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Case Histories for Mitigating

Transformer Bushing Risk
Bushings, Utility Practice & Experience
 February 4, 2022  12 min read

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Several years ago, utilities in Southeast Asia

embarked on a bushing reliability survey and,
based on 7ndings, formulated mitigation measures
to improve bushing performance. This edited 2017
contribution to INMR by S. Gobi Kannan, Chitapon
Jedwanna and Henny Ika, respectively at Tenaga
Nasional Berhad (TNB) in Malaysia, the Electricity
Generating Authority of Thailand (EGAT) and
Perusahaan Listrik Negara (PLN) in Indonesia,
reviewed experience with bushing failure for the
purpose of learning what measures can help
reduce such risk.

Case #1: Copper Migration on

300 kV Bushing Manufactured
in 1996 (ref. Figs 1 to 4)
Root Cause: Site and laboratory examination,
together with historical failure records, suggest
that the dielectric insulation breakdown in this case
was due to one or more of the following:

• Poor stress control design resulting in high

electrical stress at certain locations along the
paper/foil insulation;
• Poor manufacturing quality as seen in laboratory
examination of some paper/foil insulation layers
leading to uneven distribution of electrical stresses;
• Development of electrical treeing along the
insulation as a result of copper migration, made
worse by the high electrical stresses.

(a) (b)

Charred
insulation
Grounded
paper
Aluminium
Flange

Figure3.4(a); Figure3.4(b);

Fig 1: Arcing
ThearcingerosiondamageontheThearcingerosiondamageon
copperconductor,about300mmthecopperconductorwas
fromthealuminiumflange brushedandcleanedtoreveal
position. themeltedmetallicsurface.

erosion damage
Aluminium
groundingsleeve

Eigure3.3;
The275kVdamagedbushingwasremoved

on solid copper
fromthetransformerforteardownexamination.

conductor near
bottom <ange
area at location
of about 300
mm.

767

Eque4.10

Equre4.3:
Photographstakenwithilluminationshowedthe
presenceofpinholesalongtheedgesoftheoveriay

Fig 2: Inspection revealed penknife like marks as well

as presence of pinholes along aluminium foil layers
from poor manufacturing, possibly explaining poor
stress control.

Fig. 3: Presence of darkish substance “black trees”

visible at foil joint areas and evidence of Cu2S
formation due to possible copper migration
phenomenon.

Fig 4: Further study linked failure to potentially

corrosive oil (Shell Diala D) prior to 2008 on similar
designs of bushings, apart from poor manufacturing
practices.
(Source: DOBLE Proceedings 80th International Conference 2013)

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Case #2: Test Tap Problems

(Figs. 5 to 9)
Surveys among ASEAN utilities indicate that about
10% of bushing failures relate to test tap problems.
In this particular instance, it was found that the
test tap measurement and tap bushing had no
continuity. Insulation resistance measurements
indicated an open circuit and disassembly of the
test tap revealed:

Fig. 5: Evidence of cracks on metallic Al <ange near test

tap location.

Fig. 6: Evidence of discharge activities and oil

contamination on core fragments as result of <oating
potential and issues of improper grounding of test tap
layer.

Fig. 7: Spring mechanism jammed and sparking marks

found on slider and tap housing.

• Utility experience in the region shows that the

majority of test tap failures have been attributed to
the spring-loaded design versus the permanent
connection type (see Figs. 8 and 9). Poor spring
contact pressure over the years and possible
damage during high surge current Row was
determined as possible root cause of the failure
mode that resulted in Roating potential and arcing
at the last layer of the condenser design bushings.
This could lead to contamination of the insulating
oil at the bottom side of the bushing and
eventually dielectric failure breakdown.

Fig. 8: Spring-loaded Fig. 9: Permanent

type. soldered type.

Case #3: Draw Lead Bushing

Fast Transient Issue in GIS/RCT
Substation
Root Cause: Loss of insulation dielectric strength of
main condenser due to heat generated along the
bushing’s aluminium tube as a result of fast and
very fast transient phenomena in the system
during switching.

