FORENSIC TEARDOWN INSPECTION OF

THREE OHIO BRASS 180KV TYPE-G BUSHINGS

Santiago Chavez
AES Alamitos
Darin Mitton
Doble Power Services
ABSTRACT
A forensic teardown inspection of three Ohio Brass 180kV type-G bushings was performed at Doble Engineerings
High Voltage Lab. One of the bushings had failed in service and the other two had been installed at the same
location. The purpose of the inspection was to discover what caused the bushing to fail and determine if there was a
common problem with other bushings in the system with the same construction. The inspection consisted of an
analysis of internal dielectric stresses, visual inspection of all internal components, chemical analysis and electrical
testing of material samples taken from the bushings. A review of oil sample DGAs and power factor test records
were also performed. Evidence of partial discharge and moisture contamination was observed in all three bushings.
Gasket deterioration and moisture ingress was a root problem common to all three bushings.

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After a bushing failed in service, the decision was made to perform aC
forensic teardown analysis of it and two
identical bushings from the same bank of transformers. The bushings
were transported to the Doble High Voltage
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in and inspected. The combined findings
Laboratory in Watertown, Massachusetts where they were disassembled
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from of a dielectric stress analysis of the design, visual inspection
e during disassembly, and chemical and electrical
n
tests of samples taken from the bushings were used to
determine the cause of failure for the bushing that failed and
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the condition of the other two bushings.
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BACKGROUND
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oUnit 2 at AES Alamitos experienced a failure of A-phase Main Transformer. An
On July 16, 2010 at 10:56 p.m.
D
Allis Chalmers 180kV
transformer bushing failed violently, causing some damage to nearby equipment and
unscheduled down time. The top portion of the bushing exploded leaving only the center conductor rod and cap.
INTRODUCTION

The bottom portion of the bushing stayed together and the internal components of the transformer were not
damaged. The bushing was installed in a single phase generator step up (GSU) transformer connected to the APhase, in a bank of three transformers. The explosion caused some superficial damage to the C-Phase, but the BPhase was not damaged. Nameplate information for the bushing and transformer information are as follows:
Bushing
Manufacturer
Type
Voltage Class
BIL
Current Rating
C1 Power Factor
Manufactured

Transformer
Ohio Brass
Class-G-53X
180kV
825kV
800A
1.0%
1956

Manufacturer
Type
Capacity
Cooling Class
Temperature Rise
Voltage
Manufactured

Allis Chalmers
Single Phase GSU
56/74.6 MVA
ONAN/ONAF
55C
18,000 127,017GRDY/220,000
1956

It was decided to perform a tear down and forensic analysis of all three bushings. The serial number of the bushing
that failed (A-Phase) was 49310-8. The serial number of the B-Phase bushing was 49310-9, and C-Phase was
49310-7.

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AES Alamitos, in the City of Long Beach, is a 2,000 MW natural gas-fueled power plant, one of the largest in
Southern California.

POWER FACTOR TEST RESULTS

Power factor tests were performed in November 2007, which was approximately 2.5 years before the failure. The

measured values were very similar for all three bushing and showed a 56% increase over the factory nameplate
values. The measured results are listed here in Table 1.

Table 1
Power Factor Test Results November 2007
Connected
Phase
A (failed)
B
C

C1 Power Factor [%]

Nameplate
Tested W/Oil
1.0
1.59
1.0
1.53
1.0
1.56

Serial
Number
41390-8
41390-9
41390-7

A query of historical test records using Doble DTA Web for the C1 measurements of Ohio Brass Type G bushings
rated from 115 to 230 kV yielded 405 test results. Based on these test results, the acceptable range for the C1 power
factor, corrected to 20 C, is between 0.12 0.64 percent. Figure 1 displays the historical power factor distribution.

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115 - 230 KV OB Type G C1 Bushing Test

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40

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20

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10

0
0.12 to
0.377

0.377 to
0.634

0.634 to
0.891

0.891 to
1.148

1.148 to 1.405 to 1.662 to

1.405
1.662
1.919
%PF Corrected

1.919 to
2.176

2.176 to
2.433

2.433 to
2.69

C1 Power Factor Distribution History

Figure 1
The nameplate power factor values for the bushings under investigation were 1%. The query results showed few
measurement results in this range. Interestingly however, there were noticeably more results close to the 1.6%
measured in the latest tests. Given that all three bushing showed similar test values, the change was likely attributed
to normal aging. In retrospect, it appears that the increased power factor values were likely due to a deteriorating
condition inside the bushings, given the findings from the inspection.

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DIELECTRIC STRESS ANALYSIS

An Internal Dielectric Stress Analysis was performed to discover any inherent characteristics that can help to
determine the failure mode and potential that a similar failure was likely in other bushings of the same design and
vintage. Unlike modern capacitance graded bushing designs, which use layers of foil or conductive ink sandwiched
between layers of insulating paper, these bushings used porcelain sleeves and spirally wrapped layers of resin
impregnated cloth tape for grading the voltage between a fired-on ground shield and the bushing stud, as shown in
Figure 2.

