Ips Pre- Comm. Check List

Pre-Commissioning Checklist of SMPS based IPS REFERENCE: SPECIFICATION NO. RDSO/SPN/165 SIG0101 (Revision 1) Number of pages 13

RESEARCH, DESIGNS & STANDARDS ORGANISATION MINISTRY OF RAILWAYS MANAK NAGAR LUCKNOW - 226011

Format No. SIG 0101, Ver. 1

Pre-Commissioning Checklist for SMPS Based IPS

RDSO/SPN/165/2004

DOCUMENT DATA SHEET

Designation SIG 0101 (Revision 1) Title of Document Pre-Commissioning Checklist of SMPS based IPS Authors:

See Document Control Sheet

Name: Vipul Goel Designation: Joint Director / Signal Approved By Name: Shri G.D.Bhatia Designation: Sr.Executive Director /Signal, RDSO Abstract This document defines the guidelines for Pre-Commissioning Checklist of SMPS based IPS.

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Format No. SIG 0101, Ver. 1

Pre-Commissioning Checklist for SMPS Based IPS

RDSO/SPN/165/2004

Document control Sheet

Designation

Organization

Function

Level

Joint Director/Signal

RDSO

Member

Prepare

Sr.ED /Signal

RDSO

-

Approval

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Format No. SIG 0101, Ver. 1

Pre-Commissioning Checklist for SMPS Based IPS

RDSO/SPN/165/2004

PRE-COMMISSIONING CHECKLIST FOR SMPS BASED IPS SYSTEM 1.

STATION DETAILS

Zonal Railway Division Station Name IPS Make RE/Non RE No. of lines / Roads

Number of main signals Number of shunt signals Number of point machines Number of Axle Counters Number of Track Circuits Type of Track Circuit (AFTC/DC) Number/Type of Indoor relays Number/Type of outdoor relays Interlocking ( RRI/SSI)

Power availability hours / day DG set rating Type / capacity of battery (LM/VRLA) 2.

PRE-COMMISSIONING REQUIREMENTS

S .N.

ITEM

A

Ambience of IPS Room

A1

Availability of working 1 m (min.) from sides and space for maintenance. rear. 2 m (min.) in front of the IPS Provision of flooring to Pucca floor/ Ceramic tiles ensure proper cleaning. Provision of forced Fresh Air fans with ventilation dampers Arrangement for (i) Tight closing of doors & protection against dust. windows; use gaskets if necessary.

A2 A3 A4

Value/provision

Specified Measured Value Remark / Observation (OK/Not OK)

(ii) Washable dust filters on windows.

A5

Provision of Ventilators

(iii) Provision of double door or entry through adjoining room to reduce dust ingress As per RE Drg. No. RE/Civil/S-129-2001 (Annexure-I).

Signature of Manufacturer's Representative

Signature of Railway Supervisor

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Format No. SIG 0101, Ver. 1

Pre-Commissioning Checklist for SMPS Based IPS

S .N.

ITEM

B

Batteries

B1

Installation of secondary Installed in separate room / cell as per para 16.6 of apparatus case. SEM Pt. Acid proof flooring and tiles Exhaust fan Initial charging as per instruction of battery manufacturer Use of battery grade sulphuric acid conforming to IS: 266. Use of distilled or de-mineralised water conforming to IS: 1069 Storage period of VRLA Less than 03 months (If the batteries for IPS battery is being stored for more than 3 months, freshening charge should be given once in 3 months as given below. The charging current should be 10% to 20% (max.) of rated capacity:-

B2

B3 B4

B5 C C1

Specified Value/provision

RDSO/SPN/165/2004

Measured Remark Value / (OK/Not Observation OK)

Float Charge @ 2.25V/cell for 24 hours Boost Charge - @ 2.30V/cell for 15 hours) Measured capacity of Rated AH battery after capacity test on batteries. Feeder cable from battery to charger 120AH 10 sq.mm copper 200AH 16 sq.mm copper 300AH 25 sq.mm copper Availability of Spare cell in 05 Nos. charged condition at site Commercial/AT Supply Availability of commercial More than 6 hours in 24 hours supply (Ref: RB letter No. with least fluctuations 2002/SIG/SGF/3 dt. (Note: Nominal incoming AC supply 24.6.03). shall be 230V, 50Hz single phase AC. The specified AC voltage range for IPS is 150V-270V.)

