SIEMENS - Aisladores de Composite

PTFE Workshop / Madrid / February 2015
Composite Insulators
Design and Experience from Applications in Overhead Contact Lines
© Siemens AG 2015
2014 All
– All
rights
rights
reserved.
reserved.
Contact line designs
for urban transport and mainline services
Modular Sicat contact line

designs for every task Running speed DC AC Features
• Different traction power supply ≤ 80 km/h Sicat 3S • Economy

systems ≤ 120 km/h Sicat LD • Long service life
• All speed ranges ≤ 160 km/h Sicat SD Sicat LA • Consistently high quality
• Different performance levels ≤ 200 km/h Sicat SR Sicat SR • High running quality
• Open lines, tunnels, stations ≤ 230 km/h Sicat HD Sicat SA/ Sicat SX • Compliance with national and
and depots international safety standards
> 230 km/h Sicat HA
Sicat 3S in Thailand Sicat LD in Peru Sicat SA in Malaysia Sicat HA in China
© Siemens AG 2015 – All rights reserved.

Page 2 26/02/2015 PTFE – Composite Insulators, Siemens Mobility Division / Rail Electrification
Sicat Contact Line systems consist of
Sicat Contact Line components
Sicat contact line equipment

for every function:
§ Tensioning equipment
§ Cantilevers and supports
§ Insulators
§ Contact lines under structures
§ Tension wheel equipment
§ Section insulator, neutral section
§ Disconnectors and drive mechanism
§ Contact wires, single and stranded wires
§ Conductor rail
§ Monitoring systems
S > 1,000 pcs

Sicat CI
Siemens Composite Insulators for contact lines
Sicat CI 8WL3078
up to 25 kV AC
creepage distance > 1200 mm
Sicat CI 8WL3088
up to 3 kV DC
creepage distance > 300 mm

Sicat CI – Composite Insulators
• High number of composite insulators in contact line:

> 3,000 pcs / 100 km
• Very high impact of failures of components in contact lines
Composite insulators have significant

advantages regarding
Reliability,
Availability,
Maintainability and
Safety.

Content
Design of
composite
Benefits of composite insulators
insulators
Quality of composite insulators Applications of composite insulators Summary

in overhead contact lines

Basic design of composite insulators
2
3 3
1 - End fitting
2 - GRP (Glass fiber Reinforced Plastic) rod
3 - Housing

Types of composite insulators – I
Suspension and tension insulators Cantilever and line post insulators

acc. to IEC 61109 acc. to IEC 61952

Types of composite insulators – II
Suspension and tension insulators Cantilever and line post insulators

acc. to IEC 61109 acc. to IEC 61952
SML Specified Mechanical Load SCL Specified Cantilever Load

MDCL Maximum Design Cantilever Load
STL Specified Tensile Load
SML
“subjected mainly to tension load” “subjected to cantilever, tensile and compressive loads“

Content
Design of
composite
insulators


HTV Silicone Rubber Housing – I
Why silicone rubber? Why HTV silicone rubber?
Silicone rubber material – different types

Three general grades
• Room Temperature Vulcanizing (RTV)
• Liquid Silicone Rubber (LSR)
• High Temperature Vulcanizing (HTV)
[1] Papailiou, Konstantin O.; Schmuck, Frank: Silikon-Verbundisolatoren,

Werkstoffe, Dimensionierung, Anwendungen, Springer-Verlag Berlin
[1] Heidelberg 2012

HTV Silicone Rubber Housing – II
Key property: Hydrophoby
• Self-cleaning effect due to hydrophoby

• Improved pollution layer performance due to
• hydrophoby recovery (“healing”/ regenerating effect)
• hydrophoby transfer to pollution layer
pollution [3]
layer
[2]
polymer chains with silicone

low molecular weight rubber
[2] Prof. Dr.-Ing. Neumann, C.; RWE Net, Dortmund: Betriebsverhalten von Silikonisolatoren, in: ETG-Fachbericht Nr. 93, VDE-Verlag GmbH
[3] http://www.stri.se/metadot/index.pl?id=4671&isa=Category&op=show [4]
[4] MR Product Training Handout, 2014

