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Testing and commissioning of Electrical Equipments 10EE756

UNIT: 5, 6 & 7
INDUCTION MOTORS
a. Specifications for different types of motors, Duty, I.P. protection
b. b. Installation: Location of the motors (including the foundation details) & its control
apparatus, shaft & alignment for various coupling, fitting of pulleys & coupling, drying of
windings. 4 Hours
c. Commissioning Test: Mechanical tests for alignment, air gap symmetry, tests for bearings,
vibrations & balancing.
Electrical Tests: Insulation test, earth resistance, high voltage test, starting up, failure to speed up
to take the load, type of test, routine test, factory test and site test (in accordance with ISI code
d. Specific Tests: Performance & temperature raise tests, stray load losses, shaft alignment, and re-
rating & special duty capability.

Introduction
The induction motors are widely used as industrial drives because of simplicity, reliability and low
cost. Induction motors works with better efficiency, appreciable over-load capacity and maintenance
required is minimum. With the application of thruster control, induction motor can be used for
variable speed drive. Three - phase induction motors are available with various ratings from
fractional hp to several thousands of hp (say 10,OOOhp). Small motors below 1 hp (FHP motors)
are usually single phase induction motors. Induction motors are available with different voltage.
ratings i.e. 440V, 3.3 KV, 6.6 KV, 11 KV. Induction motors are not economical above 11 KV
because it is difficult to design slot insulation. The rated voltage generally depends on KW rating.
The following table gives ratings of 3phase induction motors.

Specifications of 3-phase induction motors

The important step in selection of an induction motor for ~pacific application is deciding the ratings
considering all affecting. parameters. Design of the motor is based on the following assigned

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numerical values of capabilities as per IS 325 - 1978.

Output rating: The preferred output rating for induction motors up to and including 110 KW are
0.06, 0.09, 0.12, 0.18, 0.25, 0.37, 0.55, 0.75, 1.1, 1.5 2.2, 3.7, 5.5, 7.5, 11, 15, 18.5, 22, 30, 37, 45,
55, 75' 90,100 KW.
Type of mounting: The mounting is to be specified like foot mounting, bed mounting, etc.
Rated voltage and rated frequency with variations:
Motors shall be able to deliver rated output with;
Aterminal voltage differing from its rated value by not more than ± 6 percent or,
 The frequency differing from its r::tied value by not more than ± 3 percent or
Combination of a and b.
The preferred voltages shall be in accordance with IS 5851962. The voltages preferred for 3 phase,
50Hz machines are 415V, 3.3KV, 6.6KV and l1KV.

Procurement of induction motor

Information to be given 'with enquiry and order: IS 3251978.When enquiring for and placing an
order for induction motor the following particulars should be supplied.
1)Site and operating conditions
2)Reference to this standard i.e. IS code number
3)Type of enclosure
4)Type of duty
5)Method of cooling
6)Type of construction
7)Frequency in Hz
8)No. of phases
9)Mechanical output in KW
10)Rated voltage and permitted variation
11)Class of insulation
12)Speed in revolutions per minute, approximate, at the rated output
13)Direction of rotation, looking from the driving end.
14)Unit or bidirectional of rotation required.
15)The maximum temperature of air and water used for cooling.

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16)Maximum permissible temperature rise

17)The height at which the motor is intended to work
18)Variation of voltage, current, frequency and speed
19)Particulars of tests required and where the tests are to be carried out

Rating plate of induction motor

Rating plate giving the following details should be supplied with each motor
Reference to the standard i.e. Ref. IS: 325
Induction motor
Name of the manufacturer
Manufacturer's number and frame reference
Type of duty
Class of insulation
Frequency in Hz
Number of phases
Speed in rpm
Rated output in KW
Rated voltage and winding connections
Current in amperes at rated output
Rotor (secondary) voltage and winding connections
Rotor (secondary) current in amperes at rated output and
Ambient temperature when above 40°C.

Types of enclosures:
The different types of enclosures are as follows I) Open ventilated motor
ii) Ventilated motor
iii) Drip proof motor
iv) Water protected motor v) Totally enclosed motor
vi) Totally enclosed fan cooled motor vii) Environment proof motor
viii) Weather proof motor

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ix) Hose proof motor

Duty
The duty requirement shall be given by the purchaser as accurate as possible. Based on the loading
pattern the duty shall be declared by the purchaser by numerical value or with the aid of time
sequence graphs of variable quantities. The assigned rating by the manufacturer gives the capa-
bilities. The ratings are to confirm IS 4722 - 1968 and IS 1885 ( art 35) 1973. The electrical motors
have time rate of temperature ~e. Duty indicates the duration for which the motor may be run at the
assigned values.

