2750 515-142 en, Rev.

Bushing diagnostics and conditioning

Product information

Original instruction
The information provided in this document is intended to be general in nature
and does not cover all possible applications. Any specific application not covered
should be referred directly to ABB or to ABB's authorized representative.
ABB makes no warranty or representation and assumes no liability for the
accuracy of the information in this document or for the use of such information. All
information in this document is subject to change without notice.
This document must not be copied without our written permission, and the contents
thereof must not be imparted to a third party nor be used for any unauthorized
purpose. Contravention will be prosecuted.

Safety information
Keep this instruction available for those responsible for the
installation, maintenance and operation of the bushing.
Installation, operation and maintenance of a bushing present
numerous potentially unsafe conditions, including but not
limited to the following:
High pressures
Lethal voltages
Moving machinery
Heavy components
Slipping, stumbling or falling
Specialized procedures and instructions are required and
must be adhered to when working on such apparatus. Failure
to follow the instructions could result in severe personal injury,
death and/or product or property damage.
Additionally, all applicable safety procedures such as
regional or local safety rules and regulations, safe working
practices and good judgment must be observed by
personnel when installing, operating, maintaining and/or
disposing of such equipment.

Safety as defined in this instruction involves two conditions:

1. Personal injury or death.
2. Product or property damage (includes damage to the
bushing or other property, as well as reduced bushing life).
Safety notifications are intended to alert personnel of possible
risk of personal injury, death or property damage. They have
been inserted in the instructional text prior to the step in
which the condition is cited.
The safety conditions are headed by one of the three hazard
intensity levels that are defined as follows:

WARNING
WARNING indicates an imminently hazardous
situation, which if not avoided will result in death or
serious injury. This level is to be limited to the most
extreme situations.
WARNING also indicates a potentially hazardous
situation, which if not avoided could result in death or
serious injury.

CAUTION
CAUTION indicates a potentially hazardous situation,
which if not avoided may result in minor or moderate
injury. It may also be used to alert of unsafe practices.
CAUTION may also indicate hazards solely related to
property damage.
INFO provides additional information to assist in
carrying out the tasks described and to provide
trouble-free operation.

Contents
1. General guide to diagnostics and conditioning of bushings....................................................7
2. Diagnostics............................................................................................................................8
2.1 Capacitance and tan measurement..............................................................................8
2.1.1 Test equipment.........................................................................................................8
2.1.2 Measuring procedure................................................................................................8
2.1.2.1 Dissipation factor test......................................................................................9
2.1.2.2 Capacitance test..............................................................................................11
2.1.3 Interpretation of measurement..................................................................................12
2.2 Partial discharge measurement.......................................................................................14
2.3 Dissolved gas analysis (DGA)..........................................................................................14
2.3.1 Oil sampling from bushings.......................................................................................15
2.3.2 Interpretation of analysis...............................................................................................16
2.4 Moisture analysis.............................................................................................................16
2.4.1 Oil sampling from bushings.......................................................................................16
2.4.2 Interpretation of analysis...........................................................................................16
2.5 Oil leakage inspection.....................................................................................................17
2.6 Insulator inspection.........................................................................................................17
2.6.1 Hydrophobicity classification.....................................................................................17
2.6.1.1 General information..........................................................................................17
2.6.1.2 Test equipment................................................................................................17
2.6.1.3 Test procedure.................................................................................................17
2.6.1.4 Classification of hydrofobicity...........................................................................18
2.6.2 Sample collection and status determination of silicone grease on porcelain insulators.18
2.6.2.1 Test equipment................................................................................................20
2.6.2.2 Sample collection.............................................................................................20
2.6.3 Instruction for thickness measurement of silicone grease on porcelain insulators.......21
2.6.3.1 Test equipment................................................................................................21
2.6.3.2 Measuring procedure.......................................................................................21
2.7 Thermovision...................................................................................................................21
2.8 De-polymerization analysis..............................................................................................21
3. Conditioning..........................................................................................................................22
3.1 Cleaning of insulators......................................................................................................22
3.1.1 Porcelain insulators...................................................................................................22
3.1.2 Silicone rubber insulators..........................................................................................22
3.2 Silicone grease treatment of wall bushings......................................................................22
3.2.1 Purchase of silicone grease solvent...........................................................................23
3.2.2 Criteria for reapplication............................................................................................23
3.2.3 Precautions during application and reapplication.......................................................24
3.2.4 Application................................................................................................................24

1. General guide to diagnostics and conditioning of bushings

In the following document, guidelines for diagnostics and

conditioning of bushings are presented. The document
is mainly based on experience from diagnostics and
conditioning at ABB Components. Utilities and the testequipment producers have considerable practical knowledge
of the tasks described in this document. Combining
the extensive knowledge possessed by utilities and test
equipment producers with the product knowledge at ABB
Components provided in this document, will result in the best
possible interpretation of bushing condition.

2750 515-142 en, Rev. 2 | Bushing diagnostics and conditioning 7

2. Diagnostics

Several methods are available for diagnostics of high voltage

bushings. In general, bushings from ABB can be considered
maintenance-free. Inspection and service however, will
sometime lead to bushing diagnostics.
In the following sections a guide is provided for various
test methods and interpretations. Some methods for site
diagnostics are not widely available on the market. They are
therefore briefly described in this document.

2.1.1 Test equipment

Measuring bridge:
The measuring bridge shall be of the transformer-ratio arm
type. Bridges of this type are available in several designs from
various manufacturers. Examples of measuring bridges:
Manufacturer

Model

Doble Engineering

M2H

Company

2.1 Capacitance and tan measurement

Tettex Instruments

2088

Tettex Instruments

2805

Multi-Amp Corporation

CB-100

CAUTION
Ensure that the transformer is de-energized and out of
service before any work is performed on the bushing.

