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Enhancing the operational reliability of circuit breaker pre-insertion resistors: failure mechanisms, modification measures, and condition assessment

Sep 2026 · European Conference on Electrical Engineering and Computer Science · Vol 14327, pp. 143271G - 143271G-10 · 0 citations · 15 references
Engineering

Abstract

Pre-insertion resistors are critical for suppressing inrush currents and switching overvoltages in Extra-High-Voltage (EHV) and Ultra-High-Voltage (UHV) circuit breakers; however, they continue to exhibit a significant failure rate. This study investigates the operational reliability of pre-insertion resistors by characterizing common mechanical and electrical failure mechanisms, specifically resistor element cracking, pollution flashover, and thermal breakdown. Through multi-physics finite-element analysis (FEA), the efficacy of mitigation measures—including aluminum foil buffering, polytetrafluoroethylene (PTFE) sleeving, and clearance optimization—is quantitatively evaluated. The results demonstrate a reduction in local stress and temperature rise of up to 30%. Furthermore, novel diagnostic methodologies, such as dynamic-resistance fitting and high-frequency impedance analysis, are proposed to facilitate both online and offline condition assessment. Finally, a lifecycle-oriented reliability framework integrating design, manufacturing, transportation, and intelligent maintenance is presented to ensure the safe and efficient operation of EHV/UHV power grids.

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