Académique Documents
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Note: *WF: Means Snags reported due to Workmanship /Human Factor.(Technical Expertise , Skills lacking. Poor Workmanship etc) PRF: Means Snags reported due to Product Factor/Issues (Product & Design issues/flaws, High fault rate etc) PF: Means Snags reported due to planning factor/Issues (Poor planning and Management etc).
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Contents:
S # No. T01
T01-01 T01-02
Tests
5 5
T02
T02-01 T02-02
T03
T03-01
T04 T05
Site Tagging and Labels Charging and Discharging of Batteries Mixed Power System (DCB600AH)
Battery Test Items
5 13 1 1 1 1
T05-01
T05-02
Battery Test
T06 T07
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Prerequisites
The Power system TP48200A installation as per site approved design. The power modules are installed in Rectifier Cabinet. Cabinet Security and Locking mechanism for TP48200A. Procedure Expected result TP48200A 1.1:The Power system is installed securely on the concrete PAD or mounting racks/ iron beams as per site layout. 1.2: No damage has been done to equipment while installation and door opening of installed power system can be > 90
0
Result
1. Installing
the
1.3: All the packing materials are removed from the equipment area after equipment installation.
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2.1: The mounting holes for the cabinet must be carried out by drilling on concrete PAD. 2.2: The 4 expansion bolts (M12 x 60) are installed and tightened by using appropriate socket wrench.
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2.3: The extra holes for cable entry are properly sealed and covered by fire resistant mud
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insulation. 3. Check the PSU 3.1: The rated output current of each PSU is 50Amps, and minimum installed quantity of PSUs must be 4 and all should be in working condition. 3.2: The empty slots of remaining PSUs are covered with dummy covers / slots.
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4. Check cabinet
the locks
TP48200A / security
4.1: The Entrance door and locks of TP48200A are installed and operate properly, door closer is operational 4.2: The TP48200A Cabinet Security Locks and mechanism as per approved design. 4.3: The TP48200A Cabinet Door sealing is adequate and proper as per approved design.
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Date:______________________
Date:______________________
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The DCB-600 cabinet installation as per site layout. DCB batteries installed for 600AH system. inter-connection Battery strings. Procedure Expected result 1.1: The DCB-600 battery cabinetis installed securely on the concrete PAD or mounting racks/ iron beams as per site layout. 1.2: No damage has been done to equipment while installation and door opening of installed IBBS cabinet can be > 90
0
Result
1.3: All the packing materials are removed from the equipment area after equipment
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installation. 2. Installation of the Expansion bolts of IBBS Battery 2.1: The mounting holes for the cabinet must be carried out by drilling on concrete PAD. 2.2: The 4 expansion bolts (M12 x 60) are installed and tightened by using appropriate socket wrench. 3. Installation of DCB battery in IBBS Battery cabinet 3.1 Check one DCB Banks are installed with 24 battery cells and the total battery bank capacity is up to 600AH.
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cabinet DCB-600.
DCB-600.
3.2 The interconnection strips for each battery string cell to cell terminal must be tightened
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Date:______________________
Date:______________________
The Power system TP48200A commissioning. The power modules are in working condition. The AC / DC and signaling cables are routed and properly connected with DCB-600. The Alarm connections are extended as per approved from customer and verified from NOC. Procedure Expected result TP48200A and check 1.1: The Power system installed is as per BOQ. No component in Rectifier cabinet is loose or damaged. 1.2: The AC power cable installed to power up the rectifier is power cable 4*16mm^2, (Cores: Red, Yellow, Green, Black) connected with ACDB to rectifier main breaker. 1.3: The Rating of DC cable from Rectifier to Battery enclosure (Wire,450/750V, 35mm^2,Blue & Black,135A)
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Result
1.
Check
the
specifications
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1.4: The power cables (AC/DC) are connected correctly, all the cable routing is proper. And all Alarms cables are connected.
2.
2.1: The PMU has been installed and in working condition and PMU Display shall be properly visible and each parameter appearing on PMU shall be viewable. Blurring &
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parameters.
disappearance of parameters shall fall PMU into faulty State. 2.2: Set all provided parameters in PMU such as DC float volts, boost volts, charging current; etc shall be appearing on PMU display. Date & Time Battery Capacity Charge Current Limit Float Voltage Boost Voltage Low battery Voltage LLVD Voltage BLVD Voltage 3. Check the alarm LEDs on PMU Set 600AH 0.1C 53.5 Volts 56.5 Volts 46 Volts 44 Volts 43 Volts
4.1: On event of alarm respective LED shall lit on to give alarm indication. 4.2: No alarm is present on the Rectifier indicator PMU. Both battery & load power ratings visible on PMU are according with the specifications.
