HIGH VOLTAGE CIRCUIT BREAKER

Lecture by
Pervez Ahmed Arain
Senior Engineer

Wapda Engineering Academy Faisalabad

History of circuit Breaker

An early form of circuit breaker was described by Thomas
Edison in 1879 patent application, although his commercial
power distribution system used fuses.
Purpose of fuse was to protect lighting circuit wiring from
accidental short-circuits and overloads.
Fuse function is to detect a fault condition and, by interrupting
continuity, to immediately discontinue electrical flow.
A fuse operates once and then has to be replaced, while a circuit
breaker can be reset (either manually or automatically) to resume
normal operation.

History of circuit Breaker

Circuit breakers are made in varying sizes, from small devices
that protect an individual household appliance and up to large
switchgear designed to protect high voltage circuits feeding an
entire city.
A circuit breaker is an automatically-operated electrical switch
designed to protect an electrical circuit from damage caused
by overload or short circuit.

HIGH VOLTAGE CIRCUIT BREAKER.

High-voltage circuit breakers are self-contained with current
transformers, protection relays, and an internal control power
source.
The circuit breaker contacts are made of copper or copper
alloys, silver alloys, and other materials.
Service life of the contacts is limited by the erosion due to
interrupting the arc.
Miniature and molded case circuit breakers are usually
discarded when the contacts are worn, where as:-

HIGH VOLTAGE CIRCUIT BREAKER.

The power circuit breakers and high-voltage circuit breakers
have replaceable contacts.
The circuit breaker must detect a fault condition; in lowvoltage circuit breakers this is usually done within the
breaker enclosure.
Circuit breakers for large currents or high voltages are
usually arranged with pilot devices to sense a fault current
and to operate the trip opening mechanism.

Purpose of Circuit Breaker

To connect generator to the system as and when required.
To permit plant and transmission circuits to be with drawn from
service for maintenance work.
To disconnect faulty plant automatically as quickly as possible.
Circuit breakers are usually able to terminate all current very quickly:
the arc is extinguished between 30 ms to 150 ms after the mechanism
has been tripped.
when the contact separates, the resistance between the contacts
increases and the current continues to flow for some time which
causes I2R losses. Due to this tremendous amount of heat is
generated . This heat is sufficient to ionize the space between the
contacts (which may be air , oil or SF- 6 gas ).

Purpose of Circuit Breaker

This ionized space acts as a conductor because of large
number of free electrons. The current therefore continues
to flow in the form of spark or arc between the contacts
which produce enormous heat which may result in
explosion forces.
The resistance of the contacts in closed position is of the
order of 50 to 80
Circuit breaker consists of current carrying contact fixed
contact and a moving contact . These are normally
engaged but under predetermined conditions separate to
interrupt the circuit.
The breaker plays an important role in interruption process.
The breaker is designed to extinguish the arc as shortly as
possible, after it has started and before the heat generated
to a dangerous value.

TYPES OF CIRCUIT BREAKERS

OIL CIRCUIT BREAKERS
Oil circuit breakers (OCBs) are circuit breakers that have their
contacts immersed in oil. Current interruption take place in oil
which cool the arc developed and thereby quenching the arc.
The pole of small oil circuit breakers can be placed in one oil tank.
The larger high voltage circuit breakers have each pole in
separate oil tank. The oil tanks in oil circuit breakers are normally
sealed.
The electrical connection between the contacts and external
circuit are made through porcelain.

OIL CIRCUIT BREAKERS

Bulk oil circuit breakers

In Bulk oil Circuit Breakers , oil is used as insulation and to

extinguish the arc. The arc heats the oil in its vicinity , so
causing it to flow and extinguish the arc.

Low oil volume circuit breakers

In low oil volume circuit breakers extinction chamber contains

a small volume of oil . In these circuit breakers quenching of
the arc is with the flow of oil . The flow of oil is due to the heat
of oil produced with arc assisted by a pump effect of the
Moving contact.

Vacuum circuit Breaker

The photo shows a

15kV V8 interrupter
(4 dia.) from the
early 1970s.

This shows the basic

design and main
components of a
Vacuum Interrupter

Modern Vacuum High Voltage Circuit Breakers

Vacuum circuit breakers have been utilized since the 1920s

Vacuum circuit breakers are circuit breakers which are used to

protect medium and high voltage circuits from dangerous
electrical situations.
In a vacuum circuit breaker, two electrical contacts are enclosed
in a vacuum. One of the contacts is fixed, and one of the
contacts is movable.

When the circuit breaker detects a dangerous situation, the

movable contact pulls away from the fixed contact, interrupting
the current.

Because the contacts are in a vacuum, arcing between the

contacts is suppressed, ensuring that the circuit remains open.
As long as the circuit is open, it will not be energized.