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Dielectric Graded Bushing Arrangement

Figure 2

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The two inner concentrically arranged porcelain sleeves were
eseparated by wedges cemented at the ends between the
e
sleeves. The ground shield porcelain was attached to the
mounting flange by wedges in a similar manner.
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It is well recognized that the radial electrical stresses are highest in the space between the bushing stud and the
E upon the strike distance between the live electrodes at the top and
ground shield. The axial stresses are dependent
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l ground shield.
bottom ends of the bushing and theb
fired-on
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It is evident that this was a graded insulation bushing design where a series of porcelain barriers were used to control

radial stresses in the space between the bushing stud and the ground shield. Since the oil gaps between these barriers
were the weakest dielectric medium, the radial stresses at the outer diameters of each solid dielectric were calculated
to check the integrity of the dielectric system. Table 3 shows dimensions and dielectric constants used to calculate
the dielectric stresses.

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Table 2
Dielectric Constants and Dimensions
Component
Bushing
Stud
Tape Layer
I
Oil Duct I
Inner
Porcelain
Tape Layer
II
Oil Duct II
Inner
Porcelain II
Oil Duct III
Shield
Porcelain
Ground
Shield

Material

Dielectric
Constant

Inside
Radius
[in]

Outside
Radius
[in]

Copper

1.25

Distance
to Stud
[in]

Effective
Distance
[in]

Effective
Radius
[in]

Gradient
At OR
[kV/in]
79.90

Cambric
Cloth
Oil

2.32

1.25

1.55

0.30

0.30

1.55

64.44

2.32

1.55

1.75

0.50

0.50

1.75

57.07

Porcelain

1.75

1.88

1.63

1.03

2.28

43.74

Cambric
Cloth
Oil

2.32

2.88

3.00

1.75

1.14

2.39

41.77

2.32

3.00

3.40

2.15

1.06

2.33

42.80

Porcelain

3.40

4.50

3.25

2.04

3.29

30.35

Oil

2.32

4.50

5.19

3.94

2.62

3.87

25.81

Porcelain

5.19

6.45

5.2

3.19

4.44

22.49

Conductive
Coating

6.45

5.2

The calculated radial stresses are tabulated in Figure 3.

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Calculated Radial Stresses

Figure 3
The analysis of radial stresses indicates that all the radial stresses were within the limits of reliable bushing design.
From the physical measurement information recorded during the teardown, the internal strike distance at the top end,
from the bushing stud to the ground shield was estimated to be 47.68 inches. Corresponding to the 825 kV BIL, this
gives an approximate average axial stress level of 17.3 kV per inch. Similarly, at the lower end, the internal strike
distance from the bottom plate to ground shield was estimated to be 22.92 inches and corresponding to the rated BIL
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of the bushing, this gives an average axial stress level of 36 kV per inch. These stress levels are well below the
recommended design limits for reliable bushings.

VISUAL INSPECTION
All of the porcelain above the ground sleeve of bushing that failed was gone, leaving only the center stud and top
cap of the bushing. Photo 1 shows the condition of the bushing when it arrived at the lab. All of the porcelain
above the flange was blown away in the failure.

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Top End of Failed BushingC
Photo 1
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Photos 2 and 3 show burn marks on the porcelain.
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Burn Marks on Ground Shield Porcelain

Photo 2

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Burn Marks on Inner Porcelain Sleeve

Photo 3

Photos 4 and 5 show burn marks on the center stud and outer flange respectively. The shape of the crater and the
burn marks indicate that this was an external flashover between the bushing stud and the bushing flange. The draw
lead and its insulation had no involvement in this failure. It appears that an internal flashover created high pressure
inside the bushing, causing the porcelain to rupture. This was likely followed by subsequent arcing Due to the
extent of the damage, the precise cause and initiation point of the failure is not evident.

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Burn Marks on Center Electrode

Photo 4

Burn Marks on Inner Surface of Flange

Photo 5

The impregnated paper layers taped over the bushing stud were examined and significant evidence of partial
discharge (PD) activity was observed. These marks were not located near the areas where the flashover damage was
observed. This indicates that a general problem existed throughout the bushing, such as contamination in the oil.
Similar marks were found in the other two bushings, as they were disassembled. Photos 12 - 14 show black marks
and burn holes in the insulation that are characteristic of partial discharge activity.

