Transformer Bushing Failures

Mode, Cause and Prevention

P Ramachandran
Transformer Consultant
prc3011@gmail.com
2020-07-18
 Transformer Bushing Failures
Killers of Transformers

Equal % share for below four failure modes -

• Breakdown of Bushings
• Break down of Tap Changers
• Short Circuit Current Forces on windings
• Insulation Ageing by Temperature with moisture

Transformer Fires can happen due to any of above 4 reasons. But maximum chance with bushing
failures. ( CIGRE Survey – 0.1 % probability /service Year - one fire/ 1000 transformers/year or %
probability in 40 year life.)
 Transformer Bushing Failures

PGCIL Survey 2014 CIGRE Survey 1996 – 2010

CBIP Conference on Trafo in Delhi Dec 2014 A2 Colloqium in Shanghai September 2015,
Lead/Tap Lead Lead/Tap Lead
9% Winding 7%
Bushing Winding
31%
17% 41%

Bushing
41%
Magnetic
Circuit
8%
OLTC Magnetic
OLTC 31% Circuit
11%
4%

FAILURE LOCATION IN POWER TRANSFORMERS

3
 Transformer Bushing Failures

Long Life Factors For Bushings

• Born Healthy

• Lived Healthy

• Treated well

Slide 4
 Transformer Bushing Failures
CIGRE Technical Brochure 755-2019 –Bushing Reliability
 Transformer Bushing Failures

Types of Bushings

• Low Voltage Bushings up to 36 kV – IS 3347 (DIN )Type/ Epoxy Cast resin

type with Silicon sheds

• HV Condenser Bushings -52~ 800 kV

- SRBP – Synthetic Resin Bonded Paper Type -1913
- OIP – Oil Impregnated Paper Type -1906 ;1944
- RIP – Resin Impregnated Paper Type -1950
- RIS - Resin Impregnated Synthetic fiber type -2005

• LV High Current Bushings >3.15 kA

-Plain Porcelain Type (as per DIN/EN standard )
- Condenser graded Type

Slide 6
Transformer Bushing Failures
LV Bushings as per IS 3347- up to 36 kV
Transformer Bushing Failures
LV Bushing –IS 3347
 Transformer Bushing Failures
LV Bushings as per IS 3347- up to 36 kV

Mode Cause Prevention

Oil Leak Damaged oil seals Visual Inspection
- Quality - Tight connections
- High Temperature - Monitor terminal
from loose temperature by
connections/ infra red
connectors Thermography
- Excessive Pull on - Avoid taut jumper
terminal connections

Porcelain Crack - Excessive Pull on - Avoid taut jumper

terminal connections

July 18, 2020 Slide 9

 Transformer Bushing Failures
LV Bushings as per IS 3347- up to 36 kV

Mode Cause Prevention

High temperature at - Loose Connections -Tighten connections
top/bottom terminal joints - Improper design +fasteners with locking
– smoke and fire from
leaked oil - Pull on terminal
-Monitor terminal
temperature by infra
red Thermography
(IEEE C57.152-2013 –
Annexure C)

-Avoid taut jumper

connections

July 18, 2020 Slide 10

Transformer Bushing Failures

Condenser Bushing- C1 & C2

Transformer Bushing Failures
Transformer Bushing Failures

Top Terminal Connection Details

 Transformer Bushing Failures
HV Condenser Bushings –OIP- 52-800 kV

Mode Cause Prevention

Bushing Flash over to Pollution deposit on Frequent cleaning
ground porcelain Application of RTV
(Room Temperature
Vulcanizing silicone
coating) on porcelain

Care during installation/

Failure at Bushing test Loss of grounding to
diagnostic testing
tap earth – defective design/
installation

July 18, 2020 Slide 14

 Transformer Bushing Failures
HV Condenser Bushings –OIP- 52-800 kV
Mode Cause Prevention

