1

Design Objectives for Spring Mechanism Generator Circuit Breaker with High Reliability
J. M. Willieme, Member, IEEE, D. Frigiere, E. Mikes and G.F. Montillet, Senior Member, IEEE
transformer. The advantages of this diagram were discussed in many papers in the past, and we could recite here items such as protection of the generator and the system against short circuit faults on either side of the circuit breaker and improved generator synchronization to the network. Flexibility during normal operations, i.e. supply power from the auxiliaries during start up phase, is noted as an added savings in this scheme. Also we could note a better process of commissioning and maintenance due to the isolating function of the circuit breaker during relay testing and startup testing.

Abstract--Generator circuit breakers are used in many medium power plants (gas or coal) today, rated from 50 MW to 200 MW. Their acceptance is based on financial criteria, and at the same time on the utmost reliability and availability of power plants. The generator circuit breaker protects the generator and the stepup transformer. Various works in the industry have proven that the reliability of these apparatuses is based on the reliability of mechanisms. The spring mechanism has been proven as being the most reliable for the type of energy involved in interrupting short circuit in circuit breakers. This paper looks at the increase of reliability and availability of generator circuit breakers due to the operation of spring mechanism. Index Terms--Generator availability. circuit breaker, reliability,

I. INTRODUCTION HIS document provides an example of the reliability improvement of a generator circuit breaker fitted with a spring mechanism applied to a maximum of 24 kV system, rated 9,500 A continuous current rating, and 63 kA rated short circuit current. The discussion of reliability is based on the CIGRE report 13-202, 1994 (Second International Inquiry) [1] that shows that high voltage circuit breaker failures and defects in service depend to a high extent on the reliability of its mechanism and auxiliary equipment. II. GENERATOR CIRCUIT BREAKER CONCEPTS The application concept of generator circuit breaker is an old one (used in the early 1930's), and it then disappeared to come back in the 1980's. This was due to the moving technologies of circuit breakers and of power generators. The modular electrical diagram is the most used today in power plants (see Figure 1). This diagram features a generator circuit breaker inserted between the main transformer and the generator and a start-up transformer for the auxiliary sources connected to the low voltage terminals of the main step-up
J. M. Willieme is with AREVA T&D Research Center, 130 rue Leon Blum, Villeurbanne, 69611 France. (E-mail: jean-marc.willieme@areva-td.com). D. Frigiere is with AREVA T&D -AHT, 130 rue Leon Blum, Villeurbanne, 69611 France. (e-mail: denis.frigiere@areva-td.com) E. Mikes is with AREVA T&D-SEH, Carl Sprecher Strasse 3, CH-5036 Oberentfelden, Switzerland.(e-mail: endre.mikes@areva-td.com) G.F. Montillet is with AREVA T&D, One Power Lane, Charleroi, PA 15022 USA (e-mail: georges.montillet@ieee.org).

Fig.1. Typical generator circuit breaker modular diagram.

III. MECHANISMS VS. RELIABILITY In the year 1994, a CIGRE survey was made on the reliability of circuit breakers and a conclusion was drawn towards the type of mechanism. Summaries of this report CIGRE 1994: 13-202 2nd surveys on reliability of Circuit Breakers. WG13-06 reveals [2] that the mechanism of the circuit breaker is responsible for: 44 % of Major Failures (MF) 39.4 % of minor failures (mf). This is a considerable amount, proportionally to other types of failures, for a circuit breaker. Outage rate for different kinds of mechanisms (for 100 circuit breaker-year) are listed in Table 1.
Table 1. Outage from Major Failure (MF) and minor failures (mf) Type of mechanism MF mf Hydraulic 0,31 2,89 Pneumatic 0,27 0,80 Spring 0,27 0,40

1-4244-0493-2/06/$20.00 2006 IEEE.

Helical compression spring for closing and tripping. Crank closing system with 220-240 travel of closing shaft excess energy at the end of the closing operation is recovered and stored in the closing spring. Patented cam design for soft engagement of roller lever with trip latch. Trip spring mounted in the operating mechanism and /or circuit breaker (allowing trip energy to be distributed as needed).

Fig.2. Graphic outage rate for different mechanisms.