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Black Hole ino
D Insulation
Photo
6

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Dark Spots on Insulation

Photo 7

They are representative of what was found in all three bushings. Many of the spots showed a tree like pattern
typical of partial discharge damage when examined under a microscope, while others did not. These spots were
determined to be inclusions from the manufacturing process,
The innermost layer of the insulation had a dark greenish appearance where it came in contact with the copper bar
running through the center of the bushing, as can be seen in Photo 8. This appears to be a copper oxide deposits
resulting from moisture on the copper. This coating was very uniform, indicating that they were caused by a
reaction that had been taking place over a long period of time.

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Green Color on Insulation on Center Conductor

Photo 8
The top seal gaskets were found to be badly deteriorated, as shown in Photo 9. Signs of moisture ingress and
corrosion were found in all three bushings. Photos 10 and 11 are representative examples of green deposits, which
appear to be copper oxide, found in many locations throughout the bushings. Photo 12 shows dark stain marks on
the center copper rod that appear to be caused by moisture in the oil.

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DeterioratedoGasket
Photo
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Green Deposits on Spring Assembly

Photo 11

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Green Deposits on Gasket Surface

Photo 10

Dark Stains on Center Copper Rod

Photo 12

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LABORATORY ANALYSIS
Samples of materials were extracted from each bushing during the teardown and labeled appropriately. These
samples were analyzed at the Doble Material Laboratory by Scanning Electron Microscopy (SEM) and Energy
Dispersive X-ray (EDX) analysis.
Scanning Electron Microscopy (SEM) Energy Dispersive X-ray (EDX) analysis are two separate tests conducted
at the same time. EDX is a technique in which an electron beam of the scanning electron microscope enters the bulk
of a sample producing an x-ray emittance. The X-ray peak positions, along the energy scale, identify the elements
present in the sample and can provide the percent concentrations of each of these elements thus providing an
elemental breakdown of the material or particles.
SEM is an analysis in which a beam of electrons, a few hundred angstroms in diameter, systematically sweeps over
the specimen. The intensity of secondary electrons generated at the point of impact on the specimen surface is
measured, and the resulting signal fed into a cathode-ray-tube display which is scanned in synchronism with the
scanning of the specimen to produce a picture.
The cellulose insulation primarily used in these three bushings is cambric cloth. Cambric cloth is open weave cloth
impregnated with varnish and was used quite extensively in the electric industry in the first half of the twentieth
century. The material shown in Photo 39 was chosen for testing as there seems to be a residue accumulating at the
edges of the cloth layer overlap. A sample of cambric cloth that had a blackened edge was analyzed. An SEM
micrograph of the edge of the cloth is shown Photo 13.

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SEM Micrograph of Cambric Cloth Edge

Photo 13
Composition from the EDX spectra of the blackened edge is provided in Table 3.

Table 3
Composition of Cambric Cloth Edge
Element
Carbon
Oxygen
Aluminum
Silicon

Composition, wt. %
57.3
40.6
0.9
1.2

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Most of what was found was just carbon and oxygen so it is most likely thermal degradation of the oil, paper and
varnish that collected in area. Edges of paper which still have individual fiber ends exposed tend to collect carbon
more readily than smooth, non-porous surfaces.
Because of the green discoloration observed on the center copper rod, a wipe sample was taken for analysis. The
EDX composition of the two predominant particles from the wipe sample is provided in the Table 4.

Table 4
Composition of Particles from Wipe Sample
Element

Particle 1, %

Particle 2, %

Carbon
Oxygen
Chlorine
Potassium
Calcium
Iron
Copper
Zinc
Silicon

61.8
26.4
1.6
0.8
0.5
0.9
5.0
3.0
--

21.9
2.9
0.4
---74.1
-1.1

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The copper is most likely from the conductor. The presence of potassium, calcium and chlorine would suggest salts
from seawater although they are in a very low percentage. The wipe sample was taken because of the green hue
which usually indicates corrosion of the copper surface. It appears that some moisture from the external
environment did enter the bushing containing some salt water and did react with the copper to a small degree.

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A sample of the innermost layer of insulation next to the conductor with green deposits was analyzed. SEM
Micrograph of insulation sample is shown in photo 14.

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SEM Micrograph of Insulation with Green Deposits

Photo 14
The EDX composition of the deposits from the sample of insulation is provided in Table 5.

Table 5
Composition of Green Deposits
Element
Carbon
Oxygen
Copper

Composition, wt. %
67.7
22.1
10.3

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A large amount of the copper was present in the cambric cloth and most likely combined with carbon and oxygen to
form copper carbonate (CuCO3) on the cambric cloth surface giving it the green coloration. The formation of copper
carbonate is a result of the slow chemical alteration of copper in which a humid (water) environment would have to
exist so that the reaction could take place.
A razor blade was used to remove some black material from one of the porcelain sleeves. Photo 15 shows the SEM
micrograph of the black material.

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SEM Micrographs of Black Material

Photo 15
The elemental composition is provided in Table 6.

