Bharat Heavy

Electricals Limited
Ceramic Business Unit

Bharat Heavy Electricals Limited

The Company

Station Post Insulators for Bus bars, support and for

Isolators from 11 kV to 400 kV

Bharat Heavy Electricals Limited is the largest Engineering

and Manufacturing Enterprise of its kind in India. It ranks
amongst the leading manufacturers of power plant
equipment in the world.

Composite Insulators for Railway Traction and

Transmission applications up to 400 kV

BHEL has 14 manufacturing plants, 4 power sector

regional centres, 8 service centres, 18 regional offices and
over 150 project sites spread all over India and abroad. It
offers a wide spectrum of products and services for core
sectors like Power Generation, Transmission,
Distribution, Industry, Transportation, Oil & Gas, Defence
and Non-Conventional Energy Systems.

Ceramic Business Unit

The Ceramic Business Unit (CBU) of BHEL, is a Strategic
Business Unit for Ceramics and Systems. This business
unit deals with High Tension Insulators, Ceramic Wear
Resistant liners, Industrial Ceramic Products and
associated Systems. CBU is headquartered at Bangalore
and is supported by:
Manufacturing units with State of the Art
technology for ceramic products and systems at
Electroporcelains Division( EPD), Bangalore
Insulator Plant (IP), Jagdishpur
Advanced Research and Development facilities
for Ceramic products, processes and
applications at
Ceramic Technological Institute (CTI), Bangalore
( A Division of Corporate Research & Development,
Hyderabad)

Products
High Tension Insulators for Transmission and
Distribution lines from 11 kV to 800 kV
Hollow Insulators for Instrument and Power
Tr a n s f o r m e r s , S w i t c h g e a r, E l e c t r o S t a t i c
Precipitators, etc.

Wear resistant materials for Thermal Power Plant

applications, Steel, Coal Washeries, Cement, etc.
Industrial Ceramic Products for various applications

BHEL The Pioneer in

Insulators
BHEL pioneered the development of composite
insulators in India in the year 1998 through in-house
development efforts. Today its State of the Art facilities
manufacture Polymer insulators that compare with the
best in the world. BHEL make Composite insulators have
superior design features that ensure reliability and
excellent performance backed by years of expertise in the
insulator business.

Our Esteemed
Customers
Our Composite Insulators are approved and
are in Service with the following customers:
Research Development and Standards
Organisation (RDSO) of Indian Railways
Powergrid Corporation of India Ltd.
NTPC Ltd.
Tamilnadu State Electricity Board
Nuclear Power Corporation of India Ltd.
Gujarat Mining Development
Corporation Ltd.
AREVA T & D
Maharashtra State Transmission Company Ltd.

The Manufacturing Shop

Modern state-of-art manufacturing facility for production of

Silicone composite insulators with complete manufacturing
and testing facilities.

The Process

Crimping

State of Art Microprocessor controlled Crimping machine

with Acoustic Crack detection ensures uniform crimping
without stress concentration

Injection Moulding
The Silicone housing is injection moulded over FRP rod in a
fully automatic Microprocessor
controlled Injection
Moulding Machine. The housing is bonded securely over the
entire length of the FRP rod

The Materials

Fiber Glass Rod

Metal Fittings

Silicon Rubber

Raw materials (Silicon Rubber, Boron free ECR grade FRP Rod & SGI Castings/Steel Forged Metal Fittings) are sourced
from reputed manufacturers after undergoing stringent quality checks.

Construction Features
Acid Resistant Core rod
(ECR Glass)

Weather Sheds
designs for pollutted
conditions

Interface Core to
Housing- Thicknesss
conforming to IEC

Forged steel Metal

Fitting - Galvanised

Interface- Silicone
Overlapping
Metal Fitting

Manufacturing features unique to BHEL

Weather shed housing overlap at end fittings
ensures no moisture penetration.

Segment joining through Lap Jointing to ensure

perfect sealing of joints

Ultrasonic cleaning of end fittings after galvanizing to

remove moisture, greasy matter and rust.

Infrared curing of FRP rod to remove moisture

Silicone dough procured from reputed manufacturer after complete technical evaluation

No binders or fillers are added to dilute the properties of Silicone

Metal fittings made of High quality forged steel / Spheroidal Graphite Iron castings.

Double sealing
Silicone Housing

Quality & Reliability

BHELs Composite insulators undergo rigorous design
tests, type tests , routine tests and acceptance tests in
conformance to IEC 61109 and IEC 62217.

b) Specific gravity and shore hardness after curing

of Silicone
c) Tensile and tear strength of Silicone compound

BHEL has facilities to carry out all the required tests for
incoming materials such as Silicone, FRP rods and metal
end fittings. Some of them are

d) Die penetration , Water absorption, density, BD

voltage tests on FRP rods

a) Rheological characteristics of Silicone compound to

determine curing characteristics

e) Tensile, microstructure, galvanisation tests on metal

end fittings.

