Project
±800 kV Longdong To Shandong UHVDC Project
Jinhao developed an extra high mechanical strength insulator of 550 kN to meet the specific needs of SGCC for this project.
Aerodynamic Profile
Cap And Pin Type Aerodynamic Profile Toughened Glass Insulator U160BD
A 160 kN aerodynamic disc with 155 mm spacing, 420 mm diameter and 380 mm creepage, weighing 8.5 kg. The widest disc in our range, shaped so wind sweeps dust off rather than packing it into ribs.
160 kN
Creepage 380 mm
Spacing 155 mm
Ø 420 mm
Coupling 20
8.5 kg
Problems It Solves
Why Line Engineers Specify The U160BD
- Ribbed profiles pack with fine mineral dust in desert conditions and lose effective creepage
- Low annual rainfall means deposits are never washed off naturally
- Abrasive sand wears surfaces that were specified for wet-pollution service
Key Benefits
What You Get In Return
- Open shed with no deep under-ribs lets natural wind self-clean the surface
- 420 mm diameter spreads creepage across a smooth profile instead of dust traps
- 160 kN rating with 20 coupling suits heavy transmission and UHV strings
- Stable under intense UV and wide day-to-night temperature swings
Technical Data
U160BD Specifications
Mechanical, electrical, radio influence and packing values as tested to IEC 60383 and GB/T 1001.1.
| Mechanical Failing Load | 160 kN |
|---|---|
| Spacing H | 155 mm |
| Diameter D | 420 mm |
| Creepage Distance | 380 mm |
| Ball And Socket Coupling Size | 20 |
| Wet Power-frequency Withstand Voltage | 50 kV |
| Dry Power-frequency Withstand Voltage | 60 kV |
| Dry Lightning Impulse Withstand Voltage | 95 kV |
| Puncture Withstand Voltage | 130 kV |
| Test Voltage RMS To Ground | 10 kV |
| Maximum RIV At 1000 kHz | 50 microvolt |
| Corona Extinction Voltage Pin/Cap | 18/22 kV |
| Power Frequency Arc | 0.12 s / 20 kA |
| Net Weight | 8.5 kg |
Materials And Construction
A toughened glass disc bonded to a hot-dip galvanized steel cap and steel pin with a zinc sleeve, using high-strength alumina cement cured in a 70 degrees C water bath for about one hour.
Certifications
- ISO 9001 Quality Management System
- ISO 14001 Environmental Management System
- ISO 45001 Occupational Health and Safety Management System
- ISO 20001:2018 Energy Management System
- SR10:2015 / ISO 26000-2011 Social Responsibility Management System
- CMA and CNAS recognition on selected products
Who It Is For
Buyers Who Standardise On This Model
- Utilities building lines across arid and semi-arid terrain
- Solar and wind evacuation projects in desert basins
- Operators dealing with seasonal sand and dust storms
Comparison
How It Compares
All three 160 kN discs share the same 155 mm spacing and 20 coupling and are mechanically interchangeable. The U160BD trades creepage down to 380 mm in exchange for a dust-shedding open profile, while the U160BSV and U160BLT buy 450 mm and 550 mm of creepage with alternating sheds that hold deposit in dry climates.
Application Scenarios
Where The U160BD Is Installed
Desert and semi-desert transmission corridors
Renewable energy collection and evacuation lines in dry basins
Routes with strong prevailing wind and minimal rainfall
Manufacturing And Quality Control
The Four Stages That Decide Whether This Disc Reaches Your Tower
Toughening sets the mechanical rating, the thermal shock test removes defective shells, cementing fixes the fittings, and every finished unit is tested before it is packed.
5
Toughening And Tempering
Shells are heated close to the softening point, then high-pressure air jets cool the surface rapidly while the core cools slowly. The surface ends in compression at roughly 100 to 200 MPa with the core in tension, giving four to five times the mechanical strength of ordinary glass.
6
Thermal Shock Test
Shells are heated to about 300 degrees C and plunged into cold water, a drop of roughly 420 degrees C. Any unit carrying internal stress or an inclusion shatters here rather than in service. Survivors move on and the broken glass is recycled as cullet. A second thermal shock test follows to IEC 60383-1 and GB/T 1001.1.
7
Metal Fitting Assembly And Cementing
A hot-dip galvanized steel cap, steel pin and zinc sleeve are bonded to the toughened disc with high-strength alumina cement, then cured in a 70 degrees C water bath for about an hour so the cement develops full strength before handling.
8
Final Inspection And Testing
Every finished insulator is checked visually for cracks, bubbles, chips and bonding defects, then tested electrically for high-voltage withstand, insulation resistance and partial discharge, mechanically for tensile, bending and torsion strength, and environmentally for thermal cycling, pollution resistance and UV ageing.
Use Guide
Installing And Maintaining The U160BD
Assemble the string with the matching ball and socket coupling size 20 and confirm that the security clip is fully seated on every unit before the string is lifted.
In service, inspect visually on routine patrols. A self-destructed disc is visible from the ground and the steel cap and pin continue to carry mechanical load until replacement. Clean in heavily polluted areas and replace broken units in the next planned outage. No complicated preventive tests are required.
We supply installation manuals, technical drawings and, for large projects, on-site installation guidance and string assembly training.
Customization Options
- Customised creepage distance for a specific pollution survey
- Special fittings and connection structures
- Colour packaging and marking customization
- Project-specific design under OEM and ODM arrangements
Related Projects
Lines Using This Class Of Disc
Project
750 kV Kuqa To Aral And Bachu Transmission Project
Jinhao developed an extra high mechanical strength insulator of 420 kN to meet the specific needs of SGCC for this project.
Related Products
Alternatives Worth Comparing
Two-alternating Profile
U160BSV · 160 kN
A 160 kN two-alternating disc with 155 mm spacing, 300 mm diameter and 450 mm creepage, weighing 8.4 kg. Alternating shed diameters…
Creepage 450 mm
Ø 300 mm
Coupling 20
Three-alternating Profile
U160BLT · 160 kN
A 160 kN three-alternating disc with 155 mm spacing, 330 mm diameter and 550 mm creepage, weighing 8.9 kg. The longest creepage…
Creepage 550 mm
Ø 330 mm
Coupling 20
Further Reading
Guides Covering This Model
Guide
How To Choose An Insulator Profile By Pollution Level
Standard, anti-fog, aerodynamic or alternating. The right answer depends on whether your deposit is a wet conductive film or a dry adherent powder.
Answers
U160BD Questions
What makes the U160BD aerodynamic?
A wide open shed at 420 mm diameter with no deep under-ribs, so wind carries dust off the surface instead of packing it into rib cavities.
What are the U160BD ratings?
160 kN mechanical failing load, 155 mm spacing, 380 mm creepage, 20 ball and socket coupling and 8.5 kg net weight.
What are its electrical withstand values?
50 kV wet power frequency, 60 kV dry power frequency, 95 kV dry lightning impulse and 130 kV puncture withstand voltage.
Is the 420 mm diameter a problem for tower clearance?
It is the widest disc in our range, so string wind load and clearance should be checked at design stage. Where clearance is tight the U160BSV at 300 mm is the alternative.
Get U160BD Pricing And Test Data
Tell us the quantity and destination port. We will confirm lead time, packing configuration and the test report set that ships with the order.