Kontaktledning/Isolator

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1 Purpose

This technical specification covers Bane NOR's requirements to insulators for use in Bane NOR's contact line system.

2 Scope

This technical specification is created for use in frame agreements.

This technical specification is written for composite insulators. Suppliers may alternatively offer insulators with other insulating materials fulfilling the electrical and mechanical requirements of this specification.

The technical specification covers the following types of insulators:

Contact line voltage level at nominally 15 kV:

  • insulators for cantilevers
  • line-post insulators for reinforcement feeders
  • long rod insulators

Return conductor voltage level at nominally 1 kV:

  • line-post insulators for return conductor
  • long rod insulators for return conductor

3 Function

Insulators in contact line system serve to electrically insulate energized parts from de-energized parts.

4 Requirements

4.1 General

Composite insulators shall conform to EN 62621:2016 and IEC 61952:2008. If glass insulators are offered, these shall satisfy EN 60383-1:1996.

Insulators shall have a design lifetime of at least 50 years.

Prefered maximal diameter of insulators is 250 mm.

Steel parts shall be hot-dip galvanized in accordance with EN ISO 1461.

For special applications, the Customer may optionally request insulators with deviating characteristics.

4.2 Environmental conditions

Environmental conditions shall be as specified in EN 62621:2016. Insulators may be offered for the following two classes of installation conditions:

  1. Installation in free air
  2. Installation below bridges and inside tunnels

4.3 Definitions

4.3.1 specified cantilever load (SCL)

as defined in IEC 61952:2008.

4.3.2 maximum design cantilever load (MDCL)

as defined in IEC 61952:2008.

4.3.3 specified tensile load (STL)

as defined in IEC 61952:2008.

4.3.4 line-post insulator

as defined in EN 60383-1:1996.

4.3.5 long rod insulator

rigid insulator intended to be subjected to tensile loads, comprising an insulating part having an approximately circular cylindrical shank, with or without sheds, and external or internal fixing devices attached to each end.
no: stavisolator

[SOURCE: IEC 60050-471:2007, 471-03-05]

4.3.6 creepage distance

shortest distance or the sum of the shortest distances along the surface on an insulator between two conductive parts which normally have the operating voltage between them
no: krypstrømsvei

Note 1 – The surface of cement or of any other non-insulating jointing material is not considered as forming part of the creepage distance.
Note 2 – If a high resistance coating is applied to parts of the insulating part of an insulator, such parts are considered to be effective insulating surfaces and the distance over them is included in the creepage distance.
[SOURCE: IEC 60050-471:2007, 471-01-04]

4.3.7 end fitting

integral component or formed part of an insulator, intended to connect it to a supporting structure, or to a conductor, or to an item of equipment, or to another insulator
no: endefeste

Note 1 – Where the end fitting is metallic, the term “metal fitting” is normally used.
Note 2 – This Note only applies to the French text.
[SOURCE: IEC 60050-471:2007, 471-01-06]

4.3.8 cantilever

support consisting of one or more transverse components projecting from a mast or structure,
no: utligger

NOTE: [SOURCE: IEC 60050-811:2017, 811-33-30, modified – "members" has been replaced by "components" ]

4.4 Electrical requirements

Bane NOR's overhead contact line system has a nominal voltage of 15 kV (phase-ground, directly earthed), at a nominal frequency of 16.7 Hz.

Return conductors must be insulated when they are used in combination with booster transformers. This insulation is achieved by means of insulated 1 kV wire or by bare conductors mounted on 1 kV insulators.

4.4.1 Voltage

4.4.1.1 Contact line and reinforcement feeders

The rated voltages of insulators shall be:

Definition Symbol Voltage [kV] Standard reference
Nominal voltage Un 15 EN 50163:2004
Rated insulation voltage UNm 17.25 EN 50124-1:2017
Rated impulse voltage UNi 125 EN 50124-1:2017 table A.2
Over-voltage category OV4

Note: A significantly higher rated impulse voltage than specified is not desirable as it will lead to a high impulse voltage level in the contact line, resulting in higher stress levels on vulnerable equipment such as transformers and cables.

