Hollow composite insulators 72-1,200 kVDesign for reliable performance

Insulation and Components

2 A century of innovation | Insulation and Components Insulation and Components | A century of innovation 3

A century of innovation

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.

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.

4 ABB Composite Insulator Technology | Insulation and Components Insulation and Components | ABB Composite Insulator Technology 5

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.

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.

High strength flange designThe 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.

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

R ≥ 2,5

≥ 8°

≥ 15°

6 ABB Composite Insulator Technology | Insulation and Components Insulation and Components | ABB Composite Insulator Technology 7

High temperature vulcanized silicone rubber for best long-term performanceABB 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.

Seamless helical extrusion process for continuous outer silicone housingOur 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.

Optimized shed profiles with large shed tip radius and high protective creepage distanceMajor 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.

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.

1. Large shed tip for minimized electrical field 2. Optimized shed profile with high protective creepage distance

21

8 Advantages of technology | Insulation and Components Insulation and Components | Advantages of technology 9

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 safetyIn 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.

Composite insulators offer outstanding safety in the event of:

The mechanism behind the hydrophobicity of silicone rubber is the diffusion of low molecular weight (LMW) silicone from the bulk of the material to the surface. LMW silicone forms a layer on the surface that is hydrophobic (non-wetting).

This layer is extremely thin, only a few molecular layers, and is distributed over the entire surface, thus forming a hydro-phobic layer. The LMW silicones diffuse to the surface over the entire life of the insulator; however, the loss of material is negligible and does not impair other insulation properties. Another benefit of silicone is its capability to encapsulate contaminated particles.

Maintenance-free and outstanding pollution performanceHTV silicone rubber has the ability to transfer its water-repellent properties into the pollution layers that cover the surface. This eliminates the need for maintenance or cleaning of the high voltage apparatuses in polluted environments. Expensive solutions normally used for porcelain, such as cleaning, greasing or coating, can be avoided.

UV stabilityHTV silicone rubber is ultraviolet (UV) and ozone resistant. Natural UV radiation from the sun has wavelengths of over 300 nanometers. Shorter and more energetic wavelengths are filtered out in the atmosphere. Silicone has its maximum absorption below this wavelength, which ensures superior stability against UV radiation.

Shatter test of live tank circuit breaker with porcelain insulator (high speed camera, 16 ms sequence)

290 300 400

Solar radation, UV

Wavelength, nm

Absorption max of SiO2 bond1

0,1

0,01

0,001

Leakage current over time at salt fog test

0,2 0,4 0,6 0,8 1

Porcelain

Silicone

Time, hours

Leak

age

curr

ent,

A

Excellent insulation for reduced creepage requirementsComposite insulators have excellent insulation properties and outstanding contamination performance due to the silicone rubber. Published field studies show that it is possible to reduce the required creepage distance by at least one pollution level when composite insulators are chosen over porcelain.

Flashover resistanceThe efficient suppression of leakage currents means that the risk of flashover is reduced compared to porcelain insulators.

Outstanding seismic performance provides safety and reliabilityThe 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 savingsComposite 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.

Additional advantagesOther advantages of composite insulators are short and reliable delivery times, best possible strength-to-weight ratio, the option of reducing gas volumes on SF6 breaker bushings with conical insulators compared to cylindrical designs, proven aging resistance and high inherent fire resistance.

− 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 damagesSince 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 hydrophobicityComposite 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.

10 Evaluating a great concept | Insulation and Components Insulation and Components | Evaluating a great concept 11

Evaluating a great concept

ABB composite insulators are thoroughly tested to international standards and higher. They have demonstrated excellent performance under all climates and harsh conditions, such as coastal, desert and industrial environments.

Service experience worldwideSince 1985, when the first ABB high voltage equipment with silicone rubber sheds were installed, ABB has delivered a vast number of high voltage apparatuses equipped with composite insulators. They have been installed in all types of environments, from marine and desert regions to areas with heavy industrial pollution.

The performance of ABB composite insulators in installations with extreme environmental conditions has been studied in detail, and the results have been published at a number of conferences and in well-known journals. The observations show excellent performance with insignificant changes in material properties.The HTV silicone material has proven its outstanding performance at test stations in severe climates and commercial installations all over the world.

More than 100,000 ABB composite insulators are installed in over 70 countries worldwide. The service history is excellent with no reports of flashovers, premature ageing or other major faults.

