Project Case / Colombia Installation Problem

Rapid Analysis and Installation Guidance for Composite Suspension Insulators

 

 

A utility customer experienced an unexpected insulator failure during installation of 36kV composite suspension insulators. The units broke while being tensioned during line stringing, causing concern for safety and project continuity.

The customer requested immediate technical support to identify the cause and prevent similar incidents in the remaining installation.

 

• Insulators were breaking during live installation.
• The breakage position and fiberglass rod damage were inconsistent with standard tension or compression failures.
• The existing installation process risked bending stresses that exceeded the insulator's local mechanical limits.
• Immediate guidance was required to prevent damage to additional units on-site.

 

Our engineering team conducted a full investigation including:

1.Breakage Analysis:

• Compared fracture surfaces and installation photos.
• Identified that bending stress from incorrect pull angles at the lower metal fittings caused the fiberglass core to fail.

2.Mechanical Testing:

• Tensile load tests confirmed the units could withstand 70kN as per specifications.

• Controlled bending load tests revealed failure occurred at ~1.55kN, indicating installation-induced bending was the critical factor.

3.Installation Guidance:

• Recommended revised pull angles and handling techniques to avoid direct contact with cross-arms.
• Provided visual guidance to minimize accidental bending and prevent damage to the silicone housing.

 

 

4.Documentation & Support:

• Supplied detailed analysis report and step-by-step corrective instructions to on-site teams.
• Ensured remaining units were safely installed without further incidents.

 

 

• No additional insulators were damaged after adopting the recommended installation method.
• Reduced installation risk and improved overall safety on-site.
• Provided the customer with actionable insights, demonstrating the reliability of our composite insulators under correct handling conditions.
• Strengthened customer trust in our engineering support and after-sales responsiveness.

 

 

• Engineering Support: On-site failure analysis and guidance prevents project delays.
• Material Reliability: Units perform within specifications when proper installation procedures are followed.
• Customer Collaboration: Quick response and clear instructions reduce risk and protect infrastructure.
• Preventive Knowledge: Installation recommendations reduce potential for damage and extend service life.