4. Check
Extended
Alarm
5.1: All alarms provided by customer are extended from TP48200A to BTS EMUA Card. 5.2: The EAS alarms of TP48200A cabinet are patched and reported at NOC. For Rectifier Cabinet:
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3. Rectifier Minor Alarm 4. Low Battery Voltage 5. Heat Exchanger (Fan) Alarm For Battery Cabinet:
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1. Door Open Alarm 2.DC Aircon fault Alarm 5. Check the status of the heat exchanger connections and working. 6. Check the status of the indicators on the PMU. 6.1: The internal fans of heat exchanger are working and air circulation inside power cabinet is adequate. 7.1 The Power-On LED is in ON state while rectifier working, 7.2: Alarm status indicators in case of any
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abnormal state or if any alarm appears on PMU screen, 7. Check the status of the indicators on the PSU. Power input indicator (top): ON Protection indicator (middle): OFF Fault indicator (bottom): OFF
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Prerequisites
The IBBS Cabinet is well installed with complete accessories (DCB Battery, DC/GND cables, etc). The IBBS DCB-600 cabinet is interconnected with TP48200A Procedure Expected result 1.1: The cell to cell connectors for each DCB cell is connected and tightened
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Result
interconnection of battery cables between cells to cell. 1.2: Check the ve cable is connected through DC breaker in power system and all connections are tightened by screw wrench.
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2. Check
DC
Air-condition
2.1: The Air-condition is in working condition and power cable for powering Air-condition is connected with rectifier output 2.2: The temperature inside IBBS cabinet is normal and no leakage of cool air observed outside IBBS cabinet. 2.3: The compressor and internal fan units of Air-condition are in working condition. 2.4: The Alarm cables of Air-condition are terminated to EMUA board
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3.1: The signal cable of cabinet DSS (Door Status Switch) of IBBS system is connected and Alarm is verified from NOC.
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Date:______________________
Date:______________________
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T03 AC / DC / GNDG and Alarm Cables T03-01 Installation of AC Power Cable, DC Cables and Grounding Cables/SPD
Objective Verify that the AC power cable, DC Cables and PGND cables &SPD are correctly processed and installed. Result: PassFailNot RunZapped Comment & Remark Prerequisites
All internal cables (AC / DC / Alarm) are installed. Procedure Expected result 1.1: The main AC power cable installed to 2 power up the rectifier is Wire 4*16mm (Cores: Red, Yellow, Green, Black) connected with ACDB to rectifier main breaker. 1.2: The AC Power cable must be routed separately from other cables and both end connections of cable are tightened with Lugs. 1.3: The AC power cable is routed and tied inside the power cabinet and no loose connection from both ends. Result
1.4: No joint lies in the middle of the AC power cable. 1.5: The OT terminals of the AC power cables are wrapped up with insulating tapes/ heat shrinks.
2.1: The Rating of DC cable from Rectifier to Battery enclosure (Wire,450/750V, 35mm^2,Blue & Black,135A) 2.2: The positive and negative DC power cables are connected with IBBS cabinet and TP48200A power system cabinet. 2.3: No joint lies in the middle of the DC power cable. 2.4: The OT terminals of the DC power cables are wrapped up with insulating tapes/heat shrinks.
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3.1: The rating of grounding cable (Wire, 450 / 750V, 25mm^2, yellow green, 110A.) 3.2: Lugs at both ends of the power cables and PGND cables are soldered or securely crimped. Flat washers and spring washers are securely and closely mounted on wiring terminals.
4. Connection of Grounding
cable to main site DC Earth plate.
4.1: Grounding Cable for Cabinet shall be properly terminated to DC Earthing Bus bar. End to End connectivity of grounding cable to Bus bar to Earthing pit shall be verified. 4.2: The lugs at both ends of the power cables and PGND cables are soldered or securely crimped. 4.3: The bare wires and lug handles at the wiring terminals are tightly wrapped up with insulating tapes or heat-shrinkable tubes. 4.4: Flat washers and spring washers are securely and closely mounted on wiring terminals.
5.1: The Surge Protection Devices installed in Rectifier Cabinet (TP48200A) shall be in healthy state. 5.2: The SPD rating installed in Built-in power system of TP48200A Cabinet shall be as per design. 5.3: Check Color of on front of SPD shall be GREEN, In case of RED/BLACK, it is declared to be faulty.
Date:______________________
Date:______________________
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Prerequisites
Check Tagging and Labels of each item for newly installed system / cabinet / cables etc. Procedure Expected result 1.1: The labeling and tags of every item inside both power & battery cabinet must be pasted as per delivered in system accessories package. 1.2: The Tags should be bold visible and pasted in printed form, 1.3: The insulation of tags must be of good quality and can sustain in the environmental conditions. 1.4: Hard Plastic type tags pasted at the outdoor routing of every cable if it is routed inside duct / GI flexible pipe. 2.1: The Tags must be pasted at the both ends of each cable (AC/DC/Alarm/Signal) inside both cabinets TP48200A and IBBS DCB-600 cabinet. - All installed DCB batteries are tagged with its battery cell number for each cell. - All alarm cables for every extended alarm must be pasted with proper tagging separately inside BTS and power system. Result
1. Labels / Tagging
specifications.
