AAA Presentation Lapp Insulators

W E P O W E R T H E F U T U R E

www.lappinsulators.deDipl.-Ing. Henning AlbrechtVisit to IEC 07. June 2012

Introduction to Lapp Insulators Europe Group


COMPANY INTRODUCTION

Sales: 130 Mio. €

Employees: 1200

Located: 5 manufacturing locations in Europe (integration of Argillon in late 2008)

Ranking EU: Nr. 1 insulator producer

Ranking WW: Nr. 3 insulator producer

Service: One-stop-shopping experience for customers, all insulator types available

Honor: Technology leader in the field of composite insulators

Economic Focus: Lapp Insulators is a German Enterprise having its economic main focus inEurope

Lapp USA Wunsiedel Selb RedwitzJedlina Zdroj

(Sophienau)

1916: FoundationLapp

1901: Foundation offactoryHolenbrunnFa.J.v.Schwarz

1921: Stemag

1889: Foundation ofporcelainfactoryRosenthal

1900: Foundation ofdepartment“E”

1913: SIEMENS inNeuhaus

1857: Foundation ofporcelainfactory JuliusSchwarz

1936: RIG

1859: PorcelainfactoryJosephSchachtel

1945: Company wasnationalized

1950: Newfoundation inRedwitz

1971: Rosenthal / Stemag

1974: Rosenthal / Technik

1985: HOECHST / CeramTec

1996: CeramTec 1996: Acquisition Jedlina Zdroj2001: Acquisition of theinsulators sector ofCeramTec

2002: Argillon

2004: Acquisition Turda

2001: Lapp Insulator GmbH & Co. KG

2008: Acquisition of Alumina andinsulators sector Argillon

2007: Joint Venture withDallian InsulatorCo. Ltd.

2012: LAPP INSULATORS

Turda

1999: Acquired bymanagement

2005: Investment byAndlinger & Co.

1981: Foundation

2001: Privatization

2011: Quadriga Capital (majority shareholder) -> Acquisition of Lapp Group

MANUFACTURING LOCATIONS

WUNSIEDEL (D)Lapp Insulators' headquarters in Europe is located at the site in Wunsiedel. A widerange of insulators up to 1100 kV are manufactured for more than 100 years.Besides the production facilities one can find the management, the R&D divisionas well as further important administrative departments for the group.

Capacity

> 6.500 t porcelain

350.000 m Composite Insulators

Production Area

100.000 m²

Employees

300

Foundation

1901

Specifics

Headquarters of Lapp Europe

Main R&D and sales departments

Chemical / Physical Laboratory

Competence center - Rodurflex®

Certification

DIN EN ISO 9001:2000

Porcelain Insulators

Long Rod Insulators

Post Insulators

Hollow Core Insulators

Composite Insulators

Long Rod Insulators - Rodurflex®

Line Post Insulators - Rodurflex®

Post Insulators - Rodurflex®

SELB (D)As one of two insulators manufacturers world wide Lapp is operating its own highvoltage laboratory. It is a significant factor of success. Therefore, customer serviceand the development and research departments do benefit. Lapp Insulators isperforming all type and design tests. Furthermore guided tours for schools anduniversities are offered.

Building Dimensions

22m x 30m x 21m

Employees

7

Year of Foundation

1928

Specifics

Industrial monument

Type and design tests of insulators and insulatorstrings according to all IEC-, ANSI- and DIN-VDEstandards:

AC testing:

· dry until 1300 KV / wet until 1000 KV

lightning impulse testing:

· until 2100 kV

switch impulse testing:

· until 1300 kV

corona- and RIV- measurements

mechanical tests:

· four point bending- and elongation tests

material tests:

· leakage current- and puncture tests

thermal and mechanical tests:

· temperature range between -50 °C and +50 °C

REDWITZ INSULATORS (D)At Lapp's insulator site in Redwitz, which belongs to Lapp Insulators since 2008,porcelain and composite insulators are manufactured. The factory is specialised tomeet the needs of the OEM - clientele. In addition one can find here LAPP'sexpertise in manufacturing the composite insulators - SIMOTEC®.

Capacity

7.500 t porcelain

> 30.000 pcs. SIMOTEC® - Insulators

Production Area

19.000 m²

Employees

180

Certification


DIN EN ISO 14001:2005

OHRIS

Specifics

Competence center - SIMOTEC®


Post Insulators



Hollow Core Composite Insulators -SIMOTEC®

LeRoy (USA)Lapp Insulators' headquarters in the US is located at the site in LeRoy, NY. A widerange of insulators are manufactured since the foundation of the Lapp Insulatorsin 1916. Besides the production facilities one can find the management, the R&Ddivision as well as further important administrative departments for the groupincluding the group holding organization.

Capacity

3.000 t porcelain

100.000 m Composite Insulators

Production Area

40.000 m²

Employees

120

Foundation

1916

Specifics

Headquarters of Lapp Insulators Holding

Certification



Suspensions (cap & pin)

Post Insulators



Long Rod Insulators - Rodurflex®

Line Post Insulators - Rodurflex®

Post Insulators - Rodurflex®

JEDLINA ZDROJ (PL)The factory, which was established in 1858, is located in the south west of Poland.It was one of the driving forces behind the development of porcelain for electricalapplications in the 19th century. Today the factory is specialized on mediumvoltage and railway insulators.

Capacity

2000 t

Production Area

42.000 m²

Employees

135

Foundation

1858

Specifics

coating of longrod insulators with

RTV silicone rubber

competence center for medium-voltage

and railway insulators

Certification

ISO 9001:2000


Long Rod Insulators

Post Insulators

Medium Voltage Insulators

TURDA (RO)The plant located in Turda (Cluj County) Romania, has a production experience ofover 30 years in the manufacturing of ceramic insulators The company delivershigh voltage ceramic insulators (>36 kV to 175 kV), therefore supporting thecompetitiveness of the Lapp Insulators business.