CAUTION
The test tap must not be left open during service.
Check that the grounding spring and the protective
cap are in position after testing. The test tap design is
shown in the installation and maintenance guides.

CAUTION
The testing equipment must not be connected to the
test object before the transformer is de-energized and
removed from service. All windings must be shortcircuited, and windings not connected to bushings
during testing must be grounded.
Prior to putting a condenser bushing in service, and when
a fault is suspected, the capacitance and dissipation factor
can be measured and compared with the values on the rating
plate or in the routine test report. In conjunction with these
tests, the electrical connection between the transformer tank
and bushing flange must be checked with a continuity tester.
In this product information, the terms tangent delta,
tand, power factor and dissipation factor can be used
interchangeably.

Can be used under good

interference conditions
For low voltage only (30 V)

Regarding the handling of the bridge, the manufacturers

manual must be consulted. For connecting the measuring
lead to the test tap, a special adapter must be used for
certain bushings. This device is described in the product
information for each type of bushing.
Power source:
When measuring the dissipation factor, a power source must
be available, either separate or integrated into the measuring
equipment. The voltage should be adjustable up to at least 10
kV, and as much as possible, free from harmonics. To avoid
problems when adjusting the null indicator, the voltage should
be synchronous with the voltage in the plant.
Measuring using digital instruments:
If only the main capacitance C1, is to be measured, and an
accuracy of 3% is acceptable, a simpler method can be
used. The method, described later in this document, only
requires a power source of 400 V/2 A, two digital instruments
and a 10 kW/10 W resistor.
2.1.2 Measuring procedure
When testing a bushing that has a capacitive test tap, i.e.
practically all our bushings, it is not necessary to disconnect
the top of the bushing. It is enough to open the disconnecting
switch.
For the sake of safety and for reduction of the influence from
winding inductance, all transformer windings must be shortcircuited. Windings not connected to the tested bushing must
be grounded. See Figure 1.

8 Bushing diagnostics and conditioning | 2750 515-142 en, Rev. 2

The bridge must be placed on a vibration-free base. If the

reference capacitor is separate, it must be placed on a dry,
insulating base.
Depending on the insulation to be tested, the voltage source
(test voltage) is connected via separate leads to the bushing
top or the capacitive test tap. Leads for test voltage or
grounding must not be common with leads for measuring.
Measuring leads must be as short as possible and must not
touch grounded objects. Bands or strings used for spacing
must be clean and dry. This also applies to the test object. If
the bushing is in its transport case, it must not be surrounded
by wet filling material. The test tap must be clean and dry.
Under humid conditions, drying of the test tap may be
required to obtain representative readings for tan over C2.
An air dryer may be used for drying. Cleaning of the air-side
insulator housing is indispensable for correct measurement of
tan over C1.

2.1.2.1 Dissipation factor test

It is assumed that the bushing to be tested is equipped with
a capacitive test tap. It is further assumed that the bridge in
use can measure ungrounded, according to the UST method
(Ungrounded Specimen Test). In this way, the influence from
the transformer on the test results (tan ) is minimized. The
test shall be carried out at the highest possible temperature.
The ground terminal on the bridge must be connected to
the ground terminal on the transformer. When measuring an
unmounted bushing, the flange must be grounded. To make
it possible to compare the test results with the value on the
rating plate or with the routine test report supplied with each
bushing, the dissipation factor must be measured at 10kV.
The measurement procedure must begin with a low sensitivity
on the bridge. The sensitivity is then gradually increased to
the highest possible. In rare cases, external interference can
make it difficult to set the detector to zero. If the interference
cannot be eliminated, the sensitivity must be lowered. Table1
shows the connections to be made when measuring the
dissipation factor of the different insulations. Note that most
bridges provide capacitance and dissipation factor in the
same measuring operation.

Test voltage

HV lead
IC1 + ICH + ICHL

Test tap
IC1
LV lead
CL

CHL
CH

Figure 1. Field testing on bushings using the UST method (Ungrounded Specimen Test).

2750 515-142 en, Rev. 2 | Bushing diagnostics and conditioning 9

Table 1. Connections for different measurements. Here with the

nomenclature of Doble Engineering.

Test sequence
Test

Level

Voltage

HV test

LV test

Switch

to

lead to

lead to

position

Measure
tan

10

CL

CL

Tap

UST

C1

Note A

Tap

Tap

CL

Ground

C1 + C2

Note A

Tap

Tap

CL

Guard

C2

Note A

Tap

Tap

CL

UST

C1

10

CL

CL

Ground

Ground

The whole

(flange)

(GST)

bushing

(GST)

Temperature correction:
The measured tan value must be temperature-corrected
according to the correction factor in Table 2. GOx stands for
all oil-impregnated paper condenser bushings (OIP), and GSx
stands for resin-impregnated paper condenser bushings (RIP).
For all bushings it must be assumed that the bushing has
the same temperature as the top oil of the transformer. The
test must be performed at a temperature as high as possible.
Correction must be made to 20C. The corrected dissipation
factor (tan ) is compared with the value on the rating plate or
in the test report.

CL

Center conductor

Tap

Capacitive test tap

C 1

Main insulation

Range C

Correction to 20C OIP

Correction to 20C RIP

C 2

Tap insulation

0-2

0.80

0.76

UST

Ungrounded measurement (Ungrounded Specimen Test)

3-7

0.85

0.81

GST

Grounded measurement (Grounded Specimen Test)

8-12

0.90

0.87

Guard In this position C1 is by-passed and only C2 is measured. This

13-17

0.95

0.93

method is not available on all bridges.

