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Insulation and Components

Hollow composite insulators 72-1,200 kV

Design for reliable performance
A century of innovation

ABB develops and manufactures power composites – high

performance insulating components made of fiber composite
materials for power and high voltage applications. Our mission
is to produce world-class, cost-efficient products for customers
all over the world.
ABB’s composite business is located in Piteå in the north
of Sweden. The company was founded by pioneers in the
Swedish polymer industry, and production of electrical
insulating material started in 1918. The present location was
established in 1967. The core expertise of the company
is knowledge of the electrical, mechanical and physical
properties of composite materials, and in the ability to
engineer unique insulation solutions for customers. The main
products are filament-wound products, breaker components
and hollow composite insulators.

2 A century of innovation | Insulation and Components Insulation and Components | A century of innovation 3
ABB Composite Insulator Technology

One piece tailored glass fiber composite tube

Best mechanical and dielectrical performance

High temperature vulcanized (HTV) silicone

rubber with high amount of aluminum trihydrate
(ATH) filler
Improved tracking and erosion performance and
best long term performance

Seamless helical extrusion process for a

continuous outer silicone housing
No mold lines where dirt or salt can accumulate

Developing various types of composite insulators for the most Optimized shed profiles with large shed tip
radius and high protective creepage distance
demanding applications known today requires not only in-depth Lowest possible leakage currents and electrical field

material and design know-how, it also requires an absolute

understanding of the production process. ABB is knowledgeable
of the requirements for high voltage applications and the
High-strength aluminum end fittings
essence of being a reliable business partner with the highest Strong, gas-tight and leak-proof joint

quality standards.

ABB currently provides hollow composite insulators rang- The tubes are cured on continuously rotating mandrels in
ing from 72 kV up to 1,200 kV AC and 1,100 kV DC, and in ovens with a precisely controlled temperature profile to ensure
lengths up to over 15 meters. ABB’s product range is wide fully cured tubes with excellent quality. The whole process Insulators of the conical/tapered type offer great advantages High strength flange design
with more than 300 different composite insulators in ensures high grade insulator tubes with low manufacturing in many applications. Cost-efficient design with less material, The fiberglass tubes are fitted into high strength and high
production. Each composite insulator design is tailor-made tolerances and superb mechanical and dielectrical properties. lower weight and gas volume reduction for SF6-filled products resistant aluminum alloy casted flanges using a special
to the customer’s requirements. By choosing ABB composite are just some of benefits of tapered insulators. process, which results in a combined shrink fit and adhesive
insulators, excellent perfomance and reliability can be assured All ABB insulator tubes are made in-house and as one bond. The result is an extremely strong, gas-tight and leak-
for the lifetime of your equipment. continuous piece. The alternative would be to join tube The composite insulators are designed according to the proof joint. Anodized flange solutions are available for extreme
segments into a full length tube but the ABB design mechanical requirements of our customers to manage both environments and special applications.
In-house production of one-piece fiberglass composite philosophy is to avoid such possible weak spots. Until bending forces and the inner pressures to which the insulators
tubes relatively recently, the maximum length of one-piece are subjected during their service lives. An inner layer of poly-
The load-bearing insulator tubes are made of electrical grade composite insulators available on the market was about 6 m. ester liner is normally used. This is a requirement for insulators
fiberglass, reinforced with epoxy resin using a wet filament This limitation has been set aside by ABB pushing it up to used in gas-insulated circuit breaker applications to be able
winding technique. Continuous fibers are impregnated in a over 15 m. to withstand the decomposition products of the insulation gas
bath of epoxy resin and then wound at a controlled pre-stress SF6.
onto the mandrel. Precise and defined winding of the fiber Today ABB manufactures the worlds largest on-piece
onto the mandrel ensures uniform laminates of the highest insulators.