Capacity

6.000 t

Production Area

57.000 m²

Employees

400

Foundation

1981

Specifics

youngest Lapp Insulators factory

Certification

DQS: October 2004: ISO 9001:2000

AFER: October 2001: ISO 9002:2000


Long Rod Insulators

Post Insulators



PORCELAIN INSULATORS PRODUCT RANGE

MANUFACTORING TECHNOLOGYContinuously enhanced - the production process of high-performance

porcelain insulators

Over the decades we have refined the manufacture of ceramic insulators toperfection. Highly sophisticated monitored processes form the basis of aproduction system in which small customized product runs are implementedwith the same precision and reliability as standard volume parts. Ourimprovement management system ensures an ongoing refinement of allprocesses and continuous advancement in cost efficiency.

Selected ingredients of high purity and homogeneous properties are weighed,mixed to formula specifications, and subjected to a grinding process. Vacuumextrusion presses form the plastic filter cake into cylindrical blanks ("body")which are subjected to a closely controlled drying process to condition them forthe following shaping steps.

Vertical lathes are used to machine the blank to its desired contour. After afurther precision drying stage the unfinished insulator already possesses a highstrength due to the clay bond and is ready for the application of the glazing by animmersion process. The subsequent firing stage creates the very hard ceramicstructure.

LONGROD INSULATOR

Suspension and tension towers in highvoltage power lines and railway systems

LONGROD INSULATORSPorcelain longrod insulators are produced according to international standards andcustomer specifications. They are used in power transmission lines and available up to400 kN mechanical tensile load. Lapp´s design experts are also capable of designingcomplete insulator strings including hardware accessories. Porcelain longrod insulatorsare also available with silicone rubber coating for improved pollution layer performance.

DIMENSIONSvoltage class 1 - 1100 kV (> 170 kV in strings)maximum length 2000 mmcore diameter 45 - 115 mmflexible creepage distances up to 50 mm / kVend fittings complying to IEC 60120, 60471 and DIN 48006special types availablePRODUCTION METHODwet turning processC130 high strength alumina porcelainglaze colours brown RAL 8017 and grey ANSI 70Experiencesince 1930SPECIFICATIONSIEC 60433, IEC 60383, IEC 60672FACTORIESWunsiedelJedlina ZdrojTurdaAPPLICATIONSsuspension and tension towers in high voltage power lines and railway systems.

POST INSULATORS

for busbar supports, disconnectswitches in high voltage substations

POST INSULATORSPorcelain station post insulators according to IEC, ANSI and other standards are used insubstations and related switching equipment. They are produced in single piece up to2300 mm and can operate voltages up to 1100 kV in stacked configuration. Post insulatorsare subjected to compression, cantilever and torsional loads during service.

Dimensions

voltage class 1 - 1100 kV (> 245 kV in stacked configuration)

maximum length 2300 mm

maximum core diameter 288 mm

flexible creepage distances up to 55 mm / kV

conical shape (mainly used when dimensioning acc. to IEC standards)

cylindrical shape (mainly used when dimensioning acc. to ANSI standards)

Production Method

wet turning process

C130 high strength alumina porcelain, ultra high strength available C130 HS

glaze colours brown RAL 8017 and grey ANSI 70

Specifications

IEC 60273, IEC 60168, IEC 60672

Experience

since 1930

Factories

Wunsiedel, Redwitz, LeRoy, Turda

Application

busbar supports in substations, disconnect switches (post insulator + operating insulators)

Platform supports for compensation systems

HOLLOW CORE INSULATORS

SF6 insulated switchgears, measuringequipment (CT, VT), bushings

HOLLOW CORE INSULATORSPorcelain hollow core insulators acc. to IEC, ANSI and customer standards are producedwith cylindrical, conical or straight inner and outer appearance up to a maximum lengthof 2800 mm in one piece. These insulator types are produced to withstand highmechanical forces such as inner pressure and cantilever. The design of these insulatorsis tailor-made to customer requirements. Lapp is capable of producing special shapesby applying latest state of the art manufacturing tools and technology.

Dimensions

voltage class 1 - 1100 kV

maximum length 2800 mm (with gluing technology up to 9000 mm)

maximum outside diameter 640 mm


conical shape (mainly used in bushings and dead tank porcelains)

cylindrical shape (mainly used in live tank systems)

Production Method

wet turning process

C130 high strength alumina porcelain, ultra high strength available C130 HS

glaze colours brown RAL 8017 and grey ANSI 70

Specifications

IEC 62155, IEC 60672, IEC TS 62371

Experience

since 1930

Factories

Wunsiedel, Redwitz, LeRoy, Turda

Application

SF6-insulated switchgears, breakers (life and dead tank designs),

current and voltage transformers, surge arresters, bushings

MEDIUM VOLTAGE INSULATORS

rural electrification, railway power lines

MEDIUM VOLTAGE INSULATORSLapp offers a wide range of low and medium voltage insulators. For applications rangingfrom 10-100 kV Lapp produces bushings, line posts, string insulators, and railwayinsulators. All these parts are also subject to the stringent quality requirements that areadopted from our high voltage products. Product quality is checked throughoutproduction continuously.

Dimensions

For detailed information on our medium voltage insulators program please contact usfor a printed copy.

