A96-Frequently Asked Questions (FAQ) on

Transformer Bushings - Part 4

Question 36: What are the basic parameters to consider
when selecting Bushing CTs, and how will CTs be calibrated
randomly?

Bushing CT parameters are selected based on the transformer

currents and type of relay protection planned. An additional test
winding can be provided in BCTs to test BCTS at the site in an
assembled position inside the transformer. Please see Annexure
H of the CBIP Transformer Manual for more details on the test
windings in BCTs.
Question 37: Do porcelain bushings need to be oven-
cycled?

It is not required. But the central lead is to be dried if insulated

with paper.

Question 38: At one GSS, all six bushings in a 230/110kV

autotransformer failed. They were replaced with new ones
and are now working fine. No defects or dislocations were
noticed, but the substation is close to the sea. What could
be the reason for their failure?

It isn't easy to find the root cause without full details. The
bushing quality seems to be the reason, as the failures stopped
after replacing the bushings. It is not clear whether GIS is
present on both sides. When GIS became popular in the 1970s
and 80s, it was suspected that fast transient surges from GIS
during isolator switching may damage the transformer
bushings. Thanks to the improvements in GIS designs, such a
possibility is remote today.

Question 39: Regarding the LV Bushing Turrets of bus-

connected GSU Transformers... In one of the Transformers,
we observed abnormal heating of LV Turrets. In this
context, my questions are:

a. What are the causes of abnormal heating of LV Bushing

Turrets?

b. How is turret material different from Tank Material?

c. How is the earthing of the Turret done?

d. What maximum temperature can LV Bushings (36kV)

sustain continuously?

LV bushings of large GSUs will carry currents of several kA (8-

36 kA). This large current will generate a strong magnetic field
that, in turn, sets up a counter-current in nearby metallic
structures. This induced current can be substantial, as in the
cover of isolated phase ducts. This current will heat metallic
structures. This current can be reduced by changing metal to
non-magnetic stainless steel (AISI 304 or 316). In addition, at
high currents, turrets will be shielded with copper sheets ( 3-5
mm thick) inside the turret. The current induced in the copper
shield will circulate, and the flux from the bushing current will
be repelled from the turret surface. The heating will be more in
turret joints where the current flow will be disturbed. Proper
conducting connections ( lead connections) are provided at
joints to carry this induced current. We can avoid the local
heating in LV turrets with appropriate design measures.
Remember, stainless steel fasteners will overheat more than
mild steel fasteners due to the higher resistivity of stainless
steel.

The maximum temperature rise is limited below 100 C to avoid

damage to the rubber oil seals provided.

Question 40: What is the maximum temperature allowed for

the regular operation of transformer bushing?

Table 2 of IEC 60137 gives the maximum allowed temperature

rises and absolute temperatures for bushings and parts. The
allowed maximum temperatures for OIP bushings are 105C, for
RIP 120C, and terminal pads 90-105C, depending on the pad's
surface coating.

Question 41. Nitrile gasket within bushing temperature

withstands limit in case of the hotspot.

Nitrile rubber can withstand 90-95C, though theoretically 105

C. Viton oil seals are used for higher temperatures.

Question 42. The period after which we need to change the

gaskets in bushings.

For hermetically sealed condenser bushings, such an oil seal

change is not required during their lifetime. However, the top
seal of LV bushings may be changed in case of oil leaks.

Question 43. The oil filled in the OIP bushing for 400 kV is
synthetic in our plant. Can we top it up with mineral oil, and
if so, which type?

No. Usually, the oil used in OIP bushings is special high-grade

mineral transformer oil with gas-absorbing properties.
Question 44. Should spare EHV transformer bushings be
stored horizontally or vertically? How should bushings
supplied as mandatory spares be preserved, as they mainly
remain unused over long periods?

Spare bushings should be stored vertically on rigid stands,

preferably indoors. In the case of RIP/RIS bushings, a metallic
cover shall be provided at the tail portion to prevent moisture
ingress into the condenser core. Sometimes, oil is kept in this
storage cover with an oil sight window and silica gel breather. If
silicon polymer envelopes are used as upper cover, care shall
be taken to protect them from rodents and small animals that
may damage the silicon sheds.

