Airrip: Operating Instructions For Bushings

HLAB200456-AI
Operating instructions for bushings

AirRIP
Preface
These operating instructions show general procedures and
guidelines that must be observed when installing and using the
product. These operating instructions makes no claim for
completeness and possibly does not cover all the activities that
can occur during the installation, operation, or maintenance, as
there can be special variations of this product. It is highly
recommended that all the necessary information and drawings
are obtained before the installation and use. If in doubt or in need
of additional information, please contact High Voltage
Components at ABB Switzerland Ltd or your local ABB partner
for further information.
General Information
Micafil bushings are designed specifically for mineral oil-filled IEC
60296 transformers and chokes for oil-outdoor applications. Our
bushings comply with the standards IEC 60137, IEEE C57.19.00
and C57.19.01. Additionally, they must be qualified according to
strict internal guidelines. Micafil bushings are produced
exclusively at the ABB industrial site in Zurich, Switzerland.
Table of contents
Table of contents ................................................................................................................................................................................. 2

1. Safety information ....................................................................................................................................................................... 5
1.1. Symbols and notes .............................................................................................................................................................. 5
1.2. Product safety ..................................................................................................................................................................... 5
1.3. Personnel-related measures ............................................................................................................................................... 5
1.4. Organizational measures..................................................................................................................................................... 5
2. Structure of the bushing .............................................................................................................................................................. 6
2.1. General structure ................................................................................................................................................................. 6
3. Packaging and delivery ............................................................................................................................................................... 7
3.1. Delivered state and reloading .............................................................................................................................................. 7
3.2. Reference measurement No. 1 ........................................................................................................................................... 7
3.3. Repackaging ....................................................................................................................................................................... 7
3.4. Transport box ...................................................................................................................................................................... 7
4. Storage ............................................................................................................................................................................................ 8
4.1. Storage ................................................................................................................................................................................ 8
4.2. Storage container with oil (variant 1) ................................................................................................................................... 9
4.3. Storage container with PETP-Alu-PE composite film (variant 2) ......................................................................................... 9
4.4. Procedure after incorrect storage ........................................................................................................................................ 9
5. Assembling.................................................................................................................................................................................10
5.1. Recommended distance from the transformer wall ........................................................................................................... 10
5.2. Lifting the bushing ............................................................................................................................................................. 10
5.3. Reference measurement N°1 ............................................................................................................................................ 11
5.4. Conductor and terminal (A, B, C) ...................................................................................................................................... 11
5.5. Dismounting the cable bolt (A) or conductor rod (B).......................................................................................................... 12
5.6. Connection cable bolt/conductor rope (A) ......................................................................................................................... 12
5.7. Split conductor rod ............................................................................................................................................................ 13
5.8. Rope conductor insulation (A) ........................................................................................................................................... 13
5.9. Insulation for the dismountable conductor rod (B) ............................................................................................................. 14
5.10. Fastening the shield .......................................................................................................................................................... 14
5.11. Bushing without shield ....................................................................................................................................................... 14
5.12. Shield for rope application ................................................................................................................................................. 14
5.13. Shield with spring-loaded thrust piece ............................................................................................................................... 14
5.14. Shield with bayonet catch .................................................................................................................................................. 15
5.15. Head shield from 420 kV ................................................................................................................................................... 15
5.16. Fixed conductor (IEEE) ..................................................................................................................................................... 16
5.17. Preparation of the terminal surface (A, B, C) ..................................................................................................................... 16
5.18. Cleaning of the bushing surface and the interface ............................................................................................................ 16
5.19. Installing of the bushing ..................................................................................................................................................... 16
5.20. Damage during installation ................................................................................................................................................ 16
5.21. Assembly of cable bolt (A) or dismountable conductor rod (B) .......................................................................................... 17
5.22. Reverse-controlled bushings with rope conductor ............................................................................................................. 18
5.23. Flat seal system ................................................................................................................................................................ 18
5.24. Ring seal system ............................................................................................................................................................... 19
5.25. Flange installation ............................................................................................................................................................. 19
5.26. Tightening sequence ......................................................................................................................................................... 19
5.27. Fastening sequence .......................................................................................................................................................... 20
2/38 | HLAB200456 | Operating instructions for AirRIP bushings

5.28. Flange earthing ................................................................................................................................................................. 20
6. Assembling................................................................................................................................................................................ 21
6.1. Evacuation of the transformer ........................................................................................................................................... 21
6.2. Ventilation and downtimes................................................................................................................................................. 21
6.3. Reference measurement No. 2 ......................................................................................................................................... 21
6.4. Voltage connection ............................................................................................................................................................ 21
7. Test tap and voltage tap ............................................................................................................................................................ 22
7.1. Measuring connection structure ........................................................................................................................................ 22
7.2. Measurement terminal purpose of use .............................................................................................................................. 23
7.3. Voltage terminal configuration ........................................................................................................................................... 24
8. Measurements of C1, C2, tan 1, tan 2 (reference n°1) .......................................................................................................... 26
8.1. Reference measurements No. 1 ........................................................................................................................................ 26
8.2. C1 and tan 1 measurement (reference n°1) .................................................................................................................... 26
8.3. C2 and tan 2 measurement (reference n°1) .................................................................................................................... 26
8.4. Reference measurement No. 1 overview .......................................................................................................................... 27
8.4.1. Capacity C1 and loss factor tan1 ..................................................................................................................................... 27
8.4.2. C2 & tan 2 (bushing with measurement terminal) ............................................................................................................ 27
8.4.3. C2 & tan 2 (bushing with voltage terminal) ...................................................................................................................... 27
8.5. Temperature-dependent correction factors for tan 1 & tan 2 ......................................................................................... 27
8.6. Temperature-dependent correction factors for C1 and C2 ................................................................................................ 28
8.7. Permissible tolerances ...................................................................................................................................................... 28
8.7.1. For bushings ≤ 145 kV....................................................................................................................................................... 28
8.7.2. For bushings > 145 kV ...................................................................................................................................................... 28
9. Measurements of C1, C2, tan 1, tan 2 (reference n°2) .......................................................................................................... 29
9.1. Reference measurements No. 2 ........................................................................................................................................ 29
9.2. C1 et tan 1 measurement (reference n°2) ...................................................................................................................... 29
9.3. C2 and tan 2 measurement (reference No. 2) ................................................................................................................. 30
9.4. Reference measurement No. 2 overview .......................................................................................................................... 30
9.4.1. Capacity C1 and loss factor tan1 ..................................................................................................................................... 30
9.4.2. C2 and tan 2 (bushing fitted with measurement terminal) ................................................................................................ 30
9.4.3. C2 and tan2 (bushing fitted with voltage terminal) ........................................................................................................... 30
9.5. Temperature-dependent correction factors for tan1 and tan2 ........................................................................................ 31
9.6. Temperature-dependent correction factors for C1 and C2 ................................................................................................ 31
9.7. Site-dependent correction for C1 ....................................................................................................................................... 31
9.8. Permissible tolerances ...................................................................................................................................................... 31
9.8.1. For bushings ≤ 145 kV....................................................................................................................................................... 31
9.8.2. For bushings > 145 kV ...................................................................................................................................................... 31
10. Maintenance.............................................................................................................................................................................. 32
10.1. Maintenance shedule ........................................................................................................................................................ 32
10.2. Bushing maintenance ........................................................................................................................................................ 33
10.3. Testing the connections with a thermal imaging camera ................................................................................................... 33
10.4. Cleaning the porcelain insulator ........................................................................................................................................ 33
10.5. Cleaning the silicone insulator ........................................................................................................................................... 33
10.6. Capacity and tan δ loss factor checks ............................................................................................................................... 33
10.7. Spare parts ........................................................................................................................................................................ 33
10.8. Replacement of bushings .................................................................................................................................................. 33
11. Dismounting (transport, repairs or disposal).............................................................................................................................. 34
11.1. Dismounting the bushing for transport, repairs or disposal................................................................................................ 34
12. Repair........................................................................................................................................................................................ 35

12.1. Bushing repairs ................................................................................................................................................................. 35
12.2. Porcelain insulator repairs ................................................................................................................................................. 35
12.3. Silicone insulator repairs .................................................................................................................................................. 35
13. Disposal .....................................................................................................................................................................................36
13.1. Special hazards during disposal ........................................................................................................................................ 36
14. Type designation ........................................................................................................................................................................36
14.1. Rating plate ....................................................................................................................................................................... 36

