Reliable transformers through

Dry-type bushings RIP and RIS

and their adapted solutions
Laurent Vlesik
Head of Sales - Bushings
Current and Voltage – our passion

As a leading technology solution provider for our customers in utilities, industry, and railways, we
supply best-in-class products, providing the highest reliability and excellent services.

5 ~900
brands employees

Fritz Hunziker
Entrepreneur / Chairman of the Board
PFIFFNER - GROUP

2
8 service &
production solutions
facilities providers
Jürgen Bernauer
CEO PFIFFNER Group

www.pfiffner-group.com / page 2 / 05/11/2024

Organisation and global locations

Group companies in Switzerland Service and solutions provider Global presence

Pfiffner Systems Pfiffner Deutschland

Pfiffner Instrument Transformers Kaiseraugst Itzehoe
Hirschthal Switzerland Germany

Pfiffner Transformers
HAVECO Ankara
Moser Glaser Gwatt Turkey
Kaiseraugst Switzerland

Pfiffner India
Nashik
India
ALPHA Elektrotechnik
Grenchen
Pfiffner Brasil
Itajaí
Brazil

HAEFELY
Basel
Haefely Beijing Office
Beijing
China
HAVECO
Gwatt, Zofingen
Moser Glaser USA
+ 175 representatives worldwide Annapolis, MD
USA

www.pfiffner-group.com / page 3 / 05/11/2024

Our brands and reputation – Swiss pioneers in HV

 Voltage and current transformers

 Resistive capacitive voltage dividers

 Isolated busbar solutions DURESCA®

 Transformer and wall bushings

 Disconnectors
 Cable solutions for rolling stock

 HV test systems
 Instrumentation
 Service

 Projects for substations

 Installation services
 Projects and services for battery energy
storage systems

www.pfiffner-group.com / page 4 / 05/11/2024

Site location and figures
 Around 170 employees
 Turnover of 48 Mio. EUR
 Total site area of 7500 m2; Production area of 3350 m2
 Manufacturing: MV+HV Busbars 12-170kV up to 8,000A
MV+HV Bushings 36-362kV (420-550kV in 2025)
PFIFFNER Group in a nutshell

Busbars Components
 Solutions for power generation plants  Wall bushings and transformer
and substations bushings

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What is a transformer bushing ?

 A transformer bushing is an electrical component

used to insulate and connect a high-voltage
transformer to other equipment or conductors.

 It serves as a protective interface, allowing

electrical power to flow smoothly between the
transformer and external systems while preventing
leakage or short circuits.

 Bushings are typically made of insulating

materials and can handle high voltages, providing
a safe and reliable means of transferring electricity
in transformer installations.

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HV Bushing Designs

Non-Condenser Condenser type

Insulator

Insulation +
Grading foils Al

Conductor

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Sources of Transformers Failures

Transformer fault due to Transformer bushing Explosion on the

a defective bushing Failures Canada High-Voltage side 230kV

www.mgc.ch / page 9 / 05.11.2024

More than 60 years of RIP technology development

1946
 Ciba, a chemical Swiss Company, launched on the market, the
Araldite - a glue based on Epoxy Resin

 Moser Glaser engineers conducted dielectric tests on this new

material, and discovered its excellent properties

1958
 MGC, together with Ciba, developed the first Resin Impregnated
Paper, as insulation material for High Voltage application

1959, one of the first Busbar with RIP insulation

www.mgc.ch / page 10 / 05.11.2024

Insulating Technology Comparison

Resin Impregnated Paper Resin Impregnated Synthetic Oil Impregnated Paper (porcelain)

Positive Positive Positive

+ Maintenance-free + Same as RIP + Partial discharge free
+ Oil and gas tight system + Lower Tan Delta + Good ageing experiences
+ No housing for oil end + Simple long-time storage + Lower production costs
necessary + Not affected by humidity + Max. temperature < 105°C
+ Non-inflammable + No oil-paper aging behavior
+ Operates with damaged housing
temporarily
+ Core is fixed to flange Negative Negative
+ Excellent mechanical behavior - NEW Product in the market - Needs complete housing
+ Partial discharge free - Inflammable
+ Excellent ageing experience - Needs mechanical support
+ Each mounting position allowed - Core may drop into the
+ Max. temperature < 120°C transformer if housing is
damaged
Negative - High maintenance and
expensive (over lifetime, more
- Higher production cost
expensive than RIP)
- Bottom part sensitive to
humidity

