66~110kV Outdoor Composite Porcelain Insulator Terminal
✅Superior Environmental & Pollution Resistance
✅Enhanced Safety & Structural Reliability
✅Highly Efficient Installation & Low Logistics Costs
✅FAdvanced Electrical Stress & Insulation Management
- Product Introduction
The 66–110kV Outdoor Composite Porcelain Insulator Terminal transitions high-voltage XLPE insulated cables from underground installations and enclosures to overhead lines or outdoor substations. Replacing traditional, fragile porcelain, the terminal features an advanced external insulation housing made of High-Temperature Vulcanized (HTV) silicone rubber. The housing and weather sheds are produced using an integral injection molding process to guarantee superior, long-term weather and pollution resistance in extreme climate
Model Meaning
Technical Specifications
| 66~110kV Outdoor Composite Porcelain Insulator Terminal Technical Parameters & Test Results | |
| Parameter Item | Parameter Value / Test Result |
| Rated Voltage and Frequency | 66/110 kV, 50 Hz |
| Maximum Operating Voltage | 128 kV |
| Ambient Temperature | -40°C to +40°C |
| Maximum Conductor Temperature in Normal Operation | 90°C |
| Maximum Conductor Temperature During Short Circuit | 250°C |
| Applicable Cable Cross-Section | 240-1600 mm² |
| Applicable Altitude | ≤1000 m (custom designs available for >1000 m) |
| Pollution Level | Suitable for highly polluted areas (Class IV) and coastal salt fog regions |
| Partial Discharge Test (Room Temperature, 96 kV) | No detectable discharge at declared sensitivity (≤5 pC) |
| Thermal Cycling Voltage Test (128 kV, 95°C-100°C, 8h heating, 16h cooling) | Completed 20 cycles |
| Partial Discharge Test (High Temperature, 96 kV) | No detectable discharge at declared sensitivity (≤5 pC) |
| Impulse Voltage Test Followed by Power Frequency Voltage Test | |
| - Impulse Voltage Test (95°C-100°C, ±550 kV, 10 times each) | No breakdown or flashover |
| - Power Frequency Voltage Test (160 kV, 15 min) | No breakdown or flashover |
| Power Frequency Voltage Test for Outdoor Termination (Wet Test, 185 kV, 1 min) | No breakdown or flashover |
| Sealing Test for Assembled Terminations | |
| a. Pressure Leakage Test (1250±10 MPa, 1 h) | No gas leakage |
| b. Vacuum Leakage Increase Test (1 h) | |
| c. Pressure Increment (B-A) | <2 kPa |
| Voltage Test on Stand-off Insulators | |
| - DC Voltage Test (25 kV, 1 min) | No breakdown or flashover |
| - Lightning Impulse Voltage Test (±375 kV, 10 times each) | No breakdown or flashover |
| Radio Interference Test for Outdoor Termination (81 kV, 1 MHz) | |
| - Generated Interference Voltage (RIV) | ≤269 μV |
Demensions and Details
1. Wire clamp 2.Insulating Liquid 3. Conductor rod 4.Composite bushing 5.Stress cone 6.Base Pedestal 7.Supporting insulator 8. Tail tube
Core Features and Advantages (Compared to Traditional Porcelain Shell Terminations)
| 66–110kV Outdoor Composite Porcelain Insulator Terminal V.S. Traditional Porcelain Shell Termination | ||
| Characteristic | Composite Shell Outdoor Termination | Traditional Porcelain Shell Termination |
| Material & Weight | Silicone rubber composite material, lightweight (approximately one-tenth the weight of porcelain), easy to transport and install. | Ceramic material, heavy and fragile, difficult to handle and install. |
| Pollution Flashover Resistance | Excellent. Silicone rubber is hydrophobic, preventing contaminants from forming a continuous water film, greatly increasing flashover voltage. Suitable for Class IV heavily polluted areas. | Poor. Porcelain surface is hydrophilic, easily forming a continuous conductive film when polluted and wet, leading to flashover; requires frequent cleaning. |
| Explosion-Proof & Safety | Superior. Composite materials are flexible; even in case of internal faults, they typically crack rather than explode, producing minimal debris, ensuring higher safety. | Inferior. Porcelain housing can explode due to internal faults, generating hazardous fragments, endangering equipment and personnel. |
