Anda di halaman 1dari 15

PROCESS MANUAL

SECTION GIPL-OEM Project and Operation & Maintenance

PROCEDURE P1-GIPL-003

PROCEDURE FOR MAINTENANCE OF SWITCHED MODE POWER SUPPLIES PROCEDURE NO.: P1-GIPL-003

PROCESS MANUAL
SECTION GIPL-OEM Project and Operation & Maintenance

PROCEDURE P1-GIPL-003

1. Purpose
This document provides instructions for carrying out Periodic Maintenance of Switched Mode Power Supply and its parts like Rectifiers, Alarm Control Module, AC distribution unit & DC distribution unit and metal clad enclosure housing these components. The AC & DC distribution unit mainly consists of components like contactors, moulded Case Circuit Breakers (MCCB), Miniature Circuit Breakers (MCB) & HRC fuses.

2. Scope
This procedure will outline the maintenance routines and responsibilities for the Switched Mode Power Supplies (SMPS) in BTS sites. This procedure provides general guidelines as applicable for different types of SMPS. The users of this procedure are advised to refer the corresponding OEM (O&M) manual for carrying out specific O&M activities.

3. Responsibilities 3.1 National Head


Based at Corporate office New Delhi is responsible for the technical integrity of this procedure. The National Head or his nominated Deputy shall be authorised for any changes with this procedure.

3.2 Circle Manager


The Circle Manager or In-charge is responsible for ensuring that all activities related to this procedure are complied with and recorded as described in this document.

PROCESS MANUAL
SECTION GIPL-OEM Project and Operation & Maintenance

PROCEDURE P1-GIPL-003

4.4 Maintenance Process 4.1 Background


The rectifiers in SMPS are in modular fashion. The rating of the rack depends on the total number of rectifier modules. All the rectifier modules provide active load current sharing. The AC distribution unit consists of MCBs for protection, contactors for mains supply to the power rack terminal and surge protection device to prevent damage to rectifier modules due to surges & spikes present in AC mains. The DC distribution unit consists of a number of miniature circuit breakers, battery fuse, terminal blocks for loads & battery distribution and protection like BLVD, LLVD. It also has the functions of detecting the signal of DC and AC power distribution units, fault alarm, and communicating with host and monitoring module. The alarm control module receives the operation information of AC & DC distribution units and rectifiers and performs the corresponding controls. When the battery voltage drops to the terminating voltage 42.5V, in order to prevent battery over-discharge, the system activates the BLVD contactor to disconnect and thoroughly protect the battery. In normal conditions, the system operates in parallel float charge state, i.e. the rectifiers and batteries operate in parallel. The rectifiers supply power to the telecom equipments & security systems and float charge current to the battery. When an AC main fails, the rectifiers stop working, the battery to maintain normal operation powers the equipment. When the AC main is recovered, the rectifiers resume powering the equipment and charging the battery to compensate for the consumed energy.

4.4.2 Maintenance Frequency and Records

PROCESS MANUAL
SECTION GIPL-OEM Project and Operation & Maintenance

PROCEDURE P1-GIPL-003

Format No. OEM/002 OEM/0013

Frequency Yearly Fortnightly

Location BTS BTS

Period to be maintained 3 Years 3 Months

Contact the vendor for any manufacturing defects or discrepancies found during the maintenance.

4.4.3 Safety Precautions


The following safety precautions need to be followed for carrying out any work on the SMPS:

4.4.3.1 Inspections SMPS in energised condition


Inform the concerned authority and start The SMPS and the components therein are LIVE and in energised state. Do NOT touch any components with bare hands as this may lead to electrocution. Maintain a safe distance while working near LIVE terminals. When the rectifier is working, the temperature of the heat sink is very high. When the working rectifier is extracted out, never directly touch the radiator of the rectifier to avoid any scald. Wear safety shoes while working. Stand on dry and insulated objects like Rubber Matt during working. Do not touch any live conductors/cables without verifying that they are dead. Use only insulated tools while working on DC circuits.