18-22

1.00

1.00

Note A Tests 2, 3 and 4 must not be performed at a voltage higher than

23-27

1.05

1.07

500 V if the test tap insulation is delivery tested at 2 kV. If the test tap is

28-32

1.10

1.14

tested at 20 kV, 2.5 kV or 5kV may be used.

33-37

1.15

1.21

38-42

1.20

1.27

43-47

1.25

1.33

48-52

1.30

1.37

53-57

1.34

1.41

58-62

1.35

1.43

63-67

1.35

1.43

68-72

1.30

1.42

73-77

1.25

1.39

78-82

1.20

1.35

83-87

1.10

1.29

It is advisable to always perform Test 1. Test 2 should also

be performed, especially if Test 1 produces a deviating result.
The capacitance C 2 can be calculated by subtracting C 1. Tests
3 and 4 are investigative tests if the previous tests produce
suspicion about a fault. The dissipation factor, measured
in Test 4, should be compared with the values measured in
Test1. Test 5 together with Tests 1 and 2, are recommended
for unmounted bushings.

10 Bushing diagnostics and conditioning | 2750 515-142 en, Rev. 2

Table 2. Correction factors for tan .

2.1.2.2 Capacitance test

Capacitance testing using a bridge:
Figure 2 shows the principle for capacitance measurement.
The measurement must be performed according to applicable
parts of Table 1.

HV lead

Test tap

LV lead

The transformer capacitance CT to ground may have an

influence on the measurement. In most cases this capacitance
is small and normally produces only negligible error. However,
a deviation between the individual bushings on all three
phases may indicate influence from the transformer.
Capacitance testing using digital instruments:
This method may produce a relatively large measurement
error (approx. 3%) and can be used only for measuring
main capacitance C1. However, the disturbance sensitivity is
less than for the bridge method, and possible influence from
transformer capacitance is eliminated.
The test circuit is shown on the principal diagram in Figure 3.

Center
conductor

C1

C2

CT
Transformer
Capacitance and
power factor
test set

Figure 2. Principal diagram for capacitance testing on bushings, mounted

on transformer.

Electrical connection of the resistors R 2 must be good. The

opposite terminal N of the transformer winding may be left
open or grounded. If it is left open, it will take the same
voltage as the top of the bushing. If grounded, the voltage
source may be overloaded.
For measuring the voltage U1 and U2 digital instruments of
the type Fluke 8020 or equivalent may be used. It should be
noted that digital instruments do not work satisfactorily at
temperatures below 0C. At temperatures below 0C, the
instruments must be heated.
Increase the voltage U1 of the voltage source until U2 reaches
at least 100 mVrms. U1 might then be between 200 and
400 Vrms. Read U1 and U2 and calculate the capacitance C1
according to the formula below.

Bushing
C1
Test tap
C2

Transformer

C1 = U2/U 1 x 1/(R2 x 2pf) [F] f = frequency [Hz]

At 50 Hz
C1 = U2/U 1 x 318 [pF]

U 2 [mV], U1 [V], R2 = 10 [kW]

At 60 Hz
C 1 = U2/U 1 x 265 [pF]

U 2 [mV], U1 [V], R2 = 10 [kW]

R2
U1

U2

R2 = 10 k, 10 W

Voltage source
0-400 V, 50-60 Hz

Figure 3. Principal diagram for capacitance testing using digital instruments.

2750 515-142 en, Rev. 2 | Bushing diagnostics and conditioning 11

2.1.3 Interpretation of measurement

Comments on dissipation factor OIP bushings:
The dissipation factor is a critical property in an oil-filled
condenser core bushing. It is mainly determined by the
moisture level in the paper and the amount of contaminants
in the insulation system. Besides this, the power factor is
also very much dependent on the temperature. The principal
behavior is shown in Figure 4 for different temperatures and
different moisture levels.

Figure 4. Tan as a function of moisture level and temperature on OIP bushings.

It is clear that the measurements at elevated temperatures

are more sensitive. At 20C, moisture levels between 0.1% to
1% show about the same dissipation factor. At an elevated
temperature (90C) they differ by a factor of 5 or more.
The conclusion from this is that the important property is
the dissipation factor at elevated temperatures and not the
dissipation factor at 20C. For bushings, the important factors
regarding dissipation factor are:
1. A dissipation factor that is constant with regard to
temperature during the entire bushing life.
2. A dissipation factor that remains constant during
the entire bushing life.

12 Bushing diagnostics and conditioning | 2750 515-142 en, Rev. 2

For the manufacturer of a condenser core bushing, the

objective is to achieve the right dissipation factor. The
contribution to the dissipation factor from contaminants is
avoided by proper material control as well as by stringent
cleanliness requirements in the workshop. The moisture
content in the bushing is determined by the winding technique
and the drying process of the condenser core.
The standard procedure in making bushings is to wind the
condenser core with the paper as such without drying. This
produces a moisture content in the final condenser core of
about 4-8%. The core is then dried in a separate heat and
vacuum drying process until sufficient dryness is achieved.
Since the water discharges axially, the core must be dried
very carefully to ensure that no water is trapped at the center
of the core. In the manufacturing of our bushings we dry the
paper at the same time as we wind the condenser core. By
doing this we attain a fully dry condenser core after winding
and a separate drying process is no longer needed. The
benefit is that no moisture is trapped at the center of the core.
Together with this we also limit the drying time, which means
minimum aging of the paper.
Both ANSI and IEC bushing standards require measurement
of the dissipation factor at room temperature as a routine test
on new bushings. This is done on all our bushings. During
normal routine testing we have requirements for not only the
level of the dissipation factor but also the change of voltage
since this might be an important sign of contamination in
the bushing. Beside this, we take a bushing from ordinary
production every second month and place it in a 90C oven.
After 24 hours the dissipation factor is measured. Our internal
instruction requires the value to meet the same requirements
as at 20C.
For the past 25 years, ABB Components has been using only
pure cellulose together with aluminum foils and insulation oil
in our condenser cores. Through experience, we have seen
that the dissipation factor remains completely constant over
the years. It is known from trade literature that different kinds
of glues have caused problems with aging and with rising
dissipation factor as a consequence. That we are using pure
raw materials, a well controlled process and careful testing
combined with our long service experience gives us the
confidence to say that the tan level of our bushings will
remain constant throughout the entire bushing life.

