Energy Division

AXICOM Composite Hollow Insulator Cevosil Design Manual

Axicom Composite Insulators from Tyco Electronics have been in service worldwide for 2 decades as important components of high voltage apparatus. Modern circuit breakers, instrument transformers, cable terminations and other components in high voltage substations utilize this advanced technology for voltages up to 800kV. Far more than 100,000 units in service confirm customers trust in Axicom composite technology. Building on two decades of experience we are able to offer station post insulators to make substations more reliable and less sensitive to environmental stresses.

Axicom. More than just a replacement for porcelain.

What are Axicom composite hollow insulators? Axicom composite hollow insulators are made of a glass fiber reinforced resin tube with silicone rubber housing. The superior material properties are especially adapted for high voltage applications in outdoor service. Which are the special properties of Axicom insulators? Composite insulators technology was first introduced more than 30 years ago. Hollow types have been in service for approximately 15 years. The advantages of composite hollow insulators compared to porcelain are well established and accepted. There are different technical and logistical advantages, depending on the specific application and service conditions. OEMs and utilities companies need to consider the following aspects when using composite hollow insulators: Increased safety for personnel and installation in the following scenarios: Inner overpressure External factors, such as vandalsim Low weight, reduced risk for transport and assembly (no broken sheds) easier and cheaper handling. Axicom composite hollow insulators: Proven performance for 10 years of service time" Available with regular shed profile and alternating shed profile Recognized advantages over porcelain in explosion safety, pollution performance, low weight, performance under seismic stress High safety in seismic active areas shock absorbers not necessary. High insulation performance under moisture stress without additional surface coating. Excellent insulation performance under simultaneous moisture stress and stress to pollution layer; cleaning or greasing not required because hydrophobic properties are transferred. Proven ageing resistance of over 20 years of service against: Degradation (temporary reduction of insulating performance). Deterioration (reduction of remaining insulation performance). Significantly shorter delivery times than porcelain insulators. Materials are in line with up to date EH+S regulations. More than 100.000 units in Service Silicone rubber housing: Applied by direct void-free moulding Optimized and modern liquid silicone rubber Superior hydrophobicity and excellent tracking resistance

What is Axicom Cevosil used for? Axicom is used for high voltage apparatus including: Bushings Chamber and support insulators for breakers Current and voltage transformers Cable terminations Surge arresters Composite hollow insulators are used for voltage levels ranging from 50 kV to 800 kV. The insulators are available in diameters up to 610 mm, with a maximum length of approximately ten meters. What are Axicom insulators made of? Axicom composite hollow insulators consist of a glass fiber-reinforced epoxy tube manufactured by AXICOM under the Cevolit brand, aluminum-casted flanges and silicone rubber housing. For over 40 years, the Advanced Composite Division at AXICOM has been manufacturing Cevolit products for the electrical industry, in particular, for the construction of power circuit breakers. Axicom composite insulators have been in service successfully for 10 years. AXICOM's many years of experience and expertise in adapting products to customer requirements is a clear advantage when it comes to manufacturing insulating tubes. The tube design can be adapted to achieve the correct tube characteristics (such as mechanical performance) and special treatments can be applied so that the tube can operate under various internal insulating conditions as required. In addition, customers benefit from AXICOM's experience in modern binding technologies, which form the basis for technical control of the interface between the flanges and tube. What gives Axicom its high insulation performance? An essential property of silicone rubber is its hydrophobic behavior. The insulator surface is hydrophobic (fast regeneration) and the water-repellent properties can also be transferred to the pollution layers that cover the surface. For a given electrical stress and conductivity of the wet pollution layer, only the hydrophobicity suppresses the leakage current to non-critical values, thus preventing flashovers without the need for cleaning.

Regulation transformer with 420 kV and 245 kV dry type bushings with Axicom insulator, installed in Switzerland

Sited in the USA, this 800kV dead tank breaker is equipped with Axicom insulators and components.

