Expert Service for the Most Critical Protection Component
Circuit breakers are your last line of defense against electrical faults. Breaker failures during fault conditions result in 3-10x more equipment damage as backup protection takes seconds instead of cycles to clear faults.
Regular testing and maintenance ensure breakers operate correctly when called upon—often after sitting idle for years between fault events.
Circuit breaker services include comprehensive testing, maintenance, and repair for all breaker technologies and voltage classes—from low voltage (under 1000V) to extra-high voltage (>230kV):
Timing & Travel Analysis
Verify operating speed meets specifications
Contact Resistance
Detect deteriorating contacts before failure
Preventive Maintenance
Mechanism inspection, lubrication, adjustment
SF6 Gas Analysis
Monitor insulation integrity in gas breakers
We service all breaker types: vacuum, SF6, air-magnetic, oil (bulk and minimum), air-blast, from manufacturers including ABB, Eaton, GE, Siemens, Westinghouse, S&C, and legacy equipment.
Perfect relaying is worthless if the breaker won't trip. Breakers must interrupt massive fault currents (often 50,000+ amperes) within 3-5 cycles. Degraded mechanisms, worn contacts, or contaminated insulation cause failures that allow faults to persist, destroying equipment and creating safety hazards.
Real Example:
Water treatment plant had a motor ground fault. Relay operated correctly but 15kV breaker failed to trip due to oxide buildup on vacuum interrupter contacts. Backup protection cleared after 2 seconds—motor destroyed ($85K), switchgear severely damaged ($180K), 9-day service disruption. Breaker contact resistance test during maintenance would have detected the problem. Test cost: $450.
NERC PRC-005 requires documented breaker maintenance programs for bulk electric system. NFPA 70B recommends testing intervals based on breaker type and operating frequency. Insurance carriers require maintenance documentation for coverage continuation.
Breaker degradation follows predictable patterns. Timing slows as mechanisms wear, contact resistance increases as surfaces oxidize, operating energy increases as friction builds. Testing detects these trends before catastrophic failure, allowing planned repairs during convenient outages.
Arc flash calculations assume breakers operate within specified time limits. Slow breaker operation increases incident energy exponentially. A breaker operating in 10 cycles instead of 5 can double incident energy—turning a survivable 8 cal/cm² event into a fatal 16 cal/cm² exposure.
Mechanisms bind or slow from lack of lubrication, corrosion, or worn components. Timing analysis detects operation outside specifications. Uncorrected, slow breakers eventually fail to interrupt faults. Maintenance restores proper operation before failure.
Vacuum breaker contacts erode with each interruption. Air and oil breaker contacts oxidize and pit. SF6 contacts can develop carbon deposits. Contact resistance testing identifies degradation requiring contact replacement before failure. Catching early prevents catastrophic breaker failure mid-fault.
SF6 breakers lose insulation integrity when gas leaks or becomes contaminated with moisture or decomposition byproducts. Gas analysis and pressure monitoring detect problems before dielectric failure. Reprocessing or replacement restores full capability.
Trip coils, close coils, auxiliary switches, and anti-pumping circuits fail from mechanical wear, coil degradation, or contact problems. Functional testing during maintenance identifies control circuit issues that would prevent breaker operation during actual faults.
System modifications can increase available fault current beyond breaker ratings. Comparing breaker interrupting ratings with current short circuit studies identifies undersized breakers requiring replacement or system modifications.
Best Practice: Cycle counting and condition monitoring allow optimal maintenance scheduling based on actual usage versus arbitrary time intervals.
Typical Duration: Comprehensive breaker service requires 4-8 hours per breaker including testing, maintenance, and documentation. Large lineups with multiple breakers may require multi-day outages.
$100K-$1M
Equipment damage from breaker failure to interrupt
$2K-$6K
Cost per breaker for comprehensive testing and maintenance
50-500x
ROI from preventing ONE interruption failure
Defines comprehensive test procedures and acceptance criteria for circuit breaker maintenance testing.
Mandates time-based or performance-based maintenance programs for breakers in the bulk electric system with documented intervals and activities.
Covers testing, application, and maintenance for all breaker types (C37.09 vacuum, C37.04 oil, C37.06 SF6, etc.)
Recommends maintenance practices and intervals based on breaker type, voltage class, and duty cycle.
Don't discover breaker problems during a fault event. Proactive testing provides confidence and prevents catastrophic failures.
📧 support@clarkte.com | ☎️ +1 (617) 396-4632 | 📍 Boston, MA