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HLAB200456

Operating instructions for bushings


AirRIP

Preface
These operating instructions show general procedures and
guidelines that must be observed when installing and using the
product. These operating instructions makes no claim for
completeness and possibly does not cover all the activities that
can occur during the installation, operation or maintenance, as
there can be special variations of this product. It is highly
recommended that all the necessary information and drawings
are obtained before the installation and use. If in doubt or in need
of additional information, please contact High Voltage
Components at ABB Switzerland Ltd or your local ABB partner
for further information.

General Information
Micafil bushings are designed specifically for mineral oil-filled IEC
60296 transformers and chokes for oil-outdoor applications. Our
bushings comply with the standards IEC 60137, IEEE C57.19.00
and C57.19.01. Additionally, they must be qualified according to
strict internal guidelines. Micafil bushings are produced
exclusively at the ABB industrial site in Zurich, Switzerland.
Table of contents

Table of contents ................................................................................................................................................................................. 2


1. Safety information ....................................................................................................................................................................... 5
1.1. Symbols and notes .............................................................................................................................................................. 5
1.2. Product safety ..................................................................................................................................................................... 5
1.3. Personnel-related measures ............................................................................................................................................... 5
1.4. Organizational measures..................................................................................................................................................... 5
2. Structure of the bushing .............................................................................................................................................................. 6
2.1. General structure ................................................................................................................................................................. 6
3. Packaging and delivery ............................................................................................................................................................... 7
3.1. Delivered state and reloading .............................................................................................................................................. 7
3.2. Reference measurement No. 1 ........................................................................................................................................... 7
3.3. Repackaging ....................................................................................................................................................................... 7
3.4. Transport box ...................................................................................................................................................................... 7
4. Storage ............................................................................................................................................................................................ 8
4.1. Storage ................................................................................................................................................................................ 8
4.2. Storage container with oil (variant 1) ................................................................................................................................... 9
4.3. Storage container with PETP-Alu-PE composite film (variant 2) ......................................................................................... 9
4.4. Procedure after incorrect storage ........................................................................................................................................ 9
5. Assembling.................................................................................................................................................................................10
5.1. Recommended distance from the transformer wall ........................................................................................................... 10
5.2. Lifting the bushing ............................................................................................................................................................. 10
5.3. Reference measurement N°1 ............................................................................................................................................ 11
5.4. Conductor and terminal (A, B, C) ...................................................................................................................................... 11
5.5. Dismounting the cable bolt (A) or conductor rod (B) .......................................................................................................... 12
5.6. Connection cable bolt/conductor rope (A) ......................................................................................................................... 13
5.7. Split conductor rod ............................................................................................................................................................ 13
5.8. Rope conductor insulation (A) ........................................................................................................................................... 13
5.9. Insulation for the dismountable conductor rod (B) ............................................................................................................. 14
5.10. Fastening the shield .......................................................................................................................................................... 14
5.11. Bushing without shield ....................................................................................................................................................... 14
5.12. Shield for rope application ................................................................................................................................................. 14
5.13. Shield with spring-loaded thrust piece ............................................................................................................................... 14
5.14. Shield with bayonet catch .................................................................................................................................................. 15
5.15. Head shield from 420 kV ................................................................................................................................................... 15
5.16. Fixed conductor (C) ........................................................................................................................................................... 16
5.17. Preparation of the terminal surface (A, B, C) ..................................................................................................................... 16
5.18. Cleaning of the bushing surface and the interface ............................................................................................................ 16
5.19. Installing of the bushing ..................................................................................................................................................... 16
5.20. Damage during installation ................................................................................................................................................ 17
5.21. Assembly of cable bolt (A) or dismountable conductor rod (B) .......................................................................................... 17
5.22. Reverse-controlled bushings with rope conductor ............................................................................................................. 18
5.23. Flat seal system ................................................................................................................................................................ 18
5.24. Ring seal system ............................................................................................................................................................... 19
5.25. Flange installation ............................................................................................................................................................. 19
5.26. Tightening sequence ......................................................................................................................................................... 19
5.27. Fastening sequence .......................................................................................................................................................... 20

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5.28. Flange earthing ................................................................................................................................................................. 20
6. Assembling................................................................................................................................................................................ 21
6.1. Evacuation of the transformer ........................................................................................................................................... 21
6.2. Ventilation and downtimes................................................................................................................................................. 21
6.3. Reference measurement No. 2 ......................................................................................................................................... 21
6.4. Voltage connection ............................................................................................................................................................ 21
7. Test tape and voltage tap .......................................................................................................................................................... 22
7.1. Measuring connection structure (3 kV) .............................................................................................................................. 22
7.2. Measurement terminal purpose of use .............................................................................................................................. 23
7.3. Voltage terminal configuration ........................................................................................................................................... 24
8. Measurements of C1, C2, tan 1, tan 2 (reference n°1) .......................................................................................................... 26
8.1. Reference measurements No. 1 ........................................................................................................................................ 26
8.2. C1 and tan 1 measurement (reference n°1) .................................................................................................................... 26
8.3. C2 and tan 2 measurement (reference n°1) .................................................................................................................... 26
8.4. Reference measurement No. 1 overview .......................................................................................................................... 27
8.4.1. Capacity C1 and loss factor tan1 ..................................................................................................................................... 27
8.4.2. C2 & tan 2 (bushing with measurement terminal) ............................................................................................................ 27
8.4.3. C2 & tan 2 (bushing with voltage terminal) ...................................................................................................................... 27
8.5. Temperature-dependent correction factors for tan 1 & tan 2 ......................................................................................... 27
8.6. Temperature-dependent correction factors for C1 and C2 ................................................................................................ 28
8.7. Permissible tolerances ...................................................................................................................................................... 28
8.7.1. For bushings ≤ 145kV........................................................................................................................................................ 28
8.7.2. For bushings > 145kV ....................................................................................................................................................... 28
9. Measurements of C1, C2, tan 1, tan 2 (reference n°2) .......................................................................................................... 29
9.1. Reference measurements No. 2 ........................................................................................................................................ 29
9.2. C1 et tan 1 measurement (reference n°2) ...................................................................................................................... 29
9.3. C2 and tan 2 measurement (reference No. 2) ................................................................................................................. 30
9.4. Reference measurement No. 2 overview .......................................................................................................................... 30
9.4.1. Capacity C1 and loss factor tan1 ..................................................................................................................................... 30
9.4.2. C2 and tan 2 (bushing fitted with measurement terminal) ................................................................................................ 30
9.4.3. C2 and tan2 (bushing fitted with voltage terminal) ........................................................................................................... 30
9.5. Temperature-dependent correction factors for tan1 and tan2 ........................................................................................ 31
9.6. Temperature-dependent correction factors for C1 and C2 ................................................................................................ 31
9.7. Site-dependent correction for C1 ....................................................................................................................................... 31
9.8. Permissible tolerances ...................................................................................................................................................... 31
9.8.1. For bushings ≤ 145kV........................................................................................................................................................ 31
9.8.2. For bushings > 145kV ....................................................................................................................................................... 31
10. Maintenance.............................................................................................................................................................................. 32
10.1. Maintenance shedule ........................................................................................................................................................ 32
10.2. Bushing maintenance ........................................................................................................................................................ 33
10.3. Testing the connections with a thermal imaging camera ................................................................................................... 33
10.4. Cleaning the porcelain insulator ........................................................................................................................................ 33
10.5. Cleaning the silicone insulator ........................................................................................................................................... 33
10.6. Capacity and tan δ loss factor checks ............................................................................................................................... 33
10.7. Spare parts ........................................................................................................................................................................ 33
10.8. Replacement of bushings .................................................................................................................................................. 33
11. Dismounting (transport, repairs or disposal).............................................................................................................................. 34
11.1. Dismounting the bushing for transport, repairs or disposal................................................................................................ 34
12. Repair........................................................................................................................................................................................ 35

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12.1. Bushing repairs ................................................................................................................................................................. 35
12.2. Porcelain insulator repairs ................................................................................................................................................. 35
12.3. Silicone insulator repairs .................................................................................................................................................. 35
13. Disposal .....................................................................................................................................................................................36
13.1. Special hazards during disposal ........................................................................................................................................ 36
14. Type designation ........................................................................................................................................................................37
14.1. Rating plate ....................................................................................................................................................................... 37

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1. Safety information
1.1. Symbols and notes 1.2. Product safety
Warnings in these operating instructions point at particular Micafil capacitor bushings of types RTKF, RTXF, RTZF, RTF,
hazards and specify measures for avoiding them. There are three RTKG, RAKF, RTKK, DMB-OA, RAF, RTAK, RTIM, RMFF, RMF,
levels of warnings: RMI, … are produced according to the state of the art and the
recognized safety rules. Despite that, when handling the bushing
and improperly using it, hazards to the health and life of the user
or third persons, or damage to the bushing and other material
This safety sign warns of immediate danger. assets can occur.
If such notices are not observed, it can lead  The bushing must be used only in technically faultless state
to heavy injuries and even death. as well as in observance of the provisions and the operating
Additionally, material damage can occur. instructions, and with awareness of safety and hazards.
 Damaged bushings must be decommissioned and replaced.
Examples of hazards: electric shock, fire
DANGER hazard, explosion, poisonous gasses,
1.3. Personnel-related measures
slipping, working at height, impacts...
 The executing personnel as well as those who supervise the
work must have adequate training, have safety-related
knowledge in connection with the various activities, and work
accordingly.
 Personnel should trained and instructed concerning the
This safety sign warns of possible danger. If
planned works with the bushing based on the operating
such notices are not observed, it can lead to
instructions.
injury and/or material damage.
 The personnel that must be trained, taught or instructed, or
Examples of hazards: burning, skin, eye or the personnel that is in the process of obtaining general
CAUTION
hearing injury, tripping hazards... training, must work with the bushing under the supervision of
an experienced technical specialist in the field of high-voltage
equipment.
 For working at height, the corresponding guidelines must be
observed.
 Use compliant tools.
This symbol identifies important information
or points at risks that can result in material  Wear suitable PPE (personal protective equipment: helmet,
working clothes, safety shoes, gloves, goggles).
damage.