Production Method

wet turning process

C130 high strength alumina porcelain

glaze colours brown RAL 8017 and grey ANSI 70, special colour: green

coating of insulators with RTV silicone rubber acc. To customer request

Specifications

IEC 60433, IEC 60383, IEC 60672, EN 50119

Experience

since 1900

Factories

Jedlina Zdroj

Application

rural and railway electrification, medium voltage transformers


COMPOSITE INSULATORS PRODUCT RANGE

MANUFACTORING TECHNOLOGYPatented manufacturing expertise for RODURFLEX® composite insulators

The first manufacturing stage is the continuous pultrusion process yielding theFRP rod. The combination of a hydrolysis resistant epoxy resin with acid resistantglass fibers (ECR glass) is a safe assurance against brittle fracture. Rods are cut tolength and visually inspected before being coated with a seamless sheath ofhigh-temperature vulcanized (HTV) silicone rubber ensuring optimum adhesion.Prefabricated sheds are mounted on to the rod to complete the insulator.

A subsequent vulcanizing stage creates a durable high-strength bond betweenthe sheds and the rod sheath. The metal hardware is mounted by a cold-formingprocess and all insulators are subjected to mechanical inspection, after which thejoints between the FRP rod and the metal components are sealed with a specialsilicone elastomer. This metastable compound creates a perfect seal whichprevents the ingress of moisture for an unlimited period of time. A modularsystem comprising FRP rods of different diameters and any desired length up to6 meters, various shed configurations (shapes, numbers, spacings) and a widerange of assorted end fittings allows the longrod insulator to be optimized forany specific application.

COMPOSITELONGROD INSULATORS

Suspension and tension insulators for highvoltage power transmission systems

LONGROD INSULATORSThe unique modular system of RODURFLEX® longrod Insulators is the key design featureto offer flexible connecting lengths, creepage distances, shed profiles and a wide rangeof end fittings matching exactly the customers requirements.

Dimensions

voltage class 1-1100 kV (>800 kV serial coupling of single pieces)

maximum connecting length 6 m as single design

max. core diameter 63 mm, up to 1500 kN SML


end fittings according to IEC 60120, 60471

Production Method

Modular assembly system

HTV silicone rubber, Generation III

ECR-FRP rod, brittle-fracture resistant

metastable silicone rubber sealing

optimized shed profiles for all pollution classes available

patented shallow underrib shed profile for enhanced creepage distances

Standards

IEC 61109, ANSI C29.11, ANSI C29.12

Experience

since 1967

Factories

Wunsiedel, LeRoy

Application

suspension and tension towers in high voltage power lines and railway systems

LINE POST INSULATORS

compact high voltage powertransmission systems

LINE POST INSULATORSThe RODURFLEX product range features horizontal and vertical line post insulators withflexible top and bottom attachments meeting all application needs.

Dimensions

voltage class 1-550 kV

maximum core diameter 101,2 mm (4"), up to 50 kNm


braced post design for increased mechanical stability available

complete assemblies including hardware fittings available

Production Method







Standards

IEC 61952, ANSI C29.17, ANSI C29.18

Experience

since 1967

Factories

Wunsiedel, LeRoy

Application

suspension and tension towers in high voltage power lines in compact configuration

STATION POST INSULATORS

for busbar supports in high‐voltage substations

POST INSULATORSThe RODURFLEX® product range features vertical line post insulators with flexibletop and bottom attachments meeting all application needs.

Dimensions

voltage class 1-550 kV

maximum core diameter 101,2 mm (4"), bis 50 kNm


DIN, IEC and ANSI flanges available

Production Method







Standards

IEC 62231, ANSI C29.19, ANSI C29.9

Experience

since 1967

Factories

Wunsiedel, LeRoy

Application

switching equipment and busbar support in substations

MANUFACTORING TECHNOLOGYOptimized manufacturing expertise for SIMOTEC® composite insulators

Latest injection moulding technology is used for vulcanization of the siliconeshed to the epoxy resin tube for insulators which can be up to 6 m long. Using aspecial primer on the tube permits chemical bonding with the shed, providing adurable connection under any condition. The point of connection between thetube and the metal end fitting is coated with silicone and is generally of a gas-tight design.

The exact number of layers and wrapping angle for the tube is calculated todesign the tubes for defined compression and bending loads. In this way LAPPINSULATORS can use tubes that are exposed to combined compressive andbending loads. As an option tubes with an inner liner made of polyester forprotection against SF6-decay products can be provided.

COMPOSITEHOLLOW CORE INSULATORS

SF6 insulated switchgears,measuring equipment (CT, VT), bushings

HOLLOW CORE INSULATORSSIMOTEC® Hollow core composite insulators acc. to IEC, ANSI and customer standards areproduced with cylindrical, inner and outer appearance up to a maximum length of 6000 mmin one piece. These insulator types are produced to withstand high mechanical forces suchas inner pressure and cantilever. The design of these insulators is tailor-made to customerrequirements. Due to the use of high quality LSR silicone rubber these insulators performextremely well even under severe climatic conditions and under pollution eliminating theneed of maintenance or cleaning of the switches they are use in. Due to the compact andlight design SIMOTEC® hollow core composite insulators play a significant role in themanufacture of high-quality and reliable switchgears.

Dimensions

voltage class 1 - 800 kV

maximum connecting length 6 m as single design

multi-part designs available, maximum outside diameter 580 mm

creepage distances up to 31 mm/kV

Production Method

injection moulding technology, LSR-silicone rubber

FRP-tubes made by filament winding process for combined bending and pressure stress

Standards

IEC 61462 (2007)

Experience

since 1995

Factories

Redwitz

Application

SF6-insulated switchgears, breakers (life and dead tank designs),

current and voltage transformers, surge arresters, bushings, cable terminations

Insulating Materials

1. PORCELAIN

2. EPOXY RESIN(not in Lapp Portfolio)

3. RUBBERSSIR (Silicon Rubber)EPR (e.g. EPDM) Ethylen Prophylen RubberEVA (Ethylen Vinyl Acetat)Blends EPDM/SIR

4. GLASS( not in Lapp Portfolio)

Products - LAPP Insulators GmbH


• Longrod insulators (up to 550 kN, 2100 mm length)• Solid core post insulators (core diameter up to 275 mm, 2600 mm length)• Hollow insulators (outer diameter up to 580 mm, 2600 mm length)• Rotary insulators (operating stacks)• Medium voltage and line post insulators

Composite Insulators System Rodurflex ®

• Tailormade longrod insulators (up to 1.500 kN, up to 6.000 mm length)• Traction line insulators• Medium voltage and line post insulators• Hollow insulators• Tailormade insulation applications (fibre optic bushings, hot sticks...)