SF6 bushing of 300 kV dead tank breakers with Axicom insulators, installed in Japan

When are Axicom insulators used? Axicom composite hollow insulators are used worldwide, especially when hydrophobicity, seismic performance, and safety against vandalism and explosion are top issues. Their excellent DC- and AC-insulation, even under severe simultaneous stress of moisture and pollution, makes Axicom insulators the first choice in areas with aggressive environmental conditions. Who makes Axicom? Only the symbiosis of well-designed apparatus and optimized materials guarantees the required lifetime of 30 years or more. Our continuous cooperation with universities and scientific institutes ensures that we constantly further our understanding of basic phenomena in the field of high-voltage engineering, especially their complexity in outdoor conditions. In the electrical engineering industry, the quality and reproducibility of material properties are highly significant. AXICOM has addressed these strict requirements and has ISO 9001 certification. We comply with these standards in all departments, including production, sales, and R&D. We also apply these standards to the inspection of incoming raw materials and the traceability of the manufacturing process. By deploying computer-controlled machines and maintaining constant ambient conditions in our manufacturing process, we are able to minimize subjective defect rates in the production phase. The high level of education and training of AXICOM employees is important and is guaranteed by supported courses. All of this is part of our ongoing effort to achieve the highest quality, precision, and reliability in the products we provide for our customers.

420 kV life tank breaker in service in Switzerland, with support insulator, chamber insulator and grading capacitor made with Axicom insulators

Cable terminations with Axicom insulators for 145 kV, installed in the Netherlands

How to Design Your Own Axicom Insulator

Diameter Set

The following pages give you an overview of how to design a composite hollow core insulator for your electrical apparatus. Step one: Select a diameter from the range of diameter set. Step two: Select one of the three different Cevolit tube types that you require according to the mechanical load and length. Step three: The creepage distance needed for your product will determine the shed form that is appropriate for your requirements. Step four: The flange design is always specific to the electrical apparatus. For your convenience, different flange designs are available. However, other designs are possible.

Type

Nominal Diameter D [mm]

Inner Tube Diameter 1) l [mm]

93 142 166 206

83 130 154 198 248 300 358 486 586

There are three standard Cevolit tube systems available Protection layer against SF6-decomposites yes A2312 A2314 A2316 no A2313 A2315 A2317 Mechanical properties Cantilever Internal load pressure + ++ ++ +++ ++ +

257 312 Deflection 374 + 510 ++ ++ 610

1)

Other inner tube diameters available by request.

Tube Materials and Mechanical Values

Cevolit A2312 / A2313

Cevolit A2314 / A2315

Cevolit A2316 / A2317

Type

Max. Mechanical Load MML [kNm]

Max. Service Pressure MSP [MPa]

Specific deflection [mm/kN/m3]

Max. Mechanical Load MML [kNm]

Max. Service Specific Pressure deflection MSP [mm/kN/m3] [MPa]

Max. Mechanical Load MML [kNm]

Max. Service Pressure MSP [MPa]

Specific deflection [mm/kN/m3]

93 142 166 206 257 312 374 510 610

0.9 2.5 3.5 3.7 6.8 13 25 68 99

3.3 2.6 2.2 1.1 1.0 1.1 1.2 1.4 1.1

17 3.9 2.4 1.8 0.81 0.34 0.15 0.04 0.02

1.4 4 6 6.4 11.2 21.6 41.2 114 165

2.9 2.2 1.9 1.0 0.9 1.0 1.1 1.2 1.0

12 2.7 1.6 1.2 0.56 0.24 0.10 0.03 0.02

1.5 4.4 6.0 6.4 11.2 22 42 116 168

2.5 1.9 1.6 0.8 0.7 0.8 0.9 1.0 0.8

9.4 2.1 1.3 0.97 0.44 0.19 0.08 0.02 0.01

deflection [mm] = specific deflection x bending load [kN] x (insulator length [m])3

Shed Form Design

Standard sheds

Alternating sheds

Type

Outer insulator E [mm]

Shed spacing T [mm]

Creepage factor Cv [mm] minimum

2)

Top O [mm]

Bottom U [mm]

Outer insulator E [mm]

Shed spacing T [mm]

Shed spacing Tk [mm]

Creepage factor Cv [mm]

Top O [mm] minimum

Bottom U [mm]

93 142 166 206 257 312 374 510 610

2)

2)

2)

2)

191 240 264 304 355 410 470 608 708

48 48 48 48 48 48 48 48 48

24 24 24 24 24 24 24 24 24

131 129 129 129 129 129 129 129 129

52 53 53 52 53 53 53 53 52

52 53 53 52 53 53 53 53 52

232 256 294 345 402 464 608

2)

45 45 45 45 45 45 50
2)

