HSP STARIS Sia+ Assembly instructions

Installation, operating and maintenance instructions
Transformer bushing
Range
STARIS®-Sia+
Version 01 11/20 en-US

Contents
1 Documentation notes................................................................. 5
1.1 How the text is displayed in this document........................................................ 5
1.1.1 Descriptions...............................................................................................................5
1.1.2 Instructions................................................................................................................ 5
1.1.3 Cross-references....................................................................................................... 5
1.1.4 Lists........................................................................................................................... 5
1.1.5 Additional applicable documents.............................................................................. 5
1.2 Storage of documents............................................................................................ 6
1.3 Validity of instructions........................................................................................... 6
1.4 Target groups.......................................................................................................... 6
2 Safety........................................................................................... 7
2.1 Classification of the handling-relevant warning instructions............................ 7
2.2 Intended use............................................................................................................ 7
2.3 General safety instructions....................................................................................8
2.3.1 Danger to life from electrocution.............................................................................. 8
2.3.2 Crush and impact danger from suspended loads.....................................................8
2.4 Obligations of the integrator/operator..................................................................9
2.4.1 Action in the event of fire......................................................................................... 9
2.4.2 Action in the event of an accident............................................................................9
2.5 Qualification of the personnel............................................................................. 10
2.6 Personal protection equipment........................................................................... 10
3 Structure.................................................................................... 12
3.1 General structure.................................................................................................. 12
3.1.1 Version with draw lead bolt or detachable conductor bolt...................................... 13
3.1.2 Version with undetachable conductor bolt.............................................................. 13
3.2 Design.....................................................................................................................13
4 Technical data........................................................................... 17
4.1 General operating conditions.............................................................................. 17
4.2 Mechanical stress................................................................................................. 18
5 Installation................................................................................. 19
5.1 Preparing the bushing..........................................................................................19
5.1.1 Checking the scope of supply................................................................................ 19
Range STARIS®-Sia+ 2/53

5.1.2 Slinging the bushing............................................................................................... 20
5.1.3 Putting the bushing down....................................................................................... 23
5.1.4 Component overview (draw lead bolt / detachable conductor bolt)........................ 23
5.1.5 Removing the draw lead bolt / detachable conductor bolt......................................25
5.1.6 Mounting the electrode on the transformer side (option)........................................27
5.1.7 Cleaning the bushing.............................................................................................. 29
5.2 Mounting the bushing on the transformer......................................................... 29
5.2.1 Slinging the bushing for installation........................................................................ 29
5.2.2 Putting the bushing at an inclination...................................................................... 29
5.2.3 Connecting draw lead bolt / detachable conductor bolt to the transformer
connection (option 1).............................................................................................. 30
5.2.4 Mounting the draw lead bolt (option)......................................................................30
5.2.5 Mounting the detachable conductor bolt (option)................................................... 31
5.2.6 Mounting the head armature of the bushing (with draw lead bolt / detachable
conductor bolt)........................................................................................................ 32
5.2.7 Connecting undetachable conductor bolt to the transformer connection (option
2)............................................................................................................................. 34
5.2.8 Screwing the bushing to the transformer................................................................36
5.2.9 Grounding the bushing flange................................................................................ 36
5.3 Post installation tasks.......................................................................................... 37
5.3.1 Releasing the ring screws...................................................................................... 37
6 Preparation for commissioning.............................................. 38
6.1 Filling the transformer..........................................................................................38
6.2 Venting the bushing..............................................................................................38
6.3 Check bushing...................................................................................................... 39
6.3.1 Visual inspection..................................................................................................... 39
6.3.2 Leak test (visual).....................................................................................................39
6.3.3 Electrical testing...................................................................................................... 39
7 Maintenance.............................................................................. 41
7.1 Maintenance schedule.......................................................................................... 41
7.2 Check and clean insulator surface (silicone insulator).................................... 41
7.3 Check bushing electrically...................................................................................43
7.3.1 Measuring equipment..............................................................................................43
7.3.2 Measuring procedure.............................................................................................. 44
7.3.3 Threshold values.....................................................................................................44
7.3.4 Test tab....................................................................................................................45
7.3.5 Voltage tap.............................................................................................................. 47
7.4 Check the temperature using a thermal image................................................. 48
8 Repair......................................................................................... 49
8.1 Smaller damages...................................................................................................49
Range STARIS®-Sia+ 3/53

