w w w. p p c i n s u l a t o r s .

c o m

The very Best.

The very Best.

Long Rod Insulators Thats what we deliver.

Only a company that develops, produces and delivers products worldwide can provide the optimal solution for your requirements. The specialists of PPC Insulators are dedicated to supplying you with superior advice and global support. PPC Insulators quality products and service provide time-tested value to fulfill your needs! Please visit us on the web at www.ppcinsuators.com

Revision 1/2003

Long Rod Insulators

Best Performance in Engineering Your Request is our Challenge

> ISO 9001 > IEC > DIN > NORM Index

Introduction

Excellent design with extra high strength

> Standards
High Voltage Overhead Transmission Lines IEC Publications DIN NORM Couplings Locking Device
PAGE PAGE PAGE PAGE PAGE PAGE 4 4 4 4 5 5

> Design
PPC Insulators is a specialist in long rod insulators with a 60 year history of experience and development of these porcelain insulators. We produce a comprehensive range of products for overhead transmission lines up to highest system voltages of 525 kV with the most progressive technology, engineering and in-service life.
Electrical Values Shed Profiles Creepage Distances
PAGE PAGE PAGE 6 6 7

> Production
Insulating Material Insulator Cap Material (Fittings) Cementing Marking Inspection and Testing
PAGE PAGE PAGE PAGE PAGE PAGE PAGE PAGE PAGE 8 8 8 8 9 10 12 14 16

> > > > >

Application and Advantages Ball and Socket Couplings Locking Devices Clevis and Tongue Couplings Long Rod Insulators with Ball and Socket Couplings > Long Rod Insulators with Clevis and Tongue Couplings

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19

Introduction

Long Rod Insulators

Long Rod Insulators

Long Rod Insulators

High Voltage Overhead Transmission Lines
To specify the correct porcelain long rod insulator, the following characteristics have to be defined:

St andards
Locking Devices
For ball and socket couplings, split pins conforming to are normally used. Most of these pins also comply with

Standards

wet power frequency withstand voltage

Designation
PPC Insulators manufactures long rod insulators according to IEC 60433 (1998) (including the former German standard DIN 48006 (1986)). According to For ball and socket couplings complying to the locking is performed by a corresponding split pin.

DIN 48063 (1978) = NORM E4130 (1988) NORM E4131 (1988) NORM E4104 (1988)

IEC 60433 a porcelain long rod insulator is, for example, defined as follows: L 160 B 550 L long rod insulator
160 B C 550 specified mechanical failing load (kN) ball and socket coupling clevis coupling (when B is replaced by C) standard lightning impulse withstand voltage [kV)

The clevis coupling is locked by a corresponding connecting bolt with grooved nut and cotter pin according to These connecting bolts are not part of regular supplies, but upon customer request, PPC can procure these connecting bolts.

DIN 48073

According to the former German standard

DIN 48006 the same insulator was defined as: LP 75/22/1250 LP porcelain long rod insulator with ball
LG 75 22 1250 and socket coupling porcelain long rod insulator with clevis coupling (when LP is replaced by LG) core diameter (mm) number of sheds total length of the long rod insulator (mm)

Couplings
Three types of couplings for porcelain long rod insulators are available:

Ball and socket couplings conforming to

1. IEC 60120 (1987) = DIN 48064 (1982) = NORM E4125 (1988) 2. NORM E4104 (1988)

According to the former Austrian standards

NORM a long rod insulator was defined as shown in the following example: L 60/15-125 L porcelain long rod insulator with normal shed spacing
60 15 125 core diameter (mm) number of sheds mechanical failing load, average value (kN)

Clevis couplings conforming to

IEC 60471 (1977) = DIN 48073 (1975) = DIN 48074 (1990) = NORM E4126 (1984)

Variations are made by changes in the initial letter as shown:

L LH VL NL WL standard design with normal creepage distance normal creepage distance with higher strength anti-pollution type fog type with alternating sheds

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PAGE 5

Standards

> > > > > >

specified mechanical failing load minimum nominal creepage distance environmental conditions and grade of pollution type of coupling standard lightning impulse withstand voltage

