Condition Monitoring of Circuit Breakers

INTERRUPTER DESIGN

Breaker Operation

Internal Details of Interrupter

Typical Operating Links

CB Operating Mechanism

Operating Mechanism

Compressed Air Open/ Close Compressed Air Open/ Spring Close Hydraulic Open/ Close Spring Open/ Close

Current interruption

Ideal Interruption of Current

Resistance Circuit

Inductance Circuit

Reactor Switching

Line/ Filter Switching

TRV

Recovery Voltage and build up of dielectric strength of the medium

Dielectric Strength

TRV

Unsuccessful arc quenching

Dielectric Strength of different mediums

FAILURE OF CBs IN POWERGRID

MECHANICAL 74% (OPERATING COMPONENETS FAILURES)
ELECTRICAL (DIELECTRIC FAILURE) OTHERS 16%

10%

Condition Monitoring

Timing Measurement Tan delta measurement of grading capacitors Dew point measurement of SF6 Static Contact resistance measurement DCRM with travel measurement

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.

NEED FOR DCRM

DURING NORMAL CONTACT RESISTANCE MEASUREMSENT, HEALTHINESS OF MAIN CONTACTS IS INDICATED. 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. DCRM ALONGWITH CONTACT TRAVEL MEASUREMENT IS HELPFUL IN COMPUTING THE ARCING CONTACT LENGTHS.

Requirement of 10kHZ sampling frequency

While current transfers from main to arcing contacts, there is sudden increase in the dynamic resistance value resulting in the resistance peak of about 0.20 to 0.30ms width. To accurately plot this peak, we require resistance measurement/ sampling atleast once every 0.1ms. This corresponds to 10kHz sampling frequency. During Contact travel, to record travel measurements with 1mm resolution (10mm/msec), this require sampling every 0.1 ms and hence requirement of 10kHz.

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

Typical DCRM Signature

Parameters to be monitored

Variations of Resistance values at the time of Arcing and main contact close/ trip. Insertion of Arcing contact. Insertion of Main Contact. Contact travel. Resistance during closed conditions and its comparison with static contact resistance value. Damping system healthiness

Contact Travel and Insertion Details

Travel Total Contact Insertion 28 mm Main Contact Insertion 12 mm

Arcing Contact Insertion

16 mm

CGL

230mm/ 140mm

BHEL
ABB AREVA

242/ 130mm
200mm 180mm

54 mm
50 mm 45 mm

34 mm
20 mm 25 mm

20 mm
30 mm 20 mm

Contact speed

Trip velocity 5-8 m/sec

Close velocity 3-4 m/sec

Precautions to be taken while carrying out DCRM test

Sampling frequency of kit is 10kHz (min) DCRM to be taken for CO operation. CO delay time to be atleast 300 ms hence requiring plot length of about 450ms. CB flanges where Current and Voltage cables are to be connected, should be thoroughly cleaned by CTC Connection should be done only on Interrupter flanges and not on PIR or grading Capacitor flanges.

DCRM case Studies

Case Study-1
400kV SF6 CB commissioned in 1997 was controlling Bus Reactor. CB had given about 8 years service with 1400 operations.

Healthy Pole

Suspected Pole

Observations

Moving Arcing contact was found de-shaped and had expanded One Counter Head Screw of Moving Main Contact assembly was found loose PTFE Nozzle of moving contact assembly found cracked. Scratch marks were also seen on Main Moving Contact

De-shaped Arcing Contact

Loose Screw and marks on main contact

Case Study-2
This CB was commissioned in 1993 at Hissar and was controlling a Transmission Line. DCRM signatures after closing operation were not stable and wide variations were observed.

DCRM Signature of defective CB

Internal Inspection of Suspected CBs

The CB was opened for internal inspection. Bearing Bush (part no. SG90011024) used for moving main contact to the operating lever had loosened This caused misalignment and subsequent damage to moving contact Finger Contact Assembly. Defective Components were replaced

Bearing Bush was missing

Case Study-3 400kV ABB make CB at Hyderabad

Disengaged coupling bolt

Long Rod Assembly Moving Contact

Helicoil problem
Helicoil

DCRM Signatures after rectification

Case-4 Interesting Case Study

CB 952 inspected in March,2006 at Hyderabad s/s. After rectification, DCRM of B pole CT side not alright. The Test kit was changed but same problem was indicated in DCRM. New spare pole was erected but same problem was again indicated. M/s Scope was called with new kit but problem continued ABB then brought Contact Assembly from factory and then rectified the problem.

