K-LINE INSULATORS LIMITED 50 Passmore Avenue, Toronto, Ontario M1V 4T1 Tel: (416) 292-2008 - Fax: (416) 292-2094 E-Mail [email protected]Web Page: www.k-line.net Dear Sir/Madam, I'm pleased to introduce you to our complete line of polymer insulated products. The attached K-LINE INSULATORS catalogue includes the products we are currently offering to the utility industry. Other products are under development and will be available shortly. As these products come on the market, we will issue you the pertinent information. In the meantime, if you require an insulator configuration not shown in the catalogue, give us a call. If you would like to receive updates to our catalogue, please mail us at [email protected]to be included in our database. We look forward to fulfilling your polymer insulator needs. Should you have any questions or need further information, feel free to call me at (416) 292-2008. Sincerely, K-LINE INSULATORS LIMITED A.J. (Tony) Carreira, P.Eng. President
Dear Sir/Madam, I'm pleased to introduce you to our complete line of polymer insulated products. The attached K-LINE INSULATORS catalogue includes the products we are currently offering to the utility industry.
Other products are under development and will be available shortly. As these products come on the market, we will issue you the pertinent information. In the meantime, if you require an insulator configuration not shown in the catalogue, give us a call. If you would like to receive updates to our catalogue, please mail us at [email protected] to be included in our database. We look forward to fulfilling your polymer insulator needs. Should you have any questions or need further information, feel free to call me at (416) 292-2008.
K-LINE INSULATORS is a quality silicone insulator manufacturer.
The company was established in 1983 with its head office located in Toronto, Ontario, Canada. K-LINE INSULATORS products are distributed world-wide through a consolidated network of representatives.
Product lines manufactured by K-LINE INSULATORS include transmission and distribution suspension, line post and station post insulators, featuring our patented Universal Line Post design. Other products include riser support insulators, dead-end extension insulators, polymer-coated guy strains, and specialty insulators for in-line switches, air-break switches, interphase spacers, railways and live line tools. These insulators are designed to the various standards (i.e. CSA, CEA, ANSI, IEEE, IEC, etc.).
K-LINE INSULATORS introduced a patented Universal Polymeric Line Post End Fitting design. The end fitting is referred to as the "K" clamp. Finally, there is one line post insulator that can be installed in either a horizontal or vertical configuration, with the clamp integrated into the insulator design. Some of the immediate benefits of the "K" clamp are that it is made of corrosion resistant aluminum casting, has the capability to accommodate a full range of conductor sizes, contains only a single captive live-line operable bolt, and no loose parts. Purchasers of the "K" clamp have been able to take advantage of labour cost savings in stringing, sagging, and conductor clamping, along with other savings related to shipping, stocking, and maintenance. The "K" clamp has performed excellently in the field since 1992.
K-LINE INSULATORS has excellent engineering resources and test facilities for product development. K-LINE INSULATORS uses its own proprietary technologies, designs and rubber formulations, in the manufacture of all its insulator products.
K-LINE INSULATORS' highly developed proprietary silicone rubber formulation is characterized by its superior contamination performance. All insulators are injection molded, one piece, and exhibit self-cleaning characteristics. The rubber is bonded to the fibreglass core strength member. These products have a long and proven performance record in severely contaminated environments.
K-LINE INSULATORS manufactures all of its products and is registered to the rigid Quality Assurance Standards of the ISO9001 program. The company is audited on a continuous basis by its customers and an internationally recognized quality management auditing firm.
K-LINE INSULATORS is known for its readiness to listen to its customers' needs for customized polymeric insulator designs that meet their special requirements. We offer appropriate support in the proper selection of insulators to suit the application, with training and documentation on special installation requirements. K-LINE INSULATORS is committed to a continuous improvement policy in quality, service, delivery, and cost reduction. Much pride comes from the innovation of new products and the continuous improvements of present products to ensure that the insulators are the most cost effective and have a long term system performance.
K-LINE INSULATORS approach to innovative insulator solutions is well demonstrated and respected by its customers.
K-LINE INSULATORS people are totally dedicated to continuous quality and performance improvement. They are dedicated to developing the best materials and designs that lead to optimum product solutions. These characteristics amongst others, have contributed to the success of the various strategic alliances K-LINE INSULATORS has forged with some of its customers.
K-LINE INSULATORS is sensitive and committed to the needs of its customers and is always prepared to give them the service they expect and deserve.
