www.fcifurukawa.hu

Table of contents

02 // 03

Table of contentsCompany Profile

MilestonesProject “1976”

ISO Certificates, Test reports - AdvantagesFlyers

Technology and Product Description Products

Medium Voltage Insulators - High Voltage Insulators Substation Post Insulators - Railway Insulators

World Map - ReferencesMedium Voltage Insulators - High Voltage Insulators

Substation Post Insulators - Railway Insulators

Quality - Sample of DrawingsMedium 20 kV - Medium 24 kV

High 120 kV - High 220 kVHigh 400 kV - High 500 kV

Substation Post 110 kV - Substation Post 400 kVRailway - Contact

2 // 34 // 56 // 78 // 9

10 // 1112 // 13

14 // 1516 // 1718 // 1920 // 21

22 // 2324 // 2526 // 27

28 // 2930 // 3132 // 3334 // 3536 // 3738 // 39

The company history stretches back to the beginning of the 70-ies, when Hungarian engineers working as employees of the state-owned

VKI (Electric Industry Research Institute) supported by several other research institutions started to develop composite insulators, which

were considered an absolute novelty in those times.

The first 400 kV insulators with a liquid silicon rubber (LSR) coating were made within this development process in 1976. The first insulators were

installed in the Hungarian section of the Göd (HU) – Léva (SK) international transmission line, and their reliability had been proved by their faultless

operation for more than 20 years!After this successful beginning and upon the request of the MVM

(Hungarian Electricity Works), the development of a fabrication technology suitable for mass-production was started in 1982. The development attracted

several purchase orders placed with the research group, which participated in successful foreign experimental projects in numerous countries (such as

Switzerland, Japan, and so on).

Due to the worldwide echo of such an important development, to the relevant experience acquired during the years and to the know-how related thereto, the

Japanese Furukawa Electric Co. bought the Insulators Technical Department of VKI in 1991, and the Furukawa Electric Institute of Technology Ltd. (FETI) was set up where

the earlier developments were carried on, supported by a Japanese background. In 1993, the FCI Furukawa Composite Insulator Ltd., a company specialized in composite

insulators mass-production was set up, and the new factory built in 1995 was the place where the production on a large scale began.

During the last 15 years, the company participated in several successful and special projects so that the range of the manufactured products is significantly wide and the

number of the insulators manufactured in this factory exceeds more than 1,000,000 pieces, by now.

Company Profile

04 // 05

Please, find herein below the most significant milestones of the company history

06 // 07

1972 - Research related to composite insulators was started at the Electrical Industry Research Institute (VKI).1976 - With the assistance of the National Power Line Company (OVIT) the first generation of 400kV composite insulators were installed in the Hungarian section of the Göd-Léva international power line.1982 - Requested by Hungarian Power Companies Ltd. (MVM Rt.) the engineers of VKI developed the technology for industrial production of composite insulators. 1986 - Requested by the Swiss ABB the research engineers of VKI, based on their own patent and know-how, took part in the establishment of a production plant for manufacturing 66-550kV high voltage apparatus equipped with composite insulators in Switzerland. 1991 - FETI (Furukawa Electric Technology Institute) was founded on the basis of the Insulation Technology Department of VKI. The insulation developments were continued already in cooperation with the Japanese Furukawa Electric.1993 - The FCI Furukawa Kompozit Szigetelô Kft. (FCI Furukawa Composite Insulator Ltd.) was founded. (Founders: Furukawa Electric Co., Itochu Corporation, MVM Rt., Longterm Credit Bank of Japan).1993 - The first 110 kV project, Pomáz – Dorog / ELMÛ.1995 - The production plant of FCI Furukawa was built in Budapest. - Introduction of the ISO 9001 Quality Assurance System.1996 - The first 220 kV project, Detk – Zugló / MVM - The first 400 kV project, Berlin West – East connection / BEWAG.2004 - The 500.000th composite insulator was produced. - Introduction of the ISO 14001 Environmental Management System.2005 - The first 110 kV substation standing insulator project, Arad / Romania.2006 - The first 400 kV substation standing insulator project, ABB / Sweden.2007 - The first 500 kV project, Kazahstan.2008 - The 1.000.000th composite insulator is produced.

Project ”1976” We produced the 400 kV insulator, that can be seen here, in 1976 so it had been serving for more than 20 years!