1. Safety information
1.1. Symbols and notes 1.2. Product safety
Warnings in these operating instructions point at particular Micafil capacitor bushings of types RTKF, RTXF, RTZF, RTF,
hazards and specify measures for avoiding them. There are three RTKG, RAKF, RTKK, DMB-OA, RAF, RTAK, RTIM, RMFF, RMF,
levels of warnings: RMI, … are produced according to the state of the art and the
recognized safety rules. Despite that, when handling the bushing
and improperly using it, hazards to the health and life of the user
or third persons, or damage to the bushing and other material
This safety sign warns of immediate danger. assets can occur.
If such notices are not observed, it can lead  The bushing must be used only in technically faultless state
to heavy injuries and even death. as well as in observance of the provisions and the operating
Additionally, material damage can occur. instructions, and with awareness of safety and hazards.
 Damaged bushings must be decommissioned and replaced.
Examples of hazards: electric shock, fire
DANGER hazard, explosion, poisonous gasses,
1.3. Personnel-related measures
slipping, working at height, impacts...
 The executing personnel as well as those who supervise the
work must have adequate training, have safety-related
knowledge in connection with the various activities, and work
accordingly.
 Personnel should trained and instructed concerning the
This safety sign warns of possible danger. If
planned works with the bushing based on the operating
such notices are not observed, it can lead to
instructions.
injury and/or material damage.
 The personnel that must be trained, taught or instructed, or
Examples of hazards: burning, skin, eye or the personnel that is in the process of obtaining general
CAUTION
hearing injury, tripping hazards... training, must work with the bushing under the supervision of
an experienced technical specialist in the field of high-voltage
equipment.
 For working at height, the corresponding guidelines must be
observed.
 Use compliant tools.
This symbol identifies important information
or points at risks that can result in material  Wear suitable PPE (personal protective equipment: helmet,
working clothes, safety shoes, gloves, goggles).
damage.
NOTE 1.4. Organizational measures

 Read the relevant chapters of the operating instructions
carefully and observe all safety and hazard instructions.
 This notice suggests a particular course of action.  Keep the full and readable operating instructions ready and
provide all-time access to it to the operating personnel.
 Observe the safety rules of the operator of the high and
medium voltage system and all the relevant provisions of the
This symbol indicates the tightening torque national and international safety authorities.
 Only authorize trained and instructed specialist personnel.
 Clearly determine, make known and observe the areas of
responsibility for the works with the bushing.
 Only the personnel that before the beginning of the work have
The structure of the warnings is as follows: read and understood the relevant chapters of the operating
instructions may be assigned for activities with bushings.
Type and source of hazard  Safety and hazard-conscious work must be inspected
regularly observing the operating instructions. Observing the
The possible results of not introducing the
5 rules for voltage-free work: Switch off, secure, test,
measures are put here.
earth/close-circuit, protect.
SYMBOLS  Dangerous conditions or actions to be
avoided are included here.
 Measures for avoiding the hazards are
located here.

2. Structure of the bushing
2.1. General structure

The AirRIP type series are dry, oil-free and capacitive-controlled Depending on the design, AirRIP bushings can be equipped
bushings. The main insulation body of the bushing comprises with a fixed conductor, dismountable conductor rod or a cable
bolt for rope conductors.
resin-impregnated paper (RIP). The conductive surfaces in the
The gap between the insulating body and the external insulator is
insulating body are used for capacitive field control.
filled with the dry MICAGEL filling, so that the bushings can be
The outdoor side is tightly sealed with a silicone or porcelain operated in any post-assembly position. Heavier bushings,
insulator, being thus protected against humidity¬. A vent screw is mostly 145 kV and larger, are limited to installation angles of up
brought to the flange of the bushing to be able to ventilate the to 30° from the vertical. The data in the dimension sheet are
transformer. The possible central pipe can also be ventilated with binding.
a vent screw mounted in the conductor. Threads located on the
flange can be used for mounting crane eyes or pushing the Micafil bushings are dimensioned and
bushing away from the transformer flange. A self-earthing designed for applications in mineral oil.
measuring connection is integrated in the flange, making possible
 For organic oils, please contact High
the measurement of the capacity and the loss factor of the
Voltage Components at ABB
bushing in the installed state.
NOTE Switzerland Ltd or your local ABB
partner for further information.
Current conductor terminal with central tube ventilation (air side)
Head with clamp for power conductor
RIP insulating body with capacitor control and central pipe
MICAGEL dry filling
Porcelain or silicone composite insulator (external insulator)
Flange with measuring connection and transformer ventilation
Measurement terminal
Lower part extension for current transformer
Oil-side shielding
Fig.1: Structure of an AirRIP bushing with cable bolt for rope conductors

3. Packaging and delivery
Prevention of reloading hazards, cutting 3.2. Reference measurement No. 1

injuries, electric shock, slipping and After the delivery, it is highly recommended that reference
tripping accidents measurement No. 1 for main capacity C1, capacity C2 and loss
 The work area must be marked and factors tan1 and tan 2 are used to determine is the bushing took
kept clear. up any humidity after transport (see Chapter 8).
 All the activities must be supervised by
a qualified person. 3.3. Repackaging
 The personnel should be trained for It must be made sure that the bushing and the blank insulating
the reloading activities. body of the bushing are packaged in the same way as for delivery
DANGER  The personnel should have with a plastic bag and a desiccant (incl. humidity indicator) to
appropriate training for work with protect them against humidity.
dangerous voltages (reference
measurement No. 1). For bushings that are repackaged without cable or conductor
 Observe weight data and markings for bolts, the opening of the conductor tube must be sealed on the
the center of gravity. air side of the bushing.
 Wear appropriate PPE
 For further information, please contact

High Voltage Components at ABB
3.1. Delivered state and reloading Switzerland Ltd or your local ABB partner.
NOTE
The bushings are sent in wooden transport boxes for protecting
them against damage. The lower part of the bushing is packaged
in a plastic bag, provided with a desiccant and possibly a humidity 3.4. Transport box
indicator to protect it from humidity.
Gross and net weight as well as dimensions are included in the
dispatch note.
In the delivery, the cable bolt or conductor rod is installed in the
bushing.
The center of gravity is normally market on the transport box if it
is longer than 2 meters and if the center of gravity is not in the
middle.
Fig. 1: Packaging, delivered state, reloading
 For every packaging type, it must be

ensured that it is fully intact after
transport.
 If the humidity indicator has turned pink
NOTE => see Storage Recommendation Tab 1.
(see Chapter 4.1).

4. Storage
Prevention of reloading hazards, cutting 4.1. Storage

injuries, electric shock, chemical hazards, Insulating bodies of bushings are dry after their production. These
slipping and tripping accidents insulating bodies are made of resin-impregnated paper (RIP)
 The work area must be marked and which could absorb moisture over the time. Therefore, the
kept clear. recommendations in the Tab.1 must be observed.
 All the activities must be supervised by
a qualified person. For storing the bushing, the storage location (protected from rain,
 The personnel should be trained for outdoor or dry indoor location) and the storage period must be
the reloading activities. taken into consideration.
 The personnel should have
DANGER appropriate training for work with  When stored, the bushing must be
dangerous voltages (reference completely sealed in humidity-protective
measurement No. 1). packaging.
 Observe weight data and markings for  If the humidity indicator has turned pink, see
the center of gravity. NOTE Storage recommendations Tab. 1.
 Wear appropriate PPE.
Storage duration Outdoor, protected against rain Indoor space, dry (not condensing)
Up to 6 months In original box, packed with PE tubular film. In original box and original packaging.
Recommended: Additional humidity
protection of the body with a second
Polyethylene (PE) tubular film and desiccant
Up to 24 months No possible => Risk of irreparable damage In original box and original packaging.
Only in dry rooms (relative air humidity <50%) at a temperature that is as constant as
possible.
Conduct regular inspections (at least once a year)
If the humidity indicator inside the sealed PE foil colors itself in the pink direction, at least
an equal quantity of desiccant units must be replaced. Within 24 hours, the indicator will
change back in the blue direction (relative air humidity < 40 %).
Long-term storage, No possible => Risk of irreparable damage Protect the unshielded parts of the bushing in the storage container:
more than 24 Bushing in protective layer material (PETP/Alu/PE) together with desiccant:
months - Conduct regular inspections (at least once a year)
- If the humidity indicator inside the sealed PE foil colors itself in the pink direction, at
least an equal quantity of desiccant units must be replaced. Within 24 hours, the
indicator will change back in the blue direction (relative air humidity < 40 %).
- For bushings that are stored for more than a year, we highly recommend a reference
measurement No. 1 (see Chapter 8).
- Desiccant amount/air conditioning: 2½ TME/m2 (moderate) and 25 TME/m2 (extreme)
- TME/m2: Desiccant units per m2 of the barrier layer surface.
Desiccant according to the standard:
1 Unit (DIN 55473A) = 1 Unit (MILD 3464 E) = 1/16 Unit (NF H-320 & 321)
Bushing with oil storage container:
- Conduct regular inspections (at least once a year)
- The oil level should be levelled between the 2 oil sight glasses (see Fig. 3).
Tab. 1: Storage recommendations

4.2. Storage container with oil (variant 1) 4.4. Procedure after incorrect storage
Prevention of dangers related to handling If there is suspicion that the insulating body has taken up
chemicals, explosions, burns humidity, it can be checked using a reference measurement No.
1 (see Chapter 8). If there is a deviation from the work report
 The transport box should be protected
found, a subsequent drying can be conducted in consultation with
against heat during the storage (to avoid a
DANGER the High Voltage Components division at ABB Switzerland Ltd. In
pressure rise in the container).
most cases, the bushing can be made operational again.

