Maintenance Ranking and Diagnostic

Algorithms for Circuit Breakers Most

Suitable for Field Installation

Technical Report

Maintenance Ranking and

Diagnostic Algorithms for Circuit
Breakers Most Suitable for Field
Installation
1002063

Interim Report, November 2003

EPRI Project Manager

B. Damsky

EPRI 3412 Hillview Avenue, Palo Alto, California 94304 PO Box 10412, Palo Alto, California 94303 USA
800.313.3774 650.855.2121 askepri@epri.com www.epri.com

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CITATIONS
This report was prepared by
EPRI
3412 Hillview Avenue
Palo Alto, CA 94304
Principal Investigator
B. Damsky
This report describes research sponsored by EPRI.
The report is a corporate document that should be cited in the literature in the following manner:
Maintenance Ranking and Diagnostic Algorithms for Circuit Breakers Most Suitable for Field
Installation, EPRI, Palo Alto, CA: 2003. 1002063.

iii

REPORT SUMMARY

Circuit breaker failures are costlyboth in load loss and in potential damage to other
transmission and distribution components. This report describes algorithms to monitor problems
that could potentially develop within power circuit breakers and auxiliary equipment. Used in
conjunction with EPRIs Maintenance Management Workstation (MMW) or other suitable
software, the algorithms can provide prioritized indication and alerts to focus attention on circuit
breaker problems before they lead to more extensive damage. The report provides concise tables
with suggested values for selected key circuit breaker parameters that can be monitored via
digital relays and require no further equipment.
Background
Utilities, under pressure to reduce costs and maintain reliability, are faced with the loss of
experienced personnel who have the expert knowledge necessary to achieve such goals. Utilities
already have much of the needed information, but it frequently resides in various databases,
monitoring equipment, and operational hardware and software systems that are not easily
accessed or generally available. EPRI has recognized a pressing need to obtain and summarize
expert knowledge addressing circuit breaker maintenance-related problems, with emphasis on
applying this knowledge to the available data. EPRIs MMW provides a powerful tool to analyze
large amounts of incoming data and present it in a way to suggest the most crucial maintenance
work. This report focuses on providing digitized files that could be accessed by MMW or an
equivalent system.
Objectives

To identify the key parameters that can be monitored at little or no cost to detect deteriorating
circuit breaker performance.

To suggest quantified limits for alarms to be used in the form of diagnostic algorithms.

Approach
EPRI assembled a team of circuit breaker experts to comment on the usefulness of various
parameters for assessing circuit breaker maintenance needs. This team produced an earlier EPRI
report on the topic, Integrated Monitoring and Diagnostics, Maintenance Ranking and Diagnostic
Algorithms for Circuit Breakers (1001952). While that report covered a wide range of possible
parameters to monitor or sample, this report suggests a short list of items that can be read
digitally using the new generation of digital relays.

Results
This report covers both medium- and high-voltage circuit breakers. The focus here is on data that
can be obtained simply and inexpensively using digital relays as a monitoring tool and
eliminating as far as possible the need for additional monitoring equipment. Such data is then
available for use by EPRIs MMW or other utility program for organizing and highlighting
maintenance-sensitive data, making it possible to detect circuit breaker problems before they
reach the point of causing damage or operational failure.
The report contains tables of suggested alarm levels associated with circuit breakers of different
types and speeds or with the type of mechanism, whichever is appropriate, with emphasis on
crucial readings and values thought to be most indicative of problems. As a starting point for
analysis, the report suggests reasonable values for circuit breaker opening and closing times, rate
of pump operations, and rate of pump operating time.
EPRI Perspective
The continuing loss of experienced personnel, occurring in parallel with increasing demands for
just in time condition-based maintenance, presents a major challenge to the utility industry.
This trend results in a growing need to institutionalize and eventually automate technical,
empirical, and experienced-based knowledge regarding the condition of critical power system
equipment. Implementing the algorithms from this project will benefit utilities by reducing their
maintenance costs, improving the reliability of their substation circuit breakers, and reducing
their reliance on stand-alone commercial monitoring packages.
Keywords
Circuit Breakers
Circuit Breaker Maintenance
Circuit Breaker Diagnostics

vi

CONTENTS

1 INTRODUCTION ................................................................................................................. 1-1