The development research of composite insulators was started by a formulation of several research institutes at VKI, predecessor of FCI Furukawa Ltd., in the

early 1970s. The first 400kV insulators, with liquid silicon rubber coating (LSR), were produced already in 1976 as part of the development works. These

first insulators were installed at the Hungarian section of the Göd-Léva (SK) international power line where, as the one that can be seen here, they proved

their reliability with trouble free operation of more than 20 years.

The first generation of LSR composite insulators proved clearly, even for the doubters, that besides their several advantages they managed to work in a

reliable and perfect way.

Of course the materials as well as the production technology have gone through a significant development process during the past three decades, since 1976.

As the result of the development works, for today the FCI composite insulators represents the most reliable and up to date technology in every respect.

08 // 09

AdvantagesISO CertificatesTest reports

10 // 11

The composite insulators of FCI represent the most developed and most reliable insulators nowadays. They eclipse the traditional

(porcelain, glass) insulators in each and every respect! Due to the combination of a special design and high quality base materials, they

have several significant advantages in comparison also with other composite insulators.

Advantages compared with the traditional porcelain and glass insulators:

• Hydrophobic, water-repellant properties, preventing the formation of any contiguous water layer on the insulator surface

• Conclusively most reliable performance in pollution areas, desert and sea-side environments

• Lower price range• Lighter weight

• Easier to be installed• Vandalism-proof, non-breaking

Advantages compared with other composite insulators:• 30 years of experience and more than 1,000,000 pieces of insulators are standing

as a reference for the reliability of our insulators, and that is the greatest surety we can offer to our customers

• Extended life-time and a more reliable operation, due to the high silicon-content LSR rubber coating

• Discharge-free end design developed by the FCI• Failures caused by joining problems are absolutely excluded, since coating is made

in only one piece• No sealing is needed between the metal fitting and the rubber coating, for this reason

there are no failures which occur in the case of the other types of composite insulators

Low weight // Hydrophobic // Vandalism-proof// Maintenance free // Pollution resistant

FCI FURUKAWA EUROINS®

The first DISCHARGE – FREE insulator

EUROINS® Composite Insulator products:– suspension/tension insulators for 24-750kV transmission line– line post insulators for 120-400kV– interphase spacers for 66-500kV– railway insulators

FCI FurukawaDischarge-Freeend-design

ConventionalNon Discharge-Freeend-design

Best quality material + High Tech + New Design » Best Performance

Carefully designed pre-grading collar of the end-

fittings control electrical stress distribution at both

ends of the insulators, where most of the

environmental stresses are concentrated.

ECR glass

End-fitting/FRP joints are totally embedded in silicone rubber to eliminate imperfections of traditional sealing technology.

Chemical bonding ofsilicone rubber to metaland FRP-rod. The specially designed embedding sealing alongside guarantees total impenetrability.

FCI FURUKAWA EUROINS®

Conventional and EUROINS® DF FURUKAWA end-design

High Voltage Laboratory TestRIV test, three different insulators in wet condition

EUROINS® DF (discharge-free) end-design

Key competencies• Optimal Design• Optimal LSR Material• Optimal Technology, Processing

Conventional endshape with discharge

• Discharge• Erosion (chalky)• Tracking• Brittle fracture Flash over

10 20 30 40 50 60 70 80 90 100 110 120 130 140 150 160 170

10 000

1 000

100

10

1

microvolt

type A type B

Furukawa end-design

kV

The Triple Junction Point is the critical point of end-design(Triple junction point: metal end fitting-silicone housing-air)

Conventional endshapes Furukawa end-design

• Triple junction point has lower stress

• Like cable sealing end, totally covered by silicone

• The thickness of the silicone – housing is following the change of the electric field

• Such an end – form which causes an optimal electric fieldtype B

type A

Technology and Product Description

It is important to emphasise that the mass production of the FCI composite insulators was started only after the base materials and the production technology had been established in detail as a result of the joint effort of the Hungarian and Japanese engineers. The process was greatly enhanced by the introduction of the world renowned Japanese quality assurance system, including a computerised production management. This is the key to the high quality of FCI composite insulators.