Company

Manufacturing process CeramicInsulators

Clay

AluminaKaolinFeldspar

Mixing andgrinding

ExtrusionPre-drying

Machining

Drying

Glazing

Sintering(Firing)

Mounting ofmetal parts

Manufacturing process Ceramic Insulators

Ceramical preparation

our raw materials:

kaolin, feldspar, quartz.

Delivered in silos,

grinding in tumbling mills:

96% Al2O3, 4% Mg2[Si2O6]


Raw material / silo and preparation

25 silos / 50 t each

5 tumbling mills 3,5 t each

70% recycled / 30% new mass

Filter pressing

filtercake pressing (70% recycled mass, 30% new mass)


Extrusion

breaking of filtercakes in the shredder and extrusion of the pugs

in the vacuum press (max. length of pugs 4 m, weight approx. 3 to)


Shaping

electrical pre-drying of pugs and shape forming (CNC).

hollows: one-step machining in - and outside


Drying

controlled conditions, temperature and air-humidity

(in dependence of shrinkage)


Glazing

dipglazing (grey and brown) sprayglazing of special articles


Firing

in reducing atmosphere using shuttle

kilns, firing times depending on the

corediameters


Cutting and grindingwith diamond tools, depending on customers‘ requirements


Mounting of end fittings

acc. to customers‘ requirements with lead antimon,

sulfur or portland cement;

conical or cylindrical with sanded ends.


Testing

Tension, cantilever, inner pressure and ultrasonic

tests (thermal mechanical cycle tests)


Final tests

type and design tests in our own laboratory


Manufacturing Process of RodurflexInsulators

More than 40 Years

of Service Experience

Composite Insulators System

Rodurflex®

Introduction

Composite Insulators System Rodurflex®

The RODURFLEX® Module System

A modular system ofvariable lengths,different shed shapesand sizes ...

...and different types ofend fittings for allcommon SML levels...

...allow RODURFLEX®

insulators to be designed forany service condition


The RODURFLEX® Module System

Station Post Insulators

A modular system ofvariable lengths,different shed shapesand sizes ...

...allow RODURFLEX®

insulators to bedesigned for anyservice condition


Production Processporcelain

Bodypreparation

ExtrusionDrying

ShapingDrying

GlazingFiring

CuttingGrindingAssembling

composite

Rod pultrusionGrinding

Extrusion

Shed mountingand vulcanization

AssemblingSealing

Transparent rods providevisible quality

Pulltrusion of ECR( Electrical Grade Corrosion Resistant)

FRP (Fibre Reinforced Plastic) rod

Manufacturing Process of Rodurflex® Insulators

THE SILCONE SHEATH IS CURED ANDVULCANIZED TO THE ROD

HIGH TEMPOVEN

CURED ANDBONDEDRUBBER

CURED ANDBONDEDRUBBER


Extrusion of seamless HTV silicone sheath


Rod Cutting & Desleeving


High pressure injection moulding of sheds

Data of rubber injection presses :

• clamping force : 5000 kN

• 2 Heating + clamping plates : 710x1050mm

• specific injection pressure : 2160 bar

• injection volume :

5200 cm³ ( 8 kg silicone)

• time effective

double tool systeme


Pre-fabricated wheather sheds Rodurflex,seam not crossing gradients, nomechanical stress


Weathersheds Rodurflex afterremoval of surplus from moulding


Shed Mounting


Duration depending onvolume of insulators

Temperature approx. 200°C

Vulcanization


Compression of end fittings


AUTOMIZEDAPPLICATION OF

META STABLESEALING SYSTEM

- permanent sticking

- permanent elastic

- no gaps: -50°C … +100°C(-58 °F … + 212 °F)


END FITTING TO ROD / INSULATING BODYMETA STABLE SEALING SYSTEM

- 2K meta stable silicone (paste)- special end fitting design (lake)- non-RTV (no gap formation at cold temp.)- temperature range: -50°C … +100°C (-58 °F … + 212 °F)- experience since 1981 (development, field trials at RWE)


RODURFLEX® Sealing System Application


Packing


Rodurflex

Field Experience

Worldwide experience with Rodurflex®

• more than 40 years• in more than 70 countriesup to Um=765 kV service voltage

Rodurflex Field Experience

EHV WORLD WIDE EXPERIENCERODURFLEX® POLYMER

KV LOCATION QTY SHIPPED

765 AEP 40 1980

765 HYDRO QUEBEC 184 1977-93

500 DC LADWP 213 1980-84500 GE/BPA 243 2003525 HYDRO QUEBEC 17 1982

525 CHINA 14,662 1992-2001

533 DC ESKOM – SO AF 637 1994-96

420 RWE – GERMANY 25,000 1979-2005

420 ESKOM – SO AF 11,195 1978-2004

420 EOS – SWITZERLAND 2,013 1992-2004

420 UAE, Iran, Middle East 18,690 1987-2005

420 VENEZUELA 2,734 1998

420 REE - SPAIN 16,108 1992-2005

SUB TOTAL >90,000

800 KEPCO - KOREA 168 1999 - 2005

Equals to approx. 8.000 km

420/550kV

765kV145/170/245/300/362kV

ADWEA,SCECO, RWE

HQ AEPBPA/LADWP

REE


Study Crossrope Design for 765 kVSouth Africa

Advanced

OHTL

Designs6 m


Design for 420 kV Compact Line „Palmiet – Stikland“

South Africa

Fv= 22 kN; Fh = 65 kN


Advanced

OHTL

Designs

Extreme SML Tensions Setse.g. River Crossings

SML=4 x 1500kN =6000kNcompare to 420 kV ElbeCrossing in Germany withPLRI: 4 x 300kN = 1200kN