Signature of Manufacturer's Representative

Signature of Railway Supervisor

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Format No. SIG 0101, Ver. 1

Pre-Commissioning Checklist for SMPS Based IPS

S .N.

ITEM

C2

Voltage drop in input feeder at full load. Provision of sources of power supply as per para 16.2 of SEM Pt. II.

C3

Specified Value/provision

RDSO/SPN/165/2004

Measured Remark Value / (OK/Not Observation OK)

Less than 30 volts RE Area Power supply drawn from AT Up/Dn/ Commercial supply/Genset with auto/ manual changeover facility in the control panel. On double/multiple line sections, at least one AT is available to ensure power supply in the event of power block. On single line sections where power supply is drown from a single AT, a DG set of suitable capacity has been provided In big yards, a DG set of adequate capacity in addition to supply from AT's and local source Non RE Area Power supply drawn from commercial feeder. In addition two standby diesel generators have been provided

C4

Size of input feeder cable as per TI Directorate's note no. TI/PSI/Project/CLS/01 dt. 04.01.02.(Annexure II) from Auxiliary Transformer (AT ) / Distribution transformer to IPS room for 5 KVA AT 10KVA AT 50KVA AT

2X25 sq.mm Al 2x70 sq.mm Al 2x300 sq.mm Al

Signature of Manufacturer's Representative

Signature of Railway Supervisor

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Format No. SIG 0101, Ver. 1

Pre-Commissioning Checklist for SMPS Based IPS

S .N.

ITEM

C5

Sanctioned Commercial feeder load (KVA)=S General Electrical Lighting load (KVA)=L Balance available for Signalling Load(KVA) = S-L

C6

D D1

D2

D3 E E1

E2

Specified Value/provision

Measured Remark Value / (OK/Not Observation OK)

4 Line Non-RE 4 Line RE 6 Line Non-RE 6 Line RE MCB/ Changeover switch

7.4 KVA 6.25 KVA 8.1 KVA 7.0 KVA 63 Amp of Merlin Gerlin (Telemecanique) / Siemens, No. Schneider or ABB. dt.

(Ref: RB letter 2004/SIG/SGF/3 25.3.2004. DG Set supply Provision of adequate capacity DG set (without AFTC) 4 Line Non-RE 10 KVA 4 Line RE/6 Line RE 10 KVA 6 Line Non-RE 12.5/15 KVA with AFTC in yard Checking of DG set at 5KW dummy load: Waveform Voltage Regulation Frequency Proper termination earth and neutral. Earthing

At least 25 KVA

Sinusoidal within 3% 50Hz ± 5% from no load to full load of Good workmanship

Earth resistance of Less than 2 Ohm (without earthing arrangement. adding water prior to measurement) Preferably maintenance free earth. Extension of earth equipotential bus bar.

to Provided

Signature of Manufacturer's Representative

S

RDSO/SPN/165/2004

ITEM

Signature of Railway Supervisor

Specified Value/provision

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Measured

Remark

Format No. SIG 0101, Ver. 1

Pre-Commissioning Checklist for SMPS Based IPS

.N. E3

F F1

G. G1

H H1

RDSO/SPN/165/2004

Value / (OK/Not Observation OK) Connection of individual with individual copper insulated equipment to cable of size equipotential bus bar: - IPS racks 4 Sq.mm - DG sets 4 Sq.mm -Surge protection devices 16 Sq.mm Lightning & Surge Protection Provision of lightning & One set surge arrestors (As per Cl. 3.12 of RDSO/SPN/165/2004 Ver 2) Instruction Manual Instruction Manual Two sets consisting of Layout drgs., Circuit/ System diagram, PCB Layout etc. (Ref: Cl. 7.1 of RDSO/SPN/165/2004 Ver 2) Training Imparting on job training 3 days to SE/SSE/JE and ESM

