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This document compares oil-impregnated paper (OIP) bushings and resin-impregnated paper (RIP) bushings used in transformers. OIP bushings use paper impregnated with oil contained in a porcelain shell, while RIP bushings use paper impregnated with resin contained in a composite silicone shell. RIP bushings have advantages over OIP bushings such as being non-flammable, lighter weight, easier to install, and requiring less maintenance. The document proposes adopting RIP bushings instead of OIP bushings for critical transformers in NTPC projects due to their increased reliability and safety.
This document compares oil-impregnated paper (OIP) bushings and resin-impregnated paper (RIP) bushings used in transformers. OIP bushings use paper impregnated with oil contained in a porcelain shell, while RIP bushings use paper impregnated with resin contained in a composite silicone shell. RIP bushings have advantages over OIP bushings such as being non-flammable, lighter weight, easier to install, and requiring less maintenance. The document proposes adopting RIP bushings instead of OIP bushings for critical transformers in NTPC projects due to their increased reliability and safety.
This document compares oil-impregnated paper (OIP) bushings and resin-impregnated paper (RIP) bushings used in transformers. OIP bushings use paper impregnated with oil contained in a porcelain shell, while RIP bushings use paper impregnated with resin contained in a composite silicone shell. RIP bushings have advantages over OIP bushings such as being non-flammable, lighter weight, easier to install, and requiring less maintenance. The document proposes adopting RIP bushings instead of OIP bushings for critical transformers in NTPC projects due to their increased reliability and safety.
OIL OIL SIDE AIR SIDE conducting rod OIP EXTERNAL VIEW
INTERNAL VIEW
test tap Porcelain
In OIP bushing paper is impregnated with transformer oil & it is contained in porcelain envelope, the space between paper & porcelain is being filled with the transformer oil.
COMPOSITE RIP BUSHING (Resin Impregnated Paper)
EXTERNAL VIEW
INTERNAL VIEW
In Composite RIP bushing, paper is impregnated with curable resin & it is contained in composite silicone envelope, the space between paper & porcelain is being filled with the insulating medium like gel, PU foam etc. . RIP Composite insulator Dry filling insulating medium Comparison between RIP & OIP Bushing TECHNICAL PARAMETERS Composite RIP Porcelain OIP
Generally Observed PD level <2 pC <5 pC Generally Observed Tan delta <0.35% <0.45% Insulation Class Class E (upto 120 o C) Class A (upto 105 o C) Weight Composite RIP bushing weight is 50% of Porcelain OIP. Transportation OIP bushings are more susceptible to damage from vandalism, shipping, handling, and installation. Installation a.) Vertical, Horizontal & at any angle. b.) Easy removal/ installation c.) Less installation time a.) Vertical<= 30 o . b.) Difficult Removal/installation c.) More installation time Maintenance RIP requires fewer maintenance checks compare to OIP due to absence of oil and porcelain. Explosion Risk Low High Flamability Non flammable Flammable Seismic Withstand capability High (as well as high mechanical strength) Low (Moderate mechanical strength)
BUSHING Failures Composite RIP Porcelain OIP
WORLDWIDE* No failure reported due to RIP bushing by any Transformer Manufacturer. World wide transformer failure rate due to HV bushing is 14%. Bushings are 3 rd major source of transformer failure after OLTC (40%) & Winding (30%). IN NTPC** Yet to be used NTPC projects like Auraiya, Khalagaon, Talcher, Vindhyachal, Rihand, dadri, Unchahar & Singrauli have experienced many failures of GT/ICT/Reactor due to direct /indirect (explosion of OIP due to fire) involvement of OIP HV bushings.