Question 45: What are your comments on plug-in bushing

in the context of installation, performance, and
maintenance?

Plug-in bushings are more convenient from the angle of

installation and maintenance when cables are directly
connected to transformer terminals. With this option, cable
boxes can be eliminated. Price and local non-availability prevent
its wider use.

Question 46: Why is the Tertiary winding chosen with

higher BIL bushings?

Tertiary bushings do not always need to have a higher voltage

rating. When the tertiary winding is near a high voltage winding,
the transferred voltage to tertiary terminals during the impact of
surges from lines may be more than the nominal rated BIL of
tertiary winding. On such occasions, the next higher kV bushing
is recommended for tertiary. So, for a 220/132/ 11 kV auto-
transformer, 36 kV bushings are recommended for tertiary; for a
400/220/33 kV transformer, 52 KV bushings are used at
tertiary. However, for a 220/33/11 kV transformer, there is no
need for a higher kV bushing for tertiary.

Question 47: What is the importance of test tap in bushings,

and what are your comments on standardizing it in the
Indian Context?
Standardization of test tap design (or at least the connection
part) is urgent as test taps may be used widely for online
monitoring. CIGRE Brochure 755 also indicated this as a
significant recommendation for future implementation. The IEEE
bushing standard has formulated test pin standard dimensions.

Question 48: Why are EHV bushings with higher BIL than
transformer winding BIL?

HV and EHV bushings are the critical components of

transformers, and a significant share of transformer failures is
attributed to them. When a surge reaches a transformer, it first
impacts bushings before reaching the windings. Hence, in some
utilities or countries, it is a practice to use a bushing of one step
higher BIL than the BIL of the windings as an additional
protection for transformer windings. The surge arresters are
selected to protect a winding of BIL 550 kV. For example,
consider a 132 kV Transformer of winding BIL 550 KV. Then,
132 kV 650 BIL will be specified for the bushing. This is
probably now redundant as an amendment in IEC 60137-2008 (
IEC standard for bushings) raised the AC test voltage of
transformer bushings by an additional 10 % for extra safety
margins. Hence, a 132kV 650 BIL Bushing will be tested at 305
kV AC for one minute instead of a standard 275 kV test voltage
for 650 BIL.

Question 49: Why are modern bushings without spark gap

arcing horns?

Before the zinc oxide lightning arresters were developed in the

1970s, lightning arresters made of silicon carbide with series air
gaps were used for surge protection. When such lightning
arresters were used for the surge protection of transformers, it
was usual to provide coordinating arcing horns across the
transformer bushings as backup protection. This was necessary
as silicon carbide arresters' operating characteristics (impulse
voltage flashover to time) were unreliable for steep fronted
surges, and the operating point was above the V-t
characteristics of transformer insulation. So, to get protection in
this region, arcing horns was necessary.

However, arcing horn operating characteristics are inconsistent

and are affected by the wave shape, weather conditions, and
surge polarity. The operation of the arcing horn results in
momentary power interruption as the current flow of power
frequency follows surge diversion. This is a severe disadvantage
with arcing horns. The chance of bird faults across the arcing
horns is also high, especially with low-voltage bushings. Corona
across the gaps of EHV bushings can cause radio interference.
EHV bushing arcing horns had a round ball at the end of the top
and bottom rods to mitigate radio interference. I still remember
making a 100 mm diameter ball from a thin copper plate for our
first 420 kV OIP bushings made in the mid-1970s.

Modern zinc oxide lightning arresters without series air gaps

are reliable and perform uniformly in the V-t range below the
transformer insulation V-t curve. Hence, protective arcing horns
are not required for bushings as a backup. Due to their inherent
limitations and operating disadvantages, arcing horns are no
longer used in transformer bushings as a surge protection
device. Today arcing horns are provided only on distribution
transformer bushings.
 LV bushings with arcing horns

Question 50: In some cases, the arcing horn of the Bushing

did not fail/melt, but the transformer failed due to Lightning
Impulse. Please add your comments.

If arcing horns flashed, the surge was bypassed and did not
reach the windings.

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