dcb power atp document

7/28/2019 DCB Power ATP Document

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ATP Document Page 1DCB Power SolutionUfone/Technical/ANO/DOC/04/00

POWER SWAP PHASE 10

Power ATP Swap Document

TP48200A with DCB

Site ID: ________________________

Location: ________________________

Date & Time: ________________________


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ACB Power Solution ATP Snags Classification

ATPDate

Snag DetailsSnag Classification

(Major/Minor)WorkmanshipFactor(WM) *

ProductFactor (PrF)

PlanningFactor (PF)

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. Test Items Tests StatusT01 Installation of Power System Pass Fail

T01-01 Installation of TP48200A Power Cabinet 5

T01-02 Installation of Mixed Power cabinet DCB600 5

T02 Commissioning of Power System

T02-01 Commissioning of TP48200A Power Cabinet8

T02-02 Commissioning Mixed Power System (DCB600AH) 4

T03 AC / DC / Grounding & Alarm Cables

T03-01Installation of AC Power Cable, DC Cables andGrounding Cables/SPD

5

T04 Site Tagging and Labels 3

T05Charging and Discharging of BatteriesMixed Power System (DCB600AH)

T05-01

Battery Test Items 5

Test Item: I Appearance, Wiring, Installation13

Test Item: II Capacity Test1

T05-02 Battery Test 1

T06 Documentation Required 1

T07 Annexure A 1


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T01 Installation of Power System

T01-01 Installation of TP48200A Power Cabinet.

Objective

Verify that the installation of the Power System with PMU, PSUs complies with the engineering specifications.

Result:

PassFailNot RunZapped

Comment & Remarks

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 Result

1. Installing the TP48200A

Power system Cabinet.

1.1:The Power system is installed securely on the

concrete PAD or mounting racks/ iron beams as

per site layout.

PassFail Not RunZapped

1.2: No damage has been done to equipment while

installation and door opening of installed power

system can be > 900


1.3: All the packing materials are removed from the

equipment area after equipment installation. PassFail Not RunZapped

2. Installation of Expansionbolts for Power system

TP48200A.

2.1: The mounting holes for the cabinet must becarried out by drilling on concrete PAD.


2.2: The 4 expansion bolts (M12 x 60) are installed

and tightened by using appropriate socket wrench. PassFail Not RunZapped


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2.3: The extra holes for cable entry are properly

sealed and covered by fire resistant mud

insulation.


3. Check the PSU

Installation inside power

cabinet TP48200A.

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. PassFail Not RunZapped

4. Check the TP48200A

cabinet locks / security

mechanism and holes for

cable entry.

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.PassFail Not RunZapped

4.3: The TP48200A Cabinet Door sealing is

adequate and proper as per approved design. PassFail Not RunZapped

Huawei Representative

Name:_____________________

Signature:__________________

Date:______________________

PTML Representative

Name:_____________________

Signature:__________________

Date:______________________


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T01-02 Installation of IBBS Cabinet DCB-600.

Objective

Verify that the installation of the IBBS cabinet DCB-600 complies with the engineering specifications.

Result:


Comment & Remark

Prerequisites

The DCB-600 cabinet installation as per site layout.

DCB batteries installed for 600AH system.

inter-connection Battery strings.


1. Installing the IBBS Battery

Cabinet DCB-600.

1.1: The DCB-600 battery cabinetis installed

securely on the concrete PAD or mounting

racks/ iron beams as per site layout.

Pass Fail Not RunZapped

1.2: No damage has been done to equipment

while installation and door opening of installed

IBBS cabinet can be > 900


1.3: All the packing materials are removed from

the equipment area after equipment

installation.

Pass

Fail

Not Run

Zapped

2. Installation of the Expansion

bolts of IBBS Battery

cabinet DCB-600.

2.1: The mounting holes for the cabinet must

be carried out by drilling on concrete PAD.Pass Fail Not RunZapped

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 cabinetDCB-600.

3.1 Check one DCB Banks are installed with

24 battery cells and the total battery bankcapacity is up to 600AH.


3.2 The interconnection strips for each battery

string cell to cell terminal must be tightenedPass Fail Not RunZapped


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Name:_____________________

Signature:__________________

Date:______________________

PTML Representative

Name:_____________________

Signature:__________________

Date:______________________

T02 Commissioning of Power System

T02-01 Commissioning of TP48200A Power Cabinet.