In NTPC, it is observed that around 25% failures of Transformers & Reactors are due to OIP HV bushings. Comparison between RIP & OIP Bushing Contd.. * Based on CIGRE WG -12 Report-1983. ** 1. Based on OS Data bank of Transformers & Reactor Failures (Doc. No:-COS-ISO-00-OIN/OPS/ELEC/005, Rev. No. : 0, March 2002) 2. OS record for Failure of Power Transformers in NTPC till 2007. Comparison between RIP & OIP Bushing Contd.. Availability Composite RIP Porcelain OIP
Manufacturers (In India) None BHEL TELK CGL AREVA
Manufacturers (outside India) ABB MICAFIL (Switzerland) Pasoni villa (Italy) Trench (UK) HSP (Germany) ABB (Switzerland) Pasoni villa (Italy) Trench (UK) HSP (Germany) PCORE Electric Company (USA) THVS (China) and many more.
Comparison between RIP & OIP Bushing Contd.. COST Composite RIP Porcelain OIP Ex works price (for 400 kV, 1250 Amp, 1550 KVp BIL ) Rs 18 lacs (approx)#
Rs. 9 lacs^ Ex works price (below 400 kV) Ex works price is approximately more than three times for RIP bushing w.r.t OIP bushing. % increase in Power Transformers package cost for standard 2x500 MW unit due to use RIP bushing 400 kV HV bushings required (typical) (7+3 spare for GTs, 2+3 spare for ICTs, 1+1 spare for reactor) = 17 nos.
Cost of of OIP bushing= 9 lacs x 17 nos= 153 lacs
Cost of of RIP bushing= 18 lacs x 17 nos= 306 lacs
Package cost = 105 Cr^
% increase in package cost due to RIP Bushing =1.45% (Approx.) ^ OIP bushing price & Package cost is taken from recent bid & CE for Mauda Power Transformer Package respectively. # Approximate price of RIP bushing is based on the Budgetary Quotation provided by two suppliers (ABB MICAFIL-Switzerland & HSP-Germany).
Experience on RIP Bushings RIP bushings were developed in Europe in early 1950s.
RIP bushings are gaining popularity in abroad & installed world wide for various thermal & hydro projects. Manufacturers claim that about 50% of bushings presently manufactured are RIP type.
Applicable international standards are IEC60137 & IEEE C57.19.00.
In INDIA, RIP bushing are supplied to various hydro projects like NHPC-TEESTA-V, DHAULIGANGA, PARBATI HEPs & APGENCO- Srisailam HEP etc.
For various NTPC Hydro projects like Tapovan Vishnugarh & Loharinagpala, bidders are inclined to provide RIP bushings (Oil to SF6) for GT.
Summary of Advantages of Composite RIP Bushings over Porcelain OIP Bushings RIP BUSHINGS Non Flammability Non Flammability Non Flammability Non Flammability Safe & Non Explosive Non Flammability Non Flammability RIP BUSHINGS Non Flammability RIP BUSHINGS Non Flammability RIP BUSHINGS Non Flammability RIP BUSHINGS Non Flammability RIP BUSHINGS Non Flammability RIP BUSHINGS High Thermal Strength Non Flammability Low Maintenance Light Weight & excellent Seismic withstand capability RIP BUSHINGS Easy Installation Non Flammability CONCLUSION / Plan for Adoption
At present, NTPC technical specification stipulates provision of OIP bushings for voltage level above 52 kV.
In view of the above justification & considering the advantages, it is proposed to adopt 400 kV Composite RIP Bushing in place of 400 kV Porcelain OIP bushing for critical transformer like:- Generator Transformers Inter Connecting Transformers Reactors & Station Transformers (as applicable)
EXPLOSION OF TRANSFORMER DUE TO FAULT IN BUSHING
MAINTENANCE ACTIVITIES CHECKS PERIOD PORCELAIN OIP COMPOSITE RIP Check the oil level from gauge glass & leakage, if any. DAILY X Examine for dirt deposition and tightness of oil filling plugs. QUARTERLY X Clean Porcelain & examine for cracks in porcelain. QUARTERLY X Measurement of capacitance and tan delta. HALF YEARLY