6/19/22, 1:47 PM High-Voltage Transformer Bushing Assessment Is Critical | T&D World

LATEST FROM SUBSTATIONS

Hearings for SRP

Application for
Transmission Line an…
June 15, 2022
Substations

A Decade after
Superstorm Sandy,
New Jersey’s…
June 13, 2022
Disaster Response

SUBSTATIONS

High-Voltage Transformer Bushing Assessment Is

Critical
July 21, 2020
Utilities need to know the health condition of their bushings in order to protect their costliest
Hawthorne
transmission asset.
Transmission Station
in Canada’s Capital… Cassandra H. Goff, Gerald W. Lindley Jr., Mark B. Goff
June 7, 2022
Substations
By clicking “Accept All Cookies”, you agree to the storing of
cookies on your device to enhance site navigation, analyze National Grid
site usage, and assist in our marketing efforts. Privacy Completes Portion of
Policy Ready Path Solution …
May 12, 2022
Accept All Cookies Substations
Why is understanding high-voltage oil-filled transformer bushings so critical?

Entergy Texas High-voltage power transformers are an essential component of our nation's electric grid
Energizes New
https://www.tdworld.com/substations/article/21137071/highvoltage-transformer-bushing-assessment-is-critical 1/11
6/19/22, 1:47 PM High-Voltage Transformer Bushing Assessment Is Critical | T&D World
Energizes New
Substation in… infrastructure. Bushings are the most critical component of a power transformer. The voltage gradient
May 10, 2022 between the ground flange and the high-voltage center conductor is much larger compared with the
Substations
voltage gradients inside the transformer or external lines coming into the transformer. In most cases, if
Construction the bushing fails catastrophically, the transformer will have to be replaced or untanked to clean up the
Underway on New
FirstEnergy… failed bushing debris. The cost of large power transformers ranges from a few hundred thousand to
May 4, 2022 over US$5 million with lead times varying from a few months to over a year.
Substations

SPONSORED CONTENT Basics of oil-filled high-voltage bushings

IEC 61850 Powers the
Journey to Digital and
Future Virtualized…
May 2, 2022
Electric Utility Operations
Cloud Full Of Assets
April 29, 2022
Smart Grid
Con Edison
Researchers Win
Awards for Reliabilit…
April 12, 2022
Substations
Bushings are interface components so that electrical energy passes through a barrier. The center core is
usually made of aluminum or copper which is properly sized to carry the current from one side of the
barrier to the other. The center core is contained in an insulation system that is covered with an
insulator. Bushing insulation systems of 26 kV and below can be designed using a solid material such
as porcelain, silicon, or resin composite. Bushings rated greater than 26 kV need layers of conductive
material or foils interspersed with layers of paper to distribute voltage stresses and to minimize large
voltage gradients. The layers of conductors and insulation form concentric capacitors between the
barrier and center core. Refer to Fig. 1 below.
Today, oil impregnated paper bushings are the most widely used types of bushing for voltages greater
than 26 kV. In this design, the paper provides the skeleton to hold the insulating oil. The oil functions
as the main insulation and coolant for the bushing. The outer shell is typically porcelain but some
manufactures have designs using other material because of long lead times and difficulty in
manufacturing of the outer porcelain shells.

Figure 1. Three illustrations of the same bushing progressing from physical to electrical.

Moisture is an enemy to bushing

Moisture is a bushing's worst enemy. As a bushing ages, gaskets lose their ability to seal, thereby paving
the most common way for moisture to enter the bushing. If moisture is allowed to enter the bushing, it
will start to break down the oil and paper insulation system. This breakdown forms various polar
By clicking “Accept All Cookies”, you agree to the storing of
compounds and acids that attack the paper. As the paper breaks down, more contamination is formed.
cookies on your device to enhance site navigation, analyze
site usage, and assist in our marketing efforts. Privacy At some point two or more conductive layers will break down and short together. When this happens,
Policy
the remaining concentric capacitors will have a larger voltage stress across each capacitor. As the
Accept All Cookies breakdown goes unchecked and moisture continues to enter the bushing, the rate at which
contamination is being generated inside the bushing increases. This causes other layers to fail. At some
i t th i t t hi f il f th b hi Ri k i d ti ll ith d lt
https://www.tdworld.com/substations/article/21137071/highvoltage-transformer-bushing-assessment-is-critical 2/11
6/19/22, 1:47 PM High-Voltage Transformer Bushing Assessment Is Critical | T&D World
point, there is a catastrophic failure of the bushing. Risk increases dramatically with age and voltage
level. Bushings rated greater than 230 kV and older than 25 years fall into the highest-risk category.