Upper Porcelain Insulation Deterioration C and Tan delta Check –

shatters and fire breaks Arcing inside vaporizes Change means
out oil –dynamic pressure insulation deterioration
wave shatters porcelain- Tan delta at different
Hot gases when reach temperatures/ different
air catch fire frequencies -15-400 Hz ;
-Natural Aging (DFR -Dielectric
- Water entry Frequency Response-
1mHz -1000 HZ)
- Thermal degradation
Limits of Tan delta-
- Transient voltages Twice the factory test
cause PD leading to value or 0.7 % max/ C
failure >5% (72.5
kV)>3%(above 72.5 kV)
July 18, 2020 Slide 15
 Transformer Bushing Failures
HV Condenser Bushings –OIP- 52-800 kV

Mode Cause Prevention

Upper Porcelain Insulation Deterioration
shatters and fire breaks Arcing inside vaporizes Stop leak by epoxy
out oil –dynamic pressure sealings- Replace
wave shatters porcelain- bushings
Hot gases when reach
air catch fire
-Natural Aging
- Water entry
- Thermal degradation
Correct jumper
- Transient voltages connections
cause PD leading to
failure

July 18, 2020 Slide 16

 Transformer Bushing Failures
HV Condenser Bushings –OIP- 52-800 kV

Mode Cause Prevention

Upper Porcelain Insulation Deterioration -Measuring tan delta at
shatters and fire breaks Arcing inside vaporizes higher temperature- with
out oil –dynamic pressure moisture high tan delta
wave shatters porcelain- at high temperatures
Hot gases when reach
air catch fire
-Natural Aging -DGA of bushing oil- IEC
- Water entry 60599-2015 Section A-5
- Thermal degradation - Thermal /PD faults can
- Transient voltages be detected
cause PD leading to
failure

July 18, 2020 Slide 17

 Transformer Bushing Failures
HV Condenser Bushings –OIP- 52-800 kV

Mode Cause Prevention

Upper Porcelain • Insulation failure-
shatters and fire breaks Arcing inside
out vaporizes oil –
dynamic pressure
• Proper co-ordination
wave shatters
with surge arresters
porcelain- Hot gases
when reach air catch • Co-ordination with
fire isolator switches of GIS
• Transient voltages • Extra Surge arrester
cause PD leading to where cable connection
failure- • Stop oil leak /Replace
• Oil leak exposes bushing
core to air /vacuum

July 18, 2020 Slide 18

 Transformer Bushing Failures
HV Condenser Bushings –OIP- 52-800 kV

Mode Cause Prevention

Lower Porcelain Excess pull on terminals Correct jumper
shatters and condenser connections
core gets burnt- Tank
Flash over to ground –
rupture from dynamic
shifted lower corona Positive Locking of
pressure wave-
shield - faulty mounting fasteners of shield-
of shield Poka yoka in shield
fixing

Improper storage of RIP Dry out bushing if tan

Bushings-Excess delta increase
moisture ingress moderate- not use in
case tan delta excessive
>3 %

July 18, 2020 Slide 19

 Transformer Bushing Failures
HV Condenser Bushings –OIP- 52-800 kV

- Excessive Mechanical Pulling Forces On Terminals

• Wrong Jumper Connection

• Short Jumper Connection

Slide 20
 Transformer Bushing Failures
Bushing Failures -Prevention
• Pull on Top Terminal
• Avoid tensile pull on bushing terminal pad from taut jumper
connections to catenary
• Avoid too much slackness as it may cause interphase shorting
during wind
• Pipe bus connection to bushing without expansion type terminal
connector can result push on terminal

Slide 21
 Transformer Bushing Failures

Bushing Failures - Design/material/ manufacturing Defects

- Defective current carrying joint design/ sealing Joint design/ imperfect locking
of fasteners