8.2 Huge damages.......................................................................................................49
9 Storage.......................................................................................50
9.1 Standard storage...................................................................................................50
9.2 Long-term storage................................................................................................ 50
10 Disposal..................................................................................... 51
10.1 Constituent parts of the bushing........................................................................ 51
11 Standard torques...................................................................... 52
11.1 Standard torques.................................................................................................. 52
11.2 Standard torques for air release screws............................................................52
Range STARIS®-Sia+ 4/53

1 Documentation notes
The following describes how the text is presented and to whom the instruction applies.
1.1 How the text is displayed in this document
1.1.1 Descriptions
Descriptions are normal running text.
1.1.2 Instructions
► Instruction
▷Sub-instruction
→ Reaction of product to instruction
1.1.3 Cross-references
Chap. XX on Page YY Reference to a different chapter
1.1.4 Lists
● Bullet point, 1st. level
○ Bullet point, 2nd. level
■ Bullet point, 1st. level for instructions
Range STARIS®-Sia+ 5/53

1.1.5 Additional applicable documents
► Please observe:
■ All instruction manuals included with the product
■ The associated bushing specification
■ The transformer manual (not part of HSP scope of supply)
1.2 Storage of documents
This documentation and all its associated applicable documents must be stored in the vicinity
of the product and be accessible to the personnel.
1.3 Validity of instructions
These instructions apply exclusively to the type range STARIS®-Sia+.
1.4 Target groups
These instructions are directed to expert operatives:
● Integrator of the bushing
● Installation and maintenance personnel
Range STARIS®-Sia+ 6/53

2 Safety
The following safety information applies for the entire instructions.
2.1 Classification of the handling-relevant warning instructions
DANGER
This warning instruction indicates a dangerous situation, which will inevitably lead to a
severe or fatal accident if it is disregarded.
► Handling instruction for danger defense
WARNING
This warning instruction indicates a dangerous situation, which may lead to a severe or
fatal accident if it is disregarded.
► Handling instruction for danger defense
CAUTION
This warning instruction indicates a dangerous situation, which may lead to slight or
medium-severity accident if it is disregarded.
► Handling instruction for danger defense
NOTICE
This warning instruction indicates a dangerous situation, which may result in material
damage if it is disregarded.
► Handling instruction for danger defense
Information and tips
2.2 Intended use
In the event of non-intended use, dangers to life and limb and damage to the product and
other assets could be created.
The transformer bushings in the range STARIS®-Sia+ (US market) are high-voltage
bushings for the integration in transformers and for use as outdoor bushings.
Range STARIS®-Sia+ 7/53

Intended use includes:
● observance of all product instructions and instructions concerning the components of the
installation
● operation of the product without changes to the product
● operation of the product within the specified operational limits (see bushing specification)
● compliance with all inspection and maintenance conditions
Any use other than those described in the existing instructions, or use that extends beyond
those described here, is considered to be on-intended.
The manufacturer is not liable for damage resulting from non-intended use. The
manufacturer’s warranty becomes void in the event of non-intended use. The operator
bears the risk exclusively.
2.3 General safety instructions
There are dangers associated with the bushings.
► Observe all the regulations that apply to the following areas:
■ Electrical voltages
■ Moving machines
■ Heavy weights
■ Moving masses
■ Injury caused by slipping, tripping, and falling down
► Observe all the relevant local regulations and legal stipulations.
► Observe the local hazardous material instructions.
► Observe the operating instructions.
2.3.1 Danger to life from electrocution
There is a danger of electrocution when working on the bushing.
► Observe the five safety rules before working on the bushing:
■ Disconnect
■ Secure against switching on again
■ Establish freedom from voltage
■ Ground and short-circuit
■ Cover or cordon off adjacent live parts
Range STARIS®-Sia+ 8/53

