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Help CenterComposite Insulator Tension String With Matching Clamps 220kv Lightweight High Insulation Free Design
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Industry Pain Points and Solutions
In high-voltage transmission lines, especially at the 220kV level, traditional porcelain or glass insulator tension strings have long suffered from three core pain points: excessive self-weight leads to increased tower loads and high transportation and installation costs; brittle materials are prone to damage, producing fragments due to external forces or temperature differences during transportation, installation, and operation, threatening line safety; high pollution flashover risk, as porcelain surfaces easily accumulate contaminants and are highly prone to pollution flashovers in humid environments, causing trip accidents. To address these long-standing problems in power operation and maintenance, Hejian Haokang Electric Co., Ltd., leveraging over a decade of insulator manufacturing experience, has launched the 220kV composite insulator tension string (with matching clamps), which adopts a composite structure of high-strength FRP core rod and silicone rubber sheds. Its weight is only 1/5 to 1/7 of porcelain insulators of the same grade, while offering excellent hydrophobicity and anti-pollution-flashover performance, fundamentally solving the pain points of traditional insulators. The company provides free design services, tailoring product parameters according to the customer's specific tower type, load, and electrical requirements to ensure compatibility and reliability.
Working Mechanism and Product Features
This tension string mainly consists of a composite insulator core rod, silicone rubber sheds, end fittings, and a matching tension clamp. Its working mechanism is as follows:
- Electrical insulation: The core rod uses pultruded fiberglass reinforced plastic (FRP) to bear mechanical tensile loads; the silicone rubber sheds provide surface insulation and creepage distance. The shed structure design optimizes electric field distribution and suppresses partial discharge.
- Mechanical load bearing: The end fittings and the core rod are connected by crimping or wedge-type connections, forming an integral load-bearing structure that meets the tensile load requirement of the tension string (typical value 100kN).
- Clamp matching: The tension clamp is of preformed or compression type and can be directly assembled with the insulator end fittings without additional connectors, making installation convenient.
Product Technical Specifications (Typical Values, Customizable According to Customer Requirements)
| Parameter item | Specifications |
|---|---|
| Rated Voltage (kV) | 220 |
| Structural Height (mm) | 2240 (adjustable) |
| Creepage Distance (mm) | 5500 (adjustable) |
| Mechanical Tensile Load (kN) | 100 (adjustable) |
| Shed Material | High-temperature vulcanized silicone rubber |
| Core Rod Material | Glass fiber reinforced epoxy resin |
| Reference Weight (kg/string) | Approx. 15 (compared with about 80kg for a porcelain string, more than 75% lighter) |
Key Advantages:
- Lightweight and High Insulation: The significant weight reduction lowers tower loads, saving tower steel and foundation costs; the high specific-strength core rod combined with long creepage distance meets stringent pollution-class requirements.
- Excellent Anti-Pollution Flashover Performance: Silicone rubber sheds are permanently hydrophobic; under damp conditions, the contamination layer forms discrete water droplets, resulting in extremely low leakage current. They have been widely used in heavily polluted areas.
- UV and Aging Resistance: Anti-UV agents and reinforcing fillers are added to the shed formulation, giving the external insulation a service life of more than 30 years.
- Maintenance-Free Design: No cleaning or zero-value testing is required; only periodic visual inspection is needed, greatly reducing operation and maintenance costs.
- Complete Accessories: A full range of accessories, including clamps, fittings, and grading rings, is provided for one-stop procurement.
- Free Design Service: For special tower configurations, special pollution-area levels, and unconventional load requirements, technical staff from Hejian Haokang Electric Co., Ltd. provide free drawings and calculation reports to ensure the products fit actual working conditions.
Trust Endorsement and Customer Value
Since its establishment, Hejian Haokang Electric Co., Ltd. has focused on technical accumulation and product iteration in the insulator field, providing stable and reliable insulator products for power companies in multiple provinces and cities, railway electrification projects, and new energy transmission supporting projects. The company is equipped with advanced fully automatic rubber injection molding machines, mandrel pultrusion production lines, crimping and fitting processing equipment, and has established a comprehensive testing system, conducting boiling water tests, electromechanical failure load tests, and sheath/mandrel interface inspections on each batch of products. In multiple 220kV line projects, the composite insulator tension strings provided by our company have passed third-party type tests at once, and have operated smoothly after commissioning without any failures caused by product quality.
We are well aware that the safety of transmission lines is of great importance, so we always insist on selecting high-quality raw materials (such as German Wacker silicone rubber, high-strength fiberglass) and implement strict process control. For this 220kV tension string requirement, we suggest customers provide the following information: tower type structure, pollution area level, design tensile load, and whether there are grading requirements, so that our company can provide the optimal design plan and quotation for free. Our technical team promises to respond within 24 hours and provide on-site installation guidance services. Welcome to call or consult online, let us jointly build safe, economical, and long-lasting transmission lines.
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Q: What is the difference between tension string and suspension string, and why must tension string be used?
A: Tension string is used to bear the conductor tension, installed on tension towers, to fix the conductor on the tower and change direction; suspension string only bears the vertical load of the conductor and is used on tangent towers. In 220kV lines, tension strings must have higher mechanical strength (usually 100kN or 120kN), and the end fittings need to closely match the tension clamps. Our company's products have optimized the connection process between the mandrel and fittings for tension conditions. -
Q: What is the service life of composite insulators? Is it shorter than porcelain insulators?
A: High-quality composite insulators with reasonable material selection can have a service life of over 30 years. Silicone rubber sheds have excellent weather resistance and hydrophobic migration. Actual operating experience shows that in pollution areas of Class II and below, their service life is comparable to or even longer than porcelain insulators. Our company's products have passed the 1000h artificial accelerated aging test and retain long-term tracking data. -
Q: What does the free design specifically include? What information is needed?
A: The free design includes: structural height calculation, creepage distance determination, shed shape selection, fitting configuration drawing, mechanical load verification, and grading ring design (if any). Customers need to provide: line voltage level, pollution area level, tower head dimensions, conductor type and tension value, hanging point method, etc. We promise to deliver the design plan within 3 working days after receiving the information.
A: The silicone rubber and fiberglass reinforced plastic (FRP) core rod are inherently resistant to acid, alkali, and salt spray corrosion. The end fittings are made with hot-dip galvanizing process or stainless steel material (customizable). In coastal high-salt-spray and chemical areas, composite insulators have more advantages than porcelain insulators, and will not cause flashover due to corrosion of the iron cap. Hejian Haokang Electric Co., Ltd. has multiple coastal engineering cases.
A: Hejian Haokang Electric Co., Ltd.'s products are strictly designed in accordance with relevant standards such as GB/T 19519 and IEC 61109, and are entrusted to authoritative testing institutions for type tests, including power frequency withstand, lightning impulse, mechanical failure load, boiling water test, etc. Before formal cooperation, copies of type test reports for the same model can be provided for reference.
A: Hejian Haokang Electric Co., Ltd. provides tension strings and can also supply pre-twisted tension clamps or compression-type tension clamps. The interface dimensions of end fittings are made according to general industry standards. Customers can also provide the existing clamp model, and Hejian Haokang Electric Co., Ltd. will be responsible for adapting the interface. All fittings have undergone factory pre-assembly and tension verification.
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