For the long-term storage, it is recommended to design protection High Voltage Components at ABB
with an oil-filled storage container. In the normal case, it ensures Switzerland Ltd or your local ABB
the immediate availability of the bushing (e.g. reserve bushing). partner.
NOTE
A yearly inspection of the oil level is recommended.
Fig. 3: Container with oil
1 High level | 2 Recommended level | 3 Low level
4.3. Storage container with PETP-Alu-PE composite

film (variant 2)
This long-term packaging comprises an inner and an outer
packaging. The inner packaging (2) is a PE foil and is placed
directly over unprotected parts of the bushing, containing a
desiccant to protect against humidity. The outer packaging (1) is
a PETP-Alu-PE composite foil that covers and seals the entire
bushing. In addition to the desiccant, the external packaging also
includes a humidity indicator in order to provide humidity
monitoring. A yearly inspection of the humidity indicator is
recommended.
Fig. 4: Long-term packaging with Al-composite film.
1 PETP-Alu-PE composite foil | 2 PE foil | 3 Desiccant

4 Humidity indicator sight window

5. Assembling
Prevention of reloading hazards, cutting

injuries, electric shock, chemical hazards,
falling, slipping and tripping accidents
 The work area must be marked and kept
clear.
 All the activities must be supervised by a
qualified person.
 The personnel should be trained for the
reloading activities.
DANGER  Appropriate climbing aids and
supporting structures should be used.
 The personnel should be authorized to
work at height.
Fig. 5: Recommended distance A from earthed parts (e.g. transformer
 The personnel should have appropriate
wall)
training for work with dangerous
voltages (reference measurement No. Recommended minimal distances A to the earthed parts of the
1). transformer [mm]
 The protective cover of the silicone AC test voltage

Ur
insulator should be laid out until the Diameter of the shields Ø [mm]
commissioning in order to avoid partial [kV] [kV] Ø109 Ø134 Ø180 Ø160 Ø180 Ø230 Ø292
discharges trough fingerprints. ≤52 ≤105 80 95 - - - - -
NOTE
140 90 105 - 120 - - -
72.5
160 100 105 - 125 - - -
185 115 115 - 130 130 - -
123
5.1. Recommended distance from the transformer wall 230 145 145 - 145 145 - -
The bushings are developed and tested for mineral oil 275 - 170 - 170 170 - -
145
applications. The field strengths in oil in the lower part of the 310 - 200 - 200 200 - -
bushing depend on the form of the surrounding parts as well as 325 - 210 - 210 210 - -
170
on the transformer oil. 365 - 230 - 230 230 - -
245 460 - - 300 300 300 - -
The corresponding gaps (A) to the earthed structures under 300 510 - - - - - 330 330
standard conditions are listed as a guideline in the following Tab. 630 - - - - - - 450
420
2. This concerns the oil-side ends of the bushings according to 680 - - - - - - 500
the data of the dimension sheet for the bushing. Due to framework 750 - - - - - - 550
550
conditions, additional insulation measures and/or greater 790 - - - - - - 600
distances can be necessary. If necessary, the distance can also Tab. 2: Recommended distances A from earthed parts
be reduced.
Non-insulated edges may only appear in the permitted area and 5.2. Lifting the bushing
should have a Rmin. = 5 mm.
Smaller bushings (< 20 kg) can be removed by hand from the
wooden crate, larger bushings require textile slings and lifting
 A possible current transformer must be
means (crane, hoist, etc.). To move the bushing from the
not be longer than L6 (see Fig. 5 and
horizontal to the vertical position, two textile slings (3) shall be
dimension sheet of the bushing), as the
fastened on each lifting eye (1) mounted on the flange of the
field is disrupted, and a destruction of
bushing, then put through the lifting eye (2) mounted on the head
CAUTION the bushing is possible.
of the bushing, and connected to the hook of the first lifting gear.
A third textile sling (4) must be fastened too on each lifting eye (1)
and connected to the hook of the second lifting gear. This lifting
configuration allows to install the bushing in the transformer turret
at a certain angle or vertically after removing the textile sling (4).

Three different conductor types are available. All with a cable bolt
for conductor rope, with dismountable conductor rod or fixed
conductor variant, depending on the order.
Fig. 6: Crane eye on flange and head
(A) (B) (C)

Cable bolt Dismountable Fixed conductor
for conductor conductor rod
Fig. 8: Details of the lower part of a bushing (schematic)
If any, future conductors, and contact terminals on the winding

side of the transformer should be oversized to avoid overheating
in the area of terminal connections.
In order to maintain sufficient and prolonged contact pressure,

strong spring washer should be placed under the screws. In order
to avoid disengagement through constant vibrations, a screw lock
Recommended tightening torque for (1) and (2)
should be used.
M10: 7 Nm
M12: 18 Nm
The connection details can be found in the dimension sheet for
M16: 42 Nm
the bushing.
Fig. 7: Fastening the bushings

 Avoid magnetic screws here.
 The surfaces of the terminals may not be
 The connections or the shield must not damaged.
be used as a suspension point for NOTE
protection against damage.
 Do not damage the silicone or porcelain
insulator during lifting operations.
No rigid connection
 If there is a shield with dismountable
spacing sleeves on the head of the  Future conductors must not be made rigid
bushing, the shield as well as the (above and below), as the bushing must
NOTE spacing sleeve should be dismounted for not pick up or transmit any movements or
lifting (see Fig. 16). Lifting eyes are vibrations.
screwed directly onto the head of the  The use of flexible terminal connections
NOTE makes it also possible to avoid vibrations
bushing.
and movements of the transformer
affecting nearby parts.
5.3. Reference measurement N°1

Before the installation, reference measurement No. 1 for main
capacity C1, capacity C2 and loss factors tan1 and tan 2 should
be obtained (see Chapter 8) to establish a reference point for later
measurements and also to determine if the bushing took up any
humidity after transport and/or storage.
5.4. Conductor and terminal (A, B, C)

When connecting the bushing a solid conductive contact surface
should be taken into account to minimize the influence of possible
contact resistance (see Chapter 5.17).

Preparing the connection
 The feed and discharge lines, including
their connection elements, such as
terminal lugs, terminals or additional 2
1
connectors, must be dimensioned in a way 5
that no heat is brought to the connections
of the bushing.
 The connective surfaces should be flat,
NOTE
even, clean and not unprocessed. The
contact surfaces should be lubricated with
contact grease and be tightened with
specified tightening torques.
5.5. Dismounting the cable bolt (A) or conductor rod (B)

Depending on the order, the bushing is delivered with a cable bolt
or a conductor rod. Before the bushing can be installed on a
transformer, it is necessary to solder a conductor wire in the cable
bolt or conductor rod.
3
In order to be able to solder the conductor rope, the cable bolt or
conductor rod must be dismounted and processed. Bushings with
a conductor rod that, oil-side, has a flat terminal, need not be 4
processed.
In order to remove the cable bolt or conductor rod, it is

recommended that the vent screw is replaced with an eyebolt. A
rope is attached to the eyebolt, preventing the slipping out of the
cable bolt or conductor rod during the dismounting. Recommended tightening torque (2)
M12: 18 Nm
As is shown in Fig. 9, first, the clamp screw (3) is loosened and
the clamp halves (4) are unfolded. Afterwards, the cable bolt or
conductor rod (including the sealing sleeve) is removed, the rope
is released, and the sealing sleeve is pulled off. Fig. 9 Steps for dismounting the cable bolt/conductor rod.
1 Vent screw | 2 Eyebolt | 3 Clamp screw
4 Clamp halves | 5 Sealing sleeve | 6 Groove
 Bushings with a central tube diameter of
26 mm additionally have a screwed-on
terminal on the cable bolt.
 Bushings with a conductor rod (B) that,
 The cable bolt or conductor rod must
oil-side, has a flat terminal, need not be not be scratched.
processed.
 Before the bushing can be installed on a CAUTION
transformer, it is necessary to solder a
NOTE conductor wire in the cable bolt. In order 5.6. Connection cable bolt/conductor rope (A)
to be able to solder the conductor rope,
the cable bolt must be dismounted and The bushings with conductor rod have an oil-side flat terminal
processed. and, thus, need no processing.
The conductor rope may be soft soldered or brazed to the cable

bolt. The temperature necessary for the soft soldering must not
A slipping out of the cable bolt or conductor exceed 450 °C, to avoid possible annealing of the cable bolt. The
rod is possible. soldering must be performed carefully in order to ensure optimal
contact. For brazing, the sealing and the terminal must be
 Secure with eyebolt and wire.
sufficiently cooled. Silver solders with melting temperatures of
NOTE
under 700 °C must be used here.

