CONDITION BASED RANKING FOR RELIABILITY CENTERED
MAINTENANCE OF CIRCUIT BREAKER
P.K.Pattanaik
Deputy Manager (ELECT.)
Orissa Power Transmission Corp. Ltd. Burla
1. SYNOPSIS
This paper deals with the concept of a quantifiable
condition assessment, by considering the data of
the circuit breakers in service. By the use of the
available advanced techniques/models/methods,
the on-line condition data of circuit breakers are
obtained. Similarly by the available laboratory set
up as well as testing methods, different other data
about the condition of circuit breakers are also
obtained. The data bank is formed with the on line
field data and testing analysis laboratory data. By
these data (Values from different Test methods),
the GMD (Geometric Mean Data) is prepared to
obtain the condition code of the equipments. The
other aspect of the equipment is its residual life
expectancy. This factor also plays an important role
to determine the condition code of the equipment.
This factor is called Survive factor (  ).
Now, by considering the history, commissioning
data, present technical and non-technical
parameters of the circuit breakers the condition
code is prepared. This code is used to determine
the ranking of the circuit breakers for
maintenance.
The detail preparation of Breaker Condition Code
(BCC) and application of the same for finding the
Condition Based Rank (CBR) of the circuit
breakers have been focused in this paper.
This technique of obtaining CBR helps to develop
CBM (Condition Based Maintenance), which
becomes economical in comparison to the old
method i.e. TBM (Time Based Maintenance).
Using this program, the circuit breaker that
required for immediate maintenance can be
identified easily. So by focusing the identified
breaker, the reliability will be improved and
maintenance cost can also be reduced. In actual
practice the BCC should be prepared annually for
in service equipment to bring a reference for
CBM. But sometimes the data that required from
testing methods do not become available in time.
Because for few tests, the equipment requires
complete shut down, which demands proper
planning for rescheduling of system loads. So
instead of annual preparation of BCC, the same
can be prepared once in two years according to
the suitability of system load availability.
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2. INTRODUCTION
Electrical equipments like Circuit Breakers (CB),
Current Transformers (CT), Voltage Transformers
(VT), Power Transformers (PT) etc are
considered as the important and costly assets for
generation, transmission, and distribution
systems. So, the condition assessments of these
high-voltage electrical equipments have become
the catchword for every electrical utility.
During service condition, due to change of
environments like voltage, current and frequency
parameters, the electrical equipment are
subjected with electrical, chemical and
mechanical stresses. The condition of the
equipment gets deteriorated. According to the rate
of deterioration, the performance and efficiency of
the equipment is also affected. So it needs
continuous condition monitoring of the materials.
The different types of conditioning monitoring
methods are available like 1.On Line Condition
Monitoring 2. Off Line Condition Monitoring etc..
From these methods, the necessary data and test
values are collected for the preparation of
condition code. For thecae of circuit breaker, the
available and suitable testing methods and
conditioning practices are considered for the
preparation of conditioning code, called Breaker
Condition Code ( BCC )
3. BREAKER CONDITION CODE (BCC)
From the available advanced
techniques/models/methods the condition data of
the equipment are obtained. To study the status
/condition, the following steps/methods are
usually attempted.
 Routine/Annual Testing.
 On line condition Monitoring
 Off line condition monitoring
 On line test analysis
 Off line laboratory analysis.
The results such obtained are usually compared
with the previous factors, by considering the
standards, reference data etc. of the equipment.
Then the data bank protocol is used to determine a
factor called GMD (Geometric Mean Data). The
other aspect of the equipment is its residual life
expectancy. This factor also plays an important role
to determine the condition code of the equipment.
This factor is called Survive factor (  ).

The fundamental theory of obtaining the
equipment condition code can be formulated by
the following rules.
Breaker Condition Code (BCC) = D 
D = Geometric Mean Data (GMD)
 = Survive Factor
3.1 GMD (Geometric Mean Data)
It is the Geometric mean of the Data factors, such
obtained from the different test results, analysis
and methods of the equipment.
GMD = (D1 x D2…….. Dn)1/n
D1 = Data Factor of the 1st type test result.
