TESTING OF CIRCUIT

BREAKERS
A.K.Tripathy
Former DG CPRI, Advisor
Research Silicon Institute
of Technology

Testing is done to evaluate the

Performance of the equipment
TESTING REQUIREMENTS OF CIRCUIT BREAKERS

The performance of a High Voltage Circuit Breaker is evaluated
in terms of its capability to
Carry rated current without temperature going beyond limits
Carry the short circuit currents
Interruption of the circuits involving
Heavy fault currents due to short circuits
Short line faults or kilometric faults
Line currents under out of phase conditions.
Closing on faulted circuits
Switching of capacitive currents: and
Switching of magnetizing and small inductive circuit currents

Testing is madatory
What Tests..?

Routine tests
Type tests
Special tests
Acceptance tests

Routine Tests

3.1.1 Measurement of no load timing:

No load opening time, closing time, contact

travel characteristics like velocity are
measured for the circuit breaker. They are
very essential parameters in determining
the condition of the contacts, operating
mechanism of the circuit breaker

Contact travel
Significance of contact travel and velocity
measurement:
This could easily be considered as the most
important function being monitored. It provides
dynamic information about the operating
components of the circuit breaker as a whole
including not only mechanical links but also the
interrupter contacts. The information that can be
extracted from these measurements is always
extremely valuable for judging the overall status of
the circuit breaker and this is one of the simplest
activities to monitor.

Signature comparison
From the measured travel
characteristics by comparing the
new data to a base line
signature for the specific circuit
breaker it should be possible to
infer not only deterioration of
linkages, but increased friction
that could mean lack of proper
lubrication and or deterioration
of bearings

Type Tests
TYPE TESTS
The various type tests as per the latest standard 62271-100(2003) are
listed as follows
Dielectric tests
RIV tests
Measurement of resistance of the main circuit
Temperature rise tests
Short time withstand and peak withstand current test
Electromagnetic compatibility tests
Mechanical operation tests
Short circuit test duties for terminal faults
Short line fault test
Out of phase making and breaking tests
Capacitive current switching tests
Small inductive current switching is covered under IEC: 61233(1994)

Strength to withstand over

voltage
1 DIELECTRIC TESTS:
Dielectric tests mainly comprise of lightning impulse test and one
minute power frequency high voltage withstand test. Both these tests
are carried out as per the guidelines given in IEC-62271-100 and IEC:
60694.These tests are conducted to verify the overall dielectric
integrity of breaker. Switching impulse tests, artificial pollution tests
and partial discharge tests are however optional tests.
Power frequency tests : Conducted on a clean new circuit breaker, the
test voltage varies with circuit breaker rated voltage. The test voltage
with a frequency between 15-100 Hz is applied as follows: (i) between
poles with circuit breaker closed, (ii) between poles and earth with
circuit breaker open, and (iii) across terminals with circuit breaker
open.
The voltage is gradually increased and maintained at test value for 1
minute.
For outdoor circuit dry and wet tests are conducted.

Against impulse
2 IMPULSE TESTS
In this test impulse voltage of
standard wave shape of 1.2/50
microseconds and magnitude is
applied to the breaker.

Temperature Rise

TEMPERATURE RISE TEST

Verification of the temperature rise limits is by a type
test that is mandatory for each design of circuit
breaker. The tests should be made on an
arrangement of the breaker, representative of its
type, carrying a current not less than it s rated
normal current, and without exceeding the limits of
temperature rise specified.
This test is carried out to verify the rated current
carrying capability of the breaker continuously
without giving rise to abnormal temperature rise, by
simulating test conditions close to service conditions

Contact Resistance
MEASUREMENT OF RESISTANCE OF THE MAIN CIRCUIT

Important in deciding the contact condition of the breaker.
The resistance across the closed contacts before and after
temperature rise test and short circuit tests shall be
recorded as reference value for routine production and
testing.
Circuit breaker contacts must first be able to carry their
assigned continuous current rating, without overheating, or
deteriorating and must do so within reasonable limits or
power consumption. In addition, during short circuit
conditions, they must be able to carry large currents for
some specified periods of time, and again they must do so
without deteriorating or arcing.

Mechanical Operation
MECHANICAL OPERATION TEST
The performance of the circuit breaker is
undoubtedly entirely dependent on the correct
behaviour of the mechanical components. In
order to have electrical operations in life it is
important to have long mechanical no-load life.
As per the new standard the breakers are
classified as class M1 suitable for performing
2000 no-load mechanical operations and class
M2 suitable for performing 10000 no-load
mechanical operations

Gas Density Supervision

SF6 tightness and gas density supervision of high voltage
circuit

breakers:

. The gas density is checked on the circuit breakers with a density
monitor. Different events can lead to density variation detected by
density monitor

SF6 leakage itself
SF6 adsorption by filtering products at low temperature,
Rapid and wide variations of temperature

Only the first event corresponds to an actual failure. The second and
third correspond to physical modifications inside the breaker but they
do not have to lead to a signal from density monitor.