2.3.2 Crush and impact danger from suspended loads
There are injury dangers from suspended loads (lifted bushings etc.).
► Be aware of uncontrolled movements of the loads with lifted bushings.
► Never work under a suspended bushing.
2.4 Obligations of the integrator/operator
The integrator/operator has the following supervisory obligations:
● Supplementation of general safety information with local regulations
● Provision of first aid kit, fire extinguisher
● Ensure that only qualified personnel work on the product
● Ensure that the personnel are trained in first aid
● Provision of appropriate personal protection equipment
● Make sure that all safety devices are always present and are operating
● Regular training of the personnel in the following subjects:
○ Observance and use of all instruction documents
○ Intended use of the product
○ Knowledge of all safety devices and safety signs at the operating location
○ Observance of the legal regulations
○ Observance of the operating instructions
2.4.1 Action in the event of fire
► Report the fire:
■ Call the local emergency phone number
► Move to a safe area:
■ Take any endangered persons with you
■ Close doors
■ Follow the marked escape route
■ Wait for instructions
► Try to extinguish the fire.
■ Use the fire extinguisher
Range STARIS®-Sia+ 9/53

2.4.2 Action in the event of an accident
► Report the accident:
■ Call the local emergency phone number
► Employ first aid:
■ Secure the site of the accident
■ Provide care for the injured persons
■ Observe the instruction manuals
► Take any other measures:
■ Direct the ambulance or fire brigade
■ Remove rubberneckers
2.5 Qualification of the personnel
All work on the product requires expert technical knowledge. In order to ensure operational
safety, only expert operatives or a technically trained person is allowed to work on the
product.
The personnel must be able to evaluate the tasks allocated to him, to recognize possible
dangers, and to take the appropriate safety measures.
The integrator/operator must ensure the qualification of the personnel.
2.6 Personal protection equipment
The integrator/operator is responsible for the provision of appropriate personal protection
equipment.
HSP recommends:
Protective clothing
Hearing protection
Range STARIS®-Sia+ 10/53

Head protection (safety helmet)
Eye protection (safety goggles, possibly close-fitting)
Hand protection (for protection from mechanical and chemical
dangers)
Foot protection (safety shoes)
For additional
special local dangers Additional appropriate protection equipment
Range STARIS®-Sia+ 11/53

3 Structure
The chapter describes the structure and design of the bushing.
3.1 General structure
Fig. 1: Structure of the bushing
Item Part Item Part
1 Connection terminal outdoor side 4 Flange
2 Head 5 Insulating body
3 Isolator 6 Connection transformer side
Range STARIS®-Sia+ 12/53

3.1.1 Version with draw lead bolt or detachable conductor bolt
Fig. 2: Version with draw lead bolt or detachable conductor bolt
3.1.2 Version with undetachable conductor bolt
Fig. 3: Version with undetachable conductor bolt
Range STARIS®-Sia+ 13/53

3.2 Design
Fig. 4: Bushing design (example)
Range STARIS®-Sia+ 14/53

Item Part Item Part
1 Hexagon screw 10 Transformer vent (not shown → on the
back of the flange armature)
2 Air release screw 11 Insulating body
3 Composite insulator 12 Central tube (draw lead or detachable
conductor bolt)
4 Flange armatures 13 Aluminum foil
5 Measuring connection/voltage splitter
connection
14 Polyurethane-elastomer
6 Sling points 15 Head armature
7 Grounding screw 16 Clamping piece
8 Lift-off screws 17 Seals
9 Screened mouth end
The main insulation of the RIS-transformer bushing is an insulating body (11).
Insulating body
The insulating body consists of a plastic fleece and grading layers:
● The plastic fleece is impregnated with epoxy resin under a vacuum.
● The grading layers are coaxially placed aluminum foils (13) which effect even voltage
distribution on the insulating body.
Bushings with undetachable conductor bolts do not have a central tube (12).
Composite insulator
The insulating body is incorporated in a composite insulator (3).
The composite insulator consists of:
● Filament winding tube
● Silicone sheds (connected to the epoxy resin tube by vulcanization)
The head armature (15) and the flange armature (4) are connected by the epoxy resin tube.
Elastomer-connection
The gap between the insulating body and the composite insulator is filled with a foamed
polyurethane elastomer (14). The elastomer rigidly connects the components together. The
components can no longer be separated without destroying them.
Bushing flange
The bushing flange is fitted with:
Range STARIS®-Sia+ 15/53