4 ABB Composite Insulator Technology | Insulation and Components Insulation and Components | ABB Composite Insulator Technology 5
1 2

≥ 15°

≥ 8°

R ≥ 2,5

1. Large shed tip for minimized electrical field 2. Optimized shed profile with high protective creepage distance
High temperature vulcanized silicone rubber for best Seamless helical extrusion process for continuous outer
long-term performance silicone housing Optimized shed profiles with large shed tip radius and The under inclination angle is ≥ 8° so as to obtain an optimum
ABB uses only high quality, high temperature vulcanized (HTV) Our fiberglass tubes are equipped with HTV silicone rubber high protective creepage distance balance between protected creepage distance, water roll-
silicone rubber to ensure the highest possible durability of weather sheds using a void-free helical extrusion process. Major development efforts have been carried out to achieve off from the sheds’ undersides and natural cleaning. Sheds
sheds, as well as outstanding tracking and erosion resistance. ABB has developed a unique patented method of extruding our optimized shed profiles. ABB primarily offers shed profiles with under inclination angles have high protected creepage
Using only hard-wearing HTV silicone rubber also ensures the sheds with a helical pattern. This method ensures the best using alternating long and short sheds, which ensure wet distances, which is very beneficial. In coastal and industrial
superior performance in sandstorm areas and minimization possible interface between the silicone and the tube. performance and self-cleaning properties. Both the bottom environments, the protected creepage distances prevent the
of damages during transportation and handling. The material The silicone rubber sheds are chemically bonded to the tube, surface and top surface of the sheds are angled. This ensures whole surface from being covered with liquid electrolytes.
also exhibits stable behavior under extreme climate conditions thus allowing no moisture or contamination to enter. The result optimal creepage distance and protected areas, resulting in Insulators with protected creepage distances also maintain
(-60°C to +110°C). is a seamless silicone coating with no molding lines. Even the lowest possible leakage currents, even in severe their initial surface hydrophobicity for a much longer time in
the longest insulators (more than 15 m) are manufactured in environments. fog conditions.
A high filler content of aluminum trihydrate (ATH) is used one step, resulting in continuous silicone housings without
to achieve superb tracking and erosion behavior. It is well molding lines (where dirt and salt can accumulate) or other The upper inclination angle is ≥15°, which is more than the The tip of each shed is well-rounded with a radius of ≥ 2.5
documented that HTV silicone rubber enriched with ATH filler potential weak joints. minimum requirement in IEC 61805-3. A steep angle causes mm to minimize the electrical field and the risk of flashover.
outperforms low viscosity silicone rubbers, such as liquid water to roll off outside the underlying sheds instead of creat- Another feature of the ABB shed profile is the drip edge at the
silicone rubber (LSR), regarding long-term performance. The flexibility of this method also ensures that any specific ing long pendant drops, which could trigger flashover. shed tip. This feature ensures water roll-off and increases the
Extensive research and development (R&D) has been customer dimensions (diameter, length or shape) can be met tear strength of the shed.
invested in our material to find the optimum balance between with even the most stringent creepage distance requirements.
hydrophobic properties and tracking/erosion resistance. The The cost of tooling is low compared to other methods, which All of ABB’s standard shed profiles comply with IEC 60815-3.
superior silicone material used by ABB involves an ATH level makes our process highly suitable for optimizing the design to Special shed profiles fulfilling requirements for UHVDC (800
of more than 45 percent in weight. The resulting material our customers’ needs in a cost-efficient way. kV DC and 1,100 kV DC) are also available.
fulfils tracking class 1A4.5 (as per IEC TR 62039) with a
hydrophobicity transfer recovery of less than 24 h. Pollution
performance is verified in both laboratory and field testing.

6 ABB Composite Insulator Technology | Insulation and Components Insulation and Components | ABB Composite Insulator Technology 7
Advantages of the technology

Silicone rubber is the fastest-growing, most dominant polymeric The mechanism behind the hydrophobicity of silicone rubber
is the diffusion of low molecular weight (LMW) silicone from
Maintenance-free and outstanding pollution performance
HTV silicone rubber has the ability to transfer its water-
insulation material for high voltage products. Composite the bulk of the material to the surface. LMW silicone forms a repellent properties into the pollution layers that cover the
layer on the surface that is hydrophobic (non-wetting). surface. This eliminates the need for maintenance or cleaning
insulators with silicone rubber offer significant benefits as of the high voltage apparatuses in polluted environments.

