Insulator Polymer Insulator High Voltage Polymer Suspension Insulator

SMICO offer different kinds of composite insulator for substation. Contact us get more details about composite insulator, such as TDS, Application Method, OEM etc.
SMICO can supply different type of composite silicone insulator, also customer required.

Composite insulators are a special type of insulation control that can play an important role in overhead transmission lines.
Composite insulators are also known as synthetic insulators, non-porcelain insulators, polymer insulators, rubber insulators, etc. The main structure is generally composed of a shed skirt, a FRP core rod and an end fitting. The shed skirt is generally made of organic synthetic materials, such as ethylene propylene rubber, high temperature vulcanized silicone rubber, etc.; FRP mandrels are generally made of glass fiber as a reinforcing material, and a oxidizing resin as a base material; The end fittings are generally carbon steel or carbon structural steel coated with hot zinc-aluminum.

Classification of Silicone Rubber Insulators

Composite insulators can be divided into: line composite insulators and power stations, electrical composite insulators. It can also be divided into rod-shaped suspension composite insulators, pin-type composite insulators, cross-arm composite insulators, pillar composite insulators, wind-proof partial composite insulators, composite post insulator and so on.

End Fitting Structure

Composite insulators vary in their structure depending on the characteristics of use. In addition to meeting the tensile strength, meeting the requirements, and reliably connecting with the mandrel, the design of the metal tip also needs to meet the special requirements for application under high voltage. Composite insulators are generally made in the shape of a rod with a small capacitance. Therefore, the voltage distribution on the surface of the insulator is very uneven. Thus, in normal operation, the generated corona will be harmful, so it is necessary to use a pressure equalization measure. In addition, the synthetic insulating material cannot withstand an electric arc of several tens of kiloamperes. In the event of a short circuit fault, it will burn the umbrella near the wire and the tower, so arcing is required. At home and abroad, the method of adding a pressure equalizing ring is generally adopted to uniform the end electric field, weaken the corona, and lead to the fault arc.

The voltage equalizing ring of the composite insulator is a component of the composite insulator. Its function is to control the electric field strength inside the insulator, avoid internal partial discharge, reduce the local electric field strength of the external surface, especially the surface of the metal connecting part, and reduce the radio interference. Leading the power frequency arc to avoid burning the surface of the insulator and minimizing the local electric field strength near the end surface to improve its anti-smudge performance.

Small size, easy to maintain;
Light weight, easy to install;
High mechanical strength, not easy to break;
Excellent seismic performance and good stain resistance;
Fast production cycle and high quality stability.

Composite Post Insulators are ideal for various high voltage installations, including:

• Transmission lines
• Distribution networks
• Substations
• Railway electrification systems
• Industrial power systems

01.What is a Composite Post Insulator?

A Composite Post Insulator, also known as a Non-Ceramic Insulator (NCI) or polymer insulator, is a high-performance insulator made from advanced materials such as silicone rubber, ethylene propylene rubber (EPR), or polytetrafluoroethylene (PTFE). They are used in power transmission and distribution systems to provide superior mechanical and electrical performance.

02.What are the main advantages of Composite Post Insulators?

The main advantages of Composite Post Insulators include:

Lightweight Design: They are lighter than traditional ceramic or glass insulators, making them easier to transport and install.

Excellent Hydrophobicity: Synthetic materials like silicone rubber are highly water-repellent, which helps prevent dirt accumulation and reduces leakage current losses.

Strong Environmental Resistance: They are resistant to UV radiation, moisture, and pollution, ensuring long-term stable operation even in harsh conditions.

High Mechanical Strength: The combination of a fiberglass core rod and highly insulating polymer materials provides excellent mechanical strength and electrical performance.

03.What are the applications of Composite Post Insulators?

Composite Post Insulators are widely used in various high voltage power systems, including:

High voltage transmission lines

Distribution networks

Substations

Railway electrification systems

Industrial power systems

04.How do I choose the right Composite Post Insulator?

When selecting a Composite Post Insulator, consider the following factors:

The system’s rated voltage and maximum continuous operating voltage (Uc)

Mechanical strength requirements (e.g., tensile strength and bending strength)

Environmental conditions (e.g., temperature, humidity, and pollution levels)

The size and installation requirements of the insulator

05.Do Composite Post Insulators require maintenance?

While Composite Post Insulators are designed to be maintenance-free, it is advisable to periodically inspect their physical condition to ensure there are no signs of damage or aging. For insulators installed in harsh environments, regular electrical testing may also be necessary to ensure they maintain their protective performance.

06.What is the typical lifespan of a Composite Post Insulator?

The lifespan of a Composite Post Insulator depends on various factors, including environmental conditions and the frequency of overvoltage events. Typically, composite insulators can last between 20 to 30 years, but this depends on usage and the quality of the insulator.

07.Can Composite Post Insulators be used in high pollution environments?

Yes, Composite Post Insulators have excellent pollution resistance. Insulators made with materials like silicone rubber have hydrophobic properties that help prevent pollution buildup, making them suitable for use in high pollution environments.