952- B Isolator side

952-B CT side

Contact Assembly changed

After rectification on 30.03.2006

Case Study-5
Jamshedpur Substation on 26.04.2007

220kV CB at Rourkela s/s overhauled by CGL Engineer B phase of 552 as on 24.11.2006

220kV CB at Rourkela s/s Y phase of 552 as on 24.11.2006

Travel
After lot of persuasion with CGL, Service Engineer was deputed on 23.05.2007. Following observations were found:
Actual Wipe of Contacts = 27-28mm Arcing Contacts Main Contacts = 15-17mm = 10-12mm

Wipe found as 21mm which was adjusted to 29mm on 24.05.2007

220kV CB at Rourkela s/s B phase of 552 as on 24.05.2007

Internal Inspection of CBs

About 48 nos. CBs have been opened so far based on DCRM evaluations. Erosion of Contacts, Misalignment, loose connection etc. problems were observed. Timely inspection of CBs could help in rectification of CBs and hence avoiding major failures.

Conclusion

DCRM Test (non-invasive diagnosis) for CBs proved useful in indicating condition of main/ arcing contacts for erosion, misalignment and looseness etc. Prevention of Major failures by timely diagnosis Major overhauling of Interrupters/ Arcing chamber can be decided based on DCRM

POWERGRID PHILOSOPHY FOR MAJOR OVERHAULING OF CBs

MANUFACTURERS RECOMMENDATIONS

AFTER 10 YEARS OF COMMISSIOINING OR AFTER 5000 OPERATIONS WHICHEVER IS EARLIER POWERGRIDS PHILOSOPHY

BASED ON EVALUATION OF CONDITION MONITORING TEST RESULTS LIKE DCRM, OPERATING TIMINGS, CONTACT TRAVEL ETC. INITIALLY, 2 NOS. CBs ARE INSPECTED/ OVERHAULED AND BASED ON THE EXPERIENCE GAINED, DECISION FOR OVERHAUL OF BALANCE CBs CAN BE TAKEN.

POWERGRID EXPERINCE ON OVERHAULING OF CBs

POWERGRID has so far overhauled total of 198 Nos. CBs

Dew point measurement of SF6

Dew point measurement gives dryness of SF6 gas SF6 is green house gas with 23,900 times more active than CO2 Care to be taken not to let the gas left to the atmosphere Can be measured at atmospheric pressure or at rated pressure and interpretation to be made accordingly

SOURCES OF MOISTURE IN CB

GAS HANDLING FILLING AND EMPTYING THE CB. AIR MAY BE LEFT DURING EVACUATION WHICH SHALL ADD TO IMPURITIES IN SF6 GAS. EVACUATION TO BE DONE UPTO 1 mbar (CIGREWG23) EXUDATION OF MOISTURE CONTAINED IN ORGANIC INSULATING MATERIALS. PERMEATION THROUGH SEALED SECTIONS

DEW POINT MEASUREMENT

DEW POINT MEASUREMENT

IF SF6 GAS CONTAINS MOISTURE, IT IS EASILY HYDRATED TO PRODUCE HIGHLY REACTIVE H2SO3 AND HF(HYDROGEN FLUORIDES).
AS THESE CHEMICALS CAUSE DEGRADATION OF INSULATION AND CORROSION IN THE INTERRUPTING CHAMBER, MONITORING OF MOISTURE CONTENT IN SF6 GAS IS VERY IMPORTANT.

CONTAMINATION OF SF6 GAS BY MOISTURE

Experience with CBs having PIR

Indian 400kV Transmission network has been conventionally using CBs with PIRs even for short lines. During 1994/95, failures involving PIR assemblies were encountered in POWERGRID networks on 22 nos. CBs. CB failures were critically analyzed with CB manufacturer. Defective components of PIR assembly like Pull Rod, moving contact assembly etc. were modified for enhancing reliability of CBs. PTI, USA System Studies suggested that PIR can be dispensed with for switching Transmission Lines up to 200km Length. CBs with maximum failures were attended and PIR assemblies removed from 70 nos. CBs. New CB procurement are without PIR assemblies for lines upto 200km length.

Questions?