Rheology

Tensile testing

Die Penetration Test

BHEL polymer insulators have successfully undergone
stringent design tests in conformance to IEC 61109
Annexure C1, at world renowned laboratories at
KEMA, Holland

Hydrophobicity test

BHEL Polymer insulators undergo various routine tests

and acceptance tests in conformance to IEC standards as
well as Customer specific test requirements
1. Routine Electrical test
2. Mechanical Strength test
3. Thermal Mechanical Performance Test

BHEL insulators successfully undergone

5000 Hrs Accelerated Aging Test at KEMA,
Holland as per IEC 62217

Advantages of Silicone based Composite Insulators

Superior Handling of Mechanical Shock Loads hence
convenient to handle, transport and erect.
Low weight ( < 80 % of conventional porcelain) easy
handling
Resistance to Vandal Damage
Superior Dielectric Strength
High Power arc resistance due to high thermal
Withstand ability
Excellent Pollution Performance (Durable &
Regenerative Hydrophobicity)
Flame resistant
Shatter resistance
Aerofoil design offering minimum Wind Resistance
Low Leakage current and Power loss due to its high
surface resistivity

Regenerative Hydrophobicity
Wide range of service Temperatures (from 50oC to
100oC)
Interchangeability can easily replace existing Porcelain
insulators
Better Aesthetics

Silicone Composite Insulators Vs Porcelain Insulators

We i g ht r a t i o
between Porcelain
Insulator and
composite long rod
insulators for
transmission
applications is more
than 10:1 making
c o m p o s i t e
insulators an ideal
insulator for lines
with limited right of
way
Weight ratio Porcelain to Silicone Composite
insulator for Railway Traction applications is 3:1

Our Range of Composite Insulators

LONG ROD
TECHNICAL PARTICULARS OF COMPOSITE LONG ROD INSULATORS

TONGUE & CLEVIS TYPE

BALL & SOCKET TYPE

Unit

11 kV

11 kV

33 kV

33 kV

1. Shed Diameter (Big / Small)

mm

142 or 132/112

142 or 132/112

142 or 132/112

142 or 132/112

2. Unit Spacing

mm

285

375

325

375

3. Creepage Distance

mm

320

370

900

1110

4. Arcover Distance

mm

140

160

340

360

5. Electro-Mechanical Min. Failing load

kN

45

120

70/90

120

6. Coupling Designation

mm

16

20

16

20

7. PF-WET Withstand Voltage

kV

35

45

75

85

8. PF-DRY Withstand Voltage

kV

40

50

85

95

9. DRY-Lightning Impulse Withstand Voltage

kVP

75

90

170

170

10. Visible Discharge Test Voltage

kV

27

27

11. Weight of Unit

kg

1.0

1.5

4.0

4.5

Parameter

1. Sketch is indicative only.

2. Specific creepage distance from 16 mm / kV to 40 mm / kV
3. Length ranges from 285 mm to 4080 mm
4. Specified mechanical loads from
a. 45 KN to 120 KN for 33 KV to 132 KV.
b. 70 KN to 160 KN for 220 KV.
c. 120 KN to 160 KN for 400 KV.
5. For specific requirement, contact: CBU / Marketing, Malleshwaram, Bangalore....560012

Our Range of Composite Insulators

LONG ROD
TECHNICAL PARTICULARS OF COMPOSITE LONG ROD INSULATORS

Parameter

Unit

66 kV

66 kV

1.

Shed Diameter (Big / Small)

mm

142 or 132/112

142 or 132/112

2.

Unit Spacing

mm

770

870

3.

Creepage Distance

mm

2250

2250

4.

Arcover Distance

mm

560

560

5.

Electro-Mechanical Min. Failing load

kN

70/90

120

6.

Coupling Designation

mm

16

20

7.

PF-WET Withstand Voltage

kV

140

140

8.

PF-DRY Withstand Voltage

kV

150

150

9.

DRY-Lightning Impulse Withstand Voltage

kVP

325

325

10.

Visible Discharge Test Voltage

kV

53

53

11.

Weight of Unit

kg

4.8

5.5

1 Sketch is indicative only.

2 BHEL Manufacture & supply
a Specific creepage distance from 16mm/kv to 40mm/kv
b Height ranges from 285mm to4080mm
c Specified mehanical load require from
120KN to 160KN for 400KV.
45KN to 120KN for 33KV to 132KV.
70KN to 160KN for 220KV.
3. For specific requirement, contact:
CBU / MARKETING, Malleshwaram, Bangalore....560012

Our Range of Composite Insulators

LONG ROD
TECHNICAL PARTICULARS OF COMPOSITE LONG ROD INSULATORS

Parameter

Unit

110 kV

110 kV

132 kV

132 kV

1.

