Insulators play a vital role in various industries, including electrical power transmission, telecommunications, and electronics. They are designed to prevent the flow of electric current and provide insulation between conductive elements. However, like any other component, insulators are not immune to technical issues. In this post, we'll explore different types of insulators and delve into some of the most common technical problems they may encounter.

Pin Insulators

Pin insulators are widely used in power distribution systems. They consist of a porcelain or glass insulator mounted on a metal pin, which is attached to the structure. The primary issue with pin insulators is cracking due to mechanical stress. Environmental factors like temperature fluctuations and excessive wind load can cause the insulator to crack, compromising its insulating properties.

Suspension Insulators

Suspension insulators are commonly employed in overhead transmission lines. They are made of a string of porcelain or glass discs connected by metal fittings. The main problem encountered with suspension insulators is pollution. When exposed to industrial pollutants or coastal environments, the insulator's surface can become contaminated. This pollution layer forms a conductive path, leading to electrical leakage and reduced insulating capacity.

Post Insulators

Post insulators are extensively used in electrical substations and switchyards. They are typically made of porcelain or composite materials and mounted vertically on supporting structures. One of the major technical issues with post insulators is flashover. Flashover occurs when the insulator's surface becomes wet or dirty, leading to the formation of an electrically conductive path. This can result in a disruptive discharge, compromising the insulation and potentially causing equipment failure.

Bushing Insulators

Bushing insulators are commonly employed in transformers, circuit breakers, and other high-voltage apparatus. They provide electrical insulation between a conductor and a grounded structure. One significant issue with bushing insulators is internal insulation breakdown. Over time, the insulation materials can deteriorate, leading to partial or complete breakdown. This can cause arcing, overheating, and ultimately, equipment failure.

Composite Insulators

Composite insulators, often used in high-voltage applications, consist of a fiberglass core covered with a weather-resistant silicone rubber housing. While composite insulators offer numerous advantages, they can still encounter issues such as corona discharge. When subjected to high electrical stresses, localized ionization can occur, leading to corona discharge. This phenomenon can degrade the insulator's surface and compromise its insulation performance.

Maintenance tips for insulators

It is important to note that regular maintenance, periodic inspection, and prompt issue detection are crucial in ensuring the longevity and effectiveness of insulators. Industry standards and guidelines provide recommendations for cleaning, testing, and replacing insulators when necessary.

RTV Coating for High Voltage Insulators

While reading this you may have noticed that most of the problems related to insulators are caused by the weather, contamination, mechanical stress, temperature fluctuations, pollutants and the environment. To avoid this and make sure the insulators work well, there is a silicone-based coating that will prevent flashovers from happening and resists resisting corona, tracking and erosion. Midsun’s High Voltage Insulator Coating will encapsulate all contaminants, including salt, coal, industrial pollutants and sand, avoiding costly power interruptions due to excessive leakage current.

Remember, addressing technical issues promptly can help prevent costly downtime, equipment damage, and ensure the safety and reliability of electrical systems. If you encounter any concerns or suspect insulator-related problems, you can contact us.

Post Insulators in Overhead Lines: The Complete Guide

Post insulators can be used in both transmission lines and substation systems. In this post, we mainly talk about post insulators in transmission lines.

A complete transmission line should have insulators. These are devices that are used for supporting conductors at different positions on the line. The fact that they are insulators means that no electric current will flow through them. This allows the insulator to provide maximum support without compromising the transmission of current or even the safety of the pole line.

One of the common transmission line insulators is the post insulator. Are you seeking to buy the best post insulators in China? Read on as we reveal everything that you should know about these transmission line accessories and how to choose one.

What is a Post Insulator?

In transmission lines, post insulators are also called line post insulators. The flanges of this insulator are sharp and narrow. This design facilitates a creepage distance that will counter the problem of electrode pollution.

Most post insulators are made of ceramic materials even though composite post insulators are quite comm. Composite post insulator types are usually tested based on the quality of each material.

The choice of the material should meet both the mechanical and electrical properties of an insulator.

What are the types of post insulators?

Top end fittings and bottom end fittings are different between types of line posts. According to the designs, there are mainly 5 types of line post insulators:

Tie top line posts: Also called core rod F neck line posts, they are technically similar to pin insulators.