K-Line Insulators Catalogue Number Designation of Distribution Class Insulators
Catalogue Number KL X X X X X X X
End Fittings * Insulator Type Company
ID Voltage Class
Shed Design Material Insulator Type
Structure End Fitting
Line End Fitting
Special Variations
Suspension/Deadend
A - Alternating sheds
No “A” - Other shed design
C- Clevis S – Socket T – Tongue Y – Y-clevis E – Oval eye
T - Tongue H - Thimble B – Ball E – Oval eye Y – Y-clevis
A - LA insulator F – Iron Fittings IEC – 16mm ball M - Medium SML
70 kN N - Non-standard R - 90° aligned
end fittings 120 – 120 kN
Line Post
K-Line
15 28 35 46 69
N/A
S - Silicone rubber
N/A
N/A
K - K-clamp V - Vertical H - Horizontal T - Tie-Top C
Neck TF - Tie-Top F
Neck E – Drop Eye
A – Lock washer Al – Alum base D - Tinned alum
line fitting G - Gain base M20 - 20 mm
tapped M22 - 22 mm
tapped M24 - 24 mm
tapped N - Non-standard
Station Post
CP - Cap & Pin
P - Post
T1 - Tapped one end T2 - Tapped both ends No “T”s - Thru holes both ends
M12 - 12 mm tapped
M16 - 16 mm tapped
M20 - 20 mm tapped
Railway N/A RW - Railway
C- Clevis S – Socket T – Tongue B – Ball
C- Clevis S – Socket T – Tongue B – Ball
Riser
A - Alternating sheds
No “A” - Other shed
design
RSI – Riser support insulator
N/A U - Clamp
D - Tin plated aluminum line fitting
X – 5/8” tapped base
Interphase Spacer See Distribution and Transmission Interphase Spacers Page
Guy
Insulated length in
inches N/A N/A N/A
C- Clevis H - Thimble T – Tongue R – Roller B - Threaded
T - Tongue H - Thimble C- Clevis R – Roller B - Threaded
R - 90 deg turn on end fittings
S - Silicone
Note: * Different fittings will be designated by the addition of a number to the letter.
December 7, 2002
K-Line Insulators Catalogue Number Designation of Transmission Class Insulators
Catalogue Number KL X X X X X X X X X
End Fittings Insulator
Type Company ID
Voltage Class
Shed Design Material Insulator
Type Line End Fitting
Structure End Fitting
No. of Sheds
Corona Ring
Other Additions
Suspension/Deadend
H – High leakage N/A
B - Ball T - Tongue Y – Y Clevis E - Eye
S – Socket C- Clevis T - Tongue Y – Y Clevis E - Eye
M – Med ringN – No ring
A - IEC B – IEC20 R – 90 Deg S – SS pin
Line Post
N/A
E -Eye V -Vertical H -Horizontal
G – Gain baseB - Curved BF – Flat 7” BF8 – Flat 8”
Station Post
K-Line
69 115 138 161 230
A -Alternating sheds
S - Silicone rubber
P - Post
T1 - Tapped one end T2 - Tapped both ends No “T”s - Thru holes both
ends
#
N/A M12 - 12 mm
tapped M16 - 16 mm
tapped M20 - 20 mm
tapped N - Non-
standard
December 6, 2002
K-Line Insulators Distribution and Transmission Interphase Spacers
Catalogue Number KL X X X X X
X X X X X X
Insulator
Company ID
Insulator X Rod X Insulator X Rod Fitting Fittings Special
Total
Interphase Spacer
K-Line Insulator rubber
X Rod length if
applicable
X Insulator rubber if
applicable
X Rod length if
applicable
P if hinged
U – Universal
Clamp K – K clamp
T – TongueC – Clevis
U – Universal
Clamp K – K clamp
T – TongueC – Clevis
D – Tin Coupler length M –
Medium ring
N – No ring
L – Large ring A -
Adapter
Number of Characters 2 3-4 0-1 0-2 0-1 0-4 0-1 0-2 0-2 1-2 1-2 0-3 7-22
Examples: Insulator and rod - KL46SNX25U1U1D & KLH19X30TT Two insulators and rod(s) - KL46SNX46SNX12U1U1D & KLH13X35XH13X30PTT Two insulators - KL28ASX15ASU1U1D6 & KLH25XH28PCC
DISTRIBUTION SILICONE INSULATORS Deadend / Suspension
15 kV to 69 kV
In general Overhead Distribution Lines tend to experience a large number of outages and interruptions due to insulation failures. These failures may be from surface contamination or wetting on line insulators that result in flashovers or pole fires. Silicone deadend/suspension insulators offer the ultimate solution in improved performance. Because of its hydrophobicity, this material inherently resists water filming thereby limiting leakage currents. Insulators with reduced leakage currents, even when contaminated, require less frequent washing. The savings in such maintenance costs are added benefits of using silicone insulators. K–Line silicone polymer distribution deadend/suspension insulators are manufactured and tested to world-class polymer insulator standards; CEA LWIWG-01, ANSI C29.13, and IEC 1109. K-Line Insulators Limited is registered to ISO 9001 Quality Systems.
PERFORMANCE BENEFITS The performance benefits of K-Line Insulators distribution deadend/suspension insulators are listed below. • Improves Reliability (by minimizing interruptions and outages due to vandalism, pole fires, and flashovers in
all types of environments) • Eliminates or Reduces Maintenance (such as washing and trouble calls) and is compatible with existing plant • Improves Power Quality (less RI and TVI) • Energy Efficiency (lower losses due to lower leakage currents) • Safety (light weight for handling and installation) • Service Life (consistent performance over its service life) • Life Cycle Cost (savings over porcelain insulators) APPLICATION Distribution deadend/suspension insulators are used on overhead lines operating at or below 69 kV. These insulators are used to support line conductors in suspension or deadend modes such as line terminations, angles, and tangents. These insulators can be used with bare or covered conductors. CORE MATERIAL
The core rod of the distribution deadend/suspension insulator is made of a high quality fiberglass that has been specially formulated for electrical and mechanical applications. HOUSING AND SHEDS The housing and sheds of the insulator are one piece, injected molded silicone rubber that is chemically bonded to the core rod. This ensures that the interface between the rubber and rod is impenetrable against moisture ingress.