IEC 60372 (1984)

Long Rod Insulators

Long Rod Insulators

Shed Profiles according to Standard IEC 60815

Long Rod Insulators

Design
Plain shed

Design

Creepage Distances
Porcelain long rod insulators are produced with different shed profiles to optimize performance according to environmental conditions and the grade of pollution. For example, this includes

Desert shed
> Fog and Salt Pollution
shed profiles for coastal areas (fog and salt pollution) which require a high

> Dust Pollution

aerodynamic shed profiles for areas with desert conditions (dust pollution)

> Industrial Pollution

shed profiles for areas with heavy industrial pollution

Standard shed acc. to DIN

protected creepage distance

Alternating shed

The recommendations of standard IEC 60815 (1986) are valid for the design of the shed profiles of porcelain insulators and for the determination of the adequate tolerances. The insulation performance of a long rod insulator is a function of the length, creepage and arcing distance of the insulating part and follows the standard IEC 60071 (1982-1996). It should be noted that to provide an accurate picture of all electrical relationships, a real tower should be constructed with all relevant distances to earth in conjunction with insulators, arcing horns and protective devices.

Electrical Values

Electric Arc Discharge along a Long Rod Insulator with Protective Fittings

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PAGE 7

Design

Long Rod Insulators

Long Rod Insulators

Long Rod Insula tors

Insulating Material
The insulator body of the unit is made from high quality aluminum oxide porcelain, C-130, which conforms to IEC 60672 (1995-1999). By customer request, we can also manufacture from aluminum oxide porcelain, C-120. Glazing provides a dirt repellent surface. Glazing is normally brown in color; however grey can also be provided upon request.

Production

Production

Marking
Each porcelain long rod insulator carries the trademark of the PPC Insulators and of the manufacturing factory and the date of manufacture as well as the type designation and the specific mechanical failing load in accordance with standard IEC 60433.

Inspection and Testing

Porcelain long rod insulators are tested according to standard IEC 60383 (1993).

Cementing
Cementing is provided with a lead-antimony alloy as standard although it is also possible to provide Portland cement or sulfur cement.

Inspection and Testing of Porcelain Long Rod Insulators according to Standard IEC 60383
Test programme Dry lightning impulse withstand voltage test Wet power-frequency withstand voltage test Mechanical failing load test Thermal-mechanical performance test Verification of the dimensions Verification of the displacements Type tests Sample tests Routine tests

             

Insulator Cap Material (Fittings)

Insulator caps are manufactured in malleable cast iron, in minimum EN-GJMB-550-4 or EN-GJMW-450-7, according to standard DIN EN 1562 (1997). The caps are hot dip galvanized according to standard DIN EN ISO 1461 (1999) with a zinc weight of min. 600 g/m 2 (min. 85 m) average value.

Verification of the locking system Temperature cycle test Porosity test Galvanizing test Routine visual inspection Routine mechanical test

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Production

Long Rod Insulators

Long Rod Insulators

Long Rod Insulators

Application and Advantages

underribs on sheds not required as the core parts between the sheds contribute to insulation long rod insulators can be checked ultrasonically for mechanical soundness

Application and Advantages

protection against power arcs is achieved by the addition of protective fittings > cascade flashovers are not possible > immune to thermal puncture

electrically and mechanically stressed zones are separated

routine test load = 80% of the specified mechanical failing load

minimum use of metal parts, which minimizes corrosion problems and also provides > lower weight for a complete insulator set > simpler mounting of strings > low level of HF interference to radio and television transmissions

long rod insulators are recommended for use in direct current applications because there is > no pin corrosion > no ion migration > no problems with thermal runaway effects

minimum total life cycle costs through high reliability long rod insulators can be used for tension and compression loads low surface leakage current resulting puncture proof Long rod insulators are solid core and the theoretical puncture path through the porcelain body is almost equal to the dry arcing distance. Since porcelain has several times the dielectric breakdown strength of air, flashover, if any, always occurs in the air outside the porcelain body. self-fractures of long rod insulators made of aluminum oxide porcelain are not known in reduced transmission losses

the creepage distance is comprised of sheds and core parts which have > good self-cleaning properties with respect to climatic conditions > better insulation performance under pollution conditions packaging in crates offers the maximum protection during shipping and storage insulator body made of aluminum oxide porcelain > high mechanical strength > free of internal stresses > no measurable aging > resistant to salt pollution > high resistance to temperature variations lowest maintenance costs > high resistance to vandalism

