HVDC

Wall Bushing
Type GEW

Mounting
Operating
and
Maintenance Instructions

Operating Instructions BAL GEW/04e Visum 04/19 T/lid Page 1 of 14

 SAFETY INSTRUCTIONS

These instructions are valid for mounting, operation and maintenance

of wall bushings type GEW.

During mounting, operation and maintenance works there are a

number of safety risks in the areas:

- Perilous electrical voltages

- High voltage
- Moving machines
- Large weights
- Equipment with internal gas pressure
- Handling of moving masses
- Injuries due to slipping, stumbling or falling

Regulations and instructions referring especially to these topics have

to be obeyed when handling such equipment. Disregarding of the
instructions may cause severe personal injuries, death, damages of
products and materials or industrial injuries and/or consequential
damages.

Beyond these rules national and international safety instructions have

to be followed.

In these instructions risks of personal injuries or death and product

damage are marked with following signs near the texts and mounting
steps:

Personal injuries or fatal damages

Industrial injury and/or consequential damages

These operating and maintenance instructions are valid for type GEW
For each bushing type these instructions are valid only together with the respective bushing
specification, which contains all technical details and the dimension drawing. It is an integral
part of these operating and maintenance instructions.

Operating Instructions BAL GEW/04e Visum 04/19 T/lid Page 2 of 14

 CONTENT

1 Description.................................................................................................. 4
1.1 Construction ................................................................................................................ 4
1.2 Design......................................................................................................................... 5
1.3 General Operating Conditions .................................................................................... 6
1.4 Mechanical Stresses ................................................................................................... 6
2 Mounting ..................................................................................................... 7
2.1 Status of dispatch ....................................................................................................... 7
2.2 Handling...................................................................................................................... 7
2.3 Lifting and Mounting.................................................................................................... 8
2.4 Putting into operation .................................................................................................. 8
2.4.1 Test Tap ................................................................................................................ 9
2.4.2 Voltage tap .......................................................................................................... 10
3 Maintenance ............................................................................................. 10
3.1 Recommended maintenance and checks ................................................................. 10
3.2 Electrical Measurements ........................................................................................... 11
3.3 Control Measurements .............................................................................................. 11
3.4 Measuring Procedure ................................................................................................ 11
3.5 Limits ........................................................................................................................ 12
4 Thermo-Control by means of thermovision ............................................... 12
5 Possibilities to Repair ............................................................................... 12
6 Storage ..................................................................................................... 13
7 Disposal after end of Operation ................................................................ 14

Operating Instructions BAL GEW/04e Visum 04/19 T/lid Page 3 of 14

1 Description
1.1 Construction

Copper connecting bolt

Top housing armature

Porcelain housing

Bushing flange

Test tap

Square wall mounting plate

Insulating body RIP indoor design

Connecting bolt

Fig.1

Design with voltage tap Fig.2

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1.2 Design
The design of the bushing may be different from the picture
in the flange and head area, but the principle functions
remain unchanged (Fig.3). 1

The main insulation of the RIP wall bushing GEW is an 2

insulating body (10). It is made of a special paper which is 3
impregnated with epoxy resin under vacuum and has 4
coaxially placed grading layers (11) made of aluminium foil 5
which guarantee uniform voltage distribution along the
6
insulating body.
The current conductor (2), a copper bolt, is undetachable 7
impregnated into this insulating body. 8

This insulating body is mounted in an insulating housing

together with its current conductor. This housing is made of a 9
porcelain body (9), which at its top and bottom is cemented
into armatures with Portland cement and sealed by O-rings 10
(6, 13). Depending upon the design the top armature is made
11
of a ring (7) and a cover (5) screwed onto it or it is a one-
piece armature with cast cover. The access of the current
conductor through the cover is sealed by O-rings (4). In 12
addition the top sealing is pressed tight by a pressure disc
(3). To avoid voltage corrosion this disc is made of non- 13
corrosive steel.
14
Depending upon the design the flange (12) can be made as a
one-piece design with cast ring for the porcelain or it can 15
consist of two or three additional elements. The flange plate 16
(16) is designed as square plate for wall mounting. The O-
17
ring sealing (15) is located in the area of the flange collar.

The gap between insulating body and porcelain body is filled 18

with foamed polyurethane elastomer (8). This forms a solid,
flexible connection of the construction parts by adhesion.
Therefore it is not possible to disassemble the parts without
destruction.
19
The flange is equipped with the test tap (14) or depending
upon the design the voltage tap, a grounding screw (17) and
lifting eyes.

