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The Company
Ceramic Business Unit
Products
Bharat Heavy Electricals Limited is the largest Engineering
and Manufacturing Enterprise of its kind in India. It ranks
amongst the leading manufacturers of power plant
equipment in the world.
BHEL has 14 manufacturing plants, 4 power sector
regional centres, 8 service centres, 18 regional offices and
over 150 project sites spread all over India and abroad. It
offers a wide spectrum of products and services for core
sectors like Power Generation, Transmission,
Distribution, Industry, Transportation, Oil & Gas, Defence
and Non-Conventional Energy Systems.
The Ceramic Business Unit (CBU) of BHEL, is a Strategic
Business Unit for Ceramics and Systems. This business
unit deals with High Tension Insulators, Ceramic Wear
Resistant liners, Industrial Ceramic Products and
associated Systems. CBU is headquartered at Bangalore
and is supported by:
Manufacturing units with “State of the Art”
technology for ceramic products and systems at
• Electroporcelains Division( EPD), Bangalore
• Insulator Plant (IP), Jagdishpur
Advanced Research and Development facilities
for Ceramic products, processes and
applications at
• Ceramic Technological Institute (CTI), Bangalore
( A Division of Corporate Research & Development,
Hyderabad)
• High Tension Insulators for Transmission and
Distribution lines from 11 kV to 800 kV
• Hollow Insulators for Instrument and Power
Trans formers , Swi tchgear, E lec t ro S ta t i c
Precipitators, etc.
Bharat Heavy Electricals Limited
• Station Post Insulators for Bus bars, support and for
Isolators from 11 kV to 400 kV
• Composite Insulators for Railway Traction and
Transmission applications up to 400 kV
• Wear resistant materials for Thermal Power Plant
applications, Steel, Coal Washeries, Cement, etc.
• Industrial Ceramic Products for various applications
BHEL pioneered the development of composite
insulators in India in the year 1998 through in-house
development efforts. Today its “State of the Art” facilities
manufacture Polymer insulators that compare with the
best in the world. BHEL make Composite insulators have
superior design features that ensure reliability and
excellent performance backed by years of expertise in the
insulator business.
BHEL – The Pioneer in
Insulators
Our Esteemed
Customers
Our Composite Insulators are approved and
are in Service with the following customers:
Research Development and Standards
Organisation (RDSO) of Indian Railways
Powergrid Corporation of India Ltd.
NTPC Ltd.
Tamilnadu State Electricity Board
Nuclear Power Corporation of India Ltd.
Gujarat Mining Development
Corporation Ltd.
AREVA T & D
Maharashtra State Transmission Company Ltd.
The Process
State of Art Microprocessor controlled Crimping machine
with Acoustic Crack detection ensures uniform crimping
without stress concentration
Crimping
The Silicone housing is injection moulded over FRP rod in a
fully automatic Microprocessor controlled Injection
Moulding Machine. The housing is bonded securely over the
entire length of the FRP rod
Injection Moulding
Raw materials (Silicon Rubber, Boron free ECR grade FRP Rod & SGI Castings/Steel Forged Metal Fittings) are sourced
from reputed manufacturers after undergoing stringent quality checks.
The Materials
Fiber Glass Rod Metal Fittings Silicon Rubber
Modern state-of-art manufacturing facility for production of
Silicone composite insulators with complete manufacturing
and testing facilities.
The Manufacturing Shop
Construction Features
Acid Resistant Core rod (ECR Glass)
Forged steel Metal Fitting - Galvanised
Weather Sheds designs for pollutted conditions
Interface – Core to Housing- Thicknesss conforming to IEC
Interface- Silicone Overlapping Metal Fitting
Double sealing Silicone Housing
Manufacturing features unique to BHEL
• Infrared curing of FRP rod to remove moisture
• Silicone dough procured from reputed manufacturer after complete technical evaluation
• No binders or fillers are added to dilute the properties of Silicone
• Metal fittings made of High quality forged steel / Spheroidal Graphite Iron castings.
• Weather shed housing overlap at end fittings
ensures no moisture penetration.
• Segment joining through Lap Jointing to ensure
perfect sealing of joints
• Ultrasonic cleaning of end fittings after galvanizing to
remove moisture, greasy matter and rust.
BHEL polymer insulators have successfully undergone
stringent design tests in conformance to IEC 61109
Annexure C1, at world renowned laboratories at
KEMA, Holland
Rheology Tensile testing Die Penetration Test
Quality & ReliabilityBHEL’s Composite insulators undergo rigorous design tests, type tests , routine tests and acceptance tests in conformance to IEC 61109 and IEC 62217.