Objective

Verify that the commissioning of the Power System connected with PMU, PSUs complies with the engineering

specifications.

Result:


Comment & Remark:

Prerequisites

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.


1. Check the TP48200A

specifications and check

AC, DC and signal cable

connections of TP48200A

Power system Cabinet.

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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1.4: The power cables (AC/DC) are connected

correctly, all the cable routing is proper. And all

Alarms cables are connected.Pass Fail Not RunZapped

2. Check PMU commissioning

with system power

parameters.

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 &

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 Set

Battery Capacity 600AH

Charge Current Limit 0.1C

Float Voltage 53.5 Volts

Boost Voltage 56.5 Volts

Low battery Voltage 46 Volts

LLVD Voltage 44 Volts

BLVD Voltage 43 Volts


3. Check the alarm LEDs on

PMU

4.1: On event of alarm respective LED shall lit

on to give alarm indication.Pass Fail Not RunZapped

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

connections to CPMU to

BTS alarm Card.

5.1: All alarms provided by customer are

extended from TP48200A to BTS EMUA Card.Pass Fail Not RunZapped

5.2: The EAS alarms of TP48200A cabinet are

patched and reported at NOC.

For Rectifier Cabinet:

1. Mains Failure Alarm Pass Fail Not RunZapped

2. Rectifier Major AlarmPass Fail Not RunZapped


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3. Rectifier Minor Alarm Pass Fail Not RunZapped

4. Low Battery Voltage Pass Fail Not RunZapped

5. Heat Exchanger (Fan) Alarm Pass Fail Not RunZapped

For Battery Cabinet:

1. Door Open AlarmPass Fail Not RunZapped

2.DC Aircon fault Alarm Pass Fail Not RunZapped

5. Check the status of the heat

exchanger connections and

working.

6.1: The internal fans of heat exchanger are

working and air circulation inside power cabinet

is adequate.


6. Check the status of the

indicators on the PMU.

7.1 The Power-On LED is in ON state while

rectifier working,Pass Fail Not RunZapped

7.2: Alarm status indicators in case of any

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



Name:_____________________

Signature:__________________

Date:______________________

PTML Representative

Name:_____________________

Signature:__________________

Date:______________________


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T02-02 Commissioning Mixed Power System (DCB-600)

Objective:

To verify various IBBS parts installed in DCB-600 cabinet (i.e. DCB Battery, Air Condition, etc) , and to check

DCBs can be normally charged and discharged after the mains power supply is switched on/off.

Result:


Comment & Remark:

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


1. Check DC cables for DCB

Batteries and check

interconnection of battery

cables between cells to

cell.

1.1: The cell to cell connectors for each DCB

cell is connected and tightenedPass FailNot RunZapped

1.2: Check the ve cable is connected

through DC breaker in power system and all

connections are tightened by screw wrench.Pass FailNot RunZapped

2. Check DC Air-condition

connections and working.

2.1: The Air-condition is in working condition

and power cable for powering Air-condition is

connected with rectifier output

Pass FailNot RunZapped

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.Pass FailNot RunZapped

2.4: The Alarm cables of Air-condition are

terminated to EMUA boardPass FailNot RunZapped


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3. Check signal cables b/w

DSS

3.1: The signal cable of cabinet DSS (Door

Status Switch) of IBBS system is connected

and Alarm is verified from NOC.



Name:_____________________

Signature:__________________

Date:______________________

PTML Representative

Name:_____________________

Signature:__________________

Date:______________________


12/20


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:


Comment & Remark

Prerequisites

All internal cables (AC / DC / Alarm) are installed.


1. Check the specifications andinstallation of AC power

cable.

1.1: The main AC power cable installed topower up the rectifier is Wire 4*16mm

2

(Cores: Red, Yellow, Green, Black)connected with ACDB to rectifier mainbreaker.


1.2: The AC Power cable must be routedseparately from other cables and both endconnections of cable are tightened with Lugs.


1.3: The AC power cable is routed and tiedinside the power cabinet and no loose

connection from both ends.


1.4: No joint lies in the middle of the ACpower cable.


1.5: The OT terminals of the AC power cablesare wrapped up with insulating tapes/ heatshrinks.


2. Check specification andinstallation of DC Power

cable.

