IMPORTANT TESTS TO BE CARRIED OUT ON CIRCUIT

BREAKERS

Following are some of the important condition based maintenance techniques being
adopted for assessing the condition of circuit breaker:

Operating timings measurement

Contact resistance measurement

Contact travel measurement

Dew point measurement of SF6 gas/air

Tan delta measurement of grading capacitors

Vibration measurement

Operational lock-out checks

Trip/close coil current measurement

SF6 gas/hydraulic oil

Air leakage monitoring

SF6 gas leakage test

Operating timings of Main / PIR contacts

Monitoring of operating timings is basically done with a aim of finding any problem in
operating mechanism, alignment of main/arcing contacts and also discrepancy in
timing between 2 poles and/or between two breaks of the same pole. Closing timing
(maximum 150ms) and trip timing (maximum 25ms) are the most critical to be
monitored very closely. Each type of circuit breaker has different operating timings.
Initial values obtained at the time of commissioning should be taken as the base
value. Any variation / drift in the timings from the guaranteed value/base value may
indicate some type of problem with the operating mechanism or operating levers.

Precautions

Ensure Proper shutdown is arranged.

Ensure that there are no joints in testing cable and the testing leads are not
touching any live point

Do not connect the test set the energized equipment

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 Ground cable must be connected first and removed at last

Ensure that high voltage plugs are free from moisture during installation
operations

CB analyzer body should be earthed (if separate earth is provided)

The testing equipment along with the testing procedure are available at site
and the testing should be done in the presence of testing personal only.

Clean the surface / terminal where the connection for testing are to be made

Clean earth point with sand paper / wire brush where earth terminal is to be
provided.

Ensure that all the pole strips simultaneously through single poles/trip
command.

Testing procedure

A typical arrangement for measurement of operating timings of circuit breaker is

given in Figure 1.

(Figure 1)

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 Make connections as per above figure. Ensure that R, Y and B phase marking
cables are connected with proper terminal with the CB (Circuit Breaker) analyzer
and maintained color Coates for all the three poles of CB.

Connection is to be made for measuring the operating timings of auxiliary

contacts

AC/DC supply to be extended to CB analyzer

Give closing command to closing coil of CB and note down the PIR and main
contact closing time. Obtain a print from a CB analyzer

Give tripping command to trip coil 1 of CB and note down the main contact
tripping time.

Repeat the same for tripping coil 2

Note the down the timings of various operations of CB viz. CO, OC, OCO by
giving appropriate command.

In the event of PIR opening time is required the same may be isolated from
the main break and treated as a separate contact using different channel of the
analyzer.

EQUIPMENT RECOMMANDED: HISAC 2406 CB ANALYZER [Make: Scope]

SCOT TIME INTERVAL METERS

Evolution of test results

The permissible pole discrepancy as per IEC 56 between 2 poles should not be
beyond 1/6 of cycle (3.33 ms) and between 2 breaks should not exceed 1/8 th of a
cycle (2.5 ms). As per the practice followed by the most power utilities the limit for
pole discrepancy between pole to pole is of the order of 5 ms for breakers under
O&M as it is difficult to make any adjustments at site. If these timings are not within
limits it may lead to over-stressing of one particular interrupting chamber. Switching
over voltage may also be high in case of larger discrepancies in closing timings of the
pole because of presence of trapped charges in the phase of circuit breakers which is
going to close last.

Variation in the operating timing of the order of 3 ms from the base values is
generally considered acceptable. However, if these are not within the limits the same
is to be corrected by:

Equalizing the SF6 pressure in different poles

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 Make necessary adjustment plunger of trip of close coil

Adjustment in operating mechanism

Changing trip / close coil if required

It is also necessary to measure the timings of auxiliary contacts from the point of
view of variations with respect to main contact. If the difference in timings of the
main or auxiliary contact is maintained within limits this reveals that there is no
problem with the auxiliary contact assembly or with the operating mechanisms or
with the operating levers of the CB.

Contact resistance measurement

Purpose of measuring contact resistance measurement is to assess the condition of

the main contacts against erosion or misalignment of the main contacts. The value of
the contact resistance for a new circuit breaker should be around 50 micro-ohms per
break.

Testing procedure

A typical arrangement of measuring the contact resistance is given in Figure 2 below.

Figure 2

The Contact Resistance meter(CRM100) is employed for measurement of pumping

resistance. To measure the value, connect the leads as per above figure and inject
approximately 100-ampere current flow through the contacts. The value of the
contact resistance is directly displayed on the digital LED display screen. By using the

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 Kelvins 4 terminal method, effects of resistance of test lead is nullified because the
input impedance of the measuring device is very high.