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Application and Advantages

Long Rod Insulators

Long Rod Insulators

Long Rod Insulators

Ball and Socket Couplings

Standard IEC 60120 Clearance between the Pin Ball and the Socket End
D
1

Ball and Socket Couplings

Designated size of coupling 11 16 20 24 28 32

* given for guidance

d1
(mm) 11.9 17 21 25 29 33
+ 0 - 1.1 + 0 - 1.2 + 0 - 1.3 + 0 - 1.4 + 0 - 1.5 + 0 - 1.6

d2
(mm) 22.8 33.3 41 49 57 65
+0 - 1.3 +0 - 1.5 +0 - 1.6 +0 - 1.8 +0 - 1.9 +0 - 2.1

h1
(mm) 9.1 13.4 19.5 21 23.5 27
+0 - 1.2 +0 - 1.3 +0 - 1.4 +0 - 1.7 +0 - 1.8 +0 - 1.9

r1
(mm) 35 23 27 40 55 70

r2
(mm) 35 50 60 70 80 90

r 3*
(mm) 3.5 3 5.7 6.6 8 10

r4
(mm) 1.5 3 3.5 4 4.5 5
+ 1 - 0
P Q

+ 1 - 0.5 + 1 - 1 + 1.5 - 1 + 1.5 - 1 + 1.5 - 1

d d
2

D D
2

The pin ball in the socket entry.

The pin ball in the socket interior.

Designated size of coupling 11 16A 16B 20 24 28 32

D1 - d1
Min. 0.6 2.2 2.2 2.0 2.5 3.0 3.0 Max. 3.0 5.0 5.0 5.4 6.4 7.4 7.9

D2 - d2
Min. 1.7 1.2 1.2 1.5 2.0 2.0 2.5

D3 - d2
Min. 1.7 1.2 1.2 1.5 2.0 2.0 2.5 1.4 1.1 3.6 1.0 2.5 2.5 3.0

P
Max. 3.9 4.0 6.5 4.5 6.7 7.2 8.2

Q*
Min. 1.6 1.6 3.7 2.0 2.8 3.0 3.5

* clearance between the pin ball and the locking device

Dimensions of the Socket End

Designated size of coupling 11 16A 16B 20 24 28 32

Dimensions of the Twin-Balled Pins

H1
(mm) 10.5 14.5 17 20.5 23.5 26 30
+ 1.3 - 0 + 1.6 - 0 + 1.6 - 0 + 2.1 +0 + 2.5 - 0 + 2.9 - 0 + 3.3 - 0

D1
(mm) 12.5 19.2 19.2 23 27 32 36
+ 1.3 - 0 + 1.6 - 0 + 1.6 - 0 + 2.1 - 0 + 2.5 - 0 + 2.9 - 0 + 3.3 - 0

D 2*
(mm) 24.5 34.5 34.5 42.5 51 59 67.5

D 3*
(mm) 24.5 34.5 34.5 42.5 51 59 67.5

H 2*
(mm) 15.5 20.5 25 28.5 33.5 36.5 42

R1
(mm) 35 23 23 27 40 55 70

R3
(mm) 4 3 3 6 5 8 10

R4
(mm) 1.5 3 3 3.5 4 4.5 5

R5
(mm) 4 5 5 7 10 12 14

T **
(mm) 4.8 5.5 7.9 7.0 8.7 10.5 11.5 Designated size of coupling

h4
(mm)