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

Aging withstand, electrical and mechanical erosion resistance, and UV stability have been fully verified. Natural pollution tests are continually performed at test stations in both marine and desert climates.

Testing is also performed at low ambient temperatures, down to -60˚C. The composite insulators comply fully with the requirements specified by the IEC. The insulators have undergone vandalism tests; a circuit breaker with composite insulators has even been subjected to gunfire to show that this kind of damage does not cause complete breakdown or explosion that could injure personnel or damage surrounding equipment.

Field testsNumerous long-term field tests of ABB composite insulators have been performed.

Test installations around the world have been made to gain information on long-term behavior and insulation performance in different environments. The test stations represent all possible climates – arctic, coastal, subtropical and desert areas – as well environments at high altitudes and with extreme pollution and strong UV light.

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.

Examples of long-term field tests

Place Type Duration

Dungeness, UK Costal, very heavy pollution 4 years

Guangzhou, CN 500 kV DC 1 year

Ludvika, SE 800 kV DC 4 years

Koeberg, ZA Extreme pollution 1 year

Examples of performed tests

High and low temperature -60°C and +110°C

Dielectric

UV radiation

Accelerated aging

5,000 hour multi-stress cycling

1,000 hour salt fog

Mechanical strength

Overpressure

Seismic

Shatter

Pressure cycling, -40°C and +100°C

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

This ensures the highest level of quality and long-term performance for the insulators. In addition, ABB has a fully equipped laboratory for material analysis. Electrical, mechanical and physical properties are measured and documented on a routine basis to ensure all important material properties.

Design, type and routine testsABB composite insulators are designed, type and routine tested in accordance with IEC 61462 and other regional standards. All requirements of IEC 62217 and IEC 60815 are fulfilled.

ABB has invested in sophisticated equipment for routine testing, and our testing goes beyond the IEC requirements. Routine testing includes cantilever bending tests, pressure tests and quantitative gas tightness measurements.

Ultra high voltages and ultra high voltage direct currentInsulators are key components for transmission at higher voltages. ABB is pioneering the development and manufacturing of hollow core composite insulators for ultra high voltage (UHV) and ultra high voltage direct current (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 insulator technology is used for all main high voltage equip-ment (transformer bushings, wall bushings, live tank circuit breakers, instrument transformers as well as voltage dividers).

UHVDC at 1,100 kV is the next step. ABB has successfully developed and tested the first 1,100 kV UHVDC converter transformer with ABB composite insulator technology, breaking the record for the highest DC voltage ever achieved.

The development of 1,100 kV composite insulators addresses several technology challenges, including sheer size and scale, electrical insulation and thermal performance parameters. The successful testing at 1,100 kV UHVDC verifies ABB composite insulators’ excellent performance.

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

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 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

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 12. Cable termination 300 kV 13. Dead tank circuit breaker 800 kV 14. Transformer bushing 800 kV DC

1 2

6 7 13

3 4 5

8

109

11 12

14

16 Design guide | Insulation and Components Insulation and Components | Design guide 17

Design guide

Shed profilesThe required creepage distance for your apparatus will determine which shed profile is suitable for your design and that will 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.

Inner diameter 1

D1 [mm]

Inner diameter 2

D2 [mm]

Length 1

L1 [mm]

Length 2

L2 [mm]

Length 3

L3 [mm]

Maximum length

Lmax [mm]

200 100 300 898 100 1298

250 219 680 855 470 2005

260 180 7330 3500 1340 12170

270 130 300 1100 500 1900

270 130 460 1100 450 2010

270 130 380 1270 160 1810

296 219 770 1595 700 3065

321 120 770 1970 190 2930

326 219 780 1965 700 3445

330 210 150 1310 680 2140

330 210 150 630 190 970

355 130 750 1776 420 2946

394 286 990 2300 990 4280

400 260 2050 6000 2050 10100

402 205 580 1570 750 2900

450 210 1450 700 2000 4150

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

740 580 3550 1000 5650 10200

983 725 5240 2448 3500 11188

983 725 3120 2448 6700 12268

L1 L2

Lmax

L3

D2D1

Lmax

D1

S

P

P1

S [mm] P [mm] P1 [mm] Cf, Creepage factor R

50 32 - 2.25 8,5

55 27 27 2.65 2,5

55 55 25 3.55 2,5

55 60 30 3.87 2,5

55 60 40 4.21 2,5

70 75 55 4.25 2,5

60 70 50 4.49 2,5

60 70 50 4.51 3

55 65 48 4.61 2,5

63 78 58 4.8 2,5

49 63 46 4.89 2,5

55 73 56 5.1 2,5

To estimate the creepage distance from the shed profiles’ creepage factor, the following equation can be used: Cd = Cf × ( ad - 300 ) + 300

