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"Suspension" and "Strain" insulators are the same thing; when
used in the vertical position (with the conductor hanging below) they are
called "suspension"; when used in the horizontal, to dead-end a conductor,
they are called "strain".
There are two basic types of suspension insulators: unipart and
multipart.
Multiparts are no longer produced, and original units are rare today.
There are only two known styles: Cochrane and Byllesby, both dating from
the late 1910s.
Uniparts (see left and right) were first developed in the 1910s and are
the common style still in production today. Each unit has a single glass
shell bonded to a steel cap (above) and a steel pin (below). The modular
units connect with each other cap-to-pin, forming a chain or "string".
The mechanical strength of a string is determined by the rating of the
metal parts of a single unit, but the electrical rating can be increased
by simply adding more units. This system allows for much higher insulation
value than any pin-type insulator: the largest one-piece pin-type power
insulator ever made in the U.S. was the Corning Pyrex
No. 701, which is rated at only 70,000 volts,
while a string a suspension insulators could be assembled that stands off
1,000,000 volts or more.
There are three basic styles of unipart suspension insulator shells:
(1) "sombrero" (so-called by collectors), which is flat, with multiple
ridges or "skirts" on the under-side which increase the leakage distance;
(2) fog or "bell", in which the disk is curved into a bell or
nearly hemispheric shape, the indent being to keep the ridgeless underside
from being wetted as easily; and (3) aero(dynamic) style, a wide flat
disc (also with no ridges) which presents little cross-section and so is
least affected by high winds.
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Multipart |
Byllesby — shells: 5 — width: 6¾" —
length: 22" — weight: 15# |

Photo: Gary Romprey

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This insulator was invented around 1917 by Henry M. Byllesby (formerly
of Edison, Westinghouse, and T.H.E. Co.), who formed his own engineering
company (H. M. Byllesby & Company) in Chicago. "The insulator consists
of a micarta core on which
are assembled glass disks separated by asbestos washers and held in place
by a simple interlocking washer and cotter key. After the parts are in
place the unit is heated uniformly to a temperature of 100 deg. Fahr. and
[tar] compound poured into the core through the top casting"
(Electrical World, April 21, 1917) It's reported that 15,000 of these units were made,
although they are very rare today, with only 2 purple strings and perhaps
3 original aqua strings known. The purple unit pictured sold on eBay
in June, 2010 for $20,000. The aqua shells were aparently produced by
Hemingray (shell fragments were found at the company dump), but the
maker of the purple shells is unknown, possibly the same glasshouse
that made the Cochrane bells. Two sizes were made, one with 5 disks
(pictured), and other with 11. "The eleven-disk insulators will be used
exclusively on the 110,000-volt line which is being built from Wisconsin
to Minneapolis to serve the Twin Cities. The line west of Stillwater is
being requipped with them. Five disk insulators are being placed on a
number of 60,000-volt lines in various parts of Minnesota. The Montana
Power Company was one of the first companies to try out the glass disk
feature." (ibid) The five disc units were also used in California.
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Cochrane — shells: 6 — width: 6" — length: 25"
— weight: 16# |
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Patented by Harry Hamilton Cochrane of Butte, Montana in 1916
(No. 1,194,957), these "Cochrane Bells"
were used only in Montana, mostly on the 65KV, 13½-mile Cochrane
line which ran from the Bertha substation near Corbin to the Porphry Dike
mine.
The shells are stacked on a parafin-soaked oak rod with cork washers
between; cast iron caps screwed to either end of the threaded rod clamped
the assembly together.
The shells come in purple shades from near-clear to a rich full purple;
pictured is the typical medium purple. A much rarer stationary version
with ten larger bells also exists.
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A Proposed Numbering System |
I propose an S-numbering system for glass suspension insulators.
The system is keyed primary off the glass shell, with a suffix
to indicate variations in the metal cap and pin.