BHEL has facilities to carry out all the required tests for incoming materials such as Silicone, FRP rods and metal end fittings. Some of them are
a) Rheological characteristics of Silicone compound to determine curing characteristics
b) Specific gravity and shore hardness after curing of Silicone
c) Tensile and tear strength of Silicone compound
d) Die penetration , Water absorption, density, BD voltage tests on FRP rods
e) Tensile, microstructure, galvanisation tests on metal end fittings.
BHEL Polymer insulators undergo various routine tests
and acceptance tests in conformance to IEC standards as
well as Customer specific test requirements
1. Routine Electrical test
2. Mechanical Strength test
3. Thermal Mechanical Performance Test
Hydrophobicity test
BHEL insulators successfully undergone5000 Hrs Accelerated Aging Test at KEMA,Holland as per IEC 62217
• Superior Handling of Mechanical Shock Loads hence
convenient to handle, transport and erect.
• Low weight ( < 80 % of conventional porcelain) – easy
handling
• Resistance to Vandal Damage
• Superior Dielectric Strength
• High Power arc resistance due to high thermal
Withstand ability
• Excellent Pollution Performance (Durable &
Regenerative Hydrophobicity)
• Flame resistant
• Shatter resistance
• Aerofoil design offering minimum Wind Resistance
• Low Leakage current and Power loss due to its high
surface resistivity
Regenerative Hydrophobicity
o• Wide range of service Temperatures (from –50 C to o100 C)
• Interchangeability – can easily replace existing Porcelain
insulators
• Better Aesthetics
Advantages of Silicone based Composite Insulators
Silicone Composite Insulators Vs Porcelain Insulators
W e i g h t r a t i o
between Porcelain
I n s u l a t o r a n d
composite long rod
i n s u l a t o r s f o r
t r a n s m i s s i o n
applications is more
than 10:1 making
c o m p o s i t e
insulators an ideal
insulator for lines
with limited right of
wayWeight ratio Porcelain to Silicone Composite
insulator for Railway Traction applications is 3:1
1. Sketch is indicative only.2. Specific creepage distance from 16 mm / kV to 40 mm / kV3. Length ranges from 285 mm to 4080 mm4. Specified mechanical loads from
a. 45 KN to 120 KN for 33 KV to 132 KV. b. 70 KN to 160 KN for 220 KV. c. 120 KN to 160 KN for 400 KV.
5. For specific requirement, contact: CBU / Marketing, Malleshwaram, Bangalore....560012
TONGUE & CLEVIS TYPE BALL & SOCKET TYPE
TECHNICAL PARTICULARS OF COMPOSITE LONG ROD INSULATORS
Our Range of Composite Insulators LONG ROD
Shed Diameter (Big / Small)
Unit Spacing
Creepage Distance
Arcover Distance
Electro-Mechanical Min. Failing load
Coupling Designation
PF-WET Withstand Voltage
PF-DRY Withstand Voltage
DRY-Lightning Impulse Withstand Voltage
Visible Discharge Test Voltage
Weight of Unit
mm
mm
mm
mm
kN
mm
kV
kV
kVP
kV
kg
142 or 132/112
285
320
140
45
16
35
40
75
9
1.0
142 or 132/112
375
370
160
120
20
45
50
90
9
1.5
142 or 132/112
325
900
340
70/90
16
75
85
170
27
4.0
142 or 132/112
375
1110
360
120
20
85
95
170
27
4.5
11 kV 11 kV 33 kV 33 kV
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
UnitParameter
1 Sketch is indicative only.2 BHEL Manufacture & supply
a Specific creepage distance from 16mm/kv to 40mm/kvb Height ranges from 285mm to4080mmc Specified mehanical load require from
120KN to 160KN for 400KV. 45KN to 120KN for 33KV to 132KV. 70KN to 160KN for 220KV.
3. For specific requirement, contact: CBU / MARKETING, Malleshwaram, Bangalore....560012
TECHNICAL PARTICULARS OF COMPOSITE LONG ROD INSULATORS
Our Range of Composite Insulators LONG ROD
Shed Diameter (Big / Small)
Unit Spacing
Creepage Distance
Arcover Distance
Electro-Mechanical Min. Failing load
Coupling Designation
PF-WET Withstand Voltage
PF-DRY Withstand Voltage
DRY-Lightning Impulse Withstand Voltage
Visible Discharge Test Voltage
Weight of Unit
mm
mm
mm
mm
kN
mm
kV
kV
kVP
kV
kg
142 or 132/112
770
2250
560
70/90
16
140
150
325
53
4.8
142 or 132/112
870
2250
560
120
20
140
150
325
53
5.5
66 kV 66 kV
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
UnitParameter
Our Range of Composite Insulators LONG ROD
TECHNICAL PARTICULARS OF COMPOSITE LONG ROD INSULATORS
Shed Diameter (Big/Small)
Unit Spacing
Creepage Distance
Arcover Distance
Electro-Mechanical Min. Failing load
Coupling Designation
PF-WET Withstand Voltage
PF-DRY Withstand Voltage
DRY-Lightning Impulse Withstand Voltage
Visible Discharge Test Voltage
Weight of Unit (approx.)
