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
≤ 80 km/h
Sicat 3S
≤ 120 km/h
Sicat LD
≤ 160 km/h
Sicat SD
Sicat LA
• Consistently high quality
• Different performance levels
≤ 200 km/h
Sicat SR
Sicat SR
• Open lines, tunnels, stations
and depots
≤ 230 km/h
Sicat HD
Sicat SA/ Sicat SX
• High running quality
• Compliance with national and
international safety standards
• Different traction power supply
systems
• All speed ranges
> 230 km/h
Sicat 3S in Thailand
Sicat LD in Peru
• Economy
• Long service life
Sicat HA
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
© Siemens AG 2015 – All rights reserved.
Page 3
26/02/2015
PTFE – Composite Insulators, Siemens
Mobility Division / Rail Electrification
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
© Siemens AG 2015 – All rights reserved.
Page 4
26/02/2015
PTFE – Composite Insulators, Siemens
Mobility Division / Rail Electrification
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.
© Siemens AG 2015 – All rights reserved.
Page 5
26/02/2015
PTFE – Composite Insulators, Siemens
Mobility Division / Rail Electrification
Sicat CI – Composite Insulators
Content
Design of
composite
insulators
Benefits of composite insulators
Quality of composite insulators
Applications of composite insulators
in overhead contact lines
Summary
© Siemens AG 2015 – All rights reserved.
Page 6
26/02/2015
PTFE – Composite Insulators, Siemens
Mobility Division / Rail Electrification
Sicat CI – Composite Insulators
Basic design of composite insulators
1
1
2
3
3
1 - End fitting
2 - GRP (Glass fiber Reinforced Plastic) rod
3 - Housing
© Siemens AG 2015 – All rights reserved.
Page 7
26/02/2015
PTFE – Composite Insulators, Siemens
Mobility Division / Rail Electrification
Sicat CI – Composite Insulators
Types of composite insulators – I
Suspension and tension insulators
Cantilever and line post insulators
acc. to IEC 61109
acc. to IEC 61952
© Siemens AG 2015 – All rights reserved.
Page 8
26/02/2015
PTFE – Composite Insulators, Siemens
Mobility Division / Rail Electrification
Sicat CI – Composite Insulators
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“
© Siemens AG 2015 – All rights reserved.
Page 9
26/02/2015
PTFE – Composite Insulators, Siemens
Mobility Division / Rail Electrification
Content
Design of
composite
insulators
Benefits of composite insulators
Quality of composite insulators
Applications of composite insulators
in overhead contact lines
Summary
© Siemens AG 2015 – All rights reserved.
Page 10
26/02/2015
PTFE – Composite Insulators, Siemens
Mobility Division / Rail Electrification
Sicat CI – 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]
[1] Papailiou, Konstantin O.; Schmuck, Frank: Silikon-Verbundisolatoren,
Werkstoffe, Dimensionierung, Anwendungen, Springer-Verlag Berlin
Heidelberg 2012
© Siemens AG 2015 – All rights reserved.
Page 11
26/02/2015
PTFE – Composite Insulators, Siemens
Mobility Division / Rail Electrification
Sicat CI – Composite Insulators
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
layer
[3]
[2]
polymer chains with
low molecular weight
silicone
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] MR Product Training Handout, 2014
[4]
© Siemens AG 2015 – All rights reserved.
Page 12
26/02/2015
PTFE – Composite Insulators, Siemens
Mobility Division / Rail Electrification
Sicat CI – Composite Insulators
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
© Siemens AG 2015 – All rights reserved.