| Seismic Performance | Good. Elastic material can absorb vibrations, suitable for seismic zones or high-vibration environments. | Poor. Ceramic is brittle and has weak seismic resistance. |
| Weather Resistance | Excellent. Resistant to UV, ozone, and extreme high/low temperatures (-50 °C to +50 °C). | Good, but extreme thermal cycling may cause glaze cracking. |
| Installation & Maintenance | Typically prefabricated, simple installation, high standardization. Maintenance-free or low-maintenance. | Complex installation, may require on-site pouring. Requires regular cleaning. |
| Manufacturing & Design | Facilitates integrated design; flexible optimization of shed shape and creepage distance. | Constrained by ceramic firing process; limited shape variations. |
Usage application
Applications of 66~110kV Outdoor Composite Porcelain Insulator Terminals：
Overhead-to-Underground Grid Transitions: Connects overhead high-voltage transmission lines smoothly to underground XLPE cable networks to maintain continuous power flow.
Substation Grid Connections: Serves as a vital link for terminating high-voltage cables into outdoor substations, transformers, and gas-insulated switchgear (GIS) yards.
Heavily Polluted & Severe Environments: Engineered with superior hydrophobic (water-repellent) silicone rubber sheds to prevent leakage currents and withstand coastal salt spray, industrial pollution, and desert dust.
High-Seismic & Extreme Climate Zones: Offers exceptional vibration resistance and zero shatter risk compared to traditional ceramic alternatives, making them ideal for earthquake-prone regions and wide temperature fluctuations.
Flashover and Arcing Mitigation: Maximizes external creepage distance and optimizes internal electrical stress distribution to drastically minimize the risk of pollution flashovers and surface arcing.
Renewable Energy Grid Integration: Facilitates the critical step of connecting large-scale onshore/offshore wind farms and utility-scale solar plants to the main transmission grid.
Urban Grid Modernization: Supports urban infrastructure upgrades by allowing utility companies to convert unsightly overhead lines into sleek, space-saving underground systems.
Heavy Industrial Power Systems: Ensures a robust, high-reliability power supply for energy-intensive industrial facilities such as petrochemical plants, steel mills, and mining operations.
Overhead-to-Underground Grid Transitions
Substation Grid Connections
Heavily Polluted & Severe Environments
High-Seismic & Extreme Climate Zones
.
Flashover and Arcing Mitigation
Renewable Energy Grid Integration
Urban Grid Modernization
Heavy Industrial Power Systems
Handling safety
1. Strict Procedural Compliance: All personnel must strictly adhere to established electrical safety standards and operational procedures without exception.
2. Pre-Use Inspection: Inspect and test all electrical equipment prior to operation. Look for abnormalities such as visible electrical arcing, tracking, or unusual heat. If a defect is identified, immediately lock out the equipment and contact certified maintenance personnel. Do not operate the equipment until the fault is officially cleared.
3. Obey Safety Tags and Lockout Labels: Never touch, alter, or operate equipment marked with safety tags such as "Do Not Start," "Danger: Men Working," or "Under Maintenance." Tagged equipment may be energized, improperly grounded, or undergoing active repair; tampering with it creates an immediate hazard to yourself and others.
4. Mandatory Personal Protective Equipment (PPE): Appropriate, rated Personal Protective Equipment (PPE) must be worn when operating electrical equipment or working within its boundaries. This includes mandatory use of dielectric insulating gloves and certified electrical hazard (EH) or insulating safety footwear.
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