Vacuum re-closers will automatically reset when conditions are

safe again, closing the circuit and allowing electricity to flow
through it.

Generally, the make/break contacts have a stationary part and a

moving part.

By bringing the moving part to touch the stationary one,

electric current flows and the breaker is closed.

By driving the moving contact away from the stationary contact

the electric arc develops and by quenching it the current stops
flowing and the breaker is open.
Vacuum circuit breakers are very durable,

SF6 ( SULPHER HEXA FLOURIDE GAS )

CIRCUIT BREAKERS

SF6 circuit breaker.

It consists of fixed and moving contacts enclosed in a chamber called
arc interruption chamber containing SF 6 gas. This chamber is
connected to SF6 gas reservoir.
When the contacts of breaker are opened the valve mechanism permits
a high pressure SF6 gas from the reservoir to flow towards the arc
interruption chamber.
The fixed contact is a hollow cylindrical current carrying contact fitted
with an arc horn.
The moving contact is also a hollow cylinder with rectangular holes in
the sides to permit the SF6 gas to let out through these holes after
flowing along and across the arc.
The tips of fixed contact, moving contact and arcing horn are coated
with copper-tungsten arc resistant material.

Since SF6 gas is costly, its reconditioned and reclaimed by a

suitable auxiliary system after each operation of the breaker.

In this circuit breaker, sulphur -hexafluoride ( SF6 ) gas is used

as the arc quenching medium. The SF6 gas is an electro
negative gas and has a strong tendency to absorb free
electrons.

The contacts of the breaker are opened in a high pressure flow

of SF6 gas and an arc is struck between them.

The SF6 circuit breakers are very effective for high power and
high voltage service.
In cold climates, supplemental heating or de-rating of the
circuit breakers may be required due to liquefaction of the SF6
gas.

Sulpher Hexa Fluoride (SF6 ) gas is an alternative to air as an

interrupting medium .
At high temperature in an electric arc, SF6 will decompose into
sulfur & fluorine which is compound of these two elements.
These compound are corrosive to glass and metals in the
presence of moisture and the corrosion products are insulators .

The principle of operation of SF6 is similar to the air blast circuit

breaker, except that SF6 gas is not discharged into the
atmosphere.

SF6 circuit breaker , design is such a way that during the

opening operation , it generates the gas pressure (due to piston
action ) needed to extinguish the arc.

It is an artificially produced gas , originally established itself as

insulating medium and replaced oil in low voltage switchyard .
Later on , it found its use in high voltage circuit breaker as
interrupting medium .
Non inflammable, non toxic under ordinary condition .

ADVANTAGES OF SF 6
High capacity of carrying heat produced by the arc .
Act as an insulating medium like oil and air but the
voltage withstand level is very high ( up to 1000 kV ) as
compared to air and oil .
High radial thermal conduction and high electron
capturing capacity . When the current passes through
zero , the arc is extinguished by the combination of
these two phenomena .
SF6 permit rapid heat from the centre of the arc
towards the exterior .

 Minimum number of components located inside the breaker

compartment .
Fluorine atoms which are highly electronegative act as traps
for electrons which make the medium insulating again .
Reduced fire risks and increased number of short circuits
operations possible without maintenance .

Simple and accessible operating mechanism of the switchgear

using SF 6 .
High breaking capacity , ability to withstand frequent switching
as compared to oil and air .
Long contact life due to minimum wear and tear

Air Blast circuit Breaker

Air blast circuit breaker depend on a steam of

compressed air directed toward the separable contacts
of the breaker to interrupt the arc, formed when the
breaker is opened.

In air-blast circuit breakers, air is compressed to high

pressures. When the contacts open, a blast valve is
opened to discharge the high-pressure air to the
ambient, thus creating a very-high-velocity flow near the
arc to dissipate the energy.

Air blast circuit breakers have recently been developed

for use in extra high-voltage applications with standard
rating 765,000Volts.

Air Blast circuit breakers

 In these type of circuit breakers when the contact separate ,

compressed air is blown through the nozzle- shape contact
resulting in quenching of the arc and Establishing the insulation
gap .
Chemically active impurities remaining after the process of
interruption can be absorbed by a substance alumina in the
breaker enclosure . This substance also absorbs moisture .
As with other inert gases , oxidation is inhibited and abrasion of
contact surface due to this process is consequently small .
The density of gas at atmospheric pressure is 6.135
i. e . five time of air .

ADVANTAGES OF AIR BLAST CIRCUIT BREAKERS.

There are no fire hazard .
The circuit breaker operate with high speed .

The duration of arc is small i.e. arc is extinguished early .

Due to small duration of contacts burns are lesser .
Maintenance is less as compared to the oil circuit breakers .
Stability of the system is increased due to high speed of
operation .

DISADVANTAGES OF AIR BLAST CIRCUIT BREAKERS .

In order to have frequent operation it requires air.
compressors of high capacity .