HTV Silicone Rubber Housing – III
• High UV resistance
• High tracking and erosion resistance
• Tracking resistance:
Silicone rubber >>> Polymers on
carbon basis
• Tracking and erosion resistance:
HTV >>> RTV, LSR
• High flammability resistant, self
extinguishing properties
(category V0)
• No additional housing interfaces due
to one-piece housing
[5]
[5] Dr.-Ing. Seifert, J.; Prof. Dr.-Ing. Bärsch, R.: Bewertung des Kriechstreckendesigns von
Silikonverbundisolatoren unter dem Aspekt von Fremdschicht-Bauartprüfungen und
langjährigen Betriebserfahrungen, in: ETG-Fachbericht Nr. 99, VDE-Verlag GmbH

Core rod with ECR-glass
Quality issue
Brittle fracture of polymer insulators

• Moisture ingress under electrical stress causes hydrolysis and acid attacks on
the GRP core rod
à Inner erosion of the core-rod leads to total mechanical failure of the insulator
Solution
Brittle Fracture [6]

ECR (Electrical - Corrosion Resistant)-glass fiber epoxy resin reinforced rod
• Boron-free GRP rod which is acid-resistant
• 100% Brittle fracture free insulator
Verification
96 h brittle fracture proof test

• Electrolytic stress with nitric acid (1n = 63 g HNO3 plus 937 g water) [6] Braunsberger, Tobias; Dziubek, Arkadiusz; Kurrat,
Michael; Seifert, Jens: Zustandsbewertung von
• 96 h tensile load with 0.7*SML glasfaserverstärktem Kunststoffkern und
Silikonschirmhülle in Verbundisolatoren, in: ETG -
Fachtagung "Diagnostik elektrischer Betriebsmittel",
Köln, 09./10.03.2004

Sealed interfaces core / fitting / housing
Quality issue
Moisture Ingress
• Connection point between metal and polymer needs additional sealing Moisture
Path
• Erosion of the sealing material causes moisture ingress
One-piece housing + Overmolding system

• Overmolding system: triple point is totally
Solution
enclosed/embedded in silicone rubber housing!

• No need of additional sealing
• No risk of moisture ingress
• Rod housing and sheds are one-piece à NO additional interfaces along housing!
No moisture ingress due to perfectly sealed interfaces

core/fitting/housing
End fittings
• Types with aluminium endfittings (special aluminium alloy) Composite insulators Porcelain
with
insulators
• high strength,
• very high corrosion resistance and
• low weight.
• Types with steel endfittings with
• high strength and
• hot dip galvanized coatings for long time corrosion

resistance.
with aluminium with steel
end fittings end fittings
~ 25 kg
~ 4 kg ~ 8 kg

Preassembling of low weight cantilevers with composite insulators
Delivery (1) or preassembly by installation company (2) – customer’s choice
Preparing for transport, stacked, marked and sorted for easy

installation
Transportation on site

Installation of low weight preassembled cantilevers with composite insulators
Prepare
installation
Installation without crane (approx. 35 kg/cantilever),

Installation only 2 workers on platform needed

Comparison: Porcelain / EPDM / HTV Silicone rubber
Properties Porcelain insulator EPDM insulator Silicone insulator Customer benefits
8WL3078 / 3088
Competitors
Competitors
Sicat CI
Hydrophoby No No Yes no pollution layer
UV-resistant Yes No Yes maximized service life
Erosion resistant Yes No Yes maximized service life
High contamination application No Varies Yes maximized system reliability
Maintenance free
No No Yes minimized costs
(self-cleaning housing surface)
Low weight No Yes Yes minimized costs
Low installation costs Varies Yes Yes minimized costs
EPDM – Ethylene Propylene Diene Monomere