 Obt . Data  Comm . Data 
= (Normal Current of the Circuit Breaker)
(Standard Data) 2
D2, D3 ………… Dn = Data Factors for 2nd, 3rd, nth
Type of test results.
It may be noted here that determination of GMD,
completely depends upon the choice of the utility.
According to the availability and practice of the
utility, the quantum of data factors is decided for
obtaining the condition code. The accuracy of the
code depends upon the number of the data
factors i.e more the data factors taken into the
account, increases the accuracy of the condition
code.
3.2 Survive Factor (  ):
Before commissioning of the equipment, generally
different pre-commissioning tests are carried out.
After obtaining the successful and suitable test
results, the equipment is taken into the service.
But after commissioning and during service
condition, due to the change of different
parameters the survival of the equipment is
affected. By considering these parameters the
condition code of equipment is determined. The
factors are described below.
 Loading Factor (L).
 Service factor (S)
 Temperature factor (T)
 Fault factor (F)
 * Other Factors (K)
The survive factor (  ) is obtained by taking the
5th root of all the possible products of five factors
such described above.
δ  (LSTFK * )1/5
 The concept of obtaining this factor depends
the choice and availability of the deciding
factors of the utility. It is also obtained by
taking the nth root of all the possible products
of ‘ n’ factors as required for deciding this
factor (K).
3.2.1 Loading Factor (L)
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The performance and efficiency depends upon
the loading pattern on the equipment. For the
case of circuit breaker the loading on the
equipment is considered as the pattern and the
magnitude of the current flow through the breaker.
Every circuit breaker is rated with certain value of
Normal current (Normal current of 145 KV Circuit
breakers is 2000 Amp.)
In actual practice, the loading pattern on the
Circuit breaker depends upon the requirement of
the circuit behavior. So as per the loading of the
current this factor can be decided to determine
the survive factor. It is calculated as follows.
(Ave. Current Flow from the Comm. Date)
L=
3.2.2 Service Factor (S)
The equipment suffers to withstand numerous
stresses, while it is kept in working condition.
These stresses are of thermal, electrical and
mechanical in nature and cause the deterioration
of the equipment. So, for calculation of survive
factor, the period of working condition and the
period of Non-working condition like maintenance
condition and Shut down Condition are also to be
considered. It has been formulated below.
(Total Time Period, that equipment in
Service)
S=
(Total Time Period, not in service or
period of maintenance)
3.2.3 Temperature Factor (T):
Ageing characteristic of oil/paper insulation mainly
depends upon the temperature such developed
inside the equipment. The origin of temperature
rise, results due to abnormal loading, imperfect
design and environmental conditions on the
equipment. For the case of Circuit breaker the
flow of current plays the role of loading pattern on
the system. So, temperature factor is also
considered for obtaining the survive factor and
described as follows:
( Ave. Min. Temperature from the
comm.. date )
T=
( Ave. Max. Temperature from the
comm.. date )
3.2.4 Fault Factor (F): -
The Short Circuit fault (External close in short
circuit) and continuous over loading situation of
equipment, the current on the equipment
becomes more than that of the rated value.
Because of this, the Radial and Axial forces act
on the equipment and result the deterioration of
the condition of the equipment.
The magnitude of the fault current depends upon
the S.C. Fault MVA of the system. Because of
the use of suitable protective relays the rating of
deterioration does not become severe and
remains within the limit of design value. But for
every situation of fault tripping, the condition of
equipment is hampered.
So, Fault factor also adjudges the quantum of
survival and calculated as follows:
(No. of fault tripping x Fault Current)
F=
(Short Time Current withstanding
Capacity)
3.2.5 Other Factor (K)
The decision of using this factor for electrical
equipment in addition to the above-described
factors depends upon choice/practice of the
utilities/organizations. Sometimes according to
the type of equipment, different other factors are
also considered for Survive Factor. For example,
flux factor may be taken into account for the
equipment like generator, transformer. For the
case of Circuit Breaker the characteristics of
Insulation can be taken as the additional factor for
calculation. For oil insulation, the factors like I.R
Value, BDV and P.I of the same are considered
for the calculation. # But for other quenching
medium like SF6 gas, vacuum etc.. this factor is
not taken into account.