11 16 20 24 28 32

47 63 83 90 97 120

+0 - 2.5 +0 - 3.0 +0

+0 - 3.5 +0 - 3.5 +0 - 4.0

* minimal value ** minimal value of the thickness of the locking device

PAGE 12

h4

- 3.2

PAGE 13

Ball and Socket Couplings

Dimensions of the Pin Ball

Long Rod Insulators

Long Rod Insulators

Long Rod Insulators

Locking Devices
Standard IEC 60372 Dimensions of the Split - Pin (V-Type) for Ball and Socket Couplings

Dimensions of the W-Clip for Ball and Socket Couplings

F1 F6

F2 L5

R1
L1

Locking Devices

R
1

Section X - X

F3 F4 F5

F2

X X
T

R 2
T

Designated size of standard coupling

Standard V-type split-pin

Alternative V-type split-pin *

Designated size of standard coupling

F1

F2

F3

F4

F5

F6

L1

L2

L3

L4

L5

R1

R 2 R 3 max

S
(mm) 11 16A 16B 20 24 28 32 2.2 0,1 3.2 0.1 3.2 0.1 3.2 0.1 4.0 0.1

T
(mm) 4.8 5.5 7.9 7.0 8.7
+ 0.2 - 0 + 0.2 - 0 + 0.2 - 0 + 0.2 - 0 + 0.2 - 0 + 0.3 - 0 + 0.3 0

R2
(mm) 3.3 3.8 4.8 4.8 5.7 6.2 7.2

F 2min
(mm) 8.2 10.3 10.7 10.7 12.8 13.8 15.8

R min
(mm) 2.5 3.0 3.0 3.0 3.5 3.5 3.5

L min
(mm) 29 38 38 49 60 71 81

F' 2

max

(mm) 7.3 9.2 9.7 9.7 11.7

24 11 16A 16B 20

(mm) (mm) (mm) (mm) (mm) (mm) 15 22 22 22 22 24 26 20 28 28 30 30 32 36 4 5 5 5 5 6 6 13 19 19 19 19 21 24 19 24 24 24 25 28 33 4 5 5 5 5 6 7

+ 0.6 -0

(mm) 37 1.5 50 1.5 50 1.5 62 1.5 72 1.5 83 1.5 96 1.5

(mm) 12.0 15.5 15.5 15.5 15.5 16.0 18.0

(mm) 24 1.5 36 1.5 36 1.5 42 1.5 50 1.5 62 1.5 71 1.5

(mm) 8.0 10.5 10.5 10.5 10.5 12.5 16.0

(mm) 3 3 3 3 3 4 4

(mm) 2.5 2.5 2.5 2.5 2.5 3.0 3.0

(mm) 3.0 3.0 4.5 4.5 5.0 6.0 7.0

(mm) 1.5 2.5 2.5 2.5 2.5 3.0 3.0

(mm) 1.2 1.5 1.5 2.0 2.0 2.2 2.6

+ 0.2 - 0

(mm) 4.8 5.5 7.9 7.0 8.7 10.0 11.5

+ 0.2 - 0

+1 -0

+ 0.2 - 0

+ 0.2 - 0

+1 -0

+ 0.2 - 0

+ 0.2 - 0

+1 -0

+ 0.2 - 0

+ 0.2 - 0

+1 -0

+ 0.2 - 0

+ 0.2 - 0

4.5 0.1 10.0 5.2 0.1 11.5

12.7
28
+1 -0 + 0.2 - 0 + 0.2 - 0

14.7
32
+1 -0 + 0.2 - 0 + 0.2 - 0

* all the dimensions are the same as for standard split-pins, except the value F 2 replaced by F' 2 The dimension L max shall be specified by the purchaser of the split-pin.