● A test tab (5)
● Sling points (6)
● Grounding screw (7)
● Lift-off screws (8)
● Transformer vent (10)
Bushing head
The clamping piece (16) is screwed to the head armature of the composite insulator.
Seals (17) are arranged in defined chambers in the interface between the pin and the
clamping piece.
Air release screw
The air release screw (2) for venting of the central tube is located at the side on the clamping
piece (16).
Undetachable conductor bolt
With a undetachable conductor bolt, there is no clamping piece, but rather a disk as the:
● corrosion protection between the copper bolt and the aluminum armature
● Cover for the bolt sealing underneath
Pulling through the bolt
Draw lead bolts / detachable conductor bolts have a threaded bore with a hexagon screw (1)
on the front for pulling through the bolt using a pulling wire or pulling rod.
Electrode
Depending on the scope of supply, a detachable insulated shield electrode is provided on the
transformer side of the bushing using a bayonet lock.
Range STARIS®-Sia+ 16/53

4 Technical data
Standard values are stated in the technical data.
► Always observe the bushing specification applicable to the bushing for the product-specific
values.
4.1 General operating conditions
STA Standard
RIS Resin impregnated synthetic
Sia Silicone insulator (ANSI Standard)
Classification (STARIS®-
Sia+)
+New product generation
Ambient temperature Outdoor side: -30 … +40°C
Transformer side: Daily mean value +95°C, maximum
value 105°C
Operation height < 1000 m above sea-level
Rain level and humidity In accordance with IEC 60060 - I
Pollution class In accordance with the specific creepage distance (as per
C57.19.100 "heavy" or "extra heavy")
Immersion medium Appropriate transformer oil
Oil level below bushing
flange
≤ 15 mm
Oil pressure Max. 200 kPa gage
Possibility to evacuate
(transformer tank)
No limitation on height and duration
Corrosion protection All armatures and fixing material made from corrosion-
resistant materials
Marking On name plate, as per IEEE C57.19.00
Range STARIS®-Sia+ 17/53

Standard packaging In heat-resistant wooden crate (or equivalent material).
Carried in bearing shells.
Sealed in film with addition of dry filling.
4.2 Mechanical stress
Test bending load Standard, in accordance with IEEE C57.19.00 and
IEEE C57.19.01
Operating load 50 % of test bending load
Range STARIS®-Sia+ 18/53

5 Installation
The chapter covers the preparation, execution and post-treatment of the installation.
NOTICE
Material damage caused by mechanical stress
The bushing can suffer damage (particularly to the porcelain or silicone insulators) from
mechanical stresses.
► When installing, make sure that the bushing is not exposed to mechanical stresses
(particularly to porcelain or silicone insulators).
5.1 Preparing the bushing
► Open the wooden crate.
► Check the film on the bushing for damage.
NOTICE
Material damage caused by knives
The bushing can suffer damage when unpacking with a knife.
► Always unpack the bushing using a safety knife (with a concealed blade).
► Open the wooden film.
► If present, remove the plastic bag with the loose parts from the bushing.
Range STARIS®-Sia+ 19/53

5.1.1 Checking the scope of supply
Fig. 5: Packaging (example illustration)
► Check the scope of supply for completeness and damage, using the:
■ Delivery note
■ Bushing specification
■ Packing note (if present)
► Check whether the bushing was delivered in proper packaging:
■ In a wooden crate
■ Carried in bearing shells
■ Sealed in film with addition of dry filling
■ For larger bushings: Flange supported with wooden cross beams
► If a data logger is included in the scope of supply, then provide the HSP data of the data
logger.
Range STARIS®-Sia+ 20/53