Breaker failure aversion tests

1. OMICRON Webinar
Avoid Circuit Breaker Failure with Comprehensive Testing
© OMICRON
Page 1

2. Agenda
 Circuit Breaker Reliability
 Circuit Breaker Testing Details
 CIBANO 500 Hardware Details
 Q&A
5 min
45 min
20 mins
20 mins

3. Circuit Breaker Reliability
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4. Breaker Maintenance
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 Breaker Failure Statistics
 281.090 HV Breakers tested worldwide
 Source: CIGRE brochure 510
Final Report of the 2004 – 2007 International Enquiry
on Reliability of High Voltage Equipment
Part 2 - Reliability of High-Voltage SF6 Circuit Breakers
Interrupters
20%
electrical
control and
auxiliary
circuit
30%
operating
mechanism
50%

5. Breaker Maintenance
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 ANSI C37.04-1999 Standard ratings defined
 ANSI C37.06-2000 Schedule of preferred ratings
 ANSI C37.09-1999 Type tests and routine tests
 ANSI C37.081, C37.082, IEEE 693
 CIGRÉ Green Book Switchgear
 IEC 62271-100, 2001
 IEC 60694, 2001
 IEC 60427, IEC 60815, IEC 60529,
IEC 61166, IEC 61233

6. Page 7
Interrupter Unit(s)
▪ Breaking chamber, interrupter chamber,
interrupter housing, etc.
▪ Contains interrupter, interrupting medium
Mechanical Linkage
▪ Line-to-ground insulator
▪ Contains insulated pull-rod,
mechanical linkage, insulating
medium
Operating Mechanism & Control
▪ Stored energy, secondary wiring
Functional breaker model

7. Page 8
Control
Operating mechanism
Mechanical linkage
Interrupter unit(s)
How to assess Reliability of a CB
▪ Identify contact wear and tear of contacts
▪ Static Contact Resistance of Main Contacts
▪ Dynamic Contact Resistance of Arcing Contacts
▪ ...
▪ Test performance of kinematic chain
▪ Timing of main and auxiliary contacts
▪ Contact travel (motion) of main contacts
▪ Test performance of Operating Mechanism
▪ Motor current analysis
▪ Under- & overvoltage tests
▪ Performance of control circuits
▪ Coil current profile analysis
▪ Under- & overvoltage tests
▪ Pick-up tests

8. Comprehensive Testing Details
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List of tests performed with CIBANO 500

9. Contact wear and tear of main contacts
Motivation
▪ Check the status of the main contact/bus bar junctions
▪ The ability to carry the rated current without big losses
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Measurement done
▪ When the circuit breaker is closed
▪ Using the four-point resistance measurement method
▪ Injection current level
▪ 50[A] (IEC)
▪ 100[A] (ANSI)
Analysis
▪ Resistance value
▪ Typical value between 10 to 100 [µΩ]
▪ Comparing to previous results
▪ High variations between phases
Static Contact Resistance test

10. Performance of Arcing Contacts
Motivation
▪ Check the timing to ensure a safe and reliable circuit breaker
operation
▪ Checking the arcing contact wear
▪ Often together with contact travel
▪ Check misalignment and/or wrong assembly in the interrupter
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Measurement done
▪ Using four-point resistance measurement method
▪ Different sequences possible
▪ O
▪ C
▪ OC (reclose)
▪ CO (trip-free)
▪ O-CO (auto-reclosing)
Analysis
▪ Operating times & Synchronicity
▪ per phase and between phases
▪ Resistance curves
▪ Comparing to previous results
▪ Contact wipe
▪ Arcing contact length
▪ Comparing to previous results
Dynamic Contact Resistance (DRM)/Timing test

11. Performance of trip and close components
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Measurement done
▪ Basically, two methods are used:
▪ Voltage divider method
▪ Resistance threshold method
▪ Different sequences possible
▪ O
▪ C
▪ OC (reclose)
▪ CO (trip-free)
▪ O-CO (auto-reclosing)
Analysis
▪ Operating times
▪ Compare against manufacture values
▪ Synchronicity
▪ between phases
▪ Contact bounces
Timing test
Motivation
▪ Check the timing to ensure a safe and reliable circuit breaker
operation

12. Challenges when testing HV GIS
▪ Timing can no longer be determined with conventional method
▪ Main contact resistance cannot be determined directly
▪ Two types of enclosures
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Single phase enclosure Three phase enclosure

13. Performance of trip and close components
Motivation
▪ Check the timing to ensure a safe and reliable circuit breaker
operation
▪ Checking the arcing contact wear
▪ Often together with contact travel
▪ Check misalignment and/or wrong assembly in the interrupter
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Measurement done
▪ Using Current Sensor Measurement (CSM)
▪ Different sequences possible
▪ O
▪ C
▪ OC (reclose)
▪ CO (trip-free)
▪ O-CO (auto-reclosing)
Analysis
▪ Operating times & Synchronicity
▪ per phase and between phases
▪ Contact wipe
▪ Arcing contact length
▪ Comparing to previous results
Timing (CSM) test

