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| Mechanical and Electrical Performance Improvement and Process Optimization of Domestic UHV Large Tonnage Suspension Porcelain Insulator |
| Li Qun1, Gao Song1, Yang Shengzhe2, Hu Qinran2, Jiang Naisong2, Wu Zaijun2 |
1. State Grid Jiangsu Electric Power Company Research Institute Nanjing 211103 China;
2. School of Electrical Engineering Southeast University Nanjing 211189 China |
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Abstract The comprehensive construction of ultra-high voltage projects require the guarantee of ultra-high voltage large-tonnage insulators. However, with the increase of service life, domestic ultra-high voltage and large tonnage insulators of 400 kN in operation frequently experience deterioration. In recent years, multiple incidents of porcelain insulator head breakage in ultra-high voltage AC and DC projects have shown that there are still blind spots in the design of insulator head structure, materials, and other aspects. Therefore, in response to the deterioration problem of ultra-high voltage insulators, this paper proposes improvement measures from three aspects: insulator head structure, insulator preform formula, and insulator production process to enhance their electromechanical performance.
Firstly, the finite element analysis software Ansys was used to analyze the mechanical characteristics and maximum field strength of the head of ultra-high voltage large tonnage suspension porcelain insulators. Based on the equilibrium equation, geometric equation, and constitutive equation of the insulator model, this paper derived the mechanical distribution and deformation of insulators under mechanical stress. The optimal structural parameters for the head of ultra-high voltage and large-tonnage porcelain insulators were determined by observing the variation trend of stress at the most easily fractured part of the insulator with the wall thickness, top thickness, and sand height of the insulator head. By jointly solving Maxwell's equations and partial differential equations of the electric field, the distribution of the field strength at the insulator head was obtained, and the trend of the maximum field strength at the insulator head changing with the wall thickness, top thickness, outer angle, inner angle, and sand height of the insulator head was obtained.
Secondly, this article has optimized and adjusted the formula of insulator preform and head glaze. By controlling the particle size in the raw material for insulator preparation, the adverse effect of coarse particles above 15 μm on the uniformity of product structure was eliminated. By increasing the crystal phase content in the insulator matrix formula, the porosity on the surface of the insulator ceramic body was reduced, making up for the defect of large dispersion of the insulator ceramic body. Meanwhile, this paper adopted the process of separately glazing the insulator head and umbrella surface, and used the optimized head glaze formula to enhance the mechanical strength of the insulator head.
In addition, based on multiple experiments, this paper proposed optimization measures for the three steps of insulator sand grinding, glazed sand coating, and burning. By comparing the bending strength of the test strips prepared with one and two-step feeding schemes in the sand grinding process, it is concluded that the two-step feeding scheme has better mechanical properties of the ceramic body. By precoating the sand particles with a layer of glaze, the gap between the porcelain embryo and the sand was filled, and the bonding strength between the porcelain and the sand was enhanced. At the same time, based on considerable experiments, this paper has adjusted the heating rates of the three stages in the sintering process of alumina ceramics, ensuring product production quality while reducing production energy consumption.
Finally, electromechanical failure load tests manifest that the mechanical and electrical failure performance of the optimized ultra-high voltage large tonnage insulators was significantly improved by about 16.5% than original insulators.
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Received: 03 July 2022
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2023, Vol. 38 
