13 ( 330)

550 kV 8.3 ( 210) 16 ( 420)

Parameter Units 3FL3 3FL4 3FL5 3FL6

Electrical data

Typical line voltagefrom kV 69 69 69 69

to kV 500 500 500 500

Low frequency flashover voltage

Dryfrom kV 285 285 285 285

to kV 1,006 1,006 1,006 1,006

Wetfrom kV 219 219 219 219

to kV 814 814 814 814

Critical impulse flashover voltage

Positivefrom kV 465 465 465 465

to kV 2,820 2,820 2,820 2,820

Negativefrom kV 465 465 465 465

to kV 2,795 2,795 2,795 2,795

Mechanical data

Specified mechanical load, SMLklbs(kN)

25(111)

30(133)

36(160)

50(222)

Section length (length increments approx. 2.05 inches [52 mm])

fromin

(mm)33.4(849)

33.4(849)

35.5 (902)

35.5 (902)

toin

(mm)219.7

(5,581)219.7

(5,581)221.8

(5,634)221.8

(5,634)

Core rod diameter in

(mm) 5/8"(16)

5/8"(16)

7/8"(22)

7/8"(22)

Accessories

Arc protection devices such as arcing horns and corona rings for reduction of electrical field stress and corona effect are carefully designed based on numer-ous electrical simulations regarding electrical field distribution. For system voltages above 170 kV corona rings are included in 3FL insulator application as a standard feature. Customer-specific solu-tions as well as other connection and ca-ble clamps are also available on request.

E-field distribution (%/mm) at 3FL insulator high-voltage end equipped with corona ring

44

C

B

A Eye acc. to ANSI C29.12

SMLDimensions in inch (mm)

A B C

25 and 30 klbs36 and 50 klbs

0.94 (24) 1.89 (48) 0.75 (19)

0.98 (25) 1.97 (50) 0.87 (22)

B A

Y-Clevis acc. to ANSI C29.12

SMLDimensions in inch (mm)

A B

25 and 30 klbs36 and 50 klbs

0.75 (19) 1.34 (34)

0.87 (22) 1.61 (41)

A B

C Tongue acc. to ANSI C29.2

Designation SMLDimensions in inch (mm)

A B C

52-6 25 and 30 klbs 0.50 (12.7) 0.69 (17.5) 1.81 (46)

52-10 36 klbs 0.75 (19) 0.81 (20.6) 1.81 (46)

52-12 50 klbs 0.87 (22) 0.94 (23.8) 2.05 (52)

B

C

A

D Clevis acc. to ANSI C29.2

Designation SMLDimensions in inch (mm)

A B C D

52-6 25 and 30 klbs 0.63 (16) 0.71 (18) 1.26 (32) 1.81 (46)

52-10 36 klbs 0.75 (19) 0.89 (22.5) 1.02 (26) 2.20 (56)

52-12 50 klbs 0.87 (22) 1.02 (26) 1.18 (30) 2.36 (60)

B

A C

Socket and Ball acc. to ANSI C29.2

Designation SMLDimensions in inch (mm)

A B C

52-5 25 and 30 klbs 1.3 (33) 0.67 (17) 0.75 (19)

52-8 36 klbs 1.65 (42) 0.87 (22) 0.98 (25)

52-11 50 klbs 1.65 (42) 0.87 (22) 0.98 (25)

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Typical line

voltage

Catalog number

Nominal polymer length

Section length*

Arcing distance

Leakage distance

Low frequency flashover

dry wet

Critical impulse flashover

positive negative

Corona ring installation

top / bottom

Approx. net weight

kV 3FLx- -3X1X210-2X3X41 inches mm inches mm inches mm inches mm kV kV kV kV inches / inches lbs kg

Typical line

voltage

Catalog number

Nominal polymer length

Section length*

Arcing distance

Leakage distance

Low frequency flashover

dry wet

Critical impulse flashover

positive negative

Corona ring installation

top / bottom

Approx. net weight

kV 3FLx- -3X1X210-2X3X41 inches mm inches mm inches mm inches mm kV kV kV kV inches / inches lbs kg

Typical line

voltage

Catalog number

Nominal polymer length

Section length

Arcing distance

Leakage distance

Low frequency flashover

dry wet

Critical impulse flashover

positive negative

Corona ring installation

top / bottom

Approx. net weight

kV 3FLx- -3X1X220-2X3X41 inches mm inches mm inches mm inches mm kV kV kV kV inches / inches lbs kg

Typical line

voltage

Catalog number

Nominal polymer length

Section length*

Arcing distance

Leakage distance

Low frequency flashover

dry wet

Critical impulse flashover

positive negative

Corona ring installation

top / bottom

Approx. net weight

kV 3FLx- -3X1X220-2X3X41 inches mm inches mm inches mm inches mm kV kV kV kV inches / inches lbs kg

Order number 3 F L 4 066 3 Y A 1 0 2 X X 1Polymer suspension/tension insulator: 3 F L

Specified mechanical load SML [klbs]:

25 klbs (111 kN) 3

30 klbs (133 kN) 4

36 klbs (160 kN) 5

50 klbs (222 kN) 6

Lightning impulse withstand voltage (1.2/50s, dry) LIWV/10 [kV], for example: if LIWV is 661 kV, then enter 066: 066