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Table 6
Composition of Black Material

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Element
Carbon
Oxygen
Sodium
Magnesium
Aluminum
Silicon
Sulfur
Chlorine
Potassium
Calcium
Iron
Copper

Composition, wt. %
43.4
25.2
3.2
0.5
1.0
5.0
8.4
1.1
2.4
4.0
1.9
4.0

Copper and a large amount of sulfur are present. There is no suspicion of corrosive sulfur being an issue as the
copper was quite clean. There is a good percentage of copper away from the copper conductor itself. This may be a
combination of sludge and other materials. Sludge usually contains carbon, oxygen, sulfur, copper and other
elements to a lesser degree and is the byproduct of oxidation within the bushing. This would confirm that possible
outside environmental contaminants such as air and water were diffusing into the system over time.

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HIGH VOLTAGE LABORATORY TESTS

Dielectric Breakdown Measurements were performed using an Associated Research Breakdown Tester in
accordance with ASTM D 149; 1 inch diameter electrodes in oil.
Dielectric strength of cambric cloth samples as determined by high voltage breakdown test are listed below.
Sample Description

[V/mil]

Clean with No Discoloration

With Green Discoloration
With Green Discoloration
With Signs of Partial Discharge

1400
1060
1190
970

The voltage breakdown tests show reasonably good insulation strength, giving no evidence that deteriorated cambric
cloth contributed to the failure.

DISSOLVED GAS IN OIL ANALYSIS (DGA)

Oil was drained from the two bushings that did not fail, prior to shipping them to the Doble high voltage lab. DGA
and moisture content measurements were taken on the two samples labels as B-Phase and C-Phase
corresponding to transformer from which they were taken. The levels of dissolved combustible gasses present are
given here:

Dissolved Combustible Gasses [ppm]

Hydrogen
Methane
Ethane
Ethylene
Acetylene
Carbon Monoxide

B-Phase
66
35
109
68
1
459

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C-Phase
69
40
167
74
1
356

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The elevated levels of ethylene and presence of acetylene indicate localized overheating was occurring within the
bushings. Elevated levels of carbon monoxide indicate overheating of the cambric insulation material. Given the
evidence of moisture air ingress observed, less soluble gasses have likely leaked out. Generation of hydrogen and
carbon monoxide was likely higher than indicated by the DGA samples, which would support the evidence of partial
discharge observed.
The levels of dissolved non-combustible gasses present are given here along with the moisture content.

Dissolved Non-Combustible Gasses and Moisture [ppm]

Carbon Dioxide
Nitrogen
Oxygen

B-Phase
20471
79821
6495

C-Phase
19556
79255
9722

Moisture in Oil

20

17

Oxygen and water content were lower than anticipated, given the evidence of moisture air ingress observed. This
suggests that they were likely consumed in the chemical reactions, and that the process had occurred steadily over
a long period of time.
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CONCLUSION
The radial and axial electrical stress analysis of these bushings indicates that the design was adequate and didnt
expose any particular weakness that could have led to the failure of S/n: 41390-8. The teardown observations from
all three bushings indicate that the failure of S/n: 41390-8 was most likely caused by moisture, oxygen, salt and
other contaminates entering the bushing through deteriorated gasket seals that compromised the dielectric integrity
of the internal bushing insulation. The elevated power factor readings from November 2007 were likely caused by
this deteriorating condition inside the bushings. The results from dielectric breakdown strength tests on solid
insulation samples taken from the bushings were quite high. This suggests that dielectric deterioration was
occurring mainly in the bushing oil. It is possible that the evidence of partial discharge activity observed during the
teardown was the result of decreased dielectric breakdown strength of the oil. The oil from bushings S/n: 41390-9
and S/n: 41390-7 was drained before they were shipped to Doble. Therefore it was not available for dielectric
strength or partial discharge testing.

BIOGRAPHY
Mr. Darin D. Mitton. Mr. Mitton is a Transformer Engineer with Doble Engineerings Global Power Services. He
has 13 years of experience in power transformer and shunt reactor design, followed by 8 years of consulting. He has
been with Doble Engineering for 3-1/2 years, providing consulting services, including Design Reviews, Factory
Inspections, Factory Test Witnessing, Forensic Analysis, and Condition Assessments. He holds a B.Sc. in
Engineering from Idaho State University and is a registered Professional Engineer.

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Mr. Santiago E. Chavez. Mr. Chavez is the Team Leader of IC&E of C
AES Alamitos. He has 30 years of power
g
generation experience. He has been with AES for 12 years; first as
Project
Support then 11 years as a Team Leader.
nas an Industrial
i
r
He previously worked at Southern California Edison for 18 years
Electrician, Maintenance Planner
e
and Safety Environmental Specialist III (CMMS) (REP 5973).
He
worked
11
years
at Magma Copper Company as
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an Industrial Electrician.

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