- Materials – Use of Kraft paper of proper grade – Type U bushing of GE

- Processing – Drying / vacuum /Oil Impregnation

- Manufacturing – Brazing of central conductor Joint

- Taping of central draw lead with paper insulation –Failure of bushings in USA

Slide 22
 Transformer Bushing Failures
Condition Assessment of Power Transformers- CIGRE TB 761-2019
 Transformer Bushing Failures
Failure Mechanism
Mechanical
• Seismic Disturbance
• Vandalism
• Rigid jumper connection to switchyard
• Electrodynamic forces from winding lead
Thermal
• Gas bubble evolution
• Current Path Issues
• Contact Problem in test tap
• Locking of Fasteners
 Transformer Bushing Failures
Failure Mechanism
Electric & Dielectric
• Condenser Core Cracking and delamination
• Bottom shield Electrode Problem
• Bushings with printing with conducting ink instead of aluminium foils
• Test Tap opening
• VFT from VCB &GIS
Chemical and Environmental
• Poor Sealing
• Moisture ingress
• Moisture from inside
• Corrosive sulphur and copper mobility (OIP)
• Damage from animals and Rodents
• Pollutant (dust, sand,cement )
 Transformer Bushing Failures
Diagnostic Monitoring- Periodic and On-line
Periodic On Line
Visual Visual
Capacitance Capacitance
Tan delta/PF Tan delta/PF

DFR (PDC,FDS) Dielectric Frequency Response

( Polarisation Depolarisation Current
Measurement, Frequency Domain
Spectroscopy)
Transformer Winding Resistance
Infrared scanning Infrared scanning
Moisture in Oil Moisture in Oil
Leakage Current
Internal Pressure
Transients
Voltage balancing between phases

DGA DGA
Transformer Bushing Failures
High Current Bushings
 Transformer Bushing Failures

High Current bushings

• If not hermitically sealed design, keep oil in bushing communicating with

main tank oil - keep tap opened

• Derating for high ambient air temperature isolated phase bus duct

• Overheating of top terminal pad from improper flexible connection to

bus duct – oil leak in to bus duct and fire

• Provide viton ( high temperature resistant than nitrile rubber) oil seal if
over heating of bushing fixing pad is suspected

Slide 28
 Transformer Bushing Failures
Air Filled Cable Box - Typical designs

With Breather With louvers

July 18, 2020 Slide 29

Transformer Bushing Failures
Connections inside cable Box
 Transformer Bushing Failures
Air Filled Cable Box

Mode Cause Prevention

Flash over of bushings; Water condensation Silicagel Breather;
support insulators Ventilation Louvers

Oil seal damage from Flexible terminal

Oil Leak from bushings loose connections of connection; proper
current carrying parts; locking
inadequate area for
current path

July 18, 2020 Slide 31

 Transformer Bushing Failures
Oil Filled Cable Box -Typical designs

132kV oil-filled cable box 220kV oil-filled cable box

July 18, 2020 Slide 32

 Transformer Bushing Failures
Oil Filled Cable Box

Mode Cause Prevention

Failure of oil to oil Arc from failure cause RIP bushings with
bushing; Fire shattering of cable box accessibility for test tap
for monitoring during
service

Avoid Lead support

Failure of Lead supports Arc cause shattering of
; Fire cable box

Failure of Cable Pot VHF transients from GIS Avoid cable box; use oil
Head ; Fire &VCB ; Ferro- to air bushing + outdoor
resonance from cable cable pot head +LA in
end between

July 18, 2020 Slide 33

 Transformer Bushing Failures
Storage of Bushings
• Indoor storage

• Store vertical if long storage ; on rigid stand

• Provide oil filled bottom metallic cap for bottom tail of RIS &RIP bushings (to avoid moisture entry) .
;if possible with oil sight window and a silica gel breather.

• Take precaution to avoid damage of silicone envelop of RIP Bushings by rodents, monkeys etc
• How to dry RIP Bushings ? – in vertical position at 70-80 C air drying