Comments on dissipation factor, RIP bushings:

When measuring tan on RIP bushings before the bushing is
put into service, deviation of the tan value compared to the
value on the marking plate might occur. The reason for this is
most probably moisture penetration into the surface layer of the
RIP. This can occur for instance, if the bushing is stored without
its sealed protective bag, allowing air with high humidity to
penetrate the outer surface layer of the bushing.
Normally the tan value will decrease to its initial, marking plate
value if the bushing is stored indoors with controlled humidity
for a week. If the transformer is energized with the bushing in
service, the value will decrease within a couple of hours.
Please read and follow the suggested measures in the
next section:
Measures for different temperature-corrected values, OIP
and RIP bushings
0-25% increase:
The value is entered in the record. No further measures are to
be taken.
25-40% increase:
The measuring circuit is checked regarding leakage and
external interference. External interference can be for
instance, influence from nearby current-carrying equipment
and bus bars. If the difference remains, the oil level plug
gasket will need to be replaced because of the moisture
that has probably entered the bushing. The measured value
is entered in the record, and the bushing can be put into
service.
40-75% increase:
The measures as above, and the measurement itself, are
repeated within one month.
More than 75% increase:
The bushing must be taken out of service. However, if the
dissipation factor is less than 0.4%, the bushing may be put
in service even if the increase in percentage from a low initial
value is greater than 75%.
Comments on power factor measurements between
the test tap and the mounting flange on OIP and RIP
bushings:
Some of our customers also want to use the capacitance
(C2) and the dissipation factor over the tap insulation as a
diagnostic tool. Based on our experience we strongly advise
against this. There are several reasons for not using these
values as diagnostic tools.

Primarily this dissipation factor is specified to be less

than 5% according to IEC 60137. This means that unless
otherwise specified, no attention is given to decreasing that
value to the same level as for the dissipation factor over the
main insulation.
The test tap is connected to the outer grounded layer
on the condenser body. The solid layer outside the
grounded layer contains an adhesive and cellulose to make
the condenser body more stable. This means that the
contribution to the dissipation factor from that part differs
from the pure cellulose in the main insulation. It also means
that this part cannot be used for diagnostic purposes
because the adhesive affects the dissipation factor
differently on different bushings.
It must be emphasized that under operational conditions, the
outer layer must be grounded. Consequently, the insulation
between the outer layer and the mounting flange is not
subjected to an electrical field and thus does not cause any
dielectric heat losses. It is likely that if the bushing is placed in
a contaminated area, contaminants on the outside of the test
tap will affect the results. Moisture around the test tap also
affects the measurement.
It must be pointed out that if the test voltage (500 V if the
test-tap insulation is delivery tested at 2 kV, and 2.5 kV to
5 kV if the test tap is delivery tested at 20 kV) is exceeded,
partial discharge may occur in the region of the test tap,
which also will affect the measurement.
Taking all the variations above into account, tan delta over
the test tap insulation varies between 0.4-3.0%.
Capacitance:
The measured capacitance C1 is compared with the value
specified on the rating plate of the bushing or with the
10kV routine test report. If an increase of more than 3% is
measured (which could indicate partial puncture) compared
to the factory measured value, or an extremely low value
(disruption), please contact ABB Components. A disruption
(low C 1) may indicate transport damage, and the bushing
must not be put into service. C 2 is influenced by the way the
bushing is mounted on the transformer and should not be
used for diagnostics.

2750 515-142 en, Rev. 2 | Bushing diagnostics and conditioning 13

2.2 Partial discharge measurement

Partial discharge measurement is primary used in the
routine testing method. Partial discharge may indicate
external corona or internal insulation failures. Used for
diagnostics on installed transformers or wall bushings, it will
show the sum of the partial discharges in the bushing and
transformer insulation. External discharges in switchyards
may be suppressed by use of external connected measuring
coils. With the use of newly developed acoustic sensors,
partial discharges can be located. This method requires
skilled personnel performing the measurements as well as
knowledge of bushing and transformer design.

2.3 Dissolved gas analysis (DGA)

CAUTION
Ensure that the transformer is de-energized and out of
service before any work is performed on the bushing.
This method of diagnostics can only be used on liquid filled
bushings, e.g. GOx types. We do not normally recommend
that our customers take oil samples from our bushings. The
bushing is sealed and tightness-tested at the time of the
manufacturing. Oil sampling entails opening of the bushing,
and consequently introduces the risk of improper sealing after
sampling is completed.
However, when a problem is known, such as a high power
factor over C1, or high overpressure (GOEK), there might
be a need for oil sampling and gas analysis. The indication
of a problem could be found on bushings connected to GIS
equipment (VTF) or installed on reactors that are
not synchronized.

GOH

GOA, GOC and GOG

GOB

GOE

Figure 5. Location of sampling plugs for GOA, GOB, GOC, GOE, GOH and GOG.