To make the system more mnemonic and useful, the numbering would
be S-DDNN where DD is the diameter in inches of the shell,
rounded down to the nearest inch. NN is an arbitrary
sub-code to distinguish the individual styles near the same size.
Within a size, numbers are assigned in petticoat order. That is,
the fewer skirts, the lower the number. "Bell" or "aero" type glass,
with just a single outer shell, would come first. Complicated
"sombrero" types with numerous inner skirts would come last.
Since the smallest size insulators is about 5", that leaves the
lower range of numbers available for multiparts and other uses.
I would put multiparts in the 00NN range, and leave 01, 02, 03
and 04 for other uses (radio strains?).
Unipart Suspension Table
S-#### |
Maker |
Style# |
Width |
Shape |
Skirts |
Hardware |
Weight |
Color(s) |
S-5## |
Sediver |
|
5" |
Disc |
1 |
Clevis |
2 lb. |
Aqua, Off Clear |
S-5## |
Sediver |
|
5¼" |
Disc |
1 |
Clevis |
3 lb. |
Olive Tint |
S-6## |
Pyrex |
65221 |
6" |
Disc |
3 |
Clevis |
4½ lb. |
Clear, Clear w/Carnival |
S-6## |
Pyrex |
65241 |
6" |
Disc |
3 |
Hook |
4½ lb. |
Clear? |
S-6## |
Pyrex |
65251 |
6" |
Disc |
3 |
Clevis+ |
4¼ lb. |
Clear? |
S-6## |
EIV |
|
6¾" |
Disc |
3 |
Ball |
4 lb. |
Aqua |
S-7## |
Pilkington |
|
7" |
Disc |
3 |
Clevis |
4 lb. |
Ice Green |
S-7## |
Pilkington |
|
7" |
Disc |
2 |
Clevis |
4 lb. |
Light Yellow Olive |
S-9## |
Pyrex |
|
9" |
Disc |
4 |
Hook |
6 lb. |
Clear w/Carnival |
S-9## |
Pyrex |
|
9" |
Disc |
4 |
Clevis |
5 lb. |
Clear |
S-10## |
EIV |
|
10" |
Disc |
4 |
Clevis |
8 lb. |
Aqua |
S-10## |
EIV |
|
10" |
Disc |
? |
Ball |
8 lb. |
Aqua |
S-10## |
EIV |
|
10" |
Disc |
3+ |
Ball |
13 lb. |
Aqua |
S-10## |
Sediver |
|
10" |
Bell |
1 |
Ball |
9 lb. |
Aqua |
S-10## |
Sediver |
|
10" |
Bell |
1 |
Ball |
8 lb. |
Aqua |
S-10## |
Sediver |
|
10 1/8" |
Bell |
1 |
Clevis |
10 lb. |
Aqua |
S-10## |
Pyrex |
65234 |
10 |
Disc |
4 |
Ball |
8¼ lb. |
Clear |
S-10## |
Pyrex |
65244 |
10 |
Disc |
4 |
Clevis |
8¼ lb. |
Clear |
S-10## |
Pyrex |
65216 |
10 |
Disc |
5 |
Ball |
12 lb. |
Clear |
S-10## |
Pyrex |
65226 |
10 |
Disc |
5 |
Clevis |
12 lb. |
Clear |
S-10## |
Pyrex |
65214 |
10 |
Disc |
4 |
Ball |
8½ lb. |
Clear w/Carnival |
S-10## |
Pyrex |
65224 |
10 |
Disc |
4 |
Clevis |
8½ lb. |
Clear w/Carnival |
S-10## |
Russian |
|
10 |
Disc |
3 |
Ball |
7 lb. |
Light Blue-Aqua |
S-11## |
EIV |
|
11¼" |
Disc |
4 |
Ball |
12 lb. |
Aqua |
S-12## |
EIV |
|
12½" |
Disc |
5 |
Ball |
21 lb. |
Aqua |
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