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ABB PowerTEC

Shaping the future power landscape

Training programme
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17 JUNE 2019

High Voltage Circuit Breakers

Routine Tests

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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)

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— 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 Breaker

moves to HV lab
Step:2 Reduce pressure to 0.70 MPa
Step:3 Routine test Step:7 SF6 gas filled up to 0.60 MPa

Step:4 Functional and visual checks Step:8 High voltage test

Step:9 Again Over pressure test at 1.05Mpa
Step:5 Milli volt test
Step:10 Reduce to transport pressure
Step:6 Reduce pressure to 0.125 MPa
Step:11 Leakage test (Immediately)
Step:12 Moved to final dispatch

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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.

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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.

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Routine test procedure for circuit breaker
TEST : 02

MECHANICAL OPERATING TEST

üTools Requirement : Digital Multimeter, Screw driver, Ampere
meter, Stop Watch, AC and DC source
üThe resistance of the control circuit checked, the closing coil and
the two opening coils along with all the auxiliary contractors,
heaters and relays.
üThe operation of the motor is checked.
üMotor current and spring charging time is noted down.
üLocal Operation of the breaker along with the local indications like
Breaker close, Breaker open, Operation Counter are checked.
üFunctional check is done
üFive operations at maximum, rated, minimum control voltage are
checked

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Routine test procedure for circuit breaker
TEST : 03

BREAKER TIMING & VELOCITY MEASUREMENT

üInstrument Requirement : Breaker Analyser (ELCON)

üThis 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.

üTo 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.

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Routine test procedure for circuit breaker

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Test Definitions for circuit breaker

OPEN OPERATION GRAPH

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Routine test procedure for circuit breaker

CLOSE OPERATION GRAPH

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Routine test procedure for circuit breaker

CLOSE OPERATION GRAPH OPEN OPERATION GRAPH

140 140

A
120 120 A
T1
a a
b b
100 100

80 80
mm
mm

60 60

40 40

20 20

T1
0
0

2
2
A

Ic
A

Ic 0
0
0 20 40 60 80 100 120 140 160 180
0 20 40 60 80 100 120 140 160 180 ms
ms

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Routine test procedure for circuit breaker

TEST : 04

Measurement of the resistance of the main circuit

üInstrument Requirement: Micro-Ohm Meter (provided in Elcon)
üClose the Breaker.
üConnect the Voltage sensing cable to the TOP and the MIDDLE flange.
üNext connect the Current injecting cables to the TOP & MIDDLE flange.
üPass DC current through the pole .
üRecord the contact Resistance

— Routine test procedure for circuit breaker

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Routine test procedure for circuit breaker

Close Dynamic resistance Contact R1

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Routine test procedure for circuit breaker

Open Dynamic resistance Contact R1

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Routine test procedure for circuit breaker

TEST : 05
Dynamic contact resistance measurement in open operation (DCRM)
üInstrument Requirement: DCRM kit (Provided in Elcon)
üClose the circuit breaker.
üConnection same as in contact resistance test.
üGive open command to circuit breaker & record the signature of dynamically contact open operation.

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Routine test procedure for circuit breaker
TEST : 06

Tightness test

üInstrument Requirement: SF6 Leak Sensing meter

üProcessed 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.

üThis same sniffing test is carried out on the Gas pipe and the Distribution
Block for tightness ,wherever applicable.

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Routine test procedure for circuit breaker

TEST : 07

Design and visual checks

üThe circuit-breaker shall be checked to verify its compliance with the

order specification
üThe language and data on the nameplates
üIdentification of any auxiliary equipment
üThe colour and quality of paint and corrosion protection of metallic
surfaces
üThe values of the resistors and capacitors connected to the main
circuit

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Routine test procedure for circuit breaker

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

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Routine test procedure for circuit breaker
Breaker in Close Breaker in Open
position position

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Routine test procedure for circuit breaker

TEST : 09
Dielectric test on auxiliary and control circuits

üInstrument Requirement: 1 kV AC voltage tester

üAll supply to the operating mechanism is isolated.
üThe Earthing of the 1 kV tester is connected to the Earthing of the
operating mechanism.
ü1 kV shots are applied on each and every terminal for 1 second.

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Routine test procedure– LTBE1 245 kV breaker
LIMITING VALUES

Close Time : Max. 28 ms Close velocity : 7.4 to 8.0 m/s

Open Time : Max. 21 ms 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 mW (At 20 º C)

— Routine test procedure– 400 kV LTBE2

breaker
n LIMITING VALUES

Close Time : 60 Max ms Close velocity : 3.9 to 4.3 m/s

Open Time : Max. 25 ms 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 mW (At 20 º C)

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Routine test procedure– 800 kV LTBE4 breaker

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

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 mW (At 20 º C)

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Routine test – 245 kV ELF SL 4-1 breaker

LIMITING VALUES
Close Time : Max. 130 ms
Open Time : 16 – 30 ms
CO Time : 35 – 45 ms
Contact Resistance : Max. 45 mW (At 20 º C)
Close velocity : 4 - 6 m/s
Trip velocity : 7.5 to 9.5 m/s
Stroke length : 200 ± 2 mm

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— Routine test procedure – 400 kV ELF SP 6-2 Breaker

LIMITING VALUES

Close Time : Max. 150 ms

Open Time : Max. 25 ms

CO Time : Max. 60 ms

Contact Resistance : Max. 96 mW (At 20 º C)

Close velocity : 3.2 to 4.7 m/s

Trip velocity : 6.5 to 8.25 m/s

Stroke length : 200 ± 2 mm

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Equipments used at test plants

Breaker analyzer (Elcon, Sweden)

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

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ABB PowerTEC™ scheduled courses Y2019
Sr. Course
Course Name Days Jan Feb March April May June July August Sep Oct Nov Dec
No. No.

HV & MV Switchgear (CB,CT/CVT,DC and For details Write to

1 INTCV181 6 18-23 8-13 4-9
SA) and Power Transformers [email protected]
2 HV Gas Insulated Switchgear (GIS) * INTCV185 3 6-8 14-16
HV, Hybrid Switchgear System, Plug &
3 INTCV312 2 9-10 17-18
switch System (PASS)
Operation & Maintenance and condition
4 INTCV477 6 8-13 5-10
Monitoring of Switchyard Equipments

5 Power Transformers - Level 2 INTCV561 5 11-15 16-20

6 Power system protection * INTCV601 3 4-6 4-6
Relion® 615 / 620 series - Operation and
7 INTCV602 2 7-8 7-8
engineering
8 Relay handling tool PCM600 INTCV603 1 9 9
Relion® 615 series - Testing and
9 INTCV620 2 11-12 11-12
commissioning * H R Gujjar
10 IEC 61850 for protection application * INTCV621 2 13-14 13-14 [email protected]
Power system studies and relay
11 INTCV476 4 6-9 10-13
coordination
12 Electrical Safety INTCV572 2 26-27 20-21 9-10
13 Substation engineering INTCV213 1 25 22 11

14 Power system earthing INTCV565 2 23-24 12-13

Bundled course - S/s engineering, power

15 system earthing, power system studies INTCV1211 6 4-9
and relay coordination

INTCV566
16 HVDC and FACTS 2 19-20
& 567 Manisha Shukla
17 Microgrids, renewables & BESS * INTCV570 3 21-23 [email protected]
18 Asset Performance management * INTCV569 2 17-18

19 Digitalization of power system * INTCV571 1 19

ABB reserves all rights for the content provided in this presentation. Reproduction, use by or
disclosures to third parties without ABB’s written permission is strictly forbidden

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