CIRCUIT BREAKER TESTING SWP

All workers must have completed Field Induction or have

1. PURPOSE AND SCOPE recognition of prior Ergon Energy Field Experience.
Provide guidelines for testing of circuit breakers. Contractors must have completed Ergon Energy's Generic
Contractor Worker Induction.
Details of specialised circuit breaker tests are not included in this
SWP.
3. DOCUMENTATION
2. STAFFING RESOURCES CS000501F115. Daily / Task Risk Management Plan

Adequate staffing resources with the competencies to safely ES000901R102. HSECH Risk Control Guide
complete the required tasks as per MN000301R165: 8 Level Field MN000301R165. 8 Level Field Test Competency
Test Competency.
SP0509R01 Circuit Breaker Testing Job Safety Analysis
These competencies can be gained from, but not limited to any or
all of the following:- SP0509C01 Circuit Breaker Test Report

 Qualifying as an Electrical Fitter Mechanic SP0509C01R01 Circuit Breaker Sample Test Report

 Qualifying as a Technical Service Person SP0509C02 Circuit Breaker HV Withstand Test Report.

 Training in the safe use of relevant test equipment SP0509C03 Circuit Breaker Testing Competency Assessment

Requirement for all live work: SP0506 Substation Primary Plant and Secondary Systems Field
Testing SWP
 Safety Observer (required for all “live work” as defined in the ESO
Code of Practice for Electrical Work). AS 1931 – 1996 – High Voltage Test Techniques Parts 1 and 2

All resources are required to: AS 2006 – 1986 – High Voltage A.C. Switchgear and Controlgear –
Circuit Breakers for Rated Voltages Above 1,000V
 Have appropriate Switching and Access authorisations for the
roles they are required to perform and have the ability to assess AS 2650 – 1986 – High Voltage A.C. Switchgear and Controlgear –
and maintain relevant exclusion zones from exposed live electrical Common Requirements
apparatus AS 2467 – 1981 – Maintenance of Electrical Switchgear
 Hold current licences for any vehicles and equipment they may be Test Equipment Manual
required to operate.
Circuit breaker Manual / Manufacturer’s Drawings
Required Training
Staff must be current in all Statutory Training relevant for the task.

SP0509

Owner: EGM Operations Release: 4, 02 Nov 2022 | Doc ID: 2934536

SME: Business Improvement Manager Uncontrolled When Printed 1 of 6
 CIRCUIT BREAKER TESTING SWP

4. KEY TOOLS AND EQUIPMENT (eg barriers, matting) to prevent inadvertent contact with adjacent
live plant or breaching exclusion zones. Furthermore, the P53
Test Equipment within calibration date, tested and tagged Operate the Network Process is applicable at all times for isolation
and earthing.
Safety Barriers
Careful consideration should be taken with the selection and
HVIA Operating Equipment – PED’s, Live Line Tester, Class 0
placement of test leads. Only use appropriately rated test leads
gloves. All equipment to be inspected and confirmed within test
that are placed to be clearly visible to reduce the risk of them
date prior to use
being not seen and removed prior to placing plant back into
PPE including full-length protective cotton clothing, safety footwear, service. Where possible, use leads that are supplied with the test
helmet. Additional PPE as required: brim for safety helmet, leather equipment since these will have suitable connectors and the
work gloves, class 00 gloves, hearing protection, safety eyewear, correct current and voltage rating. Leads should be selected and
high visibility clothing when working on or near roadways. All PPE used such that it is not possible to leave leads connected to the
to be inspected and confirmed within test date (where applicable) plant under test when the test equipment is removed (for example
prior to use an integrated lead set or trifurcated leads).

Sun protection to be used when working outdoors

As described in Carry Out Field Testing SWP SP0506, particular
5. TASK STEPS safety risks applicable to Circuit Breakers include:

5.1. Carry out an on site risk assessment  Contact with high voltage at CB primary connections.

 High fault current at CB primary connections.