NOTE 1.4. Organizational measures


 Read the relevant chapters of the operating instructions
carefully and observe all safety and hazard instructions.
 This notice suggest a particular course of action.  Keep the full and readable operating instructions ready, and
provide all-time access to it to the operating personnel.
 Observe the safety rules of the operator of the high and
medium voltage system and all the relevant provisions of the
The structure of the warnings is as follows:
national and international safety authorities.
 Only authorize trained and instructed specialist personnel.
Type and source of hazard
 Clearly determine, make known and observe the areas of
The possible results of not introducing the responsibility for the works with the bushing.
measures are put here.  Only the personnel that before the beginning of the work have
 Dangerous conditions or actions to be read and understood the relevant chapters of the operating
SYMBOLS
avoided are included here. instructions may be assigned for activities with bushings.
 Safety and hazard-conscious work must be inspected
 Measures for avoiding the hazards are regularly observing the operating instructions. Observing the
located here. 5 rules for voltage-free work: Switch off, secure, test,
earth/close-circuit, protect.

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2. Structure of the bushing

2.1. General structure


The AirRIP type series are dry, oil-free and capacitive-controlled Depending on the design, AirRIP bushings can be equipped
bushings. The main insulation body of the bushing comprises with a fixed conductor, dismountable conductor rod or a cable
bolt for rope conductors.
resin-impregnated paper (RIP). The conductive surfaces in the
The gap between the insulating body and the external insulator is
insulating body are used for capacitive field control.
filled with the dry MICAGEL filling, so that the bushings can be
The outdoor side is tightly sealed with a silicone or porcelain operated in any post-assembly position. Heavier bushings,
insulator, being thus protected against humidity¬. A vent screw is mostly 145 kV and larger, are limited to installation angles of up
brought to the flange of the bushing to be able to ventilate the to 30° from the vertical. The data in the dimension sheet are
transformer. The possible central pipe can also be ventilated with binding.
a vent screw mounted in the conductor. Threads located on the
flange can be used for mounting crane eyes or pushing the Micafil bushings are dimensioned and
bushing away from the transformer flange. A self-earthing designed for applications in mineral oil.
measuring connection is integrated in the flange, making possible
 For organic oils, please contact High
the measurement of the capacity and the loss factor of the
Voltage Components at ABB
bushing in the installed state.
NOTE Switzerland Ltd or your local ABB
partner for further information.

Current conductor terminal with central tube ventilation (air side)

Head with clamp for power conductor

RIP insulating body with capacitor control and central pipe

MICAGEL dry filling

Porcelain or silicone composite insulator (external insulator)

Flange with measuring connection and transformer ventilation

Measurement terminal

Lower part extension for current transformer

Oil-side shielding

Fig.1: Structure of an AirRIP bushing with cable bolt for rope conductors

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3. Packaging and delivery

Prevention of reloading hazards, cutting 3.2. Reference measurement No. 1


injuries, electric shock, slipping and After the delivery, it is highly recommended that reference
tripping accidents measurement No. 1 for main capacity C1, capacity C2 and loss
 The work area must be marked and factors tan1 and tan 2 are used to determine is the bushing took
kept clear. up any humidity after transport (see Chapter 8).
 All the activities must be supervised by
a qualified person. 3.3. Repackaging
 The personnel should be trained for It must be made sure that the bushing and the blank insulating
the reloading activities. body of the bushing are packaged in the same way as for delivery
DANGER  The personnel should have with a plastic bag and a desiccant (incl. humidity indicator) to
appropriate training for work with protect them against humidity.
dangerous voltages (reference
measurement No. 1). For bushings that are repackaged without cable or conductor
 Observe weight data and markings for bolts, the opening of the conductor tube must be sealed on the
the center of gravity. air side of the bushing.
 Wear appropriate PPE

 For further information, please contact


High Voltage Components at ABB
3.1. Delivered state and reloading Switzerland Ltd or your local ABB partner.
NOTE
The bushings are sent in wooden transport boxes for protecting
them against damage. The lower part of the bushing is packaged
in a plastic bag, provided with a desiccant and possibly a humidity 3.4. Transport box
indicator to protect it from humidity.
Gross and net weight as well as dimensions are included in the
dispatch note.
In the delivery, the cable bolt or conductor rod is installed in the
bushing.
The center of gravity is normally market on the transport box if it
is longer than 2 meters and if the center of gravity is not in the
middle.

Fig. 1: Packaging, delivered state, reloading

 For every packaging type, it must be


ensured that it is fully intact after
transport.
 If the humidity indicator has turned pink
NOTE => see Storage Recommendation Tab 1.
(see Chapter 4.1).

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4. Storage

Prevention of reloading hazards, cutting 4.1. Storage


injuries, electric shock, chemical hazards, Insulating bodies of bushings are dry after their production. These
slipping and tripping accidents insulating bodies are made of resin-impregnated paper (RIP)
 The work area must be marked and which could absorb moisture over the time. Therefore, the
kept clear. recommendations in the Tab.1 must be observed.
 All the activities must be supervised by
a qualified person. For storing the bushing, the storage location (protected from rain,
 The personnel should be trained for outdoor or dry indoor location) and the storage period must be
the reloading activities. taken into consideration.
 The personnel should have
DANGER appropriate training for work with  When stored, the bushing must be
dangerous voltages (reference completely sealed in humidity-protective
measurement No. 1). packaging.
 Observe weight data and markings for  If the humidity indicator has turned pink, see
the center of gravity. NOTE Storage recommendations Tab. 1.
 Wear appropriate PPE.

Storage duration Outdoor, protected against rain Indoor space, dry (not condensing)

Up to 6 months In original box, packed with PE tubular film. In original box and original packaging.
Recommended: Additional humidity
protection of the body with a second
Polyethylene (PE) tubular film and desiccant
Up to 12 months No possible => Risk of irreparable damage In original box and original packaging.
Only in dry rooms (relative air humidity <50%) at a temperature that is as constant as
possible.
Conduct regular inspections (at least once a year)
If the humidity indicator inside the sealed PE foil colors itself in the pink direction, at least
an equal amount of desiccant units must be replaced. Within 24 hours, the indicator will
change back in the blue direction (relative air humidity < 40%).
Long-term storage, No possible => Risk of irreparable damage Protect the unshielded parts of the bushing in the storage container:
more than 1 year Bushing in protective layer material (PETP/Alu/PE) together with desiccant:
- Conduct regular inspections (at least once a year)
- If the humidity indicator inside the sealed PE foil colors itself in the pink direction, at
least an equal amount of desiccant units must be replaced. Within 24 hours, the
indicator will change back in the blue direction (relative air humidity < 40%).
- For bushings that are stored for more than a year, we highly recommend a reference
measurement No. 1 (see Chapter 8).
- Desiccant amount/air conditioning: 2½ TME/m2 (moderate) and 25 TME/m2 (extreme)
- TME/m2: Desiccant units per m2 of the barrier layer surface.
Desiccant according to the standard:
1 Unit (DIN 55473A) = 1 Unit (MILD 3464 E) = 1/16 Unit (NF H-320 & 321)
Bushing with oil storage container:
- Conduct regular inspections (at least once a year)
- The oil level should be levelled between the 2 oil sight glasses (see Fig. 3).

Tab. 1: Storage recommendations

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4.2. Storage container with oil (variant 1) 4.4. Procedure after incorrect storage
Prevention of dangers related to handling If there is suspicion that the insulating body has taken up
chemicals, explosions, burns humidity, it can be checked using a reference measurement No.
1 (see Chapter 8). If there is a deviation from the work report
 The transport box should be protected
found, a subsequent drying can be conducted in consultation with
against heat during the storage (to avoid a
DANGER the High Voltage Components division at ABB Switzerland Ltd. In
pressure rise in the container).
most cases, the bushing can be made operational again.

In order to make a more precise diagnosis of its condition,


perform the measurement with the Dielectric Frequency
For the long-term storage, it is recommended to design protection
Response (DFR), which offers more precise results in humid
with an oil-filled storage container. In the normal case, it ensures
bushing.
the immediate availability of the bushing (e.g. reserve bushing).
A yearly inspection of the oil level is recommended.
 For further information, please contact
High Voltage Components at ABB
Switzerland Ltd or your local ABB
partner.
NOTE

Fig. 3: Container with oil

1 High level | 2 Recommended level | 3 Low level

4.3. Storage container with PETP-Alu-PE composite


film (variant 2)
This long-term packaging comprises an inner and an outer
packaging. The inner packaging (2) is a PE foil and is placed
directly over unprotected parts of the bushing, containing a
desiccant to protect against humidity. The outer packaging (1) is
a PETP-Alu-PE composite foil that covers and seals the entire
bushing. In addition to the desiccant, the external packaging also
includes a humidity indicator in order to provide humidity
monitoring. A yearly inspection of the humidity indicator is
recommended.