14 Bushing diagnostics and conditioning | 2750 515-142 en, Rev. 2

2.3.1 Oil sampling from bushings

Oil samples shall preferably be taken under dry weather conditions.
If due to some urgent reason the sample is taken under any other
condition, the following must be taken into account:
Carefully dry and clean the area around the sampling plug
before sampling.
Protect the area around the sampling plug from rain.
When sampling, precautions should be taken to deal with any
sudden release of oil.
The internal pressure of the bushing must not be altered
before and after the sampling as the bushing is intended to
work within a specified interval. This is satisfied if the sample
is taken when the bushing's mean temperature is between
0C and 30C.
The time during which the bushing is unsealed must be as
short as possible. Flushing with dry air or nitrogen is normally
unnecessary.
The oil sampling procedure is described in IEC 61464,
Appendix A. Sampling of oil must be carried out using
apparatus and methods complying with IEC 60567. It is
recommended that samples be taken by qualified personnel,
trained to carry out the task in accordance with IEC 60567.
Replenishment of oil is not required after a single sampling.
However, after several samplings the volume can be reduced
to such an extent that filling becomes necessary. It is
especially important for bushing type GOEK with a small
volume of oil. The new oil must comply with IEC 60296, Class
II and be clean and dry.

The tightening torque for the M8 sealing plug on GOB, GOE

and GOH is 20 Nm.
The tightening torque for the M16 sealing plug on GOE is 50
Nm.
Table 3. Dimensions of gaskets.

Gasket

d (mm)

D (mm)

T (mm)

M8

16

M16

14

35

5/8"

14

35

Sampling procedure for GOEK, GOM, GOE and other

bushings with sampling valve on flange
Connect the end of the hose to a suitable nipple and then
connect the nipple to the valve on the flange. The valve thread
is (R ") BSPT " or R " (GOEK). Extract the oil. Depending
on the temperature, the pressure inside the bushing might be
above or below atmospheric pressure.

During the sampling process, it is very important to

avoid any bubbles from entering the bushing.
The bushing can be energized after one hour if it is
ensured that no bubbles have entered the bushing
during sample procedure. The bushing is otherwise
energized after 12 hours.

The old gasket must always be replaced with a new one when
the bushing is sealed after sampling.
Sampling procedure for GOB, GOH and old GOE without a
sampling valve on the flange
The sample is taken from a plug at the top of the bushing,
preferably using a syringe with a rubber hose connected to
the top of the syringe.
Figure 5a. Oil sampling valve " on GOE flange.

The location of the sampling plug is shown in Figure 5. The

dimension of the gasket is shown in Table 3. The gasket
material must be nitrile rubber (resistant to transformer oil),
with a hardness of 70 shore.

2750 515-142 en, Rev. 2 | Bushing diagnostics and conditioning 15

Sampling procedure for GOA, GOC and GOG

On GOA, GOC and GOG bushings, the oil samples are
taken from the hole for the oil level plug on the top housing
according to Figure 5. If the bushing is vertically mounted,
the oil level is correct when even with the plug at 20C. The
sample is extracted with a syringe. If the oil temperature is
slightly higher than 20C, the oil level will be above the level
of the plug. In such a case the hose on the syringe should
be equipped with nipple according to Figure 6. The oil plug
is removed and the hose with the nipple is immediately
attached. If the temperature is slightly below 20C, the oil
level will be below the plug and the sample is extracted
according to Figure 7. The tightening torque for the 5/8"
sealing plug is 50 Nm.
2.3.2 Interpretation of analysis
Interpretation of the analysis is performed according to
IEC61464. If there are any questions, ABB Components
can assist with the evaluation.

5/8" UNC

Figure 6. Sampling on GOA at T > 20C.

2.4 Moisture analysis

CAUTION
Ensure that the transformer is de-energized and out of
service before any work is performed on the bushing.
This method of diagnostics can only be used on liquid filled
bushings, e.g. GOx types. We do not normally recommend
that our customers take oil samples from our bushings. The
bushing is sealed and tightness-tested at the time of the
manufacturing. Oil sampling entails opening of the bushing,
and consequently introduces the risk of improper sealing
after sampling is completed.
However, when a problem is known, such as a high power
factor over C1, there might be a need for oil sampling and
moisture analysis.
Attaining the proper moisture content in bushing oil is
sometimes difficult. Compared to a transformer, a bushing has
a much higher ratio of paper to oil. This means that regardless
of the bushing manufacturing process, there will always be
much more moisture in the paper than in the oil. (In paper
the moisture is measured as a percentage, whereas in oil the
moisture content is measured in ppm, "parts per million".)
Depending on the temperature of the bushing, the moisture
will migrate either from the paper to the oil or from the oil to
the paper in accordance with the equilibrium curves (piper
diagrams) for oil-paper moisture. Due to this, a bushing will
always show a much higher moisture content in the oil after a
certain time in service at a high temperature. Consequently, to
obtain a proper value, the oil sample should be taken at least 48
hours after the entire bushing has reached room temperature.
2.4.1 Oil sampling from bushings
Oil sampling is performed much the same as for DGA analysis.

Figure 7. Sampling on GOA at T < 20C.

2.4.2 Interpretation of analysis

The bushing is delivered from ABB Components with a
moisture content in the insulating oil of maximum 3 ppm. If
considerably higher concentrations are measured the sealing
system on the bushing is damaged.
At a concentration of >10 ppm a tan d measurement must
be performed according to Section 2.1.2. Measures must be
taken according to the recommendation in Section 2.1.3. At
a concentration of > 20 ppm the bushing must be removed
from service.

