A SIMPLIFIED METHOD FOR DETERMINING HV CIRCUIT BREAKER CONTACT CONDITION - DYNAMIC RESISTANCE MEASUREMENT

Jozef Levi, Application Engineer Doble Engineering Company

INTRODUCTION The primary goal of circuit breaker testing is to determine the condition of the breaker. Breakers have moving parts components which allow electrical contacts to separate (an open or trip operation) or to close. Whether those contacts are in a vacuum, in oil or in a gaseous medium, it makes sense to test the moving parts of the breaker a motion or travel test. If the motion of the contact system is in accordance with manufacturer specifications then we can reasonably conclude that all mechanical parts, from the mechanism which provides the movement to the contacts themselves, are in good condition. The question is: what measurements will give necessary but sufficient data for a correct decision regarding breaker performance? Practically all circuit breaker test instruments have the capability to detect when the impedance of the breaker contacts change from a relatively low value (circuit breaker in closed position) to a relatively high value (circuit breaker contacts in open position). A typical high voltage circuit breaker contact system consists of two sets of contacts: main contacts and arcing contacts. When a standard timing method is applied, arcing contact opening and closing time can be measured through changes in impedance. Because of the relatively small difference between arcing contacts impedance and main contacts impedance, the moment of change over between those two sets of contacts is not detected. One way to try and see the changeover is to inject a high DC current in to the breaker and, through a voltage drop measurement, determine the impedance and thus detects the moment of change over between the two sets of contacts. METHOD History The so called method of dynamic resistance measurement was introduced to time particular breakers with stationary arcing contact system. Arcing contacts are fixed at a position determined during breaker design and they do not move during circuit breaker operation. To protect the main breaker contacts an arcing ring is introduced. The material of the arcing ring is a combination of graphite and other arc resistant materials. Analyzing test results obtained during timing of these breakers is often difficult with inconsistent results. To mitigate this problem, the use of a high DC current, injected in to the main contacts, is used to try and determine slight changes in impedance. The impedance is predominantly resistive and the breaker contacts are in motion hence the misnomer dynamic resistance. Measurement of the static or non-moving contact resistance with the breaker in a closed position will give the total resistance from connection at one breaker terminal to the connection at the other breaker terminal. (Practically we can only measure the resistance with the breaker closed; an open breaker will
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have infinite resistance.) During such a static measurement the arcing contacts are bypassed and we only measure the main contacts. Consequently, the resistance value is a good indicator of breaker main contact condition, but it is not a good indicator for arcing contact condition. Breaker contacts The overall contact system of circuit breakers consists of two distinct contact elements: Contacts with primary role to conduct currents when breaker is in closed position Arcing contacts designed to be first to touch and last to part; any electrical arc formed during breaker operation will appear on the arcing contacts. Whenever an arc is present there is an element of destruction of the materials which are subjected to the arc. The arcing contacts themselves are made of a combination of metals with high temperature of vaporization (e.g. tungsten) and low temperature of vaporization (e.g. copper or silver). The reason is to allow for longer contact life than could be achieved through use of a single material. The shape of the arcing contacts is probably their most important characteristic, with individual designs based on the dynamics of opening and closing the circuit breaker. At some point during an arc the alternating current which forms the arc will pass through zero; this is the instant at which current practically ceases to flow. At that moment a transient voltage will be present across arcing contacts. If the distance between arcing contacts is sufficient to withstand transient voltage we will have a successful opening operation. If the voltage is greater, the arc will re strike and alternating current begins to flow again. Let assume that a distance L sufficient to withstand transient voltage is reached after time t. This assumes that the shape of arcing contacts is according to design and there is no damage to the contacts, and that the breaker operates to move the contacts at a given velocity (which is not constant but allows us to reach the distance L in time t). In the case