The next lower-risk category comprises bushings rated between 100 kV to 230 kV and older than 35
years.

Although moisture ingress is the leading cause of bushing failures, the good news is there are ways to
evaluate the deterioration of a bushing's insulation system. Power factor testing is the industry's
standard method for tracking and trending bushing health. Infrared (IR) and visual inspections can be
used to track health while the transformer is online. Bushing oil sampling can be used on suspect
bushing or bushings in the high-risk category.

Checking bushing health using power factor

A bushing is divided into two parts. The innermost insulation system is made up of several concentric
capacitors, commonly referred to as C1. The outermost insulation system has only a few layers and is
referred to as C2. The main purpose of this division is to allow a test connection point for off-line
electrical tests. Normally C2 is shorted out by the cap cover when the bushing is in operation. Refer to
Fig. 2 below. In rare cases, for bushings rated 69 kV or greater, this point is used to feed a potential
device. This is possible because C1 and C2 are not influenced by external factors such as the bushing
turret or tank walls. In other words, a bushing can be used as a reasonably accurate capacitor divider to
feed a potential device for measuring the voltage that is being applied to the bushing. On bushings that
allow for an external potential, the tap is referred to as a potential tap. The potential tap can be easily
spotted because it is a stud type connection opposed to a spring. See Fig. 3 below. In either case, a
potential tap or test tap can be used for off-line power factor testing.

Figure 2. Photo of a potential tap.

By clicking “Accept All Cookies”, you agree to the storing of

cookies on your device to enhance site navigation, analyze
site usage, and assist in our marketing efforts. Privacy
Policy

Accept All Cookies

https://www.tdworld.com/substations/article/21137071/highvoltage-transformer-bushing-assessment-is-critical 3/11
6/19/22, 1:47 PM High-Voltage Transformer Bushing Assessment Is Critical | T&D World

Figure 3. Potential tap with a stud versus test tap with a spring. LOG IN REGISTER SEARCH

T&D WORLD CONFERENCE & EXHIBITION

UTILITY PRODUCTS ENERGYTECH UTILITY ANALYTICS INSTITUTE SMART UTILITY SUMMIT BUYER'S GUIDE

To setup a transformer bushing for testing, only remove the bushing cap on the bushing under test. Use
a piece of wire to tie all high side bushings together and tie all low side bushings together. For a three-
winding transformer, tie the tertiary bushings together. Bare 12-gauge wire works great. This reduces
interference that can lead to erroneous test results.

The main core insulation C1 is tested using the Ungrounded Specimen Test (UST) mode, as seen in Fig.
4 below. The current travels out the high-voltage lead to the tap. Here the current splits. But only the
current that travels through the C1 capacitor returns to the test source through the meter. Therefore,
only C1 is measured in this mode.

ADVERTISEMENT

By clicking “Accept All Cookies”, you agree to the storing of
cookies on your device to enhance site navigation, analyze
site usage, and assist in our marketing efforts. Privacy
Policy
The power factor test set calculates the power factor and capacitance value for each test which allows
more insight into the health of the bushing. The power factor indicates the amount of contamination
while the capacitance value indicates the physical changes in the conductive layers. Increase in power
factor indicates the amount of contamination and increase in capacitance indicates if any layers have
been shorted out since the last test. The capacitance values reported by the power factor test set are
often overlooked but they are the main indicators of a physical change inside the bushing.

Accept All Cookies

https://www.tdworld.com/substations/article/21137071/highvoltage-transformer-bushing-assessment-is-critical 4/11
6/19/22, 1:47 PM High-Voltage Transformer Bushing Assessment Is Critical | T&D World

Figure 4. Testing C1 using the UST mode.