Prior to performing this activity any hazards associated with
prerequisite tasks at the worksite shall be identified and assessed  Stored energy (eg charged spring) in the closing and tripping
with appropriate control measures implemented and documented mechanism
in accordance with the Daily/Task Risk Management Plan
 Initiation of other protection or control functions by change in
CS000501F115 and using reference document HSECH Risk
state of circuit breaker auxiliary contacts
Control Guide ES000901R102.
If any risks cannot be managed or reduced to an acceptable level, 5.3. Record identification details.
do not proceed with the task and seek assistance from your
 Manufacturer’s name, manufacturer’s type description and
Supervisor.
manufacturer’s serial number:

5.2. All work to be done with circuit breaker de-energised  Plant number;

All of the tests described in this SWP should be carried out with  Description, ie. dead tank, live tank etc;
the CB de-energised and appropriate control measures in place

SP0509

Owner: EGM Operations Release: 4, 02 Nov 2022 | Doc ID: 2934536

SME: Business Improvement Manager Uncontrolled When Printed 2 of 6
 CIRCUIT BREAKER TESTING SWP

 Rated voltage and insulation level; Consideration shall be given where electronic components are used
in the auxiliary and control circuitry. Different testing procedures
 Rated nominal and short-circuit current and duration; and values maybe adopted subject to agreement by the
Commissioning Engineer.
 Rated operating sequence;
5.6. Measure Resistance of the Main Circuit.
 Interrupting medium;
Measurement shall be made using D.C. current of at least 50A and
 Specialised requirements such as:
less than the nominal current rating of the circuit breaker. The test
Rated Transitional Recovery Voltage envelope, Rated Out of shall be conducted as close as practical to ambient temperature.
Phase Breaking Current, Rated Cable Charging Breaking
A four wire ductor should be used for measuring the resistance of
Current, Rated Capacitor Bank Breaking and Inrush Making
the main contacts.
Currents, Rated Small Inductive Breaking Current.
Measure Insulation Resistance.
5.4. Visual inspection of Circuit Breaker condition.
DC insulation tests are to be carried out between terminals of the
Inspect the circuit breaker for any sign of damage or leaks both
circuit breaker as detailed below. Note that these connection
externally and in the circuit breaker marshalling box. Confirm that
arrangements have been specified for consistency with AS2650 and
the interrupting medium level/pressure is correct before
to allow for future insulation condition diagnostic assessment. The
commencing tests and that assembly is complete and no transport
voltage applied will be as per Table 1 for a duration of 1 minute.
bracing has been left in place.

Inspect the external surfaces and ensure the circuit breaker is clean With the circuit breaker in the closed position:
and dry.
 A or a to Earth and all other terminals
Check all connections for adequate labelling. The connections
 B or b to Earth and all other terminals
should be unambiguous, legibly and adequately marked.
 C or c to Earth and all other terminals
5.5. Auxiliary and Control Circuit Voltage Withstand.

The circuit breakers auxiliary and control circuitry shall be subjected With the circuit breaker in the open position:
to a 1 minute power frequency withstand test at 2kV to confirm
insulation integrity.  A to Earth and all other terminals

The circuitry shall be considered to have passed if no disruptive  B to Earth and all other terminals
discharge occurs during the test.
 C to Earth and all other terminals

SP0509

Owner: EGM Operations Release: 4, 02 Nov 2022 | Doc ID: 2934536

SME: Business Improvement Manager Uncontrolled When Printed 3 of 6
 CIRCUIT BREAKER TESTING SWP

 a to Earth and all other terminals 5.7. Carry out HV Testing.

 b to Earth and all other terminals AS 2006 – 1986 specifies that normally no dielectric tests are
performed at site on the main circuit, however AS 2067 – 1984
 c to Earth and all other terminals
specifies that a 90% power frequency withstand test be carried out
on site after erection. The level of high voltage testing to be applied
A, B and C refer to one set of CB high voltage terminals (eg fixed
is therefore:
contact – top of CB) and a, b, and c refer to the other set of
terminals (eg moving contact – middle of CB) a) Where no HV testing has been carried out at the manufacturer’s
works – 100%.
Minimum acceptance value for new plant is 1,000M.
b) Where HV testing has been carried out at the manufacturer’s
Table 1. Applied Voltages for IR Tests works but subsequent assembly of the HV chamber / bushings
is required on site – 90%.
Primary Voltage Rating Test Voltage in kV
(D.C.) c) Where HV testing has been carried out at the manufacturer’s
works and no on-site assembly is required – No HV withstand
Up to 1kV 1 test.

Above 1kV to 3.6kV 2 d) If the circuit breaker is aged or refurbished – 75%.