A special glass fibre (grade ECR) reinforced bar is used as a core for the composite insulators, the tensile strength of which exceeds that of steel. A weather resistant silicon elastomer cover is built around the core, which ensures an efficient water shedding and special insulating properties. The so called LSR silicon resin (which contains minimum 80-90% silicon polymer and which has been specifically developed to match the high voltage electrical requirements) is a self regenerating material, for this reason it operates efficiently in highly polluted industrial environment, as well as in desert or seashore salty climatic conditions.

FCI Composite Ltd. uses a patented technology, which allows the production of full size insulators using a single casting stage, to be used up to a voltage level of 500 kV. The casting is controlled by computers, which guarantees the consistently high quality of the insulators without human intervention.

14 // 15

Products

16 // 17

High Voltage Insulators

Technical Specification

Voltage Level: 52 – 800 kVMaximum SML: 500 kN

Maximum Connecting Lenght: up to 8 m

HousingHighest Quality Silicon Rubber

StandardsIEC 61109, ANSI C.29.11 , ANSI C.29.12

RodECR – FRP

End FittingsHot deep galvanized steel

according to IEC 60120, 60471, 61466-1 oraccording to costumer requirement.

Experiencesince 1976

Medium Voltage Insulators

Technical SpecificationVotage level: 10 – 52 kVMax. SML: 120 kNMaximum SCL: 20 kN

HousingHighest Quality Silicon Rubber

StandardsIEC 61952, IEC 61109

RodECR – FRP

End fittingsHot deep galvanized steel according to IEC 60120, 60471, or according to costumer requirement.

Experiencesince 1976

18 // 19

Substation Post Insulators Railway Insulators

Technical SpecificationVoltage Level: 10 – 400 kVMaximum SCL: 20 kNMaximum Connecting Lenght: up to 5 m

HousingHighest Quality Silicon Rubber

StandardsIEC 62231

RodECR – FRP

End FittingsHot deep galvanized steel according to IEC 60273, or according to costumer requirement.

Experiencesince 1998

20 // 21

Technical Specification

Voltage Level: 3 – 52 kVMaximum SML: 200 kN

Maximum SCL:20 kNMaximum Connecting Lenght: up to 2 m

HousingHighest Quality Silicon Rubber

StandardsIEC 61952, IEC 61109

RodECR – FRP

End FittingsHot deep galvanized steel according

to IEC 61109 or accordingto costumer requirement.

Experiencesince 1984

References

World map

22 // 23

High Voltage InsulatorsReferences

Medium Voltage Insulators References

24 // 25

Railway Insulators References

Substation Post Insulators References

26 // 27

Quality

We are convinced that the most important virtue of our product is its exceptional quality and absolute reliability in all circumstances.This is the reason why we have been paying particular attention to the perfect operation of our quality assurance system and to its continuous development from the beginning of the mass-production of the insulators. We tried to build up our quality system incorporating our experiences gained during several years of research and development and introducing the TQM (Total Quality Management) system adopted by the founder Furukawa Electric. Originally, this system was first introduced in the Japanese car industry (for instance Toyota) and its main point is to rationalize the processes and continuously reincorporate experiences, at every organizational level.Each and every FCI insulator is identified by a code number burnt in by means of a laser beam. The identification number makes our products unique insulators whose manufacturing data can be evoked even decades later. Using this code, the product history can be traced down starting from the very first manufacturing step (when was it made, the base materials used for the production, the worker’s name, etc.). Continuous control with several check points on one hand, and a thorough design taking into account quality-related experiences, on the other hand, guarantee the steady, reliable quality of our insulators.Due to the above aspects, we are proud to say that more than 1,000,000 pieces of our composite insulators are reliably operative worldwide from the North Pole to the deserts, under the most severe circumstances!

Sample of Drawings

28 // 29

Medium Voltage 24 kVMedium Voltage 20 kV

30 // 31

High Voltage 120 kV High Voltage 220 kV

32 // 33

High Voltage 400 kV High Voltage 500 kV

34 // 35

Substation Post 110 kV Substation Post 400 kV

36 // 37

Railway Contact

FCI Composite Insulator Ltd.Budapest, Késmárk str. 28/a.

1158 – HungaryPhone: +36/1-419-6620

Fax: +36/1-419-6627Homepage: www.fcifurukawa.huE-mail: info@fcicomposite.hu

38 // 39