PRESENTATION

ON
BUSHINGS

S V S PRASAD
Engineer (Design),
Switchgear Products Division,
Vijai Electricals Limited

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TOPICS TO BE COVERED

What is a bushing
Types of bushings
Salient design features
Manufacturing aspect.
Testing of bushings
Dos and donts on bushings

BUSHING

Bushings is one of the most important component

that are fitted to the electrical equipments like the
transformer, the switchgear etc. It is an insulating
structure for carrying the H V conductor through an
earthed barrier
A bushing has to provide
Electrical

insulation to the conductor for the

working voltage and for various over voltages,
which occur in service.

Mechanical

support against various Mechanical

forces & Carry the full load current.

TYPES OF BUSHINGS
1.1 Application

i) Generator bushing
ii) Transformer bushing
iii) Bushings for switch gear
iv) Wall bushing or roof bushing
1.2 Application:
i) Indoor type
ii) Outdoor type

Generator Bushing

Indoor & Out Door

Bushing

Wall bushings

Roof bushings

TYPES OF BUSHINGS
2.1 Type of Bushing:
i) Pull-through type
ii) Stem type
2.2 Type of Bushings:
i) Condenser core type
ii) Non-condenser core type
(Hollow Porcelain type)
iii) Gas filled bushing
iv) Solid Bushing
Solid Ceramic Bushing
Epoxy Bushing

Solid Ceramic Bushing

Epoxy Bushing

TYPES OF BUSHINGS
3. Type of insulation used in manufacturing
Condenser Bushing:
i) Synthetic Resin Bonded Paper (SRBP)

ii) Oil Impregnated Paper (OIP)

iii) Resin impregnated Paper (RIP)

TYPES OF BUSHINGS

Non - Condenser Bushing

In its simplest form a
bushing would be a cylinder
of insulating material ,
porcelain, glass resin etc, with
the radial clearance & axial
clearance to suit the electric
strengths.
Condenser Bushing
This is also known as
capacitance graded bushing
as it contains capacitance
layers in between the kraft
paper insulation at
predetermined positions to
build up a stress controlling
condenser insulator.

CONDENSER BUSHING

DESIGN OF BUSHINGS.
Minimum Specification required for
Design:
1. Highest System Voltage.
2. Rated Voltage.
3. Basic Insulation Level.
4. Length of CT Accommodation .
5. Creepage Distance Required.
6. Altitude.
7. Application.

SALIENT DESIGN FEATURES

Self

Earthing Test Tap for measurement

of Tan Delta and Capacitance at site.

Environmental

Bushings

friendly.

for special applications can

be designed and supplied to suit clients
specifications.

SALIENT DESIGN FEATURES

Electrostatic

Field Controlled design of

Condenser Core by Computer
Suitable for Operation under heavily
polluted atmosphere
Reliable, relatively easy erection and
practically maintenance free.
Better Dielectric Strength and Partial
Discharge free up to Working Voltage
Space for mounting of Ring Type
Current Transformer

145 KV OIP
CONDENSER
BUSHING

MAJOR PARTS OF
CONDENSER BUSHING
1. Condenser Core
2. Porcelain.
3. Oil level Gauge
4. Top cap.
5. Test Tap.
6. Mounting Flange.
7. Oil side Stress Shield.

CONDENSER CORE
The core of bushing consists of a hollow metallic
tube or solid metal rod, over which high grade
electrical kraft paper is wound .For condenser cores,
conducting layers of metallic foil are introduced at
predetermined diameters to make uniform
distribution of electrical stress. The winding of
condenser core is done in a dust free chamber. The
core is then processes. This comprises of drying in a
high degree of vacuum ( 0.005mm) , and then
impregnating with high quality, filtered and degassed transformers oil.

INSULATORS
The function of an insulator is to resist
flash over in adverse conditions.
This is determined by
a) The profile of the dielectric/ Creepage
Distance.*
b) The mounting arrangement of the
insulator i.e. , vertical, horizontal, or
inclined.
c) The properties of the surface, i.e.,
hydrophobic, toughness etc.
The shortest distance along the surface
of the porcelain between the metal
parts which normally have the
operating voltage between them.