If the value of the contact resistance exceeds the permissible limits, this could lead
to over heating of contacts. Monitoring contact resistance values is very good
techniques for assessing the condition of main contacts. Resistance values of the
order of the 100-125 micro-ohms per breaker are considered to be all right for the
CB in service.

EQUIPMENT RECOMMANDED: CRM100B, CRM100C [Make: Scope]

DCRM.Definition
Dynamic Contact Resistance Measurement is a signature of change in contact
resistance of CB during operation.
It plots the variation in contact resistance while first, the arcing, and then the main
contacts engage and disengage during C-O operation.

Why DCRM

Reflects useful information on Contact condition

Gives prior indication of deterioration Operating mechanism linkages

Certain mechanical weaknesses, undetected by travel measurement, are

reflected in DCRM measurement.

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 A Look at Contact
Assembly

Incom
Flange Out
Flange

Main
Contact, Main
Moving Contact,
Fixed
Fixed
Arcing Arcing contact
Moving Contact,
contact Moving contact, Holder

Holder Fixed

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 A Look at CB
Motion

Fixed contact The Energy stored in medium is

rapidly delivered for moving the CB
contacts in a pre-determined fashion,
Moving contact through linkages.

Linkage
DCRM
Operating
Rod

Any change in the dynamic/frictional

N
O
C
R

A
E

Mechanism
I

characteristics of the whole system,

immediately reflects as a change in
the dynamic resistance signature
Latch

Stored
Energy

Dynamic Resistance
Measurement

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 CB in Motion..!!

Voltage Pickups
Current Injection

Dynamic Resistance Oscilloscope

meter

CB Contacts during Make

Main
and Break
Contact A
C
N
T
V
E

Break
Contact
Make
Resistance
8

Time-
A Look at Practical resistance values

Our Observations in last 5 years

Main contacts: 40 to 80 micro-ohms

Arcing contacts: 125 to 600 micro-ohms

Flange to flange joints: 100 to 1000 micro-ohms

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Moving Contact

Fixed Contact

10
 Arcing Contact 10 Years
Before

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Dynamic contact resistance measurement

A typical arrangement for measurement of dynamic contact resistance of CB is given

in Figure 3.

(Figure 3 )

This another technique for measuring the contact resistance during dynamic
conditions i.e. during operations (close/trip) of CB. A DC current is injected through
the CB and the current and voltage drop are measured and the resistance is
calculated. The graphs of resistance vs. time data provide useful information on the
condition of the main contact of CB and is considered to be a modern diagnostic tool.

The variation in the measure resistance vs. time will be seen as finger print for the
breaker contacts and can be used as reference / base value for comparing future
measurement on the same breaker. If the DCRM values matches with the pre-
commissioning /base value then the arcing contact are considered to be O.K. In case
of wide variation and also there is change in arcing contact insertion time this shows

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erosion of arcing contacts. Such as situation may lead of transferring of current from
arcing contacts to main contacts and subsequent commutation failure.

EQUIPMENT RECOMMANDED: DCRM100B, 200B [Make: Scope]

Contact Travel Measurement

Transducers and fixtures are attached to operating rod or interrupting chamber for
measuring contact travel. When CB closes contact travel is recorded. Contact
bouncing and any other abnormality is also pointed out by contact travel
measurement. If contact travel is recorded with DCRM the length of the arcing
contact shall also be monitored. It is generally observed that after some time due to
erosion of arcing contact the tip length reduces and such condition may lead of
commutation failure. This may lead to shifting to arc to main contacts and results in
faster damage of main contacts. If contact travel, contact speed and contact
restoration signature are compared with the original signature it shall reveal
problems related with the operating mechanism, operating levers, main / arcing
contacts, contact alignments etc.

Tan Delta and Capacitor Measurement of Grading Capacitor

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 The purpose of this measurement is to be detected any incipient weakness in the HV
insulation. The grading capacitor play a vital role when circuit breaker trips TRV
stress conditions and also in open condition of circuit breakers. Electrical and thermal
stresses produced during operation of CB do lead to degradation of paper insulation
of capacitor, capacitor elements and also to the oil in grading capacitors. The value
of the tan delta or loss angle increases with degradation of paper or oil. A typical
arrangement of tan delta measurement is given below in Figure 4.