On the indoor side the RIP insulating body has a corrugated

profile (19), the length of the grounded grading layer (18) can
be taken from the bushing specification. This also applies for
the design and the dimension of the indoor side connecting 20
terminal (20).

The screw on the front (1) closes the hole M12. In case of Fig.3
types with a total weight <75 kgs a ring screw for vertical
lifting can be fixed in this hole.

Operating Instructions BAL GEW/04e Visum 04/19 T/lid Page 5 of 14

1.3 General Operating Conditions

Application: Bushing for application as wall/ceiling bushing

in HVDC-substations**

Classification: Epoxy resin impregnated paper, capacitive grading,

outdoor or indoor wall bushing

Ambient temperature: Outdoor and indoor side: - 30 up to + 40°C ** corresponding to

temperature class 2 acc. to IEC 60137

Installation height: < 1000 m a.s.l.**

Rain level and humidity: For outdoor side: 1-2 mm rain/min. vertical and horizontal
acc. to IEC 60060 - I

Pollution class: Corresponding to the specific creepage distance*** acc.

to IEC 60815

Immersion medium: Air

Corrosion protection: All armatures and fixing materials are made of corrosion resistant
material

Marking: According to IEC 60137

Packing: Wooden crate, ventilated, bushing supported on styro-foam

cushions at the porcelain and in the flange area, sealed in plastic
foil, desiccant added

** Standard values, deviations in special cases, see bushing specification

*** Standard min. 25 mm/kV for heavily polluted atmosphere, deviations see bushing specification

1.4 Mechanical Stresses

Test bending load: Standard acc. to IEC 60137 table 1, class II

Operating load: 50% of the test bending load values

* standard values, for deviations see bushing specification

Operating Instructions BAL GEW/04e Visum 04/19 T/lid Page 6 of 14

2 Mounting
2.1 Status of dispatch
The bushing is transported in a ventilated wooden crate.
It is supported by styro-foam cushions which are located
at the head in the flange area. In addition to that in case
of bigger bushings the flange is fixed and supported by
cross beams.

The whole bushing is covered by and sealed in plastic

foil with desiccant bags added (Fig.4).

In this packaging the bushing can be stored in covered

dry rooms for up to 12 months.
When bushing is packed in aluminium coated foil instead
it can be stored for up to 24 months under the same
conditions.

2.2 Handling
The bushing can be lifted from its crate at the flange with Fig. 4
a lifting device. In case of smaller bushings the indoor
side with less weight is led manually (see Fig.5). Bigger
bushings with a weight > 70 kg have to be lifted with two
lifting devices. Hemp or plastic ropes are fixed at the
porcelain and on the indoor side at the insulating body or
at the connecting terminal.

After the bushing is lifted from the crate it is put down

onto bearing blocks at the flange and head. The plastic
foil is removed.
With unprotected indoor side end the bushing can be
handled outdoor for a short period of time during dry
weather. Longer storage, e.g. during rain, is not
permitted. The material RIP is hygroscope and absorbs
moisture with its surface which has a negative influence
on the operating behaviour.

In case bushings are detected which show clear signs of

moisture on their indoor side the manufacturer has to be Fig. 5
contacted (discoloration of varnish, delamination,
bubbles, cracks etc.).

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2.3 Lifting and Mounting
To lift the bushing the lifting eyes on the flange have
to be used. They are either supplied as removable
ring screws at the flange and at the head or
depending upon the design there are cast lifting eyes
at the bushing flange.

The detachable lifting eyes have to be removed after

mounting and the threaded bores have to be closed
by plastic covers.

The bushing is lifted with the help of a lifting device

(Fig. 5). Generally the bushing has to be inserted into
the wall opening from the outdoor side of the wall. To screw torque (Nm) torque (kpm)
adjust the installation position it is recommended to fix
a weight to the lighter end of the bushing. Bushings
with a weight up to 70 kgs may be guided manually
from a mounting scaffold (similar to Fig.5).

In any case the safety instructions for the handling of

floating masses must be observed!

The bushing is fixed by screws with its wall mounting

plate and the anchor bolts in the wall. If determined on
site the flange plate is additionally sealed against
penetration of moisture.

Grounding is made on the grounding screw M12 in The values mentioned are orientation value.
the flange plate. They refer to screw connections with non-
corrosive steel screws. Only applicable in case
of flange connections with solid support of the
The high voltage connections are achieved with parts.
appropriate clamps. The contact preparation required
for clamps (cleaning, greasing etc.) has to be made.
Fig. 6
Take care that no unpermitted high pulling or bending
forces occur. The operating loads must not exceed
50% of the test bending loads mentioned in the
bushing specification.