16 Bushing diagnostics and conditioning | 2750 515-142 en, Rev. 2

2.5 Oil leakage inspection

CAUTION
Ensure that the transformer is de-energized and out of
service before any work is performed on the bushing.
A visual inspection for leakage may be performed during
normal station checks.
2.6 Insulator inspection
2.6.1 Hydrophobicity classification

Seven classes of the hydrophobicity (HC 1-7) have been

defined. HC 1 corresponds to a completely hydrophobic
(water-repellent) surface and HC 7 to a completely hydrophilic
(easily wetted) surface.
These classes provide a coarse value of the wetting status
and are particularly suitable for a fast and easy check of
insulators in the field.
2.6.1.2 Test equipment
The only equipment needed is a common spray bottle
that can produce a fine mist. Fill the spray bottle with tap
water. The water must not contain any chemicals, such as
detergents, tensides or solvents.

CAUTION
Ensure that the transformer is de-energized and out of
service before any work is performed on the bushing.
The following information for hydrophobisity classification is
provided with minor changes from STRI AB, Guide 1, 92/1
Hydrofobicity Classification Guide. STRI AB is an independent
company for development and testing in the field of electrical
power transmission and distribution. STRI is jointly owned by
ABB, Svenska Kraftnt (the Swedish National Grid), Vattenfall
AB and Statnett SF (the Norwegian National Grid).
2.6.1.1 General information
The superior electrical performance of composite insulators
and coated insulators stems from the hydrophobicity (waterrepellency) of their surfaces. The hydrophobicity will change
with time due to exposure to the outdoor environment and
partial discharges (corona).

Complementary equipment that could facilitate the

assessment are a magnification glass, a lamp and a
measuring tape.
2.6.1.3 Test procedure
The test area should be 50-100 cm2. If this requirement
cannot be met this should be noted in the test report.
Spray 1-2 times per second from a distance of 2510cm.
Spraying shall continue for 20-30 seconds. The assessment
of the hydrophobicity class must be performed within 10
seconds after completion of spraying.
Hydrophobicity classification can be difficult to perform in high
winds. If this or other difficulties are present, this should be
noted in the test report.

2750 515-142 en, Rev. 2 | Bushing diagnostics and conditioning 17

2.6.1.4 Classification of hydrofobicity

The actual wetting appearance on the insulator must be
identified with one of the seven hydrophobicity classes (HC),
which is a value between 1 and 7. The criteria for the different
classes are shown in Table 4. Photos of typical surfaces with
different wetting properties are shown in Figure 10.
The contact angle () between the water droplets and the
surface must also be taken into account. The contact angle is
defined in Figure 9. There are two different contact angles, the
advancing contact angle (a) and the receding contact angle(r).
A droplet exhibits these angles on an inclined surface.
The receding angle is the most important when the wetting
properties of an insulator are to be evaluated. The inclination
angle of the surface affects the r.

Description

Only discrete droplets are formed. r 80 or larger for the

Only discrete droplets are formed. 50 < r < 80 for the

General information
Location, station, line
Date and time of the assessment
Weather conditions (temperature, wind, precipitation)
Performed by
Test object
Type of insulator
Identity (item no., position)
Voltage
Date of installation or application of coating (type of
coating)
Mounting angle (vertical, horizontal, inclined x deg)
Hydrophobicity class
HC for different positions: along the insulator (shed no.),
along the surface within each shed sequence (top, bottom,
core, large shed, small shed, etc.)
Difference (if any) around the insulator circumference in
comparison to values from previous measurements.

Table 4. Criteria for hydrophobicity classification (HC).

HC

Test report:
The test report shall include the following information:

majority of droplets.
majority of droplets.
3

2.6.2 Sample collection and status determination of silicone grease on porcelain insulators

Only discrete droplets are formed. 20 < r < 50 for the

majority of droplets. They are usually no longer circular.

Both discrete droplets and wetted traces from the water runnels

CAUTION

are observed (i.e. r = 0). Completely wetted areas < 2 cm2.

Together they cover < 90% of the tested area.
5

Ensure that the transformer is de-energized and out of

service before any work is performed on the bushing.

Some completely wetted areas > 2 cm2, which cover < 90% of
the tested area.

Wetted areas cover > 90%, i.e. small unwetted areas (spots/

This instruction describes the procedure for sample collection

of silicone grease on insulators.

traces) are still observed.

7

Continuous water film over the entire tested area.

AIR
Qa = advancing angle
Qr = receding angle

LIQUID

SOLID

Horizontal plane

Figure 9. Definition of contact angles.

18 Bushing diagnostics and conditioning | 2750 515-142 en, Rev. 2

Qr

LIQUID
Q

Qa
SOLID

Inclined plane

Figure 10. Examples of typical surfaces with HC from 1 to 6 (natural size).

2750 515-142 en, Rev. 2 | Bushing diagnostics and conditioning 19

2.6.2.1 Test equipment

The following materials are required when sampling silicone:
Three copper foils, measuring 15 x 70 x (0.2 0.3) mm
Screwcapped glass jar, size sufficient to embrace the foils
Disposable gloves
Use the gloves when handling the sampling equipment.

Sample marking
Each glass jar with a grease sample should be marked with
the sample collection date, type of insulator and designation,
sample collection position and sample collection area.
Sample marking can also be performed by giving the glass
jars individual numbers and corresponding identification on a
separate list.
The description of the position should be in the following
order:

2.6.2.2 Sample collection

Procedure
Use the disposable gloves and take a foil from the jar.
The grease sample must be collected on the foil by
scratching along the porcelain surface. This shall be
performed in a way that leaves as little of the grease layer
on the insulator as possible.
The total sample collection area should not be less than
15cm2 and the total amount of collected grease should not
be less than 1 g (~1 cm2). To meet these demands it may
be necessary to use at least all three foils.
Place the foil(s) with the grease in the jar and close the cap.
Measure the sample collection area.
Change gloves for the next sample collection.
If possible, take photos of a typical sample collection area
before and after the sample collection is performed.