Fig. 4: Long-term packaging with Al-composite film.

1 PETP-Alu-PE composite foil | 2 PE foil | 3 desiccant


4 humidity indicator sight window

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5. Assembling

Prevention of reloading hazards, cutting


injuries, electric shock, chemical hazards,
falling, slipping and tripping accidents
 The work area must be marked and kept
clear.
 All the activities must be supervised by a
qualified person.
 The personnel should be trained for the
reloading activities.
DANGER  Appropriate climbing aids and
supporting structures should be used.
 The personnel should be authorized to
work at height.
Fig. 5: Recommended distance A from earthed parts (e.g. transformer
 The personnel should have appropriate
wall)
training for work with dangerous
voltages (reference measurement No. Recommended minimal distances A to the earthed parts of the
1). transformer [mm]
 Wear appropriate PPE.

 The protective cover of the silicone AC test voltage


Ur

insulator should be laid out until the Diameter of the shields Ø [mm]
commissioning in order to avoid partial [kV] [kV] Ø109 Ø134 Ø180 Ø160 Ø180 Ø230 Ø292
discharges trough fingerprints. ≤52 ≤105 80 95 - - - - -
NOTE
140 90 105 - 120 - - -
72.5
160 100 105 - 125 - - -
185 115 115 - 130 130 - -
123
5.1. Recommended distance from the transformer wall 230 145 145 - 145 145 - -

The bushings are developed and tested for mineral oil 275 - 170 - 170 170 - -
145
applications. The field strengths in oil in the lower part of the 310 - 200 - 200 200 - -

bushing depend on the form of the surrounding parts as well as 325 - 210 - 210 210 - -
170
on the transformer oil. 365 - 230 - 230 230 - -
245 460 - - 300 300 300 - -

The corresponding gaps (A) to the earthed structures under 300 510 - - - - - 330 330
standard conditions are listed as a guideline in the following Tab. 630 - - - - - - 450
420
2. This concerns the oil-side ends of the bushings according to 680 - - - - - - 500
the data of the dimension sheet for the bushing. Due to framework 750 - - - - - - 550
550
conditions, additional insulation measures and/or greater 790 - - - - - - 600
distances can be necessary. If necessary, the distance can also Tab. 2: Recommended distances A from earthed parts
be reduced.

Non-insulated edges may only appear in the permitted area and 5.2. Lifting the bushing
should have a Rmin. = 5 mm.
Smaller types (<20 kg) can be picked up manually; larger types
require a textile rope and lifting gear (crane, hoist etc.).
 A possible current transformer must be
not be longer than L6 (see Fig. 5 and The lifting of the bushing from the transport box can take place
dimension sheet of the bushing), as the with the use of lifting gear, as well as a crane, a hoist etc. and two
field is disrupted and a destruction of suspension ropes. One of the suspension ropes is fastened with
CAUTION the bushing is possible. a textile rope sling directly onto the flange or on the crane eyes
mounted on the flange. The other suspension rope is fastened
with a textile rope sling to the insulator between the shields, near
the head or using the crane eyes mounted on the head or on the
special clamp (optional).

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5.3. Reference measurement N°1
Before the installation, reference measurement No. 1 for main
capacity C1, capacity C2 and loss factors tan1 and tan 2 should
be obtained (see Chapter 8) to establish a reference point for later
measurements and also to determine if the bushing took up any
humidity after transport and/or storage.

5.4. Conductor and terminal (A, B, C)


When connecting the bushing a solid conductive contact surface
should be taken into account to minimize the influence of possible
contact resistance (see Chapter 5.17).

Three different conductor types are available. All with a cable bolt
for conductor rope, with dismountable conductor rod or fixed
conductor variant, depending on the order.

Fig. 6: Crane eye on flange and head

(A) (B) (C)


Cable bolt Dismountable Fixed conductor

for conductor conductor rod

Fig. 8: Details of the lower part of a bushing (schematic)

Fig. 7: Fastening the suspension rope for bushings without crane eyes If any, future conductors and contact terminals on the winding
side of the transformer should be oversized to avoid overheating
in the area of terminal connections.

 The connections or the shield must not In order to maintain sufficient and prolonged contact pressure,
be used as a suspension point for strong spring washer should be placed under the screws. In order
protection against damage. to avoid disengagement through constant vibrations, a screw lock
NOTE should be used.

The connection details can be found in the dimension sheet for


If the silicone insulator is in the form of a the bushing.
spiral, no rope slings should be placed
around the insulator.
 Avoid magnetic screws here.
 The first lifting eye must be mounted on  The surfaces of the terminals may not be
the flange and the second must be damaged.
mounted on the provided frontal thread
NOTE
on the head.
 If there is a shield with dismountable
NOTE spacing sleeves on the head of the
bushing, the shield as well as the
spacing sleeve should be dismounted for
lifting (see Fig. 16). Lifting eyes are
screwed directly onto the head of the
bushing.

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No rigid connection  Bushings with a central tube diameter of
26 mm additionally have a screwed-on
 Future conductors must not be made rigid
terminal on the cable bolt.
(above and below), as the bushing must
 Bushings with a conductor rod (B) that,
not pick up or transmit any movements or
oil-side, has a flat terminal, need not be
vibrations.
processed.
 The use of flexible terminal connections
NOTE  Before the bushing can be installed on a
makes it also possible to avoid vibrations
transformer, it is necessary to solder a
and movements of the transformer NOTE conductor wire in the cable bolt. In order
affecting nearby parts.
to be able to solder the conductor rope,
the cable bolt must be dismounted and
Preparing the connection processed.
 The feed and discharge lines, including
their connection elements, such as
terminal lugs, terminals or additional
connectors, must be dimensioned in a way A slipping out of the cable bolt or conductor
that no heat is brought to the connections rod is possible.
of the bushing.  Secure with eyebolt and wire.
 The connective surfaces should be flat, NOTE
NOTE
even, clean and not unprocessed. The
contact surfaces should be lubricated with
contact grease and be tightened with
specified tightening torques (see Tab. 3).
2
1
5

Strength class and


Tightening torque [Nm]
Thread A2-70 A4-70 8.8 10.9 12.9

M6 8.5 8.5 10 14 17
M8 21 21 25 35 41
M 10 41 41 49 69 83 6
M 12 72 72 86 120 145
Tab. 3: Recommended tightening torques

5.5. Dismounting the cable bolt (A) or conductor rod (B)


Depending on the order, the bushing is delivered with a cable bolt
or a conductor rod. Before the bushing can be installed on a
transformer, it is necessary to solder a conductor wire in the cable 3
bolt or conductor rod.

In order to be able to solder the conductor rope, the cable bolt or 4


conductor rod must be dismounted and processed. Bushings with
a conductor rod that, oil-side, has a flat terminal, need not be
processed.

In order to remove the cable bolt or conductor rod, it is


recommended that the vent screw is replaced with an eyebolt. A Fig. 9 Steps for dismounting the cable bolt/conductor rod.
rope is attached to the eyebolt, preventing the slipping out of the 1 vent screw | 2 eyebolt | 3 clamp screw
cable bolt or conductor rod during the dismounting. 4 clamp halves | 5 sealing sleeve | 6 groove

The grooves (6) on the cable bolt/conductor rod help shifting the
As is shown in Fig. 9, first, the clamp screw (3) is loosened and conductor in the vertical direction ±10 mm.
the clamp halves (4) are unfolded. Afterwards, the cable bolt or
conductor rod (including the sealing sleeve) is removed, the rope
is released and the sealing sleeve is pulled off.  The cable bolt or conductor rod must
not be scratched.

CAUTION

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5.6. Connection cable bolt/conductor rope (A) Tube diameter Max. hole diameter Cable boltdiameter Max. drilling
d3 (6) (1) (2) [mm] depth
The bushings with conductor rod have an oil-side flat terminal
[mm] [mm] (3)
and, thus, need no processing.
[mm]

The conductor rope may be soft soldered or brazed to the cable 40 35 38 (4)-20

bolt. The temperature necessary for the soft soldering must not 50 40 45 (4)-20

exceed 450 °C, to avoid possible annealing of the cable bolt. The 65 55 60 (4)-20
soldering must be performed carefully in order to ensure optimal 80 70 75 (4)-20
contact. For brazing, the sealing and the terminal must be 100 90 95 (4)-20
sufficiently cooled. Silver solders with melting temperatures of Tab. 4: Recommended maximum drilling depth and hole diameter for a
under 700 °C must be used here. standard cable bolt

In order to make sure that the drilling is not performed too deeply,
 Before the soldering, the vent screw and the following rules are recommended: Maximum drilling depth (3)
all the seals must be removed from the is the same as the length of the cable bolt (4) minus 20 mm.
cable bolt. The diameter of the power conductor should be at least a half of
the tube diameter Ø d3 (6).The oil supply may not be impaired in
Damage to the seal system can lead to the central bushing opening and in the open area of the shield.
NOTE malfunctions in the bushing or the
transformer. 5.7. Split conductor rod
If the bushing is equipped with a split conductor rod (see Fig. 11),
the lower part of the conductor rod must be screwed to the upper
With an appropriate tool and an adjustment of the cable bolt, a part of the conductor rod after soldering. When installing, make
pressing of the cable bolt is possible as an alternative. sure that the screw are alternately tightened.

The bolt is delivered unprocessed. For this reason, a hole suitable


for soldering the conductor rope must be drilled in the bolt. The
diameter of the drilled hole must be adjust to the diameter of the
rope. Whenever possible, the bore design without a peak is
recommended. The recommended maximum drilling depths and
hole diameters for the standard cable bolt are provided in Fig. 10
and Tab. 4.