 Before the soldering, the vent screw and In order to make sure that the drilling is not performed too deeply,
all the seals must be removed from the the following rules are recommended: Maximum drilling depth (3)
cable bolt. is the same as the length of the cable bolt (4) minus 20 mm.
The diameter of the power conductor should be at least a half of
Damage to the seal system can lead to the tube diameter Ø d3 (6). The oil supply may not be impaired
NOTE malfunctions in the bushing or the in the central bushing opening and in the open area of the shield.
transformer.
5.7. Split conductor rod
If the bushing is equipped with a split conductor rod (see Fig. 11),
the lower part of the conductor rod must be screwed to the upper
With an appropriate tool and an adjustment of the cable bolt, a
part of the conductor rod after soldering. When installing, make
pressing of the cable bolt is possible as an alternative.
sure that the screws are alternately tightened. The mounting
screws can vary depending on the size of the conductor rod.
The bolt is delivered unprocessed. For this reason, a hole suitable
for soldering the conductor rope must be drilled in the bolt. The
diameter of the drilled hole must be adjusted to the diameter of
the rope. Whenever possible, the bore design without a peak is
recommended. The recommended maximum drilling depths and
hole diameters for the standard cable bolt are provided in Fig. 10
and Tab. 3.
 Do not drill in the ventilation channel.
NOTE
Recommended tightening torque (1)

M8: 12 Nm
M10: 25 Nm
M12: 45 Nm
Fig. 11: Split conductor rod screw joint
1 Screws and spring washers | 2 Upper part of the conductor rod | 3

Lower part of the conductor rod
5.8. Rope conductor insulation (A)

To prevent partial discharges caused e.g. by switching transients
between the rope conductor and the central tube of the bushing,
the rope conductor must be wrapped in at least 1 mm of insulation
material. The use of aramide paper (heat-resistant) is
recommended).
Fig. 10: Processing on cable bolt.
Turned (left) and drilled (right) hole.
1 max. hole diameter | 2 cable bolt diameter
3 max. drilling depth | 4 cable bolt lower part length |
5 ventilation channel | 6 diameter d3 (see bushing dimension sheet)
Tube diameter Max. hole diameter Cable bolt diameter Max. drilling
d3 (6) (1) (2) [mm] depth
[mm] [mm] (3)
[mm]
40 35 38 (4) minus 20
50 40 45 (4) minus 20
Fig. 12: Rope conductor insulation. At least 1 mm insulation material
65 55 60 (4) minus 20
thickness
80 70 75 (4) minus 20
100 90 95 (4) minus 20
Tab. 3: Recommended maximum drilling depth and hole diameter for a
standard cable bolt

5.13. Shield with spring-loaded thrust piece
 If the insulation material thickness is
This shield is longer compared to shields for rope applications, for
too high, the bushing can overheat.
covering exposed edges at the terminal inside the shield.
CAUTION
The shielding is available for voltages ranging from 24 kV to
245 kV (optional, depending on the bushing type). The shielding
can be mounted on the mounting ring and dismounted from it at
5.9. Insulation for the dismountable conductor rod (B)
the factory.
For a dismountable conductor rod, spark formation is avoided
through insulating centering rings that separate the conductor  In order to dismount the shield, the 3 spring-loaded pressure
rod from the central tube. pieces must be loosened with an Allen wrench (not
completely: unscrew it enough to keep them mounted on the
5.10. Fastening the shield shield).
Depending on the execution of the bushing, fixed or dismountable  The shield can be shifted upwards or downwards.
shields are used and mounted on the end of the bushing. These  The terminal is freely accessible and can be connected to the
prevent the excessive stress on the transformer oil and simplify connection pieces. It must be made sure that the contact
the structure of the power conductor insulation under the bushing. resistance is kept as low as possible.
 Shift the shield back to its original position and place it to
The originally delivered shields are dimensioned with the help of match the three threaded holes. The spring pressure pieces
modern methods and have a high-value, solid insulation layer on (2) can be screwed on again.
the surface.
 Please observe installation recommendations (see Tab. 2).
5.11. Bushing without shield

2
Due to the resulting field strengths, bushings up to and including
72.5 kV do not need any shielding. For this reason, no further 1
measures are needed on the bushing.
5.12. Shield for rope application

This shield is explicitly dimensioned for rope applications,
because of which it is considerably shorter than the other types 3
of shields.

M8: 4 Nm
Fig. 13: Shield for rope application
The shielding is available for voltages ranging from 24 kV to

245 kV (optional, depending on the bushing type). The shield is
Fig. 14: Shield with spring-loaded thrust piece
caulked with the supporting tube at the factory.
1 Epoxy-covered shield | 2 Spring-loaded pressure piece | 3 Mounting
ring
 The rope conductor must not touch the
shield - not even due to vibration or other
displacements.  Do not let parts fall into the transformer
 The shield for rope applications must not tank.
NOTE be dismounted.  The fastening ring at the connections
NOTE must not be dismounted.

5.14. Shield with bayonet catch
This shielding is available for voltages ranging from 300 kV to  Do not let parts fall into the transformer
550 kV and is suitable for all conductor types. The shielding can tank.
normally be mounted on the mounting ring and dismounted  The fastening ring at the connections
from it at the factory. NOTE must not be dismounted.
The fixture ring is screwed onto the conductor and secured with
a locking screw. The shield has three mounting holes and is
5.15. Head shield from 420 kV
affixed with springs via a bayonet lock.
Bushings of 420—550 kV have an air-side shield for preventing
 Dismounting of the shield from the mounting ring: press the corona discharges.
shield lightly against the bushing, rotate it (approx. 12°), then The air-side shield can be mounted on the head fitting with the
pull it off. delivered screws and washers. Threaded holes are provided for
 The shielding can temporarily be inserted under the bushing this purpose on the head fitting. Depending on the bushing type,
with a power cable. two spacing sleeve variants are provided: (See Fig. 16 and
 The terminal is then freely accessible and can be connected details A / B).
to the connection pieces. It must be in any case made sure
that the contact resistance is kept as low as possible.
 Bring the shield back to its original position. It must be made
sure that the 3 holes are positioned over the hexagon socket
screws. The screws are inserted through the holes, and with
some pressure against the bushing, the shield can be turned
in the original secure position (approx. 12°) until it locks in
place again with spring load.
3
2
6 4
5
Fig. 16: Mounting and dismounting of the head shield.

1 Screw | 2 Washer | 3 Head shield | 4 Head fitting | 5 Welded spacing
sleeves (height= 10mm) | 6 Dismountable spacing sleeves (height>
10mm)
1

M6: 5 Nm
Fig. 15: Shield with bayonet catch.

1 Epoxy-covered shield | 2 Mounting ring | 3 Locking screw | 4 Hexagon
socket screw | 5 Spring
6 Washer
M16: 35 Nm

Detail A: Head shield with welded spacing sleeves (height = 10 mm)
5.17. Preparation of the terminal surface (A, B, C)

The connecting to the bushing should always be made with
special care with respect to the reduced contact resistance.
Before the connection to the silver-plated contact surface, the

protective film (grease) must be removed with a cloth. No cleaning
agents/solvents may be used.
Contact surfaces without painting must first be treated to remove

the layer of oxidation. A fine steel brush, abrasive paper or similar
can be used for this purpose. The contact grease for electric
connection surfaces is applied onto the entire surface; the surface
is then brushed crosswise until the entire oxide layer is removed.
Recommended tightening torque (1) The oxide-free surface must then be cleaned with a cloth, and
M12: 16 Nm fresh contact grease is applied.
5.18. Cleaning of the bushing surface and the interface

The sealing surfaces on the impregnation of the transformers and
Detail B: Head shield with dismountable spacing sleeves
on the bushing, flange must be free of corrosion and dirt, and have
(height > 10 mm)
a high surface texture (max. Ra 3.2). The cleaning of these
surfaces takes place by soaking a lint-free cotton cloth in the
cleaning liquid and wiping the sealing surfaces.
 Do not let parts fall into the transformer
tank.
5.19. Installing of the bushing
NOTE
 The bushing should reach the ambient
temperature before the installation to
5.16. Fixed conductor (IEEE) avoid condensation on its surface.
NOTE
The connection details can be found in the dimension sheet for
this bushing. These bushings need no additional installation work
and can be connected directly to the oil-side terminals.
Only now, the bushing can be brought to the final position. First,
the bushing is lifted with lifting gear and then slowly lowered on
the flange side until the desired position is reached.
 The use of the possible thread for the lifting eye is always
the best option to lift the bushing and install it.
 After the installation, the possibly used lifting eyes must be
removed again.
 It is recommended that the corresponding threads for the
lifting eyes are closed, e.g. with blind plugs.
5.20. Damage during installation

The insulator, whether a porcelain or a silicone variant, is
recommended for avoiding impacts and stress concentration. Any
Fig. 17: Lower part of the bushing use of tools that can cause such damage (e.g. chains, hooks)
1 Base terminal (according to IEEE C57.19.01) should be in any case avoided. For this reason, textile ropes must
be used.
 The base terminal must not be

dismounted to avoid damaging the
internal components.
NOTE

 When installing horizontally oriented
bushings in the desired position, these
must not be propped against their lower
body end. Specifically, a possibly
available electric shield must not be in
any way used for supporting or
suspending.
 During the lowering, the bushing may not
touch any nearby parts or walls, as the
insulating body or any other part can be
damaged as a result.
 The bushing may not be lifted with a rope
loop, as it can slip out.
CAUTION  The suspension rope must not touch the
measurement terminal, as the potential
connection can be broken off due to
mechanical damage.
 The thread of the vent screw may not be
used for mounting the lifting eye (this
does not apply to Chapter 5.21).
 The unshielded area of the bushing (oil-
side insulating body) must not be
scratched.
Fig. 18: Inserting the conductor rope or conductor rod
After inserting the conductor system, the sealing sleeve must be

5.21. Assembly of cable bolt (A) or dismountable securely placed, only then can the clamping halves (1) be closed
and tightened (3). Make sure that the grooves of the clamping
conductor rod (B)
halves grip securely into the grooves of the conductor system (2).
For retracting the conductor, an eyebolt can be screwed onto the
frontal thread of the cable bolt or conductor rod. This thread It is possible to adjust the cable tray/conductor bar in the vertical
direction by 10 mm.
functions at the same time as a vent screw of the central tube.
Finally, the eye bolt (4) is removed, the thread of the ventilation
Before the suspension rope is inserted through the central tube, screw (5) is lightly lubricated with connecting paste (e.g.,
the sealing sleeve with the inserted O-ring gaskets must be KLÜBER ALTEMP Q NB 50®) and screwed. Care must be taken
mounted on the central tube. In order to avoid damaging the O- to ensure that the sealing surfaces are cleaned.
ring gaskets of the sealing sleeve on the tube or bolt when
inserting, the gliding surfaces must be lubricated with an acid-
free grease. The gap between the bolt and the sleeve must be
lubricated with grease.
The cable bolt together with the soldered rope conductor or

conductor rod can now be drawn in from below through the
bushing with the help of the eyebolt and a rope.
 Silicone O-ring gaskets that are used for

temperatures < - 30 °C may not be
lubricated with silicone grease.
NOTE
Recommended tightening torque for (5)

M12: 20 Nm
Fig. 19 Steps for assembling the cable bolt/conductor rod.