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 andTP48200A power system cabinet.


2.3: No joint lies in the middle of the DCpower cable.


2.4: The OT terminals of the DC power cablesare wrapped up with insulating tapes/heatshrinks.



13/20


3. Check the specification andinstallation of GND cables.

3.1: The rating of grounding cable (Wire, 450

/ 750V, 25mm^2, yellow green, 110A.)Pass Fail Not RunZapped

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 Groundingcable 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. Check the Surge Protectionunits connections and

specifications..

5.1: The Surge Protection Devices installed inRectifier Cabinet (TP48200A) shall be inhealthy state.


5.2: The SPD rating installed in Built-in powersystem of TP48200A Cabinet shall be as per

design.


5.3: Check Color of on front of SPD shall beGREEN, In case of RED/BLACK, it isdeclared to be faulty.



Name:_____________________

Signature:__________________

Date:______________________

PTML Representative

Name:_____________________

Signature:__________________

Date:______________________


14/20


T04 Site Tagging and Labels.

Objective:

Verify that the Tagging and Labels of each new installed part /spare are proper.

Result:


Comment & Remark

Prerequisites

Check Tagging and Labels of each item for newly installed system / cabinet / cables etc.


1. Labels / Taggingspecifications.

1.1: The labeling and tags of every iteminside both power & battery cabinet must bepasted as per delivered in systemaccessories package.


1.2: The Tags should be bold visible andpasted in printed form, Pass Fail Not RunZapped

1.3: The insulation of tags must be of goodquality and can sustain in the environmentalconditions.


1.4: Hard Plastic type tags pasted at theoutdoor routing of every cable if it is routedinside duct / GI flexible pipe.


2. Labels / Tagging of Cables(AC / DC / communication /

Alarm etc)

2.1: The Tags must be pasted at the bothends of each cable (AC/DC/Alarm/Signal)inside both cabinets TP48200A and IBBSDCB-600 cabinet.


3. Labels of DCB Batteries and

Alarm cables

- All installed DCB batteries are tagged withits battery cell number for each cell. Pass Fail Not RunZapped

- All alarm cables for every extended alarmmust be pasted with proper taggingseparately inside BTS and power system.



15/20



Name:_____________________

Signature:__________________

Date:______________________

PTML Representative

Name:_____________________

Signature:__________________

Date:______________________

T05 TEST PROCEDURES

T05-01 Testing of Extended Alarms of TP48200A Rectifier from NOC

Num of Test Case EAS Alarm Test # 1Name of test Case Mains FailurePreset Conditions Alarm Testing at Wapda & D.G. Power shutdownTest Procedures 1) Check float voltages on CPMU screen.

2) Turn Off the Mains power supply from ACDB

3) Check MF Alarm signal observed at CPMU LED indicator.

4) Call to NOC for MF Alarm verification

5) Restore Wapda or D.G supply and check float voltages again.

Expected Results Mains Failure alarm reported to NOC.Test Results Pass / Fail

Num of Test Case EAS Alarm Test # 2Name of test Case Rectifier Major AlarmPreset Conditions Alarm testing at any Major fault occurs in rectifierTest Procedures 1) Check float voltages on CPMU screen and Alarm LED is OFF.

2) Unplug & remove any 2 modules (PSUs) from the rectifier.

3) Check alarm indication observed on CPMU

4) Call to NOC for Major Alarm verification

5) Connect the PSUs again with rectifier and check Alarm indication OFF.

Expected Results Rectifier Major alarm reported to NOC.Test Results Pass / Fail

Num of Test Case EAS Alarm Test # 3Name of test Case Rectifier Minor AlarmPreset Conditions Alarm testing at any Minor fault occurs in rectifier


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Test Procedures 1) Check float voltages on CPMU screen and Alarm LED is OFF.2) Unplug & remove one SPD unit from the rectifier.

3) Check alarm indication observed on CPMU

4) Call to NOC for Minor Alarm verification

5) Connect the SPD unit again with rectifier and check Alarm indication OFF.