Three phase induction motors with type of protection 'n'

It is essentially standard industrial equipment with additional attention paid to certain features
which is suitable for operating in any gas mixed with air having an ignition temperature higher than
that of the temperature class marked on it. Flame proof enclosure, intrinsic safety or type of
protection 'e' motors are also operated in hazardous Locations. However a substantial saving in cost
may be achieved by using equipment with type of protection 'n'. IS 9628-1980 is referred to provide
a common basis for the construction and testing of motors with type of protection 'n'.
A flame proof equipment installed in hazardous Locations Like mining industry ensures that
ignition occurring within the enclosure of the motor will not transmit the flame to the atmosphere
surrounding the motor. However flame proof motors are expensive and difficult to manufacture for
higher rating. The advent of technology and improvement in installation Lead to the development of
type of protection 'e'. However with type of protection 'e' the temperature rise of the apparatus lode
less than the normally permitted temperature rise for the class of
Hazardous locations and explosion or flame proof machine:
Special enclosures are used for machines operating in hazardous Locations i.e. in presence of highly
inflammable gas vapors, combustible dust, highly inflammable Liquids such as petrol, naphtha,
benzene etc.. These will explode in presence of electric spark. In case of explosion, it is confined
within the ~aching and will not be spread to atmosphere. For this reason enclosure should be strong
to withstand high pressure built

Installation of Induction Motors

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The various stages in the installation of induction motor\ are as follows:

.Acceptance and proper storage at site ./ Foundation and civil work

.Drawing of supply and control cables ./ Preparing motor for

installation
Preparing driven machine and shaft alignment ready

Checking the insulation, starter, supply and control cable\ ./ Drying

out

Checks and tests on the machine and related accessories\ ./ Trial run
on load under observation
Settings of protective relays
Final commissioning and handing over to operating staff
The electrical motors are classified as low power motif
(up to 100 KW), medium power motors (100 KW - 500KW) an~ high power motors (above 1000
KW) based on the output power,

Foundation
The civil construction and foundation of the machine roar should be spacious. The machine room is
to be equipped with~ overhead traveling cranes or jibs for handling assemble machines and any
other heavy parts. Depending upon the size o' the motor, appropriate foundation is to be designed.
However this can be referred to civil engineer for suggestions. Tiff function of the foundation is to
transmit the static and dynamic load of the running motor to the ground.

The machine is bolted to bed plate. The bed plate is fixed to the foundation. The foundation bolts
are used for securing the bed plate. Rolled I-sections are placed in concrete on which the bed plate is
place

Drying of windings

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The insulation of rotating machines is hygroscopic in nature .absorbs moisture. The moisture
reduces the insulation resistance. It is essential to remove the moisture prior to the commissioning
of the motor by drying out. There are different methods available to apply the heat for drying of
induction motor. During drying it is necessary to record the temperature at various stages of drying
out, insulation resistance and time. There are three phases in drying out of induction motor. In the
first phase the insulation resistance starts decr2asing due to the distributionoft moisture in the entire
insulation. The second phase is a steady temperature phase over certain time and the insulation
resistance remains almost constant. In the third and last phase the insulation resistance drastically
increases thereby indicating that the moisture is expelled. The high resistance of insulation gives the
degree of dryness of the insulation.

Polarization index:
It is the ratio of 10 minutes resistance to one minute resistance. PI gives the quantitative information
regarding the presence of moisture, dust and dirt. For class A insulation PI is 1.5 or more, for class
B insulation 2.0 or more. PI value less than 1 indicates the immediate need of reconditioning. Log
sheet of drying out of an induction motor:

1)Technical particulars of machine Rated voltage, rated frequency Rated KW, full load current
Connection diagram, number of windings
2)Technical particulars about connections for drying out
3)Check prior to starting the drying
4)Ambient temperature
5)Initial values of insulation resistance
6)Time of start, date, hours

Drying out of induction motor by drying chamber and resistor heater

Dry the induction motor using drying chamber. The machine to be dried is housed in a drying
chamber. The volume of drying chamber should be nearly four times the volume of the induction
motor. The heated air by using resistor heaters ~s circulated by means of fans and air circulation
system. The air temperature is measured using thermometers. The moisture 15 expelled from the
machine is let out of the drying chamber through air outlet. For large machines heater blowers of 25

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KW are suitable. The chamber should be thermally insulated to avoid heat loss. The machine body
is covered with canvas to prevent heat loss. Temperature of the air shall be controlled by turning off
the heater from time to time. The temperature is gradually raised i.e. not faster than lode per hour.
Higher rate of heating may result in damage due to differential expansion of metals and insulation.
It is required to preferably maintain steady temperature throughout the heating.
Drying out by radiating lamps
This is the convenient and simple method used for medium and small motors. The infrared lamps
are located in the chamber facing the motor windings with rotor removed. This method is applicable
to dismantled motor for drying the stator winding and rotor Winding separately.

Drying out by circulating short circuit current

This is convenient method for drying out slip-ring induction motors. The machine is connected to
low voltage source. The input voltage, current, power, the temperature of winding, temperature of
body, temperature of hot air are periodically recorded. The end covers of the machine are removed.
The machine body is covered with tarpaulin. The increase and decrease of the temperature should
be gradual. The rotor is blocked. The current through the stator winding not to exceed 50% of the
rated current.

Drying by windage losses

This method is applicable to high frequency motors having high speed. The inlet and outlet air ports
are blocked. The windings gets dried by wind age losses dissipated in the form of heat.