4.4.1.2 Return conductors

The rated voltages for return conductor insulators shall be:

Definition Symbol Voltage [kV] Standard reference
Nominal voltage Un 0.69 -
Rated insulation voltage UNm 0.9 EN 50124-1:2017
Rated impulse voltage UNi 8 EN 50124-1:2017 table A.2
Over-voltage category OV4

4.4.2 Creepage distances

Creepage distances shall be dimensioned for the rated insulation voltages UNm in accordance with EN 62621, for contact line voltage and return conductor voltage respectively. In day zones, creepage distances shall at least be dimensioned corresponding to "unfavourable operating conditions" in accordance with EN 62621. For insulators without natural wash (inside tunnels and under bridges), higher creepage distances corresponding to "extremely unfavourable operating conditions" are appropriate.

4.5 Mechanical requirements

4.5.1 Insulators in cantilevers

The cantilever insulators must be offered in one voltage level, nominal 15 kV.

4.5.1.1 Tension and compression forces

Insulators in cantilevers are subjected to tension and compression forces from the contact line and catenary wire. The magnitude of the forces depends on contact and catenary wire tension and curve radii. Because it is desirable to limit the number of types of insulators, only the maximum calculated forces for any layout are given in this technical specification.

A safety factor of at least 3.0 shall be applied.

Maximum calculated tension: 7.8 kN (including safety factor: 23.4 kN (SCL to be specified by the manufacturer))
Maximum calculated compression: -2.7 kN (including safety factor: -8.1 kN (SCL to be specified by the manufacturer))



Figur 1: Forces on insulators in cantilevers

4.5.1.2 Interfaces

End fittings shall be in two different designs. One design shall be of tongue fitting in one end and of tube fixing with two U-bolts at the other end. The other design shall be with tube fixing with two U-bolts at each end.

  1. End fitting for tubes shall cover the range of tubes Ø42 - Ø70 mm.
  2. End fitting for tongue shall be fitted with a hole of Ø20 mm.
  3. Tongue shall have a thickness between minimum 16 mm and maximum 18 mm.
  4. The tounge shall have an shape that makes unrestrikted movenet of the insulator of minimum ± 60° when mounted in a swivel with clevis showed in drawing EH-707219-000 or EH-707347-000.
  5. The insulator with tongue and tube fixing shall have a distance of 500 mm from the centre of hole in the tongue fitting to the tube fixing stop point for tube.
  6. The insulator with tube fixings at both ends shall have a distance of 500 mm between the stop points for the tubes.

If end fittings are made of iron they shall be hot-dip galvanized.

4.5.2 Line-post insulators on crossarms

The line-post insulators must be offered in two voltage levels, nominal 15 kV and nominal 1 kV.

4.5.2.1 Tension and compression forces

Line-post insulators on crossarms are subjected to forces from differenences in span lengths, additional snow and ice loads and forces dependent on curve radii.

A safety factor of at least 3.0 shall be applied.

Maximum calculated radial force: 3.3 kN (including safety factor: 9.9 kN)
Maximum calculated differential force: 3.5 kN (included safety factor: 10.6 kN)
Maximum compression force: (Vertical) 3.0 kN (included safety factor: 9.0 kN)

Figur 2: Forces on line-post insulators
ΔF - differential force
F1 and F2 - conductor tensioning force
FC - radial force due to track curvature
FW - wind force on the conductor(s)
FR - total radial force (FC + FW)
FV - vertical force due to conductor
Cg - weight of conductor (incl. snow and ice)

4.5.2.2 Interfaces

Nominal voltage 15 kV: Interface between insulator and crossarm can be of two types.

  1. Insulator pin: Line-post insulator fixed on crossarm with insulator pin with the dimension Ø30 mm. Crossarm drawing EH-704304-000. Insulator pin drawing EH-707121-000 and EH-013322-000
  2. Directly bolted: Line-post insulator with flange fixed directly with bolts on crossarm shall be fixed vith four M16 bolts. Crossarm drawing EH-800110-000.

Nominal voltage 1 kV: Interface between insulator and crossarm shall be.

  1. Directly bolted: Line-post insulator with flange fixed directly with bolts on crossarm shall be fixed vith four M16 bolts. Crossarm drawing EH-800110-000.

Nominal voltage 15 kV and 1 kV: Interface between insulator and conductor.

  1. Interface between insulator and conductor shall be end fitting suited for fixing and locking conductor of differen types of material and diameter. Preferable with a built in pulley for installation pulling of conductor(s).
  2. Interface between insulator and conductor shall apply to diameters in the range between 12.5 mm and 27.0 mm.
  3. The interface between insulator and conductor shall be able to manage different conductor materials such as aluminum, steel reinforced aluminum, copper and bronze, with the above specified diameters.

If end fittings are made of iron they shall be hot-dip galvanized.