 Do not drill in the ventilation channel.

NOTE

Fig. 11: Split conductor rod screw joint

1 screws and spring washers | 2 upper conductor rod | 3 lower


conductor rod

The mounting screws can vary depending on the size of the


conductor rod. Recommended tightening torques are:

Thread Tightening torque


[Nm]
M8 12
M10 25
M12 45
Tab. 5: Recommended tightening torques for the screws of the divided
conductor rod (non-greased)

5.8. Rope conductor insulation (A)


To prevent partial discharges caused e.g. by switching transients
between the rope conductor and the central tube of the bushing,
Fig. 10: Processing on cable bolt. the rope conductor must be wrapped in at least 1 mm of insulation
Turned (left) and drilled (right) hole. material. The use of aramide paper (heat-resistant) is
1 max. hole diameter | 2 cable bolt diameter recommended).
3 max. drilling depth | 4 cable bolt lower part length |
5 ventilation channel | 6 diameter d3 (see bushing dimension sheet)

13/38 | HLAB200456 | Operating instructions for AirRIP bushings


The shielding is available for voltages ranging from 24 kV to 245
kV (optional, depending on the bushing type). The shield is
caulked with the supporting tube at the factory.

 The rope conductor must not touch the


shield - not even due to vibration or other
displacements.
 The shield for rope applications must not
NOTE be dismounted.

Fig. 12: Rope conductor insulation. At least 1 mm insulation material


thickness 5.13. Shield with spring-loaded thrust piece
This shield is longer compared to shields for rope applications, for
 If the insulation material thickness is covering exposed edges at the terminal inside the shield.
too high, the bushing can overheat.
The shielding is available for voltages ranging from 24 kV to 245
CAUTION
kV (optional, depending on the bushing type). The shielding can
be mounted on the mounting ring and dismounted from it at the
factory.
5.9. Insulation for the dismountable conductor rod (B)
For a dismountable conductor rod, spark formation is avoided  In order to dismount the shield, the 3 spring-loaded pressure
through insulating centering rings that separate the conductor pieces must be loosened with an Allen wrench (not
rod from the central tube. completely: unscrew it enough to keep them mounted on the
shield).
5.10. Fastening the shield  The shield can be shifted upwards or downwards.
 The terminal is freely accessible and can be connected to the
Depending on the execution of the bushing, fixed or dismountable
connection pieces. It must be made sure that the contact
shields are used and mounted on the end of the bushing. These
resistance is kept as low as possible.
prevent the excessive stress on the transformer oil and simplify
 Shift the shield back to its original position and place it to
the structure of the power conductor insulation under the bushing.
match the three threaded holes. The spring pressure pieces
can be screwed on again.
The originally delivered shields are dimensioned with the help of
modern methods and have a high-value, solid insulation layer on
the surface.

 Please observe installation recommendations (see Tab. 2).

2
5.11. Bushing without shield
Due to the resulting field strengths, bushings up to and including 1
72.5 kV do not need any shielding. For this reason, no further
measures are needed on the bushing.

5.12. Shield for rope application


3
This shield is explicitly dimensioned for rope applications,
because of which it is considerably shorter than the other types
of shields.

Fig. 14: Shield with spring-loaded thrust piece


1 epoxy-covered shield | 2 spring-loaded pressure piece
3 mounting ring
Fig. 13: Shield for rope application

14/38 | HLAB200456 | Operating instructions for AirRIP bushings


Strength class &  The shielding can temporarily be inserted under the bushing
Tightening torque [Nm] with a power cable.
Thread A2-70 A4-70 8.8 10.9 12.9  The terminal is then freely accessible and can be connected
to the connection pieces. It must be in any case made sure
M6 8.5 8.5 10 14 17 that the contact resistance is kept as low as possible.
M8 21 21 25 35 41  Bring the shield back to its original position. It must be made
sure that the 3 holes are positioned over the hexagon socket
M 10 41 41 49 69 83
screws. The screws are inserted through the holes, and with
M 12 72 72 86 120 145
some pressure against the bushing, the shield can be turned
Tab. 6: Recommended tightening torques (greased and non-greased) in the original secure position (approx. 12°) until it locks in
place again with spring load.
 Finally, the screws must be tightened back with the specified
 Do not let parts fall into the transformer torque (see Table 7).
tank. Strength class &
 The fastening ring at the connections Tightening torque [Nm]
NOTE must not be dismounted. Thread A2-70 A4-70 8.8 10.9 12.9

M6 8.5 8.5 10 14 17

5.14. Shield with bayonet catch M8 21 21 25 35 41


M 10 41 41 49 69 83
This shielding is available for voltages ranging from 300 kV to
550 kV and is suitable for all conductor types. The shielding can M 12 72 72 86 120 145

normally be mounted on the mounting ring and dismounted Tab. 7: Recommended tightening torques (greased and non-greased)
from it at the factory.
 Do not let parts fall into the transformer
The fixture ring is screwed onto the conductor and secured with tank.
a locking screw. The shield has three mounting holes and is  The fastening ring at the connections
affixed with springs via a bayonet lock. NOTE must not be dismounted.

5.15. Head shield from 420 kV


Bushings of 420—550 kV have an air-side shield for preventing
corona discharges.
The air-side shield can be mounted on the head fitting with the
delivered screws and washers. Threaded holes are provided for
this purpose on the head fitting. Depending on the bushing type,
3 two spacing sleeve variants are provided: (See Fig. 16 and
2
details A / B).
6 4
5

Fig. 15: Shield with bayonet catch.


1 epoxy-covered shield | 2 mounting ring
3 locking screw | 4 hexagon socket screw | 5 spring
6 washer

 Dismounting of the shield from the mounting ring: press the


shield lightly against the bushing, rotate it (approx. 12°), then
pull it off.

15/38 | HLAB200456 | Operating instructions for AirRIP bushings


Fig. 16: Mounting and dismounting of the head shield.
1 screw | 2 washer | 3 head shield
4 head fitting | 5 welded spacing sleeves (height= 10mm) | 6
dismountable spacing sleeves (height> 10mm)

Fig. 17: Lower part of the bushing


1 base terminal (according to IEEEC C57.19.01)

Detail A: Head shield with welded spacing sleeves (height=10 mm)


 The base terminal must not be
dismounted to avoid damaging the
internal components.
NOTE

5.17. Preparation of the terminal surface (A, B, C)


The connecting to the bushing should always be made with
special care with respect to the reduced contact resistance.

Before the connection to the silver-plated contact surface, the


protective film (grease) must be removed with a cloth. No cleaning
agents/solvents may be used.

Contact surfaces without painting must first be treated to remove


Detail B: Head shield with dismountable spacing sleeves (height=10 mm)
the layer of oxidation. A fine steel brush, abrasive paper or similar
can be used for this purpose. The contact grease for electric
connection surfaces is applied onto the entire surface; the surface
Strength class & is then brushed cross-wise until the entire oxide layer is removed.
Tightening torque [Nm] The oxide-free surface must then be cleaned with a cloth, and
Thread A2-70 A4-70 8.8 10.9 12.9 fresh contact grease is applied.

M6 8.5 8.5 10 14 17 5.18. Cleaning of the bushing surface and the interface
M8 21 21 25 35 41
The sealing surfaces on the impregnation of the transformers and
M 10 41 41 49 69 83 on the bushing flange must be free of corrosion and dirt, and have
M 12 72 72 86 120 145 a high surface texture (max. Ra 3.2). The cleaning of these
M 14 115 115 135 190 230 surfaces takes place by soaking a lint-free cotton cloth in the
M 16 180 180 219 295 355 cleaning liquid and wiping the sealing surfaces.

Tab. 8: Recommended tightening torques (greased and non-greased)


5.19. Installing of the bushing

 Do not let parts fall into the transformer


tank.  The bushing should reach the ambient
temperature before the installation to
NOTE avoid condensation on its surface.
NOTE

5.16. Fixed conductor (C)


The connection details can be found in the dimension sheet for Only now, the bushing can be brought to the final position. First,
this bushing. These bushings need no additional installation work the bushing is lifted with lifting gear and then slowly lowered on
and can be connected directly to the oil-side terminals. the flange side until the desired position is reached.

16/38 | HLAB200456 | Operating instructions for AirRIP bushings


 The use of the possible thread for the lifting eye is always
the best option to lift the bushing and install it.  Silicone O-ring gaskets that are used for
 After the installation, the possibly used lifting eyes must be temperatures <-30 °C may not be
removed again. lubricated with silicone grease.
 It is recommended that the corresponding threads for the NOTE
lifting eyes are closed, e.g. with blind plugs.

