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MaintenanceofSubstationEquipment

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TableofContents
Articles
1.0Introduction

Links

2.0BreakdownMaintenanceVersusPreventiveMaintenance

Categories

3.0Inspection,Servicing,Overhaul

Tags

4.0GuidelinesforMaintenanceofSwitchgear
5.0MaintenanceScheduleCheckList
6.0MaintenanceofCircuitBreakers
7.0MaintenanceofAirBreakCircuitBreaker,FusegearforLowandMediumVoltages.

Whatisthis?
Thisisanarticlepostedon
March11,2012.

8.0MaintenanceofOilCircuitBreakers(BOCB,MOCB)
9.0MaintenanceofAirBlastCircuitBreakers
10.0MaintenanceofVacuumCircuitBreaker

Sofar,thisarticlehas0
comments.

11.0MaintenanceofSF6CircuitBreaker

Thisarticleisapartofthe

12.0Likelytroublesandessentialperiodiccheckstoavoidthem

categorySubstation

13.0MaintenanceofTransformers
14.0CareandMaintenanceofEarthing

Thisarticleistaggedwith
maintenance

15.0InsulationResistanceMeasurement
1.0Introduction

Latestarticles

Theswitchgearandprotectiverelayingsystemshouldbealwaysalerttooperateagainstan

Hydrogen

unexpectedlyfault.Switchgearwhichwasinquiescentstatehastooperateimmediately.Forsuchan

Energyand

operation,regularanddetailedmaintenanceisnecessary.Thelackofmaintenancemayresultin

FuelCells,

failureinoperation.

posted1year,

Themaintenancerequirementsofstaticequipmentsliketransformers,capacitorsetc.aremuchless
comparedtootherdynamicequipmentslikecircuitbreakers,motorsetc.

1monthago.
Energy
Conservation,

TheSwitchgearmanufacturesuppliesInstructionManualofInstallation,Operationand

posted2years,

Maintenance.Thesemanualsshouldbecarefullystudiedbytrainedmaintenancestaff.Thecodeof

7monthsago.

practicebookletspublishedbythestandardsinstitutionregulationsofelectricalinstallationsarealso

Energy

useful.Detailedprogrammeofmaintenanceofswitchgearshouldbepreparedwithpredetermined

Conservation

intervalsbetweeninspections.Theperiodmaybeonetothreemonthsifswitchgearisoperated

BuildingCode,

frequentlyandsixmonthstotwelvemonthsifswitchgearisoperatedrarely.Afteroperationofthe

posted2years,

circuitbreakeronabnormalcondition,inspectionshouldbecarriedoutasearlyaspossible.Further,

7monthsago.

itisunwisetoleavethecircuitbreakercloseforaperiodlongerthansixmonthswithoutopening,

Energy

becausethemechanismmaybecomesluggishandcontactsmayneedcleaning.Henceduringthe

Conservation

periodicmaintenance,thecircuitbreakerispurposelyopenedandclosedbymanualcommand.

Act,posted

Themaintenancescheduleisusuallyintheformoflogsheetsonwhichweeks,monthsoftheyear

2years,

aretabulated.Eachequipmentinthesubstationortheplantisprovidedwithacolumn.The

7monthsago.

maintenanceperiodisindicatedagainsteachequipment.Furthereachmajorequipmentisprovided

Utilization

withahistorycard.Thedetailsaboutinspection,operationandremarksarewritteninthesecards.

Factorof
Liminaires,

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Thesparesareimportantformaintenanceduty.Thesparesarekeptinstockwithproperinventory
control.

Liminaires,
posted2years,
7monthsago.

Themaintenanceworkisdoneaccordingtotheschedule.Incaseofdifficultjobsthemanufactureris

Latestlinks

consulted.Themanufacturerprovidestrainedpersonnelonrequestandnecessarypayment.
2.0BreakdownMaintenanceVersusPreventiveMaintenance
Maintenanceisclassifiedintwocategoriesasfollows:
1.ThebreakdownorCorrectiveMaintenanceactivitiesareundertakenafterfailureofan
equipment.Suchmaintenanceresultsinoutageofcircuitandsupply.Ingeneral,it
consistsoflocatingthetrouble,repairandrecommissioning.
2.ThePreventiveMaintenanceisundertakentoensuresmoothandefficientworkingofa
system,equipment.Preventivemaintenanceisundertakenasperschedulebefore
breakdownofasystemormachinetakesplace.
Aperformancerecordofeachcriticalcomponentismaintainedandbasicdecisionsontheservicelife
ofthecomponentandthetotalserviceithasputin.Repairsorreplacementsaremadetoensurethat
nobreakdownoccursatanytimeduringtheservice.
Preventivemaintenanceiscarriedoutinplannedmanner.Breakdownmaintenanceiscarriedoutas
andwhennecessary.ForSwitchgearandprotectiveequipment,preventivemaintenanceis
recommendedbecausefailureofaswitchgearcannotbepermitted.
3.0Inspection,Servicing,Overhaul
Maintenancecoversawiderangeofactivitiesaimedatkeepingtheequipmentinperfectworking
conditionforperformingitsfunctionasperassignedduties.Thechoiceofactivitiesandschedule
dependsuponlocalrequirements.
1.Inspection:Thisreferstothemaintenanceactivitywhichcomprisescareful
observation/scrutinyoftheequipmentwithoutdismantlingit.Itusuallyincludesvisualand
operationalchecks.
2.Servicing:Thisreferstocleaning,adjustment,lubricationandothermaintenance
functionswithoutdismantlingtheequipment.
3.Examination:Thisreferstoinspectionwithnecessarydismantling,measurementsand
nondestructiveteststoobtaindataregardingtheconditionofcomponents/sub
assemblies.
4.Overhaul:Thisreferstotheworkdonewiththeobjectiveofrepairing/replacingwornout
partsanddefectiveparts.Theequipment,subassembliesaredismantledpartlyor
completely.Theconditionofcomponentsisinspected.Dimensionsofwornout
componentsaremeasured.Thecomponentswornoutbeyondacceptablelimitare
replaced.Theassemblyisfollowedbyfunctionalchecksandmeasurementstoensure
satisfactoryoperation.
4.0GuidelinesforMaintenanceofSwitchgear
Therequirementofinspection,servicingexaminationandoverhaulvarywith:
Environmentalaspectssuchasdust,chemicalfumes,moisture/humidity,ambient
temperaturevariations,etc.
Operatingdutyfrequencyofoperation,ratedcurrent.
Switchingdutyseverity,e.g.repeatedoperations.

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Switchingdutyseverity,e.g.repeatedoperations.
Manufacturergivesgeneralguideline.Itisnotpossibletoobtainexactmaintenanceschedule
meetinglocalrequirementofeachsite.Hencemaintenancescheduleisdeterminedafterinitial
periodicinspectionateachsite.Incaseofswitchgearandcontrolandprotectionpanelsdistinction
shouldbemadebetweenthemaintenanceoffixeddeviceslikebusbars,insulatedenclosuresetc.
andmaintenanceofswitchingdeviceslikecircuitbreaker,isolator,earthingswitch,contractorsetc.
havingmovingparts.
Thefixedpartsneedregularinspectionandservicingforremovingdustdamp,corrosionetc.Moving
partsneedregularinspectionandperiodicreplacementofwornoutparts.Thefunctionalreadinessof
switchingdevicesshouldalsobeensured.
Themaintenanceofswitchingdevicesisrelatedmainlywiththewearingoutofcontacts,deterioration
ofquenchingmediumandmechanismcomponents.Themaintenancerequirementsofvacuumcircuit
breakersSF6circuitbreakersarequitemodestascomparedwiththoseofoilcircuitbreakers,
minimumoilcircuitbreakers.Invacuumcircuitbreakersinterrupterisapermanentlysealedunitand
thecontractshavelongswitchinglife.PuffertypeSF6circuitbreakershavelongswitchinglifeand
thegasesdonotneedreplacement.Hencethepresenttrendistousemaintenancefreevacuumand
SF6circuitbreakers.
Tablebelowgivesrecommendationregardingtheperiodofmaintenanceofcontactsandquenching
mediumintermsofnumberofloadoperationsandnumberofshortcircuitoperationsonratedshort
circuitbreakingcurrent.Thescheduleshouldbeestablishedforeachsitebycheckingthecontactsof
onepoleaftereverythreemonthsandobservingtherateoferosion.
MaintenanceofQuenchingMediumContacts
MaintenanceofQuenchingMedium
Replacementofcontacts
TypeofC.B.
K(In)
Load*Operation FaultOperation Load**Operation FaultOperation
AirC.B.

