SUBSTATION COMMISSIONING COURSE

MODULE FOUR CIRCUIT BREAKERS TESTING PROCEDURES

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INTRODUCTION

The electrical commissioning and acceptance testing of electric power systems is essential for the energization of any electrical system for the first time

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INTRODUCTION
Module Four Discuss theory and ratings Safety issues Test equipment operation & hands on testing

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Skills learned in MODULE FOUR: Acceptance testing for Circuit Breakers Operate Breaker analyzer Apply safe work practices Analyze test values Complete test forms

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North American Standards US Standards NEMA ANSI/IEEE IEEE standards are harmonized with IEC IEC are harmonized with IEEE

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Most Significant Standards C37.04 C37.06 C37.09 C37.010 Rating Structure for AC High Voltage Circuit Breakers AC High Voltage Circuit Breakers Rated on a Symmetrical Current Basis Preferred Ratings and Related Required Capabilities Standard Test Procedures for AC High Voltage Circuit Breakers Rated on a Symmetrical Current Basis Application Guide for AC High Voltage Circuit Breakers Rated on a Symmetrical Current Basis
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Rated Characteristics Maximum Voltage Voltage range factor Continuous current Short circuit Symmetrical current Asymmetrical current % DC component Interrupting time Maximum tripping delay
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TRV Transient recovery voltage Withstand voltage Power frequency Lightning impulse Closing and latching current

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Application Considerations Circuit Beaker definition (IEEE C37.100) A circuit breaker is a mechanical device capable of making, carrying and breaking currents under normal circuit conditions and also making, carrying for a specific time and breaking currents under specified abnormal conditions such as those of short circuit

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Maximum Voltage The upper limit of the system voltage for continuous operation Rated maximum voltage: 4.76 kV 8.25 kV 15 & 15.5 kV 25.8 kV 38 kV
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Frequency All North American Beakers are rated at 60Hz Manufacturers to be consulted for operation at other frequencies

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Continuous Current Operating within temperature rise specification Continuous current rating for normal operating conditions Ambient temperature between -30 C to 40 C Installed above sea level and below 1000 m Free of extreme environmental contamination Not affected by solar radiation Short time over current permissible for Motor starting, cold load pick-up, emergency conditions
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Continuous Current Preferred continuous current ratings: 600 A 1200 A 2000 A 3000 A > 3000A required force cooling for indoor metalclad

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Short Circuit Current - Symmetrical Rated constant symmetrical current rating in KA rms Synonymous with SF6 and vacuum breakers Older breakers rated in constant MVA (oil, airmagnetic) Isym = (Rated Isc) x (Rated Vmax / Vop) or Isym = MVA / (Vop x 3)

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Voltage Range Factor K Multiplier factor for symmetrical current rating Modern / future breakers will be rated at K = 1 Factor K to be eliminated in future standards Breakers to be rated on a constant symmetrical current rating K Factor to address older breaker rated in constant MVA

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Short Circuit Current - Asymmetrical Asymmetrical current rating Symmetrical rating multiplied by S Based on % DC rating for modern breakers %DC using standard decay curve for X/R = 17

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% DC % DC rating related to the speed of the breaker Fast breakers interrupt more DC current Peak currents can be 2X symmetrical peak value Symmetrical current rides on decaying DC current DC current decay based on X/R of system Slow breakers interrupt less DC current Current falls towards symmetrical value

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Short Circuit Current - Asymmetrical The standard DC decay time constant can be calculated by: = (X/R) / (2 f) = 45 msec

for X/R ratio of 17,

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Short Circuit Current - Asymmetrical The asymmetrical interrupting rating is calculated by: Iassym = Isym x S S = [ 1 + 2 (%dc/100)2 ] Iassym = Isym x [ 1 + 2 (%dc/100)2 ]

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Interrupting time Maximum allowable time between Energization of trip coil and arc extinction time Rating based on: Rated control voltage Maximum opening mechanical pressure Arc extinction in all 3 poles

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Permissible Tripping Delay T Why Delay tripping ? Breaker contacts works less, less wear and tear Trade-off between increased interrupter / contact heating and speed Contact heating a function of I2t