Vertical clamp top line posts: With a clamp top and a stud base, it is mounted on the top of a utility pole.

Horizontal (stud mount) clamp top line posts: When a vertical clamp top line post mounted on the side of a utility pole, it is called a horizontal (stud mount) clamp top line post.

Horizontal (gain base) line posts: With a clamp top and a gain base, it is usually mounted on the side of a pole.

Brace post insulators: A special combination of a horizontal line post and a suspension insulator, which is made of silicon rubber.

What is the difference between Pin Insulators and Post Insulators?

When buying a post insulator, you are likely to confuse it with a pin insulator. They tend to look the same even though they are different products.

The main difference with pin insulators is application areas. Post insulators are best suited for the higher voltage transmission lines.

There are many other differences that we are going to highlight.

The table below shows the differences:

Typical Features of Post Insulators

What makes post insulators ideal for their roles on the transmission lines? The specific properties of post insulators include:

-High mechanical strength: Post insulators are subjected to bending, compression, and torsion forces. The insulator must have high mechanical strength to overcome these forces. Otherwise, it would easily break and cost more to replace.

-Solid and puncture-proof: Being exposed to all vagaries of nature can put the insulator at risk of being damaged due to punctures.

-Made of porcelain and aluminum oxide ceramic: The material for making the insulator should not only be strong enough but also should be a pure insulator. This is why aluminum oxide ceramic is used as it ranks fairly well in terms of insulating properties.

Porcelain is also a perfect insulator not underscoring its immense strength.

-Flexible creepage distance: The post insulator should have a proper creepage distance that will not compromise the integrity of the insulating path. This distance protects against tracking.

Before you buy post insulators, check to verify that they meet the relevant global standards.

Like other transmission line accessories, the design and make of post insulators should meet the minimum standards for IEEE, IEC, and NEMA. These standards define the quality of the insulator.

This is just one of the many reasons why we insist that you buy from reputable post insulator manufacturerinsulator manufacturers in China. Most of them make insulators that meet the minimum global standards.

Post Insulators Strength Ratings

Post insulators for transmission lines come with different strength ratings. The standard ratings for post insulators are used in all applications(high-voltage and bus applications).

The standard strength post insulators are designed to meet all the ANSI standards for mechanical and electrical properties for their respective voltage classes.

They are the most common type of post insulators that you are likely to find in the market. The 22kV post insulator and 33kV post insulator belong to this category

High strength post insulators tend to have an extra amount of mechanical strength. They are suitable for heavy-duty bus b applications and switch transmission lines.

However, these porcelain post insulators have the same electrical strength as the standard strength post insulators.

High strength post insulators are also suitable for applications that tend to experience severe short circuits.

Under this category, you should consider getting a 69kv post insulator.

Extra-high strength post insulators are mainly used for transmission projects that require extremely heavy mechanical loads. These insulators can either meet or exceed the ANSI standards both in terms of the electrical and mechanical properties.

A 115 kV post insulator and the 150 kv post insulator belong to this group

Installation and Maintenance of Post Insulators

In most cases, post insulators are installed to assume a vertical position. However, there are some applications where the insulators are installed horizontally.

For the horizontal application, must be reduced by 50% of the total weight of the unit. This means that if the post insulator is rated 2000 Ibs, the most recommended working load should be 1000 Ibs.

Post insulators for powerline require minimum coating thanks to their exterior surface coating. It keeps dirt and other impurities from the insulator hence protecting it from chemical and physical damage.

The hot-dip galvanized metal fillings at the end of the porcelain guarantees maximum protection.

Post Insulator Manufacturer

By now you may be wondering about where to buy post insulators for power transmission lines. The surest place to get this insulator is from a reliable post insulators manufacturer in China.

The important role that a post insulator plays on an overhead transmission line requires that you buy a reliable insulator. This is something that will not fail when in operation.

At Powertelcom, we design and manufacture quality post insulators that meet all the global standards. We are ranked among the best post insulator manufacturers in China.

Would you want to know the post insulator prices, designs, or specifications? Contact us and we will avail all the information that you need.

FAQ

What is a post Insulator?