Expected Results Rectifier Minor alarm reported to NOC.Test Results Pass / Fail

Num of Test Case EAS Alarm Test # 4Name of test Case Low Battery Volt AlarmPreset Conditions Alarm testing if DCB battery bank voltages are Low.Test Procedures 1) Adjust low battery voltage value to 48V from CPMU

2) Adjust float voltage value to 47.5V

3) Check low battery voltage indication on CPMU

4) Confirm alarm from NOC

5) Adjust low battery voltage value back to 46V from CPMU and float voltage to

53.5V

6) confirm alarm disappears on CPMU and NOC

Expected Results Low Battery alarm reported to NOC.Test Results Pass / Fail

Num of Test Case EAS Alarm Test # 5Name of test Case Heal Exchange FaultPreset Conditions Alarm testing if Temperature inside HPS48300 cabinet increased.Test Procedures 1) Open the door of rectifier cabinet and turn its fan off.

2) Call to NOC for Low Heat Exchg.alarm verification.

3) Again restore power supply of Heat Exchange Unit.

Expected Results Low Battery alarm reported to NOC.Test Results Pass / Fail

T05-02 Testing of Extended Alarms of DCB 600AH Battery Cabinet from NOC

Num of Test Case EAS Alarm Test # 1Name of test Case DC AirCon Fault AlarmPreset Conditions Alarm testing if DC Aircon of Battery Cabinet not working.Test Procedures 1) Check DC Aircon of BB Cabinet is in working condition.

2) Turn Off the breaker of DC AirCon form Rectifier unit.

3) Check AirCon fault Alarm signal at EMUA card against dedicated port #.

4) Call to NOC for AirCon Fault Alarm verification.


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5) Again Turn-On the breaker of DC Aircon and check Alarm indication OFF.

Expected Results AirCon Fault Alarm reported to NOC.Test Results Pass / Fail

Num of Test Case EAS Alarm Test # 2Name of test Case Door Switch AlarmPreset Conditions Alarm testing for Door of Battery CabinetTest Procedures 1) Check DC Aircon of BB Cabinet is in working condition.

2) Open the Door of Battery cabinet.

3) Check DSS Alarm signal at EMUA card against dedicated port #.

4) Call to NOC for DSS Alarm verification.

5) Again close the door of battery cabinet and check Alarm indication OFF.

Expected Results DSS Alarm reported to NOC.Test Results Pass / Fail

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 RunZappedComment & Remark:

Prerequisites

The DCB batteries are well installed.

The mains power supply for the Rectifier TP48200A is working normally.

The BTS is working normally.


1. Health check of battery

banks

1.1: PTML standard battery health check

template (attached) is attached with ATP

documents for battery testing.



18/20


2. Voltage measurement of

batteries

2.1: Take the complete cell to cell voltage

readings before commencing battery test.


3. Battery heath check 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.



19/20


T05-02 Battery Test:

BATTERY BANK TEST CHECKLIST

ank No: of Cell Float / Discharge Cell Voltages

1

Time (mins) :: Before Test 30 mins 60 mins 90 mins 120 mins 150 mins 180 mins Restore VoCell 1

Cell 2

Cell 3

Cell 4

Cell 5

Cell 6

Cell 7

Cell 8

Cell 9

Cell 10

Cell 11

Cell 12

Cell 13

Cell 14

Cell 15

Cell 16

Cell 17

Cell 18

Cell 19

Cell 20

Cell 21

Cell 22

Cell 23

Cell 24

Output Voltage

Output Current

Ambient Temp:

Observations: REMARKS ( GOOD / AVBAD )

Last Discharge O/P Voltage Discharge Time(Hrs)


20/20


T06 Documentation Required:

Objective:

All Site related documentation and BOQ provided.

Result:


1. Equipment BOQ Available Not Available

2. Equipment Layout Available Not Available

3. DCB Battery Configuration / Connection layout Available Not Available

4. Power Parameters Available Not Available

T07 Annexure A:

Spare Type Supplier Type Marker Qty (as per BOQ)

AC Cable

ZRA-VV-0.6/1KV 4x16mm^2&100

ZRA-VV-0.6/1KV 4x16mm^2

DC Cable(Blue/Black)

60227IEC02(RV) 35mm^2

60227IEC02(RV) 35mm^2&02

60227IEC02(RV) 35mm^2&01

Ground Cable

60227IEC02(RV) 25mm^2&02

60227IEC02(RV) 25mm^2

60227IEC02(RV) 25mm^2&01

SPDLevel-B Surge Protection 60KA,8/20s,220V /225V-N - HUAWEI

1 Unit

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