# When this factor is not taken into the
calculation, the survive factor is calculated
with the available four factors and the fourth
root is accordingly taken to calculate the
survive factor(  )
4. CONDITION BASED RANKING: -
A data Protocol is formed by the logarithms of the
data that made suitable from different
test/methods/analysis used by the organizations.
Now the BCC that prepared by the data protocol
becomes helpful for ranking the equipment to
declare for maintenance. So, this new method of
CBM (Condition Based Maintenance) becomes
economical in comparison to the old method i.e.
TBM (Time Based Maintenance). Moreover
because of reduced budget, reduced working
personnel and growing of electrical equipment
population the utilities fail to maintain the
condition of the equipment in time, for which the
maintenance interval time increases.
Unfortunately as maintenance interval is
increased, the equipment reliability becomes
compromised. The best approach to overcome
this shortcoming is CBM (Condition Based
Ranking) Using this program, electrical equipment
that required for immediate maintenance can be
identified easily. So by focusing these identified
equipment, reliability will be improved and
maintenance cost can also be reduced. In actual
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practice the BCC should be prepared annually for
in service equipment to bring a reference for
CBM. But sometimes the data that required from
testing methods do not become available in time.
Because for few tests, the equipment requires
complete shut down, which demands proper
planning for rescheduling of system loads. So
instead of annual preparation of BCC, the same
can be prepared once in two years according to
the suitability of system load availability.
4.1 Advantages: -
 Reliability of the equipment rises.
 Maintenance cost becomes less.
 Maintenance intervals are increased.
 Maintenance as per requirement is done.
 Life of equipment increases.
 Preparation of Data Bank becomes helpful for
future reference.
5. PRACTICAL STUDY OF BCC
For practical study and preparation of BCC, the
circuit breakers of the selected zone are taken
into account. Preferably the equipments of same
make with same specification should be selected
for the study. For example the equipments on 220
KV systems should be categorized under a
particular selection. Similarly the other voltage
class equipment to be considered under other
selection. Sometimes the similar rating
equipments are not made available for the
comparison. Such situation can be managed by
adopting the proportionate value for the
calculation.
6. CONDITION ASSESSMENT TECHNIQUES
Every circuit breaker has different mechanism
that needs to be maintained for fault free
operation. On the basis of working operation the
maintenance practice the circuit breaker can be
classified with the following categories.
1. Maintenance of Electrical Controlling Circuit
2. Maintenance of Operating Mechanism
3. Maintenance of Quenching medium
4. Maintenance of Other supporting Mechanism
6.1 Maintenance of Electrical Controlling
Circuit
The electrical controlling circuit includes different
operational circuit for correct working of the circuit
breaker.
 Electrical Closing circuit ( Remote and Local )
 Electrical Tripping Circuit (Remote and Local )
 Protection Tripping Circuit
 Trip Coil Supervision Circuit
 Pole discrepancy operational circuit
 Anti-Pumping Operation circuit
 Auto Reclosure Circuit.
All the electrical controlling circuits as described
above include different electrical items like
contactors, relays, switches etc... For correct
operation of the circuit, these items are needed to
be monitored for its healthiness in the scheme.
The monitoring and maintenance practice of
these items does not come under the BCC.
Rather it is covered under the fault finding study
of the circuit. These items do not get disturbed
physically for the operation of the scheme. But
due to looseness or wrong voltage feeding of the
voltage the electrical items may fail to work. For
such situation, the correct supervision, diagnosis
and proper monitoring can help to rectify the
problems in the circuit. So preparation of the code
(BCC) for these elements do not hold good.
6.2 Maintenance of Operating Mechanism
Operating mechanism includes the mechanical
items like springs, cylinders, cams, pistons,
latches, pins etc.. This mechanism also includes
electrical items like Closing Coil and Tripping
Coils etc.. According to the type of the Circuit
Breaker the operating medium is classified as
follows
 Pneumatic mechanism ( Air Pressure is used
for the operating medium)
 Hydraulic Oil ( Oil pressure is used for the
medium
 Spring-Spring Mechanism ( Potential energy
of the Springs are used as the medium )
The correct adjustments, settings and installations
of these items under the operating mechanism
provide the smooth operation of the circuit
breaker. But due to mechanical movement of
these items, different wear and tear results in due
course of working operation. So the condition
monitoring of the mechanism can provide the
status of the equipments associated in the
operation.