1.1 Background ................................................................................................................. 1-1
1.2 Developing Diagnostic Algorithms for Circuit Breakers ................................................. 1-1
1.3 Focus on Field Installation ............................................................................................ 1-2
1.4 Scope ........................................................................................................................... 1-2
2 COMMENTS ON SELECTED VALUES............................................................................... 2-1
2.1 Circuit breaker opening time......................................................................................... 2-1
2.2 Circuit breaker closing time .......................................................................................... 2-1
2.3 Cycling rate for actuator pump...................................................................................... 2-1
2.4 Operating rate for actuator pump.................................................................................. 2-2
3 TABLES OF SUGGESTED VALUES .................................................................................. 3-1
Table 1, Opening Time ....................................................................................................... 3-1
Table 2, Closing Time......................................................................................................... 3-2
Table 3, Rate of Operations of Pump ................................................................................. 3-3
Table 4, Rate of Operating Time of Pump .......................................................................... 3-3

vii

1
INTRODUCTION

1.1 Background
In 1999 a group of transformer experts was assembled by EPRI to develop algorithms and to
write the necessary equations that could be used in the Maintenance Management Workstation
(MMW.) These equations will be used to determine the need for transformer maintenance and
to diagnose potential transformer problems. To the maximum extent possible, the algorithms
were to use data that is already available to a utility in various databases which MMW could
access. Many specialized monitoring devices specifically aimed at transformers and load tap
changers have been installed and the output of these was also included.
This group met for several years at regular intervals and pooled the knowledge and experience of
its members on this subject. The result was an EPRI report, Integrated Monitoring and
Diagnostics, Maintenance Ranking and Diagnostics Algorithms for Transformers, 1001951.
A parallel effort which was focused on circuit breakers rather than transformers was formed and
a report was issued covering their findings: Integrated Monitoring and Diagnostics, Maintenance
Ranking and Diagnostic Algorithms for Circuit Breakers 1001952. This report covered many
areas, but did not include specific values, an item covered in this report. Because of the greater
depth of discussion, the reader is strongly advised to refer to this predecessor report. The aim of
this report is to focus on the small set of readings that can be digitally read most easily and can
be most useful in assessing circuit breaker maintenance needs.

1.2 Developing Diagnostic Algorithms for Circuit Breakers

EPRI used a group of experienced utility engineers to consider problems, diagnosis, and
weightings of algorithms for circuit breakers. The group, which is part of EPRIs Integrated
Monitoring and Diagnostics (IM&D) User Group, met and then exchanged ideas and data by
phone and email.
The IM&D project is developing state-of-the-art tools to monitor and diagnose the thermal,
mechanical, and electrical health of major power transformers, circuit breakers and other
equipment, and to provide the means for integrated communications that would pull together
data for more efficient substation operation. The IM&D system is designed to be implemented as
part of the Maintenance Management Workstation (MMW), but could also be used for standalone use. Use of the system will increase the loading capability of existing equipment, detect
incipient failures, reduce the severity of repairs, reduce O&M costs and reduce the costs for
substation monitoring and diagnostics.
1-1

Introduction

A key focus of this project is developing new algorithms to diagnose equipment condition for
optimized maintenance and operation. To date, a select committee of experts brought together by
EPRI has developed diagnostic algorithms for power transformers. These algorithms are being
implemented at utility sites. An interim report on these algorithmsentitled Integrated
Monitoring and Diagnostics: Maintenance Ranking and Diagnostic Algorithms for
Transformers, 1001951has been published.
This is a similar approach to develop algorithms for circuit breakers, and algorithms for other
major types of substation equipment will follow. Participants who are knowledgeable about
power circuit breakers are participating in the efforts to develop algorithms
The causes of potential circuit breaker problems related to maintenance will be analyzed. Also,
the types of existing data sources that are commonly available from monitoring and testing
activities will be determined.
Additional monitoring opportunities that can be applied to detect the need for maintenance will
also be analyzed in order to develop diagnostic algorithms utilizing the data.

1.3 Focus on Field Installation

From the point of view of accuracy and proper and timely alerts it is ideal to have as complete
information as possible. This would mean monitoring all possible subsystems and taking
readings from inspection visits made on a frequent basis. But we do not live in an ideal world
and our job becomes to find the set of inexpensive readings we can best use to detect problems
with circuit breakers before they reach the point of damage or failure to operate. It will be clear
below that we are only looking at crucial readings and values that are thought to be most
indicative of problems. Part of the thinking is to eliminate as far as possible the need for
additional monitoring equipment.

1.4 Scope
Both medium voltage and high voltage circuit breakers are covered in this report. The focus here
is on data that can be obtained simply and inexpensively using digital relays as a monitoring tool.
This data is then available for use by EPRIs Maintenance Management Workstation (MMW) or
any other program a utility may want to use to organize and highlight maintenance sensitive data.
The virtue of this approach is minimal cost. Some of the deficiencies will be mentioned here as
well. Clearly not all important values can be read remotely or digitized without the cost of
further equipment. Typically digital relays have a time resolution in the range of one to four
milliseconds. If the latter is used, there will be some loss of accuracy for determining the
opening speed of fast circuit breakers. It is also true that opening and closing speeds are not read
directly, but are based on the timing of A and B contacts of the circuit breaker. This puts the
reading a step further from the actual desired value. On the other hand, we are looking for
changes in opening and closing speeds and normally expect the A and B contacts to retain the
same relationship to the actual performance of the contacts of the circuit breaker. On the whole,
it is believed that the data suggested below will be useful, inexpensive, suitable for use in MMW
and indicative of a large fraction of the maintenance needs of circuit breakers.
1-2

