CIRCUIT BREAKER TESTING
All workers must have completed Field Induction or have
1. PURPOSE AND SCOPE recognition of prior Ergon Energy Field Experience.
Provide guidelines for testing of circuit breakers. Contractors must have completed Ergon Energy's Generic
Details of specialised circuit breaker tests are not included in this Contractor Worker Induction.
SWP.
3. DOCUMENTATION
2. STAFFING RESOURCES HazChat
Adequate staffing resources with the competencies to safely EQL SWMS - Safe Work Method Statements
complete the required tasks as per 8 Level Field Test Competency
- 2597616. Health and Safety Policy - 692225
These competencies can be gained from, but not limited to any or Procedures for Safe Access to High Voltage Electrical Apparatus
all of the following:- (SAHV) - 2904212
• Qualifying as an Electrical Fitter Mechanic Electrical Safety Rules 2022 - 6503074
• Qualifying as a Technical Service Person 8 Level Field Test Competency - 2597616
• Training in the safe use of relevant test equipment Construction Tool - Circuit Breaker - 3059290
Requirement for all live work: Commissioning Tool - Circuit Breaker - 3060452
• Safety Observer (required for all “live work” as defined in the Circuit Breaker Testing Competency Assessment - 2598732
ESO Code of Practice for Electrical Work). Substation Primary Plant and Secondary Systems Field Testing -
All resources are required to: 2902800
• Have appropriate Switching and Access authorisations for the AS 1931 - 1996 - High Voltage Test Techniques Parts 1 and 2
roles they are required to perform and have the ability to AS 2006 - 1986 - High Voltage A.C. Switchgear and Controlgear -
assess and maintain relevant exclusion zones from exposed Circuit Breakers for Rated Voltages Above 1,000V
live electrical apparatus
AS 2650 - 1986 - High Voltage A.C. Switchgear and Controlgear -
• Hold current licences for any vehicles and equipment they may Common Requirements
be required to operate.
AS 2467 - 1981 - Maintenance of Electrical Switchgear
Required Training
Test Equipment Manual
Staff must be current in all Statutory Training relevant for the task.
Circuit breaker Manual / Manufacturer’s Drawings
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CIRCUIT BREAKER TESTING
4. KEY TOOLS AND EQUIPMENT Operate the Network Process is applicable at all times for isolation
and earthing.
Test Equipment within calibration date, tested and tagged
Careful consideration should be taken with the selection and
Safety Barriers placement of test leads. Only use appropriately rated test leads
HVIA Operating Equipment - PED’s, Live Line Tester, Class 0 that are placed to be clearly visible to reduce the risk of them
gloves. All equipment to be inspected and confirmed within test being not seen and removed prior to placing plant back into
date prior to use service. Where possible, use leads that are supplied with the test
equipment since these will have suitable connectors and the
PPE including full-length protective cotton clothing, safety correct current and voltage rating. Leads should be selected and
footwear, helmet. Additional PPE as required: brim for safety used such that it is not possible to leave leads connected to the
helmet, leather work gloves, class 00 gloves, hearing protection, plant under test when the test equipment is removed (for example
safety eyewear, high visibility clothing when working on or near an integrated lead set or trifurcated leads).
roadways. All PPE to be inspected and confirmed within test date
(where applicable) prior to use As described in Substation Primary Plant and Secondary Systems
Field Testing - 2902800, particular safety hazards applicable to
Sun protection to be used when working outdoors Circuit Breakers include:
5. TASK STEPS • Contact with high voltage at CB primary connections.
• High fault current at CB primary connections.