4.4.3.2 Maintenance SMPS in de-energised condition


Ensure that all supplies to the panel are switched OFF and the respective switch locked and red tags placed on them.

PROCESS MANUAL
SECTION GIPL-OEM Project and Operation & Maintenance

PROCEDURE P1-GIPL-003

In case the maintenance is to be done on part of the SMPS and where the other part is LIVE then appropriate care should be taken to mark its LIVE
portion.

Temporary stickers have to be placed to discourage working personnel from operating at the LIVE parts. To protect the system against the rise in potential of metal structures, keep the earth connections continuously on the bus-bars. Discharge the circuits using proper discharge wire. Care should be taken to first connect the discharge wire to ground bus and then connect it to the circuit. Use personal protective equipment like safety shoes and hand gloves while working on SMPS. Access to working space and escape passages shall be kept clear and unobstructed. Warning signs, if required shall be placed at appropriate places. Follow all precautions while using hand held tools like blowers, drill machines etc. Use hand held tools with ELCB boards only. Use only insulated tools while working on DC circuits.

4.4.4 Tools Required


Calibrated Digital Multimeter Spanner set Cloth, Cotton rags Nylon Brush Normal hand gloves Megger 500 V Discharge wire First aid kit Vacuum cleaner

4.4.5 Fortnightly Maintenance Tasks


5

PROCESS MANUAL
SECTION GIPL-OEM Project and Operation & Maintenance

PROCEDURE P1-GIPL-003

Ref the data sheet OEM/0013

4.4.6.1 Purpose of Inspection


The purpose of the fortnightly inspection is to assess the general condition of the SMPS including the condition monitoring check of its various parameters. This fortnightly inspection is intended to be a general quick check for the more conspicuous problems that can be encountered. Proper maintenance of SMPS ensures continuous power availability to loads. The following types of problems can be detected during the fortnightly inspection: Overheating of components like MCB, MCCB, Contactors, Relays. Oxidation of connections at terminals. Non-working or missing indicating lamps and meters. Overheating or chaffing of cables inside the panel. High amount of dust and dirt inside the SMPS. Unbalance or overloading of the circuits. Improper voltages from the supply side. Possible source of entry for vermin entry

4.4.6.2 Inspection Procedure


Refer the manufacturers manual for the maintenance guidelines and record the observations. Intention of this inspection as described above is to find out the visible abnormalities, which could lead to failures. Extreme care should be exercised while opening the door and working near or close to LIVE parts. NOTE: Whenever performing maintenance inspections ensure that the manufacturers instruction manual for the SMPS is available for review. The general steps for inspection are as outlined below:
6

PROCESS MANUAL
SECTION GIPL-OEM Project and Operation & Maintenance

PROCEDURE P1-GIPL-003

Follow all safety precautions as mentioned in section.4.4.3 Check whether all indicating lamps/alarm control module are in working condition and are as per logic designed. Check normal display parameters as per OEM. Check all the three-phase or single-phase voltage(s) from the Monitoring Module. In case of doubt check the voltage using a multimeter on the incomer switch/MCB/MCCB. Do not try to rectify the switch or meter in LIVE state as this may lead to short circuit. Check the three phase or single-phase current(s) from the Monitoring Module. Do not disconnect the secondary connections of the CT as this may lead to high voltage on the secondary side and damage the CT and as well as create a hazard for the working personnel. Check the load current and compare the same with the ratings of the breaker, MCB, MCCB etc. Check that the frequency of supply is within the range i.e. 50Hz 5% Check that the output voltage and current of rectifier is normal. The difference between the system voltage displayed by the monitoring module and that displayed by the rectifier should not exceed 0.2V. Check the output current of each rectifier. Check the normal condition of the surge protection device (SPD) and its breaker. Check that the SPD is not discoloured, deformed or torn up. Check the earthing bonding between surge arrestor ground and main earthing bus. Check the battery float voltage with the batteries in fully charged condition (for VRLA battery, it should be 2.25 + 0.02 x 24 =54.2 to 54.4 V). Check that the output current imbalance between rectifiers is less than 5%.