2007 Mozambique Phase Spacer

Caia-Marromeo


1980/90s 533 kV HVDC line Cabora Bassa, RSA

HVDC


1984

500 kV HVDC line

Pacific Intertie, USA

HVDC


Rodurflex

Lahmeyer Presentation Abu Dhabi

SERVICE EXPERIENCE WITH RODURFLEXCOMPOSITE INSULATORS AT ADWEA

(ABU DHABI WATER AND ELECTRICITYAUTHORITY, UNITED ARAB EMIRATES)

Dipl.-Ing. Peter Kleyersburg

former Lahmeyer International GmbH

Abu Dhabi, UAE

Situation 30 years ago, Arabian Peninsula

Situation with conventional insulators

Reasons for the use of composite insulators

Rodurflex Insulators as counter measure of pollutioncaused problems

Conclusion

Situation 30 years ago, Arabian Peninsula

Situation 30 years ago – A challenge for Lahmeyer International:

• 1977 oil boom: increased need for energy in Abu Dhabi

• problems with porcelain long-rod insulators, open shed profile cd = 43 mm/ kV

• new proposed OHTL 220 kV Abu Dhabi – Al Ain as well as power supply to Abu Dhabiairport by 132 kV OHTL (80ies)

• common standard IEC 815 – 1986 (still valid today)

• pollution problems during operation on OHTL with conventional insulators

• typical failure mode: flashovers during night and early morning hours

• cause: condensation on hydrophilic surfaces which have been heavily contaminated byindustrial and natural (desert, coast) pollution

• main problem: pollution accumulation happens in extreme short period of time (few months, even few days)

• power supply of expanding projects (airport, urban development, oil fields and industry)on risk


1. Cleaning of existing insulation– by hand, dry and wet, of course in de-engergized surrounding– energized, with de-mineralised water and permanently installed washing

devices– energized, with de-mineralised water and mobile washing devices

2. Hydrophobication of existing insulation– with Silicone-grease– with RTV Silicone-Elastomere (Sylgard)


• unsatisfying results with adopted cleaning methods

• unreliable equipment, especially by energized cleaning method (mobilewashing systems)

• cleaning by hand is often required de-energization of transmission lines

• generally good experience with use of hydrophobic media on existinginsulators (greases, coating), however, difficult handling and high cost ofRTV coatings

• silicone greases were not widely used due to existing difficulties in service(tendancy to pollution)



• positive experience with hydrophobic surfaces investigations ofcomposite insulators

• Selection of Rodurflex composite insulators Generation III which wasproven in service for more than 10 years already and therefore had themost successful reference available

• Rodurflex Generation III (ECR-FRP, HTV-sheds and housing, crimpedend fittings, meta stable sealing) quickly resulted in an adequate countermeasure to all encountered problems

• due to extensive electrification in the 90ies the customer (ADWEA) „wasforced to accept“ a completely new technology due to the existingproblems and so they decided to use Rodurflex composite insulators on acomplete transmission line for the first time

• this decision was backed by positive service performance of Rodurflexcomposite insulators in other parts of the world


Rodurflex Insulators as counter measure ofpollution caused problems

• Rodurflex 37 mm / kV

• not a single insulator related outage after 14 years continuous operation

• after 15 years of service the OHTL was removed and replaced by a cabledue to urban development; the removed insulators were then returned toLapp for intensive research work

• the successful performance of this line was the justification for all later 245kV and 420 kV

lines equipped with composite insulators in Abu Dhabi

Example Abu Dhabi Airport 132 kV OHTL


Design: HTV Silicone Rubber Composite Insulator GENERATION IIIwith assembled pre-moulded HTV silicone sheds, vulcanisedto an extruded HTV silicone sleeve.

Type: 30/39(148)1855Production: 1989/1990Um: 145 kVUB: 132 kVService time: 14 yearsCD’: 37 mm/kV related to UmSML: 225 kNFittings: Crimped design, forged steel, clevis



Lab. No. Position ESDD inmg/cm²

NSDDi nmg/cm²

2989/1(V)

1st

shedbottom side

0,85 2,78

2989/1(V)

shankbetween 2

nd

and 3rd

shed

1,78 7,48

2989/1(V)

4th

shed topside

0,30 1,84

2989/8(H)

1st

shedbottom side

0,17 0,94

2989/8(H)

shankbetween 2

nd

and 3rd

shed

0,31 3,18

2989/8(H)

4th

shed top 0,18 0,64

Note: V: vertical mounting; H: horizontal mounting:

Example Abu Dhabi Airport 132 kV OHTL Pollution severity

Values Measured Measured

Characteristic perdrawing

Lab.No. 2989/2 Lab.No. 2989/6

polluted cleaned polluted cleaned

[kV] [kV] [kV] [kV] [kV]

BIL pos. 965 957 969 960 966

BIL pos. 965 996 1004 1002 997

50% LIFOpos.

985 1000 988 996

50% LIFOneg.

