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1 The very Best. The very Best. That s what we deliver. ong od Insulators 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 evision /003

2 Introduction ong od Insulators Best Performance in Engineering Your equest is our Challenge Excellent design with extra high strength > ISO 900 > IEC > DIN > ÖNOM 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 55 kv with the most progressive technology, engineering and in-service life. Index > Standards High Voltage Overhead Transmission ines PAGE 4 IEC Publications PAGE 4 DIN PAGE 4 ÖNOM PAGE 4 Couplings PAGE 5 ocking Device PAGE 5 > Design Electrical Values PAGE 6 Shed Profiles PAGE 6 Creepage Distances PAGE 7 > Production Insulating Material PAGE 8 Insulator Cap Material (ittings) PAGE 8 Cementing PAGE 8 Marking PAGE 8 Inspection and Testing PAGE 9 > Application and Advantages PAGE 0 > Ball and Socket Couplings PAGE > ocking Devices PAGE 4 > Clevis and Tongue Couplings PAGE 6 > ong od Insulators with Ball and Socket Couplings PAGE 8 > ong od Insulators with Clevis and Tongue Couplings PAGE 9 Introduction ong od Insulators

3 Standards ong od Insulators High Voltage Overhead Transmission ines To specify the correct porcelain long rod insulator, the following characteristics have to be defined: > specified mechanical failing load > minimum nominal creepage distance > environmental conditions and grade of pollution > type of coupling > standard lightning impulse withstand voltage > wet power frequency withstand voltage Designation PPC Insulators manufactures long rod insulators according to IEC (998) (including the former German standard DIN (986)). According to IEC a porcelain long rod insulator is, for example, defined as follows: 60 B 550 long rod insulator 60 specified mechanical failing load (kn) B ball and socket coupling C clevis coupling (when B is replaced by C) 550 standard lightning impulse withstand voltage [kv) ong od Insulators Standards ocking Devices or ball and socket couplings, split pins conforming to IEC 6037 (984) are normally used. Most of these pins also comply with DIN (978) = ÖNOM E430 (988) ÖNOM E43 (988) or ball and socket couplings complying to ÖNOM E404 (988) the locking is performed by a corresponding split pin. The clevis coupling is locked by a corresponding connecting bolt with grooved nut and cotter pin according to DIN These connecting bolts are not part of regular supplies, but upon customer request, PPC can procure these connecting bolts. Standards ong od Insulators According to the former German standard DIN the same insulator was defined as: P 75//50 P porcelain long rod insulator with ball According to the former Austrian standards ÖNOM a long rod insulator was defined as shown in the following example: 60/5-5 G and socket coupling porcelain long rod insulator with clevis coupling (when P is replaced by G) 75 core diameter (mm) number of sheds 50 total length of the long rod insulator (mm) porcelain long rod insulator with normal shed spacing 60 core diameter (mm) 5 number of sheds 5 mechanical failing load, average value (kn) Couplings Three types of couplings for porcelain long rod insulators are available: Ball and socket couplings conforming to. IEC 600 (987) = DIN (98) = ÖNOM E45 (988). ÖNOM E404 (988) Clevis couplings conforming to IEC 6047 (977) = DIN (975) = DIN (990) = ÖNOM E46 (984) Variations are made by changes in the initial letter as shown: H V N W standard design with normal creepage distance normal creepage distance with higher strength anti-pollution type fog type with alternating sheds PAGE 4 PAGE 5

4 Design ong od Insulators Shed Profiles according to Standard IEC 6085 Plain shed ong od Insulators 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. or example, this includes Design ong od Insulators Desert shed > og and Salt Pollution > Dust Pollution > Industrial Pollution Standard shed acc. to DIN shed profiles for coastal areas (fog and salt pollution) which require a high protected creepage distance aerodynamic shed profiles for areas with desert conditions (dust pollution) shed profiles for areas with heavy industrial pollution Alternating shed Electrical Values 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 6007 (98-996). 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. The recommendations of standard IEC 6085 (986) are valid for the design of the shed profiles of porcelain insulators and for the determination of the adequate tolerances. Electric Arc Discharge along a ong od Insulator with Protective ittings PAGE 6 PAGE 7