Internal usage: 3

Upper end fitting (ground side):

SML class / klbs: according to ANSI C29.12 and ANSI C29.2 25 30 36 50

/kN 111 133 160 222

Ball, size acc. to ANSI C29.2: 52-5 52-5 52-8 52-11 A

Socket, size acc. to ANSI C29.2: 52-5 52-5 52-8 52-11 Q

Clevis, size acc. to ANSI C29.2: 52-6 52-6 52-10 52-12 D

Tongue, size acc. to ANSI C29.2: 52-6 52-6 52-10 52-12 V

Eye, size acc. to ANSI C29.12: 25 klbs 25 klbs 40 klbs 40 klbs E

Y-clevis, size acc. to ANSI C29.12: 25 klbs 25 klbs 40 klbs 40 klbs Y

Special (other end fitting types available on request): Z

Bottom end fitting (high-voltage side):

SML class / klbs: according to ANSI C29.12 and ANSI C29.2 25 30 36 50 Torsion Angle

/kN 111 133 160 222

Ball, size acc. to ANSI C29.2: 52-5 52-5 52-8 52-11 n/a A

Socket, size acc. to ANSI C29.2: 52-5 52-5 52-8 52-11 n/a Q

Clevis, size acc. to ANSI C29.2: 52-6 52-6 52-10 52-12 0 D 90 G

Tongue, size acc. to ANSI C29.2: 52-6 52-6 52-10 52-12 0 V 90 W

Eye, size acc. to ANSI C29.12: 25 klbs 25 klbs 40 klbs 40 klbs 0 E 90 H

Y-clevis, size acc. to ANSI C29.12: 25 klbs 25 klbs 40 klbs 40 klbs 0 Y 90 XSpecial (other end fitting types available on request): Z

FRP core rod diameter :

5/8" (for 3FL3, 3FL4) 1

7/8" (for 3FL5, 3FL6) 2

Internal usage: 0

Standard:

ANSI C29.11, ANSI C29.12 2

Accessories on ground end:

Arcing horn H

Corona ring R

No accessories required X

Special Z

Accessories on line end:

Arcing horn H

Corona ring R

No accessories required X

Special Z

Application:

Single string 1

Double string 2

V-string 5

Special 9

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North America

Burlington, Ontario

Richland, Mississippi

El Marques, Quertaro

Santo Domingo

San Jose

Ciudad de Guatemala

South America

Bogota

Quito

Lima

Santa Cruz de la Sierra

Jundia, So Paulo

Santiago

Buenos Aires

Africa

Algiers

Casablanca

Tunis

Cairo

Isolo, Lagos

Douala

Addis Ababa

Nairobi

Ngaliema, Kinshasa

Ingombota Luanda

Maputo

Halfway House

Australia

Macquarie Park, NSW,

Sydney

Europe

Oslo

Espoo

Dublin

Manchester

Upplands Vsby,

Stockholm

Den Haag

Istanbul

Moscow

Vienna

Grenoble

Ljubljana

Huizingen

Bratislava

Zagreb

Gebze, Kocaeli

Athens

Bucharest

Barcelona

Sofia

Madrid

Amadora

Asia

Almaty

Gurgaon

Hanoi

Bangkok

Manila

Petaling Jaya

Jakarta

Seoul

Shanghai

Hong Kong

Dhaka

Abu Dhabi

Riyadh

Marking and nameplate of 3FL insulators

A nameplate is installed on each 3FL insulator when it successfully passes the mechanical routine test. It is a weather- and UV-proof stainless steel band with locking system, placed on the ground end fitting of the insulator. The etched marking includes: catalog number, SML, RTL, CIF, creepage distance, end fittings designa-tion, and production date code.

Packaging

3FL insulators are packaged in wooden crates with the following dimensions: width is 44 inches (1,120 mm), height is equal to or lower than 37.16 inches (944 mm), the length is determined by the insulator length. The maximum weight of one crate is 2,000 pounds (900 kg).

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Published by and copyright 2012: Siemens AG Energy Sector Freyeslebenstrasse 1 91058 Erlangen, Germany

Siemens AG Energy Sector Power Transmission Division High Voltage Products Nonnendammallee 104 13629 Berlin, Germany www.siemens.com/energy/insulators

Please contact us at: Phone: +49 30 386 33 222 Fax: +49 30 386 26 721 E-mail: insulators.energy@siemens.com

US Location Siemens Energy, Inc. Power Transmission Division 444 Highway 49 South Richland, MS 39218 www.siemens.com/energy/insulators Please contact us at: Toll-free: +1 (877) 742-3309 Phone: +1 (601) 932-9800

Power Transmission Division Order No. E50001-G630-A216-X-4AUS Printed in Germany Dispo 30002, c4bs No. 7457 fb 5022 W 471777 WS 08121.0

Printed on elementary chlorine-free bleached paper.

All rights reserved. Trademarks mentioned in this document are the property of Siemens AG, its affiliates, or their respective owners.

Subject to change without prior notice. The information in this document contains general descriptions of the technical options available, which may not apply in all cases. The required technical options should therefore be specified in the contract.