PROCESS MANUAL
SECTION GIPL-OEM Project and Operation & Maintenance

PROCEDURE P1-GIPL-003

Check the individual general parameters of the SMPS available from the panel display. Use of Laptop to check all parameter is not necessary. Check that there is no blockage in equipment radiation passage. Check that the rectifiers fan and airway, dust net and cabinet ventilation are not obstructed by objects and no dust is accumulated. If dust is observed then clear the same using a vacuum cleaner or a blower or brush. Observe for any leaks over the top of SMPS. If water leaks are observed then cover the panel with plastic sheet as a temporary measure. Subsequently attend the water leak. Observe for any unwanted cable openings. This can be source for rodent/reptile entry. Plug such opening with proper material. Temporary measure can be adopted to cover the openings till permanent arrangement is made. Feel the SMPS with bare hands. As a general rule, during operation, any temperature that the palm of the hand cannot stand for about 3 seconds may indicate trouble. If found abnormally hot then switch off the concerned circuit and observe for any abnormalities. In case the circuit cannot be de-energised because of operational criticality then arrange for a planned event at the earliest. Wherever feasible observe the cable terminations and connections. Observe for insulation chaffing, frayed sheath, improper glanding, wrong sizes of glands and terminals. Take corrective actions if possible or else arrange for planned event. Check that the sockets are connected firmly. Check that the cables are routed in order and firmly and that no cables are distorted due to the pressure imposed by metallic parts. Check the neutral conductor condition for any visible signs of over-heat.

PROCESS MANUAL
SECTION GIPL-OEM Project and Operation & Maintenance

PROCEDURE P1-GIPL-003

Check the individual component like MCB, MCCB, contactors, relays and fuses for any abnormality like overheating, broken condition, discoloration, unusual noises etc. Replace if it is possible without affecting the operations else arrange a planed event for replacement. Check the grounding connections for the SMPS. Check the continuity of earthing point up-to earth pit physically. Repair if found loose, corroded or broken.

4.4.7 Yearly Maintenance & Inspection 4.4.7.1 Purpose of Inspection


The purpose of yearly inspection is to assess the overall condition of the SMPS. This is normally performed with the SMPS in OFF and DEAD condition. However, the maintenance of SMPS in fully de-energised state would lead to outage of DC power and thus outage of network. In order to avoid such a scenario, it is proposed to carry this maintenance procedure with only AC input & rectifiers in OFF condition. The load (telecom) will continue to be fed through the battery bank and the respective load MCBs. The normal course of maintenance of the SMPS shall be in PARTIALLY DEENERGISED CONDITION only. In case of any critical/pending jobs that warrants shutdown of the complete SMPS, then this job has to be done under PE window. Generally it is recommended to conduct annual inspection during the first three years of operation. Inspection and maintenance frequency can then be increased or decreased depending upon the observations and experience. The inspection followed by subsequent maintenance during the annual shutdown (Partially & fully de-energised) is quite detailed. The following repair work/maintenance jobs are taken up during the annual maintenance plan:

Replacement of all missing meters and indication lamps.


9

PROCESS MANUAL
SECTION GIPL-OEM Project and Operation & Maintenance

PROCEDURE P1-GIPL-003

Rectification of faults observed during the normal energised state inspection Cleaning of SMPS interiors Meggering of bus ducts and bus-bars Checking of trips and alarms.

4.4.7.2 Inspection/Maintenance Procedure


Refer Format No.: OEM/0002 for annual maintenance of SMPS in partially deenergised and fully de-energised condition. The general parameters of the SMPS shall be recorded in Format OEM/0003. The maintenance procedure for SMPS in partially de-energised condition includes shifting the DC load onto the batteries. Prolonged outage of SMPS panel may lead to site failure due to battery discharge Hence the shutdown work should be completed in stipulated hours of battery backup. NOTE: Whenever performing maintenance inspections ensure that the manufacturers instruction manual for the SMPS is available for review.

