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Installation and commissioning of IPS system
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0% found this document useful (0 votes)
159 views54 pagesProcedure - Installation & Commissioning
Installation and commissioning of IPS system
Uploaded by
SatyamMishraCopyright
© © All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
Available Formats
Download as PDF or read online on Scribd
HBL
HBL Power Systems Limited
Hyderabad - TS, india
Electronics Group
Procedure for Installation & Commissionii
of Integrated Power Su
Dociment NO.: EG-IC-PR-01, Rev. No: 00
Name Date
G. Muralidhar Rao oplesleor
[Link]— |\\ AQ sales [>on
AR Kishore , eles loon
CONTROL OF CONFIDENTIALITY
} The information contained in this document is the property of HBL, which reserves the
right for distribution, application or reproduction for any usage. Procedure No. [EH
1CPROL
BBE | sone fo
forts System Pageno: [20164
Revision History
Rev. | Dateor Rev. No
Detalls of Char Reason for Chat
No. | Revision cea te en To
0 | oaosit7 ‘Al Pages Initial Version| : °
Distribution List,
‘This Documented Information wil be uploaded in Configuration Management system Share
Point and wil give access to all functional area's for necessary reference. Procedure for instalation & Commissioning | Rovson No. | 0
ProcedueNe, [EGICPROT
tor PS Sytem a EC
st of Abbreviations
SLNo| Abbreviation Expansion
1% RDSO Research Designs and Standards Organtzation
2. PS Integrated Power Supply Syatem
3. FREC Foot Rectifier and Boost Charger
4 ‘ACO AC Distribution Panel
5. cor DC Distribution Panel
6. ‘SMR Switched Mode Rect
7. ‘SwPS ‘Switched Mode Power Supply
8. SER Sold state Relay
ca ‘mntirg Cru Beaker
10. VRLA [Valve Regulated Lead Aclé Batteries
" LMta/_<> [ow maintenance Lead Acid Batteries
2 Pee Printed Greut Bord
= wore? THEVAL OMDE SENICONOUCTOR HELD EFFECT
14, AVR [AUTOMATIC VOLTAGE REGULATOR
16. ovr CONSTANT VOLTAGE REGULATOR
16 sou “Supervisory Contra Unit
17 Dc scu DC Supervisory Control Unit
18. ‘ASM Pane! Assistant Station Master Panel
19. ac Tastallaton and Commissioning
20. a Lightning Arrestor
2 ‘SPD ‘Surge Protection Device
2. Mov Metal Oxide Varistor HBL)"
Procedure No, | EGICPROY
for intalation & Commissioning | Ravilon’No. [0
for #8 System Pogo [400s
23 18 Terminal Block
24, or ‘CURRENT TRANSFORMER for sensing AC current
2. HT ‘Shunt for sensing DC current
28. toc Inter Cell Connector
21 AH “Ampere Hour unit for Battery capacity
28. v Volts
29, A ‘Ampere
30. Peck Pre-Commisioning Check Uist
34 ‘OEM Origind! Equtpmeit Manufacturer
32 PFC Potential Frée Contact
3. De Direct Curent
34, no Alternating Current
3. Ho Head Office
38. SPN Specification
37. IRS Indian Raiway Standard
38 oc ‘Constant Current Charging
38. cv ‘Constant Votage Charging
40. rot Interreck Connection Layout
a. GAD General Arrangement Layout
a cB ‘Central Distribution Block
% Ew Electro Magnetic Intererence
& oov Open Gireult Voltage
%. 5E Service Engineer
#6. 2s Zonal Service Head Procedure, [EGICPROI
HBL Oe" evento
“Table of Contents
‘Scope.
Organization chart.
Roles, Responsibilities and Authority.
Process Flow Chart...