Figure 4

Testing procedure

Connect LV cable to the middle of the double interrupter

Connect HV cable to the other end of grading capacitor to be tested

Ground the opposite end of the grading capacitor using earth switch

Measurement to be done in UST mode

Follow the procedure provided by the equipment supplier.

Measurement to be made at 2 kV first and then at 10 kV.

Carry out the measurement in the standard mode and also the high quality
mode

Interpretation of test results

A large number of failures of electrical equipment have been reported due to

deteriorated condition of the insulation. The correct interpretation of test results
requires knowledge about the equipment construction and characteristics of
particular type of insulation.

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Dissipation factor measurements indicate the following conditions in the insulation of
wide range of electrical equipments:

1. Chemical deterioration due to time and temperature, including certain cases

of acute deterioration caused by localized overheating;
2. Contamination by water, carbon deposits, bad oil, dirt and other chemicals;
3. Severe leakage through cracks and over surfaces;
4. Lionization.

Dialectic strength of insulation decreases with the increase in the moisture content.
At high temperature is pushed out of the paper insulation with oil. As insulation
cooled down water starts migrating from oil into paper. The time for temperature
drop may be faster as compared to water returning to cellulose material. Depending
upon the condition the dissipation factor also changes.

An increase in the value of tan delta indicates the deterioration of cellulose insulation
whereas increase in both tan delta and capacitance reveals entry of moisture in the
insulation.

Ambient temperature

At 20 degree C the value of tan delta should not be more than 0.007. In the
present testing kit available the software is available to give the test results at 20
degree C and also at rated frequency irrespective of the measurement being
made at some other temperature.

Factors affecting test results/measurements

1. Temperature The dialectic losses of most insulation increases with

temperature. A rising temperature causes a rise in dialectic loss which in turn
causes a further rise in temperature. This is general tendency for capacitance
to increase with the temperature. Deterioration of insulation due to aging
causes exponential rise of tan delta with the increase in temperature and is
expressed as follows:

Tan T = Tan

Where T0 = 20 C

T = Temperature of the specimen

Tan To = Tan T at temp. T

= Temperature coefficient varies between 0.01 and 0.015 C

(if the value is between .05 and 0.3 it considered as questionable condition.
Value of more than .03 is a sign of alarming condition)

2. Deposit of surface moisture can have significant effect on the surface losses
and consequently on the results. With a view to minimizing the errors the

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 dissipation measurements may be made when the weather is clear and sunny
and the relative humidity is less than 80%.
3. Surface leakages Any leakage over the insulation surfaces of the specimen
will get added to the losses in the insulation and make a fake impression
about the condition of specimen. It is recommended that surfaces of
insulation should be cleaned and dry when taking a measurement.
4. Electrostatic interference In the energized switch yard, readings may get
affected by electrostatic interference current resulting from the capacity
coupling between energized line and the bus work to the specimen. To
overcome this all the jumpers connected need to be opened when taking a
measurement. In the modern automatic testing kits the effect of interference
gets nullified due to presence of interference suppression circuits.

EQUIPMENT RECOMMANDED: FT-12 [Make: Presco AG]

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Dew-point measurement of SF6 gas/air

6.4.3 Dew point is the temperature at which moisture content in SF 6 gas/air starts
condensing. Measurement of dew point of SF6 gas/air is considered to be a adequate
parameter for monitoring of SF6 gas/air.

Dew-point measurement of SF6 gas in SF6 CB

6.4.4 Measurement of dew point of SF6 gas in a circuit breaker reveals the change in
the value of dielectric properties of SF6 gas. Dielectric properties of SF6 dew get
changed with time due to mixing of impurities like moisture, decomposition products
of SF6 gas viz. hydroflouride lower valence sulphur fluorides etc. The ingress of
moisture in SF6 gas after filling in CB and during O&M could be due to:

Exudation of moistures contained during manufacturing from insulation

materials used in circuit breakers.

Permeation of moisture through sealed sections viz. gaskets O rings etc.

In the event of presence of moisture in SF6 it gets hydrated to produce highly

reactive H2SO3 and HF (hydrogen fluorides). These chemicals results in
degradation of insulation and corrosion in the interrupting chamber. As such
monitoring of moisture content in SF6 is considered to be very important.
Chemical reactions taking place during moisture control conditions are given
below:

(a) When moisture density is low

SF4 + H2O ................. SOF2 + 2 HF

SOF2 + H2O ................ SO2 + 2 HF

(b) When Moisture density is high

SF4 + 3H2O ................ H2SO3 + 4 HF

2SF2 + 3H2O ............... H2SO3 + 4 HF

Sulphur oxifulorides, hydrogen fluorides and H2SO3 formed during these reactions
attack the materials containing silicon-dioxide (SIO2) viz. glass / porcelain. Primary
and secondary decomposition in the presence of moisture forms corrosive
electrolytes which may cause damage and operation failure.