where: Cd = Creepage distance*ad = Arcing distance**Cf = Creepage factor

Inner diameter

D1 [mm]82 130 150 160 180 210 260 311 335 358 375 420 450 470 486 575

Maximum length

Lmax [mm]2300 3200 3200 3200 4350 4300 10000 5000 4300 5000 4000 4300 3800 3800 9100 3800

Explanatory text from IEC 61462

*/ Creepage distanceShortest 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

**/ Arcing distanceShortest distance in the air external to the insulator between the metallic parts which normally have the operating voltage between them

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 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 2) Choose a shed design and creepage factor 3) Choose flanges to match your installation preferences

Fiberglass tubesABB 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).

R

DBC Do

DH × NH

D1

18 Design guide | Insulation and Components Insulation and Components | Design guide 19

FlangesThe 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 standard flange designs. If none of the standard flanges meets your requirements, other designs are available on request.

Continued on next page

Tube Fittings

D1

[mm]

NH

[pcs]

DBC

[mm]

DH

[mm]

DO

[mm]

82 4 / 4 122 / 130 M8 / M10 160

100 6 213 M12 254

120 8 270 15 300

123 8 232 M12 260

130

4

135 M8 165

171,5 M8 185

225 18 270

260 15 230

28615 ¤255

19 ¤255

6 185 16 225

8215 12 242

232 M12 260

12 155 M10 213

150

4286 19 ¤255

318 18 363,5

6290 14 325

326 14 356

8280 15 310

330 18 365

160

4 160 M8 200

12 180 M10195

237

¤ = non-circular flange, square

180

4225 M16 267

326 16 356

6 326

14 356

16356

362

18 362

8

275 18310

319

280 15 310

300 18 344

325 18 365

330 18 365

200

4 182,5 M8 250

8289 M12 375

361 15 393

210

4

160 M8 245

225 M16 273

286 15 ¤255

296 M8 312

350 14 380

360 14 390

6 360 14 390

8

325 18 369

326 M10 346

356 18 400

10 326 14 390

6 / 6 362 14 / 18 400

16220 M10 278

274 11 330

219 6 308 M10 333

245 16 360 14 395

250 12 457 15 490

260

4406 14 315

406 14 436

6 406 14 436

8330

M16 365

18 365

375 18 420

12 406 15 436

16 270 M10 327

270

8 450 19 480

12 390 M12 420

16 450 16 480

286 6 389 M10 455

296 12 502 15 532

3104 160 M8 365

24 327 M12 388

¤ = non-circular flange, square

Tube Fittings

D1

[mm]

NH

[pcs]

DBC

[mm]

DH

[mm]

DO

[mm]

20 Design guide | Insulation and Components Insulation and Components | Design guide 21

Material propertiesOnly the highest quality materials from well-known suppliers are used in products.

Material specifications, fiberglass tubesComposite tubes, filament-wound with fiberglass roving impregnated with epoxy resin. The inner surface is coated with non-woven polyester. The table below shows typical properties for a tube with a 38° winding angle.