3000
10to15

BulkOilC.B. 2000
6
2000
6
2000
MOCB
1000
3
1000
6
1000
AirBlastC.B.

15000
25
15000
SF6C.B.
5000
25
15000
25
15000
V.C.B.*

20000
100
20000
*Shelflife20years.
**MechanicalEnduranceTestshouldbeperformedwithspecifiednumberofoperationsonnoloadto
confirmsuitabilityofmechanism.

Note
Duringeverybreakingoperation,contactloosessomematerialandthequenchingmediumgets
decomposed.Thedecomposedproductsgetsdepositedontheinternalinsulatingpartsofthecircuit
breakers.ThedeteriorationofcontactsandinternalinsulationisproportionaltoK,thecumulativesum
oftheproductofthenumberofbreakingoperationandsquareofthebreakingcurrentinKA(In)
andistakenasaguidetotheinspectionofcontacts,internalinsulationandthequenchingmedium.
ThevalueofKdependsuponthetypeofcircuitbreakers(ReferTableabove).
Lifeofcontactsbecomesupposedlybadaftercertainoperationsonloadandorafterclearingfaults
onratedshortcircuitcurrentanindicationofwhichisshowninTable2.
MaintenanceofContacts
LifeofContacts
Typeof
Numberofloadoperationsonrated
Numberoffaultoperationsonratedshort
C.B.
loadcurrent
circuitcurrent
VCB
10,000
50100

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VCB
10,000
SF6
4,000
MOCB
1,000
Airbreak

50100
1525
36

CB

1,000

16

AirBlast
CB

4,000

1525

5.0MaintenanceScheduleCheckList
Thechecklistofmaintenanceofswitchgeargivesthelistofactivitiesandthereperiodicity.The
periodicityofaboveactivitiesvarieswith:
Typeofswitchingdevices.
Frequencyofoperatingdutyandbreakingcurrent.
Environment.
ImportantChecksonCircuitBreakersduringRoutineMaintenance
Activity
1.Checkinsulationresistanceofeachpoleofphasetogroundacross
terminals.
2.Checkanddielectricalstrength.
3.CheckMechanicaloperations.
4.Checktightnessofbolts.
5.Checkoillevel.
6.Cleanprocelaininsulators.
7.Checkcontactlengthandsimultaneouscontacttouch.
8.Measurecontactresistance.
9.Cleancrossjetpots,reconditioncontactsfilloil(OCB).
10.Measurecontactspeed.
11.MeasureBreakTime,MakeTime.
12.Levelofoil/gaspressure.

Half
yearly

Quarterly

Annual

X
X
X
X

X
X

X
X

ThechecklistandmaintenancescheduleforvarioustypesofcircuitbreakersareindicatedinTable
below,andthefollowingabbreviationshasbeenused:
DI= DailyInspection.
WI= WeeklyInspection.
MI= MonthlyInspection.
QI= QuarterlyInspection.
HI= HalfyearlyInspection.
AI= AnnualInspectionMaintenance.
OH= Overhaul.
N= Normalduty
R= Repeatedoperationsonratedloadcurrent
CheckListandMaintenanceScheduleforCircuitbreakers
Air
Air
Indoor
Minimum Vacuum SF6
break
Blast Metalclad
OilC.B.
C.B.
C.B.
Maintenanceactivity
C.B.
C.B.
MV
N R N
R
N R N R N R Switchgear
1
2 3 4
5
6
7 8 9 10 11
12
GeneralInspection
QI MI QI MI AI QI AI QI HI QI HI
Cleaningofexternalinsulation.
QI QI QI
QI QI QI Qi QI HI
Contacts,contactsshrouds(ABCB),Nozzles
(SF6CB)ArcControlDevices(MOCB),Ext.
HI QI HI QI AI AI 5Y AI 5Y AI
Contactposition(VCB)Contactresistance(All)
Quenchingmechanismincircuitbreakerand
HI QI

AI AI QI
toppingup
CleaningofinternalinsulationofCB
AI HI AI HI

5Y AI 5Y AI
Terminalconnections,earthingconnections,
AI HI AI HI AI AI AI AI AI AI QI
structure,cabinetcableetc.
Sealingleakageofmedium,Pressureof
QI QI

QI QI QI QI
medium
Mainmechanismoperatingchecks,interpole
HI QI HI QI AI AI AI AI AI AI
linkages
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linkages
Servicing
Controlwiring
OperatingchecksandInsulationresistance
measurement,Contactresistancemeasurement
PostfaultmaintenanceafterNo.offault
operations
Overhaulafterno.ofyears
No.offaultopearations
No.ofloadoperations

5Y AI AI
AI AI AI

HI
AI

5Y AI
AI AI

5Y AI 5Y AI AI
AI AI AI AI AI

AI HI AI

HI

AI

AI AI AI AI

10

5
5
1
1
2000 1000

AI

50

25

25

25

50
10
10000

10
10

5
5

5000 5000

6.0MaintenanceofCircuitBreakers
ThefollowingstepsareinvolvedinMaintenanceofCircuitBreakers:
1.GeneralInspection:Observethecircuitbreakervisually.Notethecleanliness,terminals,
earthconnections,readingsofcounters,levelsofquenchingmedium(incaseofOil
Circuitbreaker),pressureofquenchingmediumincaseofSF6circuitbreakersetc.
2.CleaningandDrying:UseCTCLortrichloroethyleneorothercleaningagent
recommendedbymanufacturer.Thefluidshouldbecompatiblewiththesurfacetobe
cleaned.Useairpressurejet(3kg/cm2)forcleaning.Usecleanclothwhichdoesnot
leavefibresorparticlesonthesurface.
Careshouldbetakentoavoidfallingofdust,ironparticles,nutbolts,washersetc.inside
thebreaker.Avoidwater,moistureordampnessduringcleaning.Internaldustand
moisturecausesgradualdepositsoninternalsurfaceresultingingradualincreaseof
surfaceleakagecurrentsandinternalflashoverbytracking.Congealedlubricantsshould
beremovedbymeansofsolvents.Thecleaningandslidingsurfacesshouldbecleaned,
relubricated.Beforeassemblyofthecircuitbreaker,theinterruptersupportporcelain
componentsetc.shouldbecleanedindrycleanatmosphere.
Afterassembly,evacuatethebreakerpoletoremovemoisture,dustmoleculesetc.and
thenfilloilorSF6gas.GroovesforOringsonflangesshouldbecleanedwith
tricloroethylene,soastoremovehardenedgreaseanddust.Suchadustorgreasewill
givetheunevensittingofthenewOringandcausegradualleakageofSF6oil.Nodust,
chalkmarksfibres,hardgreaseetc.isallowedontheOringgrooves.
Terminalsshouldbecleanedofdust,oxidecoatingifanybyemerypaperwithoutiron
particles.
Circuitbreakerpolecanbeinternallydriedbycirculatingdryhotairorbyevacuatingto2
mmofmercury.IncaseofSF6circuitbreakerorporcelaincladvacuumcircuitbreaker,
thedryingofpoleunitsshouldbecarriedoutbeforefillingSF6gasordrynitrogen.SF6
gasordrynitrogendoesnotremovethewaterdropsanddustdepositedontheinternal
surface.Hencedryingandevacuatingisnecessary.
AsmallportablevacuumpumpwithTeflonhoseisconnectedtothevalve.Thebreakeris
keptundervacuumforafewhours.ThereaftertheSF6gas/drynitrogenisfilled.The
moistureiseliminatedduetoapplicationofvacuum.Dryingisrecommendedbeforefilling
offreshSF6gas/nitrogen/oilinthebreaker.
3.InsulationSurface:Inspectvisually,carefullyforsignsofcracks,trackingoranyother
defects.Cleantheinternalinsulatingsurfacesandexternalinsulatingsurfacesas
mentionedin2above.Insulationshouldbefreefromelectricalormechanicaldefects.
Performinsulationresistancemeasurementtestsaftercleaning.Insulationresistance
measurementgivesindicationaboutthehealthoftheinsulation.
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Incaseofoilcircuitbreakersandminimumoilcircuitbreakers,theinternalinsulation
shouldbecleanedthoroughlybymeansoftrichloroethylene,cleanclothandairjet.The
depositionofsludgeandcarbonparticles,conductingdustparticlesshallberemoved
beforereassembly.
IncaseofSF6circuitbreaker,thedecompositionproducts(graycolour)getdepositedon
internalsurfacesofinsulators.Thesearenonconductingwhendry.Ifthecircuitbreakeris
dismantledduringmoistatmosphere,thesesurfacesarenotcleanedbeforeassembly,the
internalflashoverislikelytooccurdespitethegoodpropertiesofSF6gas.Incaseof
vacuuminterruptersonlyexternalcleaningispossible.
Incaseofairblastcircuitbreakers,nointernalcleaningisgenerallynecessaryasfresh
mediumisusedforarcquenching.Incaseofporcelaincladoutdoorvacuumcircuit
breaker,thepoleunitsshouldbeinternallycleananddrytoavoidinternalflashoverby
tracking.Glassfibrepullrodsshouldbecleanedthoroughly.
Particularattentionshouldbepaidtothenozzles,arccontrolpots,arccontrolplates.They
shouldbecleaned.Ifburntordisfigured,replacethem.
AftercleaninganddryingmeasureinsulationresistancebyMegaohmmeter(Megger)
betweentwoterminalsofeachinterrupterandbetweentheterminalandearth.Insulators
ofcircuitbreakersinstalledinheavilypollutedareasandseashoresneedfrequent
externalcleaning.Themethodofmeasuringtheinsulationresistanceisshownintheend
ofthischapter.
4.Interrupter:Studytheoperationandmaintenancemanualofthecircuitbreaker.Notethe
importantsettingsandmeasurementsofmovingcontact,othermovablepartswith
referencetofixedflangesandtheallowedtoleranceinthesettings.Checksimultaneous
touchof3polesifslowclosingispossible.Mainactivitiesintheinterruptermaintenance
include:
Observation,cleaning,replacementofmain/arcingcontactsPTFEnozzles,
arccontrolpotplatesetc.
Cleaningtheotherpartsaswell.
ReplacinghardenedOrings,wornoutslidingparts.
Removalofcarbon/metallicdecomposedproducts.
Cleaningofventingsystemstoensurefreepassageofoil/gases.Thevents
shouldbemadefreebutnotenlarged.
Cleaningterminalsandslidingcontactsurfaces.
Assemblywithpropersettingsofcomponents.
5.Mechanism:Checkoperationopencloseclosingfollowedbyopeninglocally.If
operationO,C,COaresatisfactory,themechanismissatisfactoryanddoesnotneedany
majorrepair/maintenance.
Checkoperationcounter.Ifthemechanismhasoperatedmorethan1000times,itneeds
verycloseobservationandmayneedoverhaul.Checktheconditionofspringsand
dashpots.Twoimportantteststodeterminethehealthoftheoperatingmechanism,
linkagesandmovingcontactsettingsinclude:
Checkingsimultaneousopeningandclosingof3poles.
Checkingnoloadtimesvs.travelcharacteristicsofmovingcontactforO,CO,
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OCOoperations.
1.MethodofobtainingTimeTravelCharacteristiconnoload:Incaseof