Distribution Silicone Insulators Deadend / Suspension
DISTRIBUTION DEADEND/SUSPENSION INSULATOR
TECHNICAL DATA
CATALOGUE NUMBER** SPECIFICATIONS UNIT KL15ASCTM KL28ASCTM KL35SCTM KL46SCT KL46SCTA KL69HC1T116
Voltage Class kV 15 28 35 46 46 69 CEA & ANSI Class - DS15 DS28 DS35 DS46 - DS69 Section Length “L” mm (in) 322 (12.7) 433 (17.0) 486 (19.1) 574 (22.6) 646 (25.4) 733 (28.9) Dry Arcing Distance mm (in) 193 (7.6) 290 (11.4) 348 (13.7) 419 (16.5) 490 (19.3) 627 (24.7) Leakage Distance mm (in) 384 (15.1) 590 (23.2) 750 (29.5) 988 (38.9) 1059 (41.7) 1798 (70.8)
** The catalogue numbers in the above table are for “CT” clevis-tongue fittings. For other combinations of end fittings or mechanical strengths, see End Fittings Section.
END FITTINGS
There are five standard end fittings that are available on the deadend/suspension insulators: clevis, tongue, thimble eye, socket, and ball (See Below). The clevis, tongue, and thimble eye fittings are made from high strength, corrosion resistant extruded aluminum. While the socket and ball fittings are hot-dip galvanized iron. The end fittings are crimped on to the core rod to provide the mechanical performance. A watertight seal between the rubber and end fittings eliminates possible moisture ingress. This special silicone rubber to metal fittings sealing process provides total exclusion of moisture. The end fittings of the distribution class deadend/suspension are rated for a specified mechanical strength, SML of 70 kN (15,700 lb) or 90 kN (20,200 lb). The clevis and tongue end fittings are the two most common fittings used with additional adaptors and clamps. The thimble eye end fitting is a unique design that integrates the insulator tongue end fitting and a preformed conductor grip adapter to attach to the line conductor. This thimble eye essentially eliminates one item in the assembly and from inventory. For other special end fittings please contact K-Line Insulators.
Insulator contamination is a common problem on overhead lines. The fundamental element for interruptions with contaminated insulators is moisture. Wet atmospheric conditions result in water filming on surfaces and causing leakage currents to develop. On wood structures, leakage currents can cause pole top fires. On steel structures, leakage currents can develop into faults.
Silicone offers the ultimate solution in line post insulators. Because of its hydrophobicity, this material inherently resists water filming thereby limiting leakage currents. Silicone insulators reduce leakage currents, even when contaminated and require less frequent washing. The savings in such maintenance costs are added benefits of using silicone insulators.
K–Line silicone polymer distribution line post insulators are manufactured and tested to world-class polymer insulator standards, CEA LWIWG-02. K-Line Insulators Limited is registered to ISO 9001 Quality Systems.
PERFORMANCE BENEFITS The performance benefits of K-Line Insulators’ distribution line post insulators are listed below.
• Improves Reliability (by minimizing interruptions and outages due to vandalism, pole fires, and flashovers in all types of environments)
• Eliminates or Reduces Maintenance (such as washing and trouble calls) and is compatible with existing plant
• Improves Power Quality (less RI and TVI) • Energy Efficiency (lower losses due to lower leakage currents) • Safety (light weight for handling and installation) • Service Life (consistent performance over its service life) • Life Cycle Cost (savings over porcelain insulators)
APPLICATION Distribution line post insulators are used on overhead distribution lines operating at and below 69 kV. These insulators are commonly installed on metal or wooden structures to horizontally or vertically support the line conductor. Also, these insulators are used to support high voltage conductor jumpers or leads.
ROD
The core rod of the insulator is made of a high quality fiberglass that has been specially formulated for electrical and mechanical applications.
HOUSING AND SHEDS The housing and sheds of the insulator are one piece, injection molded silicone rubber that chemically bonds to the core rod. This ensures that the interface between the rubber and rod is impenetrable against moisture ingress.
* Ordering Information To catalogue number, add suffix H for horizontal, V for vertical, T for C-neck Tie-top, TF for the F-neck Tie-top, or K for K-clamp. The standard base thread is ¾”-10 UNC. Different base threads are available upon request.
** K-clamp conductor diameter range is 7.6 mm (0.30”) to 34.0 mm (1.34”). *** Section lengths are for K-clamp insulators. For others refer to Section Length Adjustment Table under End Fittings.
LINE END FITTING The line end fitting of line post insulators are available in four different configurations: horizontal or vertical clamp-top, tie-top, or K-clamp. All line end fittings on line post insulators are made of corrosion resistant aluminum alloy castings.