Similar results can be derived also from the second international survey on gas insulated substations GIS in service made by CIGRE in 1998, Report 23-102 by WG 23.10, identifying mechanism caused failures depending on age and voltage classes in the range of 20-30% of all types. Therefore, the most efficient way to improve the reliability of the circuit breaker is to focus on its mechanisms reliability. The first study also demonstrated that the most reliable mechanism, by far, is the full spring mechanism. These minor and major failures are time, energy and money consumed by utilities and manufacturers. Indeed, the worldwide trend today, for major high-voltage and medium voltage circuit breaker's manufacturers is to use, where possible, spring mechanism for all types of switchgear. IV. OBJECTIVE: RELIABILITY The development of a new family of spring-operated mechanisms began for us in 1991, after the delivery of more than 50,000 mechanisms of the Generation 1 & 2 over 60 years for high-voltage circuit breakers. The resulting new spring mechanism is a modern, functionally optimized system tailored to the requirements of the latest circuit breaker technology and well adapted also to the generator circuit breaker design (figure 3). The technology used in the spring operating mechanism is already known from the medium voltage circuit breakers: these mechanisms differ from their predecessors in the following design criteria:

The incorporation of many decades of experience with spring mechanisms has led to a resolute and dynamic optimization of their performance. Crucial advantages gained as a result include: Low impact dynamic operation. Minimum internal energy transfers (low "reactive" power dissipation), Elimination of dashpots in closing systems, and Simplified function of parts compared to prior generations.

Fig.3 Functional principle of third generation operating mechanisms.

The advantages in everyday operation of these spring mechanisms are: Lower wear, Reduced maintenance cost (no required maintenance for up to 10,000 switching operations), Very high availability combined with even longer service life, and Low noise emission. V. RELIABILITY WITH SPRING MECHANISMS The particular design concept of a motor-spring actuated mechanism has been used for more than 70 years by the same

manufacturer for the operation of minimum oil circuit breakers, SF6 live tank and dead tank circuit breakers, and Gas Insulated Substation (GIS) circuit breakers (figure 4). It is now applied to generator circuit breakers as the third generation form (figure 5).

A spring mechanism can be said to be "passive", in that once the springs are charged and latched, no further monitoring of their status is required until the circuit breaker operates. Its reliability generally will depend on its operating concept, on the suitability of the used materials and on the way in which the latches operate. Overall, spring mechanisms per se are less complex than pneumatic or hydraulic mechanisms, although their energy capability is dependent on a particular know-how and precise manufacturing process.

Fig. 4 Three generations of spring mechanisms FK

Pneumatic and hydraulic mechanisms can be described as "active", in that they require continuous monitoring of their status and even if the circuit breaker does not operate, their compressors or pumps will operate from time to time to restore pressure-operating conditions. (It is said in the colloquial language that a pneumatic circuit breaker "breathe" so the compressor has to work even if the system is not operated). Satisfactory pneumatic and hydraulic operation depends on a number of valves and seals that unfortunately, will leak more or less with time. For the general design of a generator circuit breaker, the panoply of available solutions to a designer leading to low maintenance of the operating mechanisms have chosen a spring mechanism due to: Simple principle of operation (close, latch, and trip). Energy stored in springs cannot be lost by leakage. In contrast to other systems (hydraulic or pneumatic), and entire series of monitoring elements are not required. There are no pressure lines, no pressure indications, no valves, no seals and therefore no leaks in the operating mechanism. Rotative movements are preferred, since rotating bearings are less sensitive to jamming and blocking than guidance for translatory movements with a specially developed grease possessing excellent properties at low temperatures down to -50 C, Roller bearings are treated with specially developed

Fig. 5. Sectional view of the spring operating mechanism of the third generation: Forces when the closed position is attained. 1 Closing shaft with flywheel and crank 2 Closing latch 3 Trip latch 4 Cam 5 Main shaft 6 Closing spring FO Dynamic force on the trip latch resulting from the maximum force F(t) measured in the coupling linkage circuit breaker - drive FOR Reaction force to FO FLR Reaction force to the max. force measured in the linkage.

this particular circuit breakers manufacturing with range from 25 kV to 800 kV and have proven the reliability of such a system in worldwide application over several decades, and as confirmed by various statistics. A. Analysis of the loads on the circuit breaker drives In order to quantify the dynamic loads, which the generation-2 and the generation-3 operating spring mechanisms are subjected to, and to analyse the validity of the chosen design concepts adopted for the third generation of spring operating mechanisms, tests were carried out on both types of drive. The first series of measurements was made on a circuit breaker driven by a mechanism of the third generation. A second series of measurements was subsequently carried out on the same circuit breaker, this time, driven by a mechanism of the second generation. The following values were measured on the two drives during the closing phase: - Movement of the shaft of the circuit breaker pole s(t). - Acceleration a(t) of the mechanism housing front plate, on the axes x (horizontal), z (vertical) and y (axial, depth)Force FL(t) in the coupling linkage between circuit breaker and spring operating mechanism. The trip operation was not an object of measurements, since both types of spring operating mechanisms during this phase only have a latching function. The acceleration forces on the mechanism housing are primarily generated by the circuit breaker and are of the same order of magnitude for both alternatives (approx. 300 ms-2). On figure 6, the accelerations a1(t), a2(t) are measured on the axis x over the course of the closing operation and are compared. The peaks of the acceleration can be easily associated with the different movement phases of the mechanism (see figure 3 for the operating scheme). For both types of mechanism, the highest forces and accelerations occur at the end of the closing operation at the moment when the trip spring, now fully tensioned, comes to rest on the trip latch (3) (numbers (n) refers to figure 5). In the case of the mechanism of the second generation, the drive shaft to which the flywheel (1) is coupled has completed the rotation of 360 degrees practically in the same moment. Then it comes to rest

