11 HSP Bushings

Design, production and evaluation of the reliability of bushings
Dr. Bernhard Heil

HSP Hochspannungsgerte GmbH & Trench Bushing Group
TRANSFORM Partner
Biography
Engineering Diploma from the RWTH Aachen University, Germany in 2001

PhD from the same University in 2006
From 2006 to 2008 Chief Engineer of the Insulating Systems and Diagnostics
Research Group at RWTH Aachen University

Employed with HSP Hochspannungsgerte GmbH in Cologne, Germany since
2008
Department Head of the Technical Support
Dr. Bernhard Heil, HSP Hochspannungsgerte GmbH & Trench Bushing Group
07.06.2013
Page 2
Agenda
Function of Bushings in the High Electric Field

Description of graded Condenser Bushings
Condenser graded insulating Body (Core)
RBP Resin Bonded Paper Properties
OIP Oil Impregnated Paper Properties
RIP Resin Impregnated Paper Properties
Housings for bushings Composite Insulators
Transformer Bushings: RIP vs. OIP
Aging of Bushings
Examples
07.06.2013
Page 3
Function of Bushings in the High Electric Field
Paper
Capacitive grading by conductive layers
Equipotential lines
The basic function of a bushing is the save insulation of a conductor by

suitable influencing of the dielectric
Control of electrical field strength inside and outside of the bushing.
The dielectric strength must be ensured for the whole lifetime.
07.06.2013
Page 4
Description of graded Condenser Bushings

Core insulator
- OIP oil impregnated paper
- RBP resin bonded paper
- RIP resin impregnated paper
Transformer end housing

- Porcelain
- Epoxy-Resin
- RIP (no housing needed)
Secondary insulation
- Oil (main insulation for OIP)
- Gas
- Dry material filler
Outdoor end housing

- Porcelain
- Composite insulator
07.06.2013
Page 5
Condenser graded insulating Body (Core)
RBP
START 1913
RBP-production was
shut down at HSP in 1974.
Some manufacturers do still
hold on for this technology.
OIP
RIP
SINCE 1950
SINCE 1960
The technology of resin and of oil

impregnated paper bushings at HSP
is established since more than 50 years
07.06.2013
Page 6
Insulating paper, impregnated with phenolic or epoxy

resin.
Wound under temperature and pressure.
During this process the polymerisation of the resin is

carried out.
Typical laminate material.
Partial discharges with high intensity in several gaps at

normal operating voltage during the whole lifetime.
RBP
07.06.2013
Page 7
Measurement of capacitance and loss factor

- Slight temperature dependant loss factor
Loss factor [%]
- Strong increase of the loss factor during lifetime
2,4
2,2
2
1,8
1,6
1,4
1,2
1
0,8
0,6
0,4
0,2
0
aging
max. value
RBP
thermal
instability
30 years
25 years
20 years
15 years
10 years
20
40
60
80
100
Temperature [C]
07.06.2013
Page 8
Insulating paper, e.g. cable paper, dried under temperature

and vacuum and impregnated with insulating oil.
Advantages:
No partial discharge during whole lifetime.
Good ageing experiences.
Lower production costs (compared with RIP)
Disadvantages:
-
Needs complete housing.
Core may drop into the transformer if housing is

damaged.
Inflammable
max. temperature 105C
07.06.2013
Page 9
Dissolved gas analysis (DGA), Limits according to IEC 61464:

-
Hydrogen (H2)
140 ppm
Methane (CH4)
40 ppm
Ethylene (C2H4)
30 ppm
Ethane (C2H6)
70 ppm
Acetylene (C2H2)
Carbon monoxide (CO) 1000 ppm
Carbon dioxide (CO2)
2 ppm
3400 ppm
07.06.2013
Page 10
Creped insulating paper, dried under temperature and

vacuum, impregnated under vacuum with epoxy resin.
Advantages:
No partial discharge during whole lifetime.
Excellent ageing experience.
No housing for oil end necessary.
Secondary insulation: Dry material filler
operates with damaged housing temporarily
non-inflammable
max. temperature 120C
RIP
Disadvantages:
-
higher production costs
07.06.2013
Page 11

- Capacitance and loss factor are temperature-dependent
RIP
07.06.2013
Page 12
RIP Resin Impregnated Paper Manufacturing
Impregnation
Turning shop
07.06.2013
Page 13
Housings for bushings - Composite Insulators
In 1980 HSP started to replace porcelain housings with composite insulators.
Design and features of a composite insulator:

-
Epoxy resin tube supported with fiber glass as mechanical reinforcement
On each end of the tube there is a flange made of cast aluminum alloy.
High hydrophobicity over the whole life time -> Perfect pollution performance
Surface is Water repellant & self cleaningeven through thick layers of contamination
Ableitstrommessung / leakage current
180
160
I / A
neue Durchfhrung
new bushing
alte Durchfhrung
old bushing
140
120
100
80
60
40
20
0
1996
1997
1998
1999
2000
2001
2002
2003
Long-term measurement of the leakage current

at 2 RIP-123kV bushings running since 1977 in
bad environment.
07.06.2013
Page 14
Transformer Bushings
Oil impregnated paper (OIP)
bushing with porcelain insulator
Resin impregnated paper (RIP)

bushing with composite insulator
Option: silicone coated porcelain

porcelain
OIP
Insulator
condensor core
glass fiber reinforced

epoxy resin tube with
silicon sheds
RIP
oil
secondary
insulation
SF6 or foam
epoxi resin
oil part end
not necessary
07.06.2013
Page 15
Aging of Bushings
Electrical stress: Overvoltage, VFT
Thermal stress: accelerated aging (T = 6 K
bisection of life time)
Mechanical stress
Treeing RBP-bushing
Partial breakdown OIP-bushing
Partial breakdown RIP-bushing
07.06.2013
Page 16
3 Gorges, China; RIP 500kV HVDC
07.06.2013
Page 17
ITAIPU, Brazil-Paraguay; RIP 525kV EKTG-Bushing
07.06.2013
Page 18
Yun-Guang, China; RIP 800 kV UHVDC
Weight: 4 to
Length: 13500 mm
This is the first bushing worldwide for 800 kV

UHVDC transmission in RIP dry technology.
07.06.2013
Page 19
Summary
Function of a bushings
Types of condenser cores: RBP OIP RIP
Evaluation of the reliability
Manufacturing of RIP
Types of bushings
Aging of Bushings
Examples
07.06.2013
Page 20
HSP Hochspannungsgerte GmbH

& Trench Bushing Group
Our Production Locations
Americas
Europe
Asia
Troisdorf
(GER)
Toronto (CAN)
Shenyang (CHN)
St. Louis (F)
07.06.2013
Page 21

11 HSP Bushings

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Design, production and evaluation of the reliability of bushings

Dr. Bernhard Heil

Engineering Diploma from the RWTH Aachen University, Germany in 2001

Research Group at RWTH Aachen University

Function of Bushings in the High Electric Field

Function of Bushings in the High Electric Field

The basic function of a bushing is the save insulation of a conductor by

Control of electrical field strength inside and outside of the bushing.

The dielectric strength must be ensured for the whole lifetime.

Description of graded Condenser Bushings

Transformer end housing

Outdoor end housing

Condenser graded insulating Body (Core)

The technology of resin and of oil

RBP Resin Bonded Paper Properties

Insulating paper, impregnated with phenolic or epoxy

Wound under temperature and pressure.

During this process the polymerisation of the resin is

Typical laminate material.

Partial discharges with high intensity in several gaps at

RBP Resin Bonded Paper Properties

Measurement of capacitance and loss factor

Loss factor [%]

- Strong increase of the loss factor during lifetime

OIP Oil Impregnated Paper Properties

Insulating paper, e.g. cable paper, dried under temperature

No partial discharge during whole lifetime.

Good ageing experiences.

Lower production costs (compared with RIP)

Needs complete housing.

Core may drop into the transformer if housing is

max. temperature 105C

OIP Oil Impregnated Paper Properties

Measurement of capacitance and loss factor

Dissolved gas analysis (DGA), Limits according to IEC 61464:

Carbon monoxide (CO) 1000 ppm

Carbon dioxide (CO2)

RIP Resin Impregnated Paper Properties

Creped insulating paper, dried under temperature and

No partial discharge during whole lifetime.

Excellent ageing experience.

No housing for oil end necessary.

Secondary insulation: Dry material filler

operates with damaged housing temporarily

max. temperature 120C

higher production costs

RIP Resin Impregnated Paper Properties

Measurement of capacitance and loss factor

RIP Resin Impregnated Paper Manufacturing

Housings for bushings - Composite Insulators

In 1980 HSP started to replace porcelain housings with composite insulators.

Design and features of a composite insulator:

Epoxy resin tube supported with fiber glass as mechanical reinforcement

Long-term measurement of the leakage current

Resin impregnated paper (RIP)

Option: silicone coated porcelain

glass fiber reinforced

oil part end

Electrical stress: Overvoltage, VFT

Thermal stress: accelerated aging (T = 6 K

bisection of life time)

Partial breakdown OIP-bushing

Partial breakdown RIP-bushing

3 Gorges, China; RIP 500kV HVDC