1 Clamp halves | 2 Groove | 3 Clamp screw | 4 Clamp halves | 5 Vent
screw
If the bushing has a head shield (Ur ≥ 420kV) it must be

mounted after the assembly of the clamping system (see
chapter 5.15)

 If the vent screw is not mounted
Conductor insulation min. 1 mm (in
correctly, water can get into the
transformer. the tube)
 To avoid damage to the grooves (2),

Oil gap (see Table 4)
the cable bolt or conductive rod must
NOTE be carefully adjusted to the grooves
of the half clamps (1). Transformerboard strips
2/3 voltage
Conductor
5.22. Reverse-controlled bushings with rope conductor
Conductor
insulation
For reverse-controlled bushings, the oil side of the insulating
Extension of the rope conductor
body (IKP) is designed specifically for applications in the narrow
before the bend (L1/2)
space of the transformer dome. In this case, 2/3 of the voltage
that is brought from the surface of the oil-side IKPs is still at the
lower end of the bushing. The other third of the voltage
(between the IKP end and conductor) must be borne through
the insulation of the rope conductor.
Fig. 20: Lower part of a reverse-controlled bushing with conductor rope
The insulation of the conductor rope must be removed upwards

to match the opening diameter of the oil-side IKP. A minimal oil 5.23. Flat seal system
gap between IKP and the insulation of the rope conductor must, The central position of the flat seal is located directly under the
however, be ensured. This also ensures that the oil can flow hole circle of the flange plate and must be on the both sides of the
into the tube of the bushing. The recommended minimum oil pitch circle to avoid flange deformation. The flat seal must be
gap is provided in Tab. 4 for the different nominal voltages. provided with the appropriate hole pattern for the flange. During
installation, the flat seal must be put through the mounting bolts
Recommended minimum without tensile or compressive stress. If the flat seal is warped by
Ur [kV]
oil gap [mm] the mounting bolt, the holes must be drilled out to avoid any stress
on the flat seal.
≤ 123 3
De 145 à 170 5
≥ 245 10
Tab. 4: Recommended minimum oil gap between the insulating body
and the insulation of the rope conductor
To ensure the concentricity of the conductor, the axial insertion of

Trafoboard stripes on the conductor insulation must always be
observed.
Reverse-controlled bushings are designed for use without

shield.
 Due to the remaining third of voltage

between the lower part of the IKP and
the conductor, the insulated conductor
must be moved axially for a certain
distance before it can be bent. To
determine the minimal distance, subtract
the current transformer length (L6) from
NOTA the oil-side length of the bushing (L16)
and divide this value (L1) by two: L1/2
(see Fig. 20 and dimension sheet for L6,
L16 and L1).
Fig. 21: Flat seal system

1 Flat seal | 2 Flange | 3 Transformer / switchgear / wall
4 Hole circle diameter | 5 Sealing surface
6 Washer and nut

 If available, it must be made sure that the 5.26. Tightening sequence
ventilation hole is not blocked by the flat When the bushing flange is put in place, the screws/nuts must be
seal. first screwed as far as possible by hand. The flange fastening
 The flat seal (1) must be installed over must be performed according to the following tightening
the hole circle until the flange external sequence and Fig. 23:
NOTE side (2) (Ø D4), avoiding any shearing
forces or damage. 1. Light fastening with wrench.
2. Fastening with 50 % of the recommended torque.
3. Fastening with 100 % of the recommended torque.
5.24. Ring seal system 4. Additional turn for control, with 100 % of the recommended
torque.
The position of the O-ring gasket is inside the hole circle of the
5. If possible, repeat step 3 after 24 hours, as the clamp force
flange plate, and inside the specified sealing surface (shown on
can decrease in the first 24 hours.
the dimension sheet of the bushing).
 In order not to overlook any screws/nuts, the tightened

screws/nuts must be marked with a felt pen.
Fig. 22: O-ring gasket system

1 O-ring gasket | 2 Flange | 3Ttransformer / switchgear
4 Hole circle diameter | 5 Sealing surface | 6 Washer and nut
 For systems that must be operated

under pressure, an O-ring gasket
system must be provided.
 The contact area of the flange plate (5)
as well as the surface (3) should have
NOTE
no steps to avoid shearing forces or
damage.
5.25. Flange installation

Not damaging the sealing surface
 When installing the flange, make sure
that the sealing surface is not damaged.
 If the lifting eyes are on the lower side of
the flange, these must be dismounted
before the flange is tightened.
NOTE  For transformers, the contact area must
have a flatness tolerance of no more
than 0.3 mm.

5.27. Fastening sequence
The sequence to be maintained is defined in the following
sectional drawings for the different hole patterns:
Fig. 23: Fastening sequence for different flange models
5.28. Flange earthing

The bushings have one or two threads on the flange for its
earthing.
 The flange of the bushing must always

be earthed via a secure connection
after installation.
NOTE

6. Assembling
Prevention of reloading hazards, electric Recommended tightening torque

shock, chemical hazards, falling, slipping M12: 20 Nm
and tripping accidents
 The work area must be marked and kept Bushings with a fixed conductor can only be ventilated at the
clear. flange. During the installation of the bushing, it must already be
 All the activities must be supervised by a made sure that the flange ventilation and the terminal of the
qualified person. Buchholz relay is at the highest position as possible.
 Appropriate climbing aids and  After the ventilation and before the
DANGER supporting structures should be used. commissioning of the bushing, it must be
 The personnel should be authorized to checked that all the vent screws are
work at height. tightened.
 The personnel should have appropriate  Furthermore, the indentation the vent
training for work with dangerous screw in the cable bolt/conductor rod
voltages (reference measurement No. should be filled with a flexible silicone
2). paste.
NOTE
 Wear appropriate PPE.  An initial set-up of the phase-earth
voltage must take place after operating
for at least 12 hours after completing the
filling of the transformer with oil.
6.1. Evacuation of the transformer
6.3. Reference measurement No. 2
The use of a vacuum when filling the transformer is not
problematic for the installed bushing. If the transformer oil is After the installation and before the voltage is fed, reference
drawn in under vacuum, a following ventilation for the bushing or measurement No. 2 for main capacity C1, capacity C2 and loss
the transformer dome is normally not necessary. However, there factors tan 1 and tan 2 should be obtained (see Chapter 9).
is an exception in the bushings that protrude over the expansion
vessel. For these, ventilation via the screw provided frontally on
the cable bolt/conductor rod is recommended. 6.4. Voltage connection
Explosion, fire
 An initial set-up of the phase-earth  The voltage connection should take
voltage must take place after operating place only after the nominal values for
for at least 12 hours after completing the C1 and tan 1 are successfully
NOTE filling of the transformer with oil. confirmed as implemented.
 During the initial switch-on, as well as
6.2. Ventilation and downtimes DANGER when switching back on after a revision,
Before each first-time commissioning, the central bushing tube all personnel should be removed from
must be ventilated via the screw located frontally on the cable the site of the installation for at least 2 h.
bolt/conductor rod. As a result, the transformer oil in the central
tube rises to the corresponding elevation of the transformer
expansion vessel. If the bushing is not mounted vertically, the
transformer dome should be ventilated with the vent screws on  Whenever possible, a measurement of
the flange of the bushing. C1 and tan  should take place with the
high-voltage conductor suspended,
The thread of the M12 vent screws of the cable bolt/conductor rod especially if other transformer loads the
and flange should be lightly lubricated with connection paste (e.g., network with harmonics.
KLÜBER ALTEMP Q NB 50®) and tightened as follows.  The tan  values must always be
NOTE calculated for the reference value at
20 °C.

