PRESENTATION
ON
BUSHINGS
S V S PRASAD
Engineer (Design),
Switchgear Products Division,
Vijai Electricals Limited
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TOPICS TO BE COVERED
What is a bushing
Types of bushings
Salient design features
Manufacturing aspect.
Testing of bushings
Dos and donts on bushings
BUSHING
Bushings is one of the most important component
that are fitted to the electrical equipments like the
transformer, the switchgear etc. It is an insulating
structure for carrying the H V conductor through an
earthed barrier
A bushing has to provide
Electrical
insulation to the conductor for the
working voltage and for various over voltages,
which occur in service.
Mechanical
support against various Mechanical
forces & Carry the full load current.
TYPES OF BUSHINGS
1.1 Application
i) Generator bushing
ii) Transformer bushing
iii) Bushings for switch gear
iv) Wall bushing or roof bushing
1.2 Application:
i) Indoor type
ii) Outdoor type
Generator Bushing
Indoor & Out Door
Bushing
Wall bushings
Roof bushings
TYPES OF BUSHINGS
2.1 Type of Bushing:
i) Pull-through type
ii) Stem type
2.2 Type of Bushings:
i) Condenser core type
ii) Non-condenser core type
(Hollow Porcelain type)
iii) Gas filled bushing
iv) Solid Bushing
Solid Ceramic Bushing
Epoxy Bushing
Solid Ceramic Bushing
Epoxy Bushing
TYPES OF BUSHINGS
3. Type of insulation used in manufacturing
Condenser Bushing:
i) Synthetic Resin Bonded Paper (SRBP)
ii) Oil Impregnated Paper (OIP)
iii) Resin impregnated Paper (RIP)
TYPES OF BUSHINGS
Non - Condenser Bushing
In its simplest form a
bushing would be a cylinder
of insulating material ,
porcelain, glass resin etc, with
the radial clearance & axial
clearance to suit the electric
strengths.
Condenser Bushing
This is also known as
capacitance graded bushing
as it contains capacitance
layers in between the kraft
paper insulation at
predetermined positions to
build up a stress controlling
condenser insulator.
CONDENSER BUSHING
DESIGN OF BUSHINGS.
Minimum Specification required for
Design:
1. Highest System Voltage.
2. Rated Voltage.
3. Basic Insulation Level.
4. Length of CT Accommodation .
5. Creepage Distance Required.
6. Altitude.
7. Application.
SALIENT DESIGN FEATURES
Self
Earthing Test Tap for measurement
of Tan Delta and Capacitance at site.
Environmental
Bushings
friendly.
for special applications can
be designed and supplied to suit clients
specifications.
SALIENT DESIGN FEATURES
Electrostatic
Field Controlled design of
Condenser Core by Computer
Suitable for Operation under heavily
polluted atmosphere
Reliable, relatively easy erection and
practically maintenance free.
Better Dielectric Strength and Partial
Discharge free up to Working Voltage
Space for mounting of Ring Type
Current Transformer
145 KV OIP
CONDENSER
BUSHING
MAJOR PARTS OF
CONDENSER BUSHING
1. Condenser Core
2. Porcelain.
3. Oil level Gauge
4. Top cap.
5. Test Tap.
6. Mounting Flange.
7. Oil side Stress Shield.
CONDENSER CORE
The core of bushing consists of a hollow metallic
tube or solid metal rod, over which high grade
electrical kraft paper is wound .For condenser cores,
conducting layers of metallic foil are introduced at
predetermined diameters to make uniform
distribution of electrical stress. The winding of
condenser core is done in a dust free chamber. The
core is then processes. This comprises of drying in a
high degree of vacuum ( 0.005mm) , and then
impregnating with high quality, filtered and degassed transformers oil.
INSULATORS
The function of an insulator is to resist
flash over in adverse conditions.
This is determined by
a) The profile of the dielectric/ Creepage
Distance.*
b) The mounting arrangement of the
insulator i.e. , vertical, horizontal, or
inclined.
c) The properties of the surface, i.e.,
hydrophobic, toughness etc.
The shortest distance along the surface
of the porcelain between the metal
parts which normally have the
operating voltage between them.