FOR DIFFERENT POLLUTION LEVELS

POLLUTION LEVELS

CREEPAGE DISTANCE

I. Light ( areas without industries,

16mm/kV

agricultural or mountain areas )

II. Medium ( areas with industries

20 mm/kV

not producing pollution smoke,

Low density of house areas not
exposed to the coast)

III. Heavy (Areas with high density

25mm/kV

of industries, high density of

Heating plants producing pollution,
areas close to the sea.)

IV. Very Heavy (Areas close to

31mm/kV

the coast and exposed to sea spray,

desert areas, areas exposed to
strong winds carrying salt and sand etc

Example: for 145 kV Bushing with heavy pollution level minimum creepage
distance works to be.
145 kVX 25mm/kV = 3625mm

DIFFERENT PROFILES OF PORCELAINS

Plain.

Anti-fog.

Alternate.

OIL LEVEL GAUGES

These are provided in the outer surface of the
bushing for monitoring the oil level in the bushing.
These are generally of following types.
1. Magnetic Oil level
Gauges
2. Prismatic Oil level
Gauges.
3. Button Type Oil
level Gauges.

TOP CAP
This is a metallic housing for the spring
pack . it services as an in built oil
conservator to cater for oil expansion ,
and has an oil indicator. In many cases,
it also serves the purposes of a corona
shield.

MOUNTING FLANGE
This is used for mounting the bushing on an
earth barrier, such as a transformer tank or a
wall. It may have the provisions for following:

a) CT accommodation length.
b) Rating plate giving the rating and
identification details of bushing.

TEST TAP
The test tap is provided for measurement of the
power factor and capacitance of the bushing during
testing and service. The test tap is connected via a
tapping lead to the last condenser foil of the core
within the bushing. During normal services, this
tapping is electrically connected to the mounting
flange through a self-grounding arrangement.

OIL SIDE STRESS SHIELD

This is provided at the oil side of the bushing to
controlled the electrostatic field inside the
transformer after installation

FACILITES REQUIRED FOR

MANUFACTURE BUSHING
1.

2.
3.
4.

5.
6.

Dust free / pressurized winding chamber

Winding Machines
Heating oven for baking.
Process Plants for Drying and Vacuum
Impregnation at very fine Vacuum (0.0050.001mm of Mercury)
Oil Treatment Plants for oil processing
Assembly stand and Power pack for
Tightening

MANUFACTURE OF BUSHINGS
This is done in four stages.
1. Winding .

2. Baking.
3. Assembly.
4. Drying and impregnation

WINDING
This is done in an enclosed chamber which is dust free . The
winding machine are primarily drives the bushing conductor by
three roller mounted 120 Degree. These rollers maintained at
temperature of about 120 C uniformly by thermic fluid for
driving out initially moisture from the insulating paper. Full
width paper is passed on these rollers enabling it to wound on
bushing conductor under tension and pressure. At predetermine diameters a thin and pure aluminium foil is inserted
to form capacitances to control the electrostatic field around
the bushing. On attaining the final diameter bushing is wrapped
with glue coated paper.

BAKING
The bushing is then be unloaded and transferred
to a heated the oven on a suitable trolley with in 2
hours and heated at 125C to 130C for a period of 24
Hrs. minimum. The temperature of oven is then
reduced to 50C before bushing is taken out and
allowed to cool to ambient temperature. The bushing
shall then be protected with polythene sheet and
stored in a safe place till it is taken for assembly.

ASSEMBLY.
The bushing from baking oven should be shifted near
assembly stand. The polythene cover should be
removed. An insulating lead should be soldered to
the last aluminium foil. The bushing assembly is done
sequencely as shown. Whole assembly is tightened
by a power pack at pre-determined load to achieve
leak proof assembly.

DRYING AND IMPREGNATION

Assembly of bushings are placed inside a drying and impregnation
plant for processing. These are subjected to following after closing
the plant.
1.

DRYING PROCCESS: The temperature of the impregnation plant

Is maintained at 95 5 C for a minimum period of 48 Hrs.

2.

VACUUM PROCESS: The temperature of impregnation plant is

reduced to 60 5 C simultaneously pulling vacuum inside the
plant. When a vacuum of 0.005 to 0.001 mm Hg is obtained, the
same is maintained for a minimum period of 72 Hrs.