2.4 Putting into operation

Before putting the bushing into operation all screw
connections of the bushing flange plate and the
clamps have to be checked for correct position and
torque. As orientation values see table (Fig. 6), if no
instructions from the manufacturer of the substation
or site control are available.
Above that the insulating surfaces have to be visually
checked for damages and cleanliness.

Operating Instructions BAL GEW/04e Visum 04/19 T/lid Page 8 of 14

2.4.1 Test Tap DESIGN A
It has to be checked that the cap of the test tap (if the
Insulated bushing
bushing has a test tap, see specification) is tightly with pin
closed. Ø4mm (1)

Design A older design (Fig.7)

Design B new design (Fig.8) Cap with O-ring
sealing (2)
With the test tap the last grading layer of the capacitive
grading is lead out insulated (1) by means of a small Grounding spring
bushing. The removable cap (2) has a contact sleeve or made of non-
spring (3) in which the connecting pin (4) provides corrosive steel (3)
reliable grounding when the cap is closed tightly.

The cap has an O-ring sealing (2) to guarantee a

moisture-free inner volume of the test tap.

During normal operating conditions this connection is Fig. 7

always grounded. For measurements of the bushing in
case of de-energized transformer the measuring lead is
connected to the pin to determine capacity and
dissipation factor.

The test tap is not self-grounding! Therefore during

operation the cap has always to be tightly closed! DESIGN B
Operation with open test tap leads to a destruction of
the small bushing (1) in the test tap with influence on Cap with O-ring
the inner volume of the bushing and following damage! sealing (2)

Internal contact
spring (MC-
socket) for
grounding (3)

Insulated bushing
with contact pin
Ø4mm (1)
Fig. 8

Operating Instructions BAL GEW/04e Visum 04/19 T/lid Page 9 of 14

2.4.2 Voltage tap
Depending upon the design the bushing may be POTENTIAL TAP
equipped with a voltage tap (Fig. 9) (see bushing 1 Locking cap
specification).
Construction and function is similar to those of the 2 Contact spring
test tap, only voltage output is higher.
3 Connecting pin
The voltage tap is not self-grounding and the
same remarks as fort the test tap apply! 4 Bushing

For permanent connection of voltage tap 5 O-ring sealing

equipment, which fits with its connecting plug onto
6 Opening for
the external thread of the bushing (2), after filling
mounting the inner volume has to be filled with oil 1 2 5 4 3 6
through the oil filling hole, take into account
approx. 2-3 cm3 volume for oil expansion.

The bushing has been submitted to a routine test

at HSP, therefore after the a.m. steps have been
checked it is ready for operation.

Fig. 9

3 Maintenance
3.1 Recommended maintenance and checks
The bushing is free of maintenance. Control and
maintenance specifically refer to the insulator and
its condition and the armatures regarding
corrosion on the outdoor side.

In case of heavy pollution the porcelain housing

has to be cleaned with common cleaning methods
and means. Generally damages through
corrosion are removed by cleaning and
varnishing. This type of control should be carried
.out once a year or during the usual substation

maintenance intervals.

We recommend carrying out electrical

measurements after the first 7-10 years of
operation and after that depending upon the test
results in intervals of 3 years or shorter (see 3.2).

Operating Instructions BAL GEW/04e Visum 04/19 T/lid Page 10 of 14

3.2 Electrical Measurements
By means of the final routine tests carried out by the
manufacturer the bushing is tested suitable for operation and
certified.
We recommend carrying out a so-called reference
measurement on site. This guarantees that the measuring
conditions for future measurements remain the same and
comparable results are achieved.
Comparable data is available from the final routine test in the
factory, but they can show deviations compared to the
measurements on site as a result of stray influences, which
may falsify the result because of the very small changes of
capacitance.
The measurement includes the main capacitance C1 and the
dielectric loss factor tan delta. It is possible to carry out a
measurement of the capacitance between the last grading
layer and the flange, but this does not give any information
about the main insulation. It only provides data about the
condition of the area around the test tap. Example of mobile
measuring equipment

3.3 Control Measurements

Control measurements on bushings require a certain
experience with measuring equipment, test set up and
interpretation of test values. For some part this is a result of the
relatively small capacity values, which are locally influenced
even by environment. The measurement of the dielectric
dissipation factor can be influenced by humidity, weather etc.
Above that the influence of the DC-component on the bushing
has to be included in the interpretation.