Above 3.6kV to 12kV 5 Where Um<=66kV the value of voltage applied shall be as per AS
2650-1986 as listed in the table below.
Above 12kV 10
Where Um>66kV the value of test voltage shall be in accordance
with AS 2650-1986.
Measure Timing.
Note that the test voltage used may be limited by the output
The time taken for the circuit breaker to complete an operation shall
capability of the test equipment. In this case a reduced test voltage
be measured for both opening or closing. Timing should be started
for an extended duration as specified in Table 11.1 of AS 2067 –
by the application of voltage to the trip/close coil and stopped by
1984 may be used.
operation of the main contacts. For both single and three pole CBs,
each pole is timed independently as per clause HH2.4.2.1 of The requirements of the test are satisfied if no disruptive discharge
AS2006 - 1986 occurs.

Note – test both trip coils. Time travel measurement is required for An insulation resistance test is to be repeated after the HV
110 kV and above CBs or any CBs assembled on site. withstand test to confirm that insulation degradation has occurred.
Measure spring charge time following close operation.

SP0509

Owner: EGM Operations Release: 4, 02 Nov 2022 | Doc ID: 2934536

SME: Business Improvement Manager Uncontrolled When Printed 4 of 6
 CIRCUIT BREAKER TESTING SWP

Application of a 1 minute power frequency withstand test is to be in Schedule of Tests

accordance with AS1931 Part 1 between the load and line terminals The table below details the circumstances in which different tests
of the circuit breaker as detailed below. Note that these connection are carried out:
arrangements have been specified for consistency with AS2650 and
AS2006 (Clause 7.1). Test New Circuit Breaker Aged or refurbished
Circuit Breaker
With the circuit breaker in the closed position:
High Voltage Workshop or on-site Workshop or on-site
 A/a and C/c to Earth and all other terminals Withstand test required at test required. Reduced
discretion of values apply.
 B/b to Earth and all other terminals Commissioning
Engineer *.
With the circuit breaker in the open position.
Auxiliary and Review manufacturers On-site test required if
 A, B and C to Earth and all other terminals Control test result only circuit breaker wiring
Circuit has been substantially
 a, b and c to Earth and all other terminals Voltage modified
Withstand

Insulation On-site test required On-site test required

Nominal voltage Highest Voltage Rated Short term
Resistance
of system for equipment Power-frequency
(Un) (Um) withstand voltage Resistance On-site test required On-site test required
kV r.m.s. kV r.m.s. (PFWV) Of Main
KV r.m.s. Circuit
3.3 3.6 10
Timing On-site test required On-site test required
6.6 7.2 20
Time Travel Required for Required for
11 12 28 transmission CBs or transmission CBs or
CBs assembled on site CBs assembled on site
22 24 50
*otherwise review manufacturer’s results only
33 36 70
DDF and capacitance measurement of the CB insulation may be
66 72.5 140 required at the request of the client, particularly if DLA test
equipment is available on site at the time of commissioning.

SP0509

Owner: EGM Operations Release: 4, 02 Nov 2022 | Doc ID: 2934536

SME: Business Improvement Manager Uncontrolled When Printed 5 of 6
 CIRCUIT BREAKER TESTING SWP

u) Apply a latched trip command and then a close command

5.8. Complete Pre-commissioning Checklist while the trip is maintained;
v) Check operation of interlocks;
Circuit breakers being placed in service for the first time or after
refurbishment require that the following items are checked prior to w) Check operation of all alarms;
energisation: x) Check control switches in service position;
y) Check operational nameplate and labels are in place.
a) Check closing with 85% normal supply volts;
b) Check closing with 85% normal air pressure;
c) Check tripping with 70% normal supply volts (85% if AC);
d) Check insulation medium/pressure;
e) Check gas pressure alarm;
f) Check gas pressure trip/lockout;
g) Check fuses and links in service position;
h) Check main earth on cabinet and support structure;
i) Check motor overload/excess run timer set;
j) Check local trip operation, including operation with both trip
coils in parallel;
k) Check local close operation;
l) Check remote trip operation;
m) Check remote close operation;
n) Check SCADA trip operation;
o) Check SCADA close operation;
p) Check protection trip operation;
q) Check protection reclose operation;
r) Function test all Local/Remote/Maintenance switch;
s) Check operation of pole discrepancy protection (if fitted);
t) Check anti-pumping relay operation ie apply a close
command and then a trip command while the close is
maintained;

SP0509

Owner: EGM Operations Release: 4, 02 Nov 2022 | Doc ID: 2934536

SME: Business Improvement Manager Uncontrolled When Printed 6 of 6