Testing of induction motors (mechanical tests)

The various tests conducted on the induction motor are
1)Type tests: These tests are conducted on the first machine manufactured to confirm the design.
2)Routine tests: These tests are conducted on each motor to confirm proper manufacture and to
ensure smooth performance, at manufacturer's premises (factory) or/ and at site.
3)Commissioning tests: These' tests are conducted at site, after installation, before final
commissioning to ensure desired performance under practical conditions.
4)Special tests: These tests are conducted for special investigation as per the contract made between
the manufacturer and purchaser, preferably in presence of representative of purchaser at the floor

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before dispatch.
5)Development test: These tests are conducted to analyze for design parameters and stresses. These
are helpful in development/improvement of the earlier machine or new machine.
6)Reliability tests: These tests are conducted to ascertain reliability of the motor under operating
conditions.
7)Periodic maintenance checks and tests: These tests are included in the preventive maintenance
schedule which depends on the service conditions.

Commissioning tests:
Prior to the commissioning of induction motors, the following are to be carried out to get trouble
free performance.
1. Measurement of resistance of windings
2. Measurement of insulation resistance of winding insulation
3. Power frequency high voltage test
4. Trial start
5. No load tests
6. Load tests
7. Tests on cooling system
8. Tests on lubricating system
9. Performance tests viz. no-load, full load, short circuit speed control, speed-torque
characteristics, starting; stopping/reversing/braking etc.
10. Special tests viz. vibration tests, oscillographic tests to record starting currents, switching
voltages etc.

Mechanical alignment and air gap symmetry

When the rotor is supplied without shaft assembled, is to be fitted on to the shaft before installation.
While fitting the rotor .on to the shaft the difference between the rotor and shaft temperature are to
be taken into account. The rotor hub bore and shaft diameters are to be matched properly. Installing
rotor in the stator is a difficult process. Sling the rotor with a rope and suspend it horizontally. Then
drive it to the stator bore by means of a crane. Place the rotor in position such that the air gap
between the rotor and rotor stocks is approximately uniform. Once the stator and rotor are mounted

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in position, check for clearances between shaft journal necks and the butt end of the bearing shells.
The air gap between the stator and the rotor are checked and adjusted after the shaft is fully aligned.
Set the air gap with the help of wedge type gauges on both sides of the rotor. Permissible values of
difference between maximum and minimum air gap for an induction motor is 10%.

Load Test: 154029 -1967

1f with load are conducted for the determination of performance, such as efficiency, power factor,
speed and temperature rise. For all tests with load, the machine shall be properly aligned and
securely fastened. Load characteristics are obtained usually at 125, 100, 75, 50 and 25 percent of the
full load ~lees.

Methods of Loading:
Brake method
Dynamometer method
Calibrated machine
Non-calibrated machine

The motor may be loaded by ac or dc coupled generator either directly or by belt. The output of the
generator is measured and its efficiency at various loads must be known to calculate the output of
the motor under test. The input to the motor is measured by using wattcmeters. When belt drive is
Jed, the power loss in the belt should be considered. When pony brake is used, for large machine,
then brake gets extremely hot, so the observations must be taken very quickly. This method is
suitable for small machines testing in the laboratory.

No load Test: 154029 - 1967

This test is conducted to determine the no-load current, core loss and friction and wind age losses.
The motor is run on no-load at rated voltage and frequency until the input power is constant. The
readings of voltage, frequency, current and power are noted. This test shall be preferably conducted
immediately after the temperature rise test. The input power is the sum of friction and wind age
losses, core loss and no-load primary I2R loss. The friction and wind age losses and core losses may
be separated if required. locked rotor test

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This test is a carried out by holding the rotor stationary b clamps. The stator is supplied with low
voltage of normal frequency. The applied voltage is gradually increased till the rated current is
circulated in the stator windings. The readings of voltage, current and power are noted. The leakage
impedance reduces with higher current as a result of saturation. Locked rotor test gives copper loss
for particular stator current. Iron losses are ignored.

Temperature rise test: 154029 - 1967

The aim of this test is to find out the temperature rise on different parts of the motor while running
at rated conditions. During temperature rise test, the motor should be shielded from currents of air
entering from adjacent pulleys and other machines. A small current of air may cause great
discrepancy in results obtained. The duration of temperature rise test depends on the type of rating
of the motor. For motors of continuous rating, the test should be continued till the thermal
equilibrium is reached. For motors of short time rating the duration of test corresponds to the
declared short time rating, the test should be continued till the thermal equilibrium is reached.
Methods of measuring temperature rise of parts of motor:
The following methods are approved for determining the temperature of windings and other parts of
motor.
1) Embedded temperature detector method:
Embedded temperature detectors are resistance thermometers or thermocouples built in the machine
at points which are inaccessible when the machine is assembled. This method is generally employed
for the slot portion of stator windings. At least six detectors to be built in a machine suitably
distributed around the circumference.
2) Resistance Method:
This method is generally used for stator whirling’s. Here temperature is determined by the increase
in the resistance of the windings.
3) Thermometer method:
In this method, the temperature is determined by thermometers placed at the accessible surface of
the rotor.