compared to the former porcelain technology. This layer is extremely thin, only a few molecular layers, and
is distributed over the entire surface, thus forming a hydro-
Expensive solutions normally used for porcelain, such as
cleaning, greasing or coating, can be avoided.
phobic layer. The LMW silicones diffuse to the surface over
the entire life of the insulator; however, the loss of material UV stability
is negligible and does not impair other insulation properties. HTV silicone rubber is ultraviolet (UV) and ozone resistant.
Composite insulators were first introduced more than 30 Composite insulators offer outstanding safety in the event of: Another benefit of silicone is its capability to encapsulate Natural UV radiation from the sun has wavelengths of over
years ago, and the use of hollow composite insulators on −− Internal faults/inner overpressures in the equipment contaminated particles. 300 nanometers. Shorter and more energetic wavelengths
high voltage apparatuses is now well accepted. Composite −− External influences, eg, during transportation, installation are filtered out in the atmosphere. Silicone has its maximum
insulators are proven in the field and are direct replacements and maintenance Leakage current over time at salt fog test absorption below this wavelength, which ensures superior
for porcelain insulators used in high voltage applications. −− Environmental influences, eg, earthquakes, landslides, stability against UV radiation.
Increased safety, light weight and superior pollution and tornadoes 1 Porcelain

Leakage current, A
insulation performance are some of the reasons customer −− Vandalism, eg, rock throwing, shooting Silicone Absorption max of SiO2 bond
choose composite insulators. The following benefits 0,1
are taken under consideration when OEMs and utilities Non-brittle material with reduced risk of handling
Solar radation, UV
worldwide choose composite insulators for their high voltage damages 0,01
applications. Since composite insulators are non-brittle and resistant to
shock, the risk of damage to the equipment during transport, 0,001
Explosion-proof for maximum safety installation and service is reduced. If, however, minor shed 0,2 0,4 0,6 0,8 1
In the event of an internal fault/inner overpressure or external damage occurs, it can be easily repaired in the field. This is Time, hours
influence/vandalism, a porcelain insulator will exhibit violent not the case with porcelain insulators.
failure (explosion) with dangerous fragments ejected at high Excellent insulation for reduced creepage requirements 290 300 400
speed. Leakage current control due to hydrophobicity Composite insulators have excellent insulation properties Wavelength, nm
Composite insulators with silicone rubber sheds have the and outstanding contamination performance due to the
The failure mode of a composite insulator is delamination/ added benefit of being hydrophobic, a term meaning “fears silicone rubber. Published field studies show that it is possible Additional advantages
puncture without the launch of destructive fragments. water.” This characteristic helps break up water films and to reduce the required creepage distance by at least one Other advantages of composite insulators are short and
The insulator maintains load carrying capacity and will not creates separate droplets, which reduces leakage current pollution level when composite insulators are chosen over reliable delivery times, best possible strength-to-weight ratio,
break down like a porcelain insulator. There is no damage along the insulator surface, prevents flashover and elevates porcelain. the option of reducing gas volumes on SF6 breaker bushings
to surrounding equipment and no danger to people in the the voltage withstand capability under wet and highly with conical insulators compared to cylindrical designs, proven
vicinity. This ensures maximum safety for both personnel and contaminated conditions. The low leakage current also Flashover resistance aging resistance and high inherent fire resistance.
substation equipment. minimizes discharge activity on the surface and erosion. The efficient suppression of leakage currents means that the
Hydrophobicity functions as a self-cleaning property that risk of flashover is reduced compared to porcelain insulators.
extends service life and lowers substation maintenance costs.
Outstanding seismic performance provides safety and
The low weight and the shock-proof design of composite
insulators compared to porcelain offer advantages in terms
Shatter test of live tank circuit breaker with porcelain insulator (high speed camera, 16 ms sequence)
of earthquake resistance capability. No shock absorbers or
special designs are required in seismic areas.

Low weight for cost savings

Composite insulators are much lighter and provide higher
performance than porcelain insulators. This leads to a drastic
reduction in the use of the other materials that make up high
voltage electrical substations, such as foundation materials
and bearing structures. The installation phase is also easier
due to the reduced need for heavy installation equipment.

8 Advantages of technology | Insulation and Components Insulation and Components | Advantages of technology 9
Evaluating a great concept

Subjecting the products to extensive testing well beyond the

requirements of applicable standards, such as in long-term field
tests and extreme voltage stress, has confirmed the outstanding
performance of ABB composite insulators in all types of high
voltage and ultra high voltage applications. More than 100,000
insulators are installed around the globe, representing all types
of environments.