The outer layers of the bushing insulation referred to as C2 is tested in guard mode as seen in Fig.
5. The current travels out the high-voltage lead to the tap. Here the current splits. But only the current
that travels through the C2 capacitor returns to the test source through the meter. Therefore, only C2 is
measured in this test setup.

Figure 5. Testing C2 in guard mode.

Checking bushing health using visual and IR techniques

Low oil level is a key indicator that a bushing is leaking oil. If oil is coming out then moisture is getting
in. Although power factor testing is one tool in the tool box, they are only performed every few
years. Visual inspections, which are sometimes referred to as rounds, are often used to spot signs of an
oil leak or notice a large change in oil level from the site glass or oil level gauge. It is not just spotting
something but also being aware of how to follow up with an action.

ADVERTISEMENT

By clicking “Accept All Cookies”, you agree to the storing of

cookies on your device to enhance site navigation, analyze
site usage, and assist in our marketing efforts. Privacy
Policy

Accept All Cookies

This point leads to performing an IR scan. Because of the losses in a transformer when it is energized
and carrying load, the oil is hotter that its surroundings. The heat thermally conducts from the

https://www.tdworld.com/substations/article/21137071/highvoltage-transformer-bushing-assessment-is-critical 5/11
6/19/22, 1:47 PM High-Voltage Transformer Bushing Assessment Is Critical | T&D World
transformer to the bushing which allows a temperature gradient that can be seen using an IR
camera. Fig. 6 shows a transformer bushing with normal oil level.

Figure 6. IR image showing normal oil level.

The IR image in Fig. 7 shows the bushing on the right to be full of oil. This is indicated by the heat
traveling from the warm transformer tank full of oil up the bushing all the way to the top. The scale on
the far right shows the brighter yellow (lighter shade in black and white) having a temperature
somewhere around 31°C and the bushing on the left is blue/green (darker shade in black and white)
having a much cooler temperature. The lower temperature is because of the lack of oil that allows for
good thermal heat flow. Only the very lowest part of the bushing on the left shows any signs of heat
being conducted, thus marking the location of the oil level. This was verified by Tennessee Valley
Authority's (TVA) Power Service Shop during tear-down of the bushing.

By clicking “Accept All Cookies”, you agree to the storing of

cookies on your device to enhance site navigation, analyze
site usage, and assist in our marketing efforts. Privacy
Policy

Accept All Cookies

https://www.tdworld.com/substations/article/21137071/highvoltage-transformer-bushing-assessment-is-critical 6/11
6/19/22, 1:47 PM High-Voltage Transformer Bushing Assessment Is Critical | T&D World

Figure 7. Two bushings — low oil level versus normal oil level.

Remember refilling a bushing after it has been found to be lower than the top metal bushing head is not
advised. Once the oil drops below this point, the paper layers will no longer be covered with oil. Partial
discharge will start and eat the paper like termites while the bushing is energized. See the right side of
Fig. 8, where partial discharge ate through the insulation. The damage is irreversible. This will start to
be evident in the power factor test but if oil is added before the power factor test, the results will be
masked. Refer to Fig. 8 to see the catastrophic results of refilling and then testing after finding a
bushing low on oil. The evidence brought to light this fact while performing a root cause analysis.

Figure 8. Failed 500-kV transformer after refilling a bushing that was extremely low on oil.
By clicking “Accept All Cookies”, you agree to the storing of
cookies on your device to enhance site navigation, analyze

site usage, and assist in our marketing efforts. Privacy

Policy
Checking bushing health using bushing oil sampling
Accept All Cookies
The most invasive test is to pull oil from the bushing and send the sample to a lab for analysis. This is
only recommended for the highest-risk category of bushings As stated earlier the highest-risk category
https://www.tdworld.com/substations/article/21137071/highvoltage-transformer-bushing-assessment-is-critical 7/11
6/19/22, 1:47 PM High-Voltage Transformer Bushing Assessment Is Critical | T&D World
only recommended for the highest risk category of bushings. As stated earlier, the highest risk category
comprises bushings rated greater than 230 kV and older than 25 years. The second highest category
comprises bushings rated 100 kV to 230 kV and older than 35 years.

