High-Voltage Equipment Insulation Components – Fiberglass Wound Tubes: Detailed Application in Specific Equipment
Fiberglass wound tubes, as high-performance composite insulation materials, have been widely adopted in various high-voltage equipment. The following outlines their specific application scenarios and technical advantages across different high-voltage devices:
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I. Core Equipment in Power Transmission & Distribution Systems
1. Gas-Insulated Metal-Enclosed Switchgear (GIS)
· Application Components: Insulating operating rods, operating linkages, support insulators
· Technical Specifications:
· Operating voltage: 72.5kV–1100kV
· Mechanical strength: Flexural strength ≥450 MPa
· Partial discharge: ≤3 pC (at 1.1 times rated voltage)
· Advantages:
· Replaces traditional epoxy cast parts, reducing weight by 40–50%
· Vacuum impregnation process ensures zero internal defects
· Excellent resistance to SF₆ decomposition by-products
2. High-Voltage Circuit Breakers
· Application Components:
· Arc-extinguishing chamber insulating cylinders
· Operating mechanism insulating linkages
· Support insulators
· Performance Requirements:
· Arc erosion resistance (≥180 seconds)
· Impact strength ≥50 kJ/m²
· Heat deflection temperature ≥200°C
· Typical Cases:
· 252 kV SF₆ circuit breaker insulating operating rods
· 550 kV dead-tank circuit breaker support insulators
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II. Transformer-Class Equipment
1. Dry-Type Transformers
· Application Components:
· High-voltage winding insulating skeletons
· Inter-phase barrier support tubes
· Bushing insulating cylinders
· Material Properties:
· Thermal class: Class H (180°C)
· Flame retardancy rating: UL94 V-0
· Insulation resistance: ≥10¹² Ω·m
· Design Advantages:
· Excellent heat dissipation (thermal conductivity ≥0.3 W/m·K)
· Low dielectric loss (tan δ ≤0.5%)
· Seismic performance meets IEC 60076-11 requirements
2. Converter Transformers
· Special Applications:
· Valve-side bushing insulation supports
· DC wall bushings
· Grading ring insulating brackets
· Technical Requirements:
· DC superimposed impulse voltage withstand
· Resistance to polarity reversal electric field stress
· Long-term endurance under DC electric field aging
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III. High-Voltage Measurement & Control Equipment
1. Current/Voltage Transformers
· Core Applications:
· Insulating protective sleeves (primary insulation)
· Core insulating skeletons
· Secondary winding insulating tubes
· Accuracy Assurance:
· Dielectric constant stability (±2%)
· Low dielectric loss (ensures measurement accuracy)
· Matched temperature coefficient (consistent with copper windings)
2. Surge Arresters & Voltage Limiters
· Application Locations:
· External insulating housings
· Internal resistor block support cylinders
· Grading ring insulating brackets
· Protective Performance:
· Withstand multiple lightning impulse strikes
· Resistance to power frequency follow current erosion
· Long-term UV protection performance
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IV. Special High-Voltage Equipment
1. High-Voltage Motors & Generators
· Stator Insulation System:
· Winding end support rings
· Slot wedge insulating tubes
· Inter-phase insulating cylinders
· Performance Indicators:
· Corona endurance life ≥20,000 hours
· Thermal cycling endurance (-40°C to 180°C)
· Vibration fatigue resistance (30g acceleration)
2. Pulsed Power Equipment
· Special Applications:
· Pulse forming line insulating cylinders
· Marx generator support insulation
· Pulse transformer insulating skeletons
· Key Parameters:
· Nanosecond-level pulse voltage withstand
· Extremely low dielectric loss (high-frequency characteristics)
· Resistance to space charge accumulation
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V. Power Electronic Equipment
1. High-Voltage Frequency Converters
· Insulating Structural Components:
· IGBT module insulating substrates
· DC busbar insulating supports
· Output filter insulating tubes
· Special Requirements:
· High-frequency insulation characteristics (≥20 kHz)
· Resistance to dv/dt voltage transients
· Good EMI shielding performance
2. Solid-State Circuit Breakers
· Application Components:
· Semiconductor device insulating encapsulation
· Fast mechanism insulating operating rods
· Overvoltage protection insulating structures
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VI. Technical Selection Reference Table
Equipment Type Recommended Tube Specifications Key Performance Requirements Certification Standards
GIS Equipment Φ50–200 mm High mechanical strength, SF₆ compatibility IEC 62271
Dry-Type Transformers Φ30–150 mm Class H heat resistance, flame retardancy IEC 60076
Instrument Transformers Φ20–100 mm Low dielectric loss, dimensional stability IEC 61869
Surge Arresters Φ60–300 mm Weather resistance, UV resistance IEC 60099
High-Voltage Motors Φ40–120 mm Corona resistance, vibration resistance IEC 60034
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VII. Customized Solution Capabilities
1. Structural Optimization Design
· Finite Element Analysis (FEA): Multi-physics coupled simulation of electric fields, mechanical stresses, and thermal fields
· Interface Optimization: Stress control at metal-composite interfaces
· Assembly Design: Optimization of embedded parts and connection structures
2. Special Process Treatments
· Surface Treatments:
· Silicone rubber coating (anti-pollution flashover)
· Semiconductor coating (voltage grading)
· Teflon coating (anti-adhesion)
· Functional Integration:
· Integrated temperature sensors
· Embedded fiber optic monitoring
· Conductive layer shielding design
3. Quality Control Key Points
1. Raw Material Control:
· Glass fiber moisture content ≤0.05%
· Resin volatile content ≤1.5%
· Curing agent purity ≥99.5%
2. Process Control:
· Winding tension accuracy ±2%
· Curing temperature gradient ±3°C
· Resin content control ±1.5%
3. Testing Items:
· 100% power frequency withstand voltage test
· Ultrasonic C-scan inspection
· Partial discharge pattern analysis
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VIII. Industry Application Cases
Case 1: 800 kV GIS Insulating Operating Rod
· Challenge: Length 3.2 meters, straightness requirement ≤0.5 mm/m
· Solution:
· Utilized 6-axis winding machine for precise control
· Segmented curing process to control deformation
· Machined under pre-stressed state to ensure accuracy
· Results:
· Passed 252 kV/1 min power frequency withstand voltage test
· Partial discharge ≤1 pC
· 8 years of safe operation
Case 2: Nuclear Power Class 1E Insulation Components
· Special Requirements:
· 60-year design life
· Resistance to LOCA (Loss-of-Coolant Accident) environment
· Radiation resistance: cumulative dose ≥10⁶ Gy
· Technical Solution:
· Special-formulation vinyl ester resin
· Multi-layer protective structure design
· Accelerated aging life assessment
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IX. Future Development Trends
1. Intelligent Insulation Components:
· Smart insulating tubes with integrated fiber optic sensing
· Self-diagnostic insulation condition monitoring
· Wireless transmission of temperature and strain data
2. Eco-Friendly Materials:
· Bio-based resin systems
· Recyclable composite materials
· Low greenhouse gas emission processes
3. Extreme Environment Adaptation:
· Insulation for deep-sea high-pressure equipment
· Insulation for space-based high-voltage systems
· Applications in polar low-temperature environments
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We provide end-to-end solutions—from design, simulation, and manufacturing to testing—for manufacturers of all types of high-voltage equipment. Regardless of the specific operating conditions your equipment faces, our engineering team can deliver the optimal customized fiberglass wound tube solution for you.
