A pin insulator is a device that isolates a wire from a physical support such as a pin (a wooden or metal dowel of about 3 cm diameter with screw threads) on a telegraph or utility pole. It is a formed, single layer shape that is made out of a non-conducting material, usually porcelain or glass. It is thought to be the earliest developed overhead insulator and is still popularly used in power networks up to 33 KV. Single or multiple pin insulators can be used on one physical support, however, the number of insulators used depends upon the application's voltage. [1]
Pin insulators are one of three types of overhead insulators, the others being strain insulators and suspension insulators. Unlike the others, pin insulators are directly connected to the physical support compared to being suspended from the wire. Pin insulators are shaped to allow the secure attachment of the conducting wire and avoid it coming adrift. The wire is usually attached to the insulator by being wrapped around it or in other circumstances, fixed into grooves on the insulator itself. [2]
When an insulator is wet, its outer surface becomes conductive making the insulator less effective. An insulator has an umbrella-like design so that it can protect the lower part of the insulator from rain. To keep the inner side of the insulator dry, ridges around the insulator, "rain sheds", are made. These increase the creepage distance from the energized wire to the mounting pin. [3]
Pin insulators have become collectible items. All glass pin insulators are assigned a Consolidated Design (CD) number, a system first implemented by hobbyist N.R. Woodward in 1954, and widely introduced starting in 1965 by collector Helmer Turner. CD numbers first appeared in print in Woodward’s “Glass insulators in America, 1967 report”. Each CD number corresponds to a specific glass style, shape, or manufacturer. CD numbers are only hobby-specific for collectors, and are not used or recognised by insulator manufacturers. [4]
Insulators, at the time of manufacturing, were simply viewed as an engineering product and were not meant to be an entertainment product for spectators. This meant that the quality of the insulators was not a primary concern of the manufacturers that made them. [5] The finished product was usually discoloured from impurities and foreign objects diffused within the molten glass and metal molds. These impurities give the insulator a unique character and high value as collectors would rather obtain an imperfect product rather than a perfect, common product. Impurities in the glass can create amber swirls, milk swirls, graphite inclusions, and two or three-tone insulators. Foreign objects contained within the glass are known to be nails, pennies, and screws. [6]
Although glass insulators are the most popular for the majority of collectors, many people collect porcelain insulators as well. These also come in a variety of shapes, sizes, and colors. They are classified in the U and M systems, primarily developed by Jack Tod and Elton Gish. [7]
The examples and perspective in this section may not represent a worldwide view of the subject.(August 2019) |
One of the major U.S. manufacturers that produced glass insulators during the 19th century and early 20th century in the USA was Brookfield Glass Company. It can be assumed that Brookfield may have had poor quality control as their insulators seem to be found with the most imperfections, however, this could be disputed.
Another major U.S. manufacturer that produced glass insulators was the Hemingray Glass Company. They were known for producing the most variety of colors. Some examples of colors that the company produced are yellow, golden yellow, butterscotch, glowing orange, amber, whiskey amber, "root beer" amber, orange-amber, red-amber, oxblood, green, lime green, sage green, depression green, emerald green, olive green, yellow-olive green, aqua, cornflower blue, electric blue, cobalt blue, sapphire blue, glowing peacock blue, and many others. Different colors were produced to allow two or more different utility companies to quickly identify which wires were theirs by the color of insulator if multiple wires were strung over the same utility pole. For example, one company may have a string of amber insulators, while another, on the same poles, might have their insulators in cobalt blue.
There are many manufacturers in the United States, Canada, and other countries that can be found embossed on all styles of insulators. A non-comprehensive list of these manufacturers is below:
Bakelite, formally polyoxybenzylmethyleneglycolanhydride, is a thermosetting phenol formaldehyde resin, formed from a condensation reaction of phenol with formaldehyde. The first plastic made from synthetic components, it was developed by Leo Baekeland in Yonkers, New York, in 1907, and patented on December 7, 1909.
An electrical insulator is a material in which electric current does not flow freely. The atoms of the insulator have tightly bound electrons which cannot readily move. Other materials—semiconductors and conductors—conduct electric current more easily. The property that distinguishes an insulator is its resistivity; insulators have higher resistivity than semiconductors or conductors. The most common examples are non-metals.
Porcelain is a ceramic material made by heating raw materials, generally including kaolinite, in a kiln to temperatures between 1,200 and 1,400 °C. The greater strength and translucence of porcelain, relative to other types of pottery, arise mainly from vitrification and the formation of the mineral mullite within the body at these high temperatures. End applications include tableware, decorative ware such as figurines, toilets and washbasins, and products in technology and industry such as electrical insulators and laboratory ware.
An overhead line or overhead wire is an electrical cable that is used to transmit electrical energy to electric locomotives, electric multiple units, trolleybuses or trams. The generic term used by the International Union of Railways for the technology is overhead line. It is known variously as overhead catenary, overhead contact line (OCL), overhead contact system (OCS), overhead equipment (OHE), overhead line equipment, overhead lines (OHL), overhead wiring (OHW), traction wire, and trolley wire.
A marble is a small spherical object often made from glass, clay, steel, plastic, or agate. They vary in size, and most commonly are about 13 mm in diameter. These toys can be used for a variety of games called marbles, as well being placed in marble runs or races, or created as a form of art. They are often collected, both for nostalgia and for their aesthetic colors.
A transmission tower is a tall structure, usually a lattice tower made of steel that is used to support an overhead power line. In electrical grids, transmission towers carry high-voltage transmission lines that transport bulk electric power from generating stations to electrical substations, from which electricity is delivered to end consumers; moreover, utility poles are used to support lower-voltage sub-transmission and distribution lines that transport electricity from substations to electricity customers.