Content
Design of
composite
insulators


Manufacturing
Crimping of end fittings
High pressure injection molding

Tests of composite insulators according to IEC standards
• Performance of design / type / sample / routine tests

in accordance with last issues of IEC standards
IEC 61109:2008, IEC 61952:2008, IEC 62217:2012, IEC 62621:2011
Design tests: Sample tests:
• Interfaces and Connections of end fittings • Dimensions
• Assembled load-time tests • Tightness of the interface between end fittings
• Tracking and erosion tests of insulator and insulator housing
• Housing material tests: • Verification of specified mechanical load, SML
Hardness, Weathering, Flammability, Tracking and • Verification of specified cantilever load, SCL
erosion, Tear, Tension • Galvanizing test
• Core material tests: Routine tests (on each insulator):
Dye penetration, Water diffusion
• Visual examination
• Mechanical load-time test
• Tensile load test (50 % of SML/STL)
Electrical type tests: Electrical tests Mechanical tests
• Lightning impulse withstand voltage
• Wet power-frequency withstand voltage
Mechanical type tests:
• Damage limit proof test
• Test of the tightness of the interface between end
fittings and insulator housing
• Cantilever failing load test
• Active participation in IEC working groups Dye penetration tests Tests on housing material

Proven design and technology
• Worldwide references and operating experience since

market introduction in 2000, e.g. in high speed lines,
> 200,000 pcs.
• Field data based estimation of MTBF (Mean Time
Between Failures)
• Product traceability system Batch label on end fitting of insulator

Content
Design of
composite
insulators


Applications in contact lines

Applications – Disconnectors Sicat 8WL6144
Siemens R&D activities: Evolutionary development due to

the requirement of safe and reliable operation.
Maintenance free disconnector

Disconnector with porcelain insulators Disconnector with composite insulators Sicat 8WL6144

Applications – Section insulators and neutral sections Sicat 8WL5545
Section insulators up to 25 kV AC
with:
Long rod composite insulator with
• ECR-glass (boron free) epoxy resin
reinforced rod and
• PTFE (Polytetrafluoroethylene)
housing
Suspension of section insulators

with:
Long rod composite insulator with
reinforced rod and
• HTV silicone rubber housing

Applications – Loop insulator Sicat 8WL3001-2
Loop insulator up to 1.5 kV DC

Creepage distance > 150 mm with:
reinforced loop and
• HTV silicone rubber housing

Applications – Catenary wire insulation Sicat 8WL7035-5
Catenary wire insulation up to

3 kV DC and 25 kV AC
Sleeving made of HTV silicone rubber
• Use as animal guard, protection
against bridging of insulation distance
between live conductors and earthed
components

Content
Design of
composite
insulators


Benefits of composite insulators Sicat 8WL3078 / 8WL3088 – Summary
Housing: One-piece HTV silicone rubber

• High tracking- and erosion resistance
• Self-cleaning effect due to hydrophoby Sealing
• Improved pollution layer performance due to hydrophoby transfer and recovery (overmolded sytem)
• UV resistance
• High flammability resistant, self extinguishing properties (category V0)
• No additional housing interfaces due to one-piece housing
Housing
(HTV silicone)
Core rod: ECR-glass (boron free) epoxy resin reinforced rod
• Acid-resistant, no brittle fracture GRP rod
(ECR-glass)
Sealing: Overmolding system

• No moisture ingress due to perfectly sealed interfaces core/fitting/housing
• No additional sealing necessary End fitting

Customer Benefits: Reliability, Availability, Maintainability, Safety
High System Reliability

• Best pollution performance due to water-repellent silicone housing
• Long creepage distance (compared to porcelain)
• High insulation level (compared to porcelain)
• High mechanical strength at low weight
Long Service Life
• UV-, erosion- and tracking resistant silicone housing
• Electrical corrosion resistant GRP rod è no brittle fracture!
Easy Handling & Low Costs
• Low weight è lower costs for transportation, construction & installation
• Maintenance-free (self-cleaning housing surface)
High Operating Safety
• Breakage- and cracking-resistant housing = high vandalism resistance
• No total breakage of insulating body, no shattering = high safety

Overview
We are ready to further develop our products

We electrify rail.
to fit to your needs.