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Closing and Latching Current Asymmetrical current rating for closing unto a fault Enables downstream protection to operate Can be man made faults leaving grounds on

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Dielectric Withstand Power Frequency (60 Hz) dielectric test 1 minute time duration Part of total lightning impulse tests Trivia: Rate of rise at 2%/sec of the 75% level Test voltage reached between 60-70 sec, 90 sec OK

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Lightning Impulse Withstand Voltage Series of factory dielectric tests Power frequency test; dry (1 minute), wet (10 sec) Full-wave lightning impulse Chopped wave lightning impulse Switching impulse Tests the insulation system Phase to ground Across open contacts
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TRV Transient Recovery Voltage Voltage generated across open contact after current interruption Fast rise time and can peak at 2X ac crest value Dielectric must not flash-over after contact have stopped and parted Contact separation is greater than required for current interruption Rated in dV/dT or kV peak / time to peak

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Nameplate Data Name Type Serial number Year of manufacture Maximum voltage Continuous current Frequency Withstand voltages Duty cycle Interrupting time Short circuit current % dc Short time current duration

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Nameplate Data Norm. operating pressure Min. operating pressure Volume of oil per tank Weight Instruction book number Part list number Capacitance current switching Out of phase current switching
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Mechanism Nameplate Data Close coil volt. range Trip coil volt. range Closing / closing current Motor current / voltage Low pressure alarm / lock out pressure operating points Wiring diagram number Instruction book number Parts list number
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Accessories Nameplate Data Shall include identification and pertinent operating characteristics

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Instructions and Warning Signs Essential markings should be provided Operating devices and positions Instructions for operation Special precautions Environmental warnings
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Types of circuit Breakers Air magnetic Oil Air blast SF6 Vacuum Air Magnetic Obsolete technology for MV class Uses air as the dielectric In use until 1975

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Types of circuit Breakers Air magnetic Oil Air blast SF6 Vacuum Oil (tank / minimum / bulk) Obsolete technology except for low voltage applications Cease production is the 1990s Uses oil as the dielectric Up to 230 kV Minimum oil was a replacement for airmagnetic in MV class
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Types of circuit Breakers Air magnetic Oil Air blast SF6 Vacuum Air Blast Obsolete technology Use dry air as the dielectric Up to 500 kV Hi pressure up to 3600 psi

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Types of circuit Breakers Air magnetic Oil Air blast SF6 Vacuum SF6 Todays technology Use SF6 as the dielectric Use in MV and HV class

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Types of circuit Breakers Air magnetic Oil Air blast SF6 Vacuum Vacuum Todays technology Use vacuum as the dielectric Limited to MV applications

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Functions of Circuit Breakers Switching Fault Interruption Interrupters Current interruption Switching Control the flow of electrical energy by opening or closing its main contacts Breaker can be controlled locally or remotely via SCADA Operations accomplished by energizing the tripping or closing coils

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Functions of Circuit Breakers Switching Fault Interruption Interrupters Current interruption Fault Interruption The primary equipment used for interrupting short circuit currents A circuit breaker used for three-phase is called a three pole breaker. One interrupter per pole for MV circuit breakers Series interrupters per pole for HV circuit breakers
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Functions of Circuit Breakers Switching Fault Interruption Interrupters Current interruption Interrupters Mounted on insulators Encloses main contacts in an insulating medium Moving contact connected to an insulated operating rod Operating rod connected to the operating mechanism Mechanism provides energy to operate at rated speed

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Functions of Circuit Breakers Switching Fault Interruption Interrupters Current interruption Current interruption Arcing contact separates Arc energy used to built dielectric pressure Dielectric moves between contacts at current zero crossing Maintained dielectric equates to current interruption

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SAFETY CONSIDERATION
High Voltage Safety Electrical safety using high voltage test equipment Testing performed by qualified personnel Familiarization with test set operations Know the hazards for the specific test Safe working practice and guidelines Safety practice regulations IEEE standard 510-1983; Recommended Practice for Safety in High Voltage Testing and High Power Testing
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X-Ray Radiation High voltage across vacuum gap can produce x-ray radiation Vacuum bottle integrity test voltage not to exceed manufacturers recommended levels or 75% of the factory dielectric test Indoor breaker optimally tested in the test / disconnected position for shielding Outdoor breakers tested at 1 metre distance with covers in place as per indoor breakers outside its cubicle
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SAFETY CONSIDERATION
Static High Voltage Electrostatic charge may be retained after high voltage potential is removed Ground the primary bushing and mid-band ring for at least 60 seconds

