A Preview: Timing and motion testing of high voltage circuit breakers

By: Jozef Levi dipl.El.Eng., Application Engineer, Doble Engineering Company

Life expectancy of a new installed high voltage circuit breaker is at least 40 years. Throughout
its life, under normal circuit conditions, it will operate less than ten minutes. During abnormal
circuit conditions it will operate less than one minute in its lifetime.
The primary goal of circuit breaker testing is to determine the condition of the breaker.
Breakers have moving parts, components which allow electrical contacts to separate (an
open or trip operation) or to close. Whether those contacts are in a vacuum, in oil or in a
gaseous medium, it makes sense to test the moving parts of the breaker a motion or
travel test.
If the motion of the contact system is in accordance with manufacturer specifications then we
can reasonably conclude that all mechanical parts, from the mechanism which provides the
movement to the contacts themselves, are in good condition.
What you need to know to test circuit breakers

Know your test instrument

Knowing the test instruments capabilities will widen the spectrum of tests and
measurements which will augment the quality of the test result analysis and decision
making as to the status of circuit breaker.
Know test object - circuit breaker
Knowing how the particular circuit breaker operates will raise the ability to detect and read
problems presented as graphics or tabulated test results. At the same time, this knowledge
will give us the opportunity to position transducers on places of interest.
Know transducers
Each test result is obtained with a transducer of one form or another. An understanding of
how these transducers work will, in the end, give us more accurate test results.
Know transducer positions
The position of the transducer directly influences test results.
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July 2013
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Measure motion when it is possible

A high voltage circuit breaker is a mechanical device. Knowledge of travel (displacement)
of contact system will provide a comprehensive picture of its condition.
Three stages of circuit breaker testing
1. Test preparation
2. Testing and data collection
3. Test results analysis
1. Test preparation
Before we start testing we have to be completely prepared for it. Preparation for testing is
actually the most important part of the whole process of testing and can also be the most time
consuming of the three parts in the testing process.
Test result analysis is directly connected to the preparation process. A detailed test plan
preparation will result in an improved result analysis, allowing for better decision making as to
the condition of circuit breaker under test. Tests need to be performed, collected and
analyzed. By analyzing these collected test results it will allow the maintenance technician or
asset manager to make fact-based decisions as to what next steps in the testing process are
necessary.
To start the preparation process we must answer the following questions:

What breaker are we testing?

What instrument is being used for testing?
What transducer (motion and analog) will we use?
Where to position transducers?
What is the insulating and quenching medium?
What is the contact system design?
What kind of mechanism operates the breaker?

2. Testing and data collection

After decisions for testing the circuit breaker are made, it is necessary to proceed with the
next set of preparation criteria which consists of two major parts: circuit breaker and test
instrument preparation. After the circuit breaker and the test instrument have been prepared,
the connection between instrument and transducer can start.
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July 2013
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Once again it is very important where those transducers will be positioned. Test results will be
directly affected by the transducer positioning. A majority of testing problems are a result of
poor transducer connections and positioning on the test object circuit breaker. The actual
testing component should be the shortest of the three steps; test preparation, testing and test
result analysis.

3. Test results analysis examples

It is also helpful to know about the definitions of what we are measuring or monitoring.
Definitions are a part of the applicable standards and they will aid in results comparison
between users and manufacturers results. If tests are completed according to standard
definitions, results can be compared with other test results obtained on the same or similar type
of circuit breaker. The most important standard definitions are those for timing of circuit
breakers. In some cases, manufacturers use a non-standard measurement for circuit breaker
closing time. In those cases, it is important to know how closing time is calculated, so that a
proper comparison can be made with the breaker tested according to standard definitions.
Most instruments incorporate timing measurement according to standard definitions with
options to calculate operating times with non-standard definitions.
The following are examples of measurements which are a part of circuit breaker operation, but
are without standard definitions.
Trip and close coil current
For time measurement, we need to know when measurement starts and when it stops. The
beginning of opening and closing time measurement is actually beginning of trip and close coil
current. To fully understand coil current diagram we have to understand the physics
behind trip and close coil operations. There are two distinctive parts of coil and plunger
operation. The first part is from the moment when the current starts to flow and the moment
when the plunger stops; the second one is from when the plunger stops and the moment when
current reaches a zero value after the auxiliary contacts go open circuit. Plunger movement,
mechanism mechanically collapsing and operation of the auxiliary contacts are imprinted in trip
and close coil currents. Quality of the control voltage supply is also detectable from these
currents.
First Trip
At first glance, the first trip test does not belong to timing and motion testing but is
mentioned here as test which can give a respectable indication of a circuit breakers condition.

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July 2013
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This test is best performed while the circuit breaker is in service as the object is to record the
trip coil signature. A large part of a circuit breakers life is standing in an idling condition
waiting for instruction to operate. This can last for weeks, months and in some cases, years.
Being a mechanical device, non-operation is not considered ideal for lubricated parts in the
mechanism and linkage. Poor or faulty lubrication will influence breaker performance and
can be detected when the so called first trip is tested.
The most important measurement during the first trip test is to capture the trip coil
current profile. Trip coil plunger movement and auxiliary contact operation for first trip can
be compared with the same movement during consecutive operations; differences in those
recorded movements can reveal signs of lubrication problems.
Indirectly, the opening time of a circuit breaker can be measured when currents in all three
phases are monitored together with trip coil current.
Shock absorber reaction
Arcing and main contacts of high voltage circuit breaker are separated and engaged with
relatively high velocity. After reaching sufficient distance and current is at zero, crossing
dielectric strength becomes higher than transient voltage and we have successful opening
operation. After that point, breaker velocity needs to decrease and it will reach zero at the end
of travel. This is achieved with use of shock absorbers of different design.
A good characteristic of shock absorber is that velocity reaches zero without sudden changes
and few direction changes in the shortest possible time. Same process of decreasing contact
velocity is during closing operation. An improperly adjusted shock absorber can be the
reason for mechanical damages of moving parts of mechanism, linkage and contact
system. The position and design of the shock absorber defines what kind of decreasing
velocity is detected during motion measurement. Shock absorber reaction should be part of
the test results analysis process.

This is a preview of the paper and presentation Jozef Levi will give at the
20 Annual Finepoint Circuit Breaker Test & Maintenance Training Conference hosted
by Doble Engineering Company.
th

October 7-11, 2013

Atlanta, Georgia USA

The Doble Exchange

July 2013
Doble Engineering Company. All Rights Reserved.