SECTION LENGTH ADJUSTMENT
Line End Fitting Line End Fitting Designation Section Length
K-Clamp K See Technical Data sheet Horizontal H L - 9 mm (0.4”)
Vertical V L - 23 mm (0.9”) Tie-Top (F-neck) TF L - 33 mm (1.3”) Tie-Top (C-neck) T L - 53 mm (2.1”)
Clamp-Top The conventional horizontal and vertical trunnion accommodates a standard line post insulator, bolted conductor clamp. On the horizontal design the line end fitting has an additional eye for the attachment of other devices during installation or maintenance activities. Tie-Top The tie-top is designed for tying a conductor to the neck of the insulator. It is available in two standard neck sizes: C or F-neck. K-Clamp K-Line Insulators Limited has introduced a new concept in the polymer line post live end fitting design. This end fitting is referred to as the “K” clamp. The uniqueness of this end fitting is a result of the many advantages it has over the traditional horizontal, vertical and tie-top configurations.
Some advantages of the “K” clamp include:
1) Excellent corrosion resistant aluminum casting 2) A long, smooth contoured conductor clamping zone 3) The clamp accommodates a full range of conductor sizes 4) A single captive live-line operable bolt 5) All parts are captive 6) Lower overall length permits standard cover up hoods to effectively cover all insulator sheds 7) The design can be installed in either a horizontal or vertical configuration 8) Inventory reduction is accomplished because one insulator is used for both configurations and a
separate clamp is not required 9) The price of the new insulator is cost comparative with the purchase of a standard trunnion post
insulator and a separate clamp 10) Substantial labour cost savings in stringing, sagging and conductor clamping 11) Other savings related to shipping, stocking and maintenance
BASE END FITTING The standard base for line post insulators is a round flat iron base with a threaded hole that accommodates a standard insulator stud or bolt. For other special bases contact K-Line Insulators Limited. Hot-dip galvanizing to CSA G164 and ASTM A153 specifications provides corrosion protection of the base end fitting.
K-Line Insulators has introduced a new silicone line post insulator that is applicable for 69 kV overhead lines. This insulator is designed for installations with high electrical requirements. This insulator features the highly reliable proprietary K-Line silicone rubber that is one piece, injection molded and chemically bonded to a high quality epoxy fiberglass rod. This insulator will greatly improve the electrical performance of the System, especially in contaminated environments. Insulator contamination is a common problem on overhead lines. The fundamental element for interruptions with contaminated insulators is moisture. Wet atmospheric conditions result in water filming on surfaces and causing leakage currents to develop. On wood structures, leakage currents can cause pole top fires and eventual failures. On steel structures, leakage currents can develop into faults. K-Line’s proprietary silicone material offers the ultimate solution in post insulator applications. Because of its hydrophobicity, this material inherently resists water filming thereby limiting leakage currents. These silicone insulators reduce leakage currents, even when contaminated and require less frequent if any washing. The savings in maintenance costs are added benefits of using K-Line silicone insulators. The 69 kV line post insulator has been designed to meet the requirements of CEA LWIWG-02, ANSI C29.18, and IEC 61952. The 69 kV line post insulator is available in four different configurations: horizontal, vertical, tie-top, or K-clamp. The K-clamp design offers the best and most cost effective solution in most cases. 69 kV K-Clamp Line Post The K-clamp insulator has an integral clamp for attaching the conductor directly to the line post insulator without the use of a separate conductor clamp. The K-clamp insulator can bemounted either in the vertical or horizontal position and offersseveral advantages over the conventional line post insulators. The K-clamp has a smooth clamping zone that accommodatesa conductor diameter range of 0.30 inch (7.6 mm) to 1.34 inch(34 mm). The single galvanized steel clamp bolt that secures the keeper can be operated with hot line tools from either sideof the clamp. It also extends beyond the clamp body to allowfor the attachment of stringing devices. The K-clamp insulator can provide substantial labour costsavings in stringing, sagging and conductor clamping. Thereare other savings that can be achieved in shipping, stocking and maintenance.
New Silicone Line Post Insulator For 69 kV Overhead Lines
Configuration & Hardware Accessories
The 69 kV line post is available in three other configurations: vertical, horizontal, or tie-top (ANSI F-Neck). Also, the horizontal line post can be supplied with a gain base (See below). For the clamp-top trunnions conductor clamps are also available.
Vertical Tie-Top
Horizontal with Gain Base
Technical Data
CATALOGUE NUMBER*
CATALOGUE NUMBER* SPECIFICATION UNIT
KL69S SPECIFICATION UNIT
KL69S
Test kV 45 Voltage Class kV 69 Radio Influence Voltage (RIV)
at 1 MHz Max µV 6
CEA Class - LP69M Specified Tensile Load (STL) kN (lb) 22 (5000)
Leakage Distance mm (in) 1511 (59.5) Approx. Weight kg (lb) 8.0 (17.5)
Critical Impulse Flashover (Positive) kV 360 Standard Packaging - 2
Dry 235 Low-Frequency Flashover
Wet kV
190**
* Ordering Information To Line Post Catalogue Number, add suffix KP1 for K-clamp, HP1 for horizontal, VP1 for vertical, or TFP1 for tie-top. The standard base thread is ⅞”-9 UNC. Different base threads are available upon request. ** The value shown is as per CEA and the ANSI value is 165 kV.