Methods of cooling adopted:

The squirrel cage induction machines are cooled Ii1y circulation of air. The enclosure should be

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such, that the windings are protected from unfavorable environments. When adelllJate surface area
is not available, heat exchangers are used. In self cooled motor a fan is attached to the rotor. This
fan forces air circulation over the windings to give cooling.
Starting test on 3-phase induction motor
The starting test is conducted usually on squirrel cage motors to confirm that induction motors are
capable of starting against specified load torque v.<without crawling or developing vibrations.
When the motor fails to start against load and accelerate up to full speed but runs at 1/7th normal
full load is called as crawling. The voltage is gradually applied to stator winding. The motor should
start at nearby 70% rated voltage. The time taken by the motor to reach rated speed and the current
are noted.

Running up test
Cage motors are liable to harmonic torques, productive of crawling. A running up test is conducted
on cage motors to ensure that they are capable of starting against a reasonable load torque without
failing to attend normal running speed. The test also reveals noisy running and the presence of loose
bars. The load torque applied depends upon the rating and size of the motor and its method of
starting. Thus a continuously rated motor for star delta starting might be expected to start with 25 33
% of full load torque at 175% of full load current in the line.

Noise in Motors:
The noise of a rotating machine is generated by the cooling fans. Noise may be minimized by using
unidirectional trailing bladed fans by the normal radial blades. Further reduction is achieved by inlet
and outlet silencers or the adoption of closed ventilation circuit of cooling air. The noise around a
machine is affected by the shape and dimensions of the outer surfaces of the case and reflection
from hard surfaces of wall.
The noise is also caused by magnetic effects and depends on the stator and rotor slots. The value of
the stator presence variation may be the cause, but the amplitude also depends on higher order rotor
miff space harmonics. The frequency of the noise is twice the product of the supply frequency with
that integer nearest to the number of slot per pole i.e.
fn = fix n
wherefn - frequency of noise due to slot miff harmonic, Hz f - supply frequency

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n - Number of slots per pole.

Effect of variation of supply frequency

The change in frequency results in change in synchronous speed. The change in frequency affects
the synchronous speed, percentage slip, full load speed, full load current, temperature rise on full
load and starting current.

Effect of unbalanced voltages:

Unbalanced supply voltage causes negative component in the rotating magnetic field. This will
induce high rotor current and rotor gets heated and due to overheat rotor may fail. The permissible
unbalance in supply voltage is related with duration. A prolonged unbalanced voltage of 3% results
in excessive heating and damages the rotor and stator insulation.

Dating:
Dating is operation of the machine at underrated value.
This is done when the supply quantities are not as per the specifications. Instead of putting off the
machine, it is Continued to run by making it to develop output power less than the specified.

Methods of starting induction motors

The starting current is higher than the full load current. The different techniques to start the
induction motor to limit the starting current are
1)Direct on line starting (for machines <5 hp)
2)Stator resistance starting
3)Autotransformer starting
4)Start delta starting
5)Rotor resistance starting
6)Thruster starting control
Methods of braking induction motors:
The table gives the different methods adopted for braking of an induction motor.

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Maintenance of Motors
The objective of the maintenance is to reduce the number of failures. During normal working, some
parts wear out and calls for replacement and minor defects are to be rectified to avoid failure. The
breakdown of motor results in loss / damage /outage /inconvenience. The down time of the machine
must be kept as minimum as possible. Hence preventive maintenance is justified
The preventive maintenance needs
 Proper records
 Skilled labor and staff
 Facilities for repairs
 Storage of spares
The repeated inspection leads to wastage of time and money. The neglected/hardly inspection leads
to failure. The frequency of inspection must depend on;
 Importance of the machine
 Duty cycle
 Age
 Overloads, service conditions
The maintenance schedule is always recommended by the manufacture. .Maintenance includes
activities to be taken up to keep the machine in working condition. It includes inspection,
lubrication, cleaning etc., and does not involve complete dismantling. Overhaul includes thorough
checking, inspection, repairs, adjustment and restoring good working condition. During Overhaul,
the machine is dismantled, worn out parts are replaced and the machine is completely restored to
good working Condition.

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UNIT 8:
SWITCHGEAR AND PROTECTIVE DEVICES

SWITCH GEAR & PROTECTIVE DEVICES: Standards, types, specification, installation,

commissioning tests, maintenance schedule, type & routine tests.

Introduction
The term switchgear includes wide range of equipment used for switching, interruption,
measurement, control, indication etc. The necessary units are arranged in a sequence. The
components are enclosed in sheet metal enclosure or cast iron enclosures. Hence the name metal
clad switchgear or metal enclosed switchgear. The components of indoor switchgear include (1)
switching and interruption components viz. switches, switch fuse combinations, circuit breakers,
HRC fuses, isolators and earthling switches (2) measuring components viz. CT, PT, meters etc.
Faults occur on power system due to several reasons and no part of the power system is left
unprotected. The unhealthy part is isolated immediately upon the occurrence of the fault by
protective devices like relays and circuit breakers. The functions of different devices used in
protection are mentioned below.
1.Relay: It is used to sense the change in the operating quantity when it exceeds certain preset value.
2.Fuse: It is a simple protective device which breaks the circuit when the current exceeds the rated
value. After the clearance of the abnormality, the fuse element is to be replaced to resume normal
operation.
3.Circuit breaker: It is used to break or make the circuit upon receiving the signal from the
associated relay under abnormal and normal conditions respectively. Based on the location the
making may be manual, semi-auto enclosure or auto closure.
4.Isolators: Isolators are used to isolate during off-load to ensure that the circuit breaker is de
energized for scheduled or unscheduled maintenance activity and is provided with interlocking
provision.

