Engr Saima Ali High Voltage Fa18-EPE-069

COMSATS University Islamabad,

Abbottabad Campus

Testing of Circuit
Breaker

Name Registration #

Aamir Ali khan FA18-EPE-069

Assignment
04

Subject
High Voltage

Submitted to
Engr Saima Ali

Date
December 22, 2021

AAMIR ALI KHAN 1

Engr Saima Ali High Voltage Fa18-EPE-069

Testing of Circuit Breaker

1. Definition:

A mechanical switching device, capable of making, carrying, and breaking currents under
normal circuit conditions.

1.1. Introduction:

Circuit Breaker Testing is utilized to test the

operation of each switching systems and the
programming of the entire tripping structure.
Circuit Breaker Testing is essential to ensure
the safe and reliable performance of this key
link in the power asset chain.

Testing of circuit breakers is more difficult as

compared to other electrical equipment like
transformer or machine because the short
circuit current is very large. Testing of the
transformer is mainly divided into two groups,
type tests, and routine tests.

1.1.1. Different categories of Circuit breaker are:

According to different criteria there are different types of circuit breaker. According to
their arc quenching media the circuit breaker can be categorized as:

• Oil circuit breaker. Vacuum Circuit Breaker

• Vacuum circuit breaker
• SF6 circuit breaker.
• Air circuit breaker.

Oil Circuit Breaker

AAMIR ALI KHAN 2

Engr Saima Ali High Voltage Fa18-EPE-069

SF6 (Sulfur hexafluoride) Circuit Breaker Air Blast Circuit Breaker

1.2. Type Tests of Circuit Breaker.

Type tests are conducted for the purpose of proving the capabilities and confirming the
rated characteristic of the circuit breaker. Such tests are conducted in the specially built
testing laboratory.

1.2.1. Routine Tests of Circuit Breaker.

The Routine tests confirm the proper functioning of the circuit breaker. Routine testing
doesn’t necessarily include complex gear in order to ensure that a circuit breaker is
functional. Some guidelines and recommendations for these tests include routine
maintenance and verifying that that circuit breaker performance is in line with
manufacture’s calibration curves. It is crucial that these tests are performed under stable
conditions at suitable temperature so that there are no variations in the data. Some of the
tests are listed below.

Type tests can be broadly classified as the mechanical performance test, thermal test,
dielectric or insulating test, short circuit test for checking the making capacity, breaking
capacity, short time rating current and operating duty.

AAMIR ALI KHAN 3

Engr Saima Ali High Voltage Fa18-EPE-069

1.3. Tests

1.3.1. Mechanical Test.

It is mechanical ability type test involving the repeated opening and closing of the
breaker. A circuit breaker must open and close at the correct speed and perform its
designated duty and operation without mechanical failure.

• To ensure the open and closing without mechanical failure.

• It’s requiring 500(sometimes 20,000) operation without failure and with no adjustment of
the mechanism.
• A resulting change in the material or dimensions of a particular component may
considerably improve the life and efficiency of the mechanism.

1.3.2. Thermal Test.

Thermal tests are carried out to check the thermal

behavior of the circuit breakers. The breaker under
test deal with the steady-state temperature rises
due to the flow of its rated current through its pole
in a rated condition. The temperature rise for rated
current should not exceed 40° for current less than
800A normal current and 50° for normal value of
current 800A and above.

• To check the thermal behavior of the

breakers.
• Rated current through all three types of phases of the switch gear is passed
continuously for a period long enough to achieve the steady state conditions.
• Temperature rise must not exceed 40*C when the rated normal current is less than
800 amps and 50*C. if it 800 amps and above.
• Contact resistance between the isolating contacts and between the moving and fixed
contacts is important. These points are generally the main sources of excessive heat
generation.

1.3.3. Dielectric Test.

These tests are performed to check power frequency and impulse voltage withstand
capacity. Power frequency tests are kept on a new circuit breaker; the test voltage
changes with a circuit breaker rated voltage.

AAMIR ALI KHAN 4

Engr Saima Ali High Voltage Fa18-EPE-069

The test voltage with a frequency between 15-100Hz is applied as follows.

(1) Between poles with circuit breaker closed.
(2) Between pole and earth with circuit breaker open.
&
(3) Across terminals with circuit breaker open.
In impulse tests impulse voltage of specified magnitude is applied to the breaker. For
outdoor circuit dry and wet tests are conducted.

I. Dielectric Test

• Consists of over voltage withstand tests of power frequency, lightening and

switching impulse voltages.
• Tested for internal & external insulation with CB in both the open & closed position.
• Voltage in Open position > 15% of that of closed position.
• During test, CB is mounted on insulators above ground to avoid ground flash over.
II. Impulse Test

• The test is done with switching over voltage.

• To access their performance under over voltages due to switching operation.

1.3.4. Short -Circuit Test.

Circuit breakers are subjected to sudden short-circuits in short-circuit test laboratories,

and oscillograms are taken to know the behavior of the circuit breakers at the time of
switching in, during contact breaking and after the arc extinction.

The oscillograms are studied with particular reference to the making and breaking
currents, both symmetrical and asymmetrical restriking voltages, and switchgear is
sometimes tested at rated conditions.