7. Test tap and voltage tap
7.1. Measuring connection structure

The measuring connection at capacitance-graded bushings gives
access to the outermost control layer of the bushing. With it, the
characteristic values of a busing (C & tan) can be measured
using a suitable measuring device, e.g Omicron CPC 100, Tettex
28xx or Doble. In operation, this covering must be connected to
the flange via the spring contact available in the measurement
terminal, and thus be earthed, or be connected to earth via an
accordingly large capacity, to avoid voltage of more than 300 V or
1.5 kV (see Chapter 7.2).
Fig. 25: Measurement terminal. Connecting coupling
Sealing
Spring
Protective cover
Figure 26: Measurement terminal. Transition coupler (N or UHF

Fig. 24: Measurement terminal in operating state, earthed with
connector)
protective cover
The structure of the measurement terminal provides automatic

earthing of the measurement covering via the flange. This Transition coupler N or UHF (online
earthing can be opened by full insertion of a 4 mm connecting measurement)
coupling (see Fig. 25) or by connecting a transition coupler (see
 Cable wiring must be controlled regularly
Fig. 26). If there is no measurement performed at the
for correct contact: cable oxidation and
measurement terminal, it must be closed with the provided
cable breakage lead to bushing failure. For
protective cover and an intact seal, to avoid weather effects. CAUTION
this reason, permanent reliance on online
measurements is not preferable.
The thread of the protective cover should be lightly lubricated with
connecting paste (e.g., KLÜBER ALTEMP Q NB 50®) and then
tightened as follows. Measurement terminal tampering
Recommended tightening torque  Using screwdrivers or other tools to

The protective cover must be screwed by hand until tamper with and push away the earthing
the housing, gasket and cover come into direct spring is strictly forbidden (see Fig. 27).
contact. Then an additional minimum rotation of 1/8
should be applied to ensure the compression of the flat  Use a connecting coupling or the
CAUTION
gasket. transition coupling for measurement
(see Fig. 25 and 26).
The gasket must be checked as the connection must be watertight

to prevent moisture penetration.

Fig. 27: Measurement terminal. Any manipulation prohibited
Protective cover
 The bushing must never be commissioned
DANGER
without installing the protective cover on
the measurement terminal or connecting a
monitoring system.
 The correct function of the spring contact
in the measurement terminal must always
be tested before locking the bushing.
If this is not observed, the bushing or the
transformer can suffer severe damage. Under
unfavourable conditions, heavy personal
injuries are also not out of the question.
Life-threatening voltages
 The described measurements take place
under dangerously high measuring
voltages. The local safety regulations
DANGER must be observed. 1 Bushing C1: Capacity - high-voltage conductor tapping
layer
C2: Capacity - tapping layer flange
2 Reference condenser CN
3 Schering bridge R3, R4, C4: Bridging elements
7.2. Measurement terminal purpose of use
N: Null indicator
The measuring connection serves for the measurement of the C1 = CNR4 / R3; tan δ 1 = R42πfC4
main capacity C1 of the bushing and the loss factor tan. The most
common test circuit is shown below. Fig. 28: Measuring setup
The measuring terminal can also be used to perform voltage and

partial discharge measurement as part of monitoring. It must be
made sure that the maximum permissible continuous voltage
between the measurement surface and flange is 300 V or 1.5 kV
(= U2). Depending on the voltage and capacity of the bushing, the
power put over the measurement terminal can be approx. 5...
10 VA. To limit voltage, an impedance must always be added in
parallel to C2. In most cases, this is capacity Cz, that must have
a capacity of at least:
 UN 
Cz min  C1    1  C2
 3 U 2 
The values for C1 and C2 can be found in the test report for the
bushing in question.
The capacity Cz must be used to set voltage U.
 U 
C z  C1   N  1  C2  C z min
 3 U 

To remove active power P from the bushing, an ohm resistance capacities, as well as in the connected impedance. As the
Rz must be switched on in parallel to C2. The P power is capacities are temperature-dependent, a measurement precision
produced as a result of: of about 5 % must be taken into account.
P
U N / 3 
2

1 7.3. Voltage terminal configuration
Rz a  b2
2 The bushing can be provided with a voltage terminal described in
the IEEE C57.19.01 standard. The terminal (pin) is connected to
an internal high-voltage foil of the capacitor. In normal operation,
with: the terminal is earthed through a spring inside the cover.
C2
a 1
C1 Sealing
and
Spring
1
b
C1  Rz Protective
cover
A condition in this case, however, is that U  U2. This can be

controlled with:
Fig. 29: Voltage terminal in operating state, earthed with protective
U / 3 cover
U  N2 2  a 2  b 2  U 2
a b If the voltage terminal is used with a monitoring system, the
voltage between the terminal and the earth must be limited to 8
kV. Additionally, if there is monitoring, the housing of the voltage
Secondary voltage U2 (300 V or 1.5 kV)
terminal must be filled with transformer oil. To do this, remove the
 When using the transition plug type N filling plug on the top side of the housing and fill it with clean dry
or type UHF by ABB, the secondary transformer oil (Fig. 30). Fill until 5 mm below the filling chamber
voltage must be limited to 300 V. to reserve space for expansion (Fig. 31). The thread of the filling
 When using an external transition plug, plug should be sealed with an appropriate sealant and locked
the secondary voltage must be limited back with the filling plug.
NOTE
to 1.5 kV.
Primary voltage U1 (12 kV)

 The measurement voltage must not
exceed the phase/earth voltage of the
bushing.
Voltage at the measurement terminal

Without a connection of additional
impedance, the voltage at the measurement
terminal is always higher than 300 V or 1. kV
for the C1 and C2 values.
 For this reason, for a bushing under

CAUTION voltage, the measurement terminal must The thread of the filling screw should be lubricated and bolted with
be conductively connected to the flange connecting paste (e.g., KLÜBER ALTEMP Q NB 50®).
(protective plug installed) or through a
Recommended tightening torque
connected additional impedance, to limit
M10: 12 Nm
the voltage to 300 V or 1.5 kV.
M12: 20 Nm
Fig. 30: Filling the voltage terminal with transformer oil for monitoring
The achievable measurement precision during the voltage system using
measurement depends on the changes in the C1 and C2

The voltage at the terminal of the
monitoring system must not exceed 5 kV
5 mm during loss factor and capacity
measurements
Not observing this provision can lead to
DANGER
personal injuries, including fatal personal
injuries, as well as material damage.
Fig. 31: Voltage terminal filled up to 5 mm under the filling chamber
The voltage terminal can also be used to determine the loss factor
and capacity of the bushing online. A connection to the terminal
can be implemented with a suitable connector. The voltage
between the terminal and the earth must be limited to 5 kV, as the
housing of the voltage terminal is not filled with transformer oil.
If the measurements are conducted, and the voltage terminalis

not connected to a monitoring system, the connection to the
terminal must be broken off and it must be locked with the
corresponding plug.
The thread of the protective cover should be lightly lubricated

with connecting paste (e.g., KLÜBER ALTEMP Q NB 50®) and
then tightened as follows.
Recommended tightening torque

The protective cover must be screwed by hand until
the housing, gasket and cover come into direct
contact. Then an additional 1/4 to maximum 1/2
rotation should be applied to ensure the compression
of the flat gasket.
The gasket must be checked as the connection must be

watertight to prevent moisture penetration.
Do not feed voltage if the plug of the

voltage terminal is removed
Unless the bushing is used with a monitoring
system or for loss factor measurement.
 If the terminal is not earthed, the voltage
could exceed the insulation capability,
DANGER which could lead to damage inside the
bushing resulting in electrical damage to
the bushing or the transformer.

8. Measurements of C1, C2, tan 1, tan 2 (reference n°1)
Prevention of reloading hazards, electric  When conducting the measurement, the

shock, slipping and tripping accidents surface must be cleaned and dry.
 In a humid environment, the measurement
terminal should be dried — e.g. with a hot-
clear.
air dryer.
 The measured tan and capacity must be
qualified person.
DANGER calculated taking into account the
reference value at 20 °C.
reloading activities. NOTA  In order for the bushing fully to reach the
ambient temperature before the
measurements, it should be stored for e.g.
voltages.
24 h in the ambient of the measurement
site.
Hazardous voltage
 The measurements are performed using
high voltage. The local safety
regulations of high voltage installation
DANGER must be observed.
 These measurements must be

performed before the installation, after
Fig. 32: Reloading and lifting
the delivery and after long (≥ 1 year) or
incorrect storage.
NOTE 8.2. C1 and tan 1 measurement (reference n°1)
8.1. Reference measurements No. 1

The lifting of the bushing from the transport box can take place
with the use of lifting gear, as well as a crane, a hoist etc. and two
suspension ropes. One of the suspension ropes is fastened with a
textile rope sling directly onto the flange or on the crane eyes
mounted on the flange. The other suspension rope is fastened with
a textile rope sling to the insulator between the shields, near the
head or using the crane eyes mounted on the head or on the
special clamp (optional).
The bushing should be lifted at least 1.5 m above ground to reduce Fig. 33: Typical measurement of C1 and tan1
parasitic influences when measuring main capacity C1, capacity
C2 and loss factors tan 1 & tan 2. 8.3. C2 and tan 2 measurement (reference n°1)
The purpose of the measurements is to test the condition of the
bushing. The results must be compared with the ABB test report.
Fig. 34: Typical measurements of C2 and tan2

8.4. Reference measurement No. 1 overview 8.4.3. C2 & tan 2 (bushing with voltage terminal)
8.4.1. Capacity C1 and loss factor tan1
Voltage On-site measurements On-site
measurement,
correction for
temperature
[V] [°C] C1 tan 1 C1 tan 1

[pF] [%] [pF] [%]
200 measurement,
correction for
500
temperature
1000
[V] [°C] C2 tan 2 C2 tan 2
2000 [pF] [%] [pF] [%]
3000 100
6000 200
9000 500
12000 1000
Tab. 5: C1 and tan 1 measurement overview 1000
2000
 The values of the measurements shall
3000
be compared with those indicated in
the ABB test report (for 10 kV). 6000
NOTA 10000
Tab. 7: C2 and tan 2 measurements overview