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5.Load break switch: This is used to disconnect the load and overload currents and not short circuit
current.
Circuit breaker
A circuit breaker is capable of breaking & making the circuits under abnormal and normal
conditions respectively. The parts of circuit breaker include
a)Poles with interrupter, porcelain, arc quenching medium
b)Operating mechanism
c)Support structure and
d)Control cabinet

Upon the occurrence of the fault, the current in the secondary side of CT is more than the current
under normal condition and relay connected to the CT actuates and thereby closes its contacts.
Battery supplies the" current to energize the trip coil of the circuit breaker to open the contacts.
After resuming the normal condition, the battery circuit is open & circuit breaker contacts are
closed.

Types of circuit breaker

According to the method of control of the closing operation, circuit breakers are classified as (IS
1011 (Part-II)-1982).
Dependent manual closing
Independent manual closing
Dependent power closing and
Stored energy closing

According to the interrupting medium, circuit breakers are divided into

Oil circuit breakers
Bulk oil circuit breaker - up to 33 KV (now obsolete) ./ Minimum oil circuit breaker - up to 36 KV,
1500 MVA, 132 KV, 3500 MVA
Air circuit breaker - LV circuit breaker up to 1000 V
Air blast circuit breaker - 132 KV, 220 KV, 400 KV, 760 KV
Sulfur hexafluoride circuit breaker - 132 KV, 220 KV, 400 KV, 760 KV
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Vacuum circuit breaker - 11 KV, 33 KV

The type of equipment is also further characterized by

Number of poles
Kind of current
Method of closing
Method of opening and

Types of opening mechanism used in high voltage circuit breakers

For circuit breakers above 200 MVA, stored energy type independent automatic operating
mechanisms are used. These can be classified as Spring open, spring closed mechanism: The
closing spring is of higher energy level and is charged by driven gear.
1)Pneumatic operating mechanism: Air blast circuit breakers are invariably provided with
pneumatic operating mechanism. Here the force required for closing and opening operation is
derived from compressed air at certain pressure (18 to 30 kg/cm2).
2)Hydraulic mechanism: High pressure hydraulic oil (300 to 3350 bar) is admitted from the bottom
of hydraulic cylinder by opening of hydraulic valve for opening and closing of the contacts.
3)Solenoid mechanism: In this mechanism, the closing operation is obtained by energizing a
solenoid by direct current. Solenoid mechanism is suitable for auto reclosing.

Specifications of high voltage circuit breaker

Rated voltages: A circuit breaker is defined by the following rated voltages
Rated operational voltage
Rated insulation voltage
Rated current: The circuit breaker is defined by the following currents
rated thermal current
rated uninterrupted current
Rated frequency: The rated frequency of the equipment is so chosen as to suit the service frequency
Rated short circuit breaking and making capacities: The rated short circuit breaking current is the
highest value of short circuit current which the circuit breaker is capable of breaking under specified
conditions of recovery voltage and power frequency recovery voltage. The rated making current

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must be at least 2.5 times the rams value of ac component of rated breaking current.
Rated short time withstand current: It is the rams value of the current that the circuit breaker can
carry in a fully closed position during specified time.
Short circuit performance category: The rated short circuit performance category of the equipment
states the rated operating sequence and the condition of the circuit breaker after performing this
sequence at the rated short circuit making and breaking capacities. For the same circuit breaker the
value of the rated short circuit breaking and corresponding making capacities may be different for
different short circuit performance categories.
The following characteristics should also be considered while selecting the circuit breakers .
a)For control circuits: Rated control supply voltage and type (ac or dc) of current.
b)For air supply system: Rated pressure and its limits and volumes of air at atmospheric pressure
required for each closing and opening operation.
c)For shunt release and under voltage release: Rated voltage & kind of current .
d)For over current release: Rated thermal current, kind of current and range of settings.
e)For auxiliary switches: Rated voltage & current
The circuit breakers intended for circuit operating below 1000 volts ac or 1200 volts dc are covered
under the group low voltage circuit breaker.

Tests on circuit breakers

Type tests: These tests are conducted on the first circuit breaker manufactured to prove the
capabilities and to confirm the specified characteristics of the circuit breaker of that design in a
specially built testing laboratory.
Routine test: Routine tests are performed on each and every circuit breaker as per the
recommendation of the standards to verify the performance.
Commissioning tests: These tests are conducted on the circuit breaker after installation at site to
verify the readiness and proper functioning.
Development tests: These tests are carried on components, sub-assemblies and complete circuit
breakers during and after the development of the circuit breaker. The designers and research
scientists verify the effect of various parameters.