where arcing contact shape has changed, for example through damage from previous arcs, it is probable that the distance L will not be sufficient to withstand transient voltages and time t will increase as the contacts must now travel further at a finite velocity to reach the new value of L. If we do not change opening velocity the breaker will not clear current (extinguish the arc) within the specified time; this leads to a longer arc time and consequently more material destruction and damage. Clearly, the performance of the arcing contacts is critical to the performance of the breaker. Knowledge of the shape of the arcing contacts will give us a tool to predict breaker performance and thus the probable useful life of the breaker. The characteristics of the arcing contacts can be inferred through several methods, notably the so called dynamic resistance measurement. In practice there are two basic contact systems in use in circuit breaker design: cluster type contact system with contact fingers so called butt contacts where two contact surfaces meet Maintaining contact pressure in the cluster system can be achieved with additional separate springs or with use of alloys for contact fingers which combines good mechanical and electrical characteristics. Contact fingers with springs are much more prone to bouncing than contacts made of high hardness cupper alloys. Existing dynamic resistance method In essence, dynamic resistance is calculated from a combination of: DC current is injected in to a breaker as it operates
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 DC voltage across the HV circuit breaker contacts while they are in motion Results are presented graphically and in tabulation form with resistance plotted as a function of time. From the resulting resistance plot the point of change from main contacts to arcing contacts can be detected. In the case where motion is also measured, the actual length of the arcing contacts can be calculated. There is an alternative method which uses slow motion of circuit breaker when DC current is injected. The only difference between slow motion method and regular speed method is that there is a need for additional operation of circuit breaker and power source which can supply power for prolonged period of time. Such slow motion method results do not represent a real situation because there are no breakers which will operate with such low speed. Specifically contact system will not behave as it will when breaker is operated with normal velocity. Results of this method can be described as static resistance measurement at multiple points and are usually considered to be of substantially lower value than those collected when the breaker operates normally. Simplified test method Same as existing method DC current is injected during breaker operation. Voltage drop is measured during trip free or close open operation. Difference between trip free and close open is for how long breaker will be in closed position. During trip free operation closing time is defined as dwell time and usually is between 20 and 50 ms. Dwell time is pre determined with auxiliary switches. Close open operation is combination of two separate operations closing and opening. Time when breaker is in closed position can be adjusted with test instrument. Difference between those two operations is in mechanical stress on circuit breaker contact system. During trip free operation breaker contact system is in motion all the time and open operation follows close operation. When sufficient delay is implemented between close and open operation then opening operation will be without influence from closing operation. Delay time of 250 to 350 ms is sufficient to have two separate operations and influence of closing operation on opening is minimal. Using trip free or close open operation eliminates use of DC battery protection. Battery is practically in short circuit during testing. It is recommended to test trip free or close open operation before using battery. Test procedure Circuit breaker is in open position. Regular 12 V batteries can be used as source for current injection. Circuit breaker is used to close and open battery circuit and there is no need for special safety circuit to prevent too long battery stress. Analog channel at test instrument is used for voltage drop measurement across breaker terminals. It is recommended to perform trip free test without battery to check if everything is connected properly and breaker will operate trip free. Trip free or close open operation is performed and voltage drop is recorded. Testing and test results analysis Intention of testing circuit breakers is to find in what condition is testing circuit breaker. After test is performed and testing data is collected next step is to analyze test results. Based upon test results analyze decision can be made what are next steps. Decision can be from not doing anything with breaker up to opening breaker and physically checking contact systems and mechanical parts.