5 Production ong od Insulators ong od Insula tors Insulating Material The insulator body of the unit is made from high quality aluminum oxide porcelain, C-30, which conforms to IEC 6067 ( ). By customer request, we can also manufacture from aluminum oxide porcelain, C-0. Glazing provides a dirt repellent surface. Glazing is normally brown in color; however grey can also be provided upon request. Production Production ong od Insulators 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 Inspection and Testing Porcelain long rod insulators are tested according to standard IEC (993). Cementing Cementing is provided with a lead-antimony alloy as standard although it is also possible to provide Portland cement or sulfur cement. Insulator Cap Material (ittings) Insulator caps are manufactured in malleable cast iron, in minimum EN-GJMB or EN-GJMW-450-7, according to standard DIN EN 56 (997). The caps are hot dip galvanized according to standard DIN EN ISO 46 (999) with a zinc weight of min. 600 g/m (min. 85 µm) average value. Inspection and Testing of Porcelain ong od Insulators according to Standard IEC Test programme Type Sample outine tests tests tests 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 Verification of the locking system Temperature cycle test Porosity test Galvanizing test outine visual inspection outine mechanical test PAGE 8 PAGE 9

6 Application and Advantages ong od Insulators underribs on sheds not required as the core parts between the sheds contribute to insulation protection against power arcs is achieved by the addition of protective fittings > cascade flashovers are not possible > immune to thermal puncture 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 H interference to radio and television transmissions long rod insulators can be used for tension and compression loads ong od Insulators Application and Advantages long rod insulators can be checked ultrasonically for mechanical soundness electrically and mechanically stressed zones are separated routine test load = 80% of the specified mechanical failing load 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 Application and Advantages ong od Insulators puncture proof ong 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. low surface leakage current resulting in reduced transmission losses self-fractures of long rod insulators made of aluminum oxide porcelain are not known 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 lowest maintenance costs 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 > high resistance to vandalism PAGE 0 PAGE

7 Ball and Socket Couplings ong od Insulators ong od Insulators Ball and Socket Couplings Standard IEC 600 Dimensions of the Pin Ball Designated size d d h r r r * 3 r 4 of coupling (mm) (mm) (mm) (mm) (mm) (mm) (mm) Clearance between the Pin Ball and the Socket End D d d D P D d d D 3 Q Ball and Socket Couplings ong od Insulators * given for guidance 3 33 Dimensions of the Socket End Designated size D D * D * 3 H H * T ** of coupling (mm) (mm) (mm) (mm) (mm) (mm) (mm) (mm) (mm) (mm) A The pin ball in the socket entry. * clearance between the pin ball and the locking device Dimensions of the Twin-Balled Pins Designated size h 4 of coupling (mm) The pin ball in the socket interior. Designated size D - d D - d D 3 - d P Q * of coupling Min. Max. Min. Min. Max. Min A B B h * minimal value ** minimal value of the thickness of the locking device PAGE PAGE 3

8 S ocking Devices ong od Insulators ong od Insulators ocking Devices Standard IEC 6037 Dimensions of the Split - Pin (V-Type) for Ball and Socket Couplings X Section X - X Dimensions of the W-Clip for Ball and Socket Couplings S ocking Devices ong od Insulators X T 5 T Designated size of Standard V-type split-pin Alternative standard coupling V-type split-pin * S T min min min ' max (mm) (mm) (mm) (mm) (mm) (mm) (mm). ± 0, A 3. ± B 3. ± ± ± ± ± * all the dimensions are the same as for standard split-pins, except the value replaced by ' The dimension max shall be specified by the purchaser of the split-pin. V-Type Split-Pin in ocking and in Coupling Positions Designated size max S T of standard coupling (mm) (mm) (mm) (mm) (mm) (mm) (mm) (mm) (mm) (mm) (mm) (mm) (mm) (mm) (mm) (mm) ± ± A ± ± B ± ± ± ± ± ± ± ± ± ± W-Clip in ocking and in Coupling Positions A 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 4 PAGE 5