ABB composite insulators are thoroughly tested Aging withstand, electrical and mechanical erosion resistance, Field tests Examples of long-term field tests
to international standards and higher. They have and UV stability have been fully verified. Natural pollution tests Numerous long-term field tests of ABB composite insulators Place Type Duration
demonstrated excellent performance under all climates are continually performed at test stations in both marine and have been performed. Dungeness, UK Costal, very heavy pollution 4 years
and harsh conditions, such as coastal, desert and desert climates. Guangzhou, CN 500 kV DC 1 year
industrial environments. Test installations around the world have been made to gain Ludvika, SE 800 kV DC 4 years
Testing is also performed at low ambient temperatures, information on long-term behavior and insulation performance Koeberg, ZA Extreme pollution 1 year
Service experience worldwide down to -60˚C. The composite insulators comply fully with in different environments. The test stations represent all
Since 1985, when the first ABB high voltage equipment with the requirements specified by the IEC. The insulators have possible climates – arctic, coastal, subtropical and desert
silicone rubber sheds were installed, ABB has delivered a undergone vandalism tests; a circuit breaker with composite areas – as well environments at high altitudes and with
vast number of high voltage apparatuses equipped with insulators has even been subjected to gunfire to show that extreme pollution and strong UV light.
composite insulators. They have been installed in all types of this kind of damage does not cause complete breakdown or
environments, from marine and desert regions to areas with explosion that could injure personnel or damage surrounding
heavy industrial pollution. equipment.

The performance of ABB composite insulators in installations Examples of performed tests

with extreme environmental conditions has been studied in High and low temperature -60°C and +110°C
detail, and the results have been published at a number of Dielectric
conferences and in well-known journals. The observations UV radiation
show excellent performance with insignificant changes in Accelerated aging
material properties.The HTV silicone material has proven its 5,000 hour multi-stress cycling
outstanding performance at test stations in severe climates 1,000 hour salt fog
and commercial installations all over the world. Mechanical strength
More than 100,000 ABB composite insulators are installed in Seismic
over 70 countries worldwide. The service history is excellent Shatter
with no reports of flashovers, premature ageing or other major Pressure cycling, -40°C and +100°C

Extensive testing beyond standards

ABB composite insulators have been subjected to extensive
testing to ensure high quality and to verify their mechanical
and electrical properties under all environmental conditions.

10 Evaluating a great concept | Insulation and Components Insulation and Components | Evaluating a great concept 11
Ultra high voltages and ultra high voltage direct current The development of 1,100 kV composite insulators addresses
Insulators are key components for transmission at several technology challenges, including sheer size and scale,
higher voltages. ABB is pioneering the development and electrical insulation and thermal performance parameters.
manufacturing of hollow core composite insulators for ultra The successful testing at 1,100 kV UHVDC verifies ABB
high voltage (UHV) and ultra high voltage direct current composite insulators’ excellent performance.
(UHVDC) applications. The field tests together with our
extensive deliveries for UHV and UHVDC applications is
a verification of the ABB composite insulators’ excellent
insulation properties, the durability of the design and long-
term performance.

The world`s first 800 kV DC transmission system, Xiangjiaba-

Shanghai, was put into commercial operation by ABB in 2010.
It has a capacity of 6,400 MW, and at just over 2,000 km, is
the longest power link of its kind in operation. ABB composite Design, type and routine tests This ensures the highest level of quality and long-term
insulator technology is used for all main high voltage equip- ABB composite insulators are designed, type and routine performance for the insulators. In addition, ABB has a
ment (transformer bushings, wall bushings, live tank circuit tested in accordance with IEC 61462 and other regional fully equipped laboratory for material analysis. Electrical,
breakers, instrument transformers as well as voltage dividers). standards. All requirements of IEC 62217 and IEC 60815 are mechanical and physical properties are measured and
fulfilled. documented on a routine basis to ensure all important
UHVDC at 1,100 kV is the next step. ABB has successfully material properties.
developed and tested the first 1,100 kV UHVDC converter ABB has invested in sophisticated equipment for routine
transformer with ABB composite insulator technology, testing, and our testing goes beyond the IEC requirements.
breaking the record for the highest DC voltage ever achieved. Routine testing includes cantilever bending tests, pressure
tests and quantitative gas tightness measurements.