ADVERTISEMENT

Recommended tests are as follows (oil sample size needed — two 50-cc syringes):

Oil Quality Analysis

Moisture
Interfacial Tension (IFT)
Color
PCB
Dissolved Gas-in-Oil Analysis (DGA)
Carbon monoxide, carbon dioxide
Hydrogen, methane, ethane, ethylene
Acetylene

The criteria for continued service are as follows:

Moisture — Must be less than 20 ppm.

DGA — Acetylene must be less than 1 ppm.

The TVA tested 111 500-kV bushings. Four bushings had high moisture or acetylene greater than 1
ppm. Five bushings had greater than 500-ppm PCB. This launched the TVA's 500-kV bushing
replacement program.

Conclusion

Even with new bushing designs, every utility still has thousands of high-voltage oil-filled bushings in
service. Trending the bushing's power factor, performing visual inspections, and performing IR scans
will allow tracking the health of the bushing. For those bushings in the high-risk category, the risk of
bushing oil sampling outweighs the risk of obtaining an oil sample. By using these tools, a utility will
have the ability to plan for outages by trending the health of all bushings across its fleet. This approach
will keep the power grid more secure and reduce the total ownership cost for its most costly
transmission asset.
By clicking “Accept All Cookies”, you agree to the storing of
cookies on your device to enhance site navigation, analyze
site usage, and assist in our marketing efforts. Privacy
Policy

Accept All Cookies VOICE YOUR OPINION!

This site requires you to register or login to post a comment

https://www.tdworld.com/substations/article/21137071/highvoltage-transformer-bushing-assessment-is-critical 8/11
6/19/22, 1:47 PM High-Voltage Transformer Bushing Assessment Is Critical | T&D World
This site requires you to register or login to post a comment.

Email Address*

By submitting this form and personal information, you understand and agree that the information provided here will be processed, stored and used to
provide you with the requested services in accordance with Endeavor Business Media’s Terms of Service and Privacy Policy.

As part of our services, you agree to receive magazines, e-newsletters and other communication about related offerings from Endeavor Business Media,
its brands, affiliates and/or third-party partners consistent with Endeavor’s Privacy Policy. Contact us at emailsolutions@endeavorb2b.com or by mail to
Endeavor Business Media, LLC, 331 54th Avenue N., Nashville, TN 37209.

You can unsubscribe from our communications at any time by emailing emailsolutions@endeavorb2b.com.

Continue

Latest Comments
Posted by coopers1 Aug 17th, 2020 3:34PM

Is "the risk of bushing oil sampling outweighs the risk of obtaining an oil sample." a misprint? Should it be "the risk of bushing oil
degradation outweighs the risk of obtaining an oil sample."?

Posted by mlsachdeva Aug 14th, 2020 10:40PM

IR image showing less temp in case of bushing with low oil level is bit confusing fact as the current passing thru primary conductor in
vacuum shall comparatively have higher temp and zone shall be brighter as compared to zone still having the oil.

Periodical Sampling and / or falling of oil level in the bushing shall be checked immidiately by drawing the sample and preventive action
initiated on priority as fire could cause a irrepairable damage.

Sign up for T&D World eNewsletters

Email Address SIGN UP

By clicking “Accept All Cookies”, you agree to the storing of

cookies on your device to enhance site navigation, analyze
site usage, and assist in our marketing efforts. Privacy LATEST FROM SUBSTATIONS
Policy

A Decade after
Accept All Cookies
Superstorm Sandy,
New Jersey’s…
June 13, 2022

https://www.tdworld.com/substations/article/21137071/highvoltage-transformer-bushing-assessment-is-critical 9/11
6/19/22, 1:47 PM High-Voltage Transformer Bushing Assessment Is Critical | T&D World
Ju e 3, 0
Disaster Response

Hawthorne
Transmission Station

i C d ’ C it l
June 7, 2022
Substations

National Grid
Completes Portion of
Ready Path Solution …
May 12, 2022
SUBSTATIONS
Substations

Energy Maintenance
Hearings for SRP Application for Transmission Line
Technologies/EMT Ltd
and Substation to Serve Meta Data Center
May 11, 2022
June 15, 2022
Buyers Guide
Proposed project to serve energy to data center being built for Meta, located in Mesa.
Entergy Texas
Energizes New Related To: SRP
Substation in…
May 10, 2022
Substations