9 Clevis and Tongue Couplings ong od Insulators l l Standard IEC 6047 Dimensions of Clevis and Tongue Coupling A B n d Tongue H ong od Insulators Clevis and Tongue Couplings Bolt Standard DIN Dimensions of Connecting Bolts Shape N with cotter pin and disk d d d e marking h l Shape S with grooved nut and cotter pin d d 3 d width of flats thread Clevis and Tongue Couplings ong od Insulators A m Clevis Section A - A Designation d d n B m H l (mm) (mm) (mm) (mm) (mm) (mm) (mm) (mm) Min Nom Max Min Nom Max Min Nom Max Min Nom Max Min Nom Max Min Nom Max d blind holes cotter pin h s d cotter pin Designation d l + * d d 3 e + h ± Width of Disk Cotter pin flats s acc. to acc. to (mm) (mm) (mm) (mm) (mm) (mm) (mm) DIN 44 DIN 94 N , 3, 40, S M x 5 N , 38, 43, 48, 5, 60, 05, x 45 9 S 9.6 5, 45, 65, 85, 05, 5 5 M6 x x 40 N x 45 34, 38, 43, 48, 5, 57, 60, 66 S.3 5 M8 x x 40 N , 65, 0, 30, 50, 70, 90, S 5.8 0, 30, 50, 70, 90, 30, 330 M x x 50 N , 48, 5, 57, 75, 83, 5, S , 55, 75, 95, 35, 335 M4 x x 50 N , 48, 5, 57, 83, 5, 35, S , 75, 95, 35, 335 M7 x x 7 * Section of the length depending on outside distance of clevis PAGE 6 PAGE 7

10 Ball and Socket Couplings ong od Insulators ong od Insulators with Ball and Socket Couplings d d ong od Insulators with Clevis and Tongue Couplings d Clevis and Tongue Couplings ong od Insulators d Characteristics of ong od Insulators with Ball and Socket Couplings "B" according to the Standard IEC (998) and according to the former German Standard DIN / Part Designation Core Highest Standard Wet Specified outine Minimum Maximum Standard according according diameter system lightning power mechanical mechanical nominal nominal coupling to to former d voltage impulse frequency failing test creepage length size Um withstand withstand load load distance (pin voltage voltage (6 mm/kv) diameter) d IEC DIN 48006/ (mm) (kv) (kv) (kv) (kn) (kn) (mm) (mm) (mm) 40 B 70 P 60/5/ B 70 P 60/5/ B B B 35 P 60/9/ B B 550 P 60/30/ B 35 P 60/9/ B B 550 P 60/30/ B B 35 P 75/4/ B B 550 P 75// B B 35 P 85/4/ B B 550 P 85/ / B B 550 P 95// B B 550 P 05// B Characteristics of ong od Insulators with Clevis and Tongue Couplings "C" according to the Standard IEC (998) and according to the former German Standard DIN / Part Designation Core Highest Standard Wet Specified outine Minimum Maximum Standard according according diameter system lightning power mechanical mechanical nominal nominal coupling to to former d voltage impulse frequency failing test creepage length size (con- Um withstand withstand load load distance necting bolt voltage voltage (6 mm/kv) diameter) d IEC DIN 48006/ (mm) (kv) (kv) (kv) (kn) (kn) (mm) (mm) (mm) 00 C C C 35 G 60/4/ C C 550 G 60/30/ C 35 G 60/9/ C C 550 G 60/30/ C C 35 G 75/4/ C C 550 G 75// C C 35 G 85/4/ C C 550 G 85// C C 550 G 95// C C 550 G 05// C PAGE 8 PAGE 9