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Dry-type insulations

RIP resin impregnated paper

RIS resin impregnated synthetic

Bushing core, made of resin impregnated paper Bushing core, made of resin impregnated synthetic (MGC)

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New generation RIS

Bushings with paper free insulation

RIS (Resin Impregnated Synthetic) share the same
benefits as RIP:
 Non-inflammable
 Partial discharge-free Population of RIS bushings
Year of
 Installation at any angle delivery
RIP RIS Total Share

2016 3362 3362

Enhanced with new features: 2017 3247 27 3274 1%
2018 5290 90 5380 2%
 Not affected by humidity and oil/paper degradation 2019 4589 206 4795 4%
2020 4148 485 4633 10%
during the lifetime of the transformer
2021 5077 417 5494 8%
 Easier handling for long transportation and storage 2022 5161 1264 6425 20%

 Reduced tan delta and capacitance 2023 6680 1176 7856 15%

2024 5821 2256 8077 28%

2025

09.10.2024

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On-going test: multiple years test

Time Temperatur @ 20kV, T_mes @ 20kV, +20°C

Nr. Date
[h] T_mes [°C] Tan d [%] Capacitance [pF] Tan d [%] Capacitance [pF]
Humidity
chamber

0.390 167.0 0.429 166.5

Pfiffner

0 14.02.2019 15:00 0 26
167.7 0.377 170.7
12 08.05.2020 11:00 10772 24 0.350
13 11.06.2020 11:00 0
14 27.10.2020 11:00 14084 22 0.360 167.9 0.376 167.7
Water
tank

15 02.03.2021 12:30 17110 21 0.370 167.8 0.379 167.5

16 03.01.2022 10:00 24475 19 0.390 167.7 0.379 167.8
17 19.09.2022 15:00 30696 25 0.350 171.1 0.381 169.5

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DURESCA® Transformer bushings

Application: Oil to Air / Oil to Oil / Oil to SF6

Standard: IEC60137 / IEEE C57.19.01-2017 & C57.19.00-2004

Insulation: RIP (resin impregnated paper)

Voltage range: 24kV to 550kV

Insulation: RIS (resin impregnated synthetic)

Voltage range: 24kV to 300kV

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 Bushings designation

 DTOI = Transformer bushing RIP Oil-Air with silicone insulator direct molded IEC
 DTOIS = DTOI with RIS insulation IEC
D = Durchführung T = Trafo
 DTOIH = Transformer bushing RIP Oil-Air with hollow core silicone insulator IEC
 DTOISH = DTOIH with RIS insulation IEC
 DTOIA = RIP Transformer bushing Oil-Air with silicone insulator direct molded IEEE standard
 DTOIAS = DTOIA with RIS insulation
 DTOIAH = DTOIA with Hollow Core insulator
O = Oil I = Isolator  DTO = RIP Transformer bushing Oil - Oil
 DTOX = RIP Transformer bushing Oil-SF6
 DTXI = RIP Transformer bushing Special Pfisterer Plug-In

S = RI S A = Ansi standard
Insulation ( IEEE )

X = SF6 application
H = Hollow core
insulator

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Turnover evolution

Transformer bushings

30'000

25'000

20'000

Turnover kCHF
15'000

10'000

Wall bushings
5'000

0
2012 2013 2014 2015 2016 2017 2018 2019 2020 2021 2022 2023 2024 2025
Fiscal Year Year Sept Y-1 to Oct Y

Transformer bushings Wall bushings Linear (Transformer bushings)

Sept 2024

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Solving customer-specific challenges

Seismic areas Cold environment Warm environment

Off-shore and highly-polluted

environment Transformer bushing retrofit Ester oil

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Maintenance Overview

MIDAS micro 2883 - Insulation Diagnosis Set

One Box – rugged and easy to transport
 Weight 25 kg / 55 lb
 Robust case with casters

Reliable results even under difficult conditions

 Noise suppression function
 Stable standard gas capacitor

Quick results
 Three operating modes
 Convenient setup and storing

The features you need

 12 kV output voltage, variable frequency
 Extensive safety features

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RIS recognized by the Industry Standards

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 Standardisation of Silicone Insulators

Directly molded solutions

where the outdoor insulating material is applied directly onto
the high voltage equipment.

