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Circuit Breaker Monitoring

Visual comparison of operations
Secure remote management

Complete Visibility into Circuit Breaker Health and Performance

The Qualitrol Breaker Condition Monitoring (QBCM) system is a comprehensive, next‑generation solution for monitoring high‑voltage circuit breakers. It captures the full range of electrical, mechanical and environmental parameters required to accurately assess circuit breaker condition, providing a clear snapshot of every operation and powerful trending tools to track asset health over time. 

 

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Application Overview

QBCM is designed for condition‑based maintenance of high‑voltage circuit breakers across transmission and distribution networks. It can be installed on the most common breaker types, including:

  • Gang Operated (GOB) circuit breakers
  • Independent Pole Operated (IPOB) circuit breakers
  • SF₆‑insulated circuit breakers
  • Dead‑tank circuit breakers
  • Live‑tank circuit breakers

The system supports both retrofit and new installations, typically completed in under one day, enabling rapid deployment without extended outages.

What We Solve For

Circuit breakers are critical protection assets, yet their condition is often assessed using periodic offline testing that provides limited visibility. QBCM solves this by delivering:

  • Continuous, real‑time breaker health monitoring
  • Insight into mechanical wear, electrical degradation and SF₆ performance
  • Early detection of deviations from normal operation
  • Trend‑based decision support for predictive maintenance

This reduces unplanned failures, eliminates unnecessary maintenance, and helps utilities optimise asset life and maintenance resources. 

TECHNICAL

Features & Functionality

Substation
Fingerprinting and Trend Analysis

QBCM captures a full waveform signature for every breaker operation and compares it against a reference “fingerprint”. Changes and rates of change are automatically identified, providing early warning of developing issues.

ZHW58A Hybrid Gas Insulated Switchgear 800x800
Advanced SF₆ Monitoring Algorithms

Built‑in SF₆ density algorithms provide continuous monitoring with ±1‑day precision to predicted lock‑out levels, along with annual and cumulative SF₆ emissions tracking.

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Intuitive Web‑Based User Interface

A secure, web‑based UI presents all data in a clear, intuitive layout. Users can visually compare breaker operations, analyse trends, configure alarms and receive audio‑visual feedback for key actions.

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Scalable, Secure Architecture

QBCM’s modular design supports phased investment across a breaker fleet. Secure remote access is enabled through HTTPS and 256‑bit encryption, with single‑admin access control for cybersecurity assurance.

Functionality & Options

  • Stores up to 10,000 operations with full waveform signatures
  • Real‑time deviation alerts from benchmark waveforms
  • Three configuration levels:

QBCM‑LT – Basic monitoring for GOB breakers
QBCM‑ST – Adds motor, heater and battery bank monitoring
QBCM‑IP – Full monitoring suite for IPOB breakers

  • Optional travel transducer for travel curve profiling
  • Non‑intrusive coil sensors for safer installation
  • Multiple mounting configurations and compact footprint
  • Removable connectors for improved safety during installation
  • COMTRADE file import for offline test data analysis

Key Technical Specifications

  • Data storage: 8 GB microSDHC (up to 10,000 operation records)

  • Sampling resolution: User‑selectable 32, 64 or 128 samples per cycle

  • Communications: Ethernet (RJ‑45 & fibre), RS‑485, USB

  • Protocols: IEC 61850, DNP3, Modbus

  • Operating temperature: –40 °C to +75 °C

  • Enclosure: IP20 standard, optional IP67 for external mounting

  • Power supply: 100–240 V AC / 110–250 V DC universal input

  • Cybersecurity: HTTPS with 256‑bit encryption

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Circuit Breaker Monitoring

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EXPERIENCE

Our Projects featuring Insulect Substations

Explore our project highlights to see where Insulect Substations are making an impact.
For tailored advice on whether this solution suits your network, please connect with our team here.

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Where you'll find our Substations

You'll find Insulect-supplied and installed Substations across Australia and New Zealand -- our locally built Insulect range and imported Sieyuan range.

ADVANTAGES

Why Choose QBCM

Designed to support smarter, safer and more efficient condition‑based maintenance, Qualitrol QBCM combines comprehensive monitoring, advanced analytics and secure connectivity in a single, scalable platform. It gives asset owners the confidence to detect issues early, standardise monitoring across breaker fleets and make informed decisions that improve reliability and extend circuit breaker life.

Comprehensive Breaker Insight
QBCM captures electrical, mechanical and environmental data in a single platform, delivering a complete and accurate picture of circuit breaker condition without relying on periodic offline testing.
Faster Installation and Fleet Consistency
With configuration cloning and compact hardware, QBCM can be installed quickly and consistently across similar breakers, reducing engineering effort and lowering lifecycle costs.
Proven Technology from a Global Leader
Qualitrol combines deep expertise in asset monitoring with advanced analytics and secure system design, giving utilities confidence in long‑term performance, scalability and support.
IMPLEMENTATION

Services & Support

Insulect offers comprehensive services and support for the products we manufacture and specialise in, enhancing value for local utilities, major energy users, equipment manufacturers, and service operators. 

LOCAL TECHNICAL TEAM

Our local technical team provides exceptional support and expertise, ensuring quick response times and personalised service to tackle any challenges that may arise during project execution.

  
ENGINEERING DESIGN

Our team utilises advanced technology and industry knowledge to develop innovative and efficient high-voltage switchgear solutions, customised to fit the unique requirements of each project.


  
PROCUREMENT & LOGISTICS

We facilitate smooth procurement and logistics processes by sourcing from trusted, proven partners and coordinating timely deliveries, ensuring projects remain on schedule and within budget.


  
TESTING & COMMISSIONING
Professional testing and commissioning support ensure that every high-voltage switchgear system functions safely and reliably, adhering to all regulatory standards and client expectations.
  
TURNKEY PROJECT DELIVERY

We are able to oversee every phase from concept to completion, providing comprehensive solutions that simplify complex projects and ensure successful outcomes.

  
FACTORY VISITS
We facilitate client visits to our local manufacturing sites here in Australia, as well as overseas, for initial inspection as well as factory acceptance testing.
  
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