5.20. Damage during installation


The insulator, whether a porcelain or a silicone variant, is
recommended for avoiding impacts and stress concentration. Any
use of tools that can cause such damage (e.g. chains, hooks)
should be in any case avoided. For this reason, textile ropes must
be used.
 When installing horizontally oriented
bushings in the desired position, these
must not be propped against their lower
body end. Specifically a possibly
available electric shield must not be in
any way used for supporting or
suspending.
 During the lowering, the bushing may not
touch any nearby parts or walls, as the
insulating body or any other part can be
damaged as a result.
 The bushing may not be lifted with a rope
loop, as it can slip out.
CAUTION  The suspension rope must not touch the
measurement terminal, as the potential
connection can be broken off due to
mechanical damage.
 The thread of the vent screw may not be
used for mounting the lifting eye (this
does not apply to Chapter 5.21).
 The unshielded area of the bushing (oil-
side insulating body) must not be
scratched.
Fig. 18: Inserting the conductor rope or conductor rod

After the insertion, the cable bolt and conductor rod is fastened to
the head of the bushing, and a possible head shield is mounted
5.21. Assembly of cable bolt (A) or dismountable
using the clamp system. The torques provided below must be
conductor rod (B)
observed (see Tab. 9).
For retracting the conductor, an eyebolt can be screwed onto the
frontal thread of the cable bolt or conductor rod. This thread Strength class &
functions at the same time as a vent screw of the central tube. Tightening torque [Nm]
Thread A2-70 A4-70 8.8 10.9 12.9
Before the suspension rope is inserted through the central tube,
the sealing sleeve with the inserted O-ring gaskets must be
M6 8.5 8.5 10 14 17
mounted on the central tube. In order to avoid damaging the O-
M8 21 21 25 35 41
ring gaskets of the sealing sleeve on the tube or bolt when
inserting, the gliding surfaces must be lubricated with an acid- M 10 41 41 49 69 83

free grease. The gap between the bolt and the sleeve must be M 12 72 72 86 120 145
lubricated with grease. M 14 115 115 135 190 230
M 16 180 180 219 295 355
The cable bolt together with the soldered rope conductor or
M 18 245 245 290 400 485
conductor rod can now be drawn in from below through the
M 20 345 345 410 580 690
bushing with the help of the eyebolt and a rope.
Tab. 9: Recommended tightening torques (greased and non-greased)

17/38 | HLAB200456 | Operating instructions for AirRIP bushings


After dismounting the eye screw, the vent screw must be mounted
Conductor insulation min. 1 mm (in
back again. The recommended tightening torque is as follows
non-lubricated 30 Nm, lubricated 25 Nm (see Fig. 9). the tube)

If the vent screw is not mounted Oil gap (see Table 10)
correctly, water can get into the
transformer.
Transformerboard strips
NOTE
2/3 voltage

Conductor
5.22. Reverse-controlled bushings with rope conductor
Conductor
insulation
For reverse-controlled bushings, the oil side of the insulating
Extension of the rope conductor
body (IKP) is designed specifically for applications in the narrow
before the bend (L1/2)
space of the transformer dome. In this case, 2/3 of the voltage
that is brought from the surface of the oil-side IKPs is still at the
lower end of the bushing. The other third of the voltage
(between the IKP end and conductor) must be borne through
the insulation of the rope conductor.
Fig. 19: Lower part of a reverse-controlled bushing with conductor rope

The insulation of the conductor rope must be removed upwards


to match the opening diameter of the oil-side IKP. A minimal oil 5.23. Flat seal system
gap between IKP and the insulation of the rope conductor must, The central position of the flat seal is located directly under the
however, be ensured. This also ensures that the oil can flow hole circle of the flange plate and must be on the both sides of the
into the tube of the bushing. The recommended minimum oil pitch circle to avoid flange deformation. The flat seal must be
gap is provided in Tab. 10 for the different nominal voltages. provided with the appropriate hole pattern for the flange. During
installation, the flat seal must be put through the mounting bolts
Recommended minimum without tensile or compressive stress. If the flat seal is warped by
Ur [kV]
oil gap [mm] the mounting bolt, the holes must be drilled out to avoid any stress
on the flat seal (see Fig. 20).
≤ 123 3
De 145 à 170 5
≥ 245 10
Tab. 10: Recommended minimum oil gap between the insulating body
and the insulation of the rope conductor

To ensure the concentricity of the conductor, the axial insertion of


Trafoboard stripes on the conductor insulation must always be
observed.

Reverse-controlled bushings are designed for use without


shield.

 Due to the remaining third of voltage


between the lower part of the IKP and
the conductor, the insulated conductor
must be moved axially for a certain
distance before it can be bent. To
determine the minimal distance, subtract
the current transformer length (L6) from
NOTA the oil-side length of the bushing (L16)
and divide this value (L1) by two: L1/2
(see Fig. 18 and dimension sheet for L6,
L16 and L1).

Fig. 20: Flat seal system


1 flat seal | 2 flange | 3 transformer / switchgear / wall
4 hole circle diameter | 5 sealing surface
6 washer and nut

18/38 | HLAB200456 | Operating instructions for AirRIP bushings


 If available, it must be made sure that the 5.25. Flange installation
ventilation hole is not blocked by the flat
Not damaging the sealing surface
seal.
 The flat seal (1) must be installed over  When installing the flange, make sure
the hole circle until the flange external that the sealing surface is not damaged.
NOTE side (2) (Ø D4), avoiding any shearing  If the lifting eyes are on the lower side of
forces or damage (see Fig. 20). the flange, these must be dismounted
before the flange is tightened.
NOTE  For transformers, the contact area must
have a flatness tolerance of no more
5.24. Ring seal system than 0.3 mm.
The position of the O-ring gasket is inside the hole circle of the
flange plate, and inside the specified sealing surface (shown on
the dimension sheet of the bushing). 5.26. Tightening sequence
When the bushing flange is put in place, the screws/nuts must be
first screwed as far as possible by hand. The flange fastening
must be performed according to the following tightening
sequence and Fig. 22:

1. Light fastening with wrench.


2. Fastening with 25% of the recommended torque.
3. Fastening with 75% of the recommended torque.
4. Fastening with 100% of the recommended torque.
5. Additional turn for control, with 100% of the recommended
torque.
6. If possible, repeat steps 4 and 5 after 24 hours, as the clamp
force can decrease in the first 24 hours.

 In order not to overlook any screws/nuts, the tightened


screws/nuts must be marked with a felt pen.

Fig. 21: O-ring gasket system


1 O-ring gasket | 2 flange | 3 transformer / switchgear
4 hole circle diameter 4 hole circle diameter | 5 sealing surface6
washer and nut

 For systems that must be operated


under pressure, an O-ring gasket
system must be provided.
 The contact area of the flange plate (5)
as well as the surface (3) should have
NOTE
no steps to avoid shearing forces or
damage (see Fig. 21).

19/38 | HLAB200456 | Operating instructions for AirRIP bushings


5.27. Fastening sequence
The sequence to be maintained is defined in the following
sectional drawings for the different hole patterns:

Fig. 22: Fastening sequence for different flange models

5.28. Flange earthing


The bushings have one or two threads on the flange for its
earthing.

 The flange of the bushing must always


be earthed via a secure connection
after installation.
NOTE

20/38 | HLAB200456 | Operating instructions for AirRIP bushings


6. Assembling

Prevention of reloading hazards, electric  After the ventilation and before the
shock, chemical hazards, falling, slipping commissioning of the bushing, it must be
and tripping accidents checked that all the vent screws are
tightened.
 The work area must be marked and kept
 Furthermore, the indentation the vent
clear.
screw in the cable bolt/conductor rod
 All the activities must be supervised by a
should be filled with a flexible silicone
qualified person.
paste.
 The personnel should be trained for the NOTE
 An initial set-up of the phase-earth
reloading activities.
voltage must take place after operating
 Appropriate climbing aids and
for at least 12 hours after completing the
DANGER supporting structures should be used.
filling of the transformer with oil.
 The personnel should be authorized to
work at height.
6.3. Reference measurement No. 2
 The personnel should have appropriate
training for work with dangerous After the installation and before the voltage is fed, reference
voltages (reference measurement No. measurement No. 2 for main capacity C1, capacity C2 and loss
2). factors tan 1 and tan 2 should be obtained (see Chapter 9).
 Wear appropriate PPE.
These can serve as a good basis for condition assessment for
later measurements. In order to make a more precise condition
diagnosis, perform the measurement using Dielectric Frequency
6.1. Evacuation of the transformer Response (DFR).

The use of a vacuum when filling the transformer is not


6.4. Voltage connection
problematic for the installed bushing. If the transformer oil is
drawn in under vacuum, a following ventilation for the bushing or
 An initial set-up of the phase-earth
the transformer dome is normally not necessary. However, there
voltage must take place after operating
is an exception in the bushings that protrude over the expansion
for at least 12 hours after completing the
vessel. For these, ventilation via the screw provided frontally on
NOTE filling of the transformer with oil.
the cable bolt/conductor rod is recommended.

 An initial set-up of the phase-earth


Explosion, fire
voltage must take place after operating
for at least 12 hours after completing the  The voltage connection should take
NOTE filling of the transformer with oil. place only after the nominal values for
C1 and tan 1 are successfully
6.2. Ventilation and downtimes confirmed as implemented.
 During the initial switch-on, as well as
Before each first-time commissioning, the central bushing tube DANGER when switching back on after a revision,
must be ventilated via the screw located frontally on the cable
all personnel should be removed from
bolt/conductor rod. As a result, the transformer oil in the central
the site of the installation for at least 2 h.
tube rises to the corresponding elevation of the transformer
expansion vessel. If the bushing is not mounted vertically, the
transformer dome should be ventilated with the vent screws on
the flange of the bushing. The M12 vent screws are tightened on
 Whenever possible, a measurement of
the cable bolt/conductor rod and on the flange as follows: 30 Nm
C1 and tan  should take place with the
unlubricated and 25 Nm lubricated. Bushings with a fixed
high-voltage conductor suspended,
conductor can only be ventilated at the flange. During the
especially if other transformer load the
installation of the bushing, it must already be made sure that the
network with harmonics.
flange ventilation and the terminal of the Buchholz relay is at the
 The tan  values must always be
highest position as possible. NOTE calculated for the reference value at 20
°C.