67 68 66 66 66 66 74
2)

50 50 49 50 50 50 63
2)

50 50 49 50 50 50 54
2)

Number of sheds = n Arcing distance standard sheds SW = O + (n - 1) x T + U Arcing distance alternating sheds SW = O + (n - 1) x T + Tk + U Creepage distance L = (n x Cv) + SW
2)

not available

Standard Flanges

Type

Standard flange part number

F or K [mm]

FB [mm]

F5 [mm]

FT [mm]

nxd [mm]

93

93-R1 142-R1 142-R2 142-R3 166-R1 166-R2 166-R3 166-R4 206-R1 206-R2 206-R3 257-R1 257-R2 257-R3 312-R1 312-R2 312-R3 312-R4 374-R1 374-R2 374-R3 374-R4 374-R5 510-R1 510-R2 510-R3 510-R4 610-R1

51 50 80 105 50 60 80 105 50 60 80 60 80 105 60 80 105 125 60 80 105 125 155 80 105 125 155 126

12 8 12 15 8 10 12 15 8 10 12 10 12 15 10 12 15 15 10 12 15 15 20 15 15 20 20 30

170 205 205 205 232 232 250 250 262 286 286 314 344 344 380 380 400 410 442 442 462 462 465 598 598 602 602 715

145 185 185 185 212 212 220 220 242 260 260 294 314 314 360 360 370 380 422 422 432 432 435 568 568 572 572 680

4 x 11 12 x 11 12 x 11 12 x 11 16 x 11 16 x 11 16 x 11 16 x 11 16 x 11 16 x 11 16 x 11 16 x 11 16 x 11 16 x 13.5 24 x 11 24 x 11 24 x 13.5 24 x 13.5 24 x 11 24 x 11 24 x 13.5 24 x 13.5 24 x 13.5 30 x 13.5 30 x 13.5 30 x 13.5 30 x 13.5 32 x 13.5

142

166

206

257

312

374

510

610

K = Top flange F = Bottom flange

Specification Sheet for Axicom Composite Hollow Insulators

Please fill out this specification sheet and send it to us by fax at +41 56 61 88 701 or e-mail System data Company: Contact person: Tel.: Insulating medium: Service temperature range: Quantity per year / batch size: Geometry data Insulator length Min. arcing distance mm mm o SF6 to o Oil C / o Other: Max. short time temp.: C

Nominal diameter

mm

Min. creepage distance

mm

Mechanical requirements acc. IEC61462 Max. Mechanical Load, MML: Max. deflection at MML: Max. service pressure, MSP: kN: mm MPa:

Flange data Standard flange designation: Special flanges (optional): Outer flange diameter: Bolt circle diameter: Number and size of holes: Remarks

Bottom flange

Top flange

mm mm mm

mm mm mm

Components for GIS applications, made of fiber-reinforced epoxy resin with metal fittings

While Tyco Electronics and its affiliates referenced herein have made every reasonable effort to ensure the accuracy of the information contained in this catalog, Tyco Electronics cannot assure that this information is error free. For this reason, Tyco Electronics does not make any representation or offer any guarantee that such information is accurate, correct, reliable or current. Tyco Electronics reserves the right to make any adjustments to the information at any time. Tyco Electronics expressly disclaims any implied warranty regarding the information contained herein, including, but not limited to, the implied warranties of merchantability or fitness for a particular purpose. Tyco Electronics' only obligations are those stated in Tyco Electronics Standard Terms and Conditions of Sale. Tyco Electronics will in no case be liable for any incidental, indirect or consequential damages arising from or in connection with, including, but not limited to, the sale, resale, use or misuse of its products. Users should rely on their own judgement to evaluate the suitability of a product for a certain purpose and test each product for its intended application. In case of any potential ambiguities or questions, please dont hesitate to contact us for clarification. AXICOM, Cevolit, TE (logo) and Tyco Electronics are trademarks of the Tyco Electronics group of companies and its licensors.

Energy Division innovative and economical solutions for the electrical power industry: cable accessories, connectors & fittings, insulators & insulation, surge arresters, switching equipment, lighting controls, power measurement and control.

Tyco Electronics Logistics AG Werk Axicom Wohlen Wilerzelgstr. 17 5610 Wohlen/Switzerland Tel: +41 56 6188700 Fax: +41 56 6188701 http://energy.tycoelectronics.com

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