The maintenance of the compressors and their allied

equipment is also required .
It has high rate of rising of restricting voltages.

Possibility of leakage air due to high pressure .

Due to presence of oxygen , oxidation occurs which causes
abrasion of contact surfaces .

MAJOR PARTS OF CIRCUIT BREAKER

A.

Interrupting Head, It mainly consists of :-

1.

Main interrupter / Extinction chamber

It is the main current carrying parts , normally contacts
consists of a Fixed contact and a Moving contact .

2.

Auxiliary Interrupter/Resister chamber

Its function is to aid interruption or limit switching over
voltages .

3.

Capacitor
To ensure that the series contacts share the total recovery
voltage as equally as possible.

B.
1.

Pulse transmission Mechanism, can be:Hydraulic.

2.

Solid Insulating Rods.

3.

Combination of above.

Operating Mechanism
(i) Spring Operation

Spring operation is effected by a power full coil , leaf or

torsion springs , which may be automatically recharged by a
small motor with reduction gear .

The spring is usually released by a solenoid operated lever .

The advantages of spring operation are rapid action and

elimination of air problems in case of pneumatic operation .

The only disadvantages are falling - off of thrust towards

the end of stroke .

(ii)

Pneumatic operation

This type of operating mechanism is applied to almost all type

of Circuit Breakers.

Pneumatic operation is un-doubted superior when high speed

operation is required . Where air is not required for

Arc extinction in case of SF 6 breakers, low pressure and

small compressor can be used .

For the Air Blast Circuit Breakers , dry air is required for arc
extinction and insulation between contacts special High
Pressure compressors with drier are required and frequent
maintenance and repairs work on compressors are essential .

(iii) Pneumatic Hydraulic .

This type of mechanism is basically similar to pneumatic

mechanism and has two major advantages ;

1.

Reduces the size of pistons and cylinders .

2.

Hydraulic circuits are more efficient and require little

maintenance and have little wear and tear compared to
these of pneumatic system .

Maintenance of Circuit Breaker

Maintenance of circuit breakers can be divided into two
categories .
a) Routine / Running Maintenance
1.

This maintenance restore the serviceability of the equipment

and ensure its working condition within the period before
major Maintenance .

2.

The objective of this maintenance is to ensure the normal

operation of the plant .

(b) Major Maintenance / Overhauling

Overhauling of an equipment is carried out after a specific

period to bring its technical Parameters nearest to the design
valves .

During this process all the discovered defects are corrected

and worn out parts are re-conditioned or replaced .

Importance of Adequate Maintenance

Circuit breaker is often open or closed for long time, they

remain idle for 6 months or more, due to this reason need to
open and closed several times. Remove any accumulation of
dust or foreign material on moving parts and contacts.

Maintenance of Circuit Breakers

The accumulation of dust on the latch surfaces may affect the

operation of the breakers
Routine trip testing should be performed every 3 to five year.

Routine Maintenance Tests

Following test during routine maintenance need to be carried
out.

1. Insulation Resistance Test

This test should be carried out between the line and load
terminal with the breaker in the open position.
Precaution:Load and the conductors should be disconnected from the
breaker

Resistance value below 1 mega- ohm is considered unsafe

and the breaker should be inspected for possible
contaminating on its surface.

2. Milli-volt Drop Test

A millivolt drop test can be disclosed several abnormal
condition inside the breaker such as eroded contacts,
contaminated contacts or loose internal connections.
The millivolt drop test should be made at a nominal direct
voltage at 50 ampere or below rating for smaller breaker.
The millivolt drop test result should be compared against
manufacturers data.

3. Connection Test

The connections to the circuit breaker should be inspected to

determine that good joint is present and overheating is not
occurring.
It overheating is indicated, then connection should be removed
and the cleaned the surface.

4. Overload Tripping Test

The overload tripping of circuit can be verified by applying 300%
of breaker rated continuous current.
The significant part of this test is the automatic opening of the
circuit breaker.

5. Mechanical Operation
The mechanical operation of the circuit breaker should be
checked by turning the breaker on and off several times.

Maintenance of Low-Voltage Circuit Breakers

Low voltage circuit breakers are those which operate at 800
Volts and below should be inspected and maintained very 1-3
years depending on their service and operating conditions.

Conditions necessary for frequently maintenance are:a)

b)
c)
d)
e)

High humanity and high ambient temperature.

Dusty or dirty atmosphere.
Corrosive atmosphere.
Frequent switching operations
Oldest equipment.
Breaker should be inspected and maintained if necessary
whenever it has interrupted current at or near its rated value.

Maintenance Procedure Low voltage Air Circuit

Breakers
Manufactures instructions for each circuit breaker should be
carefully read & followed.
Following are the general procedure that should be followed in
the maintenance of low voltage air circuit breakers:1. Check the breaker in test position.
2. Insulation pars, including bushing should be wiped clean of
dust and smoke.
3.The alignment and condition of the moveable and stationary
contacts should be checked.
4. Check the chutes and replaces any damaged parts.