One of the most critical assets of an electrical Distribution System is the station. Not only is this asset the heart of the supply to large electrical loads but it also serves many customers from industrial to residential. Therefore, outages or interruptions due to insulation failures are costly and impact negatively on customer service. With K-Line silicone station post insulators these are greatly minimized through improved performance to reliability and savings in the life cycle cost. Silicone’s hydrophobic property allows K-Line station post insulators to electrically outperform porcelain insulators. The lightweight feature of polymer insulators makes them easy to handle and install. The size and fittings of polymer station post insulators ensure that they are compatible with existing station post hardware and arrangements. Experience with silicone polymer insulators has proven their superiority over porcelain insulators. K–Line silicone polymer distribution station post insulators are manufactured and tested to world-class polymer insulator standards, CSA and ANSI. K-Line’s Quality System is registered to ISO 9001 Quality Systems.
PERFORMANCE BENEFITS The performance benefits of K-Line Insulators distribution station post insulators are listed below.
• Improved Reliability (interruptions and outages due to vandalism, and flashovers in all types of environments are a thing of the past)
• Eliminates or Reduces Maintenance (such as washing and trouble calls) and are compatible with existing porcelain insulators
• Improves Power Quality (lower RI and TVI) • Energy Efficiency (reduced losses due to lower leakage currents) • Safety (light weight for handling and installation, eliminates catastrophic mechanical failures) • Service Life (consistent performance over its service life) • Life Cycle Cost (savings over porcelain insulators)
APPLICATION Distribution station post insulators are used in open-type stations operating at and below 46 kV. These insulators support the bus, leads, or other apparatus within the station.
ROD
The core rod of the distribution station post insulator is made of a high quality fiberglass that has been specially formulated for electrical and mechanical applications. HOUSING AND SHEDS The housing and sheds of the insulator are one piece, injected molded silicone rubber that chemically bonds to the core rod. This ensures that the interface between the rubber and rod is impenetrable against moisture ingress.
Distribution Silicone Insulators Station Post
DISTRIBUTION STATION POST INSULATOR
TECHNICAL DATA
* Ordering Information:
1. Above catalogue numbers apply to insulators with through holes on both ends. (Except for KL46SPT2). 2. Add T1 to catalogue numbers for insulators with one end tapped & the other with through holes. 3. Add T2 to catalogue number for insulators with both ends tapped.
Number of Sheds No. 2 3 5 5 6 10 Approx. Weight kg (lb) 3.4 (7.4) 3.7 (8.0) 4.2 (9.2) 4.3 (9.4) 6.0 (13.4) 9.1 (20.0)
END BASES
The standard base fittings are flat round iron bases that are available with bolt circle mounting holes with either through or tapped holes. These bases are compatible with the porcelain station post insulator standard. The end bases are radially swaged on to the core rod to provide the mechanical performance and reduce the stress concentration. Our proprietary design ensures a watertight seal between the rubber and end fitting. This special silicone rubber to metal fittings sealing process prevents moisture ingress to the core fiberglass rod. For other special base requirements, please contact K-Line Insulators Limited. Corrosion protection of the end bases is provided by hot-dip galvanizing to CSA G164 and ASTM A153 specifications.
One of the most important items on any transmission overhead line is the insulator. This item is the backbone of the transmission system in minimizing interruptions and outages, and providing for a safe plant. Therefore, it is essential to have high quality and dependable insulators on the system. With K–Line silicone polymer transmission insulators these objectives can be easily achieved with a substantial savings in the life cycle cost. Experience with silicone polymer insulators has proven their superiority over porcelain insulators. Today more Electric Utilities are shifting to silicone polymer insulators to improve overall performance on transmission overhead lines. K–Line silicone polymer transmission suspension/deadend insulators are manufactured and tested to world-class polymer insulator standards, CSA C411.4, ANSI C29.11 and IEC 1109. K-Line Insulators Limited is registered to ISO 9001 Quality Systems. PERFORMANCE BENEFITS
The performance benefits of K-Line Insulators transmission suspension/deadend insulators are listed below.
• Improved Reliability (interruptions and outages due to vandalism, pole fires, and flashovers in all types of environments are a thing of the past)
• Eliminates or Reduces Maintenance (such as washing and trouble calls) and is compatible with existing plant • Improves Power Quality (less RI and TVI) • Energy Efficiency (reduced losses due to lower leakage currents) • Safety (light weight for handling and installation) • Service Life (consistent performance over its service life) • Life Cycle Cost (savings over porcelain insulators)
APPLICATION Transmission suspension/deadend insulators are used on transmission lines operating at and above 66kV. These insulators are installed on metal or wooden structures on cross arms to hold the conductor longitudinally (dead-end) or vertically (suspension). The connections to the structures or arms and line vary depending on the Utilities preference. ROD
The core rod of the transmission suspension/deadend insulator is made of a high quality fiberglass that has been specially formulated for electrical and mechanical applications.