Fig. 10: Flashover

evident at top
location of
bushing draw lead
and aluminium
tubing.
Transformer re-
energized safely
after bushing
replacement.

Fig. 11: Arcing damage evident at draw lead conductor

and at corresponding aluminium draw tube.

Fig. 12: Tube divided into 8 sections

designated A to H, revealed arcing
marks, explained by possible very fast
transient activities due to GIS
switching activities at station.
Observation indicated arcing marks
along tube being more concentrated
at air-side and having greater severity
compared to oil side.

Fig. 13:
Arcing and Fig. 14: Signs of overheating
<ow of erosion and arcing marks along
internal aluminium tube.
circulating
current
between
draw leads
and
aluminium
tubing.

Measurement of Power Factor and Capacitance on

the bushing prior to failure did not reveal any
abnormalities (see Table 1).

Table 1: 10 kV Power Factor & Capacitance

Measurement

Fig. 15: Damaged paper insulation for draw lead of

bushings.

The phenomenon of fast transient on a bushing’s

draw lead is still not fully understood in the Yeld.
Evidence of arcing/sparking between draw lead
and aluminium tube at common potential raises
concerns, especially in regard to risk of failures at
reactive compensator or in GIS substation
installations. As improvement, the speciYcation for
bushings with a draw lead connection has been
revised. The transformer manufacturer must now
ensure the draw lead cable within the tube is
insulated using thermally upgraded insulation
material with minimal thickness of 1mm. The goal
is to avoid causing any signiYcant rise in hot spot
temperature of the bushing and thereby prevent
any arcing between draw lead and aluminium
tubing during all fast transient phenomena in the
system.

Case #4: Monkey Damage to

Polymeric Insulators (Still
Unresolved)
To reduce risks from explosion and pollution, some
utilities have started to use bushings with
polymeric insulator housings. Recently, some of
these bushings have been attacked by monkeys
that chewed on the insulators. Discussions with
suppliers on use repellents or other inhibitors have
been in progress but without a commercial
solution in the case of transformer bushings. Some
severely damaged sheds have required urgent
replacement to prevent external Rashes and risk of
ingress into the main condenser layers.
Nonetheless, no utility members reported any
Rashovers since a\ected bushings were
immediately replaced once identiYed during
routine substation inspections.

Fig. 16: Damaged sheds due to monkey attack on

polymeric-housed bushings.

Case #5: Hygroscopic Issues for

Resin Impregnated Paper
Bushings
Hygroscopic properties of resin impregnated paper
(RIP) bushings need to be addressed in the event of
exposure to high humidity during storage or
handling. Prolonged exposure under environments
with high humidity can lead to the bottom of these
bushings absorbing moisture that can impact
performance. Change in colour at the bottom of
RIP bushings is indicative of this issue, which is a
major concern for utilities operating in high
humidity environments.

Fig 17: Wet RIP surface due to exposure to humidity

• While measurements show no signiYcant change

in C1 parameters, Table 2 illustrates changes in pF
C2 (after assembly) values that are sensitive to
humidity ingress at the bottom of a bushing’s
surface/core.

Table 2: 10 kV Power Factor & Capacitance

Measurement

For those RIP bushings with high humidity, drying

in an oven has been found to be e\ective in
removing moisture from bottom surfaces. Data
from one case study (see Fig. 18 and Table 3)
highlighted such issues, usually detectable by high
pf C2 values after assembly. Typical values of 2-3%
are acceptable limits recommended by OEMs. PF
for the overall bushing (HV terminal to Range) is
typically near to C1 values for dry bushings and this
is a useful parameter to monitor during any drying
process since PF C2 measurement may not be
accurate when a bushing is tested by itself, before
being mounted.

Fig. 18: RIP drying curve with PF (overall) monitoring

over drying cycle.