MOCBorSF6CBpoles,thischaracteristicisextremelyimportantbecausethe
breakingcapacityisrelatedwiththetime/travelcharacteristicsofmoving
contact.Noloadcharacteristicgivessufficientindicationaboutthehealthof
mechanismlinkages.
Forsatisfactoryareinterruptionthemovingcontactshouldopenandtravelwith
optimumcharacteristic.Slowinitialmovementindicatesexcessivefriction
betweenslidingparts.Slowmovementduringmiddleofstrokeindicatesvery
highdynamicloadduringarcquenching.Slowmovementduringfinalpartof
thestrokeindicatesexcessivedampingorlowenergyofoperatingmechanism
duringopening.
Astraightrodisconnectedtothemovingcontactormovablepart(contactor
mechanism).Thisrodisinturnconnectedtothecurvorollerorrectilinear
transducer(TravelRecorded).Curvorollerisaspeciallydesignedmotordriven
drummountedonthetophoodoftheMOCB.Thepencilattachedtotherod
fixedonthemovingcontacttouchesthepaperonthedrum.Themotoris
drivenelectrically.Thedrumrotatesatknownspeed.Thegraphsheetfixedon
thedrumhasdefinitecircumferentialspeed.Duringtheopeningstrokeand
closingstrokes,thepencilgivesthetime/travelcharacteristicmarkingonthe
graphsheetonthecurvoroller.
ForhighspeedSF6circuitbreakerthecurvorollersarenotsuitable.
Rectilineartransducerisfittedsuitablyonthebreakerframe.Ithasacylindrical
resistancewithinternalmovingpiston.Thepistonisattachedtotherodwith
andswiveljointattheend.Theswiveljointandrodoftherectilineartransducer
areconnectedtothemovingrodattachedtothecontactmovementsystem.In
caseofSF6oroilCB,asuitablerectilinearsealshouldbedesignedtopermit
movementwithoutleakageofSF6/oil.Therectilineartransducerisconnected
likeapotentiometer.Thecentralterminalgivesvariationproportionaltothe
travelofthecontact.
TheoutputisgiventoUVrecorder.ThetraceofTime/Travelisobtainedon
U.V.Recorder.Thetripsignal/closingsignalisalsorecordedsimultaneously.
TheTime/Travelcharacteristicshouldmatchwiththatobtainedinthe
manufacturersworks.
2.MethodofcheckingtheContactSetting:Followmanufacturersinstruction
booklet.IncaseofMOCBandSF6,measurementofdistancefromthetop
flangesurfacetothetipofclosedcontactmaybepossible.Incaseofvacuum
interrupter,agaugewithpointermayhavebeenprovidedbythemanufacturer
toindicatecontacterosion.
MeasurementofContactResistance:Theresistancebetweenterminalsof
eachinterrupterandeachpoleismeasuredbymeansofmicroohmmeter.
Theresistanceshouldbewithinafewtensormicroohms.Apairofcontacts
hasaresistanceofabout15microohms.
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Contactresistanceisinverselyproportionaltothecontactpressure.Low
contactpressuremaybeduetoweekspringsorwornoutcontacts.High
contactresistancecauseexcessiveheatingofcontactswhilecarryingnormal
currentandpossibleweldingduringthroughshortcircuit.
3.MechanicalAssembly:Checkthatallthenutboltsareintheirpositionand
checktheirtightness.Checkcirclips,splitpins.Cleanandlubricatesparingly.
Oildashpotsshouldbecheckedforcurrentlevelandoperation.AirDashpots
shouldbecheckedforcurrentoperation.
Cleaninspectandreplacewornoutpartsduringoverhauls.Incaseofspring
operatedmechanismchecktheratchetwheelsandprawtsforbrokenor
chippedteeth.
Valvesofpneumaticmechanismorhydraulicmechanismshouldnotbe
disturbedunlessthediagnostictestsindicatetheneedfortheirreadjustment.
4.Interpolelinkages:Forensuringsimultaneousoperationof3poles(within
polediscrepancyof5milliseconds),theinterpolelinkagesshouldbechecked
fordeteriorationofsprings,othercomponents.Linkagepins,circlips,nutbolts,
etc.shouldbechecked.Verifythatfixingsaretightandpivotpinsaresecure.
Maloperationofmechanism,interpolelinkage,dashpotsetc.canberevealed
bythetime/travelrecordof3polesplottedonUVrecorderasdescribedearlier.
Congealedlubricantsshouldberemovedfromsliding,rollingsurfaces.The
partsshouldberelubricatedaspertheinstructionsofthemanufacturer.
Themovingcontactsofeachphaseshouldmeetthefixedcontactpractically
SpecialOffers.

AdspoweredbyWajam

simultaneously.Anelectricalmethodofcheckingthecontactsisillustratedin
Fig.1.Alowvoltagesupply,lampsareneeded.Simultaneousglowingoflamps
indicatessimultaneousmakingofcontacts.