HOUSING AND SHEDS The housing and sheds of the insulator are one piece, injected-molded silicone rubber that chemically bonds to the core rod. This ensures that the interface between the rubber and rod is impenetrable against moisture ingress.
Notes: 1. Section lengths are based on ball and socket hardware. For lengths of insulators with alternate end fittings combination see
Section Lengths.
2. Weight includes standard rings where applicable. See section on Corona Rings.
SECTION LENGTHS
The section lengths (L) published on the Technical Data sheet are for the ball and socket end fittings. For alternate combinations of end fittings, use the following table to establish section lengths.
SECTION LENGTH ADJUSTMENT
End Fitting End Fitting Designation Section Length
ANSI Ball / Socket BS L (see Technical Data sheet) ANSI Ball / Y-clevis BY L + 36 mm (1.4”) ANSI Ball / oval Eye BE L + 41 mm (1.6”) oval Eye / oval Eye EE L + 84 mm (3.3”) Clevis / Tongue CT L + 21 mm (0.8”)
CORONA RINGS
High voltage lines above 88 kV phase-to-phase can generate unnecessary noise (RI and TVI) and corona due to the high electrical stress concentration. To minimize these effects gradient or corona rings are installed on the end fitting of the insulator. Guidelines used in the application of these rings are noted below. Insulators that are used on system voltages above 88 kV and below 150 kV are supplied with a built-in gradient ring. Insulators that are used on system voltages from 150 kV and above are supplied with a separate corona ring for assembly in the field before installation. The ring is designed for installation in only one orientation and location to avoid miss application. These rings are made from aluminum that make them light weight and corrosion resistant.
Gradient (Built-in) Ring 88 kV to below 150 kV
Corona Ring 150 kV to 230 kV
END FITTINGS
The end fittings on the transmission insulator are made of high strength, cast (forged) steel. The insulators have a specified mechanical load (SML) rating of 120 kN (27,000 lbs.). Also, all insulators are proof tested to 60 kN (13,500 lbs.) in tension. The end fittings are radialy swaged on to the core rod to provide the mechanical performance and reduce the stress concentration. Our proprietary design insures a watertight seal between the rubber and end fitting. This special silicone rubber to metal fittings sealing process prevents moisture ingress to the core fiberglass rod. Hot-dip galvanizing to CSA G164 and ASTM A153 Standard provides corrosion protection of the end fittings. The cotter key is made from stainless steel.
The standard end fittings that are available are listed and detailed in the below. For other special end fittings contact K-Line Insulator Limited.
END FITTING COMBINATIONS
ORDERING INFORMATION
For ordering the catalogue number of the specific insulator is formulated as shown below.
Cat. No. KL 115 H BS 28
Company ID No. of Sheds (See Tech Data)
Voltage Class (See Tech Data) End Fitting Designation (See End Fittings)
Today transmission lines are required to be more aesthetically pleasing and are routed through narrow right-of-ways or along roadways. Also, at the lower transmission voltages (e.g., 115 kV and 69 kV) these lines are routed through urban areas and along roadways similar to distribution circuits to supply substations and larger customers. In some situations these lines share the same route and poles with distribution circuits. With K-Line silicone line post transmission insulators an aesthetic compact line design can be easily achieved with a substantial savings in the life cycle cost. K–Line silicone polymer transmission line post insulators are manufactured and tested to world-class polymer insulator standards, CSA and ANSI. K-Lines’ Quality System is registered to ISO 9001 Quality Systems.
PERFORMANCE BENEFITS The performance benefits of K-Line Insulators transmission line post insulators are listed below.
• Improved Reliability (interruptions and outages due to vandalism, pole fires, and flashovers in all types of environments are a thing of the past)
• Eliminate or Reduce Maintenance (such as washing and less trouble calls) and is compatible with existing plant
• Improves Power Quality (lower RI and TVI) • Energy Efficiency (reduced losses due to lower leakage currents) • Safety (light weight for handling and installation) • Service Life (consistent performance over its service life) • Life Cycle Cost (savings over porcelain insulators)
APPLICATION Transmission line post insulators are used on overhead transmission lines operating at and above 66 kV. These insulators are commonly installed either vertically or horizontally on metal or wooden structures to support the conductor. Also, these insulators are used to support high voltage conductor jumpers or leads.
ROD
The core rod of the transmission line post insulator is made of a high quality fiberglass that has been specially formulated for electrical and mechanical applications.
HOUSING AND SHEDS The housing and sheds of the insulator are one piece, injected molded silicone rubber that is chemically bonded to the core rod. This ensures that the interface between the rubber and rod is impenetrable against moisture ingress.
Note: Section length based on a horizontal trunnion and without any support base. For alternate bases and line fittings (as well as overall lengths and weights of these) refer to the section on fittings and weights.