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One of most important request during analyzing process is that someone who actually analyzes test results has full knowledge of tested circuit breaker design and operation. In case of voltage drop measurement different contact system designs will have different finger prints. There are two major groups of high voltage circuit breaker contact system designs: cluster and butt type. In this article we will concentrate on cluster type contacts. Both main and arcing contact system can be of cluster type. Main characteristic of cluster contact system is that separated contacts are positioned in circle and each contact element will have at least one contact point. To achieve good contact pressure there are two different approaches. Contact pressure is produced with additional springs and second one where contact pressure is produced with material characteristics. Each type of contact system will have own signature characteristics. Figure 1, shows voltage drop measurement with cluster contact system with springs. Contacts with springs allow relatively large movement of fingers perpendicular to moving contact travel. As results voltage drop diagram shows changes during closing and during opening part of operation. Contact elements are separate before closing operation and during penetration changes on voltage drop measurement are much more visible than during opening operation. In case that there is misalignment between stationary and moving contacts that can be detected at closing. Moving and arcing contacts are fully engaged before opening operation and that will show les changes on voltage drop diagram.

Close Open voltage drop test results with cluster type contacts with springs Figure 1

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Figure 2, shows voltage drop measurement with cluster contact system with no spring for arcing and main contacts. Contacts made of copper chromium alloy do not require springs and movement of contact fingers is short in comparison with contacts with springs. As results voltage drop diagram shows very small changes during closing and during opening part of operation.

Close Open voltage drop test results cluster type contacts made with cupper chromium alloy. Figure 2

Case study Cluster type contacts with no springs The Simplified method for detecting HV breaker contact condition tests were performed on 420 kV live tank SF6 breaker at a client site in Mexico. Circuit breaker contact system is without springs and contact fingers are made of cupper chromium alloy. Arcing stationary contact is also without springs and has two halves. Timing CLOSE test showed that there are bouncing on some of breaking element of two breaks per phase breakers. Car battery was used as power source for high current injection. Voltage drop was measured across each breaking element during trip free operations. Grounding cables where used as conductors.

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Timing results of one phase of 420 kV breakers with bouncing on one breaking element (digital test results) Figure 3 Simplified method showed that there are bouncing starting on arcing contacts and finishing when main contacts are engaged. Main contacts are adjusted properly and arcing contact bouncing is not visible after main contacts are engaged. Arcing contact separation shows no signs of imperfection. Trip free dwell time was too short and that required additional adjustment.

Bouncing on arcing contacts voltage drop measurement After adjustment of arcing contact test was repeated and there were no bouncing on arcing contacts Figure 4

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Test results after adjustment without bouncing Figure 5 In case when motion and voltage drop are measured in same time, length of arcing contact can be determined. Following figure shows how arcing contact length is determined.

Arcing contact length calculation Figure 6 Conclusions Simplified method for detecting HV breaker contact condition proved valuable in detecting contacts problems. Test preparation is simple and there is no need for additional hardware except ready available car battery. Grounding cables can be used as conductors for high DC current injection. Both Close and Trip operation can be used for detection contact system quality. VDM results depend on breaker contact system design and can be compared with previous test of same or same breaker type. VDM results can be combined with motion measurement for arcing contact length calculation. Test method can be used as quality control in production and in service. Different contact system will give different voltage drop patterns and for test results analyze contact system design and breaker operation has to be known.

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REFERENCES
Jose RODRIGUEZ ARIAS, Application of the Dynamic Resistance Measurement Technique in the Measurement of Operating Times for High Voltage Circuit Breakers, Doble European Colloquium, Seville 1995 Charles C. Serrie, DYNAMIC RESISTANCE TESTING AS A TOOL FOR ASSESING SF6 BREAKER CONTACT CONDITION, Doble Spring Conference 2005 H.F.A. Verhaart and Andre E. Lux, A DIAGNOSTIC TO DETERMINE THE CONDITION OF THE CONTACTS OF LOAD TAP CHANGERS IN POWER TRANSFORMER, Doble Spring Conference 2004

BIOGRAPHY
Jozef Levi is an application engineer at Doble Engineering Company, focusing on TDR instruments and Circuit Breaker testing. Born in Sarajevo, former Yugoslavia, he received his Diploma Electrical Engineer from Electrotechnical Faculty of University of Sarajevo. Before joining Doble in 1999 he worked at the Energoinvest Electrical Institute in Sarajevo, Energomex in Mexico City and E Manufacturing in Mentor, Ohio. Jozef designed SF6 circuit breakers and high voltage disconnects switches.

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