mm
mm
mm
mm
kN
mm
kV
kV
kVP
kV
kg
142 or 132/112
1460
3870
1175
70/90
16
185
200
450
88
6.0
142 or 132/112
1460
3870
1175
120
20
185
200
450
88
6.8
142 or 132/112
1450
4300
1210
70/90
16
275
325
650
105
7.5
142 or 132/112
1460
4300
1210
120
20
290
335
650
105
8.0
110 kV 110 kV 132 kV 132 kV
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
UnitParameter
1. Sketch is indicative only.2. Specific creepage distance from 16 mm / kV to 40 mm / kV3. Length ranges from 285 mm to 4080 mm4. Specified mechanical loads from
a. 45 KN to 120 KN for 33 KV to 132 KV. b. 70 KN to 160 KN for 220 KV. c. 120 KN to 160 KN for 400 KV.
5. For specific requirement, contact: CBU / Marketing, Malleshwaram, Bangalore....560012
1. Sketch is indicative only.2. Specific creepage distance from 16 mm / kV to 40 mm / kV3. Length ranges from 285 mm to 4080 mm4. Specified mechanical loads from
a. 45 KN to 120 KN for 33 KV to 132 KV. b. 70 KN to 160 KN for 220 KV. c. 120 KN to 160 KN for 400 KV.
5. For specific requirement, contact: CBU / Marketing, Malleshwaram, Bangalore....560012
Our Range of Composite InsulatorsLONG ROD
TECHNICAL PARTICULARS OF COMPOSITE LONG ROD INSULATORS
Shed diameter (Big/small)
Unit Spacing
Creepage Distance
Arcover Distance
Electro-Mechanical Min. Failing load
Coupling Designation
PF-WET Withstand Voltage
PF-DRY Withstand Voltage
DRY-Lightning Impulse Withstand Voltage
Visible Discharge Test Voltage
Weight of unit (approx)
mm
mm
mm
mm
kN
mm
kV
kV
kVP
kV
Kg
142 or 132/112
2610
8000
2300
70/90
16
500
575
1080
154
11.5
142 or 132/112
2610
8000
2300
120
20
500
575
1080
154
12.2
142 or 132/112
3335
10500
3050
120
20
680
720
1550
305
18.5
142 or 132/112
3910
13020
3400
160
20
680
720
1550
305
21
220 kV 220 kV 400 kV 400 kV
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
UnitParameter
Railway Traction for Standard and Polluted applications
TECHNICAL PARTICULARS OF COMPOSITE RAILWAY TRACTION INSULATORS
STAY ARM BRACKET 9-TONNE
Shed Diameter
Unit Spacing
Creepage Distance
Arcover Distance
Bending Strength
Electro-Mechanical Min. Failing load
PF-WET Withstand Voltage (horizontally)
PF-WET Withstand Voltage (vertically)
DRY-Lightning Impulse Withstand Voltage positive
DRY-Lightning Impulse Withstand Voltage negative
Visible Discharge Test Voltage
Weight of Unit (approx.)
mm
mm
mm
mm
kgfm
kgf
kV
kV
kVP
kVP
kV
kg
185/145
489
1050
390
200
7000
125
100
240
260
35
4.4
185/145
555
1050
390
200
7000
125
100
240
260
35
5.0
185/145
540
1050
390
210
11000
125
100
240
260
35
5.4
Stayarm Insulator Bracket Insulator 9-tonne Insulator
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
Sketch is indicative only.
UnitParameter
Bharat Heavy Electricals Limited
Bharat Heavy Electricals Limited
(A Government of India undertaking)
Registered and Corporate OfficeBHEL House, Siri Fort, New Delhi - 110 049.Tel: 011-2600 1010 Fax: 011-2649 3021
www.bhel.com
Efforts are constantly being made to improve the product design and hence the products supplied may differ in minor details from that given in the catalogue.
For enquiries please contact:
(A Government of India Undertaking)
Ceramic Business UnitProf. C.N.R. Rao Circle,Opp. Indian Institute of ScienceMalleswaram, Bangalore-560 012 (India)Ph: 080-23442988, 22182247 Fax: 080-23560741, 23344231
www.bhelceramics.com