Repair of damaged porcelain insulator

Repair of damaged porcelain insulator will be introduced from the glaze, evaluation of faults, porcelain damage, repairs, repair of porcelain with the broken piece available, filling of chips and voids, procedure, etc.

porcelain insulator   porcelain insulator

Repair of damaged porcelain insulator:
Safety information
Keep this instruction available to those responsible for the installation, maintenance, and operation of the bushing.
The installation, operation, and maintenance of a bushing present numerous potential unsafe conditions, including, but not limited to, the following:
High pressures
Lethal voltages
Moving machinery
Heavy components
Slip, stumble or fall

Specialised procedures and instructions are required and must be adhered to when working on such apparatus. Failure to follow the instructions could result in severe personal injury, death, and/or product or property damage.

Additionally, all applicable safety procedures such as regional or local safety rules and regulations, safe working practices, and good judgement must be used by the personnel when installing, operating, maintaining and/or disposing such equipment.

Safety, as defined in this instruction, involves two conditions:
1. Personal injury or death.
2. Product or property damage (includes damage to the bushing or other property, and reduced bushing life).
Safety notations are intended to alert personnel of possible personal injury, death or property damage. They have been inserted in the instructional text prior to the step in which the condition is cited.
The safety conditions are headed by one of the three hazard intensity levels which are defined as follows.

This product information gives a description how to repair a damaged porcelain insulator. Advices are given for how the repair is made and acceptable damages for repair. ORIENT Components takes no responsibility for the quality of the repairs.

General personal protection:
The epoxy products are irritating to eyes and skin. May cause sensitization by skin contact.
Provide sufficient air exchange and/or exhaust in work rooms.
Handle and open container with care.
Avoid contact with skin, eyes and clothing.
Disposal considerations:
The epoxy products must be incinerated, when in compliance with local regulations.
Empty containers can be landfilled after cleaning, when in compliance with the Environmental Protections (Duty of Care) Regulations.

The glaze:
The glaze on the insulators is primarily intended go give a good surface appearance which is smooth and rejects dirt and is therefore also easy to keep clean.
The glazing is not needed to stop moisture entering the insulator since the porcelain itself after firing is nonporous and does not absorb moisture.
Due to manufacturing techniques, glaze defects cannot always be avoided and standards allow minor defects within certain limits.
Glaze faults, not exceeding the limits according to IEC publ. 168 and IEC publ. 233, are permitted on porcelain insulators used by ORIENT on bushings. The ORIENT acceptance rules are, however, more stringent especially regarding the upper side of the sheds and especially the top shed.
Unglazed spots and small chipped areas do not impair the function or the life of the insulator because the porcelain body is completely vitrified and non-porous.

Evaluation of faults:
Faults which may effect the function of the insulator shall not be repaired a further the acceptance for repair shall be limited depending on the visual appearance. The defect surface shall be free from cracks.

Porcelain damage:
Acceptable damages for repair are:
1. Glaze defects, scratches and scraping in the glazing.
Only faults which exceed the requirements according to the relevant IEC publication are repaired.

2. Smaller damages on the sheds.
When the broken piece exists, the size of the damage must be below:
Length = 10 % of shed diameter
Width = 5 % of shed diameter
Depth = 1.5 % of shed diameter
When the broken piece is missing the size of the damage must be below:
Length = 5 % of shed diameter
Width = 3 % of shed diameter
Depth = 1 % of shed diameter

3. Smaller damages on the porcelain body and smaller chips broken out from the flange surface.
The size of the damage must not exceed:
Length = 4 % of shed diameter
Width = 4 % of shed diameter
Depth = 3 mm for shed diameter > 500 mm
Depth = 2 mm for shed diameter < 500 mm

The repair must be done personnel with a good knowledge about the material used. The repaired part shall be free from pores.
Repair of porcelain with the broken piece available
Filling of chips and voids where the piece is missing

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Orient is an international line post insulator manufacturer and supplier of high quality porcelain line post insulators and porcelain pin post insulator.
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