3. IPS LOAD DETAILS N= Number of modules provided in hot standby S .N. 1. 2. 3. 4. 5. 6. 7. 8. 9.

ITEM

Specified Measured Remark Value/provision Value / (OK/Not OK) Observation OK Not OK Signalling Equipment load 80% of the DG Set (KVA) capacity provided at station Relay internal 24-32V/5A 5 *(N-2) Amp Relay external 24-32V/5A 5 *(N-1) Amp Axle counter 24-32V/5A 5 *(N-1) Amp Block local 12-28V/5A 5 *(N-1) Amp Panel Indication12-28V/5A 5 *(N-1) Amp HKT/magneto 12-28V/1A 1 *(N-1) Amp Block UP 12-40V/1A 1 *(N-1) Amp Block DN 12-40V/1A 1 *(N-1) Amp

Signature of Manufacturer's Representative

Signature of Railway Supervisor

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Format No. SIG 0101, Ver. 1

Pre-Commissioning Checklist for SMPS Based IPS

S.N

ITEM

10 11

Block Tele UP 3-6V/0.1A Block Tele DN 3-6V/0.1A

RDSO/SPN/165/2004

Specified Measured Remark Value/provision Value / (OK/Not OK) Observation OK Not OK 0.1*(N-1) Amp 0.1*(N-1) Amp

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12 13 14 15 16 17 18 19 20 21 22 23 24 25 26

27 28 29

Pre-Commissioning Checklist for SMPS Based IPS

Data logger 24-32V/5A SSI 24-32V/5A Load on each Signal Tx UP Load on each Signal Tx DN Load on Inverter 4 Line 6 Line Load on Signalling AVR 4 Line 6 Line Load on Track Tx UP DN Load on Track AVR 4 Line 6 Line High voltage disconnect Low voltage disconnect Battery capacity Battery charging current Total Current drawn from FRBC at 110 V after one hour of discharge. Current drawn from FRBC at 110 V when battery is in float condition Input feeder current at full load 4 Line Non-RE 4 Line RE 6 Line Non-RE 6 Line RE Input feeder voltage at full load Functioning of dynamic current control Supply fuse

5 *(N-1) Amp 5 *(N-2) Amp 500 VA 500 VA 1.5 KVA 2.0 KVA 1.5 KVA 2.0 KVA 500VA 500VA 1.0 KVA 1.5 KVA 275 V 160V 300/200AH 30/20A =Y 20* (N-2) Amp=X X-Y

32 Amp 27.2 Amp 35 Amp 30.2 Amp 160 Volts (Minimum) Operational 63 A

Signature of Manufacturer's Representative

S.N

ITEM

RDSO/SPN/165/2004

Signature of Railway Supervisor

Specified Measured Remark Value/provision Value / (OK/Not OK) Observation OK Not OK

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Pre-Commissioning Checklist for SMPS Based IPS

RDSO/SPN/165/2004

Working of Status Monitoring Panel (Para 4.10 of spec.) RED & Audio alarm DOD 50% RED & Audio alarm 60% RED & Audio alarm till 70% DG is started

31 32 33 34 35

Stop DG Set Call S&T due to failure of any module Changeover inv. 1 to 2 and vice versa Changeover inv. to CVT and vice versa DC-DC Converter for spare cells 2-12V, 5Amp Temperature compensation

GREEN & Audio alarm

RED & Audio alarm Inverter failure Both inverter fail 02 Nos. Provided for VRLA battery

4. Performance Monitoring of IPS S.N 1

ITEM

Specified Observation Provision Monthly calculation of MTBF / As per Annexure-III MTTR and sending it to Zonal Railways for onward transmission to RDSO.