Testing procedure

A typical arrangement for dew point measurement is given below in Figure 5.

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 (Figure 5)

Make the connection to the kit from circuit breaker ensuring that regulating valve is
fully closed at the time of connection of the dew point kit. Regulate the flow rate of
SF6 (0.2-0.5 L/minute) as per IEC 480, the value of the dew point is observed till it
becomes stable.

Note.: If the regulating valve is provided at the outlet of the dew point kit then dew
point value for rated pressure are to be monitored.

Frequency of Dew Point Measurement

The discharge of moisture from the organic insulating material is faster initially and
the rate of release becomes almost negligible after 4 to 5 year of commissioning, and
thereafter moisture entry in the CB is through permeation. Recommended frequency
of dew point measurement is as given below:

First time at the time of commissioning

After six months

After one year thereafter

Once in two years

EQUIPMENT RECOMMANDED: SHAW MOISTURE METER

Monitoring of Dew Point Values

Dew point of SF6 gas varies with the pressure due to the fact that saturation vapor
pressure decreases with increase of SF6 pressure. Dew point of SF6 at higher
pressure is lower than the dew point at atmospheric pressure. Table given below give

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the value of dew point at rated pressure and at atmospheric pressure for various
makes of CBs.

Sl.No. Make of CB Dew point at rated Dew point at Remarks

pressure (Min. Atmospheric
C) Pressure
(limit) (Min
C)

-15 - 36 At the time of

commissioning

1. BHEL
-7 - 29 During O&M

-5 - 27 Critical

-- - 39 At the time of
commissioning
2 M&BG

-- - 32 During O&M

- 15 - 35 At the time of
commissioning
3 CGL

- 10 - 31 During O&M

- 15 - 35 At the time of
commissioning
4 ABB

-5 - 26 During O&M

-15 -36 At the time of

commissioning

5 NGEF
-7 - 29 During O&M

-5 - 27 Critical

Dew Point Measurement of Air in ABCB

The dialectic properties / arc quenching properties of dry air do get change with the
aging of CB and quality of air deterioration if moist air travel to the interrupting
chamber. This will lead to deterioration of internal insulation and resulting in
unsuccessful arc quenching. It is therefore necessary to carryout measurement of

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dew point of air in ABCBs. The permissible limits of due point of ABCB is given in
Section 7.

Other Condition Based Maintenance Techniques

Besides the above mentioned condition based techniques, the other techniques
adopted includes monitoring of trip / close coil current, coil current measurement,
SF6 gas/air leakage test rate and operating mechanism medium oil/air pressure.
Friction in the plunger movement gap between the plunger and the pin of the coil
assembly are reflected in the recorded current values / wave shapes. Leakage rate of
SF6 gas indicates healthiness of the ceiling system, O ring and strength of cementing
joints. SF6 gas leakage upto 1% per annum is considered to be within acceptable
limits.

Operation Lockout Checks for CB

Following operation lockout checks are carried out:

a) SF6 gas pressure lockout:

Low pressure alarm

Operation lockout alarm

b) Pneumatic operating system lock-out

Compressor star / stop switch

CB auto reclose lock-out switch

CB closing lockout

CB operation lockout

Mechanical closing interlock (applicable for air blas CBs)

c) Hydraulic operating system lockout

Pump start/stop

CB auto re-close lockout

CB closing lockout

CB operation lockout

Evaluation of Test Results

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a )SF6 gas pressure lockout: All the SF6 gas pressure switches
settings should be checked and corrected with ambient temperature.
Settings of SF6 gas pressure switches should be within + 0.1
bar/Kg/cm2 of the set value (after taking into account the temperature
correction factor).

b) Air pressure lockout: All the air pressure switches settings should be
checked and corrected and should be within + 0.1 bar/Kg/cm2 of the
set value.

c) Oil pressure lockout: All the oil pressure switches settings should be
checked and corrected and should be within + 0.1 bar/Kg/cm2 of the
set value.

GO TO TRANSFORMER
TESTING

CIRCUIT BREAKER
TRANSFORMERS CT/CVTS SURGE
ARRESTERS

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