6.CheckandMaintenanceofotherimportantaccessories:
MainConnections.Ensurethatgoodcontactismaintainedandconnectionsarerightand
secure.
SecondaryWiringandFuses.Ensuretightandsecureconnections,cleanlinessand
freedomfromdustandmoisture.Heaterinthecabinetshouldbecheckedandrepaired,if
AdspoweredbyWajam

necessary.
EarthConnection.Themainandsecondaryearthconnectionshouldbetightandfree
fromdustandrust.
Heater.Theheaterprovidedinthecontrolcabinetshouldbeinworkingcondition.
SafetyShutters.Theshuttersmechanisminmetalcladmediumvoltageswitchgear
shouldbeverifiedafterpullingoutofdrawoutunitanddeenergizingthebusbars.
BusbarsandBusbarChambers.Thebusbarsandthebusbarchambersshouldbe
checkedforcleanlinessofinsulators,tightnessofjointsandfreedomfromdust,dampand
foreignmaterials/insectsetc.Thereshallnotbeanyloosejointsorsignsofoverheating,
meltingsparking.
AuxiliarySwitches,IndicatingDevicesandInterlocks.Auxiliaryswitchesshallbekept
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AuxiliarySwitches,IndicatingDevicesandInterlocks.Auxiliaryswitchesshallbekept
incleanandsoundconditionbecausethecorrectfunctioningofotheritemsofequipment,
includingprotectivegeardependsonauxiliaryswitch.
Inspectthecontactsandcleanorrenewifnecessary,wherepossibleverifycorrect
contactforceandcorrecttimingofcontacts.IndicatingdevicessuchasmechanicalON
andOFFindicators,semaphoresetc.shallbeinspectedtoensurethattheyareingood
orderandoperatingcorrectly.
Interlocksandlockingdevicesshallreceiveparticularattentionespeciallythose
associatedwithearthingandtestingfacilities.Adefectiveorworndevicemayresultina
dangerouscondition.Itshallbeverifiedthatanyincorrectoperationissatisfactorily
inhibitedlubricateasnecessary.
Particularattentionshallbepaidtotherequiredtimingoftheauxiliarycontactscontrolling
thetripcircuit.
IsolatingContacts.Cleaninspectforsignsofoverheating,reneworreconditionif
necessary,lubricateasrequired.

OverloadDevicesandProtectiveRelays.Routinemaintenanceshouldbecarriedoutat
correctintervals.
InstrumentsandProtectiveTransformer.Routinemaintenanceshouldbecarriedout
accordingtoinstructions.
ControlRelaysorContractors.Inspectmechanicalpartsforfreemovementwithcontrol
andmainsolenoidormotorcircuitisolatedcleanarcchutes.Inspectcontactsandrenew,
ifnecessary.
Anyflexiblebraidsshallbeinspected,especiallyforfrayingattheterminations,and
renewedifnecessary.Whereexposedtoexternalatmosphere,thebraidsshallbetreated
withasuitableprotectivecompoundwhichwillnotimpairtheirflexibility.
PressureGaugesandPressureSwitches.Thereadingsofpressuregaugesare
checkedagainstastandardgauge.Theoperationofpressureswitchesshouldbe
checkedagainsttheirsetting.
7.FinalVerification:Beforereturningtoserviceaftertheoverhaul,thecircuitbreakeris
subjectedtooperationalchecksbyperformingC,O,COoperationsfromlocalcontrol
cabinetandfromthecontrolroom.Simultaneoustouchingofthecontactsofthreephases
isverified.Insulationresistanceismeasuredbetweentheterminalsofopeninterrupter
andbetweenthelowerterminalandearth.Insulationresistanceofauxiliarywiringisalso
measured.
8.TypicalMaintenanceRecordCard:Historycardiskeptforeachcircuitbreaker.
:CircuitbreakerS.N.:
:Make:
:YearofManufacture:
:Ratings:
:Making/BrakingCapacity:
:ShortTimeRating:
:Inspectiondate:
:Permittoworknumber:
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Component

Observation Actiontaken Initials

Mechanism
Linkages
Quenchingmedium
Maincontacts
Arcingcontacts
Terminals
Finalverification
7.0MaintenanceofAirBreakCircuitBreaker,FusegearforLowandMediumVoltages.
Thescheduleofmaintenancedependsuponthefrequencyofloadoperationsandfaultoperations.
Forfrequentloadoperations/faultoperations,maintenancerequirementishigh.Forindoor,dustfree
installationwithinfrequentloadoperations,thefollowingscheduleisrecommended:
Inspectasoftenaspossiblewithmaximumintervalof12months.
Examineat5yearsinterval.
Overhaulwhenexaminationanddiagnostic,testsindicateneed.Maximumintervalof15
years.
Maintenanceforaircircuitbreakerandswitchgear
RoutineMintenance
Maintenanceoperation
Examinationand
Inspection
overhaul
Operationalchecks.
X
X
VisualInspection.
X
X
Cleaning.

X
Insulationresistance.
X
X
Circuitbreakerenclosure.

X
Main/archingcontacts.

X
ArccontroldevicesandInterphase

X
barriers.
Mechanisms.

Auxiliaryswitches,indicatingdevicesand

X
interlocks.
Isolatingcontacts.

X
Overloaddevicesandprotectiverelays.
X
X
Instrumentandprotectivetransformers.

X
Controlrelayorcontractor.

X
Mainconnection.

X
Secondarywiringandfuses.

X
Earthconnection.

X
Heaters.

X
Shutters.
X
X
Switchgearspouts.

X
Busbarsandbusbarschamber.

X
Weathershields.

X
Finalverification.
X
X
Maintenanceofauxiliaryequipment.

X
Diagnostictesting

Postfault
maintenance

X
X

X
X

8.0MaintenanceofOilCircuitBreakers(BOCB,MOCB)
Thescheduleforinspectionandmaintenancedependsuponthefrequencyofloadoperationsand
faultoperations.Oilcircuitbreakerinstalledoutdoorandindamp/rainyareasneedfrequent
inspection.Themainrequirementisinspectionofoil,contactsandinternalinsulation.
1.Undernormalconditionsforfrequentoperations:Oncein6monthswithmaximumperiod
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1.Undernormalconditionsforfrequentoperations:Oncein6monthswithmaximumperiod
of9months.
2.Forfrequentoperations:Onceinthreemonths.
3.Afterfaultclearance.Iffaultlevelishighinspectasearlyaspossible.Iffaultlevelislow,
inspectafterfaultopeningoperations.

4.Overhaul.Oncein5yearsfornormalandoncein3yearsforrepeated/frequentfaultduty.
5.Duringtheperiodiccheckupthefollowingchecksshouldbemade:
1.Checkthelevelandconditionofoil.
2.Cleantheinsulatorswithfinefabriccloththatwillnotleavefibres.Donotuse
cottonwasteinanycase.Forremovingoil,grease,carbondeposituse
trichloroethyleneorotherchemicalrecommendedbythemanufacturer.
3.Checkcontacts.
4.Checkoperatingmechanism.
5.Checkoil.
6.Checkauxiliaryswitches.
7.Tightennuts,boltsetc.
8.Testinsulationresistancebymeansofhighvoltage(1000V.D.C.)meggerin
caseofhighvoltagecircuitsandby500Vmeggerin220Vcontrolcircuits.
9.Carryouttestsaccordingtothespecifications.
10.Takethestepsasmentionedinthesubsequentparagraphs.
6.Whenthebreakeroperatesonfault,theinternalandexternalinspectionshouldbecarried
outassoonastheoperatingschedulepermits.
1.Examinetheoil.Ifbadlydeteriorated,changeit.
2.Checkarcingcontacts.Cleanwithsmoothfile.Ifbadlydamaged,replace
them.
3.Inspecttheinsulation,carefullycheckthesurface.
4.Checkthearccontroldevice.Ifdamaged,replacetheplates.
5.Checkthetrippingcircuitandoperatingmechanism.
6.Besurethatnotoolsareleftinthetank.Somefurtherdetailsaregivenbelow.
7.Checkthedielectricpropertiesofoil.Inoilcircuitbreakersandminimumoil
circuitbreakers,oilservesasinsulationandarcextinguishingmedium.
Insulatingoilfortransformersandswitchgear(IS3351963)(BS1481959)is
recommendedintheseapplications.Propertiesoftransformeroil(BS:148
1959)aregivenintheTable6.
PropertiesofDielectricOil
Characteristic

Limitingwave

Sludge(maximum)

1.200%

Flashpoint(closedminimum)

295(146C)

Viscosityat700F

37CS

Electricstrength,1minuteminimum 40kVr.m.s.
Saponificationvalue(maximum)

1.00mgKOH/gm

Copperdiscoloration

Negative

Crackle

Shallpasstest

Impuritieshaveabadeffectonthepropertiesofoil.Theoilsampleistakenin
astandardoiltestingcup(90mmx60mmx100mmhigh).Electrodeare