END BASES
The standard base fittings are flat round iron bases that are available with bolt circle mounting holes with either through or tapped holes. These bases are compatible with the porcelain station post insulator standard. The end bases are radially swaged on to the core rod to provide the mechanical performance and reduce the stress concentration. Our proprietary design insures a watertight seal between the rubber and end fitting. This special silicone rubber to metal fittings sealing process prevents moisture ingress to the core fiberglass rod. For other special base requirements, please contact K-Line Insulators Limited. Corrosion protection of the end bases is provided by hot-dip galvanizing to CSA G164 or ASTM A153 specifications.
One of the most critical assets of an electrical Transmission System is the station. Not only is this asset the heart of the supply to large electrical loads but it also serves many customers from industrial to residential. Therefore, outages or interruptions due to insulation failures are costly and impact negatively on customer service. With K-Line silicone station insulators these are greatly minimized through improved performance to reliability and savings in the life cycle cost. Silicone’s hydrophobic property allows K-Line station insulators to electrically outperform porcelain insulators. The lightweight feature of polymer insulators makes it easy to handle and install. The size and fittings of polymer station insulators ensure that they are compatible with existing station post hardware and arrangements. Experience with silicone polymer insulators has proven their superiority over porcelain insulators. K–Line silicone polymer transmission station post insulators are manufactured and tested to world-class polymer insulator standards, CSA and ANSI. K-Line’s Quality System is registered to ISO 9001 Quality Systems.
PERFORMANCE BENEFITS The performance benefits of K-Line Insulators transmission station post insulators are listed below.
• Improved Reliability (interruptions and outages due to vandalism, and flashovers in all types of environments are a thing of the past)
• Eliminate or Reduce Maintenance (such as washing and trouble calls) and is compatible with existing porcelain insulators
• Improves Power Quality (lower RI and TVI) • Energy Efficiency (reduced losses due to lower leakage currents) • Safety (light weight for handling and installation, eliminates catastrophic mechanical failures) • Service Life (consistent performance over its service life) • Life Cycle Cost (savings over porcelain insulators)
APPLICATION Transmission station post insulators are used in open-type stations operating at and above 66 kV. These insulators support the bus, leads, or other apparatus within the station.
ROD
The core rod of the transmission station post insulator is made of a high quality fiberglass that has been specially formulated for electrical and mechanical applications. HOUSING AND SHEDS The housing and sheds of the insulator are one piece, injected molded silicone rubber that chemically bonds to the core rod. This ensures that the interface between the rubber and rod is impenetrable against moisture ingress.
1. Above catalogue numbers apply to insulators with through holes on both ends. 2. Add T1 to catalogue numbers for insulators with one end tapped & the other with through holes. 3. Add T2 to catalogue number for insulators with both ends tapped.
End Bases
The standard base fittings are flat round iron bases that are available with bolt circle mounting holes with either through or tapped holes. These bases are compatible with the porcelain station post insulator standard. The end bases are radialy swaged on to the core rod to provide the mechanical performance and reduce the stress concentration. Our proprietary design insures a watertight seal between the rubber and end fitting. This special silicone rubber to metal fittings sealing process prevents moisture ingress to the core fiberglass rod. For other special base requirements, please contact K-Line Insulators Limited. Corrosion protection of the end bases is provided by hot-dip galvanizing to CSA G164 and ASTM A153 specifications.
K-LINE INSULATORS LIMITED Catalogue GI TORONTO, ONTARIO, CANADA
Silicone Guy Strain Insulators
Silicone Guy Strain Insulators
Safety codes mandate the electrical strength of guy insulators to have a dry flashover voltage at least twice the voltage to ground of the highest voltage supply circuit with which the guy could come in contact, and a wet flashover equal to the highest voltage between any two conductors. When using porcelain, two or more insulators are usually needed to comply with these requirements. Fibreglass guy strain insulators so located that there is a possibility of contact with the supply conductors are prone to electrical tracking and failure. Paint coatings are easily removed in handling, and by weathering, and do not adequately protect the rod. Unprotected fiberglass core exposed to the elements can fail as a result of brittle fracture. K-Line guy strain insulators are protected from the environment including the effects of voltage, ultra-violet rays and acid rain by a fully bonded, electrically track-free, and impenetrable silicone rubber sheath. The electrical and mechanical requirements of the safety codes are easily met by K-Line Insulators. K-Line Insulators Limited is registered to ISO 9001 Quality Systems. Each assembled insulator is proof tested, and permanently marked to show the date of test.
GUY STRAIN INSULATORS
TECHNICAL DATA
CATALOGUE NUMBER * SPECIFICATIONS UNIT
KL11 KL24 KL36 KL54 KL78
CEA Class - GI30 GI60 GI90 GI140 GI200
Insulated Length A * * mm (in) 280 (11) 610 (24) 910 (36) 1370 (54) 1980 (78)
Standard Packaging - 24 15 15 15 15 Ordering Information: * To catalogue number, add suffix CTS for clevis-tongue, CCS for clevis-clevis, RRS for roller-roller, or HHS for thimble eye-thimble eye, (other
custom fittings can be accommodated). ** Other lengths are available on request.