12 Evaluating a great concept | Insulation and Components Insulation and Components | Evaluating a great concept 13
Application examples

1. Wall bushing 800 kV DC 2. Compact transmission line post insulator 275 kV 3. Wall bushing 1,100 kV DC 4. Live tank circuit breaker 550 kV 9. By pass switch 1,100 kV 10. UHVDC station post insulator and voltage divider 800 kV DC 11. Composite station post insulator 145 kV
5. Coupling Capacitor 1,100 kV DC 6. Surge arrester 420 kV 7. Outdoor instrument transformer 550 kV 8. Dead tank circuit breaker 145 kV 12. Cable termination 300 kV 13. Dead tank circuit breaker 800 kV 14. Transformer bushing 800 kV DC
1 2 9 10

3 4 5 11 12

6 7 13 14

14 Application examples | Insulation and Components Insulation and Components | Application examples 15
Design guide

ABB offers a wide range of composites with more than 300 different insulator types in production. Together with
flexible production methods, ABB can deliver composite insulators that will meet and exceed your requirements.

This design guide makes it is easy to choose a composite insulator that meets your requirements. If none of our standard D1
designs match your needs, other designs can be easily developed on request.

The easiest way to design an insulator is as follows:

1) Specify the inner diameter and length of the tube from the diameter set table
Inner diameter
2) Choose a shed design and creepage factor 82 130 150 160 180 210 260 311 335 358 375 420 450 470 486 575
D1 [mm]
3) Choose flanges to match your installation preferences
Maximum length
2300 3200 3200 3200 4350 4300 10000 5000 4300 5000 4000 4300 3800 3800 9100 3800
Lmax [mm]
Fiberglass tubes
ABB can offer composite insulators with cylindrical, conical and combinations of cylindrical and conical sections. Lengths
over 15 m can be manufactured as a single tube without adhesive joints. All tubes are customized (wall thickness and winding
angles) to meet customers’ mechanical requirements (pressure and bending). Shed profiles
The required creepage distance for your apparatus will determine which shed profile is suitable for your design and that will
L max meet your requirements. ABB offers a wide range of standard shed profiles, see table below. Standard shed profiles from ABB
comply with IEC 60815-3. Other shed profiles can be arranged quickly and cost-efficiently on request. Extreme creepage
requirements (> 50 mm/kV) can also be arranged.

D1 D2

S [mm] P [mm] P 1 [mm] Cf, Creepage factor R S

L1 L3 50 32 - 2.25 8,5
55 27 27 2.65 2,5
55 55 25 3.55 2,5
Inner diameter 1 Inner diameter 2 Length 1 Length 2 Length 3 Maximum length 55 60 30 3.87 2,5
D1 [mm] D 2 [mm] L 1 [mm] L 2 [mm] L 3 [mm] Lmax [mm] 55 60 40 4.21 2,5
200 100 300 898 100 1298 70 75 55 4.25 2,5
250 219 680 855 470 2005 60 70 50 4.49 2,5 P1
260 180 7330 3500 1340 12170 60 70 50 4.51 3
270 130 300 1100 500 1900 55 65 48 4.61 2,5
270 130 460 1100 450 2010 63 78 58 4.8 2,5
270 130 380 1270 160 1810 49 63 46 4.89 2,5
296 219 770 1595 700 3065 55 73 56 5.1 2,5
321 120 770 1970 190 2930
326 219 780 1965 700 3445 To estimate the creepage distance from the shed profiles’ creepage factor, the following equation can be used:
330 210 150 1310 680 2140
330 210 150 630 190 970 Cd = Cf × ( ad - 300 ) + 300
355 130 750 1776 420 2946
394 286 990 2300 990 4280 where:
400 260 2050 6000 2050 10100 Cd = Creepage distance*
402 205 580 1570 750 2900 a d = Arcing distance**
450 210 1450 700 2000 4150 C f = Creepage factor
486 385 1860 1615 2090 5565
486 124 1420 2940 350 4710
500 311 1400 1800 1100 4300
517 245 3170 2515 730 6415
550 400 2700 625 3250 6575
630 480 1950 1100 3200 6250 Explanatory text from IEC 61462