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astandardoiltestingcup(90mmx60mmx100mmhigh).Electrodeare
polishedbrasssphere12.7mmdiamountedhorizontally.Thegapspacingis
4mm+0.02mm.Dielectricstrengthofoilisveryimportant.
Asampleofinsulatingoilistakenfromthebottomofthecircuitbreakertank.
Darkandbrowncloudsindicatedeterioration.Oilingoodconditionhaspale
yellowishuniformcolour.Itistestedbymeansofportableoiltestingsetwhich
consistsofaautotransformer,voltmeter,trippingdeviceetc.Thevoltagecan
begraduallyincreased.Oilingoodconditionshouldwithstand40kVr.m.s.for
oneminuteinastandardoiltestingcupwith4mmgapbetweenelectrodes.A
gapof2.5mm,shouldhavebreakdownvalueabove40kV.Theoilshouldbe
testedduringtheperiodiccheckupandwheneverthecircuitbreakerclearsa
fault.
OilMaintenance:Oilmaintenanceiscarriedoutinaccordancewiththe
standardtitledCode,PracticesofMaintenanceofInsulatingOils.Thecode
referstothecontaminationofoilanddeterminationofwhethertheoilis
suitableforfurtherservice.Itgivestheprocedureoftreatmentofoilatsite.
Contaminationofoilduetomoistureorsolidscanbedealtwithsatisfactorilyat
site.Centrifugalseparatorsareeffectiveinremovingfreewaterandfinesolid
impurities.Filtersremovethesolidimpurities.Theoilisheatedtoabout700C
bymeansofelectricheater.Thepurificationsetconsistsofpurifier,heater,
deaerator,oilpumps,strainerandotheraccessories.Theoiliscirculated
throughthepurifiertillthedesireddielectricstrengthisobtained.
Thedielectricoilshouldnevercontainsuspendedparticles,watersolubleacids
andbases,activesulphurorcolloidalcarbon.Theseimpuritiesaccelerate
deteriorationoftheinsulatingpropertiesofthedielectricoilresultingininternal
flashovers.Thedustparticles,carbonparticlesandsludgeintheoilwhichisin
suspendedformintheoilgathersalongtheconductorandinsulatorsurfacesin
presenceofelectricfield.Therebyathinconductinglayerisformedgradually
alongthesurfaceofinternalinsulationduringservice.Theflashovercanoccur
alongthesurfaceoftheinsulationduetotracking.Dustandotherparticlesare
removedbymeansoffiltersintheoilfilteringunit.
Moistureinoillowersthedielectricstrength.Therebycausinginternal
flashover.Moistureisintroducedinthecircuitbreakerthroughdefectiveseals.
Sometimes,oilfilledinbreakermayitselfhavemoisturecontent.
Viscosityindicatesfluidity.Oilwithlowviscosityhavemorefluidityandgives
bettercoolingandshorteropeningtime.Atlowerambienttemperaturethe
viscositysharplyrisesandthespeedofcontacttravelreduces.Henceviscosity
shouldbemeasuredatvarioustemperaturesandthecharacteristicofcontact
travelshouldbeplottedatvarioustemperatures.
Higher,flashpoint(145C)ispreferred.Flashpointindicatestendencyto
evaporate.Forflashpointslowerthan135C,theoiltendstoevaporate
rapidly,therebytheviscosityrisesandvolumeofoilreduces.
Whenfillingswitchgeartankwithoilitisagoodpracticetofirstrinsethetank
andtheimmersedpartwithcleanoil.Itisessentialthatthetankandthe
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surfacesofconductorsandinsulatorbekeptfreefromfibresandmoistureas
contaminationwhichlowertheelectricstrengthoftheoil.

Thereshouldbeaslittleaerationofoilaspossibleduringthefillingofthetank.
Astandingtimeshouldbeallowedafterthetankisfilledbeforecommissioning
theequipment.Hotoilshouldnotbeusedtofillswitchgear.
Inadditiontotheabove,aregularinspectionshouldbemadeofoillevels.
8.SilicajelBreather:IncaseofMOCBsandOCBs,porcelaincladVCB,silica
jelbreathermaybeprovided.Itisinstalledataslightlyhigherlevelthantop
chamberofMOCB.Duringhigherloadstheoilinthetankexpandsandthe
levelofoilinthetopchamberraises.Theaircushioninthetopchamber
permitsexpansionandcontractionoftheoilinthepolewithoutcontactwith
moistexternalair.Theaircushioninthetopchamberisconnectedtothe
externalatmosphereviaasilicajelbreatherensuringdrynessofincomingair
duringthebreathing.IncaseofporcelaincladVCB,thebreathermaybefitted
atthebottomofpole.Silicajelbreathersarefittedwithasightglassthrough
whichthecolourofthecrystalscanbeseen.Thecolourchangesfromtheblue
topinkasthecrystalsabsorbmoisture.Whenthecrystalsgetsaturatedwith
moisturetheybecomepinkandshould,therefore,bereactivated.
Thecrystalsshouldbebakedatatemperatureofabout2000Cuntilthewhole
massisatthistemperatureandthebluecolourhasbeenrestored.Cleanthe
breatherandreplacethedrycrystalsandrenewtheoilinthesealingcupatthe
bottom.
Silicajelbreathermaynotbeprovidedwithsomeoilcircuitbreakersinwhich
theupperchamberisfilledwithdrynitrogenpermanently.
MaintenancerecommendedforOCB,MOCBaresummarizedinTablebelow.
MaintenanceforOilCircuitBreakersinMetalenclosedSwitchgear
RoutineMaintenance
Maintenanceoperation

Examination

Postfault

and

maintenance

Inspection

overhaul
1.OperationalcheckC,O,CO

2.Generalinspection

3.Cleaning

4.Insulation,Insulatingoil

5.Circuitbreakerenclosure

6.Mainarcingcontacts

7.Arccontroldevices

8.Isolatingcontacts

9.Ventingandgasseals

10.Mechanism

11.Auxiliaryswitches,indicating
devicesandinterlocks
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12.Overloaddevicesandprotective

13.InstrumentandCTs,VTs

14.Controlrelayorcontactor

15.Insulatingoil

16.Tankandtanklining

17.Tankliftingmechanism

18.Mainconnections

19.Secondarywiringandfuses

20.Earthconnections

21.Heaters

22.Shutters

23.Switchgearspouts

24.Busbarsandbusbarchambers

25.Weathershields

26.Finalverification

27.Jointsandseals

28.Generalmechanicalinspection

29.Maintenanceofoilswitchesetc

relays

30.Highvoltagefuseconnectionand
associatedlinkage
31.Maintenanceofairbreakisolating
devicesassociatedwithoil
switchgear
32.Maintenanceofauxiliary
equipment

Postfaultmaintenanceofoilcircuitbreakersinmetalenclosedswitchgear:Dependingonthe
designanddutyoftheOCB,MOCB,inspectionmaybenecessaryafteraboutsixfaultoperationsor
thenumberspecifiedbythemanufacturersandbasedonlocalfaultlevel.Whensuchaninspectionis
necessaryspecialattentionshallbegiventothepointslistedbelow.Isolationofwithdrawablemetal
cladcircuitbreakersshallbedelayedforatleast10minutesafteroperationonfaulttoallowforthe
disposalofanyexplosivegases.
1.Cleaning.Insulationtankliningandotherpartsliabletodispositionfrommetalvapour
shallbecleanedandinspectedforsignsofcracking,burningorotherdamage.An
inspectionforsignsoftrackingshouldalsobemade.
2.ContactsandArccontrolDevices.Contactsshouldbeinspectedforburningorother
damageandreconditionedorrenewedifnecessaryverifycontactforalignmentandwipe.
Toremovetracesofmetaldepositsitwillgenerallybefoundnecessarytoremovethearc
controldevicesorreconditionorrenewthem.
3.Mechanism.Itshallbeverifiedthatthemechanismoperatescorrectly.Attentionshallbe
paidtosettingandclearancesaftercontactsorarccontroldevicesarereplaced.
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paidtosettingandclearancesaftercontactsorarccontroldevicesarereplaced.