1024 1004 1031 1027

PF Wet 490 355 550 410 544

PF CFO Wet 452 564 466 567

PF Dry 575 575 590 575 603

PF CFO Dry 590 610 598 617

[µA] [µA] [µA] [µA]

Leakagecurrent @84kV

325-314 285-278

320-318 290-280

Example Abu Dhabi Airport 132 kV OHTLResults of electrical tests

Lab. No. UTSBreaking

Load in kN

Kind of rupture

2989/1 275 Pull out top fitting

2989/2 299 Pull out top fitting

2989/3 285 Pull out bottom fitting



2989/6 301 FRP rod fracture bottomfitting

Example Abu Dhabi Airport 132 kV OHTLResults of mechanical tests (SML = 225 kN)

Conclusion

Conclusion

• severe pollution problems lead to the pioneer use of Rodurflex compositeinsulators in UAE

• Rodurflex insulators used for more than 14 years showed no problemsand secured the interference free power transmission in Abu Dhabi andare by far superior to the conventional insulators

realized with less specific creepage distance (37 mm / kV vs. 52 mm /kV)

• A detailed study on Rodurflex insulators used in service for 15 yearsshowed

– electrical and mechanical performance was equal to the new state– no signs of erosion or traces of electrical activity– no signs of ageing

• since the 90ies ALL new OHTLs in Abu Dhabi up to 420 kV areexclusively designed with composite insulators

Conclusion

• in total more than 500.000 insulator years of positive service performanceunder extreme conditions are available

• further to just being a solution to pollution related line problems Rodurflexcomposite insulators help to cut costs, for example the tower cost for a400 kV line can be reduced by approx. 25% and so the total cost of theline gets reduced by 8% because composite insulators offer equal orsuperior insulating performance with reduced section length.

• Similar composite insulators of other manufacturers have been introducedto the UAE market and also showed no failure up to now, however,without the RODURFLEX-typical long reference period

Advantages of Composite Insulators compared toCap & Pin Insulators

1. Insulators with passiv surface

2. Insulators with active surface

and this means: is there interaction with the pollution layer?

CLASSIFICATION OF INSULATORS

the insulating material interacts with the pollution layere.g. transferring hydrophobicity

Interaction means:

What is Hydrophobicity?

New Surface

New ceramic surface

In a new, non-polluted stage most surfaces arewater repellent = hydrophobic.

New silicone surface

HydrophobicityTransfer

Comparision Rodurflex® with Ceramic Surface

(Pollution Conditions IEC 815)

Polluted passiv surface

E.G.:The pollution layer on a ceramic/glass/EPR surface is hydrophilic.E.G.:The pollution layer on a silicone surface becomes hydrophobic.

Polluted active surface

Hydrophobicity Transfer

Surface polluted by quartz slurry

Comparision Rodurflex® with CeramicSurface

Polluted ceramic surface

The pollution layer on a ceramic or glass surface is wettable.The pollution layer on a silicone surface becomes hydrophobic.

Polluted silicone surface

Hydrophobicity Transfer

Surface polluted by sand

Comparision Rodurflex® with Ceramic Surface

Effect of Hydrophobicity

• pollution layer waterrepellent

• low leakagecurrents

• low risk offlashover

• low line losses

• no cleaningrequired


Hydrophobicity

Characteristics of Hydrophobicity Transferof Silicone rubbers (SIR)

Effect: - Hydrophobization of surface/pollution layers- Recovery of temporarily reduced hydrophobicity,

e.g. by excessive sparking

Mechanism: Diffusion of low molecular weight silicone components

Speed: depending on:- type of SIR material- thickness of surface layer- thickness of bulk material- temperature- age

Losses: with Rodurflex silicone rubber no loss of siliconerubber material is measureable


Hydrophobicity

Hydrophobicity of a 0.6 mm Layer on SIR Plates of VariousThickness After a Storage of 16 Days at T = 20 °C

Wett

ing

an

gle

[d

eg

]

thickness of silicone rubber plate [mm]

Hydrophobicitytransfer depends on :

thickness of SIRmaterial


Hydrophobicity

Hydrophobic Effect

MolecularSiliconeLMW(low molecular weights)

Hydrophobicity

Water

Pollution Layer

Silicone Shed HTV SIRthe best solution to have

-> excellenthydrophobicity

-> good trackingbehaviour

Hydrophobic Effect

Outdoorperformance

ATH content in % by weightSilicone content in % by weight

100% PDMS0% ATH

0% PDMS100% ATH

41% PDMS46% ATH

Performance of HydrophobicityTransfer Effect

T&E (creepage) Resistance

80% PDMS10% ATH

30-35% PDMS60-70% ATH

Balanced filling

Highly ATH filled silicone rubber

RTV2/LSR

Performance and SiliconeCompoundation

BREAK ?

Brittle Fracture

Normal fracture caused by overloadDelamination of the rod occurs


Brittle Fracture

Brittle fracture:

The fracture surface is mainlyperpenticular to the rod axis.

Most of the E-glass fibres seemsto be cut.

The remaining fibres cannotbear the load => fracture due tooverload.

Insulator with widely used standard E-Glass fibres


Brittle Fracture

Standard E-glass fibreafter 10 days ofimmersion in 1nHNO3.

(nitric acid)

The glass fibre isdestroyed due to adissolving process ofthe glass network.

The mechanicalstrength is drasticallyreduced.


Brittle Fracture

ECR( Electrical GradeCorosion Resistant)-glass fibre after 30 daysof immersion in 1nHNO3.

(nitric acid)

The glass fibre isresistant to the acid dueto modification of theglass network.

The mechanicalstrength is notinfluenced.


Brittle Fracture

Stress corrosion or brittle fracture can occurif acid attacks glass fibres under tensile load.

Acids are already in the environment or may be produced underinfluence of moisture and electrical discharges.

Combination of moisture and electrical discharges can result inthe creation of nitric acid (HNO3).

To avoid line dropping due to stress corrosion brittle fractureresistant FRP( Fibre Reinforced Plastic) rods must be used.

Brittle fracture resistant rods can be produced by usingcorrosion resistant glass fibres, such as ECR fibres (Electricalgrade corrosion resistant).


Brittle Fracture

Test set-up for stress corrosion test of FRP rods

weight(equivalentto 67% SML)

ball bearing

sample

acid container(1n nitric acid)

The test is passed if no fracture of the core occurs within 96h under load.


