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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.
PROCESS MANUAL
SECTION GIPL-OEM Project and Operation & Maintenance
PROCEDURE P1-GIPL-003
PROCESS MANUAL
SECTION GIPL-OEM Project and Operation & Maintenance
PROCEDURE P1-GIPL-003
Contact the vendor for any manufacturing defects or discrepancies found during the maintenance.
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.
PROCESS MANUAL
SECTION GIPL-OEM Project and Operation & Maintenance
PROCEDURE P1-GIPL-003
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.
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.
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.
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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.
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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
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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.
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.
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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.
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