Types of test:

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1.No Load mechanical operation test: This test is to verify speed of travel, operating time and
closing time and is carried out at 85% and 110% rated voltage of shunt trip release.
2.Mechanical performance tests (endurance): It is to check the mechanical ability of opening and
closing of the contacts by carrying out 1000 close and open operations or more.
3.Temperature rise test: Steady temperature of conducting part and insulating parts measured for
rated continuous alternating current.
4.Dielectric tests:
1.2/50 IPSec Lightning impulse withstand
One minute power frequency voltage withstand
250/2500 Ills switching impulse withstand
5.Short time current test: Rated short circuit current is passed through closed breaker for less or 3
sacs .
6.Short circuit breaking and making tests: This test is conducted at 10%, 30%, 60% and 100% rated
short circuit braking current with specified operating sequence and specified TRV (transient
recovery voltage).
7.Line charging current breaking test: This test is conducted for circuit breakers 72.5 KV and above.
8.Cable charging current breaking test: This test is applicable to circuit breakers intended for long
cable network.
9.Single capacitor bank breaking test: This test is applicable for circuit breakers used for capacitor
switching.
10.Small inductive current breaking test: This test is to be conducted on circuit breakers with
reactors, transformers, motors etc.

Commissioning tests:
After the installation, the circuit breakers and protective gear are subjected to certain tests at site to
ensure proper assembly and readiness of the circuit breaker. The commissioning tests include:

Mechanical operation tests

Measurement of travel, simultaneous closure of contacts Measurement of insulation resistance
between terminals
of pole

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Pre commissioning checks

Checking close and open operation by energizing the manual operating signal
Checking close and open operation by energizing relays etc
The insulation resistance is measured using megger. It consists of a built in hand driven dc
generator. The two terminals of megger are connected across the insulation i.e. one to the conductor
and other to the earthed body. Then the dc generator is driven & corresponding resistance indicated
by the mugger is recorded. For the switchgear 1000V or 2500V mugger is preferred. Insulation
resistance of the control circuit, trip circuit, relay circuit etc. is measured using 500V mugger.

High voltage test at site

High voltage test as per the relevant IS code is conducted after the erection of the circuit breaker. By
conducting this test the defect in the insulation can be checked. The test voltage is generally applied
for duration of one minute. The circuit breaker is isolated suitably during the test. The test voltage is
applied between the to be 'tested part' and earthed parts as follows.
1)With breaker closed:
a)Tested part: R - phase
earthed part: Y - phase, B - phase, frame of the circuit breaker
b)Similarly for the phase Y and B
2)With breaker open: This test is conducted on breaker contacts by shorting R,Y,B phases on bus-
bar side~ Voltage is applied from other side consecutively to each phase.

The purpose of high voltage test on circuit breaker is as follows:

To define the insulation characteristics
To standardize the insulation levels
To specify the markings on the rating plates indicating insulation levels
To confirm that, there are no cracks in porcelain, no dust
and moisture is present in the circuit breaker

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High voltage tests on circuit breaker include the following.

Impulse voltage dry withstand test
One minute power frequency voltage dry withstand test
One minute power frequency voltage wet withstand test Power frequency voltage withstand tests
are conducted by applying specified high voltage alternating quantity for one minute. High voltage
testing transformer is an important component of the high voltage testing of circuit breakers. Sphere
gaps are used for the measurement of high voltage. The sphere gap gives the peak voltage from the
known spacing and standard table, the peak Voltage at the instant of disruptive discharge can be
obtained.

Temperature rise test

This test is to be conducted on a circuit breaker that is the representative of a batch of circuit
breakers manufactured Alternating current of rated value at rated frequency is passed through the
circuit breaker by keeping the contacts in the closed position, continuously till the steady
temperature is reached. Readings of various conducting, insulating and structural parts are taken at
an interval of one or half an hour. When steady temperature is reached, the maximum temperature
rise of each part should be less than the permitted values.

Mechanical test (Endurance test)

The breaker should consistently open and close its contacts. In mechanical endurance test the circuit
breaker is opened and closed many times (nearly 1000 times). Few opening & closing operations
(nearly 50 times) is done by energizing the relay and the remaining are by closing the trip circuit by
other means. Mechanical tests on high voltage ac circuit breakers are conducted without charging
the main circuit. During mechanical tests adjustment or replacement of any part of the circuit
breaker is not allowed. However lubrication is to be applied as per the instructions of the
manufacturer. After repeated closing and opening operation, the contacts and other parts of circuit
breaker must be in good position and there should not be any permanent deformation of any parts.
The dimensions should be within original limits. During repeated operations, the breaker parts in the
assembly may fail. The circuit breaker is then considered to have failed in the mechanical test. The
tests are to be conducted after the improvement in the design and manufacture. Successful

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performance in mechanical endurance test proves the adequacy of design and also good quality of
material used in manufacture. Though 1000 close and open operation are specified in the standard,
the manufacturer may conduct nearly 10000 times or more operations to ascertain the reliability and
for getting design data.

Test for contact resistance of circuit breaker pole

The resistance of the pole should be less than about m x 20j..all where m is the number of joints,
contacts in series per pole. This is measured by one of the following two methods.
1)Micro ohmmeter: A micro ohmmeter is connected across terminals of the pole to measure the
resistance directly.
2)Mill volt drop method: The voltage drop across the circuit breaker pole is measured for different
values of dc current. The voltage drop gives a measure of current carrying part and contacts. The dc
current should be sufficiently high but must be less than the rated current. The resistance
measurement of circuit breaker pole should be done at ambient temperature. The resistance must be
of the order of few tens of micro ohms. This test is a routine test to be carried out to ascertain the
performance when the circuit breaker is put in actual operation.