8.4.2. C2 & tan 2 (bushing with measurement terminal)
 The measured values should be

compared with the ABB test report
values at 10 kV).
NOTA
8.5. Temperature-dependent correction factors for tan 1

& tan 2
measurement, The tan values must be calculated for the reference value at 20
correction for °C, see below:
temperature 1. During the measurement, the ambient temperature must be
[V] [°C] C2 tan 2 C2 tan 2 measured (T ambient = T bushing).
[pF] [%] [pF] [%] 2. With the curve or the table specified below, the correction
100 factor fc can be determined at the corresponding ambient
temperature, with which tan  relative can be calculated with
200
the following formula:
500
700 tan  relative = tan  measured / fc

1000
1500
2000
Tab. 6: C2 and tan 2 measurement overview
 The voltage of 2 kV must not be

exceeded during this test.
DANGER

RIP body temp. tan  Corr.
[°C] Factor
fc
10 1.20
20 1.00
30 0.85
40 0.77
50 0.75
60 0.77
70 0.82
80 0.90
Tab. 8: Correction factors
8.6. Temperature-dependent correction factors for C1

and C2
The C1 and C2 values must be calculated for the reference value
at 20 °C as described below (the capacity increases by about
0.4 ‰ per °C):
1. During the measurement, the ambient temperature must be
registered (T ambient = T bushing). The temperature difference
should be calculated with the following formula:
∆T = T bushing - 20 [°C]
2. The measurement should be corrected with the following

formula:
C 20°C = C measured * (1 - ∆T * 0.0004)
8.7. Permissible tolerances

8.7.1. For bushings ≤ 145 kV
C1 tan 1 C2 tan 2
+/- 5 % +/- 0.05 % +/- 20 % +/- 0.15 %

(Relative) (Absolute) (Relative) (Absolute)
8.7.2. For bushings > 145 kV

C1 tan 1 C2 tan 2
+/- 3 % +/- 0.05 % +/- 20 % +/- 0.15 %

Tab. 9: Tolerances
 If the measured values do not fit with the

set tolerances, please contact High
Voltage Components at ABB Switzerland
Ltd or your local ABB partner.
NOTE

9. Measurements of C1, C2, tan 1, tan 2 (reference n°2)
Prevention of falling accidents, electric  When conducting the measurement, the

shock, slipping and tripping accidents surface must be cleaned and dry.
 In a humid environment, the measurement
terminal should be dried — e.g. with a
clear.
dryer.
 The measured tan and capacity must be
qualified person.
calculated taking into account the
 Appropriate climbing aids and supporting
reference value at 20 °C. It must be made
structures should be used.
NOTE sure that the transformer (for
transformers) cools down very slowly and
work at height.
that the tan d value of the bushing is
DANGER heavily influenced by the transformer oil
temperature in this period.
voltages.
 The system is switched-off, secured and
tested.
 The primary and secondary side of the
transformer or the switchgear is short- 9.2. C1 et tan 1 measurement (reference n°2)
circuited and earthed.
 The work can only be started after a
complete electric discharge of the
system.
 These measurements shall be

performed after installation of the
bushings on the transformer as well as
while maintenance.
NOTE
9.1. Reference measurements No. 2

After the installation of the bushings and before switching on the
system or during the maintenance, main capacity C1, capacity C2
and the tan 1 & tan 2 loss factors must be measured. The results
must be compared with the ABB test report. These measurements
function as an important assessment basis during the entire
service life of the bushings. Fig. 35: Typical measurements of C1 and tan1

9.3. C2 and tan 2 measurement (reference No. 2) 9.4.2. C2 and tan 2 (bushing fitted with measurement
terminal)
Voltage On-site measurement On-site

measurement,
correction for
temperature.
[V] [°C] C2 tan 2 C2 tan 2

[pF] [%] [pF] [%]
100
200
500
Fig. 36: Typical measurements of C2 and tan2 700
1000
1500
9.4. Reference measurement No. 2 overview 2000
9.4.1. Capacity C1 and loss factor tan1 Tab. 11: C2 and tan 2 measurement overview
Voltage On-site measurement On-site

measurement,  The voltage during this test must not
correction for exceed 2 kV.
temperature
[V] [°C] C1 tan 1 C1 tan 1

DANGER
[pF] [%] [pF] [%] 9.4.3. C2 and tan2 (bushing fitted with voltage terminal)
200
500
1000
2000
3000
6000 Voltage On-site measurement On-site measurement,

correction for
9000
temperature
12000
[V] [°C] C2 tan 2 C2 tan 2
[pF] [%] [pF] [%]
100
 The measured values are regarded as 200

the first measurement in the installed
500
state, and cannot be compared with
the test report. 1000
NOTE
1000
2000
3000
6000
10000

9.6. Temperature-dependent correction factors for C1
 The measured values are regarded as and C2
the first measurement in the installed
The C1 and C2 values must be calculated for the reference value
state and cannot be compared with the
at 20 °C as described below (the capacity increases by about
test report.
NOTE 0.4 ‰ per °C).
1. After the measurement, the temperature ∆T difference should
be calculated with the following formula:
9.5. Temperature-dependent correction factors for tan1
∆T = T bushing - 20 [°C]
and tan2
The tan values must be calculated for the reference value at 2. The measurement should be corrected with the following
20 °C, see below: formula:
1. While the measurement, record ambient and oil C 20°C = C measured * (1 - ∆T * 0.0004)
temperature, and calculate the temperature of the condenser 9.7. Site-dependent correction for C1
core:
The measurement of the C1 capacity of installed bushings on site
is always smaller than in the test area. The difference is ∆C inst
T bushing = (2 * T air + T oil) / 3 [°C]
[pF].
Ur ∆C installed
[kV] [pF]
2. With the curve or the table specified below, the
≤ 123 approx. 4
correction factor fc can be determined at the corresponding
ambient temperature, with which tan  relative can be calculated ≤ 245 approx. 6
with the following formula: ≤ 420 approx. 8
Tab. 14: Capacity corrections
tan  relative = tan  measured / fc
These values are based on conservative empirical values. ∆C inst
depending on the type of the bushing and its lower part, the length
of the current transformer (for transformers) can deviate from
these values
1. The measurement should be corrected with the following

formula:
C1 relative = C1 20°C + ∆C installed
C1 relative can now be verified with the ABB test report.

9.8. Permissible tolerances
9.8.1. For bushings ≤ 145 kV

RIP body temp. tan  Corr. C1 tan 1 C2 tan 2
[°C] Factor
fc +/- 5 % +/- 0.05 % +/- 20 % +/- 0.15 %
10 1.20
20 1.00
30 0.85 9.8.2. For bushings > 145 kV
40 0.77 C1 tan 1 C2 tan 2
50 0.75
+/- 3 % +/- 0.05 % +/- 20 % +/- 0.15 %
60 0.77
70 0.82
Tab. 15: Tolerances
80 0.90
Tab. 13: Correction factors  If the measured values do not fit with
the set tolerances, please contact High
Voltage Components at ABB
Switzerland Ltd or your local ABB
NOTE partner.

10. Maintenance
10.1. Maintenance shedule

tan 1 & Capacitance Visual Thermal Insulator Risks
tan 2 C1 & 2 inspection cleaning
Level A System under - - X X (all 5 years - See Tab. 17
voltage until
replacement)
Level B System switched X X X - X See Tab 18
off and earthed
Maintenance
Ans
End of
waranty Service
Level A: Visual inspection (diagnostics recommended, depending on the condition)

Niveau B: diagnosis
Niveau C: replacement or conservation
Tab. 16: Maintenance schedule and maintenance intervals
Prevention of falling accidents, chemical Prevention of electric shock, slipping and

hazards, electric shock, slipping and tripping accidents
tripping accidents
 The work area must be marked and kept clear.
clear.  The personnel should have appropriate
 All the activities must be supervised by a DANGER training for work with dangerous voltages.
qualified person.  Wear appropriate PPE.
 Appropriate climbing aids and supporting Tab. 18: Risk analysis level B
structures should be used.
work at height. The maintenance schedule according to
DANGER
 The personnel should have appropriate Tab. 16 shows the typical maintenance
training for work with dangerous voltages. intervals recommended for rated loads of
 The system is switched-off, secured and the bushing. The service life estimates are
tested. NOTE based on conservative empirical values
 The primary and secondary side of the and are as a rule higher.
transformer or the switchgear is short-
complete electric discharge of the system.
Tab. 17: Risk analysis level A

10.2. Bushing maintenance its water-repellent properties even with high contamination and
age.
Tab. 16 provides a schedule for the expected service life as well
as the maintenance intervals of the RIP product. This overview
is only a recommendation. However, if the silicone surface becomes dirty, it can be cleaned
with water. If it is not enough, the following can be used for
cleaning:
10.3. Testing the connections with a thermal imaging
camera - Light contamination: 5 % water solution of cleaning agents (e.g.
It is recommended during the inspection and after the first soap).
commissioning that the connections are tested with a thermal - Medium to strong contamination: alcohol.
imaging camera (reasons: possible loose or oxidized
connections, insufficient crimping). The cleaning of these surfaces takes place by soaking a lint-free
cotton cloth in the cleaning liquid and wiping the silicone surface
 Thermography is only useful after 24