Types of conductor: According EN 50182:2001 and DIN 48201:1981

4.5.3 Long rod insulators in anchoring

The long rod insulators must be offered in two voltage levels, nominal 15 kV and 1 kV.

4.5.3.1 Tension and compression forces

Long rod insulators are subjected to tensioning forces applied to the different types of conductors used in the overhead contact line systems.

A safety factor of at least 3.0 shall be applied.

Maximum tensioning force: 17.73 kN (including safety factor: 53.2 kN (STL to be specified by the manufacturer))

4.5.3.2 Interfaces

Nominal voltage 15 kV: End fittings shall be of tongue fitting at both ends.

  1. End fitting for tongue shall be fitted with a hole of Ø20 mm.
  2. Tongue shall have a thickness between minimum 16 mm and maximum 18 mm.
  3. The tounge shall have an shape that makes unrestrikted movenet of the insulator of minimum ± 60° when mounted in a swivel with clevis showed in drawing EH-707219-000 or EH-707347-000.
  4. The insulator shall have a distance of 500 mm between the centres of hole in the tongue fitting.

If end fittings are made of iron they shall be hot-dip galvanized.

Nominal voltage 1 kV: End fittings shall be of tongue fitting at both ends.

  1. End fitting for tongue shall be fitted with a hole of Ø20 mm.
  2. Tongue shall have a thickness between minimum 16 mm and maximum 18 mm.
  3. The tounge shall have an shape that makes unrestrikted movenet of the insulator of minimum ± 60° when mounted in a swivel with clevis showed in drawing EH-707219-000 or EH-707347-000.
  4. The insulator shall have a distance of 150 mm between the centres of hole in the tongue fitting.

If end fittings are made of iron they shall be hot-dip galvanized.

5 Identification and documentation

Insulators shall be identified as specified in EN 62621:2016. In addition, the insulators shall be marked with the Supplier's batch number.

Documentation shall be delivered in accordance with EN 62621:2016.

The supplier shall provide .STEP files of the tendered products to the customer (Bane NOR), intended for use in planning of the OCL.

Instructions for installation, maintenance and operation shall be available in Norwegian, other documentation can be in English.

  • MDCL for cantilever insulators shall be specified by the manufacturer and documented in the tender documentation.
  • SCL for cantilever insulators shall be specified by the manufacturer and documented in the tender documentation.
  • STL for long rod insulators shall be specified by the manufacturer and documented in the tender documentation.

6 Reference

6.1 Norms

  • EN 62621:2017 Railway applications - Fixed installations - Electric traction - Specific requirements for composite insulators used for overhead contact line systems
  • IEC 61952:2008 Insulators for overhead lines - Composite line post insulators for A.C. systems with a nominal voltage greater than 1 000 V - Definitions, test methods and acceptance criteria
  • EN 60383-1:1996 Insulators for overhead lines with a nominal voltage above 1000 V - Part 1: Ceramic or glass insulator units for a.c. systems - Definitions, test methods and acceptance criteria
  • ISO 1461:2009 Hot dip galvanized coatings on fabricated iron and steel articles - Specifications and test methods
  • EN 50163:2004 Railway applications - Supply voltages of traction systems
  • EN 50124-1:2017 Railway applications - Insulation coordination - Part 1: Basic requirements - Clearances and creepage distances for all electrical and electronic equipment
  • IEC 60050-471:2007 International Electrotechnical Vocabulary (IEV) - Part 471: Insulators
  • IEC 60050-811:2017 International Electrotechnical Vocabulary (IEV) - Part 811: Electric traction
  • EN 50182:2001 Conductors for overhead lines - Round wire concentric lay stranded conductors
  • DIN 48201:1981 Part 1: Copper stranded conductors

6.2 Drawings

  • EH-704304-000 Crossarm for one and two line-post insulator(s) with insulator pin on topp of mast. (Isolatortravers for 1Fl. og 2Fl. på mastetopp)
  • EH-800110-000 Crossarm 100x120 made of extruded aluminum. (Travers 100x120 i ekstrudert aluminium)
  • EH-707121-000 Insulator pin, types I, U and S mounted in yoke.
  • EH-013322-000 Insulator pin on crossarm acc. drawing EH-704304-000
  • EH-707219-000 Swivel with clevis, Cast iron. (Ledd for utliggerkonsoll, støpejern)
  • EH-707347-000 Swivel with clevis, Aluminum. (Ledd for utliggerkonsoll, aluminium)
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