Case study 4

Faulty Moulded Case Circuit Breaker Location: Main switch room; Branch 125A TPN MCCB of Main Switch Board. Fault User reported intermittent tripping of MCCB at main switchboard & suspected the fault was due to harmonics from electronic ballast & unbalanced load. Observation As the floor level of lecture theatre was still under construction for architectural finishes, i.e. furniture & carpeting, only partial lighting circuits were turn on for general lighting. Coincidentally, those lighting circuits were mostly red phase. The main protection of MDB located in the theatre is 125A TPN MCCB & the branch MCB serving the lighting circuits is 60A TPN MCB. Throughout the tripping incidents, none of the MDB protective devices has operated (Refer Fig.1)
Existing MSB To other loads trip
125A TPN MCCB A To Lighting DB

New MDB no trip no trip

125A TPN MCCB B 60A TPN MCB

Fig.1 Illustration of tripping occurrences

Post Fault Synopsis The load measured at the main of MDB was: Red phase 42A, Yellow phase 5A & Blue phase 8A. The unbalanced load should not affect the protective devices thermal tripping element as none of the phase was overloaded. Though the unbalanced load could overheat the neutral conductor if harmonics existed, the protective devices had no protection on the neutral conductor. Based on the recount from user that the switch at MCCB A could not be closed immediately after tripping, bi-metallic thermal tripping was rather obvious. Furthermore, there was no evident of electromagnetic tripping on high fault currents. As the fault was intermittent, the complexity of non-linear loads study was eliminated. Apparently the old breaker (MCCB A) might operate prematurely due to degradation of internal components, such as heater element, bi-metallic strip etc.

PE REPORT LEE KHEE SIONG

I proposed to conduct a thermography on MCCB A but due to cost constraint, the user decided to spend their budget on the replacement of old MCCB A & skip the scanning test. Root Cause For ease of operation, the rear fiberboard was removed for insulation test on submains & checking all cable terminations; the front portion of was unattended.

During the replacement of MCCB A, discoloration was significant on red phase load terminal at the front portion of existing MCCB. There was a small gap between the phase conductor & the connection, i.e. loose contact.

Unfortunately, thorough inspection at MCCB A was overlooked & simple fault was made complicated by theories, fundamentals & the mysterious harmonics. Ironically all parties came to an agreement that MCCBA was faulty, the breaker had tripped in a proper & safe manner that was designed for this purpose.