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Help Center35kv Suspension Insulator, Suspension Porcelain Insulator for Power Lines, Steel Cap Disc Porcelain Insulator
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Product Overview
In power line operation, insulators are key components that ensure conductor-to-ground insulation and mechanical support. With the development of power grid construction toward long-distance and large-capacity transmission, the environment along line corridors has become increasingly complex. Factors such as dust, salt spray, and industrial pollution lead to frequent pollution flashover accidents of insulators. Meanwhile, as porcelain insulators are brittle materials, excessive electromechanical loads may cause serious failures such as string breakage and conductor dropping, directly affecting power supply reliability. How to balance pollution flashover resistance, mechanical strength, and long-term operational stability has long been a pain point for power line designers and maintenance personnel. To address this need, Hejian Haokang Electric Co., Ltd., leveraging its product R&D and manufacturing experience in the field of electric porcelain insulators, has launched this 35kV suspension porcelain insulator. From raw material selection, glaze treatment to steel cap assembly, the product implements full-process control, optimizes the porcelain body head structure and cement bonding process, and enhances mechanical load margin. Meanwhile, by increasing creepage distance and adjusting shed configuration, the pollution flashover resistance is improved, striving to provide safe and durable insulation support in harsh environments.
Structure Composition and Working Mechanism
This product is a disc-type suspension porcelain insulator, mainly composed of porcelain body, steel cap, steel pin, and locking pin. The steel cap and porcelain body are assembled with high-strength cement adhesive, and the steel pin is connected through a ball-socket structure, forming a flexible chain lock. During operation, the insulator string is suspended on the tower cross-arm, bearing the conductor gravity, ice load, wind deflection, and system short-circuit impact, while utilizing the high resistivity and low dielectric loss of the porcelain body to block current leakage paths. The shed and rib structure on the porcelain surface increases leakage distance, enlarges the contaminated surface resistance, suppresses leakage current development, and thereby reduces the probability of pollution flashover. The suspension structure features that each insulator independently shares the mechanical load, so a single-point fault in the string will not cause the entire string to drop, and maintenance and replacement are also convenient.
Core Features
- Using high-strength porcelain material, through grinding, forming, glazing, and high-temperature firing, the porcelain body is dense with high mechanical strength.
- The steel cap is made of malleable cast iron, hot-dip galvanized, with good corrosion resistance.
- The ball-socket connection structure facilitates installation and replacement, and the string length can be adjusted flexibly.
- Products with different creepage distances can be selected according to the pollution level, suitable for common environments.
- During production, each piece undergoes power-frequency voltage test and mechanical load sampling inspection to ensure consistency.
- The disc structure has good self-cleaning performance under wind and rain, which helps reduce the frequency of manual cleaning.
Technical Specifications
The following table shows typical specification parameters. Specific supply parameters can be customized according to engineering requirements.
| Rated Voltage | 35kV |
| Structural type | Disc suspension |
| Material | High-strength electrical porcelain |
| Steel cap material | Malleable cast iron (hot-dip galvanized) |
| Nominal diameter | Approx. 255mm |
| Structural height | Approx. 146mm |
| Creepage distance | Approx. 320mm |
| Mechanical failing load | 70kN (optional 40kN/100kN) |
| Locking pin material | Stainless steel |
| Operating ambient temperature | -40℃ to +40℃ |
Please note that the above parameters are listed according to typical specifications of common suspension porcelain insulators in the industry; actual selection should be determined based on pollution level, mechanical load, and installation dimensions.
Application scenarios
This product is widely used in suspension strings and tension strings of 35kV transmission lines, and can also be used for insulation support of substation incoming line frameworks and distribution lines. In complex environments such as mountainous areas, lightning-prone areas, and industrial pollution areas, reliability requirements can be met by adjusting the number of insulator units in series and selecting models with large creepage distance. When selecting, users should determine the type, number of units, and mechanical safety factor of the insulator string according to line design specifications.
Selection key points
During selection, the mechanical strength safety factor of the insulator must be carefully checked: under maximum working load, the mechanical safety factor of suspension insulators should not be less than 2.0; for important crossing spans, the safety factor should be appropriately increased. At the same time, the specific creepage distance of the insulator string should be verified according to the rated voltage of the line and the neutral grounding mode; in heavily polluted areas, bell-type porcelain insulators with big-small shed or double-shed structures can be selected to improve anti-pollution flashover capability.
Installation and maintenance recommendations
During installation, check whether the ball-and-socket connections of the insulator string are properly seated, and the locking pins should be installed fully and face the same direction; avoid impact on porcelain parts during lifting and tensioning, and never tie porcelain parts directly with iron wire. After commissioning, regular inspections are recommended: check whether the steel caps are corroded, whether the porcelain parts have cracks, and whether the cement joints have water seepage; during pollution seasons, cleaning during outages can be arranged, and if necessary, live-line water washing or anti-pollution flashover coating can be applied. For zero-value insulators, use a voltage distribution detector to test at least once a year, and replace them promptly when zero-value is found to ensure the insulation level of the whole string. During storage, keep the packaging intact, and the warehouse should be well-ventilated and dry to avoid moisture and collision damage to porcelain parts.
Company Advantages and Consultation Suggestions
Hejian Haokang Electric Co., Ltd.'s main products include various types of suspension, pin, porcelain cross-arm, and porcelain pull rod insulators, as well as glass insulators, station porcelain, wall bushings, etc., covering different voltage levels and working conditions. The company's product line is mature, and customers can obtain corresponding product selection and supporting services based on specific project requirements. For 35kV line projects, it is suggested that you provide information such as the pollution level of the area where the line is located, altitude, span, and conductor specifications. Our technical staff can assist in calculating the number of insulator discs and mechanical load margin to avoid operational risks caused by improper selection. Design institutes, construction units, and technical personnel of power companies are welcome to inquire and visit our factory. We will uphold a pragmatic attitude and work with you to determine a reasonable insulator configuration plan.
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