21/38 | HLAB200456 | Operating instructions for AirRIP bushings


7. Test tape and voltage tap

7.1. Measuring connection structure (3 kV)


The measuring connection at capacitance-graded bushings gives
access to the outermost control layer of the bushing. With it, the
characteristic values of a busing (C & tan) can be measured
using a suitable measuring device, zB Omicron CPC 100, Tettex
28xx or Doble. In operation, this covering must be connected to
the flange via the spring contact available in the measurement
terminal, and thus be earthed, or be connected to earth via an
accordingly large capacity, to avoid voltage of more than 350 V or
1.5 kV (see Chapter 7.2).
Figure 25: Measurement terminal. Transition coupler (N or UHF
connector)

Transition coupler N or UHF (online


measurement)
 Cable wiring must be controlled regularly
Sealing for correct contact: cable oxidation and
Spring
cable breakage lead to bushing failure. For
CAUTION
this reason, permanent reliance on online
Protective cover measurements is not preferable.

Measurement terminal tampering


 Using screwdrivers or other tools to
tamper with and push away the earthing
spring is strictly forbidden (see Fig. 26).

Fig. 23: Measurement terminal in operating state, earthed with  Use a connecting coupling or the
CAUTION
protective cover transition coupling for measurement
(see Fig. 24 and 25).
The structure of the measurement terminal provides automatic
earthing of the measurement covering via the flange. This
earthing can be opened by full insertion of a 4 mm connecting
coupling (see Fig. 24) or by connecting a transition coupler (see
Fig. 25). If there is no measurement performed at the
measurement terminal, it must be closed with the provided
protective cover and an intact seal, to avoid weather effects.

Fig. 26: Measurement terminal. Any manipulation prohibited

Protective cover
 The bushing must never be commissioned
DANGER
without installing the protective cover on
the measurement terminal or connecting a
Fig. 24: Measurement terminal. Connecting coupling
monitoring system.
 The correct function of the spring contact
in the measurement terminal must always
be tested before locking the bushing.
If this is not observed, the bushing or the
transformer can suffer severe damage. Under
unfavorable conditions, heavy personal
injuries are also not out of the question.

22/38 | HLAB200456 | Operating instructions for AirRIP bushings


Life-threatening voltages parallel to C2. In most cases, this is capacity Cz, that must have
a capacity of at least:
 The described measurements take place
under dangerously high measuring
 UN 
voltages. The local safety regulations Cz min  C1    1  C2
DANGER must be observed.  3 U 2 

The values for C1 and C2 can be found in the test report for the
bushing in question.
7.2. Measurement terminal purpose of use
The measuring connection serves for the measurement of the The capacity Cz must be used to set voltage U.
main capacity C1 of the bushing and the loss factor tan. The most
common test circuit is shown below.  U 
C z  C1   N  1  C2  C z min
 3 U 

To remove active power P from the bushing, an ohm resistance


Rz must be switched on in parallel to C2. The P power is
produced as a result of:

P
U N / 3 
2


1
Rz a  b2
2

with:

C2
a 1
C1

and

1
b
C1  Rz

A condition in this case, however, is that U  U2. This can be


controlled with:

UN / 3
U  a 2  b2  U 2
1 Bushing C1: Capacity - high-voltage conductor tapping
a b
2 2

layer
C2: Capacity - tapping layer flange Secondary voltage U2 (350 V or 1.5 kV)
2 Reference condenser CN  When using the transition plug type N
3 Schering bridge R3, R4, C4: Bridging elements or type UHF by ABB, the secondary
N: Null indicator voltage must be limited to 350 V.
C1 = CNR4 / R3; tan δ 1 = R42πfC4  When using an external transition plug,
the secondary voltage must be limited
Fig. 27: Measuring setup NOTE
to 1.5 kV.
The measuring terminal can also be used to perform voltage and
partial discharge measurement as part of monitoring. It must be Primary voltage U1 (12 kV)
made sure that the maximum permissible continuous voltage
 The measurement voltage must not
between the measurement surface and flange is 350 V or 1.5 kV
exceed the phase/earth voltage of the
(=U2). Depending on the voltage and capacity of the bushing, the
bushing.
power put over the measurement terminal can be approx. 5... 10
VA. To limit voltage, an impedance must always be added in

23/38 | HLAB200456 | Operating instructions for AirRIP bushings


Voltage at the measurement terminal
Without a connection of additional
impedance, the voltage at the measurement
terminal is always higher than 350 V or 1.5 kV
for the C1 and C2 values.

 For this reason, for a bushing under


CAUTION voltage, the measurement terminal must
be conductively connected to the flange
(protective plug installed) or through a
connected additional impedance, to limit
the voltage to 350 V or 1.5 kV.

The achievable measurement precision during the voltage


measurement depends on the changes in the C1 and C2
capacities, as well as in the connected impedance. As the
capacities are temperature-dependent, a measurement precision Fig. 29: Filling the voltage terminal with transformer oil for monitoring

of about 5% must be taken into account. system using

7.3. Voltage terminal configuration


The bushing can be provided with a voltage terminal described in
the IEEE C57.19.01 standard. The terminal (pin) is connected to
an internal high-voltage foil of the capacitor. In normal operation,
the terminal is earthed through a spring inside the cover.

5 mm

Sealing

Spring

Protective
cover

Fig. 30: Voltage terminal filled up to 5 mm under the filling chamber

The voltage terminal can also be used to determine the loss factor
and capacity of the bushing online. A connection to the terminal
can be implemented with a suitable connector. The voltage
between the terminal and the earth must be limited to 5 kV, as the
Fig. 28: Voltage terminal in operating state, earthed with protective
housing of the voltage terminal is not filled with transformer oil.
cover

If the voltage terminal is used with a monitoring system, the If the measurements are conducted, and the voltage terminalis
voltage between the terminal and the earth must be limited to 8 not connected to a monitoring system, the connection to the
kV. Additionally, if there is monitoring, the housing of the voltage terminal must be broken off and it must be locked with the
terminal must be filled with transformer oil. To do this, remove the corresponding plug. The thread of the voltage terminal plug must
filling plug on the top side of the housing and fill it with clean dry be lightly greased beforehand. It is important to screw the plug
transformer oil (Fig. 29). Fill until 5 mm below the filling chamber onto the housing tightly.
to reserve space for expansion (Fig. 30). The thread of the filling
plug should be sealed with an appropriate sealant and locked
back with the filling plug.

24/38 | HLAB200456 | Operating instructions for AirRIP bushings


Do not feed voltage if the plug of the
voltage terminal is removed
Unless the bushing is used with a monitoring
system or for loss factor measurement.
 If the terminal is not earthed, the voltage
could exceed the insulation capability,
DANGER which could lead to damage inside the
bushing resulting in electrical damage to
the bushing or the transformer.

The voltage at the terminal of the


monitoring system must not exceed 5 kV
during loss factor and capacity
measurements
Not observing this provision can lead to
DANGER
personal injuries, including fatal personal
injuries, as well as material damage.

25/38 | HLAB200456 | Operating instructions for AirRIP bushings


8. Measurements of C1, C2, tan 1, tan 2 (reference n°1)

Prevention of reloading hazards, electric  When conducting the measurement, the


shock, slipping and tripping accidents surface must be cleaned and dry.
 In a humid environment, the measurement
 The work area must be marked and kept
terminal should be dried — e.g. with a hot-
clear.
air dryer.
 All the activities must be supervised by a
 The measured tan and capacity must be
qualified person.
DANGER calculated taking into account the
 The personnel should be trained for the
reference value at 20 °C.
reloading activities. NOTA  In order for the bushing fully to reach the
 The personnel should have appropriate
ambient temperature before the
training for work with dangerous
measurements, it should be stored for e.g.
voltages.
 Wear appropriate PPE. 24 h in the ambient of the measurement
site.

Hazardous voltage
 The measurements are performed using
high voltage. The local safety
regulations of high voltage installation
DANGER must be observed.

 These measurements must be


performed before the installation, after
Fig. 31: Reloading and lifting
the delivery and after long (≥ 1 year) or
incorrect storage.
NOTE 8.2. C1 and tan 1 measurement (reference n°1)

8.1. Reference measurements No. 1


The lifting of the bushing from the transport box can take place
with the use of lifting gear, as well as a crane, a hoist etc. and two
suspension ropes. One of the suspension ropes is fastened with a
textile rope sling directly onto the flange or on the crane eyes
mounted on the flange. The other suspension rope is fastened with
a textile rope sling to the insulator between the shields, near the
head or using the crane eyes mounted on the head or on the
special clamp (optional).

The bushing should be lifted at least 1.5 m above ground to reduce Fig. 32: Typical measurement of C1 and tan1
parasitic influences when measuring main capacity C1, capacity
C2 and loss factors tan 1 & tan 2. 8.3. C2 and tan 2 measurement (reference n°1)
The purpose of the measurements is to test the condition of the
bushing. The results must be compared with the ABB test report.

In order to make a more precise condition diagnosis, perform the


measurement using Dielectric Frequency Response (DFR).