Leakage of Gas
The possible origins and causes are various for the
SF6 leakage, for example

- Corrosion near a seal
- Damage of a seal,
- Impurity under a seal,
- Porosity of metal component (casting, brazing),
- Break or crack of the enclosure (porcelain),

Is leakage a failure?
It must be noticed that the false SF6 leakage can
exist; it is due to physical event like important
temperature variations, due to failure of density
monitor, also due to incorrect refilling after
maintenance. Moreover every equipment has an
accepted failure rate which allows a minimum
interval to be determined during which
replenishment will not be required (typically 10-20
years). If the leakage exceeds this accepted rate,
resulting in a need for more frequent replenishment,
then this would be considered as a failure.

Failure modes
The main cause of the major failures and minor failures is the
leakage of SF6, oil or air.
In Hydraulic operating mechanism oil leakage is the major problem
and in pneumatic Operating mechanism air leakage is the major
problem.
The major causes for the SF6 gas leakages are defective leap seal,
poor gaskets, defective gas density monitor etc. Most of these
failures occur due to manufacturing problems as it can be verified
from the experiences of the utilities.
The oil leakages in hydraulic operating mechanism are from
pipings, rusting of pipes, sludge formation, problems due to air
bubbles in oil, tripping of hydraulic pumps etc. The air leakages are
due to the defects in air pressure valves etc.
Most of these defects are due to manufacturing problems. Poor
maintenance schedule is also responsible for most of these failures

Current Tests
SHORT TIME WITHSTAND AND PEAK
WITHSTAND CURRENT TEST.
This test introduces mechanical forces in
the breaker particularly during the initial
peak current. The contacts tend to open if
the contact pressure is not adequate. The
duration of test is generally one second
and in some special cases it is three
seconds

Short ckt. tests

SHORT CIRCUIT TEST DUTIES FOR TERMINAL FAULTS.]

Methods of Testing :
Broadly two methods of testing are prescribed:
Direct Testing
- Using one source for current
and recovery voltage.
Synthetic Testing - Using separate sources for current
and recovery voltage.

Three Phase Testing

Complete 3 Phase Testing:

It is obvious that 3-phase test is the best as

the circuit breaker is properly stressed and
not over stressed as is often the case in
single phase testing. However due to
limitations of the testing stations, IEC
allows single pole testing as well as unit
testing provided certain conditions are met.

Single pole Testing

Single Pole Testing:

According to this method, a single pole of a 3 pole

CB is tested by single phase method applying to
the pole the same current and the same power
frequency voltage which would be impressed upon
the most highly stressed pole during 3 phase
making and breaking by the complete 3 pole CB
under corresponding conditions. Here the power
requirement is less, circuitry is less complicated,
the time required for test set up and reconditioning
are less

Unit Testing
Unit Testing :
When a testing laboratory is not equipped
to test even on complete single pole of a
circuit breaker, tests are carried out on one
or more Units of a pole. This is known as
Unit Testing. Hence the power requirement
is further reduced. However it is essential
that the units are identical with proper
voltage distribution between the units.

Short Circuit Test Procedure

Basic Short Circuit Test Procedure:

Requirement of Standards for Transient Recovery
Voltage (TRV) and Power Frequency Recovery Voltage:
The system or circuit TRV is modified by the circuit
breaker due to the arc characteristics of the interrupting
media and by the use of opening resistors, grading
capacitors, surge capacitors etc,. The unmodified TRV
referred to as inherent TRV is taken as a standard for
testing of the circuit breaker. The inherent TRV is a1so
known as Prospective IRV. In laboratories the TRV is set
using lumped R, L, C elements.

TRV 2 and 4 parameter

The inherent or prospective TRV envelope of the test circuit

should lie above the specified TRV envelope and should not
cross the envelope at any point (as shown in Figure 3.2.7.5).
During a short circuit test it is desirable to record the actual test
TRV.

Figure - 3.2.7.5 : Prospective TRV envelope of the test
circuitandthespecifiedTRVenvelope,

Power Frequency test

voltage

The Power Frequency Recovery

Voltage shall not be less than 95% of
the specified value and shall be
maintained for at least 0.1 second.

Short circuit Test duties

BASIC SHORT CIRCUIT TEST DUTIES

TEST DUTY- T10
This duty demonstrate the capability of the breaker when
it is connected on the primary circuit of a transformer
and fault occurs on secondary side. The fault current is
limited by high impedance of the transformer and hence
the current for this test is 10% of the rated short circuit
current. Owing to high inductance of the transformer the
rate of rise of recovery voltage is very high, which is
generally depends on the natural frequency of the
transformer. The dielectric failures during recovery period
are very common while carrying out this duty.