3.4 Measuring Procedure

Mainly the measuring procedures differ by the coupling of the
measuring signal. In case of so-called “not grounded”
measurements the test voltage is applied to the conductor of
the bushing and the measuring signal is taken at the test tap of
the bushing. Fig. 10
The “grounded” measuring procedure for bushings without test
tap is not applicable for bushings of type GEW…..
The devices required for measurement are usually equipped
specifically for the measurement of bushings. The
measurement methods are described in comprehensive
manuals.
Test equipment is available from several suppliers. Data about
the manufacturers can be found in the internet or enquired at
HSP (Fig.10).

Operating Instructions BAL GEW/04e Visum 04/19 T/lid Page 11 of 14

3.5 Limits
For measurements the influence of the ambient
temperature has to be taken into account to achieve a
comparison to earlier measurements. In the diagram on
the left hand side for C and tan delta the variation
through temperature is shown (Fig. 11).

For
. the material RIP, resin impregnated paper, there
are limit values for the deviation of the capacitance and
the dielectric dissipation factor with relation to the „new
value“. This value is reliably deducted from the
reference measurement (see 3.3).

If the deviation is larger than mentioned in the table

(Fig. 12) HSP should be contacted in any case.
Fig. 11

4 Thermo-Control by means of thermovision Voltage level BIL* C – Deviation

If as a routine thermovision controls (Fig. 13) are
≤ 200 kV 10 %
carried out in the installations following items have to
≤ 550 kV 3%
be taken into account: > 550 kV 1%
An increase of temperature by up to 40 K can as a rule
be detected at the external contact point, i.e. at the lead Orientation value
clamp and is not unusual. Higher temperatures or tan delta 0.004-0.006
excess temperatures during low load should lead to a
check of the contacts. * from Type designation,
Irregularities in the temperatures along the outdoor e.g. GEW f/i 200-52-2500 spez.
insulator length, though, may be caused by hotspots
and have to be investigated more closely, if necessary
Fig.12
contact manufacturer.

5 Possibilities to Repair
For the wall bushings which are filled with dry filling
material possibilities to repair are restricted to the parts
which are accessible from outside, because due to the
design the bushings cannot be disassembled.

Fig.13

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These operating and maintenance instructions are valid for
the type range GEW… with its different designs, therefore
in case of repair different sectional drawings and parts lists
are required. If the case occurs both documents can be
ordered from HSP by quoting the specification number of
the bushing and will be sent immediately (Example of a
sectional drawing and a parts list (Fig. 14).

Depending upon the repair measures required short

instructions can be given.

As it is not possible to disassemble the bushing, repair

measures are restricted to external damages of porcelain
or silicone housings, which are possible with the help of
special procedures according to instructions of or carried
out by HSP.

In case of internal damages the inner construction parts are

accessible only after destruction of the porcelain housing.
We recommend returning the bushing to the manufacturer
who has suitable means and measures and professional
investigation methods.
Fig.14

6 Storage
The bushing can be stored in its original packaging for up to
12 months in rooms protected from rain. When the bushing
is packed in aluminium coated foil the storage period is 24
months.
This storage can be made in the original packaging as long
as it is protected from decomposing and imbruing in a
protected storage place.
The bushing of type GEW with one side for indoor use have
to be equipped with a metal sealed protection tank for long
term storage (Fig. 15), if it is not possible to store the
bushing in dry rooms. An adequate number of desiccant
bags has to be added and the packaging has to be opened
in 2-3 years intervals to replace the desiccant bags.
In case water or moisture is detected the bushing has to be
dried depending upon its condition (in an autoclave at a
temperature of approx. 100°C for several hours) and after
that the bushing has to be put into the protection tank Fig.15
again.
Before putting the bushing into operation after a long period
of storage we recommend to carry out a measurement of
capacitance and tan delta to guarantee functioning.

Operating Instructions BAL GEW/04e Visum 04/19 T/lid Page 13 of 14

7 Disposal after end of Operation
The bushing does not contain any liquids, the parts are neither
toxic, self-inflammable nor physically burdening. All parts can be
disposed of as industrial waste.

It is made of following components:

- Porcelain
- Portland cement
- Polyurethane elastomer (dry filling)
- Epoxy resin impregnated special paper with aluminium
foils as layers
Armatures made of aluminium alloy
- Conductor bolt made of E-Cu
- Fixing elements, test tap, screws etc. made of non-
corrosive steel, aluminium alloy or brass

The insulating body and the porcelain housing are joint inseparably
by the dry filling, therefore the porcelain housing must be
destroyed. For this the porcelain housing has to be covered by
suitable canvas as protection against porcelain chips, touch the
porcelain parts with gloves!

Operating Instructions BAL GEW/04e Visum 04/19 T/lid Page 14 of 14