ASSIGNMENT #3

To: Ma’am SAIMA ALI

 High-Voltage Bushing Testing Explained

The primary function of a bushing is to provide an insulated entrance for an energized conductor
into a high-voltage apparatus tank or chamber. A bushing may also serve as a support for other
energized parts of the apparatus.

About 90% of all preventable bushing failures are caused by moisture entering through leaky
gaskets, cracks, or seals. Moisture causes deterioration of the bushing insulation and can result in
explosive failure, causing extensive transformer and other equipment damage, as well as hazards
to personnel.

To prevent electrical catastrophes and optimize HV bushing service life, the following
preventive maintenance and testing procedures should be performed at regular intervals.

Article Contents

 Visual Inspection of High Voltage Bushings

 Infrared Inspection of High Voltage Bushings

 Cleaning Methods for High-voltage Bushings

 Power Factor Testing of High-Voltage Bushings

 Bushing Construction Classification and Type

 Maintenance Tips for High-Voltage Bushings

Visual Inspection of High Voltage Bushings

Porcelain bushings should be regularly checked for cracks and/or contamination. If the bushing
is damaged or heavily contaminated, leakage current will become excessive, sometimes
appearing as carbon tracking, or "treeing", on the bushing surface. Flashovers may occur if the
bushings are not cleaned periodically.

Inspect the bushing carefully for oil leaks. Check the oil level in the bushing by viewing the
liquid through the oil-sight glass or by observing the oil level gauge. If the level gauge is
equipped with a pointer, document its position, as the level should vary slightly with temperature
changes.
If the liquid level never changes, even with a wide range of ambient temperatures, the gauge is
most likely stuck and should be inspected at the next available outage. A defective gauge pointer
along with a small oil leak can result in catastrophic failure of a bushing, causing damage to the
apparatus and other switchyard equipment nearby.

Low oil levels in the busing should be corrected by checking the mounting bolts for adequate
torque and inspecting the gasket for proper compression. If torque and compression are found to
be correct, the leak requires bushing replacement. It is very important that the correct type of
gasket be installed, and the correct compression be applied.

Gaskets with poor seals will leak water and air into the transformer. Photo: ABB.

Gaskets with poor seals are probably also leaking water and air into the transformer, in which
case DGA samples should be obtained to check for high water and oxygen content inside the
main tank. If oil levels are low and there is no evidence of external leaks, an internal leak could
be present around the lower seal leading into the transformer tank.

If possible, re-fill the bushing with the same type oil and carefully monitor how much volume it
takes to reach the proper level. Bushings that require more than 1 quart of oil should be marked
and replaced at the next available outage. Defective bushings should be factory refurbished, as
they cannot be repaired in the field.
Thermographic Inspection of High Voltage Bushings

In addition to visual inspections, high voltage bushings should be examined with an infrared
camera. If any of the bushings are abnormally hot when compared to a unit under similar
loading, there is probably a loose connection.

Infrared inspections can reveal connection issues on high-voltage bushings. Photo: Fluke

Corporation.

It's not uncommon to find problems with the connection at the top of the bushing; however, a
defective connection inside the transformer tank will also show a higher temperature at the top of
the bushing. Bad connections inside of a transformer will usually exhibit hot metal gasses such
as ethane and ethylene in DGA samples.

Corona (air ionization) may be visible at the tops of bushings at twilight or night, especially
during periods of rain, mist, fog, or high humidity. Corona is considered normal near the top of
the bushing; however, as contamination builds, corona will creep lower and lower.

A corona scope may be used to view and photograph low levels of corona indoors under normal
illumination and outdoors at twilight or night. High levels of corona may be viewed outdoors in
the daytime if a dark background is available, such as trees, canyon walls, buildings, etc. This
inspection will be required more often in atmospheres where salts and dust deposits appear on
the bushings.
If corona seems to be lower than the top of the bushing, visually inspect, electrically test, and
clean the bushing as quickly as possible. The corona scope design is primarily for indoor and
night use; it can't be used with blue or cloudy sky background.

Cleaning Methods for High-voltage Bushings

If bushings are not periodically cleaned, a phase to ground fault can occur when corona nears the
grounded transformer tank, potentially destroying the bushing and causing an extended outage.

Consult the manufacturer's literature for detailed instructions on cleaning and repairing specific
bushing surfaces. Different solvents, wiping materials, and cleaning methods may be required for
different bushings.

Cleaning high voltage insulators are important to maintain the insulator operating and insulator
service time. Photo: Composite Insulator

Hairline cracks in the surface of the porcelain should be sealed because accumulated dirt and
moisture can work its way into the crack, potentially resulting in flashover. Epoxy can be used to
repair larger chips but different repair techniques may be required for small cracks and chips.