V-Type Split-Pin in Locking and in Coupling Positions

W-Clip in Locking and in Coupling Positions

Socket entry

Socket entry

Socket entry

Socket entry

A
Split-pin in locking position Split-pin in coupling position W-clip in locking position W-clip in coupling position

PAGE 14

PAGE 15

Locking Devices

Long Rod Insulators

R3
L2 L3 L4
R2
S

Long Rod Insulators

Long Rod Insulators

Clevis an d Tongue Couplings

Standard DIN 48 073 Dimensions of Connecting Bolts Standard IEC 60471
Shape N Shape S
with grooved nut and cotter pin marking width of flats with cotter pin and disk

Clevis and Tongue Couplings

Dimensions of Clevis and Tongue Coupling

B

n A

Tongue

d1

d1 thread

Bolt

d1

d2

d2
F

d3 cotter pin h d2

d2 A Clevis Section A - A

Designation

d1
(mm) 12.8 13 13.5 18.6 19 19.4 21.8 22 22.6 24.2 25 25.6 27.2 28 28.6 31.2 32 32.6

d2
(mm) 14 14 15 19.8 20 21.4 23 24 24.6 26 27 28 29 30 31 33 34 35

n
(mm) 12 13 13.5 17.5 19 19.5 17.5 19 19.5 23 24 25.5 23 24 25.5 23 24 25.5

B
(mm) 14 14 15.5 20 20 22 20 20 22 26 26 28 26 26 28 26 26 28

m
(mm) 10 13 15 14.5 18 22 17.5 22 25 18 23 26.5 21.5 26 30 24.5 29 33

F
(mm) 32 34.5 46 48.5 53 55.5 57.5 60 67 69.5 77 79.5

H
(mm) 15 22 25 26.5 30 33

l
(mm) 45 65 75 80 90 100 -

blind holes

13L

19L

22L

25L

28L

32L

Min. Nom. Max. Min. Nom. Max. Min. Nom. Max. Min. Nom. Max. Min. Nom. Max. Min. Nom. Max.

Designation

d1
(mm)

l + 2*
(mm) 28, 32, 40, 45 34, 38, 43, 48, 52, 60, 105, 125, 145, 165, 185, 205, 225 34, 38, 43, 48, 52, 57, 60, 66 48, 65, 110, 130, 150, 170, 190, 210, 230, 250, 270, 290, 310, 330 43, 48, 52, 57, 75, 83, 215, 235, 255, 275, 295, 315, 335 43, 48, 52, 57, 83, 215, 235, 255, 275, 295, 315, 335

d2
(mm) 5* 5 6 5 6 5 6 6 6

d3
(mm) M12 M16 x M18 x M22 x M24 x M27 x

e +

d2

cotter pin

h 2 Width of
flats s (mm) 14 16 16 16 20 20 (mm) 19 24 27 32 36 41

Disk acc. to
DIN 1441

Cotter pin acc. to

DIN 94

(mm) 5 6 6 6 8 8 -

N 13 S 13 N 19 S 19 N 22 S 22 N 25 S 25 N 28 S 28 N 32 S 32

13 19 22 25 28 32

+ 0.3 - 0.6 + 0.3 - 0.6 + 0.5 - 0.3 + 0.3 - 0.8 + 0.4 - 0.8 + 0.5 - 0.8

1.5 1.5 1.5 2 2

15 21 23 26 29 33 -

4 x 25 5 4 5 4 x x x x 45 40 45 40

5 x 50 5 x 50 5 x 71

* Section of the length depending on outside distance of clevis

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PAGE 17

Clevis and Tongue Couplings

Long Rod Insulators

Long Rod Insulators

Long Rod Insulators

Long Rod Insulators

with Ball and Socket Couplings

with Clevis and Tongue Couplings

d2

Ball and Socket Couplings

d1

Characteristics of Long Rod Insulators with Ball and Socket Couplings "B" according to the Standard IEC 60433 (1998) and according to the former German Standard DIN 48006 / Part 1
Designation according according to to former Core Highest Standard Wet Specified Routine Minimum Maximum Standard diameter system lightning power mechanical mechanical nominal nominal coupling d2 voltage impulse frequency failing test creepage length size Um withstand withstand load load distance L (pin voltage voltage (16 mm/kV) diameter) d1
(mm) (kV) (kV) (kV) (kN) (kN) (mm) (mm) (mm)