4.InsulationResistance.Atestshouldbemadeoftheinsulationresistancebeforeputting
theswitchgearbackintoservice.
5.InsulatingOil.Iftheoilisbadlydiscolouredorshowevidenceofcarbonparticlesin
suspension,itmayrequirechanging.
6.JointsandSeals.Alljointsandsealsshouldbeinspectedfortightnessandparticular
attentionshouldbepaidtotankgasketswherethesearefitted.
GeneralMechanicalInspection.Thisshouldbemadeformechanismstructure,internalorexternal
tothetank.Theswitchgearshouldbetrippedandclosed.
9.0MaintenanceofAirBlastCircuitBreakers
Thecircuitbreakerusesfreshcompressedairforarcquenchinganddoesnotrequiremaintenanceof
quenchingmedium.Onlythedrynessofairshouldbeensured.Thecompressedairsystemneeds
routineinspection.
Afterspecifiednumberofoperationscontactsandnozzlesininterruptersneedcheck.Thediameter
ofnozzleabove5%callsforreplacement.Themaintenancerecommendedforairblastcircuit
breakersissummarizedintablebelow:
MaintenanceforAirBlastCircuitBreakers
RoutineMaintenance
Maintenanceoperation
Examinationand
Inspection
overhaul
1.Operationalcheck
X
X
2.GeneralInspection
X
X
3.Cleaning

X
4.Airconditioning
X
X
5.Insulation

X
6.Loadcontrolkiosk

X
7.Pressuregauge

X
8.Pressureswitches

X
9.Mainconnection

X
10.Secondarywiringandfuses

X
11.Interpolelinkages

X
12.Mainmechanism

X
13.Auxiliaryswitches,indicatingdevicesand

X
interlocks
14.Sequenceisolator

X
15.Localairreceiversandpressurevessels
X
16.Interrupters

X
17.Isolatingandarcingswitches

X
18.Earthconnection

X
19.Enclosures
X
X
20.Overloaddevicesandprotective
X
X
transformers
21.Instrumentsandprotectivetransformers X
X
22.Controlrelaysorcontractors

X
23.Finalverification
X
X

Postfault
maintenance

X
X

X
X

X
X

Thefollowinglistgivesoperationswhichmayberequiredtobecarriedoutduringmaintenance:
1.Cleaning.Allthedirtsshouldbebrushedoffandanyjointorgasketshallbecleanedprior
tocommencing,anydismantling,toavoidingressofdirtintoanyinternalportionofthe
breaker.Thisisparticularlyimportantinthecaseofpneumaticvalvegearsincerelatively
smallparticlesofdirtcancauseadisproportionalamountofdamageleakageor
malfunction.
2.MaintenanceofCompressedAirPlant.Compressedairplantsshouldbeinspectedas
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MaintenanceofCompressedAirPlant.Compressedairplantsshouldbeinspectedas

partoftheregularsubstationinspection.Itisgoodpracticetocarryoutperiodicstart/stop
testsontheplant.
Therearestatutoryobligations,toinspect,testandcertifyairreceivers(pressurevessels)
periodically.Safetyandreducingvalues,shouldalsobeinspectedduringthesametime.Guidance
onthemaintenanceofthisequipmentgivenbythemanufacturershouldbefollowed.Thedriers
shouldbeinspected.Ifnecessary,thedryingagentshouldbechanged.
10.0MaintenanceofVacuumCircuitBreaker
Vacuuminterrupterissealedforlifeanddoesnotrequireanyreplacementofcontactsforseveral
thousandsloadoperationsandabout50operationsonratedshortcircuit.Mechanismneedsperiodic
lubricationasrecommendedbythemanufacturer.Theotherpartsneedcleaningandgeneral
inspection.ThedetailsaregiveninTablebelow:
MaintenanceforVacuumCircuitBreaker
RoutineMaintenance
Maintenanceoperation
Examinationand
Inspection
overhaul
1.Operationalcheck

X
2.GeneralInspection

X
3.Cleaning

X
4.Openingdevice(trip)

X
5.Insulation
X
X
6.Circuitbreakerenclosure(Interrupter)

X
7.Mainconnections

X
8.Secondarywiringandfuses

X
9.Mechanism

X
10.Auxiliaryswitches,indicatingdevicesand

X
interlocks
11.Shutters
X
X
12.Switchgearspouts
X
X
13.Isolatingcontacts
X
X
14.Vacuuminterrupter

X
15.Isolatingandearthingswitchgear

X
16.Earthconnection
X
X
17.Overloaddevicesandprotectiverelays
x
X
18.Instrumentprotectivetransformers

X
19.Controlrelaysorcontracts

X
20.Busbarsandbusbarchambers

X
21.Finalverification
X
X

Postfault
maintenance

11.0MaintenanceofSF6CircuitBreaker
Duringperiodicmaintenance,thegassamplefromSF6circuitbreakeriscollectedandtestedfor
moistureandotherimpurities(IEC376).Thegasiscirculatedthroughfilterscontainingactivated
alumina.TheactivatedaluminaabsorbstheimpuritieslikeS2F2,SF4moistureetc.Thegascanbe
usedagainafterregeneration.
ForinstallationandmaintenanceofSF6circuitbreakeragashandlingunitisnecessary.This
consistsofavacuumpump,valves,pipings,acompressorandaservicetank.
TheSF6gasinthebreakergetsdecomposedduringquenchingprocess.Mostofthelowerfluorides
recombine,butsomeremain(S2F2,SF4etc.)inthedecomposedform.Theyarepartlyabsorbedby
activatedaluminafiltersanddissicants.SF6gassubjectedtoarcingbecomescorrosive,irritantand
hasbadodour.Itshouldnotbeinhaledorleftinatmosphere.Itiscollectedintoservicetankofgas
handlingunitbymeansofthecompressor.
ThebreakerpolesarenotdismantledbeforereclaimingtheSF6gasintheservicetankofthegas
handlingunit.SparecylindersofSF6gasinsufficientquantityshouldbearrangedinadvancebefore
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startingthemaintenanceworkofSF6circuitbreakers.IfthesubstationhasonlyafewSF6circuit
breakers,thesimplesmallergashandlingunitisadequate.ForlargesubstationshavingseveralSF6
filledequipment,alargergashandlingunitisnecessary.AchemicallaboratoryfortestingSF6gasis
alsorecommended.
PoleUnitandInterrupter:Atasuitableintervaloneinterrupterperpoletobeexaminedtoestablish
therateofburninganderosionofthecontactsandthegeneralconditioninordertoassessthe
necessityforfurthermaintenanceetc.Thisworkmustbecarriedoutunderdryweatherconditions
andprecautionstakentoavoidtheingressofanymoisturedirtintothepoleunits.
Slightburningofcopperorcopperalloycontactsshouldnotcauseanytroublebutheavierburning
shouldberemovedwithafinefile(emeryorcarborundumpapershouldnotbeused).Copperalloy
andotherarcresistingmetalcontactsshouldbeinspectedforanysignsofexcessiveburning.In
general,considerableburningofcontactscanbetoleratedbeforereplacementbecomesnecessary
butitisrecommendedthatwherecontactsrequiredressing,theminimumamountofmaterialshallbe
removedandthemanufacturersrecommendedprofilemaintained.
Itisimperativethattheforcebetweencontactshallnotbemateriallyreduced.Anyburningawayfrom
thearcingareashouldbenotedandinvestigated.Transfercontactsshallbeinspectedforanysigns
ofburningandcleanedasnecessary.
ThenozzleoftheinterrupterisusuallymadefromPTFE.Itshallbeexaminedforexcessiveburning
orerosionandthiscanbedonebycomparisonwithanewnozzle.Ingeneralthedimensionsand
profileofthenozzlearenotascriticalinSF6circuitbreakerand,therefore,agreateramounterosion
canbetoleratedbeforereplacementbecomesnecessary(5%).However,themanufacturers
recommendationsinthisrespectshouldbecarefullyfollowed.
Theinsulationadjacenttothearcingareashouldbecleanedasnecessary.Burningofthisinsulation
willindicateamisplacedarcandiffoundthismustbeinvestigated.
TheentireinterrupterisgenerallyfilledwiththindustoferosionofTeflonnozzlecombinewith
fluoridesofcontactmaterial.ThisdustisinsulatingwhennotexposedtoSF6gas.Immediatelyafter
dismantlingofthebreaker,thisdustabsorbsmoistureandbecomesconducting.Henceitshouldbe
wipedoutcompletelybymeansofairjet,cloth,trychloroethelene.Thiscleaningisessentialincase
ofcircuitbreakers.Ifassembledwithoutcleaning,theinsulationresistancegoesdownandinternal
flashoveroccursduringthenormalclosedpositionbetweenthelivepartandearthduetosurface
trackingalonginternalinsulation.
TheimportantstepsinthemaintenanceofSF6circuitbreakerincludeinternalcleaningand
replacementofSF6gas.Theoperatinglinkagesshouldnotbedisturbedunlessdiagnostictestsora
visualexaminationindicatethatthisisnecessary.Thesettingdimensionsshouldbeverified.
FiltersandDessicants:Filtersand/ordissicantsareinstalledinSF6circuitbreakertofilteroutor
absorbsomeofthebreakdownproducts.Asalastoperationpriortoclosingupthechambersofthe
circuitbreakerthefiltersanddessicantsshouldbereplaced.Undernocircumstancesshould
untreatedfilterordessicantmaterialremovedfromthecircuitbreakerafterservicebeheated.
MaintenanceforSF6CircuitBreakers
RoutineMaintenance
Maintenanceoperation
Examinationand
Inspection
overhaul
1.Operationalchecks
X
X
2.GeneralInspection
X
X
3.Cleaning