K-Line dead-end extension insulators are manufactured by coupling either silicone sleeved rod to polymer dead-end insulators. Extension insulators are made using the same manufacturing methods and quality assurance program as the dead-end and guy insulators. Each dead-end extension insulator is mechanically proof tested to 44kN, (10,000 lbs). For installations in normal operating environments, K-Line insulators are recommended. For extremely contaminated, salt laden or chemical environments, K-Line SILICONE insulators are the ultimate solution. The Technical Data table (See Next Section) shows the standard lengths available. Custom lengths are available on request. APPLICATION Extension insulators are used when more length is needed than the standard insulator can supply. ROD
The core rod of the extension insulator is made of a high quality fiberglass that has been specially formulated for electrical and mechanical applications.
HOUSING AND SHEDS The housing and sheds of the dead-end insulator are one piece, injected-molded silicone rubber that chemically bonds to the core rod. This ensures that the interface between the rubber and rod is impenetrable against moisture ingress.
FITTINGS The extension insulator comes standard with aluminum clevis and tongue end fittings, and a coupler.
Notes: 1) For the complete specifications of the insulator, refer to Distribution Insulators – Deadend/Suspension, Catalogue D-DS. 2) The silicone covered rod in series with the insulator will add to the total insulation level.
With the environmental exposure to ice and/or wind Overhead Transmission and Distribution Lines that are bare open-wire design are quite susceptible to conductor motion that may result in outages or interruptions on the electrical system due to conductor contact, flashovers, or any plant damage. Interphase spacers were developed to minimize the probability of these occurrences by insuring that conductors remain apart during their movement. K – Line interphase spacers consist of silicone rubber insulation over a fiberglass rod. They are very light and flexible. They are connected on the conductor with clamps with or without armour rods. The interphase spacers meet the requirements of CEA LWIWG-01, IEEE 1024, ANSI C29.11 and CSA C411.4. K-Line Insulators Limited is registered to ISO 9001 Quality Systems.
PERFORMANCE BENEFITS The performance benefits of K-Line Insulators interphase spacer insulators are listed below. • Improves Reliability (by minimizes interruptions and outages due to vandalism and flashovers in all types of
environments) • Eliminates or Reduces Maintenance (such as washing and trouble calls) and is compatible with existing plant • Improves Power Quality (less RI and TVI) • Energy Efficiency (lower losses due to lower leakage currents) • Safety (light weight for handling and installation) • Service Life (consistent performance over its service life) • Life Cycle Cost (savings over porcelain insulators) APPLICATION One or two interphase spacers are installed in each span. One spacer is installed if there are two vertically positioned conductors and it is installed at one-third of the span. Two spacers are installed if there are three vertically positioned conductors. The first spacer is installed between the mid and lower conductors one-third of the span from one end. The second spacer is installed between the mid and upper conductor one-quarter of the span from the other end. CORE MATERIAL
The core rod of the interphase spacer insulator is made of a high quality fiberglass that has been specially formulated for electrical and mechanical applications. HOUSING AND SHEDS The housing and sheds of the insulator are one piece, injected molded silicone rubber that is chemically bonded to the core rod. This ensures that the interface between the rubber and rod is impenetrable against moisture ingress
Transmission & Distribution Silicone Interphase Spacer Insulators
On distribution overhead lines there are numerous tap-offs from the main line to provide connections to equipment (e.g., transformers, switches, fuses, underground cables, etc.) or lines (e.g., services, junctions, etc.). Normally leads are used to connect the equipment or line to the main line. These leads can be long and difficult or hazardous to operate. The use of riser support insulators can provide a safe and economical support for these leads. K–Line silicone riser support insulators are manufactured and tested to world-class polymer insulator standards, CSA, CEA, ANSI and IEC. K-Line Insulators Limited is registered to ISO 9001 Quality Systems. APPLICATION Distribution riser support insulators are used on distribution lines operating at or below 69 kV. These insulators are installed on metal, concrete or wooden structures and on cross arms to hold and insulate the conductor leads. ROD
The core rod of the distribution riser support insulator is made of a high quality fiberglass that has been specially formulated for electrical and mechanical applications.
HOUSING AND SHEDS The housing and sheds of the insulator are one piece, injected-molded silicone rubber that chemically bonds to the core rod. This ensures that the interface between the rubber and rod is impenetrable against moisture ingress.
FITTINGS The riser insulator comes standard with a clamp to hold the conductor and a threaded hole for mounting. Conductor Clamp The clamp is an aluminum clamp that can accommodate copper or aluminum conductors # 6 AWG (0.20”) to 556.5 kcmil (0.95”). Threaded Base The base is typically threaded for ⅝”-11, ¾”-10, M16x2, or M20x2.5 galvanized bolt. For other special clamp features or base threads please contact K-Line Insulators Limited.
The ultimate in labour saving and convenience is provided by K-Line's single circuit pole-top framing assembly (35 kV shown). The assembly comes complete in kit form with mounting bracket, polymer line post insulators, trunnion clamps and insulator mounting studs. Install with two bolts and the structure is ready to sag.The hot dip galvanized steel bracket comes with predrilled holes for mounting of riser support insulators and a grounding lug. The insulators are of silicone, the ultimate in polymer line post insulators for maintenance-free operation.