14. Connection for CSM based timing measurement
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Kelvin
clamp

15. Connection at GIS with both sides grounded
Current sensor measurement (CSM) with CIBANO 500 & CB MC2
Page 16
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16. Connection at GIS with both sides grounded
Current sensor measurement (CSM) with CIBANO 500 & CB MC2
Page 17
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17. Current sensor (Rogowski coil)
▪ Used to measure the operating time of both-side grounded GIS
(with grounding switches)
▪ Detects the change of current flow through the measured ground connection of the grounding switch
Page 18
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18. Principle current sensor
▪ 1st condition: breaker contacts closed
▪ Current through ground path and main contacts of
interrupter unit
▪ 2nd condition: breaker contacts open
▪ Current through ground path only,
▪ induction of voltage through current change in the path
Page 19
© OMICRON
1st condition: current through contact & ground
2nd condition: current through ground path only
t
close
ig
t
urog
close
open
induced
voltage
open
ig
ig
urog
urog

19. Resistance Measurement for GIS
Static/contact resistance test (µΩ)
Contact resistance with Grounded Contact Resistance (GCR)
▪ Takes use of the Ohm’s law for parallel resistances
1
𝑹𝑐𝑙𝑜𝑠𝑒
=
1
𝑹𝑔𝑟𝑜𝑢𝑛𝑑
+
1
𝑹𝐶𝐵
⇒ 𝑹𝐶𝐵 =
1
1
𝑹𝑔𝑟𝑜𝑢𝑛𝑑
−
1
𝑹𝑐𝑙𝑜𝑠𝑒
▪ Restriction: only possible with single-phase GIS
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20. CIBANO 500 solutions for safe testing of GIS
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Single phase enclosure Three phase enclosure
Timing BSG CSM CSM
Contact Resistance BSG GCR x
Single phase enclosure Three phase enclosure

21. Performance of trip and close components
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 Voltage-Based Timing measurement (VTM)
In-service measuring method
Measures main voltages of MV SF6 switchgear via
the voltage detection system (VDS)
Measures trip/close signals
Determines trip/close times
 On MV GIS the VDS is the only access point
where timing can be measured

22. Performance of trip and close components
Motivation
▪ Trip circuit breaker after long idle time for the very first time
▪ Trip time slower because of drying out grease
▪ Check the timing to ensure a safe and reliable circuit breaker
operation
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Measurement done
▪ Connect current clamps on secondary leads from CT
▪ Connect current clamp to coil lead
▪ Connect coil supply as trigger signal
▪ Done on O-sequence
Analysis
▪ Operating times
▪ Compare against manufacture values
▪ Comparing to previous results
▪ Synchronicity
▪ between phases
First Trip test
Opening time ≠ Break time
(similar for closing)

23. Connection for First Trip Timing Test
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Current clamps

24. Performance of kinematic chain
Motivation
▪ Reveals mechanical defects of the kinematic chain
▪ Overall mechanical performance
▪ Slow operation due to jammed mechanism
▪ Deterioration of mechanical damping (dashpots)
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Measurement done
▪ Use of a linear or rotary transducer mounted to the kinematic
chain
▪ Motion measurement done during the Timing test
Contact travel (motion) of main contacts
Analysis
▪ Check values like
▪ Total travel (TT)
▪ Contact wipe (CW)
▪ Over travel (OT)
▪ Rebound (RB)
▪ Speed
▪ Motion trace
▪ Graphical comparison

25. Performance of charging motor
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Measurement done
▪ Supply motor and record the current
▪ Use a current clamp to record the current when motor
supplied from station battery
Analysis
▪ Charging time
▪ Compare against manufacture values
▪ Comparing to previous results
▪ Inrush current
▪ Compare against manufacture values
▪ Comparing to previous results
▪ Current trace
▪ Graphical comparison
Motor current test
Motivation
▪ Detect if motor or operating mechanism drive is in good health
▪ Not sufficient lubrication
▪ State of the spring/hydraulic/pneumatic drives

26. Performance of trip and close components
Motivation
▪ Detection of potential problems in actuating coils
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Measurement done
▪ Supply coil and record the current
▪ Done together with the DRM/Timing test
Analysis
▪ Current peak value
▪ Comparing to previous results
▪ Coil resistance value
▪ Comparing to previous results
▪ Current trace
▪ Graphical comparison
Coil current analysis

27. Under-Voltage Test
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 Checks behavior of coils in case of under-voltage
Do the coils work?
Are there any delays compared to nominal voltage?
 To date, impact of under-voltage supply on close
and trip operation was only a rough simulation
 CIBANO 500 approach
set exact under-voltage
check the behavior of the coils
 Operating times at different voltage levels
Un