Top

Position:
Top
12 oclock
SW
Upper

Corresponds
Corresponds
Corresponds
transducers)
Corresponds

to the position along the insulator

to the position along the insulator
to the point on the compass (for
to the position on the shed

The positions for wall bushings are also shown in Figure 11.
Packing
Securely place the glass jars in a box with the caps upwards.
Mark the box This side up.
Send the sample for analysis to ABB Components.

12

Middle

Base

Front view
Side view

Under

Area where the grease

shall be scraped off

Upper

Detail of shed

Figure11. Sample collection positions on a wall bushing.

20 Bushing diagnostics and conditioning | 2750 515-142 en, Rev. 2

Figure 12.

2.6.3 Instruction for thickness measurement of silicone

grease on porcelain insulators

CAUTION
Ensure that the transformer is de-energized and out of
service before any work is performed on the bushing.

In Table 5 the coating thickness is listed in relation to the

number of scrapings. This table is valid for a shortlong 95/95
profile only, which is used on ABB pole wall bushings at
Radisson, Nicolet and Sandy Pond.
Table 5. Conversion, number of scrapings to coating thickness.

Number of scrapings

Coating thickness (mm)

1.1

0.85

0.68

2.6.3.1 Test equipment

The equipment needed for measuring thickness consists of
one squared copper strip measuring 15 x 200 x 2 mm and
one measuring cup with a volume of 5 ml. (A tea spoon with a
well defined volume.)

0.57

0.49

0.42

0.38

11

0.31

2.6.3.2 Measuring procedure

Use the 15 mm side of the copper strip as a scraper. Collect
the grease by scraping from the outer tip of the large shed
to the inner valley in a strict radial direction as described in
Figure12.

For other shed profiles, please contact ABB Components for

advice.

This instruction describes the procedure for thickness

measurements of silicone grease on insulators.

No grease may be visible after the copper strip scraper has

passed the surface.
Place the scraped grease in the measuring cup.
Repeat the scraping procedure until the cup is full (5 ml).
The coating thickness is calculated by using the number of
times the scraping procedure is performed.

2.7 Thermovision
Using an IR/sensitive camera, see Figure 13, hotspots on the
bushing surface can be detected. At maximum rated current,
the bushing's outer terminal reaches a temperature of about
35-45C higher than the ambient air. Significantly higher
temperatures, especially with lower current loading, can
indicate bad connections.
2.8 De-polymerization analysis
De-polymerization analysis is a method of determining aging
of cellulose in OIP bushings. The method requires that the
bushing be disassembled and a paper sample taken from the
condenser body.

Figure13. Measurement indicating poor current path between bushing inner and outer terminals.

2750 515-142 en, Rev. 2 | Bushing diagnostics and conditioning 21

3. Conditioning

In general bushings delivered from ABB Components can be

considered as maintenance-free. However, inspection and
service experience will in some cases lead to conditioning
of bushings.
In the following sections, cleaning of insulators and silicone
grease treatment are described. There are several other
possible conditioning methods for bushings, such as painting,
RTV coating, preparation with shed extenders (booster
sheds), etc., not covered in this document. For guidance,
please contact ABB Components.
3.1 Cleaning of insulators

3.2 Silicone grease treatment of wall bushings

The following method was primary developed for grease
application on wall bushings in DC operation where uneven
wetting may be problem for bushing operation. However, the
treatment may also be useful at installations close to the sea
where salty winds may cause external corona even if extreme
arcing/creepage distances are specified.

CAUTION
Ensure that the transformer is de-energized and out of
service before any work is performed on the bushing.

CAUTION

CAUTION

Ensure that the transformer is de-energized and out of

service before any work is performed on the bushing.

Care should be taken to avoid contact with the skin,

face and eyes.

Avoid solvent coming in contact with the gasket and

porcelain joints.

CAUTION

Under conditions with extreme pollution it may be necessary

to clean the insulator surface.
3.1.1 Porcelain insulators
Clean the porcelain insulator with a water jet or wipe with a
moist cloth. If necessary, ethyl alcohol or ethyl acetate may
be used.
3.1.2 Silicone rubber insulators
Clean the porcelain insulator with a water jet or wipe with
a moist cloth. If necessary, ethyl alcohol or ethyl acetate
may be used. 1,1,1, -Thrichlorethane or methylchloride
are not recommended due to their possibly harmful and
environmentally detrimental properties.

Contamination of the eyes should be treated by

flushing with clean water.
Contamination of the skin should be treated by
washing with soap and water.
If solvent is used, wear goggles, protective gloves,
and if appropriate, a respiratory mask. Precautions
must be taken in accordance with the manufacturers
recommendations.

CAUTION
When a skylift is used, local safety recommendations
must be followed. Move the skylift carefully when
working close to the insulators to avoid damage to
the porcelains.
Finally, care should be taken not to leave traces of
grease on floor, ladders, scaffoldings or supporting
structures, as the grease makes them slippery and
dangerous for personnel.

22 Bushing diagnostics and conditioning | 2750 515-142 en, Rev. 2

CAUTION
Silicone grease has a high flash point but will burn if
exposed to fire. Normal extinguishing media may be
used.