Post insulator is a type of high voltage (HV) insulator designed according to IEC, ANSI, and other standards, they are used in power system up to 1100 kV.

Where is the post insulator used?

Post insulator can be used in either transmission lines or substations,

The post insulator used in the transmission lines is also named line post insulator, and called station post insulator or bus post insulator in the substations.

What are typical features of post insulators?

• High mechanical strength.
• Solid and puncture-proof.
• Made of porcelain or composite material.
• Flexible creepage distance

What is the main difference between post insulators and pin insulators?

The main difference with pin insulator is application areas. Post insulators are best suited for the higher voltage transmission lines.

What tests should do with post insulators?

• Routine Tests: Electrical Routine tests, Mechanical Routine tests, Visual examination and check for compliance.
• Sample Tests, insulators took at random from batches should take Verification of dimensions, Temperature cycle test, mechanical failing load test, and so on.
• Type Tests, thermal mechanical performance tests:
• Dry lightning impulse and Wet power frequency withstand voltage test.

All the tests are performed in accordance with the relevant standards supplemented by the specific requirements.

Maintenance tips for insulators

It is important to note that regular maintenance, periodic inspection, and prompt issue detection are crucial in ensuring the longevity and effectiveness of insulators. Industry standards and guidelines provide recommendations for cleaning, testing, and replacing insulators when necessary.

RTV Coating for High Voltage Insulators

While reading this you may have noticed that most of the problems related to insulators are caused by the weather, contamination, mechanical stress, temperature fluctuations, pollutants and the environment. To avoid this and make sure the insulators work well, there is a silicone-based coating that will prevent flashovers from happening and resists resisting corona, tracking and erosion. Midsun’s High Voltage Insulator Coating will encapsulate all contaminants, including salt, coal, industrial pollutants and sand, avoiding costly power interruptions due to excessive leakage current.

Remember, addressing technical issues promptly can help prevent costly downtime, equipment damage, and ensure the safety and reliability of electrical systems. If you encounter any concerns or suspect insulator-related problems, you can contact us.

Post Insulators in Overhead Lines: The Complete Guide

Post insulators can be used in both transmission lines and substation systems. In this post, we mainly talk about post insulators in transmission lines.

A complete transmission line should have insulators. These are devices that are used for supporting conductors at different positions on the line. The fact that they are insulators means that no electric current will flow through them. This allows the insulator to provide maximum support without compromising the transmission of current or even the safety of the pole line.

One of the common transmission line insulators is the post insulator. Are you seeking to buy the best post insulators in China? Read on as we reveal everything that you should know about these transmission line accessories and how to choose one.

What is a Post Insulator?

In transmission lines, post insulators are also called line post insulators. The flanges of this insulator are sharp and narrow. This design facilitates a creepage distance that will counter the problem of electrode pollution.

Most post insulators are made of ceramic materials even though composite post insulators are quite comm. Composite post insulator types are usually tested based on the quality of each material.

The choice of the material should meet both the mechanical and electrical properties of an insulator.

What are the types of post insulators?

Top end fittings and bottom end fittings are different between types of line posts. According to the designs, there are mainly 5 types of line post insulators:

Tie top line posts: Also called core rod F neck line posts, they are technically similar to pin insulators.

Vertical clamp top line posts: With a clamp top and a stud base, it is mounted on the top of a utility pole.

Horizontal (stud mount) clamp top line posts: When a vertical clamp top line post mounted on the side of a utility pole, it is called a horizontal (stud mount) clamp top line post.

Horizontal (gain base) line posts: With a clamp top and a gain base, it is usually mounted on the side of a pole.

Brace post insulators: A special combination of a horizontal line post and a suspension insulator, which is made of silicon rubber.

What is the difference between Pin Insulators and Post Insulators?

When buying a post insulator, you are likely to confuse it with a pin insulator. They tend to look the same even though they are different products.

The main difference with pin insulators is application areas. Post insulators are best suited for the higher voltage transmission lines.

There are many other differences that we are going to highlight.

The table below shows the differences:

Typical Features of Post Insulators

What makes post insulators ideal for their roles on the transmission lines? The specific properties of post insulators include:

-High mechanical strength: Post insulators are subjected to bending, compression, and torsion forces. The insulator must have high mechanical strength to overcome these forces. Otherwise, it would easily break and cost more to replace.