740 580 3550 1000 5650 10200 */ Creepage distance

Shortest distance or the sum of the shortest distances along the surface on an insulator between two conductive parts which normally have the operating voltage between them
983 725 5240 2448 3500 11188
**/ Arcing distance
983 725 3120 2448 6700 12268 Shortest distance in the air external to the insulator between the metallic parts which normally have the operating voltage between them

16 Design guide | Insulation and Components Insulation and Components | Design guide 17
Flanges Tube Fittings
The flange design is critical for the fit of the insulator on the apparatus to which it will be attached. ABB offers a wide range of D1 NH DBC DH DO
standard flange designs. If none of the standard flanges meets your requirements, other designs are available on request. [mm] [pcs] [mm] [mm] [mm]
225 M16 267
326 16 356
14 356
6 326 16
18 362
D BC D1 Do 275 18
280 15 310
300 18 344
325 18 365
330 18 365
4 182,5 M8 250
200 289 M12 375
DH × NH 361 15 393
160 M8 245
225 M16 273
Tube Fittings 286 15 ¤255
D1 NH DBC DH DO 296 M8 312
[mm] [pcs] [mm] [mm] [mm] 350 14 380
82 4/4 122 / 130 M8 / M10 160 360 14 390
100 6 213 M12 254 6 360 14 390
120 8 270 15 300 325 18 369
123 8 232 M12 260 8 326 M10 346
135 M8 165 356 18 400
171,5 M8 185 10 326 14 390
225 18 270 6/6 362 14 / 18 400
260 15 230 220 M10 278
15 ¤255 274 11 330
130 286
19 ¤255 219 6 308 M10 333
6 185 16 225 245 16 360 14 395
215 12 242 250 12 457 15 490
232 M12 260 406 14 315
12 155 M10 213 406 14 436
286 19 ¤255 6 406 14 436
318 18 363,5 M16 365
260 330
290 14 325 8 18 365
150 6
326 14 356 375 18 420
280 15 310 12 406 15 436
330 18 365 16 270 M10 327
4 160 M8 200 8 450 19 480
160 195 270 12 390 M12 420
12 180 M10
237 16 450 16 480
¤ = non-circular flange, square 286 6 389 M10 455
296 12 502 15 532
4 160 M8 365
24 327 M12 388
¤ = non-circular flange, square Continued on next page

18 Design guide | Insulation and Components Insulation and Components | Design guide 19
Tube Fittings Material properties
D1 NH DBC DH DO Only the highest quality materials from well-known suppliers are used in products.
[mm] [pcs] [mm] [mm] [mm]
6 456 14 486 Material specifications, fiberglass tubes
360 M12 390 Composite tubes, filament-wound with fiberglass roving impregnated with epoxy resin. The inner surface is coated with non-
311 456 14 486 woven polyester. The table below shows typical properties for a tube with a 38° winding angle.
395 M12 430
520 22 600 Properties Unit Typical value Test method
320 8 500 19 536
326 12 527 15 560 Winding angle Degree 38
8 360 M12 390 Density g/cm 3 2 ISO 1183
16 450 16 480 Glass content % weight 75 ISO 1172
4 160 M8 415
24 380 M12 441 Interlaminar shear strength*, ILSS MPa EN 2377
4 425 M10 543 RT 40
16 570 14 614 110°C 28
385 16 555 M12 580 140°C 12
394 24 605 15 635
530 14 565 Flexural strength MPa 250 ISO 178
400 600 22 645 Flexural modulus GPa 16 ISO 178
16 550 14 587 Compressive strength, axial MPa 200 ISO 604
8 360 M12 466 Dielectric strength, tangential, oil. 90°C kV/mm min 3.6 IEC 60243
420 20 480 M12 523 Dielectric strength, axial oil. 90°C kV/mm min 3.6 IEC 60243
30 509 8 560 Partial discharge at 3.6 kV/mm pC <10 ABB 309-01
450 15 558 M10 573 Tracking index**, CTI >600 IEC 60112
480 20 610 18 645 Dielectric constant, RT 5.75 IEC 60250
16 700 18 740 Dissipation factor, RT 0.0047 IEC 60250
30 605 14 640
8 600 18 640 Volume resistivity ohm IEC 60093
12 675 18 715 3 000 V 2x1,014
517 24 656 18 697 5 000 V 3x1,014
550 16 680 18 720
581 24 710 18 745 Surface resistivity ohm IEC 60093
630 30 780 26 830 Outside 3 000 V 2x1,016
720 24 880 18 920 Outside 5 000 V 2x1,016
740 32 890 26 940
970 32 1130 26 1180 Surface resistivity ohm IEC 60093
Inside 3 000 V 8x1,016
Inside 5 000 V 8x1,016

