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This article presents a case study on the application of X-ray non-destructive testing for identifying internal defects in ultra-high voltage (UHV) gas insulated switchgear (GIS) circuit breakers. During a specialized inspection campaign, X-ray detection revealed fractures in the closing resistors of 500 kV GIS circuit breakers at a UHV substation. The study combines on-site X-ray imaging, factory-based insulation verification tests, mechanical characteristic analyses, and disassembly inspections to diagnose the root cause. Results indicate that the fractures were likely due to assembly contact issues, leading to stress concentration during transportation and operation. While simulation tests showed no immediate insulation breakdown risks, the defects pose potential long-term hazards. This integrated approach of X-ray detection and comprehensive testing provides a reliable methodology for defect identification and safety assessment in high-voltage equipment, offering valuable insights for operation and maintenance practices.

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Application of High Penetration X-Ray Detection in Analyzing Closing Resistor Fracture of GIS Circuit Breakers

  • 会议论文

  • 发表日期：

    2026年

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  • Guobao Zhang,
  • Mengyi Cai,
  • Wei Yang,
  • Haotian Sun,
  • Weiping Guan,
  • Xi Yang

摘要

This article presents a case study on the application of X-ray non-destructive testing for identifying internal defects in ultra-high voltage (UHV) gas insulated switchgear (GIS) circuit breakers. During a specialized inspection campaign, X-ray detection revealed fractures in the closing resistors of 500 kV GIS circuit breakers at a UHV substation. The study combines on-site X-ray imaging, factory-based insulation verification tests, mechanical characteristic analyses, and disassembly inspections to diagnose the root cause. Results indicate that the fractures were likely due to assembly contact issues, leading to stress concentration during transportation and operation. While simulation tests showed no immediate insulation breakdown risks, the defects pose potential long-term hazards. This integrated approach of X-ray detection and comprehensive testing provides a reliable methodology for defect identification and safety assessment in high-voltage equipment, offering valuable insights for operation and maintenance practices.