Why Choose Us?
Advanced Equipment
Our Factory is well equipped with all worldclass facilities, such as programmable tensile load testers, crimping systems with acoustic emission detectors, fully automated rubber injection moulding machines, vulcanization testers, a complete set of power frequency transformers and impulse voltage generators.
Wide Product Range
Main products include composite insulators for electric power lines from 10 to 800kV, composite insulators for electric railways, phase spacers, disconnecting switches, bushings, surge arrestors, etc. Our products have a good reputation in international markets.
Complete Qualifications
We implemented the ISO 9001:2015 Quality Control and the ISO14001:2015 environmental management systems. DCI's management and comprehensiv ecompetitiveness, quality of products and services, benefited enormously.
Broad Market
DCI's products have been exported to Europe, America, Oceania, Africa and Asia. We also have long-term cooperation with a lot of large international electricity companies like TYCO, ABB, AREVA, ALSTOM, PLP, Victor, EB, NTP and Siemens.
A composite pin insulator consists of a nonconducting material polymer silicon rubber that is formed into a shape. It is a device that is designed to support cable or wire, from direct contact with whatever structure is used in the configuration of the wiring.
1. Stable and reliable mechanical performance.
The end connection fittings (steel feet, iron caps) of the insulator all adopt the structure of the disc-shaped suspended porcelain insulator, and the core plate is made of high-strength porcelain. Every process from the supporting parts to the finished product is made and inspected in strict accordance with national and industry standards.
2. Excellent pollution flashover resistance.
As the silicone rubber composite jacket has good hydrophobicity and hydrophobicity migration, it improves the power frequency wet flashover voltage and the ability to resist pollution flashover. Through the artificial pollution flashover voltage comparison test, the pollution flashover voltage of each porcelain composite insulator is increased by more than 70% compared with the porcelain insulator of the same type and specification. At the same time, the umbrella shape also has better wind and rain self-cleaning ability and pollution speed. Slow, manual water washing and cleaning are also extremely convenient, especially in dusty and dirty environments, it is more and more excellent. The insulator is easy to adjust the creepage distance of the external insulation, which can meet the requirements of the creepage distance of the insulator string for the operation line in the heavy pollution area.
3. Strong impact resistance
The surface of Porcelain Pin Insulators is firmly covered with a silicone rubber composite jacket, which makes it have good impact resistance. At the same time, since the porcelain parts are not directly exposed to the air, the frequency of breakdown or bursting of the porcelain parts caused by sudden changes in environmental temperature or lightning strikes is reduced, thereby greatly reducing the line maintenance cost.
4. Light weight, convenient for transportation, installation and maintenance.
The weight of the porcelain composite insulator is 1/3 lighter than the same type of porcelain insulator, thus reducing the installation labor intensity and the load bearing pressure of the iron tower. It can well withstand the bending distance on the tensile string and slow down the damage to the iron tower caused by the periodic impact force.
5. Unique and reasonable structure
The shape structure of the porcelain composite insulator, the iron cap adds a concave groove to the base of the porcelain insulator iron cap, which is convenient for the insulator to be clamped by tools during installation and replacement. The connection size and structural height of the iron cap and the steel foot of the insulator are exactly the same as the original porcelain insulator, which has good interchangeability. Especially on the current running line, the composite insulator can be replaced directly without adjusting the sagging of the original line, and the replacement is extremely convenient.
What is Composite Pin Insulators Made of?
Composite insulator is also called synthetic insulator, non-ceramic insulator, polymer insulator, rubber insulator, etc. The main structure is generally composed of umbrella skirt, FRP core bar and end fittings.
The umbrella skirt is generally made of organic synthetic materials, such as ethylene propylene rubber, high temperature vulcanized silicone rubber, etc.; the FRP core bar is generally reinforced with glass fiber and based on oxidized resin; the end fittings are usually carbon steel or carbon structural steel coated with hot zinc aluminum.
End Fitting Structure - Composite Pin Insulators
Composite Pin Insulatorss vary in their structure depending on the characteristics of use. In addition to meeting the tensile strength, meeting the requirements, and reliably connecting with the mandrel, the design of the metal tip also needs to meet the special requirements for application under high voltage. Composite insulators are generally made in the shape of a rod with a small capacitance. Therefore, the voltage distribution on the surface of the insulator is very uneven. Thus, in normal operation, the generated corona will be harmful, so it is necessary to use a pressure equalization measure. In addition, the synthetic insulating material cannot withstand an electric arc of several tens of kiloamperes. In the event of a short circuit fault, it will burn the umbrella near the wire and the tower, so arcing is required. At home and abroad, the method of adding a pressure equalizing ring is generally adopted to uniform the end electric field, weaken the corona, and lead to the fault arc.
The voltage equalizing ring of the composite insulator is a component of the composite insulator. Its function is to control the electric field strength inside the insulator, avoid internal partial discharge, reduce the local electric field strength of the external surface, especially the surface of the metal connecting part, and reduce the radio interference. Leading the power frequency arc to avoid burning the surface of the insulator and minimizing the local electric field strength near the end surface to improve its anti-smudge performance.