Fig. 33: Typical measurements of C2 and tan2

26/38 | HLAB200456 | Operating instructions for AirRIP bushings


8.4. Reference measurement No. 1 overview 8.4.3. C2 & tan 2 (bushing with voltage terminal)
8.4.1. Capacity C1 and loss factor tan1
Voltage On-site measurements On-site
measurement,
correction for
temperature

[V] [°C] C1 tan 1 C1 tan 1


[pF] [%] [pF] [%]
Voltage On-site measurements On-site
200 measurement,
correction for
500
temperature
1000
[V] [°C] C2 tan 2 C2 tan 2
2000 [pF] [%] [pF] [%]

3000 100

6000 200
9000 500
12000 1000
Tab. 11: C1 and tan 1 measurement overview 1000

2000
 The values of the measurements shall
3000
be compared with those indicated in
the ABB test report (for 10kV). 6000
NOTA 10000

Tab. 13: C2 and tan 2 measurements overview


8.4.2. C2 & tan 2 (bushing with measurement terminal)

 The measured values should be


compared with the ABB test report
values at 10 kV).
NOTA

8.5. Temperature-dependent correction factors for tan 1


& tan 2
Voltage On-site measurements On-site
measurement, The tan values must be calculated for the reference value at 20
correction for °C, see below:
temperature 1. During the measurement, the ambient temperature must be
[V] [°C] C2 tan 2 C2 tan 2 measured (T ambient = T bushing).
[pF] [%] [pF] [%] 2. With the curve or the table specified below, the correction
100 factor fc can be determined at the corresponding ambient
temperature, with which tan  relative can be calculated with
200
the following formula:
500

700 tan  relative = tan  measured / fc


1000

1500

2000

Tab. 12: C2 and tan 2 measurement overview

 The voltage of 2 kV must not be


exceeded during this test.

DANGER

27/38 | HLAB200456 | Operating instructions for AirRIP bushings


RIP body temp. tan  Corr.
[°C] Factor
fc
10 1.20

20 1.00

30 0.85

40 0.77

50 0.75

60 0.77

70 0.82

80 0.90

Tab. 14: Correction factors

8.6. Temperature-dependent correction factors for C1


and C2
The C1 and C2 values must be calculated for the reference value
at 20 °C as described below (the capacity increases by about
0.4%0 per °C):
1. During the measurement, the ambient temperature must be
registered (T ambient = T bushing). The temperature difference
should be calculated with the following formula:

∆T = T bushing - 20 [°C]

2. The measurement should be corrected with the following


formula:

C 20°C = C measured * (1 - ∆T * 0.0004)

8.7. Permissible tolerances


8.7.1. For bushings ≤ 145kV
C1 tan 1 C2 tan 2

+/- 5% +/- 0.05% +/- 20% +/- 0.15%


(Relative) (Absolute) (Relative) (Absolute)

8.7.2. For bushings > 145kV


C1 tan 1 C2 tan 2

+/- 3% +/- 0.05% +/- 20% +/- 0.15%


(Relative) (Absolute) (Relative) (Absolute)

Tab. 15 : Tolerances

 If the measured values do not fit with the


set tolerances, please contact High
Voltage Components at ABB Switzerland
Ltd or your local ABB partner.
NOTE

28/38 | HLAB200456 | Operating instructions for AirRIP bushings


9. Measurements of C1, C2, tan 1, tan 2 (reference n°2)

Prevention of falling accidents, electric  When conducting the measurement, the


shock, slipping and tripping accidents surface must be cleaned and dry.
 In a humid environment, the measurement
 The work area must be marked and kept
terminal should be dried — e.g. with a
clear.
dryer.
 All the activities must be supervised by a
 The measured tan and capacity must be
qualified person.
calculated taking into account the
 Appropriate climbing aids and supporting
reference value at 20 °C. It must be made
structures should be used.
sure that the transformer (for
 The personnel should be authorized to
transformers) cools down very slowly and
work at height.
that the tan d value of the bushing is
 The personnel should have appropriate NOTE
DANGER heavily influenced by the transformer oil
training for work with dangerous
temperature in this period.
voltages.
 The advantage of the DFR method is that
 The system is switched-off, secured and
it always gives the same curve of the tan
tested.
 The primary and secondary side of the
 value over the frequency independently
from the temperature; this curve can be
transformer or the switchgear is short-
used with the Arrhenius equation to apply
circuited and earthed.
to any temperatures.
 The work can only be started after a
complete electric discharge of the
system.
 Wear appropriate PPE. 9.2. C1 et tan 1 measurement (reference n°2)

 These measurements shall be


performed after installation of the
bushings on the transformer as well as
while maintenance.
NOTE

9.1. Reference measurements No. 2


After the installation of the bushings and before switching on the
system or during the maintenance, main capacity C1, capacity C2
and the tan 1 & tan 2 loss factors must be measured. The results
must be compared with the ABB test report. These measurements
function as an important assessment basis during the entire
service life of the bushings.

In order to make a more precise condition diagnosis, perform the


measurement using Dielectric Frequency Response (DFR), as this
method allows for a more precise condition assessment as a
reference measurement of the bushing in the installed condition. Fig. 34: Typical measurements of C1 and tan1

29/38 | HLAB200456 | Operating instructions for AirRIP bushings


9.3. C2 and tan 2 measurement (reference No. 2) 9.4.2. C2 and tan 2 (bushing fitted with measurement
terminal)

Voltage On-site measurement On-site


measurement,
correction for
temperature.

[V] [°C] C2 tan 2 C2 tan 2


[pF] [%] [pF] [%]

100

200

500

Fig. 35: Typical measurements of C2 and tan2 700

1000

1500

9.4. Reference measurement No. 2 overview 2000

9.4.1. Capacity C1 and loss factor tan1 Tab. 17: C2 and tan 2 measurement overview

Voltage On-site measurement On-site


measurement,  The voltage during this test must not
correction for exceed 2000 V.
temperature

[V] [°C] C1 tan 1 C1 tan 1


DANGER
[pF] [%] [pF] [%] 9.4.3. C2 and tan2 (bushing fitted with voltage terminal)
200

500

1000

2000

3000

6000 Voltage On-site measurement On-site measurement,


correction for
9000
temperature
12000
[V] [°C] C2 tan 2 C2 tan 2
Tab. 16: C1 and tan 1 measurement overview
[pF] [%] [pF] [%]

100

 The measured values are regarded as 200


the first measurement in the installed
500
state, and cannot be compared with
the test report. 1000
NOTE
1000

2000

3000

6000

10000

Tab. 18: C2 and tan 2 measurement overview

30/38 | HLAB200456 | Operating instructions for AirRIP bushings


9.6. Temperature-dependent correction factors for C1
 The measured values are regarded as and C2
the first measurement in the installed
The C1 and C2 values must be calculated for the reference value
state, and cannot be compared with
at 20 °C as described below (the capacity increases by about
the test report.
NOTE 0.4%0 per °C).
1. After the measurement, the temperature ∆T difference should
be calculated with the following formula:
9.5. Temperature-dependent correction factors for tan1
∆T = T bushing - 20 [°C]
and tan2
The tan values must be calculated for the reference value at 2. The measurement should be corrected with the following
20°C, see below: formula:

1. While the measurement, record ambient and oil C 20°C = C measured * (1 - ∆T * 0.0004)
temperature, and calculate the temperature of the condenser 9.7. Site-dependent correction for C1
core:
The measurement of the C1 capacity of installed bushings on site
is always smaller than in the test area. The difference is ∆C inst
T bushing = (2 * T air + T oil) / 3 [°C]
[pF].

Ur ∆C installed
[kV] [pF]
2. With the curve or the table specified below, the
≤ 123 approx. 4
correction factor fc can be determined at the corresponding
ambient temperature, with which tan  relative can be calculated ≤ 245 approx. 6
with the following formula: ≤ 420 approx. 8
Tab. 20: Capacity corrections
tan  relative = tan  measured / fc
These values are based on conservative empirical values. ∆C inst
depending on the type of the bushing and its lower part, the length
of the current transformer (for transformers) can deviate from
these values

1. The measurement should be corrected with the following


formula:

C1 relative = C1 20°C + ∆C installed

C1 relative can now be verified with the ABB test report.


9.8. Permissible tolerances

9.8.1. For bushings ≤ 145kV


RIP body temp. tan  Corr. C1 tan 1 C2 tan 2
[°C] Factor
fc +/- 5% +/- 0.05% +/- 20% +/- 0.15%
(Relative) (Absolute) (Relative) (Absolute)
10 1.20

20 1.00

30 0.85 9.8.2. For bushings > 145kV

40 0.77 C1 tan 1 C2 tan 2

50 0.75
+/- 3% +/- 0.05% +/- 20% +/- 0.15%
(Relative) (Absolute) (Relative) (Absolute)
60 0.77

70 0.82
Tab. 21: Tolerances
80 0.90
Tab. 19: Correction factors  If the measured values do not fit with
the set tolerances, please contact High
Voltage Components at ABB
Switzerland Ltd or your local ABB
NOTE partner.

31/38 | HLAB200456 | Operating instructions for AirRIP bushings


10. Maintenance

10.1. Maintenance shedule


tan 1 & Capacitance Visual Thermal Insulator Risks
tan 2 C1 & 2 inspection cleaning
Level A System under - - X X (all 5 years - See Tab. 23
voltage until
replacement)
Level B System switched X X X - X See Tab 24
off and earthed

Maintenance

Ans

End of
waranty Service

Level A: Visual inspection (diagnostics recommended, depending on the condition)


Niveau B: diagnosis
Niveau C: replacement or conservation

Tab. 22: Maintenance schedule and maintenance intervals

Prevention of falling accidents, chemical Prevention of electric shock, slipping and


hazards, electric shock, slipping and tripping accidents
tripping accidents
 The work area must be marked and kept
 The work area must be marked and kept clear.
clear.  The personnel should have appropriate
 All the activities must be supervised by a DANGER training for work with dangerous voltages.
qualified person.  Wear appropriate PPE.
 Appropriate climbing aids and supporting Tab. 24: Risk analysis level B
structures should be used.
 The personnel should be authorized to
work at height. The maintenance schedule according to
DANGER
 The personnel should have appropriate Tab. 22 shows the typical maintenance
training for work with dangerous voltages. intervals recommended for rated loads of
 The system is switched-off, secured and the bushing. The service life estimates are
tested. NOTE based on conservative empirical values
 The primary and secondary side of the and are as a rule higher.
transformer or the switchgear is short-
circuited and earthed.
 The work can only be started after a
complete electric discharge of the system.
 Wear appropriate PPE.

