HV Breakers Testing

High Voltage Circuit Breakers

Routine Tests

Type of testing & its importance

TYPE TEST This test is done on a product for the

certification of the design parameters. (According to clause
6 of IEC 62271-100)
ROUTINE TEST This test is done on each product
produce at manufacture end. (According to clause 7 of IEC
62271-100)

Routine test sequence for 72.5 kV breaker

TEST CHAMBER

Step:1 Over pressure test at 1.05 MPa

Step:2 Reduce pressure to 0.70 MPa
Step:3 Routine test
Step:4 Functional and visual checks
Step:5 Again Over pressure test at 1.05Mpa
Step:6 Reduce to transport pressure
Step:7 Leakage test (Immediately)
Step:8 Milli volt test
Step:9 Fill pressure up to 0.60 MPa
Step:10 High voltage test
Step:11 Reduce to transport pressure

Routine test sequence above 145 kV breaker

TEST CHAMBER

Step:1 Over pressure test at 1.05 MPa

Step:2 Reduce pressure to 0.70 MPa

Breaker
moves to HV lab

Step:8 High voltage test

Step:4 Functional and visual checks

Step:7 SF6 gas filled up to 0.60 MPa

Step:3 Routine test

Step:9 Again Over pressure test at 1.05Mpa

Step:5 Milli volt test

Step:6 Reduce pressure to 0.125 MPa

Step:10 Reduce to transport pressure

Step:11 Leakage test (Immediately)
Step:12 Moved to final dispatch

Routine test procedure for circuit breaker

SCOPE
Routine test of circuit breaker as per clause no. 7 of IEC 62271-100 & ABB
specification.

CONTENT
Over pressure test (ABB specification)
Mechanical operating tests (Cl. No. 7.101)
Timing & velocity measurement (Cl. No. 7.101)
Measurement of the resistance of the main circuit (Cl. No. 7.3)
Dynamic contact resistance measurement (ABB specification)
Tightness test (Cl. No. 7.4)
Design and visual checks (Cl. No. 7.5)
Dielectric test on the main circuit (Cl. No. 7.1)
Dielectric test on auxiliary and control circuits (Cl. No. 7.2)
Before the starting the above tests, the following points are to be taken care off:
i) Proper electrical connections are made as per the schematic.
ii) Gas is filled up to 7.0 bar absolute pressure.

Routine test procedure for circuit breaker

TEST : 01
OVER PRESSURE TEST
Processed circuit breaker assembled on the support frame is
Overpressure tested with dry SF6 gas at 1.5 times max. working
pressure = 1.5 x 0.7 MPa = 1.05 MPa overpressure for 1 minute.
Perform 1 Close Open operation at this pressure.

Routine test procedure for circuit breaker

TEST : 02
MECHANICAL OPERATING TEST
Tools Requirement : Digital Multimeter, Screw driver, Ampere meter,
Stop Watch, AC and DC source
The resistance of the control circuit checked, the closing coil and the
two opening coils along with all the auxiliary contractors, heaters and
relays.
The operation of the motor is checked.
Motor current and spring charging time is noted down.
Local Operation of the breaker along with the local indications like
Breaker close, Breaker open, Operation Counter are checked.
Functional check is done
Five operations at maximum, rated, minimum control voltage are
checked

Routine test procedure for circuit breaker

TEST : 03
BREAKER TIMING & VELOCITY MEASUREMENT
Instrument Requirement : Breaker Analyser (ELCON)
This test determines Operating Time & velocity of the breaker. The
main contacts are monitored to obtain instant of contact separation or
contact make through a suitable Breaker analyzer. The closing and
tripping signals are given to the respective coils at the terminals
provided on the operating mechanism.
To begin this Test, the Breaker is totally ISOLATED . Contact sensing
cables are connected to all the three phases. The Breaker is triggered
from Breaker Analyser and all the parameters are recorded. A sample
of CLOSE & TRIP Graphs are attached for reference.

Routine test procedure for circuit breaker

Test Definitions for circuit breaker

OPEN OPERATION GRAPH

Routine test procedure for circuit breaker

CLOSE OPERATION GRAPH

Routine test procedure for circuit breaker

CLOSE OPERATION GRAPH
140

OPEN OPERATION GRAPH

140

120

120

40

40

60

60

80

80

100

100

T1
a

20

20

T1

2
Ic

0
20

40

60

80

100
ms

120

140

160

Ic

0
0

180

20

40

60

80

100
ms

120

140

160

180

Test Definitions for circuit breaker

OPEN OPERATION GRAPH

Routine test procedure for circuit breaker

CLOSE OPERATION GRAPH

Routine test procedure for circuit breaker

TEST : 04
Measurement of the resistance of the main circuit
Instrument Requirement: Micro-Ohm Meter
(provided in Elcon)
Close the Breaker.
Connect the Voltage sensing cable to the TOP and
the MIDDLE flange.
Next connect the Current injecting cables to the TOP
& MIDDLE flange.
Pass DC current through the pole .
Record the contact Resistance

Routine test procedure for circuit breaker

Routine test procedure for circuit breaker

TEST : 05
Dynamic contact resistance measurement in open
operation (DCRM)
Instrument Requirement: DCRM kit (Provided in Elcon)
Close the circuit breaker.
Connection same as in contact resistance test.
Give open command to circuit breaker & record the
signature of dynamically contact open operation.