Signature of IPS Manufacturer's Representative Name Designation Date

Signature of Railway Supervisor Name Designation Date

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Remark

Format No. SIG 0101, Ver. 1

Pre-Commissioning Checklist for SMPS Based IPS

RDSO/SPN/165/2004

Annexure-II Telephone : 2451200 Extn. 42394 Tele Fax : 91-0522-2452332 E-mail : [email protected]

Government of India - Ministry of Railways Research Designs & Standards Organisation LUCKNOW - 226011

No.TI/PSI/PROJECT/CLS/01

Dated 04.01.2002

The Chief Electrical Engineer i) ii) iii) iv) v) vi) vii) viii)

Central Railway, Mumbai CST-400 001. Western Railway, Churchgate, Mumbai-400 020. Eastern Railway, Fairlie Place, Kolkata-700 001. South Eastern Railway, Garden Reach, Kolkata-700 043. Northern Railway, Baroda House, New Delhi-110 001. Southern Railway, Park Town, Chennai-600 003. South Central Railway, Rail Nilayam, Secunderabad-500 371. CORE, Nawab Yusuf Road, Civil Lines, Allahabad-211 001. Sub: The cable sizes between Auxiliary Transformer and Distribution Panel.

The existing cable between auxiliary transformer and distribution panel is of 2x25 Sq.mm Aluminium cable for 5 KVA and 10KVA auxiliary transformers. The problem of excessive voltage drop and failure of fuse / tripping of MCB in distribution panel especially during low OHE voltage have been reported by the Signal Directorate. The cable size has been accordingly reviewed considering the voltage drop as well as energy loss in the cable. Presently, 10KV ATs are being provided at the end of platforms at the stations for signalling loads. 5KVA ATs are being provided at IBH stations and level crossing gates. The signalling load for ¾ line station in double line section on 10KV AT is about 8.5KVA. The signalling load at IBH and level crossing gate is about 2.0KVA. 50KVA ATs are presently planned for Mumbai area under DC-AC conversion where the requirement of load is higher. The estimated max. signalling load on 50KVA AT is about 40KVA. These 50KVA ATs may be used in future in other areas depending on the requirement of load. Due to provision of voltage stabilizer, the signalling load is normally of constant VA type i.e. if the voltage decreases the current will increase correspondingly. The input voltage range of the voltage stabilizer is 160-270V. Considering this the optimum cable sizes for different types of ATs are worked out and are given as follows: AT type 5KVA 10KVA 50KVA

Cable sizes 2 x 25 Sq.mm Aluminium 2 x 70 Sq.mm Aluminium 2 x 300 Sq.mm Aluminium

The above cable sizes of 1100V, PVC insulated, PVC sheathed, Al-conductor, Armoured Power cable as per IS: 1554-Part-I are to be provided for the respective type of ATs. The cable lugs and connectors are to be suitably provided. The taps of ATs should be judiciously kept so that the available voltage is maintained in the range of 160-270 V, which is the input voltage range of signalling voltage stabilizer. (B.P.Singh) for Director General/TI

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Annexure-III Suggested Format of field MTBF to be submitted by Zonal Railways Make

Total working hours IPS

SMR**

Inv.**

DC-DC Conv**

Total number of failures IPS*

SMR

Inv

DC-DC Conv

MTBF IPS

SMR

Inv.

DCDC Conv

AMR BSMC HBL Statco n *IPS failures shall be those failures which have affected the final performance of signalling system i.e failures affecting signals, complete shut down, failure of complete function. ** Total working hours of SMR = ∑ number of SMR provided x working hours of IPS system Total working hours of Inverter = ∑ number of Inverters provided x working hours of IPS system Total working hours of DC-DC Conv = ∑ number of DC-DC Conv. Provided x working hours of IPS system Total working hours MTBF = Number of failures of sub system

Format of field MTTR to be submitted by Zonal Railways Make

Total number of failures

Total duration of failures (hours)

AMR BSMC HBL Statcon

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MTTR (hours)

Format No. SIG 0101, Ver. 1

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RDSO/SPN/165/2004