CAUTION
Regarding solvent used, see the manufacturer\s
recommendations.

CAUTION
Silicone oil or grease could cause problems in low
voltage contacts or relays since SiO2 (with insulating
properties) is produced in connection with arcing.
3.2.1 Purchase of silicone grease solvent
Approved quality: Wacker P4
Supplier: Wacker
The grease shall satisfy the requirements in the material
specification 1173 7011113, which can be obtained upon
request from ABB Components.
Tests to be performed by the supplier:
Unworked penetration
Worked penetration
A certificate regarding the measured values shall be supplied
with each batch of grease.
3.2.2 Criteria for reapplication
The expected service life for a silicone grease coating
according to this specification is 3 years or more. Plan for
reapplication of the grease every second year initially, but
extend the interval to three years or more as long as the
grease fulfills the requirements below. Application shall be
performed during the yearly maintenance stop. During the
yearly stop between the year for application, the status of the
grease must be assessed.
This manual comprises two primary methods for supervision
and diagnosis of grease in service:
Assessment of hydrophobicity
This check should be performed in accordance with the
method described in the section Hydrophobicity classification.

Twelve test areas on each insulator must be selected as

follows:
Three positions along the bushing, top (energized end),
middle and the base end of the insulator. At each position
the hydrophobicity is checked on the upper and under side
of the larger shed for both the upper (12 oclock) and under
(6oclock) side of the bushing.
If the hydrophobicity is of Class 4 or higher, a check of
hydrophobicity must also be performed on the adjacent shed.
This provides an assessment as to whether the reduction in
hydrophobicity is local or extends over the entire insulator.
Photo documentation of representative surfaces during the
test is desirable and should always be performed for surfaces
with the classification 4 or higher.
Renewal of silicone grease is recommended as soon as
possible if the surface of Class 6 or 7 exceeds 50% of the
total creepage length of the insulator.
Visual inspection
Visual inspection shall take into consideration changes in the
form of cracks, blisters, peeling, sliding and erosion.
The inspection should be performed on all silicone-greased
insulators once a year. The inspections should be recorded on
a form. If any changes are observed, photo documentation is
desirable.
Additional requirements for recoating interval of more
than two years
After two years in service, the insulator shall have a surface
less than Class 4 for 50% of the total creepage length of the
insulator and less than Class 5 for 25% of the total creepage
length of the insulator. No more than one of twelve isolated
test areas from the test described above are of Class 6 or7.
Removability
Remove the grease on a half turn on one shed sequence
using the scraper 9779 023A. The time required to do this,
and to fulfill the criteria under the heading Pretreatment before
reapplication in the section Precautions upon application and
reapplication, must not be more than 30 seconds.

2750 515-142 en, Rev. 2 | Bushing diagnostics and conditioning 23

Electrical activity
The bushing shall be observed using a pair of binoculars
under rainy and foggy conditions regarding partial discharges.
No activity is permitted.
Chemical analysis
A sample collection of silicone grease should be performed
according to the section above, Sample collection and status
determination of silicone grease on porcelain insulators.
One bushing is selected in each station. Three samples
shall be taken. Two of the samples shall be taken in the
area where the highest hydrophobicity class is measured.
The third sample shall be taken in the area where the lowest
hydrophobicity class is measured.
The samples may be sent to ABB Components for analysis
regarding molecular weight distributions, contamination and
silicone oil content. Changes in the chemical composition
will provide further information about the aging status of the
grease.
3.2.3 Precautions during application and reapplication
Pretreatment before the first application
Before the silicone grease is applied for the first time, the
porcelain surface must be thoroughly cleaned by rinsing with
plenty of water followed by hand wiping of the insulator with
an alkaline detergent solution and finally rinsing the insulator
with plenty of water. If the insulator is light polluted, cleaning
with just water and rags is sufficient.
Pretreatment before reapplication
Before the application of a new layer of grease can begin,
the old layer must be removed. Removal is accomplished
using specially shaped handheld scrapers (provided by ABB,
No. 9779 023A). Most of the visibly polluted grease must
be removed. At least 90% of the insulator surface must
be scraped. Traces of old grease left on the surface are
acceptable as it helps to ensure good contact between the
new layer and the insulator surface.
If hand wiping is employed, the following solvents are
recommended in order to soften the polluted layer:
Isopropanol and xylene.

24 Bushing diagnostics and conditioning | 2750 515-142 en, Rev. 2

3.2.4 Application
Ambient conditions
Because the insulator surface must be dry when the grease
is applied, application must either be performed when the
weather is dry or when there is protection against rain. For
practical reasons application shall not be performed at a
temperature below 10C or with a wind speed higher than 10
meter/second.
Thickness
The target for average thickness is 0.30.9 mm. The function
of the grease is not in any way sensitive to unevenness in
the coating. After a certain time in service, bare spots on
the insulators will be coated by self-spreading silicone oils
migrating from more grease rich areas.
Isolated areas with grease thicknesses up to 4 mm are
permitted, as well as isolated areas with coating thicknesses
below 0.05 mm. The area of each such surface must be
limited to 100 cm2.
The thickness of the coating must be checked according to
the section Instruction for thickness measurement of silicone
grease on porcelain insulators.
Procedure
Apply the grease by hand using a painters glove.
To minimize the time for application, it is advisable to use two
skylifts with two workers in each skylift.

ABB AB
Components
SE-771 80 Ludvika, Sweden
Phone: +46 240 78 20 00
Fax:
+46 240 121 57
E-Mail: sales@se.abb.com
www.abb.com/electricalcomponents

Copyright 2014 ABB, All rights reserved. 2750 515-142 en, Rev. 2, 2014-10-30

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