Fig. 6. Comparison of dynamic characteristics of generation 2 at 200 joules in red to a mechanism of generation 3 at 200 joule in green. A1, A2, Actuation of the closing shaft (CS). B1, B2, Actuation of the main shaft (MS). C1, C2, Frictional connection with the circuit breaker shaft. D1, D2, Actuation of the circuit breaker shaft. FL(t) Force in the linkage of the coupling circuit breaker spring operating mechanism. FCL(t) Force on the main closing latch. a1(t), a2(t) Acceleration measured on the mechanism housing, on the axis of the x, filtered at 500 Hz. s1(t), s2(t) Movement of the pole shaft (linear potentiometer linked to the mechanism of the circuit breaker).

grease possessing excellent properties at low temperature down to -50 C, having also a very high aging resistance. The operating mechanisms are incorporated in a naturally ventilated sheet metal box and are constantly heated (50 to 100 W). The formation of condensed water and thus of corrosion is excluded. Easy commissioning: no delicate adjustments with spring mechanism, which could cause subsequent malfunctions. The motor operated spring mechanisms are factory-tested units, which are delivered to the site ready for use. Spring operating times with permanent availability, also after long standstills, require from the operating mechanism that its quality must not deteriorate in the course of years. The mechanical spring operating mechanism meets these requirements with the connotation of being practically maintenance-free. The characteristics are verified by type tests, which include more than 10,000 operating cycles on a spring mechanism. More than 80,000 spring mechanisms are in operations in

on the closing latch again and produces a much higher impact (vectors in the z-x plane, figures 5). The accelerations associated with this, despite the friction coupling with the flywheel, reach values of up to 45 g. This component of force associated with this, despite the friction coupling with the change of the spring movement direction, which the link (1) undergoes. The surplus closing energy is therefore transferred into the closing spring. The special geometry of the cam of that mechanism type enables the trip spring, once tensioned, to gently come to rest on the trip latch. The difference between the dynamic force and the final static force in the coupling linkage to the circuit breaker is thus reduced by half in comparison with the mechanism type of the second generation. B. Analysis of the measurements
Table 2. Comparison of the measured values between second and third generation. Spring operating Measured values mechanism Third Second Generation (1) (2) Max. acceleration during closing, x [ms-2] 88 393 Max. acceleration during closing, y [ms-2] 88 334 Max. acceleration during closing, z [ms-2] 167 461 Dynamic force in the linkage [kN] 13...16 10...17

C. Reliability of full spring mechanism operating generator circuit breaker The generation three - spring mechanisms range is produced in Oberentfelden (Switzerland). This specific factory has been developing and producing spring mechanisms since 1933. It can be stated that more than 80,000 spring mechanisms are today in operation.

The above table provides a summary of the results and shows the comparison between the second mechanism generation (2) and the solutions adopted for the third mechanism generation (1). The utilisation of a crank-type mechanism for recovering the surplus closing energy in a harmonic manner as well as the special geometry of the cam have made it possible to significantly reduce the acceleration peaks in the interior of the system. The speeds resulting from the accelerations are representative for the internal transformation of energy within the drive. This part of the energy is not available outside the system "operating mechanism", but is converted into friction and deformation energy and has over the long term an adverse effect on the wear and resistance against fatigue of its components. The smoother acceleration curve of the third mechanism generation with a helicoidal spring represents the positive influence of the chosen design on the dynamic behaviour and, in the long term, on its durability. With the third spring operating mechanism generation a more balanced and more enduring function and thus also a more economical solution has been achieved by: A minimum transformation of energy within the interior of the drive, An optimised use of the closing energy, A minimum expenditure for shock absorbing devices, A lighter construction of the drive and thus a significant reduction of the number of components, A minimised wear and maintenance requirement.

Fig.7. Spring mechanisms in SF6 Gas Insulated Substation circuit breakers. The last generations of live tank, dead tank and gas insulated breakers (52-1100 kV) and generator circuit breaker are now operated by this generation-3 spring mechanism. No major failures and no minor failures on the 184 generator circuit breakers in service and equipped with the generation-3 spring mechanism occurred. This corresponds to 1209 years of operation without any minor and major failure for one pole of generator circuit breaker. This demonstrates the very strong reliability of the spring mechanism generator circuit breaker and the users have a very low maintenance costs.

Fig.8. Side view of a new spring mechanism generator breaker type FKG.