28. Performance of trip and close components
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Measurement done
▪ Start with low voltage level
▪ Try to operate
▪ If not working, increase voltage and try again
▪ Repeated until circuit breaker operates
Analysis
▪ Minimum pickup value
▪ For Trip coil should be below 70[%] of the rated voltage
▪ For Close coil should be below 85[%] of the rated voltage
Minimum pickup test
Motivation
▪ Check the lowest voltage to operate the Trip or Close coil

29. Minimum Pick-Up Test
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30. Under-Voltage (UV) Release Test
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 Decreasing voltage ramp
 Determines the trip voltage
 Common value: 70% of nominal voltage
 Under-voltage coils are commonly used with
breakers without supply voltage backup

31. Hardware Details
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CIBANO 500 and its accessories

32. CIBANO 500: 3-in-1 Breaker Test System
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 Multi-channel timing and travel analyzer
Checks the mechanical performance
Detects problems during coil actuation
Reveals defects of the trip or close coils
 High-accuracy micro-ohm (µ) meter
Assesses the condition of the main and arcing
contacts and resistor switches
 Powerful coil and motor supply of 2.4 kW
Applies stable DC voltage even when no station
battery is available
Timing and
travel analyzer
Digital
micro-ohm-meter
Coil and
motor supply of 2.4 kW

33. CIBANO 500: Your Benefits
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 Unique connection concept
Minimized wiring effort
No rewiring between tests
Reduced testing time
Improved operator safety
Reduced interference through digital data transmission
 Mobile solution: 20 kg / 44 lbs
 One combined report for all tests
 Videos
State-of-the-art circuit breaker testing MV / HV
Testing circuit breakers with CIBANO 500
Simultaneously testing multiple breaking elements

34. CIBANO 500: Modular Concept for Simplified Testing
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 Equipment to perform all common electrical tests
on HV 3-phase breakers without rewiring:
CIBANO 500
CB MC2 (3 x)
CB TN3
 Unique connection concept
minimizes wiring effort
reduces testing time
improves operator safety
CIBANO 500
CB MC2
CB MC2
CB MC2
CB MC2
CB TN3
CB TN3

35. Main unit CIBANO 500
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 Supply interface
Use station battery or built-in supply
Breaker/motor/control circuit supply
 Measuring interface
Current/voltage for static resistance measurements
Voltage/binary to analyze timing
Current clamp interface
 Communication interfaces
Ethernet port for PC connection
Optional: EtherCAT® interface
Safety port to connect remote safety switch
 Accessories
CB MC2: dynamic contact resistance measurement
CB TN3: motion analysis
IOB1: analysis of breakers with complex design

36. Main contact module CB MC2
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 Benefits
Same wiring set-up for all breaker tests
Wiring minimized and clearly arranged
Simple and fast measurement set-up
Measure with both sides grounded
Timing
Static contact resistance
 Outputs and inputs
Two high-current outputs
Two sensitive voltage measurement channels
 Connections
Short high-current cables
Light-weight digital connection cables for interference-
free measurement value transmission

37. Transducer node CB TN3
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 Accessory for motion measurement
 Three analog and digital data acquisition channels
 Interference-free measurement value transmission
 Connects to linear or rotary transducers

38. SAA2 Warning Lamp Set
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 Benefits
Warns that prohibition zone must not be entered
Marks your testing area
 Cascadable
Two channel system
Up to six signal lamps (optional)
 TÜV (octagon) and IP52 Level
 Features
Magnetic holders and hook
Audible Measurement Active signal (optional)
Emergency stop button
Red-green test status indication
Indoor/outdoor light intensity

39. Primary Test Manager™
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1. Hardware configuration as per
selected tests
2. Testing parameters like voltage
selection for operating coils and
motor
3. Advanced setting like transducer
setting, sampling rate, etc
4. Easy assessment of results and
starting multiple tests with single
button
3
4
1
2

40. Primary Test Manager™
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1. Binary traces
2. Cursors allow detailed result analysis
3. Coil and motor currents, voltages, or
calculated resistances
4. DRM analyzes the wear of the arcing contact
1
2
3
4

41. Primary Test Manager™
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 Automatically generated  Customized reports

42. Circuit Breaker Testing Library (CBTL)
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 Contains all breaker-specific default data
 Loads data into PTM with the click of a button
 Only breaker serial number must be entered
 Provides pre-defined breaker configuration data
nameplate data
operating mechanism configuration
 Holds additional information
motion sensor mounting instructions
manufacturers assessment limits
motion measurement conversion data
 Existing data can be used
 Create data and share in your firm

43. Primary Test Manager™
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 Multiple teams synchronize data with
PTM DataSync
Testing data
CBTL entries
Customer specific reports
 Connect other databases with OData / Power BI

44. Emotions are energy. Our energy moves.
CIBANO 500
 One system for all types of breakers
 3-in-1 test system
micro-ohm meter
AC/DC supply
timing analyzer
 Unique connection concept
minimizes wiring effort
reduces time
improves safety
 Digital data transmission eliminates interference
 Mobile solution with a weight of 20 kg / 44 lbs
 One combined test report
© OMICRON
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Thank you for your attention.