2
COMMENTS ON SELECTED VALUES

2.1 Circuit breaker opening time

The operating speed is critical for all circuit breakers. Contact travel distance versus time is
therefore measured on many circuit breakers at the time of installation and subsequently repeated
at regularly scheduled intervals.
Traditionally, time travel measurements are performed after the breaker has been removed from
service. Thus, this analysis has some of the same limitations as contact timing because the
breaker is normally operated before measurements are made. Newer breakers may have optional
time travel analyzers built in as part of their condition monitoring.
When readings are taken using special equipment, it is almost certain that the value or trace
recorded will not be the first operation, but more typically something like the fifth operation. We
have learned that circuit breakers that sit for more than six months may have lubrication
problems which can only be seen on the first and second operation. Use of a system that
captures all operating times (e.g. Monitoring through digital relays) has the distinct advantage of
alerting a utility that this lubricating problem is occurring.
Another reason to pay close attention to opening time is that a change in this value can be caused
by so many problems. Although an alert on this issue does not determine what the exact cause
is, it can be used to decide to have a crew check the device for a more exact diagnosis and action.

2.2 Circuit breaker closing time

Closing time, in a manner similar to opening time, provides an overview of several subsystems
and so is very useful. The majority of problems for circuit breakers are mechanical and it is the
actuator system that is the major source of maintenance needs. Since closing often arms the
opening action, checking the closing can detect misalignment of critical parts in the opening
mechanism.

2.3 Cycling rate for actuator pump

If the pump that supplies the storage tank of the actuator is operating more often than expected, it
is a good sign that there is a leak or that some other problem is occurring. It is a simple matter to
monitor the power switch to the pump and determine this value.

2-1

Comments on Selected Values

2.4 Operating rate for actuator pump

If the pump that supplies the storage tank of the actuator is operating longer each day than
expected, it is a sign that there is a leak or that the pump is not performing as efficiently as
expected. If the number of operating cycles per day has not increased, but the running time has
increased, then it appears the pump is not working satisfactorily.

2-2

3
TABLES OF SUGGESTED VALUES

Table 1, Opening Time

Breaker Type

Nominal (msec)

Opening Time Variation (msec)

Bulk Oil
3 cycle
5 cycle
10 cycle

50
83
167

5
9
18

Minimum Oil
2 cycle
3 cycle
5 cycle

33
50
83

3
5
8

Air Magnetic
3 cycle
5 cycle
7 cycle

50
83
117

5
8
10

Air Blast
2 cycle
3 cycle
5 cycle

33
50
83

3
4
6

SF6 Two Pressure

2 cycle
3 cycle
5 cycle

33
50
83

3
4
6

SF6 Puffer
1.5 cycle
2 cycle
3 cycle
5 cycle

25
33
50
83

3
3
4
6

Vacuum
1.5 cycle
2 cycle
3 cycle
5 cycle

25
33
50
83

2
2
3
4

3-1

Tables of Suggested Values

Table 2, Closing Time

Nominal (msec)

Closing Time Variation (msec)

Breaker Type
Bulk Oil
6 cycle
10 cycle
15 cycle
20 cycle
25 cycle

100
167
250
333
418

12
18
29
37
50

Minimum Oil
6 cycle
10 cycle
15 cycle
20 cycle

100
167
250
333

10
17
26
35

Air Magnetic
6 cycle
10 cycle
15 cycle
20 cycle

100
167
250
333

12
18
29
38

Air Blast
3 cycle
6 cycle
10 cycle
15 cycle

50
100
167
250

5
10
17
26

SF6 Two Pressure

3 cycle
6 cycle
10 cycle
15 cycles

50
100
167
250

5
10
18
28

SF6 Puffer
3 cycle
6 cycle
10 cycle
15 cycle

50
100
167
250

4
9
16
25

Vacuum
3 cycle
6 cycle
10 cycle
15 cycle

50
100
167
250

4
8
16
25

3-2

Tables of Suggested Values

Table 3, Rate of Operations of Pump

Actuator Storage

Expected
Operations per
day

Operations per
day for alarm

Hydraulic

Pneumatic

Table 4, Rate of Operating Time of Pump

Expected
Operating time
per day

Operating time per

day for alarm

Hydraulic

40 minutes

60 minutes

Pneumatic

60 minutes

90 minutes

Actuator Storage

3-3

Program:
Transmission Substations

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2003 Electric Power Research Institute (EPRI), Inc. All rights

reserved. Electric Power Research Institute and EPRI are registered
service marks of the Electric Power Research Institute, Inc.
EPRI. ELECTRIFY THE WORLD is a service mark of the Electric
Power Research Institute, Inc.
Printed on recycled paper in the United States of America
1002063

EPRI 3412 Hillview Avenue, Palo Alto, California 94304 PO Box 10412, Palo Alto, California 94303 USA
800.313.3774 650.855.2121 askepri@epri.com www.epri.com