Electrical wiring is an electrical installation of cabling and associated devices such as switches, distribution boards, sockets, and light fittings in a structure.
Cobalt blue is a blue pigment made by sintering cobalt(II) oxide with aluminum(III) oxide (alumina) at 1200 °C. Chemically, cobalt blue pigment is cobalt(II) oxide-aluminium oxide, or cobalt(II) aluminate, CoAl2O4. Cobalt blue is lighter and less intense than the (iron-cyanide based) pigment Prussian blue. It is extremely stable and historically has been used as a coloring agent in ceramics (especially Chinese porcelain), jewelry, and paint. Transparent glasses are tinted with the silica-based cobalt pigment "smalt".
The Hemingray Glass Company was an American glass manufacturing company founded by Robert Hemingray and Ralph Gray in Cincinnati in 1848. In its early years, the company went through numerous and frequent name changes, including Gray & Hemingray; Gray, Hemingray & Bros.; Gray, Hemingray & Brother; Hemingray Bros. & Company; and R. Hemingray & Company before incorporating into the Hemingray Glass Company, Inc. in 1870. The Hemingray Glass Company had factories in Cincinnati and Covington, Kentucky with main production in Muncie, Indiana. Although Hemingray was best known for its telegraph insulators, the company produced many other glass items including bottles, fruit jars, pressed glass dishes, tumblers, battery jars, fishbowls, lantern globes, and oil lamps. In 1933, the Owens-Illinois Glass Company purchased the company, but the Hemingray name was retained at the production facility in Muncie.
A utility pole is a column or post, usually made out of wood or aluminum alloy, used to support overhead power lines and various other public utilities, such as electrical cable, fiber optic cable, and related equipment such as transformers and street lights. It can be referred to as a transmission pole, telephone pole, telecommunication pole, power pole, hydro pole, telegraph pole, or telegraph post, depending on its application. A Stobie pole is a multi-purpose pole made of two steel joists held apart by a slab of concrete in the middle, generally found in South Australia.
An overhead power line is a structure used in electric power transmission and distribution to transmit electrical energy along large distances. It consists of one or more conductors suspended by towers or poles. Since the surrounding air provides good cooling, insulation along long passages and allows optical inspection, overhead power lines are generally the lowest-cost method of power transmission for large quantities of electric energy.
Ceramic glaze, or simply glaze, is a glassy coating on ceramics. It is used for decoration, to ensure the item is impermeable to liquids and to minimise the adherence of pollutants.
A strain insulator is an electrical insulator that is designed to work in mechanical tension (strain), to withstand the pull of a suspended electrical wire or cable. They are used in overhead electrical wiring, to support radio antennas and overhead power lines. A strain insulator may be inserted between two lengths of wire to isolate them electrically from each other while maintaining a mechanical connection, or where a wire attaches to a pole or tower, to transmit the pull of the wire to the support while insulating it electrically. Strain insulators were first used in telegraph systems in the mid 19th century.
In electrical distribution, a fuse cutout or cut-out fuse is a combination of a fuse and a switch, used in primary overhead feeder lines and taps to protect distribution transformers from current surges and overloads. An overcurrent caused by a fault in the transformer or customer circuit will cause the fuse to melt and the switch mechanism to visibly open, disconnecting the transformer from the line. The device can also be opened manually by utility linemen standing on the ground and using a long insulating stick called a "hot stick".
In the electric power distribution industry, a hot stick is an insulated pole, usually made of fiberglass, used by electric utility workers when engaged on live-line working on energized high-voltage electric power lines, to protect them from electric shock. Depending on the tool attached to the end of the hot stick, it is possible to test for voltage, tighten nuts and bolts, apply tie wires, open and close switches, replace fuses, lay insulating sleeves on wires, and perform various other tasks while not exposing the crew to a large risk of electric shock.
An aerial cable or air cable is an insulated cable usually containing all conductors required for an electrical distribution system or a telecommunication line, which is suspended between utility poles or electricity pylons. As aerial cables are completely insulated there is no danger of electric shock when touching them and there is no requirement for mounting them with insulators on pylons and poles. A further advantage is they require less right of way than overhead lines for the same reason. They can be designed as shielded cables for telecommunication purposes. If the cable falls, it may still operate if its insulation is not damaged.
The Insulator Museum of the firm NGK Insulators, located in Nagoya, Japan, is the only museum of porcelain insulators in the world.
A wedge base is a type of electrical connector used as a fitting for small light bulbs. It is similar to the bi-pin connector, except that the two "pins" are the same wires that extend into the bulb, and the wires are bent up onto the sides of the base, where they make contact with the socket. The wires are usually inserted into a plastic base that the bulb is mounted in, and which is often narrower at the tip than at the bulb, giving it a wedge shape and usually ensuring a tight connection, depending on manufacturing tolerances. Some bulbs have no plastic base, and the wires are simply bent up to the sides of the bulb's glass base.
Optical attached cable (OPAC) is a type of fibre-optic cable that is installed by being attached to a host conductor along overhead power lines. The attachment system varies and can include wrapping, lashing or clipping the fibre-optic cable to the host. Installation is typically performed using a specialised piece of equipment that travels along the host conductor from pole to pole or tower to tower, wrapping, clipping or lashing the fibre-optic cable in place. Different manufacturers have different systems and the installation equipment, cable designs and hardware are not interchangeable.
Brookfield Glass Company was an American glass company based in Brooklyn, New York, from 1864 to c. 1912, and in Old Bridge, New Jersey, from c. 1906 to 1921. it was known for producing industrial glassware such as jars, bottles, and electrical insulators. The company's business began as the Bushwick Glass Works in Brooklyn in c. 1860, and operated as the Brookfield Glass Company from 1898 until dissolution of the company in 1922.