Material, Liquid Silicone Rubbers (LSR)

Two components addition-curing systems with low viscosity
allowing them to be injected or pumped into molds after an
initial mixing step.
A B

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Insulation Technologies Focus

Characteristics of composite insulators Characteristics of porcelain

+ hydrophobic surfaces + smooth glazed surfaces
+ good characteristics under pollution + surface leakage current resistant
+ low leakage current + high life expectancy
+ low manufacturing tolerances + mechanical stability
+ low weight - easier handling + easy forming
+ high mechanical stability + economically reasonable material
+ elasticity in case of bending
+ optimal solution for seismic stress - MV bushings missing test tap
+ no damage of splintering, no bursting - restricted bending strength
+ no danger of scattering - high manufacturing tolerances
+ pressure resistant - sensitive to temperature changes
+ significantly shorter delivery times - high danger of scattering in case of bursting
- restricted pressure resistance
- higher price - low impact strength
- long delivery times
- high weight

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Porcelain / Composite Insulator

Porcelain very vulnerable to mechanical Composite insulator mainly less

impact mechanical damage

 During a failure, consequences are  Mechanical structure retained

devastating  Safety, no risk of damaging nearby
 Porcelain pieces up to 60m radius equipment
 Nearby components are affected  Lower stress during earthquakes
Source of ABB on

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MGC Moisture Barrier

MGC Exclusive design: The Moisture Guard

 Additional moisture barrier - MGC performs special long duration tests to prove the
excellent behavior under moist condition of its bushings

Up to 3mm
Pure Resin Barrier
Moisture Guard

Cross section cut of bushing

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Sources of Transformers Failures

90% of all preventable bushing failures are Maintenance free and environmental
caused by moisture entering the bushing friendly/safe operation as no oil
through leaky gaskets, cracks or seals with inside the bushing
OIP bushings
OIP Seals Arrangements RIP / RIS

1
1
2
2
3

6
Reference: LinkedIn
Mr. Nami Mahmoudi
– Power Transformer 3
Specialist

Reference: Bushings for Power Transformers Handbook for Power Engineers

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 Epoxy Bushing - Most Common Failures

The most common failures that develop as a result of improper processing include:

Bushing leaks developing over time in operation

Most commonly, bushing leaks are caused by ageing or by improper gaskets, as well as the weak adhesion
between the epoxy and the conductor

Excessive partial discharge

If the material is not de-aired properly, this may result in excessive partial discharge.

Cracking during mounting or under maximum cable load

Cracking can be caused by using improper epoxy.
To avoid this problem, the epoxy should be customized to different temperatures.

Tearing when conductor temperature rises due to high current

In order to avoid this issue, it is important to know the coefficient of thermal expansion of the conductor and
the epoxy, as well as the glass transition temperature.

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Maintenance Overview

Power factor and capacitance measurements record during installation

Clean the bushing (e.g., isopropyl alcohol) to remove any dust/contaminants, avoid moisture condensation
Clean and dry the voltage or test tap to remove any contamination or condensation inside
Don’t perform measurements in wooden crates avoiding surface leakage currents
Keep clearance between the bushing and other objects to minimize the effects of stray capacitance
Avoid taking measurements below 10 °C
General guidelines for evaluating the C1 power and dissipation factor test data are as follows:
 Between nameplate pf and up to 1.5 nameplate pf - bushing acceptable
 Between 1.5 nameplate pf and up to twice nameplate pf - monitor bushing closely
 Above twice nameplate pf - replace bushing

General guidelines for evaluating the C1 capacitance data are as follows:

 Nameplate capacitance +/-5% - bushing acceptable
 Nameplate capacitance +/-5% to +/-10% - monitor bushing closely
 Nameplate capacitance +/-10% or greater - replace bushing

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Seismic test

Fig.2: Shaking Table Set Up

Fig.1: Bending Test

Seismic Test as per the strongest requirement from the

IEEE 693 – 2018 // High Performance Level 2.0 g

www.mgc.ch / page 28 / 05.11.2024

Off-shore and highly polluted environment (C5-M)

Terminal Copper
Tin Plated

Anodized flange
and head

www.mgc.ch / page 29 / 05.11.2024

Off-shore and highly polluted environment (C5-M)

Water cannot spread out on silicones; pollution layers turn hydrophobic due to the
hydrophobicity transfer effect

Minimizes the risk of pollution flashovers in the case of dirty surfaces

Hydrophoby Class = 3…4 HC = 2…3

110 kV bushing insulator after 20 years of service at moderate to heavy industrial pollution
www.mgc.ch / page 30 / 05.11.2024
Low temperature test -40°C

Multi-bending test for RIP and RIS bushings: 50 000 Cycles -40°C / +50°C

www.mgc.ch / page 31 / 05.11.2024

Low temperature test -60°C

Power frequency voltage withstand tests before

Low Temperature Test (Tested by: MGC)

Low Temperature Test of -60°C (68 hours)

(Tested by: Institute of Electric Energy Systems

and High-Voltage Technology)

What about silicone insulator?