-Solid and puncture-proof: Being exposed to all vagaries of nature can put the insulator at risk of being damaged due to punctures.

-Made of porcelain and aluminum oxide ceramic: The material for making the insulator should not only be strong enough but also should be a pure insulator. This is why aluminum oxide ceramic is used as it ranks fairly well in terms of insulating properties.

Porcelain is also a perfect insulator not underscoring its immense strength.

-Flexible creepage distance: The post insulator should have a proper creepage distance that will not compromise the integrity of the insulating path. This distance protects against tracking.

Before you buy post insulators, check to verify that they meet the relevant global standards.

Like other transmission line accessories, the design and make of post insulators should meet the minimum standards for IEEE, IEC, and NEMA. These standards define the quality of the insulator.

This is just one of the many reasons why we insist that you buy from reputable post insulator manufacturers in China. Most of them make insulators that meet the minimum global standards.

Post Insulators Strength Ratings

Post insulators for transmission lines come with different strength ratings. The standard ratings for post insulators are used in all applications(high-voltage and bus applications).

The standard strength post insulators are designed to meet all the ANSI standards for mechanical and electrical properties for their respective voltage classes.

They are the most common type of post insulators that you are likely to find in the market. The 22kV post insulator and 33kV post insulator belong to this category

High strength post insulators tend to have an extra amount of mechanical strength. They are suitable for heavy-duty bus b applications and switch transmission lines.

However, these porcelain post insulators have the same electrical strength as the standard strength post insulators.

High strength post insulators are also suitable for applications that tend to experience severe short circuits.

Under this category, you should consider getting a 69kv post insulator.

Extra-high strength post insulators are mainly used for transmission projects that require extremely heavy mechanical loads. These insulators can either meet or exceed the ANSI standards both in terms of the electrical and mechanical properties.

A 115 kV post insulator and the 150 kv post insulator belong to this group

Installation and Maintenance of Post Insulators

In most cases, post insulators are installed to assume a vertical position. However, there are some applications where the insulators are installed horizontally.

For the horizontal application, must be reduced by 50% of the total weight of the unit. This means that if the post insulator is rated 2000 Ibs, the most recommended working load should be 1000 Ibs.

Post insulators for powerline require minimum coating thanks to their exterior surface coating. It keeps dirt and other impurities from the insulator hence protecting it from chemical and physical damage.

The hot-dip galvanized metal fillings at the end of the porcelain guarantees maximum protection.

Post Insulator Manufacturer

By now you may be wondering about where to buy post insulators for power transmission lines. The surest place to get this insulator is from a reliable post insulators manufacturer in China.

The important role that a post insulator plays on an overhead transmission line requires that you buy a reliable insulator. This is something that will not fail when in operation.

At Powertelcom, we design and manufacture quality post insulators that meet all the global standards. We are ranked among the best post insulator manufacturers in China.

Would you want to know the post insulator prices, designs, or specifications? Contact us and we will avail all the information that you need.

FAQ

What is a post Insulator?

Post insulator is a type of high voltage (HV) insulator designed according to IEC, ANSI, and other standards, they are used in power system up to 1100 kV.

Where is the post insulator used?

Post insulator can be used in either transmission lines or substations,

The post insulator used in the transmission lines is also named line post insulator, and called station post insulator or bus post insulator in the substations.

What are typical features of post insulators?

• High mechanical strength.
• Solid and puncture-proof.
• Made of porcelain or composite material.
• Flexible creepage distance

What is the main difference between post insulators and pin insulators?

The main difference with pin insulator is application areas. Post insulators are best suited for the higher voltage transmission lines.

What tests should do with post insulators?

• Routine Tests: Electrical Routine tests, Mechanical Routine tests, Visual examination and check for compliance.
• Sample Tests, insulators took at random from batches should take Verification of dimensions, Temperature cycle test, mechanical failing load test, and so on.
• Type Tests, thermal mechanical performance tests:
• Dry lightning impulse and Wet power frequency withstand voltage test.

All the tests are performed in accordance with the relevant standards supplemented by the specific requirements.

If you want to learn more, please visit our website porcelain insulator manufacturer.