MAINTENANCE OF SMPS IN PARTIALLY DE-ENERGISED CONDITION


The following activities shall be carried out during the annual maintenance in partially de-energised condition: Identify the section that will be shut down for maintenance. Identify the switches, MCCB, breakers that need to be isolated for deenergizing the section of SMPS. Inform the NNOC about the work. Follow all safety precautions as mentioned in section 4.4.3 Switch OFF the input MCB on the AC side. This will shift the load on to the batteries. In case of two sources of power shut OFF both the power sources. Ensure that the upstream MCB/SFU in the LT panel is also switched OFF. Place a red tag on the LT panel to indicate that the circuit is deenergised.
10

PROCESS MANUAL
SECTION GIPL-OEM Project and Operation & Maintenance

PROCEDURE P1-GIPL-003

Isolate the section planned for maintenance. Ensure that the load is transferred to the battery backup. Switch OFF individual rectifiers by switching OFF the corresponding MCBs. Ensure that proper red tags are placed at appropriate places. Open the SMPS door and check the enclosure door gasket for proper placement & replace if damaged. Check for AC loose connections. Loose connections or bad terminations will cause heat buildup. If any signs of heat are noticed at any termination point, that connection should be disconnected, inspected & replaced, if necessary, before resuming operation. Check that all the nuts & bolts are tightened properly, being careful not to overstress the bolts. Clean the air filter to provide filtered air. Do not install a wet filter in the unit. Observe the AC cable terminations and connections. Observe for cracked insulation, frayed sheath, improper glanding, wrong sizes of glands and terminals and take corrective actions if required. Check the cables for evidence of overheating. Check the SMPS earthing continuity. Check the normal operation of the surge protection device. Check that it is not damaged and replace if necessary. Check that there is no fault indication displayed on surge protector. Check the wiring between SMPS and the remote alarm management system (either at DDF or SCADA system). All the switches and breakers (AC input MCCB and rectifiers circuit breaker) should be in OFF position and the lightning protection circuit breaker is closed before switching on the AC power. Switch on the MCCB corresponding to the SMPS at the ACDB Switch ON the AC input MCCB of the SMPS. At this time, the AC contactor closes. Check that the AC operation indicator turns ON. Switch on the rectifiers circuit breakers in front of the AC distribution Module one by one.
11

PROCESS MANUAL
SECTION GIPL-OEM Project and Operation & Maintenance

PROCEDURE P1-GIPL-003

Measure the mains voltage. Check the output voltage displayed on the monitoring module. Using a digital voltmeter verify that the output voltage is in accordance with the systems voltage. Verify that all the rectifier modules are ON and without any fault alarms. If any alarm is observed then it should be checked & rectified. Ensure that the load is transferred to the normal power supply. Note down the load currents. Check the parameters of the alarm simulation and check the alarms accordingly. Follow the OEM manual for the procedure of checking of alarms.

MAINTENANCE OF SMPS IN FULLLY DE-ENERGISED CONDITION


In addition to the above-mentioned procedures for SMPS maintenance in partially de-energised condition, the following activities shall be carried out during fullyde-energised maintenance: Switch OFF the input MCB on the AC side. In case of two sources of power shut OFF both the power sources. Ensure that the upstream MCB/SFU in the LT panel is also switched OFF. Place a red tag on the LT panel to indicate that the circuit is de-energised. Remove the HRC battery fuse ensuring the battery is not connected to the system. Use an insulated fuse puller. Ensure that the power has been properly locked out i.e. verify that no parts of the power or control circuitry are energized by back feed from alternate power or control sources and proper red tags are placed at appropriate places. Check for AC & DC loose connections. Inspect inside the enclosures for damage & corrosion of metallic objects. Repair & paint as required. Completely clean the SMPS interiors if dust is observed using vacuum cleaner or blower. Be careful to use insulated tools.