5.1. Carry out an on site hazard assessment
• Stored energy (eg charged spring) in the closing and tripping
Prior to performing this activity any hazards associated with mechanism
prerequisite tasks at the worksite shall be identified and assessed
with appropriate control measures implemented and documented • Initiation of other protection or control functions by change in
in accordance with the HazChat on-site hazard assessment. state of circuit breaker auxiliary contacts
If any hazards cannot be managed or reduced to an acceptable 5.3. Record identification details.
level, do not proceed with the task and seek assistance from your
Supervisor. • Manufacturer’s name, manufacturer’s type description and
manufacturer’s serial number:
5.2. All work to be done with circuit breaker de-energised • Plant number;
All of the tests described in this SWP should be carried out with • Description, ie. dead tank, live tank etc;
the CB de-energised and appropriate control measures in place
(eg barriers, matting) to prevent inadvertent contact with adjacent • Rated voltage and insulation level;
live plant or breaching exclusion zones. Furthermore, the P53 • Rated nominal and short-circuit current and duration;
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CIRCUIT BREAKER TESTING
• Rated operating sequence; 5.6. Measure Resistance of the Main Circuit.
• Interrupting medium; Measurement shall be made using D.C. current of at least 50A and
less than the nominal current rating of the circuit breaker. The test
• Specialised requirements such as: shall be conducted as close as practical to ambient temperature.
Rated Transitional Recovery Voltage envelope, Rated Out of
A four wire ductor should be used for measuring the resistance of
Phase Breaking Current, Rated Cable Charging Breaking Current,
the main contacts.
Rated Capacitor Bank Breaking and Inrush Making Currents,
Rated Small Inductive Breaking Current. Measure Insulation Resistance.
DC insulation tests are to be carried out between terminals of the
5.4. Visual inspection of Circuit Breaker condition.
circuit breaker as detailed below. Note that these connection
Inspect the circuit breaker for any sign of damage or leaks both arrangements have been specified for consistency with AS2650
externally and in the circuit breaker marshalling box. Confirm that and to allow for future insulation condition diagnostic assessment.
the interrupting medium level/pressure is correct before The voltage applied will be as per Table 1 for a duration of 1
commencing tests and that assembly is complete and no transport minute.
bracing has been left in place.
Inspect the external surfaces and ensure the circuit breaker is With the circuit breaker in the closed position:
clean and dry.
• A or a to Earth and all other terminals
Check all connections for adequate labelling. The connections
should be unambiguous, legibly and adequately marked. • B or b to Earth and all other terminals
• C or c to Earth and all other terminals
5.5. Auxiliary and Control Circuit Voltage Withstand.
The circuit breakers auxiliary and control circuitry shall be With the circuit breaker in the open position:
subjected to a 1 minute power frequency withstand test at 2kV to • A to Earth and all other terminals
confirm insulation integrity.
• B to Earth and all other terminals
The circuitry shall be considered to have passed if no disruptive
discharge occurs during the test. • C to Earth and all other terminals
Consideration shall be given where electronic components are • a to Earth and all other terminals
used in the auxiliary and control circuitry. Different testing
procedures and values maybe adopted subject to agreement by • b to Earth and all other terminals
the Commissioning Engineer. • c to Earth and all other terminals
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CIRCUIT BREAKER TESTING
A, B and C refer to one set of CB high voltage terminals (eg fixed specifies that a 90% power frequency withstand test be carried out
contact - top of CB) and a, b, and c refer to the other set of on site after erection. The level of high voltage testing to be
terminals (eg moving contact - middle of CB) applied is therefore:
Minimum acceptance value for new plant is 1,000MΩ. a) Where no HV testing has been carried out at the
manufacturer’s works - 100%.
Table 1. Applied Voltages for IR Tests b) Where HV testing has been carried out at the manufacturer’s
Primary Voltage Rating Test Voltage in kV works but subsequent assembly of the HV chamber /
(D.C.) bushings is required on site - 90%.
c) Where HV testing has been carried out at the manufacturer’s
Up to 1kV 1 works and no on-site assembly is required - No HV withstand
Above 1kV to 3.6kV 2 test.
d) If the circuit breaker is aged or refurbished - 75%.
Above 3.6kV to 12kV 5
Where Um<=66kV the value of voltage applied shall be as per AS
Above 12kV 10 2650-1986 as listed in the table below.
Where Um>66kV the value of test voltage shall be in accordance
Measure Timing with AS 2650-1986.