Composite Pin Insulators State Detection
Composite insulators have the advantages of light weight, high strength, strong resistance for pollution flashover, and convenient maintenance, and are extensively used in the power system. However, with the increase of operating time and quantity, the rate of information faults for composite insulators is gradually increasing.
Therefore, it is very important to guarantee the safe operation of the power grid by carrying out state detection research on composite insulators. Composite insulators have a variety of structures, but mainly comprise by four Parts: A core rod, sheds and sheath, fitting (base connector and oval eye), and a grading ring.
Applications of Composite Pin Insulators
Composite Pin Insulators, also known as polymer pin insulator, is an innovative alternative to porcelain insulators. It is manufactured using a combination of high-strength fibreglass rods and silicone rubber housing. Composite pin insulator provides comparable insulation performance to porcelain insulators while offering advantages like lighter weight, higher mechanical strength, superior resistance to vandalism and pollution, and better performance in areas prone to seismic activity.
Overhead Transmission Lines
Pin insulator is extensively used in overhead transmission lines to support and insulate conductors, ensuring safe and efficient power transmission over long distances.
01
Distribution Lines
Pin insulator is also utilized in distribution lines, ensuring reliable power supply to residential, commercial, and industrial areas.
02
Substation
Pin insulator finds applications in substations, where they provide insulation and support for busbars and other equipment.
03
Railways
Pin insulator is employed in electrified railway systems to insulate the overhead catenary wires from support structures, enabling safe and efficient train operations.
04
The Composition of Composite Pin Insulators
Extreme environmental conditions, like temperature variations, moisture and ultraviolet (UV) radiation, can't harm composite insulators, which can endure high amounts of mechanical stress, such as wind and ice loading. They can withstand conditions where pollution and corrosion are common because of their resistance to these elements. A composite insulator is an electrical insulator made from a combination of materials, typically
Fiberglass or other reinforcing fibers
These fibers provide strength and support to the insulator.
Polymer or resin matrix
This material binds the fibers together and provides electrical insulation. Silicone rubber is a common polymer type that is used but other materials such as epoxy resin may also be utilized.
Metal end fittings
These fittings are attached to the ends of the insulator and provide a way to connect it to other electrical equipment.
· Nominal dimensions of the pin insulator shall be in accordance with the Specific Technical Particulars. No joints in pin will be allowed. Outer portion of Pin should be Zinc coated with minimum 99.95% purity of electrolytic high grade Zinc.
· The finished surface shall be smooth and shall have a good performance. The surface shall not crack or get chipped due to ageing effect under normal and abnormal service conditions or while handling during transit or erection.
· The design of the fittings and the insulators shall be such that there is no local corona formation or discharges likely to cause the interference to either should or vision transmission.
· Bottom end metal fitting (Shank) of Pin Insulator should be as per IS: 2486. Length of thread on shank should be minimum 110 mm f o r 1 1 K V P i n and 130 mm for 33 KV Pin insulator. Shank diameter is 20 mm for 11 KV Pin Insulator & 24 mm for 33 KV Pin Insulator. Minimum Collar diameter should be 40 mm and its minimum thickness should be of 5 mm.
How Do You Test Composite Pin Insulators?
High voltage test
This test is usually carried out for pin insulators. In this test, the insulator is inverted and placed into the water up to the neck. The spindle hole is also filled with water and a high voltage is applied for 5 minutes. The insulator should remain undamaged after this test.
Proof load test
In this test, each insulator is applied with 20% in excess of working mechanical load (say tensile load) for one minute. The insulator should remain undamaged after this test.
Corrosion test
In this test, the insulator with its metal fitting is suspended into a copper sulfate solution for one minute. Then the insulator is removed from the solution and wiped and cleaned. This procedure is repeated for four times. Then the insulator is examined for any metal deposits on it. There should be zero metal deposits on the insulator.
International Co.,Limited was established in 1996 which focuses on electric products, marketing, services and logistics. It is an important manufacturer and export trader with several decades of experience in designing, researching, manufacturing, testing and logistics. TCI, located in , with the largest port in North-East of China, has strong capacity of technological research and development.
More than 70% of TCI's staff has bachelor degrees or higher. Many senior engineers and technicians are knowledgeable and experienced in the fields of high voltage, macromolecule research and machine manufacturing. We also have a well-established skilled workforce. We have a long-time close relationship with the China Electric Power Research Institute, CESI, all supporting our technological research and development.
We implement the ISO 9001:2015 Quality Control and the ISO14001:2015 environmental management systems. TCI's experience in this competitive market has formulated a well regulated management style for product sales, quality and services.
Ultimate FAQ Guide to Composite Pin Insulators
As one of the most professional composite pin insulators manufacturers and suppliers in China, we're featured by quality products and good service. Please rest assured to buy customized composite pin insulators made in China here from our factory.
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