Silicone elastomers have an above-average and permanent elasticity.
Below -45°it will become brittle but will retrieve its properties when temperatures go up again.

www.mgc.ch / page 32 / 05.11.2024

 Retrofit / Replacement

Draw lead connector adaptor Adapted air side length

Brazing

One long+one short shed

= 50mm; ~ 2 in

Crimping

Adaptor

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Retrofit Projects

Retrofit Bushings = Replacement Bushings: OIP replaced by MGC RIP

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Retrofit Projects

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Retrofit Projects

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Retrofit Projects

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Wall bushings

 Up to 300kV and 8000A

 Applications :
Indoor-Indoor / Indoor-Outdoor / Outdoor-Outdoor

 Conductor:
Round or hollow
aluminum or copper

 Insulation:
RIP with capacitive grading

 Outer insulator:
Indoor: Polyamide tube or
high quality coating
Outdoor: Silicone rubber sheds
Member of the PFIFFNER Group
Integrated current transformer

DURESCA® Wall bushing type DM2I, 24 kV / 4000 A

 With integrated current transformer

 For fast and easy installation

Member of the PFIFFNER Group 05.11.2024

Warm temperature

All standard MGC bushings are given for the maximum temperature they can withstand

Minimum +40°C up to +55°C

If more is needed, it has to be designed for that special condition

That means a larger conductor and possibly larger active part diameter.

Impact to the silicone insulator?

The stability of the Si-O backbone makes silicones permanently resistant to the UV portion of solar
radiation

Silicones have long-term thermal stability, even in the presence of atmospheric oxygen.

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Components of Bushings

Conductor Types: - Draw Lead

- Removable/split conductor
- Fix Conductor
- Flexible top connection designs

Creepage Distance (typical 31mm/kV)

Each MGC Bushing equipped with Test Tap
Customized Flange sizes upon customer’s request
Customized CT (BCT) extensions e.g. 0, 100, 300, 500mm
Flexible under flange oil length available
BCT
Flexible bottom oil connection designs available - Round, flat pad, flat pad terminals

Transportation and Mounting Angles 0°…90°

Ambient Temperature ranges -40 / +40°C (-55 / +55°C on request)

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Ester oil

IEC design
Field grading length has to be increased by 25% to fulfil the insulation requirements,
considering the different dielectric properties of both synthetic and natural ester oils.

IEEE / CSA design

Up to Um = 138/145kV, no modification of standard design required. CT extension

Above 145kV, field grading length has to be increased by 10%.

Field grading
length

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Storage of RIP bushings

The bushing must always be protected from moisture and permanently stored in a dry room.

RIP oil-air RIP air-oil RIP oil-oil/SF6

Storage up to 6 months
Packed in protective foil with desiccant bag

Storage longer than 6 months and up to 24 months

Packed in protective aluminium foil with desiccant bag (oil-oil bushings)

Storage longer than 24 months

Oil-side protected in a tank filled with dry transformer oil

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Storage of RIS bushings

 No special condition for the storage of RIS bushings

 They can be stored horizontally in their original wood crate

 Or placed verticaly in a rack

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MGC Factory
Paper – Synthetic Winding

 2 Fully automated winding machine: for RIP and RIS active parts
7 impregnation ovens
Quality control of all batches

Glass transition
After impregnation: Intermediate dielectric test
Machining
Tightness test: 100% of the bushings
Silicone molding
MGC Test Laboratory

Test Object
AC Test
System

Impulse
Generator

 AC Test Transformer cascade up to 800kV

 Impulse test system 2200kV for
- lightning impulse LI
- switching impulse SI
 Background level <1pC
Summary, questions & answers

Almost 60 years of experience in RIP Technology and manufacturing RIP Wall -

bushings and Busbars

Manufacturing of 72.5 kV RIP Transformer-Bushings with porcelain insulator in the

1970/80`s

Standard range fully in accordance with the IEEE and IEC std

High flexibility to offer customized, and interchangeable solution

RIP and RIS technology, with silicone insulator

Increasing production capacity, 3500 bushings in 2016 -> 8000 in 2024

www.mgc.ch / page 54 / 05.11.2024

www.pfiffner-group.com / page 55 / 05.11.2024