 Cleaning of the bushing may only take
hours under nominal load.
place with the installation shut down.
NOTE
DANGER
10.4. Cleaning the porcelain insulator

A cleaning of the porcelain insulator can become necessary if
 Clean only in well-ventilated rooms.
there is a lot of contamination due to adverse ambient influences.
 Avoid skin and eye contact with the
The cleaning takes place with a wet lint-free cloth or a stream of
cleaning liquid, do not inhale the
water (high pressure cleaner not recommended).
vapors.
 No open flames with volatile solvents.
 Work and protective measures must
 Cleaning of the bushing may only take comply with the safety data sheet and
place with the installation shut down. CAUTION
local guidelines.
 Wait for 24 hours after the cleaning
DANGER
before commissioning.
A porcelain surface contaminated as a result of transport and
handling can be cleaned as follows:
10.6. Capacity and tan δ loss factor checks

- Light contamination: wet cleaning cloth
- Medium to strong contamination: ethanol / ethanol acetate. Detailed information about measuring the capacity and tan δ can
be found in Chapters 8 and 9.
The cleaning of these surfaces takes place by soaking a lint-free
cotton cloth in the cleaning liquid and wiping the porcelain surface 10.7. Spare parts
When ordering spare parts, the production ¬number from the
 Clean only in well-ventilated rooms. rating plate on the flange of the bushing must always be provided.
 Avoid skin and eye contact with the
cleaning liquid, do not inhale the vapors. 10.8. Replacement of bushings
 No open flames with volatile solvents.
If a reserve bushing is needed, the production number from the
 Work and protective measures must
rating plate on the flange of the bushing must always be provided
comply with the safety data sheet and
if requested.
CAUTION local guidelines.
 Wait for 24 hours after the cleaning before
commissioning.
10.5. Cleaning the silicone insulator

Cleaning the silicone insulator is not normally necessary in
operation, as silicone due to its hydrophobic nature and the
transfer of the hydrophobia in the contaminated surface maintains

11. Dismounting (transport, repairs or disposal)

injuries, electric shock, chemical hazards,
falling, slipping and tripping accidents
clear.
qualified person.
 Appropriate climbing aids and
work at height.
DANGER voltages.
 The system is switched-off, secured and
tested.
system.
 For transformers, the available current
transformer must always be short-
circuited and earthed at the transformer,
preferably in the terminal box. This is to
suppress the displaced earth potentials.
11.1. Dismounting the bushing for transport, repairs or

disposal
The work steps described in Chapter 5 must be performed in
reverse order.
To ensure safety for this activity, the above recommendations

must be observed.
 For further information, please

contact High Voltage Components at
ABB Switzerland Ltd or your local
NOTE ABB partner.

12. Repair
Prevention of falling accidents, chemical Depending on the damage case, a repairs kit can be provided. For
hazards, cutting injuries, electric shock, this reason, in every case please consult High Voltage
slipping and tripping accidents Components at ABB Switzerland Ltd before repairs.
In case of repairs, the surfaces of the interfaces and their
clear.
environment must be cleaned with lint-free cloth soaked in
acetone; alternatively, a narrow piece can be cut out from the
qualified person.
damaged area with a knife to reach a clean surface.
 Appropriate climbing aids and
 Apply the repair compound and vulcanize.
work at height.
 The personnel should have appropriate  For further information, please contact
DANGER
training for work with dangerous High Voltage Components at ABB
voltages. Switzerland Ltd or your local ABB
 The system is switched-off, secured and partner.
NOTE
tested.
system.
12.1. Bushing repairs

Extensive repairs should be conducted in consultation with High
Voltage Components at ABB Switzerland Ltd. The production
number as well as a precise description of the damage do be
repaired are necessary for this.
12.2. Porcelain insulator repairs

Damaged insulators must be replaced or repaired. Repairs are
only possible if there are light scratches in the glazing or light
damage to the shield.

NOTE partner.
12.3. Silicone insulator repairs

Damaged silicone insulators must be replaced or repaired.
As the manufacturers of the silicone insulators use different types

of silicone for shielding, different repair compounds (LSR or HTV)
must be used, and the corresponding vulcanization times must be
observed. For this reason, in case of repairs please consult High
Voltage Components at ABB Switzerland Ltd, providing them with
photographs of the damaged area as well as the serial number of
the bushing.

13. Disposal

injuries, chemical hazards, falling, slipping
and tripping accidents
clear.
qualified person.
DANGER  Appropriate climbing aids and
work at height.
13.1. Special hazards during disposal

After the service life of the bushing expires, it should be disposed
of in accordance with the local laws and regulations.
The disposal should be performed by a recycling company that

specializes in these activities.
The product, including accessories, does not contain any toxic

basic components

NOTE partner.
14. Type designation
14.1. Rating plate

RTKF 72.5 – 350 / 1600 B KSI Composite insulator (not specified for porcelain insulator)
Conductor type B = Removable conductor rod | F = Fixed conductor

(not specified for cable conductor)
Rated current [A]
Lightning impulse voltage 1.2/50 µs (BIL) [kV]
Max. voltage [kV]
R: RIP technology | T: transformer application

K: length oil part (K = short, X = medium, Z = long, no spec. = any length)
F: outdoor application
37 Installation and commissioning | AirRIP Transformer bushings manual

For further information, please contact
ABB Switzerland Ltd.
HLAB200456-AI
High Voltage Components, Micafil Bushings
Badenerstrasse 780
8048 Zurich, Switzerland
Phone: +41 (0)58 586 02 33
www.abb.com/electricalcomponents
Customer Service
Hotline for technical issues, 24h a day including weekends
Mobile: +41 (0)58 586 07 70
E-mail: ch-service.micafil@abb.com
Note
We reserve the right to technical modifications or changes to the
contents of this document without prior notice. In case or placing
orders, the agreed terms and conditions shall apply. We reserve
all rights in this document and the items and illustrations
contained therein. Any reproduction, transfer to third parties or
the utilization of the contents, in part or in whole, shall be
prohibited without the prior approval by ABB in writing.
Copyright ©2021 ABB

All rights reserved

Airrip: Operating Instructions For Bushings

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HLAB200456-AI

Operating instructions for bushings

Table of contents ................................................................................................................................................................................. 2

2/38 | HLAB200456 | Operating instructions for AirRIP bushings

3/38 | HLAB200456 | Operating instructions for AirRIP bushings

4/38 | HLAB200456 | Operating instructions for AirRIP bushings

NOTE 1.4. Organizational measures

5/38 | HLAB200456 | Operating instructions for AirRIP bushings

2.1. General structure

Current conductor terminal with central tube ventilation (air side)

Head with clamp for power conductor

RIP insulating body with capacitor control and central pipe

MICAGEL dry filling

Porcelain or silicone composite insulator (external insulator)

Flange with measuring connection and transformer ventilation

Lower part extension for current transformer

6/38 | HLAB200456 | Operating instructions for AirRIP bushings

Prevention of reloading hazards, cutting 3.2. Reference measurement No. 1

 For further information, please contact

Fig. 1: Packaging, delivered state, reloading

 For every packaging type, it must be

7/38 | HLAB200456 | Operating instructions for AirRIP bushings

Prevention of reloading hazards, cutting 4.1. Storage

Tab. 1: Storage recommendations

8/38 | HLAB200456 | Operating instructions for AirRIP bushings

 For further information, please contact

Fig. 3: Container with oil

1 High level | 2 Recommended level | 3 Low level

4.3. Storage container with PETP-Alu-PE composite

Fig. 4: Long-term packaging with Al-composite film.

1 PETP-Alu-PE composite foil | 2 PE foil | 3 Desiccant

9/38 | HLAB200456 | Operating instructions for AirRIP bushings

Prevention of reloading hazards, cutting

 The protective cover of the silicone AC test voltage

10/38 | HLAB200456 | Operating instructions for AirRIP bushings

Fig. 6: Crane eye on flange and head

(A) (B) (C)

for conductor conductor rod

Fig. 8: Details of the lower part of a bushing (schematic)

If any, future conductors, and contact terminals on the winding

In order to maintain sufficient and prolonged contact pressure,

Fig. 7: Fastening the bushings

5.3. Reference measurement N°1

5.4. Conductor and terminal (A, B, C)

11/38 | HLAB200456 | Operating instructions for AirRIP bushings

5.5. Dismounting the cable bolt (A) or conductor rod (B)

In order to remove the cable bolt or conductor rod, it is

The conductor rope may be soft soldered or brazed to the cable

12/38 | HLAB200456 | Operating instructions for AirRIP bushings

 Do not drill in the ventilation channel.

Recommended tightening torque (1)

Fig. 11: Split conductor rod screw joint

1 Screws and spring washers | 2 Upper part of the conductor rod | 3

5.8. Rope conductor insulation (A)

13/38 | HLAB200456 | Operating instructions for AirRIP bushings

 Please observe installation recommendations (see Tab. 2).

5.11. Bushing without shield

5.12. Shield for rope application

Recommended tightening torque (2)

The shielding is available for voltages ranging from 24 kV to

14/38 | HLAB200456 | Operating instructions for AirRIP bushings

Fig. 16: Mounting and dismounting of the head shield.

Recommended tightening torque (3)