Smart rail electrification
We power rail. We wire rail. We manage rail. We make rail smart.

Solutions for Solutions for Solutions for Solutions for rail
traction power supplies contact lines power system management electrification of the future

Page 33 26/02/2015 PTFE – Composite Insulators, Siemens Mobility
siemens.com/rail-electrification
Division / Rail Electrification
Contact
Sonja Leistner
R&D Project Manager Catenary Components
Siemens AG
MO TPE RE PI CPO
Mozartstr. 33 B
91052 Erlangen, Germany
Tel.: +49 9131 7-20267

Mobil: +49 172 1087467
Mail: sonja.leistner@siemens.com


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PTFE Workshop / Madrid / February 2015

Modular Sicat contact line

• Different traction power supply ≤ 80 km/h Sicat 3S • Economy

Sicat 3S in Thailand Sicat LD in Peru Sicat SA in Malaysia Sicat HA in China

© Siemens AG 2015 – All rights reserved.

Sicat contact line equipment

§ Cantilevers and supports

§ Contact lines under structures

§ Tension wheel equipment

§ Section insulator, neutral section

§ Disconnectors and drive mechanism

§ Contact wires, single and stranded wires

S > 1,000 pcs

© Siemens AG 2015 – All rights reserved.

• High number of composite insulators in contact line:

Composite insulators have significant

© Siemens AG 2015 – All rights reserved.

Quality of composite insulators Applications of composite insulators Summary

© Siemens AG 2015 – All rights reserved.

© Siemens AG 2015 – All rights reserved.

Suspension and tension insulators Cantilever and line post insulators

© Siemens AG 2015 – All rights reserved.

Suspension and tension insulators Cantilever and line post insulators

SML Specified Mechanical Load SCL Specified Cantilever Load

© Siemens AG 2015 – All rights reserved.

Quality of composite insulators Applications of composite insulators Summary

© Siemens AG 2015 – All rights reserved.

Why silicone rubber? Why HTV silicone rubber?

Silicone rubber material – different types

• High Temperature Vulcanizing (HTV)

[1] Papailiou, Konstantin O.; Schmuck, Frank: Silikon-Verbundisolatoren,

© Siemens AG 2015 – All rights reserved.

Key property: Hydrophoby

• Self-cleaning effect due to hydrophoby

polymer chains with silicone

© Siemens AG 2015 – All rights reserved.

© Siemens AG 2015 – All rights reserved.

Brittle fracture of polymer insulators

Brittle Fracture [6]

96 h brittle fracture proof test

© Siemens AG 2015 – All rights reserved.

One-piece housing + Overmolding system

enclosed/embedded in silicone rubber housing!

No moisture ingress due to perfectly sealed interfaces

• very high corrosion resistance and

• Types with steel endfittings with

• high strength and

• hot dip galvanized coatings for long time corrosion

© Siemens AG 2015 – All rights reserved.

Delivery (1) or preassembly by installation company (2) – customer’s choice

Preparing for transport, stacked, marked and sorted for easy

© Siemens AG 2015 – All rights reserved.

Installation without crane (approx. 35 kg/cantilever),

© Siemens AG 2015 – All rights reserved.

Properties Porcelain insulator EPDM insulator Silicone insulator Customer benefits

© Siemens AG 2015 – All rights reserved.

Quality of composite insulators Applications of composite insulators Summary

© Siemens AG 2015 – All rights reserved.

Crimping of end fittings

High pressure injection molding

• Performance of design / type / sample / routine tests

© Siemens AG 2015 – All rights reserved.

• Worldwide references and operating experience since