Both porcelain disc insulators and glass insulators are widely used in high-voltage power transmission and distribution systems. Their primary function is to mechanically support conductors while ensuring electrical insulation from transmission towers. While both perform this task effectively, there are significant differences in their performance.
The main differences between porcelain disc insulators and glass disc insulators in terms of materials, performance, and applications are as follows:
Different Insulator Materials
- Porcelain Disc Insulators: Made of high-strength electrical porcelain (typically alumina porcelain) with a glazed surface to enhance insulation and resistance to pollution.
- Glass Insulators: Made of tempered glass, which undergoes a tempering process during manufacturing to achieve higher mechanical strength.
Mechanical and electrical properties
| Performance | Porcelain Disc Insulator | Glass Insulator |
| Mechanical strength | High strength, good tensile strength, but easy to crack | Easily broken by external impact, but tempered glass has higher strength |
| Impact resistance | Easy to produce micro cracks and easy to age over time | Glass surface is smooth and has strong impact resistance |
| Insulation performance | Affected by humidity and pollution | Glass material has more stable insulation |
| Aging resistance | Long-term use may reduce performance due to temperature changes or environmental corrosion | Glass has self-aging detection function (breakage means shattering) |
Operation and Maintenance
Porcelain Disc Insulators:
- Prone to developing hidden cracks, which are difficult to detect and require regular inspections.
- Highly affected by environmental conditions and susceptible to aging in humid or polluted environments.
Glass Insulators:
- Self-destructive property: If the internal structure is damaged, the glass insulator will automatically shatter, preventing defective units from remaining in service. This makes it easy to identify and replace faulty insulators.
- Less affected by environmental factors, with a long service life. Even after 30-40 years of operation, glass insulators retain their mechanical strength and electrical performance, ensuring reliability and reducing replacement costs.
Applicable Environments
- Porcelain Disc Insulators: Suitable for various climatic conditions but may require additional anti-pollution measures in highly polluted or humid environments.
- Glass Insulators: Due to their smooth surface, they resist dirt accumulation and are ideal for highly polluted and high-humidity areas, such as coastal and industrial regions.
Economic Considerations
- Glass insulators are generally more cost-effective due to their mature manufacturing process and relatively lower material costs.
- Porcelain disc insulators may have higher overall costs due to their complex manufacturing process and the need for more frequent maintenance.