Some of the techniques that to be used for
condition assessment of Circuit breakers are
stated below.
 Dynamic Contact Resistance Measurement
( DCRM)
 Contact Travel Measurement
 Contact Resistance Measurement
 Tan delta Measurement
 Speed and time Measurement of Main and
auxiliary Contact
 Trip/ Close coil Current and resistance
measurement.
 Mechanical Operation Test (Vibration
Measurement)
These described techniques are the usual
available methods for the status measurement of
the circuit breakers. But different Power utilities
adopt their own selected and suitable methods for
condition assessment of Circuit breakers. So the
particular and defined methods as described
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above can not be exactly selected for the study.
As per the choice and available methods of the
concerned utility, the BCC for the set of Circuit
Breakers can be chosen for the study.
6.2.1 Notes on Dynamic Contact Resistance
Measurement
DCRM is the technique for the measurement of
Contact Resistance of the Main Contact during
the operation of the Circuit Breaker. The
Resistance versus time data provides the useful
information on the condition monitoring of the
circuit breaker. The data such obtained can be
compared with the pre- commissioning data of the
circuit breaker. The standard data can also be
referred to obtain the Data factor of the particular
breaker. Finally the obtained data factor can be
used for the preparation of GMD and BCC of the
breaker.
6.2.2 Notes on Contact Travel Measurement
Circuit Breaker Analyzer is used to determine the
contact travel of the operating rod and also the
actual travel of the main insertion contacts. The
set of transducers and fixtures are fitted to the
operating mechanism or in the interrupting
chamber to record the contact travel. From the
data obtained the other factors like Contact
velocity, acceleration etc.. are also calculated for
the comparison with the pre-commissioning data.
Similarly by the use of standard values, obtained
value and commissioning value, the data factor
for preparation of the GMD and BCC can be
calculated.
6.2.3 Notes on Operating Time Measurement
The disturbance and displacement of the
elements used in the operating mechanism during
the operation of the breaker affects the operating
time of the breaker contact. The closing, opening
(Tripping) and Close Open (CO timing) of the
contacts are changed. So by the measurement of
the timings of the contacts, the intensity of the
disturbance can be assessed. This method of
monitoring and the values such obtained can be
used for the preparation BCC. According to the
data, the problems in the mechanism like
alignment of contact, adjustment of moving rod
and replacement of faulty parts can be attended.
It is also important to measure the timings of the
auxiliary contacts, because these contacts are
also taken in the electrical operating circuit. The
adjustment in the link rod can manage the
problem of the auxiliary contact.
6.2.4 Notes on Trip/ Close coil Current and
Resistance measurement.
The operating coil mechanism contains mainly of
housing with an electrical coil. The operation of
the Coil and consequent operation of the
mechanism depends upon the current in the coil
and the movement of the plunger upon the latch
of the operating mechanism. Sometimes due to
incorrect current through the coil or mis-
adjustment of the gap of the plunger, causes
abnormal operation or non-operation of the
breaker. So the study of the associated
parameters like resistance measurement, current
measurement from correct application of the
supply voltage and the gap measurement of the
plunger can indicate the status of the operating
mechanism. This monitoring method is quite
helpful for obtaining the maintenance requirement
of the circuit breaker.
6.2.5 Notes on Mechanical Operation Test
(Vibration Measurement)
The operation of the breaker and the vibration on
the system can also be considered as one of
techniques for monitoring of the status of the
operating mechanism. The vibration during
closing and opening operation can be recorded by
using accelerometers on the system. The
vibration signature such obtained can be
compared with the reference signature. As per the
variation in the comparison, the problems in the
mechanism like the mechanical malfunction,
excessive contact wear, mis-alignment of
mechanism and problem in damping system can
be detected and corrective action can be taken
accordingly. The data such obtained can also be
used for the preparation of the BCC.