FOR DIFFERENT POLLUTION LEVELS
POLLUTION LEVELS
CREEPAGE DISTANCE
I. Light ( areas without industries,
16mm/kV
agricultural or mountain areas )
II. Medium ( areas with industries
20 mm/kV
not producing pollution smoke,
Low density of house areas not
exposed to the coast)
III. Heavy (Areas with high density
25mm/kV
of industries, high density of
Heating plants producing pollution,
areas close to the sea.)
IV. Very Heavy (Areas close to
31mm/kV
the coast and exposed to sea spray,
desert areas, areas exposed to
strong winds carrying salt and sand etc
Example: for 145 kV Bushing with heavy pollution level minimum creepage
distance works to be.
145 kVX 25mm/kV = 3625mm
DIFFERENT PROFILES OF PORCELAINS
Plain.
Anti-fog.
Alternate.
OIL LEVEL GAUGES
These are provided in the outer surface of the
bushing for monitoring the oil level in the bushing.
These are generally of following types.
1. Magnetic Oil level
Gauges
2. Prismatic Oil level
Gauges.
3. Button Type Oil
level Gauges.
TOP CAP
This is a metallic housing for the spring
pack . it services as an in built oil
conservator to cater for oil expansion ,
and has an oil indicator. In many cases,
it also serves the purposes of a corona
shield.
MOUNTING FLANGE
This is used for mounting the bushing on an
earth barrier, such as a transformer tank or a
wall. It may have the provisions for following:
a) CT accommodation length.
b) Rating plate giving the rating and
identification details of bushing.
TEST TAP
The test tap is provided for measurement of the
power factor and capacitance of the bushing during
testing and service. The test tap is connected via a
tapping lead to the last condenser foil of the core
within the bushing. During normal services, this
tapping is electrically connected to the mounting
flange through a self-grounding arrangement.
OIL SIDE STRESS SHIELD
This is provided at the oil side of the bushing to
controlled the electrostatic field inside the
transformer after installation
FACILITES REQUIRED FOR
MANUFACTURE BUSHING
1.
2.
3.
4.
5.
6.
Dust free / pressurized winding chamber
Winding Machines
Heating oven for baking.
Process Plants for Drying and Vacuum
Impregnation at very fine Vacuum (0.0050.001mm of Mercury)
Oil Treatment Plants for oil processing
Assembly stand and Power pack for
Tightening
MANUFACTURE OF BUSHINGS
This is done in four stages.
1. Winding .
2. Baking.
3. Assembly.
4. Drying and impregnation
WINDING
This is done in an enclosed chamber which is dust free . The
winding machine are primarily drives the bushing conductor by
three roller mounted 120 Degree. These rollers maintained at
temperature of about 120 C uniformly by thermic fluid for
driving out initially moisture from the insulating paper. Full
width paper is passed on these rollers enabling it to wound on
bushing conductor under tension and pressure. At predetermine diameters a thin and pure aluminium foil is inserted
to form capacitances to control the electrostatic field around
the bushing. On attaining the final diameter bushing is wrapped
with glue coated paper.
BAKING
The bushing is then be unloaded and transferred
to a heated the oven on a suitable trolley with in 2
hours and heated at 125C to 130C for a period of 24
Hrs. minimum. The temperature of oven is then
reduced to 50C before bushing is taken out and
allowed to cool to ambient temperature. The bushing
shall then be protected with polythene sheet and
stored in a safe place till it is taken for assembly.
ASSEMBLY.
The bushing from baking oven should be shifted near
assembly stand. The polythene cover should be
removed. An insulating lead should be soldered to
the last aluminium foil. The bushing assembly is done
sequencely as shown. Whole assembly is tightened
by a power pack at pre-determined load to achieve
leak proof assembly.
DRYING AND IMPREGNATION
Assembly of bushings are placed inside a drying and impregnation
plant for processing. These are subjected to following after closing
the plant.
1.
DRYING PROCCESS: The temperature of the impregnation plant
Is maintained at 95 5 C for a minimum period of 48 Hrs.
2.
VACUUM PROCESS: The temperature of impregnation plant is
reduced to 60 5 C simultaneously pulling vacuum inside the
plant. When a vacuum of 0.005 to 0.001 mm Hg is obtained, the
same is maintained for a minimum period of 72 Hrs.