12

PROCESS MANUAL
SECTION GIPL-OEM Project and Operation & Maintenance

PROCEDURE P1-GIPL-003

Check that the fuses of appropriate ratings are completely inserted in the clips. Check clips for adequate spring pressure. Test the conductivity of DC cables by using micro-ohm meter or determine voltage drop under test load conditions. Perform insulation resistance test on each phase-to-phase and phase-toground using a Megger on buses, breakers and cables. Insulation resistance would be low if there is any dust or moisture in the interiors of the panel. Before connecting the battery, confirm with a multimeter that the polarity of the battery cables, DC bus and battery terminals match. When connecting the battery, careful attention is required to prevent short circuit of the positive and negative poles of the battery. If two batteries are connected at the same time, attention should be paid to prevent battery mutual charging due to unequal end voltages of the two batteries. Insert the HRC battery fuse thus connecting the battery to the system. All the switches and breakers (AC input MCCB and rectifiers circuit breaker) should be in OFF position and the lightning protection circuit breaker is closed before switching on the AC power. Switch on the MCCB corresponding to the SMPS at the ACDB Switch ON the AC input MCCB of the SMPS. At this time, the AC contactor closes. Check that the AC operation indicator turns ON. Switch on the rectifiers circuit breakers in front of the AC distribution Module one by one. Measure the mains voltage Check the output voltage displayed on the monitoring module. Using a digital voltmeter verify that the output voltage is in accordance with the systems voltage. Check and record the battery charging current. Verify that all the rectifier modules are ON and without any fault alarms. Check that all the rectifiers communicate properly with the alarm module by observing the LED indications. If any alarm is observed then it should be checked & rectified. Check that the rectifier cooling fans are working properly. Turn ON the load MCBs to put the load on the system
13

PROCESS MANUAL
SECTION GIPL-OEM Project and Operation & Maintenance

PROCEDURE P1-GIPL-003

Ensure that the load is transferred to the normal power supply. Note down the load currents.

4.4.8 Alarm Simulation


The alarm module in the SMPS facilitates Potential Free Contacts (PFC) for remote monitoring of alarms. All alarms are potential free and may be connected to external displays/equipment as closed or open circuit when alarm is reported. Simulation can be done by shorting these terminals at the output relays or by actual operation of relays through keypads. The output alarms of SMPS in case of Avansys make are grouped and these can also be checked either through keypad or shorting the terminals. Various alarms are configured to functional relays in such a way that a single relay operates when one or more alarms configured to it appear. These alarms are then extended to the OMCR. The entire SMPS related alarms and electrical parameters need to be verified after conjunction with OMCR. General alarms available in the SMPS are: 1. Battery On Line (BOL) 2. Fuse failure 3. Rectifier failure 4. Battery Low Voltage Disconnect (BLVD) 5. High and Low DC voltage 6. AC mains failure For details of various alarms available for each model, please refer the OEM manual.

7. Simulation of Alarms
1. By switching OFF the AC mains check that the BOL alarm (or/and AC mains failure alarm) appears. Switch ON the AC mains and check that the alarm is cleared.

14

PROCESS MANUAL
SECTION GIPL-OEM Project and Operation & Maintenance

PROCEDURE P1-GIPL-003

1. Either by shorting the terminals on DDF or SCADA or by operating the relay through keypads check that the Fuse Failure alarm appears and the same is cleared when resetted. 2. Pull out the redundant rectifier module and check that the Rectifier Failure alarm appears. Refit the rectifier module back in its place and check that the alarm clears. 3. Check the BLVD alarm only by shorting the terminals of the relay and NOT through actuation. While carrying out the above alarm simulation, check that the alarms are extended to the OMCR when they appear and the same are cleared when the relays are resetted.

4.5 Formats, Records & Frequency Period to be maintained 3 Years 3 Months

Format No. OEM/002 OEM/0013

Frequency Yearly Fortnightly

Location BTS BTS

15

Anda mungkin juga menyukai