High Voltage Bushing Flange Interior Seal Design
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Solution Overview
Problem
High voltage bushings face challenges in preventing hydrogen gas leakage from utility generators to the external environment due to inadequate sealing, as hydrogen is flammable and explosive, posing safety risks.
Innovation Solution
A high voltage bushing design featuring a flange with an interior seal comprising O-ring channels, O-rings, a sealant channel, and ports for sealant injection, which provides a robust sealing mechanism to prevent hydrogen leakage, using materials like VITON O-rings and fluorosilicone sealant to ensure a tight seal.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a simple flange structure is used to secure the high voltage bushing, then the device complexity is reduced, but the sealing reliability deteriorates due to inadequate prevention of hydrogen gas leakage
Solution Approach 1:
The sealing system is divided into multiple independent components: O-rings placed in grooves, sealant channels filled with sealant, and multiple sealing layers. This segmentation allows each component to contribute to the overall sealing reliability without requiring the entire system to be overly complex, as each element provides a specific sealing function.
Solution Approach 2:
The sealant channels are pre-formed within the flange structure during manufacturing, and O-rings are pre-installed in their grooves. This preliminary action ensures that sealing components are already in position before the bushing is assembled, improving sealing reliability without adding operational complexity during installation.
2Reliability
If multiple sealing components (O-rings, sealant channels) are added to prevent hydrogen leakage, then the sealing reliability is improved, but the device complexity increases
Solution Approach 1:
Multiple sealing functions are merged into a single integrated flange structure. The flange incorporates O-ring grooves, sealant channels, and mounting features all in one component, which improves sealing reliability through multiple sealing mechanisms while avoiding the complexity of assembling separate sealing components.
Solution Approach 2:
The flange serves multiple functions simultaneously: structural support for the bushing, hydrogen sealing through O-rings and sealant, and electrical insulation. This multi-functionality improves overall system reliability without proportionally increasing complexity, as one component performs multiple critical roles.
3Ease of manufacture
If a robust sealing system with multiple components is implemented, then the prevention of hydrogen gas leakage is improved, but the manufacturing complexity increases
Solution Approach 1:
The sealant channels are pre-formed within the flange during manufacturing, and O-rings are pre-installed in their grooves before final assembly. This preliminary action simplifies the overall manufacturing process by preparing sealing components in advance, making the assembly process more straightforward despite the multiple sealing elements.
Solution Approach 2:
The sealant channels are designed to be self-filled during the assembly process, where sealant is injected through accessible ports and automatically fills the channels. This self-service approach reduces the need for complex manual sealing operations, improving ease of manufacture despite the presence of multiple sealing components.
4Reliability
If sealant channels with injection ports are added to the flange, then the sealing reliability is improved, but the device complexity and manufacturing steps increase
Solution Approach 1:
The sealant channels are designed with injection ports that allow sealant to be self-filled during assembly. The sealant automatically flows into the channels and cures in place, eliminating the need for complex pre-filled sealant applications or post-assembly sealing operations. This self-service approach improves sealing reliability while maintaining manufacturing simplicity.
Solution Approach 2:
The sealant channels are pre-formed with precise geometry and injection ports during flange manufacturing. This preliminary preparation of the sealing infrastructure allows for simple, rapid sealant injection during assembly, improving sealing reliability without significantly increasing manufacturing complexity.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The solution effectively reduces hydrogen gas leakage from the generator's internal environment to the external environment, enhancing safety by providing a reliable and durable sealing system that secures the high voltage bushing in place.
Implementation Method 1
The interior surface of the flange may be used to seal the gap between the internal operating environment of the generator and the environment external to the generator
Implementation Method 2
a quantity of sealant filling the at least one sealant channel
Data Source
AI summary
A high voltage bushing and flange with an interior seal. The high voltage bushing includes an outer insulating material. The high voltage bushing includes a flange with an interior seal comprised of at least two flange O-ring channels; at least two O-rings; a sealant channel; and a quantity of sealant filling the sealant channel.