3. IMPREGNATION PROCESS: On Completion of vacuum drying,
filtered & degassed oil of the following parameters is admitted
inside the bushing at a slow speed at vacuum of 0.005 to 0.001
mm of Hg. Speed of filling is so controlled that the bushing is
completely filled in about 12 Hrs time.
i)
TEST
Electric strength
VALUES REQUIRED
70 min.
ii)
iii)
(BDV in kV)
Tan delta at 90 C
Resistivity at 90 C
0.02 max
10 x 1012min
iv)
(Ohm - cm)
Water content {mg/kg or
10 max.
ppm by weight)
4. SOAKING PROCESS: Bushings are then
allowed to soak the filled oil naturally for a
period of minimum 3 days. In between oil is
topped up to the desired level in the bushing
whenever needed.
Bushings are then finally closed and final
assembly done before taking to test.
OIL IMPREGNATION
PLANT
ROUTINE TESTS
Routine test: Tests are carried out on each bushing to check
requirement which are likely to vary during production.
These are follows:
1.
2.
3.
4.
5.
6.
Measurement of dielectric dissipation factor (Tan Delta)
and capacitance at ambient temperature.
Dry power frequency voltage withstand test.
Measurement of partial discharge quantity.
Tests of tap insulation.
Pressure test on liquid filled and liquid insulated bushings.
Tightness test at flange/ Fixing Device.
TESTING FACILITIES
Tests on Bushings are conducted in electromagnetically shielded Test Laboratory which is
provided with.
Impulse Generator
Test Transformer for power frequency voltage.
Standard capacitors
Voltage Divider.
PD measuring equipment
Schering bridge
DOs AND DO NOTs FOR BUSHINGS
DOs
1.
Check the packing externally for possible damage
before un packing.
2.
Unpack with care to avoid any direct blow on the
bushing or porcelain insulator.
3.
Store the bushing in a shed or covered with tarpoline to
protect it from moisture and rains. If removed from
the crate keep it indoors with lower end protective
intact.
4.
Handle the bushing with manila rope slings without
any undue force on porcelain insulators.
DOs AND DO NOTs FOR BUSHINGS
DOs
5.
Clean the porcelain insulator thoroughly before taking
any measurement or mounting the bushing on the
transformer. Check for any foreign body adhered to the
bottom porcelain.
6.
Check the oil level by making the bushing vertical
7.
Check for leakage of oil from any of the gasket joints. Each
bushing is tested with the oil immersed in oil tank and so
some traces of oil can be found which is actually not leakage.
8.
Check tan delta and capacitance ( if possible on mounted
bushing without making any connections ).
9.
Maintain the log book of records of periodical checks.
DOs AND DO NOTs FOR BUSHINGS
DO NOTs
1.
DO NOT unpack the bushing from crate unless
required to be mounted on the transformer.
2.
DO NOT use metal slings on porcelain and avoid un
due jerks while handling.
3.
DO NOT store the bushing outdoors with out any
protective covering
4.
DO NOT measure IR value and tan delta with out
thoroughly cleaning the porcelain and oil end
portion.
DOs AND DO NOTs FOR BUSHINGS
DO NOTs.......
5.
DO NOT fill oil in the bushing without specific
instructions from BHEL .
6.
DO NOT climb the porcelain to tighten the top terminal.
Use elevators or seperate ladder for this purpose.
7.
DO NOT dismantle or attempt to repair the bushing in
case the defect or mechanism is not clear.
REFERENCES
IS: 2099
IS: 3347
IEC: 60137
SITE TESTS ON BUSHING
BEFORE INSTALLATION ON TRANSFORMER
After thoroughly cleaning the bushing with non-fluffy cloth,
mount the bushing on a stand before carrying the tests at
site.
1. Measurement of Tan Delta and Capacitance at 10 kV.
(For this purpose a Schering Bridge Kit with 10kV in-built
Source is needed along with shielded cable
SITE TESTS ON BUSHING
AFTER INSTALLATION ON TRANSFORMER
After mounting the bushing on the transformer thoroughly
clean the bushing with non-fluffy cloth,
1. Measurement of Tan Delta and Capacitance at 10 kV.
(For this purpose the same Schering Bridge Kit should be
Used.)