If a bushing insulator has a large chip that reduces the flashover distance, or has a large crack
totally through the insulator, the bushing should be immediately replaced. Some manufacturers
offer repair service to damaged bushings that cannot be repaired in the field. Contact the
manufacturer for your particular bushings if you have repair questions.
In high humidity and wet areas, a high-quality silicone wax applied to the porcelain will cause
water to form beads, rather than a continuous sheet, which reduces the risk of flashover.

Beads of rainwater on the surface of a high voltage insulator.

Cleaning bushings may involve simply applying a silicone wax and wiping with a soft cloth.
Contaminants that are more stubborn may require solvents, steel wool, and brushes. High-
pressure water may be required to remove salt and other water-soluble deposits. Limestone
powder blasting with dry air will safely remove metallic oxides, chemicals, salt cake, and almost
any hard contaminant.

Other materials known to safely remove hard contaminants from high-voltage bushings include
potter's clay, walnut or pecan shells, or crushed coconut shells. Carbon dioxide (CO2) pellet
blasting is a more expensive alternative that virtually eliminates cleanup through evaporation.

Ground-up corncob blasting can be used to remove soft pollutants, such as old coatings of built-
up grease. A competent, experienced contractor should be employed, and a thorough, written job
hazard analysis (JHA) should be performed when any of these treatments are used.

Power Factor Testing of High-Voltage Bushings

Insulation power-factor tests are used to measure dielectric losses, which relate the wetness,
dryness or deterioration of high voltage insulation. Leakage current comprises of two
components: Resistive current and Capacitive current. In practice, no insulation is perfect, but
has a certain amount of loss and the total current leads the voltage by a phase angle less than 90°.
 Testing power factor is a means of measuring the integrity of electrical insulation.

High voltage bushings are usually equipped with a tap for test measurements. The bushing
nameplate should list the tap capacitance and power factor of the C2 insulation, as measured
from the tap to the grounded flange.

Perform power-factor or dissipation-factor tests on each bushing equipped with a

power-factor/capacitance tap. In the absence of a power-factor/ capacitance tap, hot-collar tests
should be used. The methods of power factor testing in regards to procedure are beyond the
scope of this article, consult manufacturer literature for detailed test methods.

The various types of power factor tests applicable to high-voltage bushings may include:

 Overall Test (from Center Conductor to Flange).

 Ungrounded-Specimen Test, or UST (Center Conductor to Tap, C1).

 Inverted UST Test (Tap to Center Conductor, C1).

 Cold Guard (Center Conductor to Flange).

 Tap Insulation Test (Tap to Flange, C2).

 Alternate C2 Test: C1 and C2 in Parallel.

 Collar Tests (Externally Applied Collar to Center Conductor).

Investigate bushing power-factor and capacitance values that vary from nameplate values by
more than ten percent. Hot-collar tests are evaluated on a milliampere/milliwatt loss basis, and
the results should be compared to values of similar bushings.

Bushings should be cleaned prior to power factor testing. Contamination on the insulating
surface will cause the results to be inaccurate. Testing may also be done before and after
cleaning to observe the effectiveness. Keep accurate records of results so that replacements can
be ordered in advance, before removing HV bushings from service.

Bushing Construction Classification and Type

High voltage bushings may be classified generally by design as follows:

High voltage bushings are available in various classifications and styles.

Condenser Type
Condenser bushings provide greater dielectric strength and uniform voltage gradient. These
bushings form a capacitor between the live conductor and the equipment body which is at ground
potential.

 Oil-Impregnated Paper Insulation, with Interspersed Conducting (Condenser)

Layers or Oil-Impregnated Paper Insulation, Continuously Wound with
Interleaved Lined Paper Layers.

 Resin-Bonded Paper Insulation, with Interspersed Conducting (Condenser)

Layers.

Non-condenser type

Used in both low voltage and high voltage applications. In low voltage applications, the ceramic
casing alone provides adequate insulation to the conductor.

 Solid Core, or Alternate Layers of Solid and Liquid Insulation.

 Solid Mass of Homogeneous Insulating Material (e.g., Solid Porcelain).

 Gas Filled.

Bushing Maintenance Tips

New bushings should be tested outside of their shipping crate as wood does not insulate as well
as porcelain and will cause power factor readings to be inaccurate. Test results should be retained
as a baseline record to compare with tests in the future.

Some bushings have a nitrogen blanket on top of the oil, which pressurizes as the oil expands.
This pressurized hot oil may suddenly gush from the fill plug if it is removed while at elevated
temperature, causing burn hazards.

Oil fill plugs should never be opened if the bushing is at an elevated temperature. Always consult
the manufacturer's instruction manual, which will give the temperature range at which the
bushing may be safely opened.