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Circuit Breaker- Failures

Gyanendra Sharma
 Make wise CBs in service

Make Population
ABB 650 nos.
CGL 500 nos.
M&G 50 nos.
BHEL 300 nos
Alstom 140 nos.
Total 1640 nos.

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 Performance of CBs

2 .5
2
1 .5
%age CB
failures

1
0 .5
0

Y EA R

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 400kV BHEL CB

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 Internal Details of Interrupter

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 420kV INTERRUPTER CLOSING
OPERATION

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 Operating Links

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 BHEL make CB Operating
Mechanism

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 420 kV SF6 GCB
With SP/Pneumatic Mechanism
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 INTERRUPTER DESIGN

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 Main and Arcing Contacts

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 Driving Mechanism

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 Reasons of CB Failures in
POWERGRID
MECHANICAL - 74%
(OPERATING COMPONENTS FAILURES)

ELECTRICAL - 16%
(DIELECTRIC FAILURE)

OTHERS - 10%

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 Circuit Breaker Failures

• Due to
manufacturing
defects
• Due to design
defects

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 CB failure - Helicoil problem

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 Mechanical disengagement of moving
contact assembly from helicoil joint

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 PIR ASSEMBLY FAILURES
• MECHANICAL • BLASTING OF CB
BREAKAGE OF PTFE
ROD DUE TO PIR
PROBLEM

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 Bending of PIR pull rod

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 PIR ASSEMBLY FAILURES
• PIR FIXED • BREAKAGE OF
CONTACT PTFE ROD FROM
JAMMING METALLIC TIP

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 INTERRUPTER ASSEMBLY

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Condition Monitoring through DCRM

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 Healthy Contacts of CB after 16
years

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 Contact Condition of CB after 16 Years

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 Some CB contacts even after 16 years of
service

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 Eroded finger contact after 7-8 years
Old

New

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 PROBLEMS IN CB AFTER 7-8 YEARS

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 NEED FOR DCRM

 During normal contact resistance

measurement, healthiness of main
contacts is evaluated
Req = R*r/(R+r)= r/(1+r/R), r = Main contact
R = Arcing contacts
 DCRM signatures/finger prints indicate
true condition of CB arcing contacts.
 Arcing contact play vital role during CB
operation

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 DYNAMIC CONTACT RESISTANCE
MEASUREMENT (DCRM)
 CONTACT RESISTANCE MEASUREMENT DURING
CLOSING AND TRIPPING OPERATION. C-O DELAY
TIME ABOUT 300MS.

 100 AMP CURRENT IS INJECTED THROUGH CB

CONTACTS.

 VOLTAGE DROP AND CURRENT IS MEASURED TO

COMPUTE CONTACT RESISTANCE.

 VARIATION IN FINGER PRINT OF DCRM INDICATE

PROBLEM IN ARCING AND MAIN CONTACTS.

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 Basic connection arrangement for
DCRM Measurement

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 DCRM can detect…
• Erosion of Arcing Contact
• Erosion of main contact
• Contact misalignments
• Contact wipe of main and arcing
contact
• Main & arcing contact resistance
• Healthiness of damping system
• Contact travel & speed

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 BHEL Moving Contact

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 Contact Configuration

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 Operating Links

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 Tie Rod

Loosening of Tie Rod

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 Driving Mechanism

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 Contact Travel and Insertion Details
Travel Total Main Arcing
Contact
Contact Contact Insertion
Insertion Insertion
CGL 230mm/ 28mm 12mm 16mm
140mm
BHEL 242/ 54 34 20
130mm
ABB 200mm 50mm 20mm 30mm
AREVA 180mm 45mm 25mm 20mm

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 Contact insertion/ speed

Make Trip velocity Close

velocity
ABB 6-8 m/sec 3-4 m/sec

CGL 5-6 m/sec 3-4 m/sec

BHEL 6-8 m/sec 3-4 m/sec
AREVA 5-8 m/sec 2-4 m/sec

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 Failure of PIR at Trichy
• Details
• PIR link failed
• Observations
• Reasons

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