Brittle Fracture

Back

Advantages of Composite Insulators comparedto

Cap & Pin Insulators

Design of Rodurflex® Generation III

chemicalbonding

ECR- 1983INTRODUCTION

HTV silicone

1979FORMULATION

HTV silicone

1979FORMULATION

Forgedsteel

1985

silicone rubber

sealing 1982


“Kaerner‘s Matrix“ (1994)

Design

Materialsbad

bad

good

good

Impossible

Know howneeded

Verydifficult

Usual Case

What makes a good composite insulator?

RODURFLEX®


• pollution layer waterrepellent

• low leakagecurrents

• low risk offlashover

• low line losses

• no cleaningrequired

Hydrophobicity Transfer Mechanism (HTM), CIGRE D1.14

Prof. Kindersberger (1989)


Pollution Performance - Comparison

Required geometrical Creepage distances to obtain the same electrical performance under pollution

(KIWIT 1970: „Practical Experience with Outdoor Insulation)

Silicone Rubber Composite Porcelain Longrod Glass/Porcelain Disk

75% 100% 120%

reference-45%

CONCLUSION: To operate under same pollution conditions, a silicone rubber composite insulator

only requires 40..45% of the CD required for Glass/Porcelain Disks. A silicone rubber composite is

Therefore more economical or can withstand a level of 2 pollution classes higher than glass.

Advantages of Composite Insulators compared to


HTM impact on LCC and Service Costs

0

50

100

150

200

250[$/year]

132 kV line 275 kV line

Silicone insulator

coated ceramic disc

ceramic disc with washing

Calculated by M/s Powerlink, Australia


Pin Corrosion

Glass/Porcelain Disks: nothydrophobic surface highLeakage currents DCcomponent in Leakage current

galvanic cell PIN CORROSION

Silicone rubber composite withHTM & hydrophobic surface: nothydrophobic surface very lowLeakage currents no DCcomponent in Leakage current

no galvanic cell NO PROBLEMS

Maintenancecosts, lowerlifetime, worseLCA

Life expectancy: 17…30a

Advantages of Composite Insulators compared to


Composite insulatorsoffer low weight

=> low transport andinstallation costs


Advantages of RODURFLEX® Composite Insulators Enables new OHTL Insulation Design (Crossarms,Crossropes etc.)

Superior Pollution Performance (Hydrophobicity Transfer Mechanism)

Extreme UV, Weather and Environmental Resistant HTV Silicone Housing

Enables Extreme Creepage Designs (Patented Underrib Sheds)

Earthquake Resistant

Brittle Fracture Resistant (ECR Glass Epoxy FRP Core)

Fail-safe meta stable sealing system

Extreme strength classes SML up to 2000 kN possible for single unit

Vandalism Proof

Able to withstand Extreme Dynamic and Impact loads

Light Weight: Easy Transport, Handling, Installation

Light Weight: offers EHV OHTL designs

Short Lead-Time

Flexible in Design

Reduced Life-Cycle Costs

Proven for more than 40 years


Main Advantages (Summary):


RODURFLEX®: High Pollution Applications

• China (525, 750 kV)

• Arabic Peninsula (420 kV*) UAE, Qatar, Saudi Arabia, Oman, Jemen

• REE Spain (420 kV*)

• USA California (525 kV*)

• USA Florida (525 kV*)

• South Africa (420, 765 kV*)

• India (420, 765 kV)

• Australia (525 kV*)

• North Africa (420 kV*)

• Chile, Peru (245 kV*)

• Iran (420 kV*)

* up to


• Applications of Composite Insulators• New Transmission Lines• Due to the light weight and compact design of composite insulators new line and

new tower designs are possible resulting in lower construction and erection costs.•• Replacement of Conventional Insulators,• which experienced flashover or require extensive maintenance. Line hardware need

not to be changed. Silicone rubber insulators offer superior performance in pollutedareas.

• Upgrading of existing lines or designing Compact Lines• Composite insulator strings are in many cases shorter than conventional ones.

• Interphase spacers• to prevent galopping conductors from clashing together.

Composite insulators offer light weight combined with high mechanical strength andhigh flexibility.

• Post and Line Post insulators• Due to their light weight composite line post insulators may be mounted directly on

the pole without using crossarms.

• Hollow insulators/Line Arrestors• Housings for current transformers, bushings or surge arresters.

Advantages of Composite Insulatorscompared to Cap& Pin Insulators

optimalself cleaningPerformanceHydrophobicity

limitedself cleaningperformance

protectableagainstpower arcs(arcing devices)

not fullyprotectableagainstpower arcs

lower radiointerferencevoltage

higher radiointerferencevoltage

Long Rod Types Cap & Pin Types

Easier tohandle

6 times the weightand erection atsite

no cascadeflashovers

cascadeflashoverspossible

no thermalpuncture

no self fractures

V-strings:narrow stringspossible withspecial intermediatefittings

thermal puncturepossible

self fractureswith glass(shattering)

V-strings:angel betweentwo substringsdepends onwind/weight load


CompositeLongrod vs. Cap & Pin

Price 20-30% lower


CompositeLongrod vs. Cap & Pin

Reseach & Development

R&D Partners

Prof. Kindersberger

Prof. Kurrat

Prof. Bärsch

Prof. Hinrichsen

Prof. Clemens

Prof. Grossmann


„Technology Survey“

Transmission Distance in km

Ca

pa

cit

yin

GW

0.01

0.1

1

10

100

0.0011 10 100 1000 10000

UHV

1200kV

HVDC

765kV

400/500kV

Subtransmission

„Smartgrids“HVDC - Smart

R&D: New Design Tools (FEM)


R&D : FEM/BEM Tools


R&D on Field Calculations (HSU Hamburg)


R&D: New Design Tools (STRI Insulator Selection Tool IST®)