X
4.Openingdevice(Trip)
X
X
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5.Circuitbreakerenclosure
6.Gassystem
7.Sulphurhexafluoridegas
8.Insulation
9.Localcontrolkiosk
10.Pressuregauges
11.Pressureswitches
12.Mainconnection
13.Secondarywiringandfuses
14.Earthconnection
15.SF6gasheaters
16.Interpolelinkages
17.Mainmechanism
18.Auxiliaryswitches,indicatingdevicesand
interlocks
19.Interrupters
20.Localairreceivesandpressurevessels
21.Filtersanddesiccants
22.Overloaddevicesandprotectiverelays
23.Instrumentandprotectivetransformers
24.Controlrelayorcontractor
25.BusbarsandBusbarchambers
26.Finalverification

X
X
X
X

x
X
X
X
X
X
X
X
X
X
X
X
X

X
X

X
X
X
X

X
X
X

MaintenanceofSF6CBinG.I.S.:Afterinterrupting25shortcircuitsatratedbreakingcapacityor
after5000interruptionsofratedcurrentorpartload,thecircuitbreakershouldbeoverhauled.Forthis
reasonthebreakersissodesignedthatitcanbeeasilyremovedfromtheinstallation.
Havingswitchedoffandearthedthebreaker,thegasisfirstpumpedusingtheservicetruck.Thenthe
casingcontainingtheoperatingmechanism,situatedoneend,canbeopened.Alloperating
elements,trippingdevices,auxiliarycontactsandsoonarenowaccessible.Theextinctionchambers
canberemovedfromthetankwithaspecialdevice,havingfirstwithdrawntheisolatingchamber
attachedtothecasingcontainingtheoperatingmechanism.
Thepartsofthebreakerandisolatorsmustbecleanedverycarefully,throughthistaskiseasily
performed.Havingreassembledthebreaker,itmustfirstbeevacuatedbeforeitisrefilledwithSF6
gas.Assoonasthebreakerhaspasseditsfunctionaltest,itcanbeputbackinservice.
12.0Likelytroublesandessentialperiodiccheckstoavoidthem
Thepointtobecheckedduringtheperiodicmaintenanceincludethefollowing:
1.Theoperatingmechanismofthecircuitbreakershouldbeingoodworkingconditionboth
mechanicallyandelectrically.
2.Insulationresistancephasetogroundofeachpoleshouldbeabove2000megaohms,
(upto1.1kV)10,000megaohmsforabove36kV.
3.Contactpressureisimportant.Whenthecontactpressureisenoughevenalinecontact
canpassnormalcurrentwithoutoverheating.Theresistanceofpoleunitshouldbeless
than50microohms.
Tripcircuitandbatterysupply.Maintenanceofthetripcircuitandbatterysupplyis
essentialforthesatisfactoryoperationofallprotectiverelays(shunttriptype).Thebattery
shouldbeinspecteddailyforcorrectvoltage,specificgravityetc.anditshouldbekepton
tricklecharge.Theintercellconnectorsshouldbeingoodcondition.Thereshouldbea
pilotlamporalarmindicationtodrawtheattentionoftheoperator,ifthetripcoilbattery
voltagefallsbelowcertainlimits.
1.Electrolytelevelmustbemaintained10to15mmabovetheplatesforthe
properreactionoftheconstituents.
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properreactionoftheconstituents.
2.Terminalvoltageofthecellmustnotbeallowedtofallbelow1.8V.
3.Batteryshouldbechargedtoitsratedcapacitytoincreaseitsefficiency.
4.Donotallowbatterytoremaininsemidischargedconditionforlong,
otherwisethelifeofbatterywillbereduced.
5.Commercialsulphuricacidshouldnotbeusedotherwisetheactive
componentswillbedamagedverysoon.
6.Usedistilledwaterfortoppingupthelevelofelectrolyte.
7.Avoidexcessivecharging,asitreducesthelifeofthebattery.
8.Bareandinsulatedleadshouldbepaintedwithrecommendedpainttoavoid
accidentalshortcircuit.
9.Batteryshouldbekeptcleananddryandbatteryroomshouldbewell
ventilatedtoavoidsuffocation.
10.Ifacidfallsoutofthebattery,wipeoverwithwetraganddrythoroughlyto
savethecomponentsfrombeingdamaged.
11.Terminalpostsandconnectorsshouldbecleanandfreefromcorrosionto
increasethelifeofthebattery.
12.Nutsandboltsofcellconnectorsshouldbekepttightenedandsmearedwith
Vaselinetoavoidrusting.
13.Itshouldnotbeleftindischargedconditionforlong,otherwisethedefectsof
sulphasionwilloccur.
4.Everyrelayshouldbetestedonceinsixmonths,withsuitabletestingsetandtherecords
ofsuchtestsshouldbeloggedinamaintenanceresistor.Duringtestsacheckshouldbe
madeifanyoftheoverloadortimesettingontherelayrequirechangeduetotheincrease
ordecreaseintheloadconditionssincethedateoflasttest.
Followingdefectsarepossible:
1.Impropercontactormisalignmentofthecontactprongsofthetripbattery
circuits,betweenthecubicleandthedrawouttruck.
2.Pointinanauxiliarywiringofsupplyfrombattery,ordischargedbattery.
3.Circuitbreakeroperatingmechanismnotbeingsluggishduetomechanical
defects,orstiffnessduetodustorrust,lackoflubrication,etc.
4.Wrongcurrenttransformerconnections.
5.Wrongrelaysettingsfortheloadconditions.
PreliminaryPreparation:Thepreliminarypreparationsincludestudyofdrawings,acceptance,report
checkingcertificatesandtestreportsoftheequipment,completionofcivilengineeringworkarranging
thetools,liftinggearsetc.organizingthelabour,preparethescheduleofinstallation,preparing
sequencecardsforerectionofmajoritemsetc.Suchcardsindicatethesequenceofoperationitems
involved,procedureinbriefetc.
Trouble

CommonTroublesandRemedialActions
Possiblecauses
PossibleRemedialActions
Circulatedryhotairor

1.LowinsulationResistance(below
2000Megaohms)between

Moisture
Dirtyinsulation
surfaceinternal

Phaseterminaland
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and/orexternal

oilthroughthebreaker
polefor4t06hours.
Dismantle,clean,
reassembleInsulation
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earthedframe,with

Pooroil

breakerclosed

Carbon/copper

Phaseterminalsofa

particlessticking

pole.

tointernal

for1.1kVandabove

surface

10,000megaohms

resistanceshouldbe
above2000Megaohm,

above36kV

Reduced
contact
pressure
Loose
2.ResistancebetweenTerminalsof
Poletoohigh(above100
microhms)(15microohmperjoint)

connections
Contactsurface
damageddue
torepeated

contact

operations

Dismantle,repairand
assembleagain.If
necessary,replacethe
contacts

Insufficient
contactwipe
Oxidefilmon
contactsurface

Contacterosion
3.UnequalcontactWipeandTravel

duetorepeated

in3poleMeasuredfromtopsurface

loadoperations

Inspectcontacttips

ofinterrupterflangeandthecontact

orshortcircuit

Replaceifbadlyeroded

tipbyasimplerodwith

operations

Adjustcontactiflengths

Unequallength

areunequalinthree

duetowrong

pole.

breakeropen
breakerclosed

adjustmentsof
linkages

Pullrodfor
contact
damaged
Onethelinksof
4.Oneofthepoledoesnotclose.

thatpole
broken

Dismantlethepoleand
repairthedefect.

Contactofthat
poleseverely
damaged.

Excessive
frictioninthe
poleunit.
Contactgripto
5.BreakeroperationtooSlowDuring
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high

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5.BreakeroperationtooSlowDuring
opening(Timingfromtripcommand
tocontactseparationinstanttoo
large(60msinsteadofsay40ms)

ElectricalInfo:Article|Articles|MaintenanceofSubstationEquipment

high
Tripcoil

Identifythecause

operation
sluggish.

TakeRemedialaction.

Lowbattery
voltage,hence
highertripcoil
pickuptime.

Opencontrol
circuit
Spring
defective
Tripcircuit
open
Triplatch/coil
6.Breakerdoesnotoperateon
Electricalcommand.

defective
Springnot
changed

Checkcontrolcircuit
Checkclosingspring
visually
Identifythecauseand
takeremedialaction
Checksupplytospring
changingmotor.