VI. CONCLUSION Specific spring mechanism solutions have been developed to answer generator circuit breakers requirements focusing on reliability, availability and easy and quick maintenance. It has been demonstrated that the availability of the circuit breakers depends on the reliability of its mechanism. CIGRE studies have shown that the most reliable mechanism, by far, is the full spring mechanism. A new team has designed the last generation of spring operating mechanisms, and its application to generator circuit breakers, that has led to reduce stresses during operation and thus to improve significantly the reliability of generator circuit breakers. VII. ACKNOWLEDGMENT The authors gratefully acknowledge the contributions of B. Portal, A. Ludwig, L. Chailleux and the designer team for Generator Circuit Breakers of Villeurbanne, France for their work on the development on the increase of reliability. VIII. REFERENCES
[1] CIGRE Report 13-202, 1994 (Second International Inquiry), Inquiry on high voltage circuit breakers failures and defects in service, Paris, France, 1994. CIGRE WG 13.06; Paper 13-20, 1994; Final report of the second international enquiry high 'voltage circuit breaker failures and defects in service. Paris, France, 1994. CIGRE WG 23.10; Paper 23-102, 1998 ; Report on the second international survey on high voltage gas insulated substations (GIS) service experience, Paris, France, 1998. IEEE Std C37.013-1997. IEEE Standard for AC High-Voltage Generator Circuit Breakers Rated on a Symmetrical Current Basis. New York N.Y. 1997. CEPSI 1996, "Reliable Operation, Operating Time Consistency And Condition Dependent Maintenance of HV Circuit Breakers with Spring Mechanisms", Kuala Lumpur, Malaysia, 21-25 October 1996. CEPSI 1998, Improved performance and reliability of HV circuit breakers with spring mechanisms through new breaking and operating elements, Pattaya, Thailand, 2-6 November 1998

IX. BIOGRAPHIES
Endre Mikes was born in Budapest, Hungary, he studied electrical engineering, automatization and telemechanics, recieving M.Sc.E.E. In 1968. He worked in various fields of electrical, electromechanical and electronic apparatus design, construction and testing. In 1973, he joined Sprecher Energie Ltd. High Voltage Switchgear now AREVA T&D, Gas Insulated Substations in Oberentfelden, Switzerland. After working in different areas of circuit breaker testing, performance engineering and product support, he is today in the area of Technical Services as Manager of Technical Consulting in the field of product application, engineering and general consulting in the field of Transmission and Distribution Switchgear and GIS. He is a Member of various company internal and external working groups, such as IEC 17C WG 17, Assemblies of HV Devices, IEC SC17A - WG 31, Combined Apparatus and IEC 17A - MT 40, Electrical Endurance. Georges F. Montillet (M 1970, SM 2003) was born in Nice, France. He graduated from the Polytechnic Institute of Grenoble (Ecole Nationale Superieure d'Ingenieur) in 1968 in Power Electrical Engineering (MSc) and in 1974 obtained a MBA in Finance/Operational Research from NYU-Stern School of Business in New York (BetaKappa-Sigma). He received his Doctorate in 2005. He joined Cogenel, now AREVA T&D, New York, in 1971 after working on several projects in France, Algeria and New York. He was Assistant to the President from 1976 to 1990, and he was the US Executive Vice President of GEC ALSTHOM T&D from 1990 to 1997, Deputy General Manager of the ALSTOM US High Voltage Switchgear from 1997 to 2000, and Vice President Marketing and is now on the Board of the AREVA T&D Research and Technology for the High Voltage Switchgear Research Centre. He is a member of the High Voltage Switchgear Committee, and the High Voltage Circuit Breakers Subcommittees. He is also a member of CIGRE, IEC and SEE. He is the Chair of the IEEE Working Group PC37.06. Jean-Marc Willime (M 1980) was born in Bron, France on June 8th, 1956. He graduated from ECAM Lyon with a Master of Electrical and Mechanical Engineering. In 1980 he joined ALSTOM (then Delle Alsthom) as Quality Control engineer, in the Live-Tank Circuit Breaker Department. Since 1985, he has been involved as a research engineer in ALSTOM Switchgear Research Center, first in GIS, then in HV Live-Tank Circuit Breaker. He is presently Head of Research of Generator Circuit Breaker for AREVA T&D.

[2]

[3]

[4]

[5]

[6]

Denis Frigire was born in 1961 in Lyon (France). Denis graduated in 1985 from ECAM Lyon with a Master of Electrical and Mechanical Engineering. In 1992 after 6 years at "Sextant Avionique" he joined GEC ALSTHOM as Design Quality engineer in the Live-Tank Circuit Breaker Department. Since 1999, he has been involved as a R&D engineer in AHT HV Switchgear Technical Department. Currently he is the Generator Circuit Breaker Design Manager of AREVA/AHT Technical Department.