Characteristics of Long Rod Insulators with Clevis and Tongue Couplings "C" according to the Standard IEC 60433 (1998) and according to the former German Standard DIN 48006 / Part 2
Designation according according to to former Core Highest Standard Wet Specified Routine Minimum Maximum Standard diameter system lightning power mechanical mechanical nominal nominal coupling d2 voltage impulse frequency failing test creepage length size (conUm withstand withstand load load distance L necting bolt voltage voltage (16 mm/kV) diameter) d1
(mm) (kV) (kV) (kV) (kN) (kN) (mm) (mm) (mm)

IEC 60433

DIN 48006/1

L 40 B 170 L 60 B 170 L 100 B 170 L 100 B 250 L 100 B 325 L 100 B 450 L 100 B 550 L 120 B 325 L 120 B 450 L 120 B 550 L 120 B 650 L 160 B 325 L 160 B 450 L 160 B 550 L 160 B 650 L 210 B 325 L 210 B 450 L 210 B 650 L 250 B 550 L 250 B 650 L 300 B 650

LP 60/5/380 LP 60/5/390 LP 60/19/870 LP 60/30/1240 LP 60/19/870 LP 60/30/1240 LP 75/14/870 LP 75/22/1250 LP 85/14/900 LP 95/22/1300 -

60 60

36 36 36 52

170 170 170 250 325 450 550 325 450 550 650 325 450 550 650 325 450 550 650 550 650 550 650

70 70 70 95 140 185 230 140 185 230 275 140 185 230 275 140 185 230 275 230 275 230 275

40 60 100 100 100 100 100 120 120 120 120 160 160 160 160 210 210 210 210 250 250 300 300

32 48 80 80 80 80 80 96 96 96 96 128 128 128 128 168 168 168 168 200 200 240 240

576 576 576 832 1160 1968 1968 1160 1968 1968 2320 1160 1968 1968 2320 1160 1968 1968 2320 1968 2320 1968 2320

380 400 450 580 870 1085 1240 870 1085 1240 1430 885 1100 1255 1445 905 1120 1275 1465 1305 1500 1330 1520

11

IEC 60433

DIN 48006/2

L 100 C 170 L 100 C 250 16 L 100 C 325 L 100 C 450 L 100 C 550 L 120 C 325 16 L 120 C 450 L 120 C 550 L 120 C 650 L 160 C 325 20 L 160 C 450 L 160 C 550 L 160 C 650 L 210 C 325 20 L 210 C 450 L 210 C 550 L 210 C 650 24 24 L 250 C 550 L 250 C 650 L 300 C 650

LG 60/14/860 LG 60/30/1270 LG 60/19/900 LG 60/30/1270 LG 75/14/900 LG 75/22/1270 LG 85/14/940 LG 85/22/1310 LG 95/22/1340 95 105 85 75 60 60

36 52 72.5 123 123 72.5 123 123 145 72.5 123 123 145 72.5 123 123 145 123 145 123 145

170 250 325 450 550 325 450 550 650 325 450 550 650 325 450 550 650 550 650 550 650

70 95 140 185 230 140 185 230 275 140 185 230 275 140 185 230 275 230 275 230 275

100 100 100 100 100 120 120 120 120 160 160 160 160 210 210 210 210 250 250 300 300

80 80 80 80 80 96 96 96 96 128 128 128 128 168 168 168 168 200 200 240 240

d1

576 832 1160 1968 1968 1160 1968 1968 2320 1160 1968 1968 2320 1160 1968 1968 2320 1968 2320 1968 2320

475 605 900 1120 1270 905 1120 1275 1465 920 1135 1290 1465 940 1155 1310 1500 1335 1530 1365 1560 22 25 22 19 19 19

60

72.5 123 123 72.5 123 123 145 72.5 123 123 145 72.5 123 123 145 123 145 123 145

60

75

L 210 B 550 LP 85/22 /1270

85

95 105

L 300 B 550 LP 105/22/1330

L 300 C 550 LG 105/22/1370

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PAGE 19

Clevis and Tongue Couplings

d2

Long Rod Insulators