How to chose the polymer insulator core rod?
Polymer insulators ,Which include polymer suspension insulators, polymer tension insulator, polymer stay insulators ,polymer post insulators , polymer line post insulators,polymer railway insulators,loop insulators, tramway insulators,ESP insulators and so on ,more info can be get from website www.tidpower.com ,are used more and more recently year in transmission and distribution power line,caused by the advantage of the polymer insulator ,light weight, anti-pullution and safety ,
The insulator content 3 parts ,fiberglass core rod,silicone rubber and the metal fittings.The function of the fiberglass is inner insulation and afford the mechanical load, the metal fittings are used for connecting the insulation parts with live line and the tower. Silicone rubber is the parts for protecting the fiberglass rod against the UV and increase the creapage of the insulator.
Based on above , We can got that the quality of the insulator relayed on the quality of the fiberglass rod.So that how to chose a fiberglass rod is very important for manufacture the polymer insulator.
Generally,There are two type of insulator core rod, one is E glass epoxy fiberglass rod,the other is ECR glass epoxy fiberglass rod, Normally ,we suggest to use ECR rod for 132KV insulator and above ,especially for suspension and tension insulator, 132KV and below insulator ,we can chose E glass fiberglass or ECR glass rod, We have reports in China that the 110KV insulator failed on line and we found that always broken on the 150mm parts away from the live line part and checked the insulator ID record and we found the common info that the insulator made by E glass rod,In China,we did a lot of research and finally we got that the arcing always occurred at the place 150mm away from the live line parts.The arcing burned the silicone rubber and the fiberglass rod bored out . And the arcing electrolyze the water from the fog ,dew and rain into the soft acid.The acid corrode the fiberglass continually and finally if the manufacture use the Eglass rod for the composite insulator, then it will break very soon and fall down from the line. However if the manufacture chose the ECR fiberglass rod ,This kinds of story will not happen.
There are so many fiberglass rod manufacture ,How can we find out the right one ? If anyone want to catch the point only by the fiberglass rod out look and the price,who will take a big risk.There is almost no any big different only by inspect the appearance.We should do the test according to IEC 61109 or relative ASTM or GB/T standard by ourselves and trial on the manufacture process to make sure. There below is the technical character of the fiberglass for our reference:
Insulator Core Rod （E glass and ECR-glass )
| No. | Technical specification | Unit | Specification value |
| 1 | Density(at 20℃±2℃) | g/cm3 | ≥2.2 |
| 2 | Water absorption rate (at 20℃±2℃,24h) | % | ≤0.05 |
| 3 | Tensile strength | Mpa | ≥1100 |
| 4 | Bending strength | Mpa | ≥960 |
| 5 | Dye penetrated test | Min | ≥15 |
| 6 | Water diffusion test (1%NaCl,Boiling for 100h 12kv/1min) | mA | ≤0.1 |
| 7 | Shearing strength along laminas | Mpa | ≥50 |
| 8 | Volume resistivity (140℃,96h) | Ω.M | ≥1010 |
| 9 | DC withstand voltage (10mm) | kV | ≥50 |
| 10 | Lighting surge withstand voltage (100kv,10mm) | Times | ≥5 |
| 11 | Bending strength at heating conditions | Mpa/150℃ | ≥350 |
| 12 | Stress corrosion (1mol/1HNO3,at 67%stress) | h | 96 (ECR rod only) |
| 13 | Torsion strength | Mpa | ≥800 |
Insulator core rod made of ECR fiberglass reinforced the epoxy resin.Insulator core rods also are also called fiberglass rod,FRP rod,GRP rod,fiberglass bar,Insulation rod,fiberglass stick ,ECR rod and so on.
1. 1. Standard: IEC61109
2. 2. Material: E glass and epoxy resin.
3. 3. Process: Continuous pultrusion.
4. 4. Main Specification
5. Size
The second thing we will meet when we select the fiberglass core rod,How can we know the which diameter of the rod is suitable for our polymer insulators, especially for chose the insulator core rod for a post insulator which need a high bending strength. There are two way to got it ,one is calculate based on above technical character which is different between different manufacture ,the other is testing to verify the design. We also can ask the experience and the suggestion by the experience engineer by contact www.tidpower.com .Finally we also need to consider the size which the manufacture normally have to avoid make a new mold which cost money and time.Here below is the size of TID TECH fiberglass rod for our reference. Engineer can chose a right size based above calculate and testing.
Note:
1.Color: light green or brown.
2.Length: according to Customer requirement.
3. We offer customized products,including the new size, New surface treatment, Jointing the fitting, screw or mechanical.
| Products Code | D(mm) | L (mm) | Weight (kg) | Products Code | D(mm) | L (mm) | Weight (kg) |
| TECR00500 | Φ5 | 1000 | 0.05 | TECR03800 | φ38 | 1000 | 2.44 |
| TECR00800 | Φ8 | 1000 | 0.11 | TECR04000 | φ40 | 1000 | 2.70 |
| TECR01000 | Φ10 | 1000 | 0.17 | TECR04100 | φ41 | 1000 | 2.77 |
| TECR01200 | Φ12 | 1000 | 0.25 | TECR04200 | Φ42 | 1000 | 3.05 |
| TECR01600 | φ16 | 1000 | 0.43 | TECR04500 | φ45 | 1000 | 3.42 |
| TECR01670 | Φ16.7 | 1000 | 0.49 | TECR05000 | φ50 | 1000 | 4.22 |
| TECR01748 | Φ17.48 | 1000 | 0.53 | TECR05300 | φ53 | 1000 | 4.74 |
| TECR01800 | φ18 | 1000 | 0.55 | TECR05500 | φ55 | 1000 | 5.11 |
| TECR02000 | φ20 | 1000 | 0.68 | TECR06000 | φ60 | 1000 | 6.10 |
| TECR02200 | φ22 | 1000 | 0.82 | TECR06350 | Φ63.5 | 1000 | 6.97 |
| TECR02400 | φ24 | 1000 | 0.98 | TECR06800 | φ68 | 1000 | 7.80 |
| TECR02500 | φ25 | 1000 | 1.05 | TECR07000 | φ70 | 1000 | 8.27 |
| TECR02600 | φ26 | 1000 | 1.14 | TECR07620 | Φ76.2 | 1000 | 10.03 |
| TECR02800 | φ28 | 1000 | 1.29 | TECR08000 | φ80 | 1000 | 10.80 |
| TECR03000 | φ30 | 1000 | 1.52 | TECR09000 | φ90 | 1000 | 13.67 |
| TECR03200 | φ32 | 1000 | 1.73 | TECR11000 | φ110 | 1000 | 20.42 |
| TECR03400 | φ34 | 1000 | 1.95 | TECR12000 | Φ120 | 1000 | 24.87 |
| TECR03600 | φ36 | 1000 | 2.19 | TECR13000 | Φ130 | 1000 | 29.19 |
Polymer insulator manufacture is a very complex process ,the quality base on all aspect ,TID Tech who have more than 15 years polymer insulator manufacture ,always open mind and very glad to share the experience with any transmission and distribution line manufacture engineers to improve the quality of the polymer insulators,If anyone want to discuss with our experienced engineer ,you can get the contact info from www.tidpower.com.