HVAC

HVDC

AC/DCSolid Layer

AC / KIPTS



Pollution Severity: 2% ESDD Level (mg/cm²)0,001 0,01 0,1 1

Insula

tion

Length

(m)

1,8

1,7

1,6

1,5

1,4

1,3

1,2

1,1

1,0

0,9

0,8

0,7

0,6

0,5

Specific

Cre

epage

Dis

tance

(mm

/kV

syste

m)

48

46

44

42

40

38

36

34

32

30

28

26

24

22

20

18

16

14

AC KIPTS Natural Pollution Performance 123kV

Glass Antifog 33mm/kV


Insula

tion

Length

(m)

1,1

1,0

0,9

0,8

0,7

0,6

0,5

Specific

Cre

epage

Dis

tance

(mm

/kV

syste

m)

30

28

26

24

22

20

18

16

14

12

Rodurflex ® 31mm/kV



Insula

tion

Length

(m)

3,6

3,4

3,2

3,0

2,8

2,6

2,4

2,2

2,0

1,8

1,6

1,4

1,2

1,0

Specific

Cre

epage

Dis

tance

(mm

/kV

syste

m)

48

46

44

42

40

38

36

34

32

30

28

26

24

22

20

18

16

14


Insula

tion

Length

(m)

2,2

2,1

2,0

1,9

1,8

1,7

1,6

1,5

1,4

1,3

1,2

1,1

1,0

0,9

Specific

Cre

epage

Dis

tance

(mm

/kV

syste

m)

30

28

26

24

22

20

18

16

14

12


Rodurflex ® 31mm/kV


Insula

tion

Length

(m)

6,0

5,5

5,0

4,5

4,0

3,5

3,0

2,5

2,0 Specific

Cre

epage

Dis

tance

(mm

/kV

syste

m)

48

46

44

42

40

38

36

34

32

30

28

26

24

22

20

18

16

14


Insula

tion

Length

(m)

3,8

3,6

3,4

3,2

3,0

2,8

2,6

2,4

2,2

2,0

1,8

1,6 Specific

Cre

epage

Dis

tance

(mm

/kV

syste

m)

30

28

26

24

22

20

18

16

14

12



Rodurflex® 25mm/kV


Insula

tion

Length

(m)

8,0

7,5

7,0

6,5

6,0

5,5

5,0

4,5

4,0

3,5

3,0

2,5 Specific

Cre

epage

Dis

tance

(mm

/kV

syste

m)

48

46

44

42

40

38

36

34

32

30

28

26

24

22

20

18

16

14



Insula

tion

Length

(m)

5,0

4,8

4,6

4,4

4,2

4,0

3,8

3,6

3,4

3,2

3,0

2,8

2,6

2,4

2,2

2,0

Specific

Cre

epage

Dis

tance

(mm

/kV

syste

m)

30

28

26

24

22

20

18

16

14

12

Rodurflex® 28mm/kV



Insula

tion

Length

(m)

12,0

11,5

11,0

10,5

10,0

9,5

9,0

8,5

8,0

7,5

7,0

6,5

6,0

5,5

5,0

4,5

4,0

3,5

Specific

Cre

epage

Dis

tance

(mm

/kV

syste

m)

48

46

44

42

40

38

36

34

32

30

28

26

24

22

20

18

16

14

AC KIPTS Natural Pollution Performance 765/800kV


Insula

tion

Length

(m)

7,0

6,5

6,0

5,5

5,0

4,5

4,0

3,5

3,0 Specific

Cre

epage

Dis

tance

(mm

/kV

syste

m)

30

28

26

24

22

20

18

16

14

12


Rodurflex® 24mm/kV

800kV Design for Pollution


Insula

tion

Length

(m)

13,0

12,0

11,0

10,0

9,0

8,0

7,0

6,0

5,0

4,0

3,0 Specific

Cre

epage

Dis

tance

(mm

/kV

syste

m)42

40

38

36

34

32

30

28

26

24

22

20

18

16

14

12

10

8


Insu

latio

nLe

ngth

(m)

6,2

6,0

5,8

5,6

5,4

5,2

5,0

4,8

4,6

4,4

4,2

4,0

3,8

3,6

3,4

3,2

3,0

2,8

2,6

Spec

ific

Cre

epage

Dis

tanc

e(m

m/k

Vsys

tem

)

28

27

26

25

24

23

22

21

20

19

18

17

16

15

14

13

12

Very Light Light Medium Heavy Very Heavy

RODURFLEX - IST

Disk String:

Heavy: 9.0 m

Very Heavy: 12.0 m

RODURFLEX String:

Heavy: 5.0 m

Very Heavy: 5.9 m

Required Insulation Length:


Materials – Functional Properties

Electrical Field Control (µVars, BaTiO3…)

Research & Development

Mikro Varistors


Mikro Varistors

Research & Development

Voltage

Resi

sta

nce

µ Varistors – Field Control(prevent so called dry band arcing)

„Discharge free Insulators“


Water Film

ARC

µ varistor filled Silicon

Current Flow through Insulating Material

µ Varistors – Field ControlBlack=µVars applied to sheds (patent PCT/EP2009/000983), owner Lapp


µ Varistors – Field Control




Normal Insulator µ Varistor ControlledInsulator

0

0,1

0,2

0,3

0,4

0,5

0,6

0,7

0,8

0,9

1

0 500 1000 1500 2000 2500 3000 3500

Linear (A-B: 2915mm) "Referenz

3 x LG 75/22/1270 (A-B: 3215mm))

1 x CS160 30/65(134)3000

(A-B: 2600mm)

Lichtbogenzwischenarmaturen

xA-B

mm

U(x)/Uo



Date post:	02-Jan-2016
Category:	Documents
Upload:	wambugu-maina
View:	310 times
Download:	13 times

AAA Presentation Lapp Insulators

Documents