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Date:______________________
Date:______________________
T05 TEST PROCEDURES T05-01 Testing of Extended Alarms of TP48200A Rectifier from NOC
Num of Test Case Name of test Case Preset Conditions Test Procedures EAS Alarm Test # 1 Mains Failure Alarm Testing at Wapda & D.G. Power shutdown 1) 2) 3) 4) 5) Expected Results Test Results Check float voltages on CPMU screen. Turn Off the Mains power supply from ACDB Check MF Alarm signal observed at CPMU LED indicator. Call to NOC for MF Alarm verification Restore Wapda or D.G supply and check float voltages again.
Num of Test Case Name of test Case Preset Conditions Test Procedures
EAS Alarm Test # 2 Rectifier Major Alarm Alarm testing at any Major fault occurs in rectifier 1) 2) 3) 4) 5) Check float voltages on CPMU screen and Alarm LED is OFF. Unplug & remove any 2 modules (PSUs) from the rectifier. Check alarm indication observed on CPMU Call to NOC for Major Alarm verification Connect the PSUs again with rectifier and check Alarm indication OFF.
EAS Alarm Test # 3 Rectifier Minor Alarm Alarm testing at any Minor fault occurs in rectifier Page 15
Test Procedures
1) 2) 3) 4) 5)
Check float voltages on CPMU screen and Alarm LED is OFF. Unplug & remove one SPD unit from the rectifier. Check alarm indication observed on CPMU Call to NOC for Minor Alarm verification Connect the SPD unit again with rectifier and check Alarm indication OFF.
Num of Test Case Name of test Case Preset Conditions Test Procedures
EAS Alarm Test # 4 Low Battery Volt Alarm Alarm testing if DCB battery bank voltages are Low. 1) 2) 3) 4) 5) 6) Adjust low battery voltage value to 48V from CPMU Adjust float voltage value to 47.5V Check low battery voltage indication on CPMU Confirm alarm from NOC Adjust low battery voltage value back to 46V from CPMU and float voltage to 53.5V confirm alarm disappears on CPMU and NOC
Num of Test Case Name of test Case Preset Conditions Test Procedures
EAS Alarm Test # 5 Heal Exchange Fault Alarm testing if Temperature inside HPS48300 cabinet increased. 1) 2) 3) Open the door of rectifier cabinet and turn its fan off. Call to NOC for Low Heat Exchg.alarm verification. Again restore power supply of Heat Exchange Unit.
T05-02 Testing of Extended Alarms of DCB 600AH Battery Cabinet from NOC
Num of Test Case Name of test Case Preset Conditions Test Procedures EAS Alarm Test # 1 DC AirCon Fault Alarm Alarm testing if DC Aircon of Battery Cabinet not working. 1) 2) 3) 4) Check DC Aircon of BB Cabinet is in working condition. Turn Off the breaker of DC AirCon form Rectifier unit. Check AirCon fault Alarm signal at EMUA card against dedicated port #. Call to NOC for AirCon Fault Alarm verification. Page 16
Again Turn-On the breaker of DC Aircon and check Alarm indication OFF.
Num of Test Case Name of test Case Preset Conditions Test Procedures
EAS Alarm Test # 2 Door Switch Alarm Alarm testing for Door of Battery Cabinet 1) 2) 3) 4) 5) Check DC Aircon of BB Cabinet is in working condition. Open the Door of Battery cabinet. Check DSS Alarm signal at EMUA card against dedicated port #. Call to NOC for DSS Alarm verification. Again close the door of battery cabinet and check Alarm indication OFF.
T05 Charging and Discharging T05-01 Charging and Discharging of DCB Batteries
Objective: Verify that the Batteries can be normally charged and discharged after the mains power supply. Result: PassFailNot RunZapped Comment & Remark:
Prerequisites
The DCB batteries are well installed. The mains power supply for the Rectifier TP48200A is working normally. The BTS is working normally. Procedure Expected result 1.1: PTML standard battery health check template (attached) is attached with ATP documents for battery testing. Result
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2.1: Take the complete cell to cell voltage readings before commencing battery test. 3.1: Shutdown the AC Input supply of Rectifier to take batteries on load 3.2: Check the batteries feeding power to load after disconnection of AC power. 3.3: Take the complete bank & cell voltage readings after every 30 minutes. 3.4: Check that tested battery backup for cabinet is as per designed backup. 3.5: Is tested battery backup is up to/greater than designed backup.
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Float / Discharge Cell Voltages Before Test 30 mins 60 mins 90 mins 120 mins 150 mins 180 mins Restore Volt.
Observations:
Last Discharge O/P Voltage Discharge Time(Hrs)
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Available Not Available Available Not Available Available Not Available Available Not Available
T07 Annexure A:
Spare Type
AC Cable ZRA-VV-0.6/1KV 4x16mm^2 60227IEC02(RV) 35mm^2 DC Cable (Blue/Black) 60227IEC02(RV) 35mm^2&02 60227IEC02(RV) 35mm^2&01 60227IEC02(RV) 25mm^2&02 Ground Cable 60227IEC02(RV) 25mm^2 60227IEC02(RV) 25mm^2&01 Level-B Surge Protection 60KA,8/20s,220V / 225V-N - HUAWEI
SPD
1 Unit
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