Page 13
26/02/2015
PTFE – Composite Insulators, Siemens
Mobility Division / Rail Electrification
Verification
Solution
Quality issue
Sicat CI – Composite Insulators
Core rod with ECR-glass
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
ECR (Electrical - Corrosion Resistant)-glass fiber epoxy resin reinforced rod
Brittle Fracture [6]
• Boron-free GRP rod which is acid-resistant
• 100% Brittle fracture free insulator
96 h brittle fracture proof test
• Electrolytic stress with nitric acid (1n = 63 g HNO3 plus 937 g water)
• 96 h tensile load with 0.7*SML
[6] Braunsberger, Tobias; Dziubek, Arkadiusz; Kurrat,
Michael; Seifert, Jens: Zustandsbewertung von
glasfaserverstärktem Kunststoffkern und
Silikonschirmhülle in Verbundisolatoren, in: ETG Fachtagung "Diagnostik elektrischer Betriebsmittel",
Köln, 09./10.03.2004
© Siemens AG 2015 – All rights reserved.
Page 14
26/02/2015
PTFE – Composite Insulators, Siemens
Mobility Division / Rail Electrification
Quality issue
Sicat CI – Composite Insulators
Sealed interfaces core / fitting / housing
Moisture Ingress
• Connection point between metal and polymer needs additional sealing
• Erosion of the sealing material causes moisture ingress
Moisture
Path
Solution
One-piece housing + Overmolding system
• Overmolding system: triple point is totally
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
© Siemens AG 2015 – All rights reserved.
Page 15
26/02/2015
PTFE – Composite Insulators, Siemens
Mobility Division / Rail Electrification
Sicat CI – Composite Insulators
End fittings
• Types with aluminium endfittings (special aluminium alloy)
with
Composite insulators
Porcelain
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
end fittings
~ 4 kg
with steel
end fittings
~ 8 kg
~ 25 kg
© Siemens AG 2015 – All rights reserved.
Page 16
26/02/2015
PTFE – Composite Insulators, Siemens
Mobility Division / Rail Electrification
Sicat CI – Composite Insulators
Preassembling of low weight cantilevers with composite insulators
Delivery (1) or preassembly by installation company (2) – customer’s choice
1
2
Transportation on site
Preparing for transport, stacked, marked and sorted for easy
installation
© Siemens AG 2015 – All rights reserved.
Page 17
26/02/2015
PTFE – Composite Insulators, Siemens
Mobility Division / Rail Electrification
Sicat CI – Composite Insulators
Installation of low weight preassembled cantilevers with composite insulators
Prepare
installation
Installation
Installation without crane (approx. 35 kg/cantilever),
only 2 workers on platform needed
© Siemens AG 2015 – All rights reserved.
Page 18
26/02/2015
PTFE – Composite Insulators, Siemens
Mobility Division / Rail Electrification
Comparison: Porcelain / EPDM / HTV Silicone rubber
Silicone insulator
Customer benefits
Sicat CI
8WL3078 / 3088
EPDM insulator
Competitors
Porcelain insulator
Competitors
Properties
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
(self-cleaning housing surface)
No
No
Yes
minimized costs
Low weight
No
Yes
Yes
minimized costs
Varies
Yes
Yes
minimized costs
Low installation costs
EPDM – Ethylene Propylene Diene Monomere
© Siemens AG 2015 – All rights reserved.
Page 19
26/02/2015
PTFE – Composite Insulators, Siemens
Mobility Division / Rail Electrification
Content
Design of
composite
insulators
Benefits of composite insulators
Quality of composite insulators
Applications of composite insulators
in overhead contact lines
Summary
© Siemens AG 2015 – All rights reserved.
Page 20
26/02/2015
PTFE – Composite Insulators, Siemens
Mobility Division / Rail Electrification
Sicat CI – Composite Insulators
Manufacturing
Crimping of end fittings
High pressure injection molding
© Siemens AG 2015 – All rights reserved.
Page 21
26/02/2015
PTFE – Composite Insulators, Siemens
Mobility Division / Rail Electrification
Sicat CI – Composite Insulators
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:
• Interfaces and Connections of end fittings
• Assembled load-time tests
• Tracking and erosion tests of insulator
• Housing material tests:
Hardness, Weathering, Flammability, Tracking and
erosion, Tear, Tension
• Core material tests:
Dye penetration, Water diffusion
• Mechanical load-time test
Electrical type tests:
• Lightning impulse withstand voltage
• Wet power-frequency withstand voltage
Sample tests:
• Dimensions
• Tightness of the interface between end fittings
and insulator housing
• Verification of specified mechanical load, SML
• Verification of specified cantilever load, SCL
• Galvanizing test
Routine tests (on each insulator):
• Visual examination
• Tensile load test (50 % of SML/STL)
Electrical tests
Mechanical tests
Dye penetration tests
Tests on housing material
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
© Siemens AG 2015 – All rights reserved.
