How is it manufactured?

100% of our processes are concentrated in our plant in La Granja, from the production of glass parts, assembly, silicon application and the testing laboratory.

This provides higher control over the production process and guarantees us a higher assurance over the quality of our final product.

Suspension insulator components

Dielectric: One dielectric made of toughened glass with the appropriate properties and shape for the specified mechanical rating and the environmental conditions in which it must function.
Cap: One hot-dip galvanized cast iron cap. It is marked with our brand name “ESA” and with the other engraved and inked marks required by the applicable standards to keep a correct identification and individual traceability.

Pin: One hot-dip galvanized forged steel pin. It may come with anti-corrosion zinc sleeve (sacrificial anode) when requested. This zinc sleeve is strongly recommended for insulators which are going to be used in heavily polluted environments.
Aluminous Cement: The cap and the pin are assembled on the glass piece using aluminous cement with the appropriate properties to withstand the thermomechanical efforts.
Split pin: Lastly, the insulator cap has a stainless steel or phosphor bronze locking device (split pin) which secures the coupling units.

DIELECTRIC MANUFACTURING

Melting Furnace: The raw material is introduced into the furnace to be melted and then it is allowed to pass through the feeder channel(s) to transport the glass from the furnace to the pressing machine.
Feeder: Its functions are to transport the glass to the pressing machine, to condition the glass in temperature and, in its final part, to dispense portions of glass to be produced. Once we have obtained a portion of glass determined by the model being produced, a blade mechanism will be used to cut/separate it from the mass of the feeder channel. Through this process the glass will drop by its own weight into the molds that will be placed in the press.
Pressing Machine: By means of a hydraulic pressing system we conform the shape of the glass piece (dielectric). After this process, it will be conditioned in temperature to be able to temper the glass. In case of not being able to ensure the correct temperature, the pieces will be introduced into an equilibrium furnace to equilibrate the temperature of all parts of the piece.
Equilibrium Furnace: To ensure that the entire piece of glass has a homogeneous temperature, 100% of these pieces go through an equilibrium furnace prior to tempering.

THERMAL SHOCKS

1st Thermal shock: "Cooling. To cool the pieces to room temperature, they are placed in a first unit consisting of several forced fans.
2nd Thermal shock: “Hot-cold" shock. To remove any defective pieces (inclusions, infusions, etc.), all the samples are given a thermal shock which consists of increasing the temperature of the glass abruptly from room temperature to approximately 400ºC. Behind this tank, there is a glass conditioning unit to lower the temperature a little.
3rd Thermal shock: “Hot-cold" shock. The next shock consists of cooling the part abruptly by placing it in a water tank. Those pieces that are not properly tempered will be destroyed. The standard stipulates that glass must be at least 100ºC above the water temperature. Our pieces are approximately 160ºC and the water is about 20ºC.
Soak Test: In this test we will exclude those samples that contain nickel sulfide particles. This particle is generated in the fusion of the raw materials and makes the pieces shatter after their manufacture, so, when passing all the pieces through this process, we can directly assemble them without the risk of explosion.
Tempering Machine:In this equipment we generate the tensions in the glass. These tensions are essential to guarantee that the dielectric will withstand the tensile and compressive stresses to which it will be subjected in the supply lines.

INSULATORS ASSEMBLY

Component supply: : In this first step, the necessary components for the glass insulator are procured and verified, which generally include the dielectric, cap, pin and split pin.
Cement Dosing:Cement is carefully dosed to ensure a proper assembly. It acts as a bonding agent that will hold the insulator parts together. We use 100% alumina cement, which is immune to cement growth expansion phenomena.
Assembly Machines: The insulator parts are assembled in specific machines that apply the cement homogeneously and ensure a solid bond. This involves attaching the cap and pin to the of the dielectric.
Cement Curingt: After assembly, the insulators are placed in a curing water tank where the cement hardens, and the stability of the bonds is ensured. Curing time and conditions are critical to the final strength of the insulator.
Routine Mechanical Testing (to 100% of Production): Each assembled insulator undergoes routine mechanical testing and visual inspection, which ensures its quality and strength. This is done to ensure that each insulator meets design specifications and is safe for use in electrical applications.
Packaging: Once the insulators have passed the quality tests, they are suitably packaged for distribution and delivery. Packaging must protect the insulators from damage during transport and storage, and often includes safety measures to prevent breakage of the glass.

CONTACT

P.º Pocillo, 16
40100 – Real Sitio de San Ildefonso Segovia (Spain)

+34 921 41 75 00

INSULATORS

XPERTISE SERVICES

INFORMATION – GDPR

CATALOGUES

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Proyectos de I+D financiados por el Fondo Europeo de Desarrollo Regional (FEDER) de la Unión Europea y la Junta de Castilla y León, a través del Instituto para la Competitividad Empresarial de Castilla y León.