The time taken for the circuit breaker to complete an operation Note that the test voltage used may be limited by the output
shall be measured for both opening or closing. Timing should be capability of the test equipment. In this case a reduced test voltage
started by the application of voltage to the trip/close coil and for an extended duration as specified in Table 11.1 of AS 2067 -
stopped by operation of the main contacts. For both single and 1984 may be used.
three pole CBs, each pole is timed independently as per clause
The requirements of the test are satisfied if no disruptive discharge
HH2.4.2.1 of AS2006 - 1986
occurs.
Note - test both trip coils. Time travel measurement is required for
An insulation resistance test is to be repeated after the HV
110 kV and above CBs or any CBs assembled on site.
withstand test to confirm that insulation degradation has occurred.
Measure spring charge time following close operation.
Application of a 1 minute power frequency withstand test is to be in
5.7. Carry out HV Testing. accordance with AS1931 Part 1 between the load and line
terminals of the circuit breaker as detailed below. Note that these
AS 2006 - 1986 specifies that normally no dielectric tests are connection arrangements have been specified for consistency with
performed at site on the main circuit, however AS 2067 - 1984 AS2650 and AS2006 (Clause 7.1).
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CIRCUIT BREAKER TESTING
Schedule of Tests
With the circuit breaker in the closed position: The table below details the circumstances in which different tests
are carried out:
• A/a and C/c to Earth and all other terminals
Test New Circuit Breaker Aged or refurbished
• B/b to Earth and all other terminals
Circuit Breaker
With the circuit breaker in the open position. High Voltage Workshop or on-site Workshop or on-site
Withstand test required at test required. Reduced
• A, B and C to Earth and all other terminals discretion of values apply.
Commissioning
• a, b and c to Earth and all other terminals
Engineer *.
Auxiliary and Review manufacturers On-site test required if
Nominal voltage Highest Voltage Rated Short term Control test result only circuit breaker wiring
of system for equipment Power-frequency Circuit has been substantially
(Un) (Um) withstand voltage Voltage modified
kV r.m.s. kV r.m.s. (PFWV) Withstand
KV r.m.s.
Insulation On-site test required On-site test required
3.3 3.6 10
Resistance
6.6 7.2 20
Resistance On-site test required On-site test required
11 12 28 Of Main
Circuit
22 24 50
Timing On-site test required On-site test required
33 36 70
Time Travel Required for Required for
66 72.5 140 transmission CBs or transmission CBs or
CBs assembled on site CBs assembled on site
*otherwise review manufacturer’s results only
DDF and capacitance measurement of the CB insulation may be
required at the request of the client, particularly if DLA test
equipment is available on site at the time of commissioning.
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CIRCUIT BREAKER TESTING
5.8. Complete Pre-commissioning Checklist u) Apply a latched trip command and then a close command
while the trip is maintained;
Circuit breakers being placed in service for the first time or after
refurbishment require that the following items are checked prior to v) Check operation of interlocks;
energisation: w) Check operation of all alarms;
a) Check closing with 85% normal supply volts; x) Check control switches in service position;
b) Check closing with 85% normal air pressure; y) Check operational nameplate and labels are in place.
c) Check tripping with 70% normal supply volts (85% if AC);
d) Check insulation medium/pressure;
e) Check gas pressure alarm;
f) Check gas pressure trip/lockout;
g) Check fuses and links in service position;
h) Check main earth on cabinet and support structure;
i) Check motor overload/excess run timer set;
j) Check local trip operation, including operation with both trip
coils in parallel;
k) Check local close operation;
l) Check remote trip operation;
m) Check remote close operation;
n) Check SCADA trip operation;
o) Check SCADA close operation;
p) Check protection trip operation;
q) Check protection reclose operation;
r) Function test all Local/Remote/Maintenance switch;
s) Check operation of pole discrepancy protection (if fitted);
t) Check anti-pumping relay operation ie apply a close
command and then a trip command while the close is
maintained;
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