Water absorption, RT mg 7.5 ISO R 62

Glass transition temp. °C min 130 ISO 11357-2
Temperature index °C 160 IEC 60216

*/ Interlaminar shear strength-tangential

**/ Criteria 50 % reduction of flexural strength after 20,000 h, plan laminate fiber directional

20 Design guide | Insulation and Components Insulation and Components | Design guide 21
Customer request form

Please use this request form to specify your ABB composite insulator
Material specifications, high temperature vulcanized silicone rubber
Platina curing, solid high temperature vulcanized (HTV) silicone rubber based on polydimethylsiloxane (PDMS) with aluminum Company:
trihydrate (ATH) filler. Contact person: Phone no:
Type of apparatus:
Properties Unit Specific value Test method Annual quantity: Batch size:
Insulating medium:
Vulcanized rubber Service temperature range: to °C
Silicone (polydimethylsiloxane, PDMS) content > 33%
Aluminum trihydrate (ATH) filler content > 45% Mechanical requirements acc. IEC 61462
Tracking and erosion resistance 4.5 kV in class 1A IEC 60587 Max. mechanical load, MML: kN
Recovery of hydrophobicity WC 1-3 within 24 hours IEC TS 62073 Max. deflection at MML: mm
Color ANSI 70 5.0BG 7.0/0.4 Max. service pressure, MSP: MPa
Tensile strength, RT MPa min. 3.0 ASTM D412
Elongation at break, tensile % min. 170 ASTM D412 Electrical requirements
Hardness Shore A 65-75 ASTM D2204 Min. arcing distance: mm
Tear strength kN/m min. 15 ASTM D 624B Min. creepage distance: mm
Dielectric strength, 1 mm sheet, RT_I_ kV/mm 23 IEC 60243
L1 L2
Tracking resistance 1A4.5 IEC 60587
Dielectric constant 100 Hz, RT 3.7 IEC 60250
Dissipation factor 50 Hz, RT 0.017 IEC 60250
Volyme resistivity Ωcm 2.0x10 14 IEC 60093
D2 D o DBC

Material specifications, aluminum alloys DH x NH

Alloy description Numeric short Material Tensile Yield Elongation Brinell
(DIN EN 1706) symbol number strength strength at break hardness Dimensions
Chemical symbol Numeric (DIN 1725-2) (DIN 1725-2) Rm (MPa) Rp 0.2 (MPa) A5 % HBS If it is possible, please give us dimension limits (max. and min.)
GK-AlSi7Mg EN AC-AlSi7Mg0.3 EN AC-42100-T6 G-AlSi7Mg 3.2371 290 210 4 90
GK-AlSi10Mg EN AC-AlSi10Mg(a) EN AC-43000-T6 G-AlSi10Mg 3.2581 260 220 1 90 Cylindrical Max. Min.
EN AC-AlSi10Mg(b) EN AC-43100-T6 260 220 1 90 Length of insulator, L: mm mm
Inner diameter, D1: mm mm

Conical Max. Min.

Length of insulator, L: mm mm
L1: mm mm
L 2: mm mm
Inner diameter 1, D 1: mm mm
Inner diameter 2, D 2: mm mm

Flange design
Top flange Bottom flange
Outer diameter, Do: mm mm
Hole dimension, D h: mm mm
Bolt circle diameter, DBC: mm mm
Number of holes, NH: pcs pcs

Additional information:

22 Design guide | Insulation and Components

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1ZSP000001 revision B, 2013-06

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