Table 3: PF (Overall) Data Over Drying Cycle

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Initiatives in Mitigating Bushing

Failure Risk
While the risk of transformer Yre due to bushing
failure is relatively low, it is not negligible.
Implementing strategies to prevent injuries,
minimize impact on adjacent assets and avoid loss
of supply is therefore an essential part of
management of transformer assets. The aim of
these strategies and initiatives is to address and
quantify risk of Yres and provide guidance on how
this risk can be managed in a safe and cost
e\ective manner.

The following risk mitigation measures are based

on discussion and best practices among utility
members and have been deemed e\ective at
improving performance of bushings in power grids:

1. RIP bushings are preferred over OIP for

condenser bushing classes 52 kV and above;
2. Procurement only from suppliers with proven
designs. Product pre-qualiYcation process is
recommended;
3. Oil-Ylling and sampling is NOT recommended for
OIP style bushings, unless performed by
competent personnel or under OEM supervision:
4. Enhanced maintenance practices should include:

• Replacing and/or monitoring bushings that

exceed acceptable criteria;
• Relying on power factor and capacitance
measurements deemed sensitive in detecting
incipient problems;
• Conducting thermal scans at least once every 6
months;
• Carrying out visual inspection at least bi-monthly,
checking for leakage or severe external
contaminants.

5. Storage and handling for RIP and OIP bushings

should follow OEM recommendations. For
example, Fig. 19 shows typical storage practice for
periods exceeding 12 months using specially
designed metallic covers Ylled with dry transformer
oil.

Fig. 19: Current practice for long-term storage.

6. Use of RIP protection coating as a moisture

barrier has been under evaluation for e\ectiveness
in the Yeld.

Fig. 20: Standard and moisture barrier-coating for RIP

bushing.

Fig 21: 145 kV bushings with moisture barrier

protective coating.

Fig. 22 illustrates a moisture ingress test comparing

a standard bushing and one with special coating,
as currently used by some member utilities.

Fig. 22: Standard bushing under moisture ingress test

(courtesy ABB Sweden).

Testing the standard bushing versus one with a

water barrier coating (under Yeld evaluation)
concluded that:

• compared to uncoated RIP, the barrier coating

prolonged onset duration of moisture or water
ingress into bushing layers by a multiple of about
80.
• increase in power factor, despite use of coating,
proved that the coating is e\ective ONLY for
handling purposes but not for long-term storage.

Design/SpeciUcation
• No migration of moisture must be possible
through the external insulation to the RIP
condenser body. All bushings rated voltage 52 kV
and above shall have either Ybreglass or
alternative proven material that acts as moisture
barrier between the RIP condenser body and the
external composite insulator. Fig. 23 illustrates a
Ybreglass moisture barrier for RIP bushing designs.
Other OEMs use pure resin or SF6 foam for similar
purposes, also deemed acceptable.

Fig. 23: Water barrier for RIP bushing construction

 using `breglass.

7. For purposes of inter-changeability and

standardization, oil-air bushings of rated voltage 52
kV and above have to comply with standard
requirements in terms of dimensions and rating
(see Fig. 24), as already successfully implemented
by one utility member.

Table 1: Standard Oil-AirType Type Bushing

Dimensional Requirement

Fig. 24: Sample bushing dimensional standardization

for diberent ratings.

8. For replacement or refurbishment purposes on

units already in service, it is recommended that the
new bushing supplied exactly match existing
dimensions in order to ensure bottom clearances
are met, as per initial design, and to prevent
substantial modiYcation and need for retroYtting
work on site;

9. All type tests and routine tests shall be carried

out according to the latest requirements of IEC or
IEEE standards. Type test reports and certiYcates
must be submitted to users on delivery;

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10. Partial discharge testing shall be performed in

accordance with the latest IEC 60137
requirement(s) or routine measurements for
detection of internal PD. These shall be, at
maximum, virtually discharge free (i.e. ≤5pC at 1.05
Um/Ö3 and ≤5pC at 2.0 Um/Ö3 when more
stringent requirement(s) apply). If a bushing fails
the PD test, it is to be rejected and not to be
reconditioned for later use in the system.