Ifbreaker
operateswith
manual

Checkpressure
switches,relays,control
wiring.

operationoftrip
release,the
mechanismis
O.K.
13.0MaintenanceofTransformers
Transformerswillgivetroublefreeserviceforlongperiods,ifattentionispaidtothepointslistedin
Table13and14.Properrecordofalltheobservationsandrepairandmaintenanceoperationswill
forewarnofanyimpendingtroubles.
Acidity.Acidsareformedintransformeroilduringoperation.Theirformationisparticularlyrapidat
operatingtemperaturesabove75oC.Acidsarecorrosiveinnatureanddamagethewindings,core,
tanketc.Theyarealsoresponsibleforsludgeformation.Acidityisexpressedintermsofthenumber
ofmilligramsofpotassiumhydroxiderequiredtoneutralizethetotalfreeacidsinonegramofthe
material.
Therecommendedlimitsforacidityareasfollows:
Aciditybelow0.5mg.KOH/g.
Permissible,ifoilissatisfactoryotherwise.
Aciditybetween0.5and1.0mg.KOH/g. Keepoilunderobservation.
Acidityabove1.0mg.KOH/g.
Discardoil.
Theacidityofoilshouldbecheckedeverytwoyearsfortransformersupto1000KVAcapacity,and
annuallyfortransformersabovethissize.Theactualperiodmaybevarieddependinguponthe
severityoftheserviceandobservationofresults.Thistestmaynotbeperformedonpolemounted
transformersbecauseofthecostinvolved.Detailedprocedurefordeterminingacidityislaidin
I.S:18661960.
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I.S:18661960.

RecommendedMaintenanceScheduleofTransformers(AttendedSubstationsIndoororOutdoors)
Inspection
ItemstobeInspected
Remarks
Frequency
1.Ambienttemperature,Windingtemp,Oil
(1)Daily

temp,Load,Voltage.

1.Oillevel
2.Reliefdiaphragm.
(2)Monthly

3.Dehydratingbreather.Checkthatair
passagesarefree.Checkcolourofsilica
gel,whichshouldbeblue.

(3)
Quarterly

1.Lubricatebearingsetc.ofcoolerfans,
circulatingpumpsetc.ifany

Adjustloadif
temperatureishigh.

Iflow,topupwithdry
oil.Lookforany
signsofleakage.
Replaceifbroken.
Changeifcolouris
pink.

Replaceifnecessary

1.Checkoilfordielectricstrengthand
(4)Half
yearly

presenceofmoisture.
2.Checkbushes,insulatorsetc.

Filterorchangeoil
asnecessary.

3.Checkcableboxes.

Filterorreplace,if
1.Checkoilforacidity,sludge,andflushpoint,
ifpossible.
(5)Yearly

necessary.
Formethodsof

2.Checkrelays,alarms,contactsetc.

loweringearth

3.Checkearthresistance.

resistance,see

4.Checklightningarrestors.

Chapter3.
Lightning

(6)Five
yearly

1.Overallinspectionincludingliftingofcore
andcoils.

Washbyhosing
downwithcleandry
oil.

Notes:
Theabovescheduleisonlyindicativeandtestsmaybeperformedatmorefrequentintervals
dependingupontheseverityofservice.Theopeningtemperatureandthequalityofoilarethemost
importantfactorsindeterminingthelifeandperformanceofatransformer.Earthresistanceshouldbe
checkedtwiceayear,onceindryandhotseasonandonceatanyothertimeduringtheyear.
Period

MaintenanceScheduleofOutdoorUnattendedSubstation
Itemstobechecked

Action

1.Cleanbushesofalldirtandoil.
2.Examineconditionofswitchesandtightenconnections.
3.Lookforanyleaks.
Quarterly

4.CheckconditionofSilicagel.(Seethattheairpassages

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inthedehydratorarefree.)
5.Checkoillevelandtopup,ifnecessary
6.Lookforbrokenbushes.

1.Checkdielectricstrengthofoil.Testoilformoisture.
Yearly

2.Checkearthresistance.

Filterorreplace,as
Convenient.

3.Checklightningarrestors.

Five
yearly

1.Opentankforcleaningandreassembly.

Washdownwithclean
oil.

14.0CareandMaintenanceofEarthing
1.Checktheearthresistivityduringdryseasonhalfyearlyandmaintainandcomparethe
recordswithpreviousreadings.
2.Watershouldbepouredatregularintervalsduringdryseasonatthesmallsubstations.
3.Whenthesystemisexpanded,theearthingsystemshouldalsobeexpandedbyusing
additionalearthelectrodeandearthwireseparately.
4.Electrodeshouldbeplacesintheearthintheuprightverticalposition.
5.Theelectrodesandtheearthcontinuityconductorusedinthecircuitshouldbeofthe
samemateriali.e.copperorGI.
6.Checktheearthconnectionandtightenthemproperly.
7.Passtheearthcontinuityconductorthroughthegalvanizedpipefrombeingdamaged.
8.Inspectthebrokenorrustedearthcontinuityconductorsandreplacethemwithproper
size.
9.Theearthresistanceofthefollowingequipmentmustbemeasuredduringthedriestpart
oftheyear:
Transformerbodyandothermetalparts.
Lightningarrestor
Neutralofthetransformer.
10.Mixtureofsaltandwatermaybeaddedtoimprovetheearthresistance.
11.Inthecorrosiveearth,thesteelelectrodeshouldbereplacedbycoppercoatedsteel
electrode.
12.Theearthcontinuityconductorshouldbeproperlyweldedwiththeearthelectrode.
13.Avoidanyjointingsfromearthingconductor.
15.0InsulationResistanceMeasurement
Itistheresponsibilityoftheusertoensurethattheinsulationofelectricalswitchgearhasbeentested
andtheresultrecordedbeforecommissioningtheequipment.Duringthelifeofelectricalequipment
insulationresistancetestingwillgiveagoodindicationoftheconditionoftheequipmentandifthese
testsarerecordedcanhelpindecidingmaintenancerequirementforthewholeequipment.
Insulationresistancemeasurementsbetweenpolesandeartharecomparativelyeasilymadeandare
themostsuitableforroutinetests,buttofacilitatetheirproperinterpretationsystematictestingand
recordingmethodsareessential.Insulationresistancetestsarestrictlycomparative,inthatforeach
itemtestedarejectionvaluecanonlybefixedonthebasisofexperiencebycomparisonwithearlier
results.Forthisreasonthetestequipmentandmethodsusedshouldbethesameoneachoccasion.
Testvaluesobtainedshouldbeloggedonastandardformdesignedforthepurpose,togetherwith
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thehumidityandtemperatureatthetimeofthetest,andingeneralasteadyfallofinsulation
resistanceoveraperiodoftimeisamorereliableindicationofdeteriorationthanisarelativelylow

valuewhichremainsreasonablyconstant.
Onlongpiecesofinsulation,suchaspullrodsonsomecircuitbreakerdeteriorationmaynotoccur
uniformlyandresistancemeasurementstakenovertheentirelengthmaynotreveallocalized
deterioration.Particularattentionshouldbepaidtothepullrodsofcircuitbreakers.Wherepracticable
theinsulationtobetestedshouldbeallowedtoreachambienttemperaturebeforeresistancetests
aremade.
Duringoverhauloftheelectricalequipment,theinsulationsurfaceshouldbecleanedwith
trichloroethlene,cleanclothcompressedair.
InsulationresistanceismeasuredbymeansofMegohmmeter(Megger).Themeggercomprisea
megohmmeterwithbuiltind.c.generator.Theminimumreadingiszeroandmaximumisinfinity.The
scaleisinmegohms.Thetwoterminalsofmeggerareconnectedacrosstheinsulation,i.e.onetothe
conductorandothertoearthbody.Thehandleisrotatedbyhandormotor.Theinsulationresistance
indicatedbythepointerinmegohms.
Forh.v.switchgear1000Vor5000V(d.c.)meggerispreferred.Theinsulationresistanceofh.v.
circuitbreakerisveryhigh(above10000megohmsofinfinity).Insulationresistanceofcontrolcircuit,
tripcircuit,relaycircuit,secondarycircuit,etc.ismeasuredbymeansof500Vmegger.Value
obtainedshouldnotbelessthan1megohm.
Forprimarycircuit,theinsulationresistanceistestedwiththebreakerclosedbetweenlowerterminal
andearthedframeforeachinterrupter.Withbreakeropen,insulationresistanceismeasured
betweenterminalsofeachinterrupter.
Testvoltagewhichcouldbeappliedtoprimaryinsulationwhenmakingresistancetestvaries
accordingtothevoltageratingoftheswitchgearandisshownintablebelow:
3phasesystemratingofprimary
insulatingofswitchgear
Upto1kV
Above1kV3.6kV
Above3.6kVto12kV
Above12kV

TestVoltages
Testvoltagerecommendedforinsulationresistancetest
(toearthandbetweenphases)kV(d.c.)
1
2
5
5

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