3. IMPREGNATION PROCESS: On Completion of vacuum drying,

filtered & degassed oil of the following parameters is admitted
inside the bushing at a slow speed at vacuum of 0.005 to 0.001
mm of Hg. Speed of filling is so controlled that the bushing is
completely filled in about 12 Hrs time.

i)

TEST
Electric strength

VALUES REQUIRED
70 min.

ii)
iii)

(BDV in kV)
Tan delta at 90 C
Resistivity at 90 C

0.02 max
10 x 1012min

iv)

(Ohm - cm)
Water content {mg/kg or

10 max.

ppm by weight)

4. SOAKING PROCESS: Bushings are then

allowed to soak the filled oil naturally for a
period of minimum 3 days. In between oil is
topped up to the desired level in the bushing
whenever needed.

Bushings are then finally closed and final

assembly done before taking to test.

OIL IMPREGNATION
PLANT

ROUTINE TESTS
Routine test: Tests are carried out on each bushing to check
requirement which are likely to vary during production.
These are follows:

1.

2.
3.
4.
5.
6.

Measurement of dielectric dissipation factor (Tan Delta)

and capacitance at ambient temperature.
Dry power frequency voltage withstand test.
Measurement of partial discharge quantity.
Tests of tap insulation.
Pressure test on liquid filled and liquid insulated bushings.
Tightness test at flange/ Fixing Device.

TESTING FACILITIES

Tests on Bushings are conducted in electromagnetically shielded Test Laboratory which is

provided with.
Impulse Generator
Test Transformer for power frequency voltage.
Standard capacitors
Voltage Divider.
PD measuring equipment
Schering bridge

DOs AND DO NOTs FOR BUSHINGS

DOs
1.

Check the packing externally for possible damage

before un packing.

2.

Unpack with care to avoid any direct blow on the

bushing or porcelain insulator.

3.

Store the bushing in a shed or covered with tarpoline to

protect it from moisture and rains. If removed from
the crate keep it indoors with lower end protective
intact.

4.

Handle the bushing with manila rope slings without

any undue force on porcelain insulators.

DOs AND DO NOTs FOR BUSHINGS

DOs
5.

Clean the porcelain insulator thoroughly before taking

any measurement or mounting the bushing on the
transformer. Check for any foreign body adhered to the
bottom porcelain.

6.

Check the oil level by making the bushing vertical

7.

Check for leakage of oil from any of the gasket joints. Each
bushing is tested with the oil immersed in oil tank and so
some traces of oil can be found which is actually not leakage.

8.

Check tan delta and capacitance ( if possible on mounted

bushing without making any connections ).

9.

Maintain the log book of records of periodical checks.

DOs AND DO NOTs FOR BUSHINGS

DO NOTs
1.

DO NOT unpack the bushing from crate unless

required to be mounted on the transformer.

2.

DO NOT use metal slings on porcelain and avoid un

due jerks while handling.

3.

DO NOT store the bushing outdoors with out any

protective covering

4.

DO NOT measure IR value and tan delta with out

thoroughly cleaning the porcelain and oil end
portion.

DOs AND DO NOTs FOR BUSHINGS

DO NOTs.......
5.

DO NOT fill oil in the bushing without specific

instructions from BHEL .

6.

DO NOT climb the porcelain to tighten the top terminal.

Use elevators or seperate ladder for this purpose.

7.

DO NOT dismantle or attempt to repair the bushing in

case the defect or mechanism is not clear.

REFERENCES
IS: 2099
IS: 3347
IEC: 60137

SITE TESTS ON BUSHING

BEFORE INSTALLATION ON TRANSFORMER
After thoroughly cleaning the bushing with non-fluffy cloth,
mount the bushing on a stand before carrying the tests at
site.
1. Measurement of Tan Delta and Capacitance at 10 kV.
(For this purpose a Schering Bridge Kit with 10kV in-built
Source is needed along with shielded cable

SITE TESTS ON BUSHING

AFTER INSTALLATION ON TRANSFORMER
After mounting the bushing on the transformer thoroughly
clean the bushing with non-fluffy cloth,
1. Measurement of Tan Delta and Capacitance at 10 kV.
(For this purpose the same Schering Bridge Kit should be
Used.)