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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
Measurement terminal
Oil-side shielding
Fig.1: Structure of an AirRIP bushing with cable bolt for rope conductors
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).
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).
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. 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.
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
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
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.
NOTE
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.
M6 8.5 8.5 10 14 17
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.
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.
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)
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
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).
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.
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.
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
P
U N / 3
2
1
Rz a b2
2
with:
C2
a 1
C1
and
1
b
C1 Rz
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
5 mm
Sealing
Spring
Protective
cover
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.
Hazardous voltage
The measurements are performed using
high voltage. The local safety
regulations of high voltage installation
DANGER must be observed.
The bushing should be lifted at least 1.5 m above ground to reduce Fig. 32: Typical measurement of C1 and tan1
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.
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
1500
2000
DANGER
20 1.00
30 0.85
40 0.77
50 0.75
60 0.77
70 0.82
80 0.90
∆T = T bushing - 20 [°C]
Tab. 15 : Tolerances
100
200
500
1000
1500
9.4.1. Capacity C1 and loss factor tan1 Tab. 17: C2 and tan 2 measurement overview
500
1000
2000
3000
100
2000
3000
6000
10000
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
20 1.00
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.
Maintenance
Ans
End of
waranty Service
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.
RTKF 72.5 – 350 / 1600 B KSI Composite insulator (not specified for porcelain insulator)
HLAB200456-August 2017
High Voltage Components, Micafil Bushings
Badenerstrasse 780
8048 Zurich, Switzerland
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.