Tab. 23: Risk analysis level A

32/38 | HLAB200456 | Operating instructions for AirRIP bushings


10.2. Bushing maintenance its water-repellent properties even with high contamination and
age.
Tab. 22 provides a schedule for the expected service life as well
as the maintenance intervals of the RIP product. This overview
is only a recommendation. However, if the silicone surface becomes dirty, it can be cleaned
with water. If it is not enough, the following can be used for
cleaning:
10.3. Testing the connections with a thermal imaging
camera - Light contamination: 5% water solution of cleaning agents (e.g.
It is recommended during the inspection and after the first soap).
commissioning that the connections are tested with a thermal - Medium to strong contamination: alcohol.
imaging camera (reasons: possible loose or oxidized
connections, insufficient crimping). The cleaning of these surfaces takes place by soaking a lint-free
cotton cloth in the cleaning liquid and wiping the silicone surface

 Thermography is only useful after 24


 Cleaning of the bushing may only take
hours under nominal load.
place with the installation shut down.
NOTE
DANGER

10.4. Cleaning the porcelain insulator


A cleaning of the porcelain insulator can become necessary if
 Clean only in well-ventilated rooms.
there is a lot of contamination due to adverse ambient influences.
 Avoid skin and eye contact with the
The cleaning takes place with a wet lint-free cloth or a stream of
cleaning liquid, do not inhale the
water (high pressure cleaner not recommended).
vapors.
 No open flames with volatile solvents.
 Work and protective measures must
 Cleaning of the bushing may only take comply with the safety data sheet and
place with the installation shut down. CAUTION
local guidelines.
 Wait for 24 hours after the cleaning
DANGER
before commissioning.
A porcelain surface contaminated as a result of transport and
handling can be cleaned as follows:

10.6. Capacity and tan δ loss factor checks


- Light contamination: wet cleaning cloth
- Medium to strong contamination: ethanol / ethanol acetate. Detailed information about measuring the capacity and tan δ can
be found in Chapters 8 and 9.
The cleaning of these surfaces takes place by soaking a lint-free
cotton cloth in the cleaning liquid and wiping the porcelain surface 10.7. Spare parts
When ordering spare parts, the production ¬number from the
 Clean only in well-ventilated rooms. rating plate on the flange of the bushing must always be provided.
 Avoid skin and eye contact with the
cleaning liquid, do not inhale the vapors. 10.8. Replacement of bushings
 No open flames with volatile solvents.
If a reserve bushing is needed, the production number from the
 Work and protective measures must
rating plate on the flange of the bushing must always be provided
comply with the safety data sheet and
if requested.
CAUTION local guidelines.
 Wait for 24 hours after the cleaning before
commissioning.

10.5. Cleaning the silicone insulator


Cleaning the silicone insulator is not normally necessary in
operation, as silicone due to its hydrophobic nature and the
transfer of the hydrophobia in the contaminated surface maintains

33/38 | HLAB200456 | Operating instructions for AirRIP bushings


11. Dismounting (transport, repairs or disposal)

Prevention of reloading hazards, cutting


injuries, electric shock, chemical hazards,
falling, slipping and tripping accidents
 The work area must be marked and kept
clear.
 All the activities must be supervised by a
qualified person.
 Appropriate climbing aids and
supporting structures should be used.
 The personnel should be authorized to
work at height.
 The personnel should be trained for the
reloading activities.
 The personnel should have appropriate
training for work with dangerous
DANGER voltages.
 The system is switched-off, secured and
tested.
 The primary and secondary side of the
transformer or the switchgear is short-
circuited and earthed.
 The work can only be started after a
complete electric discharge of the
system.
 For transformers, the available current
transformer must always be short-
circuited and earthed at the transformer,
preferably in the terminal box. This is to
suppress the displaced earth potentials.
 Wear appropriate PPE.

11.1. Dismounting the bushing for transport, repairs or


disposal
The work steps described in Chapter 5 must be performed in
reverse order.

To ensure safety for this activity, the above recommendations


must be observed.

 For further information, please


contact High Voltage Components at
ABB Switzerland Ltd or your local
NOTE ABB partner.

34/38 | HLAB200456 | Operating instructions for AirRIP bushings


12. Repair

Prevention of falling accidents, chemical Depending on the damage case, a repairs kit can be provided. For
hazards, cutting injuries, electric shock, this reason, in every case please consult High Voltage
slipping and tripping accidents Components at ABB Switzerland Ltd before repairs.
 The work area must be marked and kept
In case of repairs, the surfaces of the interfaces and their
clear.
environment must be cleaned with lint-free cloth soaked in
 All the activities must be supervised by a
acetone; alternatively, a narrow piece can be cut out from the
qualified person.
damaged area with a knife to reach a clean surface.
 Appropriate climbing aids and
supporting structures should be used.
 Apply the repair compound and vulcanize.
 The personnel should be authorized to
work at height.
 The personnel should have appropriate  For further information, please contact
DANGER
training for work with dangerous High Voltage Components at ABB
voltages. Switzerland Ltd or your local ABB
 The system is switched-off, secured and partner.
NOTE
tested.
 The primary and secondary side of the
transformer or the switchgear is short-
circuited and earthed.
 The work can only be started after a
complete electric discharge of the
system.
 Wear appropriate PPE.

12.1. Bushing repairs


Extensive repairs should be conducted in consultation with High
Voltage Components at ABB Switzerland Ltd. The production
number as well as a precise description of the damage do be
repaired are necessary for this.

12.2. Porcelain insulator repairs


Damaged insulators must be replaced or repaired. Repairs are
only possible if there are light scratches in the glazing or light
damage to the shield.

 For further information, please contact


High Voltage Components at ABB
Switzerland Ltd or your local ABB
NOTE partner.

12.3. Silicone insulator repairs


Damaged silicone insulators must be replaced or repaired.

As the manufacturers of the silicone insulators use different types


of silicone for shielding, different repair compounds (LSR or HTV)
must be used, and the corresponding vulcanization times must be
observed. For this reason, in case of repairs please consult High
Voltage Components at ABB Switzerland Ltd, providing them with
photographs of the damaged area as well as the serial number of
the bushing.

35/38 | HLAB200456 | Operating instructions for AirRIP bushings


13. Disposal

Prevention of reloading hazards, cutting


injuries, chemical hazards, falling, slipping
and tripping accidents
 The work area must be marked and kept
clear.
 All the activities must be supervised by a
qualified person.
DANGER  Appropriate climbing aids and
supporting structures should be used.
 The personnel should be authorized to
work at height.
 The personnel should be trained for the
reloading activities.
 Wear appropriate PPE.

13.1. Special hazards during disposal


After the service life of the bushing expires, it should be disposed
of in accordance with the local laws and regulations.

The disposal should be performed by a recycling company that


specializes in these activities.

The product, including accessories, does not contain any toxic


basic components

Special case for bushings equipped with


spring assemblies
Depending on the type of the bushing,
spring assemblies can be included on the air
side. Due to the high mechanical tensioning,
sawing the bushing apart is complex and
dangerous.
DANGER
 Danger from flying objects. The release
of tension in the spring assembly must
be performed with utmost caution.

 For further information, please contact


High Voltage Components at ABB
Switzerland Ltd or your local ABB
NOTE partner.

36/38 | HLAB200456 | Operating instructions for AirRIP bushings


14. Type designation

14.1. Rating plate

RTKF 72.5 – 350 / 1600 B KSI Composite insulator (not specified for porcelain insulator)

Conductor type B = Removable conductor rod | F = Fixed conductor


(not specified for cable conductor)

Rated current [A]

Lightning impulse voltage 1.2/50 µs (BIL) [kV]

Max. voltage [kV]

R: RIP technology | T: transformer application


K: length oil part (K = short, X = medium, Z = long, no spec. = any length)
F: outdoor application

37/38 | HLAB200456 | Operating instructions for AirRIP bushings


For further information, please contact

ABB Switzerland Ltd.

HLAB200456-August 2017
High Voltage Components, Micafil Bushings
Badenerstrasse 780
8048 Zurich, Switzerland

Phone: +41 (0)58 586 02 32


Fax : +41 (0)58 586 04 44
www.abb.com/electricalcomponents

Customer Service
Hotline for technical issues, 24h a day including weekends
Mobile: +41 (0)58 586 07 70
E-mail: ch-service.micafil@abb.com

Note
We reserve the right to technical modifications or changes to the
contents of this document without prior notice. In case or placing
orders, the agreed terms and conditions shall apply. We reserve
all rights in this document and the items and illustrations
contained therein. Any reproduction, transfer to third parties or
the utilization of the contents, in part or in whole, shall be
prohibited without the prior approval by ABB in writing.

Copyright ©2017 ABB


All rights reserved