Live Tank Circuit Breakers

Routine testing
Routine tests
Live tank circuit breakers

2 | ABB Live tank circuit breaker routine testing

All circuit breakers are tested
ABB has a well established process to ensure on-time delivery
of circuit breakers to its customers with the highest level of
quality and reliability. At the live tank circuit breaker produc-
tion facility in Ludvika, over 3000 circuit breakers are manu-
factured and routine tested annually.
The routine tests are performed for the purpose of ensur-
ing the quality and guaranteed performance of the material,
design and assembly of the circuit breaker and are made
on each apparatus manufactured. We welcome customer
witnessing of these tests. The routine tests are part of the
process of producing the circuit breakers and are always per-
formed with the same test procedures, irrespective whether or
not the tests are witnessed by the client’s representative.
Performance of routine tests
The main steps of the order process related to routine testing
are described in the example timeline shown below. The exact
timing of these steps may vary depending on the size and
complexity of the order.
An invitation to witness routine testing is part of the order
acknowledgement, when planned dates for routine testing
and shipping are given. Confirmation is sent to the customer
normally six weeks before the planned routine test dates.
When the final dates have been advised, participation of any
inspector(s) shall be confirmed by the customer at least three
weeks before the planned dates for routine tests.
Any requests for special or additional test procedures shall
always be advised well in advance, preferably with order
placement, but at the latest with the confirmation of witness-
ing participation.

It must be noted that any requested changes to the test

process or the planned date for routine testing will affect the
deli­v ery time.

Week Activities
1 Order received from customer
2 Order acknowledgement sent by ABB with preliminary date for routine testing
Order design work complete. Drawings sent for customer approval. After customer design approval, materials
purchased for circuit breaker
X-7 ABB confirms date for routine tests and requests confirmation of customer intention to witness testing
X-4 Customer confirms intention to witness or not
X-2 Circuit breaker assembly work
X-1 Routine testing done
X Circuit breaker packed and shipped ex-works

Delivery time = "X" weeks, ex-works

After each routine test, a test review meeting is held together

with the client's witness in order to summarize the tests,
documentations and for resolving any questions which may
have arisen during tests.

For each circuit breaker a complete routine test report,

approved and certified by an ABB test supervisor, is issued
and distributed to the customer as part of the order
documentation.

ABB Live tank circuit breaker routine testing | 3

Production process

Goods receiving Routine test

Materials and components for circuit breaker assembly are
inspected on arrival and before use for compliance to ABB
requirements. Many items are also routine tested in advance
by the suppliers in accordance with ABB instructions, the
documentation for which can be shown on request.
Breaker pole, Mechanical and Electrical assembling
Tests are also conducted on major modules of the circuit
breaker during the factory assembly process, prior to the
final routine testing of the complete circuit breaker poles and
operating mechanism(s).
The final routine test process is described further on pages 6
and 7.
Packing
After completion of routine testing the circuit breaker is disas-
sembled into its shipping modules for packing.
Delivery to customer
After packing the circuit breaker is shipped to the customer
according to agreed order requirements.

Any non-compliant components are clearly marked and

isolated from production for further analysis.

4 | ABB Live tank circuit breaker routine testing

 Manufacturing Breaker pole
Interrupters assembly

Operating
Delivery to
Goods recieving mechanism Routine test Packing
customer
Mechanism assembly

Operating
mechanism
Electrical assembly

ABB Live tank circuit breaker routine testing | 5

Routine test process

Summary of routine tests IEC ANSI/IEEE ABB

Nameplate and design check X X X
Resistance measurement X X X
(Components in auxiliary and control circuits)
Function check of auxiliary and control circuits X X X
Mechanical operating test X X X
Resistance measurement (Main circuit) X X X
Dielectric test (Auxiliary and control circuits) N/A X X
Dielectric test (Main circuit) X X X
Tightness test X X X

Delivery time = "X" weeks, ex-works

Meeting the standards

Routine testing of ABB circuit breakers is a tightly controlled
part of our quality production process. All testing follows the
protocols strictly, and is highly automated to ensure accuracy
of the applied test levels and result measurements, in
accordance with international standards.
The main routine test steps with respect to IEC, ANSI and ABB
standards are summarized in the table on this page. A more
detailed description of these steps can be provided on request.

6 | ABB Live tank circuit breaker routine testing

 Minutes Activities completed
0 Start of routine test
10 Nameplate and design check
40 Function check of auxiliary and control circuits
60 Operating mechanism adjustment tests
90 Mechanical operating test
100 Motor and closing spring charging tests
115 Resistance measurement (Main circuit)
125 Dielectric test (Auxiliary and control circuits)
155 Overpressure test, tightness test
175 Dielectric test (Main circuit)
180 Transfer to packing department

The entire process is normally completed within approximately 3 hours per three pole operated breaker.
The routine test report is automatically generated from the computerized test system and can be reviewed in full by the customer witness shortly after test completion.

Workflow
To ensure timely production flow and maintain on-time deliv-
ery commitments for all customers, the routine test process
is planned to follow a strict time schedule. The timing of the
routine test process for a three-pole operated breaker (or one
phase of a single pole operated breaker) is summarized in the
timeline on this page.
The entire routine test for each circuit breaker is documented
in a detailed routine test report, generated by the computer-
ized testing system. After verification by the ABB certified test
supervisor, this report is provided to the customer as part of
the order documentation.

ABB Live tank circuit breaker routine testing | 7

Contact us

Publication Live tank circuit breaker routine testing 1HSM 9543 21-03en, Edition 3, 2013-10, High Voltage Products, Photo: Hasse Eriksson.
ABB AB ©Copyright 2013 ABB
High Voltage Products All rights reserved
SE-771 80 Ludvika, Sweden
Phone: +46(0)240-78 20 00 NOTE! ABB AB is working continuously
Fax: +46(0)240-78 36 50 to improve the products. We therefore re-
www.abb.com/highvoltage serve the right to change designs, dimen-
sions and data without prior notice.