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Stored Energy Mechanical adjustments and checks should only be attempted after: Stored energy have been discharge / isolated Operating mechanism have been blocked Circuit breaker operation rely on the release / application of energy for closing and tripping operations Charged spring / pneumatic pressure / hydraulic pressure Energizing large operating coils
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Mechanical Testing Inspection Manual tripping and closing Mechanical interlocks Contact timing Electrical Testing Insulation resistance Dielectric withstand Vacuum bottle integrity Contact resistance Operations PF (maintenance test as required)

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Mechanical Testing Inspection Manual tripping and closing Mechanical interlocks Contact timing Inspection Verify the ratings matches the design specifications Verify installed correctly Determine of any physical damage during installation or transport Check all auxiliary equipment are supplied

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Mechanical Testing Inspection Manual tripping and closing Mechanical interlocks Contact timing Manual tripping / closing Energy storage devices Trip / latch mechanism Manual charging system Operations counter

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Mechanical Testing Inspection Manual tripping and closing Mechanical interlocks Contact timing Mechanical Interlocks Positive interlock Spring discharge interlock Rating interference plate

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Mechanical Testing Inspection Manual tripping and closing Mechanical interlocks Contact timing Contact Timing Measure the operating parameters Closing / tripping time Discrepency time Operating rod travel performance Two types of timer Digital timer Digital timer and travel analyzers
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Electrical Testing Insulation resistance Dielectric withstand Vacuum bottle integrity Contact resistance Operations PF (maintenance test as required) Insulation Resistance DC voltage test 100% of the Rated AC phase-ground crest value Crest value = 1.414 x VAC rms Preliminary to the dielectric withstand test

Note: Value > NETA recommended test value

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Electrical Testing Insulation resistance Dielectric withstand Vacuum bottle integrity Contact resistance Operations PF (maintenance test as required) Dielectric Withstand AC 60 Hz test at 75% of the factory test value Voltage applied across open contacts Voltage applied across phase to ground with contacts closed Untested terminal grounded

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Electrical Testing Insulation resistance Dielectric withstand Vacuum bottle integrity Contact resistance Operations PF (maintenance test as required) Vacuum bottle integrity AC 60 Hz test at 75% of the factory test value Voltage applied across open contacts Test time can be limited to 10 sec for some breaker type

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Electrical Testing Insulation resistance Dielectric withstand Vacuum bottle integrity Contact resistance Operations PF (maintenance test as required) Contact Resistance 100 Adc Resistance from bushing terminal to bushing terminal Using 4-wire resistance measurement test set

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Electrical Testing Insulation resistance Dielectric withstand Vacuum bottle integrity Contact resistance Operations PF (maintenance test as required) Operations Breaker in the normal posn Control circuit wiring tested (shorts / grounds) Operation tests for: Close and trip test Trip-free test Ant-pump test Anti-slam test Interlock test
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Electrical Testing PF Test (Classified as a maintenance test Insulation test Bushing test Power Factor Test Establish initial baseline reading for comparison and trending Similar to the capacitance and power dissipation test Test voltage below operating phase-toground value

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Electrical Testing PF (maintenance test as required) Insulation test Bushing test Insulation Test

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Electrical Testing PF (maintenance test as required) Insulation test Bushing test Bushing Test Hot collar test Non condenser bushing GST Collar material Conducting Uniform dimension

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NETA STANDARD
6. NETA Acceptance Testing Procedure 6.1 Visual and Mechanical Inspection 6.2 Electrical Test 6.3 Test Values

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TEST SET MANUAL

Module 4: Breaker Timing Test set Power Factor Test Set Module 2 & 3 CT Tester 15 KV Insulation Resistance Test set AC High Potential Test set DC High Potential Test set Digital Low Resistance Test set

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