Earthing 7
6.1 Earthing DO's & DON'Ts ” B
62, Earthing Detail... : —— SB
7 Site Survey
TA Sie survey —detais a
72 Material receipt detail,
73 Site equipments load details,
8 Verification of PS Racks, Modle, LA& Batten
81 DO'S and DON”
82 Verification of FRBC Rack vn x
83 Verification of ACDP Rack received state.
84 Veriation of DCDP Rack received a it...
35 Verification of LA Box recived at site
36 SMR Modules. oy
87 Inverter Module y
88 Transformer Module x
89 CVT Modul. A y
810 DC-DCModsies aa
B11 LMLA Batteries, yas
B12__VREABaterioy
9 IPS Racks, LA Box, ASii Rack installation and Cable Routing.
9.1 IPS rack erecting aod cable routing the folowing procedure has tobe fliowed.
92. Lox erection and able routing the fllowing procedure has to be followed
93. ASM rack m
10. Testing of IPS Racks and Modules.
10.1 FRBC Rack and SMR modules testing.
102. ACDP rack and Inverter module esting
Battery Charging - Ist Cycle:
124 Batery Charging -2nd Cycle:
125 Final Charging:
18 IPS System Testing.
14 PREPARATION OF PRE Cows SiONING CHECK List (PECL)
14.1 Performance Monitoring of IPS,
418. Specifications & Documentation.
Specifications:
Documentation
Pre Commissioning Check List (PCC)
‘Original Equipment Manufscturer (OEM) Cerificate,
Failure Information & Service Report. HBL "ne"
Powe No
EGicPRa!
‘Revisor No,
Page Ne
oom
156 TPS1&C Chock List...
16 Tools for I&C..
47 Document Retention... HBE
Procedure for instalation & Commissioning
for iPS System
ProcedireNe. [EGIGPROT
Resin No, [0
Papen: | Tots
1 Purpose
|. The installation & Commissioning procedure glves activites, which Service
Engineer should, ensures that the required product commissioned at sites meets
allthe
‘customer requirements.
it, “These instructions also give necessary specification, documents / parameters to
quality assurance testing / audit.
“The objectives of Installation and Commissioning are
‘To complete I&C works at optimum cost and within the Schedules
‘To ensure continuous functioning of Systems In the respective installed
b.
4
2 Scope
sites,
-. To ensure the completeness and. correctness of installation and
‘commissioning by adhering to RDSOguldelines and’ comply to the
activities as specified in pre-cortmissicning checklist
‘To ensure that I8C team follows the JAC Procedure and User Manuals
Installation & Commissioning tnstruetioné are prepared to cover all the quality
‘assurance in IPS system Instalgtion, Testing, Commissioning activities.
3 Organization chart,
Figure 1:
Organization Chart
‘General Manager
1&C and Service Head
Dy. General Manager|
IC and Service Head
1
SeMgrI&G, Serie
tS
‘Nomth Zone 1&C, ‘East Zone 18C, ‘South Zone 18C, ] [West Zone lc,
Service Head Service Head Service Head Service Head
“Team “Team Team Team
1&C, Service T&C, Service IWC, Service ec, Service BBE | ttc [Resort fo
Procedure Ne, [EGIC PROF
for #3 3yst0m Pais masses scree
4. Roles, Responsibilities and Authority
Goneral Manager
Responsibilities:
4) Framing / defining objectives of I&C department, monitoring
Corrective action for achieving the same.
2) Controling and Monitoring of RE PRODUCTS-I8C and Service,
Including Spares and Manpower Management
3) Ensuring that employee skis set to meet job requirements.
44) Control and Monitoring of I&C payments.
'5)_Monitoring of Qualty Audits after completion of 1&C.
Authority:
For Approval ofthe folowing:
1), Manpower planning & recntiment
2) Advance Payment to secs engjnéers for tours.
3). Service engineers sélary(OMt Rl) and monthly expenditures of
ice branches:
4) Vendors work orders, cledrance for release of payments after
completing works.
5)_AMC, ARC snd Spire prices for tender / budgetary quote.
Dy. General
Manager
Responsibilities;
4, Framing / defting objectives of 1&C department, monitoring
Corrective ction for achieving the objectives,
.2.\Controling and monitoring of REPD PRODUCTS 418¢, including
‘Spares and Manpower Management.
3, Ensuring that employee skls set to meet job requirements.
44, Evaluation of Training being conducted to service engineers.
5. Ensuring & Implementation of ‘Quality Ault ater competion of
lac.
©. Conirol and Monitoring of 1&C payments.
| Ptanning & Monitoring of Quality Audis ater competion of &C__|
Authority:
For Approval ofthe folowing:
1, Manpower planning & recruitment.
2, Advance Payment io service engineers for tours.
3. Service engineers salary (Off Rol) and monthly expenditures of
‘service branches,
4. Vendors work orders, clearance for release of payments after
completing works HBL
Procedue Ne. [EGICPROI
Procedure for iatallation & Commissioning | Revision No. fo
for P3 3ystem Pogeno: | oose
1) Identify, Plan, monitor and Execute 18 activities for each PO.
2) Obtaining the deals trom Production (or from Share Point) to got