11. For those bushings having a draw lead

connection, the transformer manufacturer shall
ensure that the draw lead cable within the tube is
insulated using thermally upgraded insulation
material with minimal thickness of 1 mm. There
must not be a signiYcant rise in hot spot
temperature of the bushing so as to prevent risk of
arcing between draw lead to aluminium tubing
during system fast transient phenomena.

12. When Yxed solid conductors are used, the

transformer manufacturer must ensure a Rexible
lead is provided between transformer and bushing
to avoid any vibration or dilatation being
transmitted during operation;

13. Current rating of supplied bushings shall be

inclusive of an overload factor of at least 1.2 times
maximum rated current for transformer rated
capacity;

14. The test tap shall be manufactured from non-

corrodible material and be sealed by means of a
non-corrodible screw-on dust cover during service.
A reusable (oil, heat and UV resistance) seal shall
be provided to prevent moisture and/or other
impurities from entering the test tap. Use of a
nitrile rubber material with sujcient hardness is
preferred in this regard;

15. Internal connection of the test tap to the

outmost condenser foil layer is accomplished using
a permanent electrical connection. Spring-loaded
type internal connections are not recommended
due to experience with poor performance due to
loss of spring contact pressure over time;

16. Air insulated cable boxes on transformers shall

have arc venting to prevent risk of damage to the
cable box, dislocation of cables and breakage of
bushings (see Fig. 25);

Fig. 25: Air insulated cable box with arc venting

facility.

17. In regard to on-line monitoring systems for

critical installations, it is the prerogative of users to
study the suitability of di\erent technologies that
can assess bushing condition in the Yeld. Fig. 26,
for example, illustrates installation of bushing
monitoring on a power transformer and Yndings of
a case study are elaborated below:

Fig. 26: Bushing monitoring system installation on

power transformer.

Findings have revealed that information from o\-

line and on-line monitoring mostly agree in the
case of healthy bushings (refer to Table 4) and such
a system can therefore serve as a tool to monitor
relative change in bushing condition. However,
beneYts have to be assessed on a case-by-case
basis prior to implementation, given the risks to
equipment being monitored as well as the cost and
reliability of such a monitoring system.

Case Study
Power Transformer 3×250 MVA, 500/230-11 kV
Bushing on-line installation: 2015

Table 4: Power Factor/Capacitance Data

On-Line Measurements vs. 10 kV Ob-Line Values

18. Use of resin impregnated synthetic Ybre

technology for dry bushings mitigates possible
issues related to hygroscopic properties of epoxy
resin impregnated bushings with conventional
paper insulation. For example, TNB, embarked on a
pilot project in 2013 using the new RIS technology
at 170 kV. Results, shown in Fig. 27 and Table 5,
indicated superior performance versus
conventional RIP bushings.

Fig. 27: First RIS bushing installation at TNB in

Malaysia.

Table 5 summarizes measured parameters over

the course of the evaluation period versus
acceptance criteria established by the project
team.

Table 5: Results of Measurements of On-Line Bushing

Monitoring

Overvoltage Protection

• Metal oxide surge arresters are an important part

of transformer protection in reducing risk of a
failure due to surges or transient activities in the
system. All line terminals of a transformer should
be protected by surge arresters.

Fig. 28: Use of surge arrester protection near

transformer terminal.

Conclusions
Despite a relatively low failure rate given their
population, failures of bushings can have a
catastrophic impact on grid reliability, availability
and safety. Conducting a survey and developing an
ASEAN Bushing Guidebook yielded signiYcant
beneYts in terms of standardizing and reviewing
existing practices to ensure these are in line with
best practices as well as the latest international
standards. Several e\ective risk mitigation
measures and improvements have been outlined
based on experience from past incidents of failure.
E\ective implementation of these measures has
helped improve overall bushing performance with
reduced rates of failures among member utilities.

________________

RELATED ARTICLES:

Test Requirements for HV Bushings

Testing for Safety & Risks A\ecting Operation of HV

Cable Terminations, Bushings & Arresters

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