5. Check breaker operating mechanism for loose hardware and mission

or broken cotter pins etc. Examine cam, latch and roller surface for
damage or wear.
6. Clean and re-lubricate operating mechanism and bearings with a light
machine oil & non-hardening greases for wearing surfaces of cams,
rollers, etc.
7. Set breaker mechanism adjusts described in the manufacturers
instruction book.
8. Replace contacts if badly worm or burned and check control device
for free operation.
9. Inspect wiring connection for tightness.
10. Check after servicing circuit breaker to verify the contacts move
fully open and fully closed positions.

Maintenance of Medium voltage Air Circuit Breakers

Medium voltage breaker are those which operates in the range
600 to 15,000 volts, should be inspected and maintained annually
or after every 2,000 operations, which come first.
Following points required special attention.
Be sure the circuit breaker and its mechanism are disconnected
form all electric power.
Both high voltage and control voltage, before it is inspected or
repaired.
Exhaust the air pressure form receiver of any compressed air
circuit breaker before it is inspected.
When the circuit breaker has been disconnected from electrical
power, attach the grounding leads properly before toughing any
of the circuit breaker parts.

Maintenance Procedure Medium voltage Air Circuit

Breakers
1.

Clean the insulating parts including bushings.

2.

Check the alignment and condition of moveable and stationary

contacts & adjust them.

3.

See the nuts, bolts, washers, cotter pins and all terminal
connections are placed tight.

4.

Check arc chutes for damage & replace damaged parts.

5.

Clean and lubricate the operating mechanism.

6.

Check after serving circuit breaker to verify that contacts move

to fully opened and fully closed position

Maintenance Procedure Medium voltage Oil Circuit

Breakers
1.

Check the condition, alignment, and adjustment of

the contracts.

2.

Thoroughly clean the tank and other parts which

have been contact with the oil.

3. The oil should be filtered or replaced whenever an

excessive amount of carbon traced out, even if the
dielectric strength is satisfactory.
4.

Check the breaker and operating mechanism for

loose hardware ns missing or broken cotter pins,
retaining rings, etc.

Maintenance Procedure of High voltage Oil Circuit

Breakers
1.

Most manufactures recommended complete inspections, external

and internal at interval of from 6-12 months.

Following inspection schedule is recommended.

6month after erection

Complete inspection & adjustment

12 months after
previous inspection

Complete inspection & adjustment

12 months after
previous inspection

External checks & inspection, if checks are

satisfactory, no internal inspection

12 months after
previous inspection

Complete inspection & adjustment

Following are the external inspection of a high voltage

oil circuit breaker:1. Check the dielectric strength and color for oil
breaker. It is advice able to maintain dielectric strength
22 KV, where as some manufactures allow 16 KV.
2. Observe breaker operation under load.
3. Operate breaker manually and electrically to observe
the malfunction.
4. Trip from protective relays.

Circuit breaker routine maintenance include ;

(a) Daily / Weakly Checks
Recording of any damage to insulator or any other parts .

Recording of any leakage of oil , air , SF6 gas in case of oil ,

air blast or SF6 gas circuit breakers respectively .

Recording of counter reading of main and single Poles

cubicles .

Checking of cabinet heaters .

(b) Annual Maintenance

Before getting approval from NPCC, all the preliminary
operation need to be completed ,these includes:

Repair works list .

List of spare parts to be replaced and their availability .

Availability of tools and plants to be used .

Technical staff required to carry out the maintenance work .

Safety precaution Required before Starting Work

Isolation of the breaker from the system .

Earthling the incoming and outgoing terminals of the

breakers, under maintenance and leaving it for at least five
minutes for the complete discharge of the capacitors
before staring work.

The procedure as per Wapda safety codes should strictly be

followed .

Dismantling / Reassembling of the parts be made in Dust

free and Moisture free area .

Generally the following works are being carried out

during Annual Maintenance ;

Checking proper operation of pressure gauges , switches ,

operation counter meters etc .

Checking / tightening of all L .V / H .V terminal connections

.

Checking operation of all relays and contactors .

Checking satisfactory operation of damp proofing.

Cleaning of filters .

Checking insulation of the control and power wiring

Checking proper operation of the Auxiliary Switches .

Cleaning of the Insulators and exposed live parts from dust and
other particles .
Measuring resistance of main contact and comparing it with its
recommended Value .
The contact resistance should be normally 40 to 80 .
Note. In case of resistance of the contact is more than the
recommended valve , the contacts need to be inspected and
precautionary measures should be taken .
Check the Opening, Closing , Dead and short circuit timings of the
breakers .

Thanks
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