Shed Diameter (Big/Small)

mm

142 or 132/112

142 or 132/112

142 or 132/112

142 or 132/112

2.

Unit Spacing

mm

1460

1460

1450

1460

3.

Creepage Distance

mm

3870

3870

4300

4300

4.

Arcover Distance

mm

1175

1175

1210

1210

5.

Electro-Mechanical Min. Failing load

kN

70/90

120

70/90

120

6.

Coupling Designation

mm

16

20

16

20

7.

PF-WET Withstand Voltage

kV

185

185

275

290

8.

PF-DRY Withstand Voltage

kV

200

200

325

335

9.

DRY-Lightning Impulse Withstand Voltage kVP

450

450

650

650

10. Visible Discharge Test Voltage

kV

88

88

105

105

11. Weight of Unit (approx.)

kg

6.0

6.8

7.5

8.0

1. Sketch is indicative only.

2. Specific creepage distance from 16 mm / kV to 40 mm / kV
3. Length ranges from 285 mm to 4080 mm
4. Specified mechanical loads from
a. 45 KN to 120 KN for 33 KV to 132 KV.
b. 70 KN to 160 KN for 220 KV.
c. 120 KN to 160 KN for 400 KV.
5. For specific requirement, contact: CBU / Marketing, Malleshwaram, Bangalore....560012

Our Range of Composite Insulators

LONG ROD
TECHNICAL PARTICULARS OF COMPOSITE LONG ROD INSULATORS

Parameter

Unit

220 kV

1.

Shed diameter (Big/small)

mm

142 or 132/112

2.

Unit Spacing

mm

2610

2610

3335

3910

3.

Creepage Distance

mm

8000

8000

10500

13020

4.

Arcover Distance

mm

2300

2300

3050

3400

5.

Electro-Mechanical Min. Failing load

kN

70/90

120

120

160

6.

Coupling Designation

mm

16

20

20

20

7.

PF-WET Withstand Voltage

kV

500

500

680

680

8.

PF-DRY Withstand Voltage

kV

575

575

720

720

9.

DRY-Lightning Impulse Withstand Voltage

kVP

1080

1080

1550

1550

10. Visible Discharge Test Voltage

kV

154

154

305

305

11. Weight of unit (approx)

Kg

11.5

12.2

18.5

21

1. Sketch is indicative only.

2. Specific creepage distance from 16 mm / kV to 40 mm / kV
3. Length ranges from 285 mm to 4080 mm
4. Specified mechanical loads from
a. 45 KN to 120 KN for 33 KV to 132 KV.
b. 70 KN to 160 KN for 220 KV.
c. 120 KN to 160 KN for 400 KV.
5. For specific requirement, contact: CBU / Marketing, Malleshwaram, Bangalore....560012

220 kV

400 kV

400 kV

142 or 132/112 142 or 132/112 142 or 132/112

Railway Traction for Standard

and Polluted applications
TECHNICAL PARTICULARS OF COMPOSITE RAILWAY TRACTION INSULATORS

STAY ARM

BRACKET

9-TONNE

Parameter

Unit

Stayarm Insulator

Bracket Insulator

9-tonne Insulator

1.

Shed Diameter

mm

185/145

185/145

185/145

2.

Unit Spacing

mm

489

555

540

3.

Creepage Distance

mm

1050

1050

1050

4.

Arcover Distance

mm

390

390

390

5.

Bending Strength

kgfm

200

200

210

6.

Electro-Mechanical Min. Failing load

kgf

7000

7000

11000

7.

PF-WET Withstand Voltage (horizontally)

kV

125

125

125

8.

PF-WET Withstand Voltage (vertically)

kV

100

100

100

9.

DRY-Lightning Impulse Withstand Voltage positive

kVP

240

240

240

10.

DRY-Lightning Impulse Withstand Voltage negative

kVP

260

260

260

11.

Visible Discharge Test Voltage

kV

35

35

35

12.

Weight of Unit (approx.)

kg

4.4

5.0

5.4

Sketch is indicative only.

Bharat Heavy Electricals

Limited
(A Government of India undertaking)

Registered and Corporate Office

BHEL House, Siri Fort, New Delhi - 110 049.
Tel: 011-2600 1010 Fax: 011-2649 3021

www.bhel.com
Efforts are constantly being made to
improve the product design and hence the
products supplied may differ in minor
details from that given in the catalogue.
For enquiries please contact:

Bharat Heavy Electricals Limited

(A Government of India Undertaking)

Ceramic Business Unit

Prof. C.N.R. Rao Circle,
Opp. Indian Institute of Science
Malleswaram, Bangalore-560 012 (India)
Ph: 080-23442988, 22182247
Fax: 080-23560741, 23344231

www.bhelceramics.com