Properties Unit Typical value Test method

Winding angle Degree 38

Density g/cm3 2 ISO 1183

Glass content % weight 75 ISO 1172

Interlaminar shear strength*, ILSS MPa EN 2377

RT 40

110°C 28

140°C 12

Flexural strength MPa 250 ISO 178

Flexural modulus GPa 16 ISO 178

Compressive strength, axial MPa 200 ISO 604

Dielectric strength, tangential, oil. 90°C kV/mm min 3.6 IEC 60243

Dielectric strength, axial oil. 90°C kV/mm min 3.6 IEC 60243

Partial discharge at 3.6 kV/mm pC <10 ABB 309-01

Tracking index**, CTI >600 IEC 60112

Dielectric constant, RT 5.75 IEC 60250

Dissipation factor, RT 0.0047 IEC 60250

Volume resistivity ohm IEC 60093

3 000 V 2x1,014

5 000 V 3x1,014

Surface resistivity ohm IEC 60093

Outside 3 000 V 2x1,016

Outside 5 000 V 2x1,016

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

311

6 456 14 486

8360 M12 390

456 14 486

16395 M12 430

520 22 600

320 8 500 19 536

326 12 527 15 560

3358 360 M12 390

16 450 16 480

3584 160 M8 415

24 380 M12 441

3754 425 M10 543

16 570 14 614

385 16 555 M12 580

394 24 605 15 635

40012

530 14 565

600 22 645

16 550 14 587

420

8 360 M12 466

20 480 M12 523

30 509 8 560

450 15 558 M10 573

480 20 610 18 645

48516 700 18 740

30 605 14 640

5008 600 18 640

12 675 18 715

517 24 656 18 697

550 16 680 18 720

581 24 710 18 745

630 30 780 26 830

720 24 880 18 920

740 32 890 26 940

970 32 1130 26 1180

Tube Fittings

D1

[mm]

NH

[pcs]

DBC

[mm]

DH

[mm]

DO

[mm]

22 Design guide | Insulation and Components

Material specifications, high temperature vulcanized silicone rubber Platina curing, solid high temperature vulcanized (HTV) silicone rubber based on polydimethylsiloxane (PDMS) with aluminum trihydrate (ATH) filler.

Material specifications, aluminum alloys

Properties Unit Specific value Test method

Vulcanized rubber

Silicone (polydimethylsiloxane, PDMS) content > 33%

Aluminum trihydrate (ATH) filler content > 45%

Tracking and erosion resistance 4.5 kV in class 1A IEC 60587

Recovery of hydrophobicity WC 1-3 within 24 hours IEC TS 62073

Color ANSI 70 5.0BG 7.0/0.4

Tensile strength, RT MPa min. 3.0 ASTM D412

Elongation at break, tensile % min. 170 ASTM D412

Hardness Shore A 65-75 ASTM D2204

Tear strength kN/m min. 15 ASTM D 624B

Dielectric strength, 1 mm sheet, RT_I_ kV/mm 23 IEC 60243

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 2.0x1014 IEC 60093

Material

designation

Alloy description

(DIN EN 1706)

Numeric short

symbol

(DIN 1725-2)

Material

number

(DIN 1725-2)

Tensile

strength

Rm (MPa)

Yield

strength

Rp 0.2 (MPa)

Elongation

at break

A5 %

Brinell

hardness

HBSChemical symbol Numeric

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

EN AC-AlSi10Mg(b) EN AC-43100-T6 260 220 1 90

Customer request form

Please use this request form to specify your ABB composite insulator

Company: Contact person: Phone no:Type of apparatus: Annual quantity: Batch size:Insulating medium: Service temperature range: to °C

Mechanical requirements acc. IEC 61462Max. mechanical load, MML: kNMax. deflection at MML: mmMax. service pressure, MSP: MPa

Electrical requirementsMin. arcing distance: mmMin. creepage distance: mm

DimensionsIf it is possible, please give us dimension limits (max. and min.)

Cylindrical Max. Min. Length of insulator, L: mm mmInner diameter, D1: mm mm

Conical Max. Min.

Length of insulator, L: mm mmL1: mm mmL2: mm mmInner diameter 1, D1: mm mmInner diameter 2, D2: mm mm

Flange design Top flange Bottom flange

Outer diameter, Do: mm mmHole dimension, Dh: mm mmBolt circle diameter, DBC: mm mmNumber of holes, NH: pcs pcs Additional information:

L

L2

D2

L1

Do

D1 DBC

DH x NH

1ZS

P00

0001

rev

isio

n B

, 20

13-0

6

Contact us

ABB AB CompositesBox 273 SE-941 26 Piteå, Sweden Phone: +46 911 728 00 Fax: +46 911 728 84 E-Mail: OrderComposites@se.abb.com www.abb.com/composites

NoteWe reserve the right to make technical changes or modify the contents of this document without prior notice. With regard to purchase orders, the agreed particulars shall prevail. ABB AB does not accept any responsibility whatsoever for potential errors or possible lack of information in this document. We reserve all rights in this document and in the subject matter and illustrations contained therein. Any reproduction, disclosure to third parties or utilization of its contents – in whole or in parts – is forbidden without prior written consent of ABB AB.

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