Page 22
26/02/2015
PTFE – Composite Insulators, Siemens
Mobility Division / Rail Electrification
Sicat CI – Composite Insulators
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)
Batch label on end fitting of insulator
• Product traceability system
© Siemens AG 2015 – All rights reserved.
Page 23
26/02/2015
PTFE – Composite Insulators, Siemens
Mobility Division / Rail Electrification
Content
Design of
composite
insulators
Benefits of composite insulators
Quality of composite insulators
Applications of composite insulators
in overhead contact lines
Summary
© Siemens AG 2015 – All rights reserved.
Page 24
26/02/2015
PTFE – Composite Insulators, Siemens
Mobility Division / Rail Electrification
Sicat CI – Composite Insulators
Applications in contact lines
© Siemens AG 2015 – All rights reserved.
Page 25
26/02/2015
PTFE – Composite Insulators, Siemens
Mobility Division / Rail Electrification
Sicat CI – Composite Insulators
Applications – Disconnectors Sicat 8WL6144
Siemens R&D activities: Evolutionary development due to
the requirement of safe and reliable operation.
Disconnector with porcelain insulators
Disconnector with composite insulators
Maintenance free disconnector
Sicat 8WL6144
© Siemens AG 2015 – All rights reserved.
Page 26
26/02/2015
PTFE – Composite Insulators, Siemens
Mobility Division / Rail Electrification
Sicat CI – Composite Insulators
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
• ECR-glass (boron free) epoxy resin
reinforced rod and
• HTV silicone rubber housing
© Siemens AG 2015 – All rights reserved.
Page 27
26/02/2015
PTFE – Composite Insulators, Siemens
Mobility Division / Rail Electrification
Sicat CI – Composite Insulators
Applications – Loop insulator Sicat 8WL3001-2
Loop insulator up to 1.5 kV DC
Creepage distance > 150 mm with:
• ECR-glass (boron free) epoxy resin
reinforced loop and
• HTV silicone rubber housing
© Siemens AG 2015 – All rights reserved.
Page 28
26/02/2015
PTFE – Composite Insulators, Siemens
Mobility Division / Rail Electrification
Sicat CI – Composite Insulators
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
© Siemens AG 2015 – All rights reserved.
Page 29
26/02/2015
PTFE – Composite Insulators, Siemens
Mobility Division / Rail Electrification
Content
Design of
composite
insulators
Benefits of composite insulators
Quality of composite insulators
Applications of composite insulators
in overhead contact lines
Summary
© Siemens AG 2015 – All rights reserved.
Page 30
26/02/2015
PTFE – Composite Insulators, Siemens
Mobility Division / Rail Electrification
Sicat CI – 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
• Improved pollution layer performance due to hydrophoby transfer and recovery
Sealing
(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
© Siemens AG 2015 – All rights reserved.
Page 31
26/02/2015
PTFE – Composite Insulators, Siemens
Mobility Division / Rail Electrification
Sicat CI – Composite Insulators
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
© Siemens AG 2015 – All rights reserved.
Page 32
26/02/2015
PTFE – Composite Insulators, Siemens
Mobility Division / Rail Electrification
Overview
We are ready to further develop our products
to fit to your needs.
We electrify rail.
Smart rail electrification
We power rail.
We wire rail.
We manage rail.
We make rail smart.
Solutions for
traction power supplies
Solutions for
contact lines
Solutions for
power system management
Solutions for rail
electrification of the future
© Siemens AG 2015 – All rights reserved.
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
© Siemens AG 2015 – All rights reserved.
Page 34
26/02/2015
PTFE – Composite Insulators, Siemens
Mobility Division / Rail Electrification