Impulse voltage test

This test is carried· out on indoor and outdoor circuit breakers. Standard impulse wave of specified
amplitude is applied five times in succession. During the test impulse wave with reversed polarity is
also applied. The impulse wave is obtained from an impulse voltage generator. One terminal of the
impulse generator is connected to the terminal of the circuit breaker pole and the other terminal is
connected to the earth and frame of the circuit breaker. The peak value of the impulse wave and its
shape is recorded using RO with calibrated voltage divider. The different impulse voltages will have
different front Wave and tail wave. During the test if there is failure of the insulation or puncture,
will be considered as the circuit breaker has failed

Time versus travel characteristics

There are two methods to obtain the time versus travel characteristics of a high voltage circuit
breaker.
1.Use of potentiometer: In this method, the two fixed terminals of potentiometer is supplied with 3

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volts de. The stem connected to the variable terminal of the potentiometer is connected to the lever
of the circuit breaker. As the lever moves during opening and closing operation, the current through
the variable terminal changes proportional to the travel.

2.The curve-roller: This method is suitable for obtaining the travel. A drum with a paper fixed on it
is driven by a motor. The curve roller is fixed vertically on the top hood of the interrupter of the
circuit breaker. A pencil attached leaves mark on the paper as the drum rotates at the time of closing
and opening.

Short circuit testing station and short circuit test

Short circuit test is conducted to prove the ratings and to obtain the behavior of the circuit breaker
for research and development. The short circuit testing plants are built specially to provide facility
for short circuit testing. Provisions are made to test the complete capability of circuit breaker by
direct and indirect tests. The short circuit power is supplied by specially built short circuit
generators. There are normally two or more generators. These generators are driven by three phase
induction motors and special type of excitation called impulse series resistors and reactors are
provided for adjusting the magnitude of short circuit current and power factor. The master circuit
breaker has higher capacity than that of the circuit breaker under test and protect the breaker under
test. In addition the equipments in short circuit stations are measuring, recording and control
instruments, sequence switch to obtain sequential operation of auxiliaries tee. The preliminary
preparations of circuit breaker testing include connecting the equipments, adjusting the magnitude
of the reactors, contacts on sequence switch to get desired timing etc. are done, while testing, short
circuit is created and the switch is closed. The breaking current is obtained by using oscillograph.
The circuit breaker should be capable of performing the opening and closing operations as per rated
operating sequence for all values of short circuit currents up to its rated short circuit breaking
current at specified test voltage and relevant conditions of transient recovery voltage for terminal
short circuits. Steps in installation and commissioning of outdoor circuit breakers:
In installation and commissioning, the guidelines given by manufacturers are to be followed.
1)Prepare foundation, support structure of the circuit
breaker in position as per the plan
2)Check for the horizontal level

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3)Assemble operating mechanism

4)Extend supply to auxiliary system egg: for motor, for trip·
circuit and closing circuit
5)Measure insulation resistance
6)Check open and closing contacts
7)Make terminal connections
8)Operate breaker from local control panel
9)Operate the breaker from control room as per the instructions and also by operating the respective
10)Put it in actual service

Selection of circuit breakers:

Circuit breakers are used at various voltage levels. The following factors are to be given
consideration while selecting the circuit breakers.
1)Ratings
2)Break time
3)Ambient conditions
4)Type; indoor or outdoor
5)Control desired
6)Type of operating mechanism
7)Type of breaker based on arc extinction medium
8)To be operated alone or in group
9) Frequency of operation
10) Other protective equipment’s with which to be co-ordinate

Installation procedure for circuit breakers:

In the process of installation of circuit breakers, the preliminary preparations such as study of
drawings, acceptance, report checking certificates, test reports of the equipment, completion of civil
engineering work, arranging the tools, organizing the labor, preparation of schedule of installation,
preparation of sequence cards for erection etc. are to be d~.ne. The different steps of installation
include:
1)Sequence card for erection of switchgear equipment

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2)Location of switchgear
3)Unpacking
4)Foundation
5)Erection
6)Bus bar earthling connections
7)Connection of main cables
8)Earthling

Low voltage circuit breakers

Low voltage ac circuit breakers are used in control gear for controlling power by the consuming
devices. LV circuit breakers are for indoor applications. LV circuit breaker operates more frequently
than he circuit breakers. LV circuit breakers are different from the circuit breakers from the point of
view of both ratings and constructional features. LV circuit breakers are more compact as the phase
to phase and phase to. ground clearances for low voltage are less. LV circuit breakers are used for
repeated switching of low currents and overload currents and have capability to break short circuit
currents. The circuit breakers operating below 1000 volts ac or 1200 volts dc are covered under low
voltage switchgear.