• To check the ability to safely interrupt the fault current.

• To determine the breaking capacities at different load current.

Methods of conducting short circuit test.

I. Direct Test.
• Using the power utility system as the source.
• Using a short circuit generation as the source

AAMIR ALI KHAN 5

Engr Saima Ali High Voltage Fa18-EPE-069

II. Synthetic Test.

• Heavy current at low voltage.
• Recovery voltage is simulated
by high voltage, small current
source.

• Procedure:
When auxiliary breaker 3 and test circuit breaker T are closed making
switch 4 and master breaker 1 is closed. Hence, current flows through
test CB.

1.3.4.1. Short Circuit breaker test in laboratory.

• To test the CBs at different voltages & different SC currents.

• The setup consists of,
➢ A SC generator
➢ Mater CB
➢ Resistors
➢ Reactors & Measuring devices

• To make switch initiates the circuit short circuit & master breaker isolates the
test device from the source at the end of predetermined time.
• If the test device failed to operate, master CB can be tripped.

1.4. Routine Test:

1.4.1. Preventative Maintenance of Circuit Breaker, Inspection, and Testing

Preventative maintenance depends operating

conditions for circuit breakers. Primary
inspections of CB (circuit breakers) will look
at particulate matter that’s contaminating the
inner workings of the CB. Accumulation of
particulates can generally be disposed of by
flipping the lathe on the breaker “Off” and
“On” switch to clear away the accumulated
dust.

AAMIR ALI KHAN 6

Engr Saima Ali High Voltage Fa18-EPE-069

1.4.2. Circuit Breaker Trip Test

By analyzing the current consumed by the trip coil

during the circuit breaker’s operation, it is possible to
determine whether there are mechanical or electrical
issues present. In many cases, such issues can be
localized to aid in finding the root cause. Optionally,
monitoring the tripping supply’s voltage during the
operation can detect issues arising with tripping
batteries.

1.4.3. Insulation Resistance Test

For individual breaker resistance

testing, load and line conductors
should be preferably disconnected.
If not detached the test values will
also involve the characteristics of
the connected circuit. Resistance
testing is crucial for verifying that the insulating material which makes up the molded
cases breakers are performing correctly. In order to test for insulation resistance, an
instrument known as a megger is used. A megger instrument applies a known DC voltage
to a given wire for a given period of time in order to test the resistance within the
insulation on that particular wire or winding. It is vital that voltage is employed as the
resistance checked with an ohmmeter may differ when there are no report of potential
differences. It should also be noted that if you apply a voltage that is too high for that
insulation to withstand, then you could potentially damage the insulation.

1.4.4. Connection Tests

Connection testing is important to make sure that an

appropriate electrical connection is available and to
recognize traces of overheating denoted by color
difference. It is important that electrical connections
are properly installed to the CB to prevent and reduce
overheating.

AAMIR ALI KHAN 7

Engr Saima Ali High Voltage Fa18-EPE-069

1.4.5. Contact Resistance Test

Normal wear and tear of contacts within the

CB emerges after extended usage. An easy
method to identify traces of weakening within
the circuit breaker is to quantify the resistance
across every pole of the breaker. Indications of
abnormal conditions within the CB such as
erosion and contamination of contacts are
evident if there are excessive millivolt drops
across the breaker. The contact resistance test
is important in finding out if or not a circuit
breaker is still apt for functioning.

1.4.6. Overload Tripping Test

Overload tripping components of CBs

can be tested by inputting 300% of the
breaker rating into each pole of the
circuit breaker to determine that it will
open automatically. The motive of
this is to make sure that the circuit
breaker will operate or not. Refer to
NETA standards for trip times that are
acceptable for the overload tripping
test. When trying to find out tripping
characteristics, it is advisable to
consult with manufacturer’s manuals.
Fig. Tripping again and again

1.4.7. Instantaneous Magnetic Tripping

In routine tests, it is relevant to find out that the magnetic

feature is functional and will trip the circuit breaker instead
of finding the precise value at which the instantaneous
magnetic feature functions.

Fig. Inverse Time Circuit Breaker

AAMIR ALI KHAN 8

Engr Saima Ali High Voltage Fa18-EPE-069

1.5. Circuits Breaker Importance:

Circuit Breaker Testing is used to test both the performance of individual switching
mechanisms and the timing of the overall tripping system. Circuit Breaker Testing is
essential to ensure the safe and reliable performance of this key link in the power asset
chain.

1.6. Circuit Breaker Benefits.

Circuit Breaker Testing is vital to make sure a safe and reliable performance of the
circuit:

• Quick and easy to perform on site

• Circuits can be tested on or off load
• Tests performance of whole tripping cycle
• Tests overall timing of tripping system
• Identifies need for maintenance

1.7. Disadvantage:

The disadvantage to using a circuit breaker is that it can be more expensive to install,
repair and replace. Circuit breakers won’t react as quickly as a fuse in power surges. This
means it would be possible that electronics connected to the circuit could be damaged by
energy that is just let through. It can be more sensitive to vibration and movement, which
may allow for a switch to trip for reasons that are unrelated to electricity overloads.

THE END

AAMIR ALI KHAN 9