T30 Test duty

TEST DUTY-T30
In an interconnected system only one source out of bunch
feeding the fault represents this duty. The current in this
duty is 30% of rated short circuit current and TRV
conditions are same as that of T-10 duty.

TEST DUTY T60
This duty is specified to prove the breaker capability to
withstand the moderate thermal as well as dielectric
stresses. Hence the short circuit current is increased to
60% of its rated value and TRV stresses are also reduced
compared to the T-10 and T-30 duties.

T100 test duty

TEST DUTY T100s
This duty demonstrates the capability of breaker to re-close
on fault following interruption of fault current and ability to
complete the rated operating sequence assigned. The
sequence may be O-3min-CO-3min-CO
or
O-0.3sec.-CO-3min-CO
Or
CO-15sec.-CO
The interruption current will be equal to its rated short
circuit breaking current. The TRV is full TRV specified in the
standard.

T100a duty
TEST DUTY T100a
This duty verifies the interrupting capability after maximum
arcing conditions and verifies sufficient operating energy.
Maximum arcing occurs due to the fact that the breaker
clears the current with offset due to the dc component. In
the event of fault the contact separation may take place at
a moment close to zero in the minor loop so that final
extinction takes place only after arcing during full
subsequent major loop. The arc energy seen by the breaker
will be larger than compared to the case where extinction
takes place only after arcing during minor loop. The
duration of major loop for different time constant of the
system is specified in the standard.

DOUBLE EARTH FAULT AND SINGLE

PHASE EARTH FAULT:
Double earth fault and single phase test are
applicable for 3-phase breakers intended for
use in isolated neutral and solidly earthed
neutral system respectively, with three poles
coupled mechanically and fitted with
common operating release. These tests are
conducted on any one of the three poles,
farthest from the symmetrical mechanism to
verify the operation of the breaker not
adversely affected by the unbalanced forces
produced.

SHORT LINE FAULT TEST:

. By experience and computations it has been
found that when a fault occurs on a transmission
line a short distance from the C.B. terminals, an
onerous fault condition results with a TRV of
extremely high RRRV. This is due to the travelling
wave reflected between the C.B. and the fault
location. The peak value and the frequency of
oscillation of the saw tooth transient are directly
and inversely proportional respectively to the
distance of the fault from the C.B. terminal. There
is a critical length of the line at which the breaker
is most severely stressed.

Test as per IEC

IEC recommends these tests to 3 phase CB's
designed for direct connection to overhead
transmission lines and having rated voltage of
52 kV and above and a rated short circuit
breaking current exceeding 12.5kA. For rating
and testing purposes, it has been agreed
internationally to consider only a short line
fault occuring from phase to earth in an
earthed neutral system, the severity of this
being sufficient to cover other cases.

Short line fault:Contd

Two test duties L90 and L75 each
consisting of the rated operating
sequence confined to opening
operations only at 90% and 75% of
the rated S.C. breaking current and
appropriate respective TRV, % dc
component at contact separation
shall not exceed 20%.

 This test is applicable for breakers above 52 kV

class and duty seems to be more onerous .This
duty represents the situation where the fault
occurs close to the line side terminal of the
breaker ( a range of about 1 to 8km). The line side
recovery voltage after current interruption, which
is a saw tooth wave resulting from series of
traveling waves reflected back and forth along the
line between the circuit breaker and the fault
point, causes a sharp increase in rate of rise of
recovery voltage in the initial stages represented
as ITRV .

OUT OF PHASE
SWITCHING DUTY
:
Out of phase conditions occur in the
interconnected systems due to overloading,
short circuits or synchronizing faults. The
coupling breaker in this type of system has
to clear fault currents between two sections.
To verify this out of phase switching duty is
performed at higher recovery voltage, the
magnitude of which depends on method of
earthing of the system

CAPACITIVE CURRENT
SWITCHING TESTS:

.
Switching ON of capacitor bank results in inrush current,
the natural frequency of which depends up on the
inductance limiting this current and capacitance of the
capacitor bank. Switching OFF of capacitor current may
results in restrikes after opening due to current
chopping phenomena. As per the existing standard
62271-100(2003) the HT breakers are classified based
on their numerical probability of restriking during their
entire specified duty. Class C1 breakers exhibit low
probability of restrikes and Class C2 exhibit very low
probability of restrikes.

LOW INDUCTIVE CURRENT

SWITCHING TEST

.
The interruption of low inductive currents involves switching ON
and OFF of transformer no-load currents, induction motor
switching and shunt reactor switching.
Switching ON of induction motor at standstill and shunt reactors
will produce traveling waves which will be reflected back from the
load (induction motor or shunt reactor) due to high surge
impedance and appear as high voltage spikes, the magnitude of
which depends upon the ratio of surge impedance of the load to
that of the cable or line.
Over voltages are inevitable due to current chopping while
switching OFF these low inductive currents. The magnitude of
these over voltage depends on voltage before chopping,
chopping current and surge impedance of the load and the
system.