Ratings of LV circuit breakers

The important ratings of low voltage circuit breakers are as follows
 Rated voltage and frequency
 Rated currents
 Rated duty
 Rated short circuit making and breaking capacity
 Rated short time withstand categories
 Rated voltages: Rated operational voltage, rated Insulation voltage
 Rated currents: Rated thermal current, rated uninterrupted current
 Rated duty: short time, uninterrupted duty
 Rated short circuit making capacity
 Rated short circuit breaking capacity

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 Rated short circuit withstand capacity

Tests on low voltage ac circuit breakers
The different tests to be carried out on live circuit breakers are as follows.
Type tests: To be conducted to confirm the design, on the first piece manufactured.
 Temperature rise limits test
 Dielectric tests
 Short circuit making and breaking tests
 Short time withstand current test
 Mechanical endurance test
 Overload performance

Routine tests: To be conducted to predict the performance behavior on each circuit breaker.
 Mechanical operation tests
 Calibration of releases
 Dielectric tests
 Insulation resistance test

For low voltage load control, the switchgear used may be one of the following
Low voltage air break circuit breaker
Low voltage contactor
Switch fuse combination
Miniature circuit breaker
Molded case breaker

Maintenance of circuit breakers

The circuit breaker is intended for repeated operations as the occurrence of the faults in the system
is unpredictable. Hence to ensure the protection of system components, more emphasis is to be
given to the maintenance of circuit breakers. The maintenance procedure differs from breaker to
breaker based upon the quenching medium used. The maintenance to be carried out includes the
following.

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1)Period of maintenance Under normal condition On clearing faults

2)Checking of contacts
3)Checking of arc control devices
4)Checking of insulators
5)Checking of relays

Precautions to be taken during maintenance:

The maintenance work should be carried out with authentic permission by the concerned authority.
The following steps are to be followed.
1)Isolate the live part
2)Danger notices should be displayed
3)The neighboring switch should be locked to avoid accidental switch nag
4)The equipment and conductors should be earthed
5)Power tools and safety devices to be provided to the electricians
6)Well trained people must be allowed for the work
7)First aid should be available
8)There should not be any chance of negligence

HVDC circuit breaker

In HVDC system, dc current is controlled by blocking the valves. The arc extinction in ac circuit
breakers takes place at natural current zero of the wave. Thus, the energy in system inductance at
current zero is nil and current interruption is relatively easy. In dc system a LC resonant circuit is
introduced in parallel, just after contact separation of main circuit breaker, thereby oscillations are
produced artificially as shown in fig 4.4. The circuit breaker uses one of the current zeros so as to
extinguish the arc. Such breakers are used for transferred nag current from earth return path to
metallic return

Fuses
Fuse is the weakest link in electrical circuit. It is the simplest current interrupting device used to
protect from excessive currents. It is used for low voltage applications. However modern High

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Rupturing Capacity cartridge fuses (HRC) provide reliable discrimination and accurate
characteristics. In some respects HRC fuses are superior to circuit breakers. The main difference
between the two is that, fuse can break the circuit under abnormal conditions but cannot make the
circuit on its own after the system returns to normal condition, whereas a circuit breaker can make
and break the circuit under normal and abnormal conditions res pectin vet lee.

Types of fuse:
Semi enclosed or re wearable fuse
Totally enclosed or cartridge type
o D-type
o Bolted type
o Expulsion fuse
o High Rupturing capacity fuse (HRC)

The following details pertaining to fuse are considered while selecting the fuse for particular
application.
Rated current
Minimum fusing current
Perspective current
Pre-arcing time
Arcing time
Total operating time
Fusing factor

Metal clad switch gear

The indoor switchgear is generally factory assembled and unit type. The term switchgear covers a
wide range. of,equ.ipment for switching, interruption, measurement, control, mdlCatlOn etc. The
components of switching and interruption include s.witches, switch fuse combinations, circuit
breakers, HRC fuses, isolators and earthling switches. These components are assembled and
enclosed in sheet metal enclosure or cast iron enclosures. Hence these switchgears are called as
metal clad or metal enclosed switchgears. The components for measurement include current and
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potential transformers. In draw-out type metal enclosed switchgear, the components are mounted on
withdraw able carnage. Interlocking for safety is another important feature of such switchgear.
Contactor is a mechanical switching device capable of making, carrying and breaking electric
current under normal conditions including operating overload conditions. Contactors are used
basically for operation under normal conditions and overload conditions. Contactors are required to
operate more frequently. During mechanical endurance test contactors are operated more than
10,000 times on no load to verify the resistance to mechanical wear. Contactors are designed
according to the method of energizing the control circuit viz. electro m;,gnetic, pneumatic and
electro pneumatic. The ratings of the contactors are as follows.
1)Type of contactor
2)Interrupting medium
3)Rated voltage
4)Rated current
5)Rated duty and service conditions

Utilization categories of contactors:

AC-l: Non inductive or slightly inductive, resistance furnaces AC-2: Slip ring induction motors,
starting, plugging
AC-3: Squirrel cage induction motors, starting & to stop AC-4: Squirrel cage induction motors,
starting, plugging & inching
DC-l: Non-inductive, slightly inductive loads DC-2: Shunt motors, starting & to stop
DC-3: Shunt motors, starting, plugging & inching DC-4: Series motors, starting & to stop
DC-5: Series motors, starting, plugging & inching.

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