Construction
Underway on New
FirstEnergy…
May 4, 2022
Substations
On May 10, Salt River Project filed an application for Certificate of Environmental Compatibility
SPONSORED CONTENT
(CEC) with the Arizona Corporation Commission (ACC) for the proposed “Project Huckleberry,” a half-
IEC 61850 Powers the
Journey to Digital and mile 230 kV transmission line and 230 kV substation to serve energy to the data center being built for
Future Virtualized…
Meta and slated to be fully operational by 2024.
May 2, 2022
Electric Utility Operations
The data center continues the Phoenix area’s growth in the technology sector and is expected to create
Cloud Full Of Assets
approximately 100 high-wage jobs upon its completion and around 1,500 jobs during its construction.
April 29, 2022
SRP supports long-term economic development in the communities it serves by providing reliable
Smart Grid
power to its customers.
Con Edison
Researchers Win
Awards for Reliabilit… Meta’s data center is under development at the southeast corner of Elliot and Ellsworth Roads. Project
April 12, 2022 Huckleberry consists of a proposed 230 kilovolt (kV) double-circuit transmission line that will connect
Substations the proposed Prickly Pear 230 kV Substation to the certificated Southeast Power Link 230 kV
By clicking “Accept All Cookies”, you agree to the storing of
cookies on your device to enhance site navigation, analyze
transmission line by following along an existing flood control channel and a 69kV transmission line
site usage, and assist in our marketing efforts. Privacy
Policy under development for a half mile. As the primary beneficiary of Project Huckleberry, Meta is funding
the cost of SRP’s electrical infrastructure required to serve their facility. 
Accept All Cookies

The ACC’s Power Plant and Transmission Line Siting Committee will consider the application at a
bli h i b i i h l l b i h i
https://www.tdworld.com/substations/article/21137071/highvoltage-transformer-bushing-assessment-is-critical 10/11
6/19/22, 1:47 PM High-Voltage Transformer Bushing Assessment Is Critical | T&D World
public hearing beginning on June 27, 2022, at 1 p.m. at the Delta Hotels by Marriott Phoenix Mesa at
200 N. Centennial Way, Mesa, AZ, 85201.

The hearing will continue June 28, 2022, at 9 a.m. and each following weekday through completion of
the hearing. The hearing will be available to view online, by phone or in-person. Zoom links for the
hearing will be added to the project webpage srp.net/huckleberry. You may also visit azcc.gov for
information regarding the hearing schedule.

Public comment will be taken in a special evening session on Monday, June 27, 2022, at 5:30 p.m. in
person and virtually.

Following the hearings, the siting committee will issue or deny the certificate, which requires final
approval by the ACC.

VOICE YOUR OPINION!

This site requires you to register or login to post a comment.

Email Address*

By submitting this form and personal information, you understand and agree that the information provided here will be processed, stored and used to
provide you with the requested services in accordance with Endeavor Business Media’s Terms of Service and Privacy Policy.

As part of our services, you agree to receive magazines, e-newsletters and other communication about related offerings from Endeavor Business Media,
its brands, affiliates and/or third-party partners consistent with Endeavor’s Privacy Policy. Contact us at emailsolutions@endeavorb2b.com or by mail to
Endeavor Business Media, LLC, 331 54th Avenue N., Nashville, TN 37209.

You can unsubscribe from our communications at any time by emailing emailsolutions@endeavorb2b.com.

Continue

No comments have been added yet. Want to start the conversation?

Sign up for T&D World eNewsletters

Email Address SIGN UP

Load More Content

By clicking “Accept All Cookies”, you agree to the storing of

cookies on your device to enhance site navigation, analyze
About Us Contact Us Advertise California Do Not Sell Privacy & Cookie Policy Terms of Service Utility Analytics Institute Transmission Hub Utility Products
site usage, and assist in our marketing efforts. Privacy
Policy
© 2022 Endeavor Business Media, LLC. All rights reserved.

Accept All Cookies

https://www.tdworld.com/substations/article/21137071/highvoltage-transformer-bushing-assessment-is-critical 11/11