6.3 Maintenance of Quenching medium
Every circuit breaker has certain quenching
medium to puff up the arc developed during the
operation of main contact. According to the use
of this medium, the breaker is named. Usual
quenching mediums are as follows
 Oil Medium
 Vacuum
 SF6 ( Sulfur Hexafluoride)
For higher voltage range, SF6 gas is used as the
arc-quenching medium in a hermetically sealed
chamber. SF6 gas is extensively used now-a-days,
due to its inherent property of immunity to the
climatic and environmental condition. It has other
advantages such as it is electronegative in nature
with high quenching property and high dielectric
strength.
For monitoring of this medium the following
techniques are used
 SF6 gas leakage rate Measurement
 SF6 dew point Measurement
The SF6 gas once filled in the interruption
chamber are needed to be maintained in dry
condition. The leakage of the same if any is to be
arrested properly. The leakage is monitored and
detected by the suitable leakage detector. If
detected SF6 is more than 10 ppm, the joint is
considered as the leaking joint, needs to be
attended for its arrest. Some detector is also
5
available that produces a tuned sound and varies
as per the intensity of leakage. This detection
easily helps to monitor the leakage for quick
rectification.
SF6 is an inert and stable gas, but decomposes
under heavy discharging condition after a long
period of arching. The presence of moisture in the
SF6 gas causes chemical degradation, develops
corrosion in the interruption chamber and affects
the insulation. During chemical reaction some
components like Hydrogen fluoride (HF), H2SO3
etc... are resulted and harmful for the insulation.
As these chemicals cause degradation of
insulation and corrosion in the chamber,
monitoring of moisture content in SF 6 is very
important. The SF6 dew point Measurement
method monitors the availability of moisture
content in the gas.
To maintain the moisture level low now-a-days a
good quality absorbent is used in the apparatus to
remove gaseous decomposed bi-products. So the
quantity of bi-product is remained very low.
6.4 Maintenance of Other supporting
Mechanism
Every Circuit Breaker has some other supporting
equipment to satisfy the working operation of the
system. These equipments need to be maintained
for correct operation also. These items are as
follows
 Different micro switches, operation switches
 Indicators
 Control valves
 Auxiliary switches
 Thermostat, heaters
 Containers, Covers etc..
 Holding Items like screw, clamps, bolts etc…
 Terminal blocks
These items are also to be maintained properly,
because the status of these items also affects the
operating mechanism of the circuit breaker.
7. PREPARATION OF BCC
As per the normal practice it is seen that power
utilities adopt the maintenance techniques as per
the recommendation of the manufacturers or
according to the time schedules, mentioned in the
reference catalogues/manuals. It is also seen that
the maintenance group adopt the maintenance
activities with out knowing the consequence of the
end results. So this method of TBM (Time Based
Maintenance) does not help much for actual
maintenance of the electrical equipments. More
over it is also found that most of the equipment do
not show any abnormality during the normal cycle
of time base maintenance program. So
maintenance of the equipment by the TBM
method becomes useless and costly in
comparison. Now the CBM (Condition Based 8. CONCLUSION:
Maintenance) method becomes advantageous to For preparation of BCC, the survive factor (  )
the TBM. plays an important role. Sometimes for the
determination of its associated factors,
Based on the described theories like GMD, assumptions are taken for the case of any non-
Survive Factor and the involved Condition availability of the data. However the condition
Assessment Techniques, the practical study for Based Ranking (CBR) becomes quite economic
obtaining Condition Code of the Circuit Breaker for the maintenance of the equipment. And also
can be done. becomes helpful to maintain the data bank of the
Breakers.
7.1 Limitation of the BCC
The preparation of BCC does not hold good for
the following conditions.
 By the method of condition Assessment
Techniques, sometimes the values such
obtained become severe and exceed the
allowable limit of the standard. Such severity
condition must be treated separately and the
action towards the maintenance of those
equipments to be attended immediately
without proceeding the CBR (Condition Based
ranking) for the maintenance practice.
 Some of the condition techniques and testing
methods do not provide any absolute
data/value to decide the status of the
equipment. The results obtained directly
decide the working condition of the
equipment.. For such case either the
equipment is declared faulty or healthy. So
the calculation of the BCC does not hold
good.
 Some case recommendations by the
manufacturer and maintenance practice there
in becomes economic as compared to the
BCC method of Condition Based Ranking of
the Circuit Breaker. For such case also this
method does not hold good.