Routine test procedure for circuit breaker

TEST : 06
Tightness test
Instrument Requirement: SF6 Leak Sensing meter
Processed circuit breaker assembled on the support frame is overpressure
tested with dry SF6 gas at 1.5 times max. working pressure = 1.5 x 0.7 MPa =
1.05 MPa overpressure for 5 minutes. Leak detection is done at 0.125 MPa
(1.25 Bar abs) by sniffing within 10 minutes after this pressure is reached. If
traces of leakage are indicated at any of the test points, the place is blown
clean with compressed air. A new sniff control is performed at 0,125 MPa (abs)
after a new overpressure test with maximum working pressure. If no leakage is
indicated the pole is accepted.
This same sniffing test is carried out on the Gas pipe and the Distribution Block
for tightness ,wherever applicable.

Routine test procedure for circuit breaker

TEST : 07
Design and visual checks
The circuit-breaker shall be checked to verify its
compliance with the order specification
The language and data on the nameplates
Identification of any auxiliary equipment
The colour and quality of paint and corrosion
protection of metallic surfaces
The values of the resistors and capacitors connected
to the main circuit

Routine test procedure for circuit breaker

TEST : 08
Dielectric test on the main circuit
Instrument Requirement: HV Transformer & control
panel
This test is conducted at blocking pressure
As per the testing standard , all Circuit Breakers
have to pass the Power frequency dry voltage
withstand test for one minute.
Connection from the Transformer is taken to the top
flange of pole column with a GI wire and bottom is
earthed.
With circuit breaker in close position, the support
insulator of pole column of the breaker is tested for
its dielectric strength
Similarly with circuit breaker in open position, if
middle flange is earthed then arc chamber of pole
column gets tested.

Routine test procedure for circuit breaker

Breaker in Close position

Breaker in Open position

Routine test procedure for circuit breaker

TEST : 09
Dielectric test on auxiliary and control circuits
Instrument Requirement: 1 kV AC voltage tester
All supply to the operating mechanism is isolated.
The Earthing of the 1 kV tester is connected to the
Earthing of the operating mechanism.
1 kV shots are applied on each and every terminal
for 1 second.

Routine test procedure LTBE1 245 kV breaker

LIMITING VALUES

Close Time : Max. 28 ms

Open Time : Max. 21 ms

Close velocity : 7.4 to 8.0 m/s

Open velocity : 8.0 to 8.7 m/s

CO Time
:
Max. 30 ms
Stroke
:
160 3 mm
Motor Current
:
10 Amp(220 V)
20 Amp(110 V)
Spring Charging Time : 15 Sec Max.
Contact Resistance : 49
(At 20 C)

Routine test procedure 400 kV LTBE2 breaker

LIMITING VALUES

Close Time : 60 Max ms

Open Time : Max. 25 ms

Close velocity : 3.9 to 4.3 m/s

Open velocity : 7.4 to 8.2 m/s

CO Time
:
Max. 70 ms
Stroke
:
160 3 mm
Motor Current
:
10 Amp(220 V)
20 Amp(110 V)
Spring Charging Time : 20 Sec Max.
Contact Resistance : 102
(At 20 C)

Routine test procedure 800 kV LTBE4 breaker

LIMITING VALUES
Close Time : Max. 60 ms
4.2 to 4.7 m/s
Open Time : Max. 25 ms
7.2 to 7.5 m/s

Close velocity :
Open velocity

CO Time
:
Max. 70 ms
Stroke
:
160 3 mm
Motor Current
:
15 Amp(220 V dc)
30 Amp(110 V dc)
Spring Charging Time : 30 Sec Max.
Contact Resistance : 260
(At 20 C)

Routine test 245 kV ELF SL 4-1 breaker

LIMITING VALUES
Close Time
Open Time
CO Time
Contact Resistance
Close velocity
Trip velocity
Stroke length

:
:
:
:
:
:
:

Max. 130 ms
16 30 ms
35 45 ms
Max. 45
(At 20 C)
4 - 6 m/s
7.5 to 9.5 m/s
200 2 mm

Routine test procedure 400 kV ELF SP 6-2 Breaker

LIMITING VALUES

Max. 96

Contact Resistance :

Max. 60 ms

CO Time

Open Time

Close Time

Stroke length

Trip velocity

Close velocity

Max. 150 ms
Max. 25 ms

(At 20 C)

3.2 to 4.7 m/s

6.5 to 8.25 m/s
200

2 mm

Equipments used at test plants

Breaker analyzer (Elcon, Sweden)

SF6 gas handling plant (Dilo, Germany)
High voltage set-up