POWER PLANT
ISSUE - I: March 2014
______
SPECIFICATION ON
SMPS BASED POWER PLANT
No. : BSNL/Specification/SMP– 001/01/March.2014
BHARAT SANCHAR NIGAM LIMITED
(A Government of India Enterprise),
Bharat Sanchar Bhawan, Janpath, Website:
NEW DELHI – 110001,INDIA
All Rights Reserved and no part of this publication may be reproduced, stored in a retrieval system or transmitted, in any form or means, electronic or mechanical, photocopied, recorded, scanned, without written permission from the Bharat Sanchar Nigam Ltd., New Delhi (A Government of India Enterprise), Bharat Sanchar Bhawan, Janpath, New Delhi – 110 001. Website:
CONTENTS
Clause No. / Description Of Items / Page No.History Sheet / 3
References / 4
PART 1 / TECHNICAL REQUIREMENTS / 5
1.0 / Scope / 6
1.2 / Functional & Technical requirements / 7
1.2.1 / Functional Requirements / 7
1.2.1.1 / Lightning and Surge Protection / 7
1.2.2 / Technical Requirements / 7
1.2.2.1 / System application / 8
1.2.2.2 / DSCA / 8
1.2.2.3 / Power plant compatibility with Engine Alternator / 9
1.2.2.4 / Load sharing (Parallel Operation) / 9
1.2.2.5 / Battery Monitoring / 9
1.2.2.6 / Protections / 11
1.2.2.7 / Monitoring/Alarm and Indicating Lamps / 12
1.2.2.8 / Remote control and monitoring / 13
1.2.2.9 / Electrical Requirements / 13
1.2.2.9.1.2 / Power Derating / 14
1.2.2.9.1.3 / Neutral Path Current / 14
1.2.3 / Power Plants compatible with Conventional batteries / 16
1.2.3.4 / Sleep Mode Operation / 18
PART 2 / GENERAL REQUIREMENTS / 19
2.0 / General Requirements / 20
2.1 / RFI Suppression / 20
2.2 / Power Plant system configuration / 22
2.3 / Rack Configuration / 23
2.4 / Constructional Features / 23
2.4.1.9 / SMPS Power Plant System Ultimate Capacity / 24
2.5 / Accessibility / 26
2.6 / Terminations / 26
2.7 / Bus-bars / 27
2.8 / Cabling and wiring / 27
2.9 / Earthing / 27
2.10 / Mounting of Components and Lay out / 28
2.11 / Documentation / 28
2.12 / Quality Requirements / 29
2.13 / Name Plate / 31
2.14 / MTTR and MTBF / 31
2.15 / Field Observations / 32
2.16 / Packing / 32
2.17 / Environmental Requirements / 32
PART 3 / GUIDELINES FOR THE PURCHASER/USER / 34
3.0 / Guidelines for the Purchaser/User / 35
Annexure-1 / Protocol or Sequence of Exchange of Information between Power plant & Remote Site monitoring equipment / 36
Annexure-2 / Ordering Information / 45
Abbreviations / 46
HISTORY SHEET
Sr.No. / Name of the Generic Requirements / No. of the Generic Requirements / Remarks
1 / SMPS Based Power Plants / G/SMP-01/01 JUL 94 / First issue
2 / SMPS Based Power Plants / G/SMP-01/02 SEP 96 / Second issue
3 / SMPS Based Power Plants / G/SMP-01/03 MAR 97 / Third issue
4 / SMPS Based Power Plants / GR/SMP-01/04 FEB 2001 / Fourth issue
5 / SMPS Based Power Plants / GR/SMP-01/05 JAN 2005 / Fifth issue
6 / SMPS Based Power Plants / (No. : TEC/GR/FLA/SMP- 001/06/June.2010) / Sixth issue: Clauses pertaining to surge protection devices for protecting the telecom site, have been separated from the GR. Changes in few parameters have been incorporated to accommodate advancement. All cases for certification shall be treated as fresh cases, and no incremental tests are recommended for renewal of type approval
REFERENCES
1. / QM-115 / Quality standard for calculation/verification of MTBF2. / QM-118 / Quality reliability in product design.
3. / QM-202 / Pictorial guidelines for Visual assessment of quality of printed board assemblies (PBA) & discrete terminal assemblies.
4. / QM-204 / Guidelines for workmanship standards for repair & modification of printed wiring board assemblies.
5. / QM-205 / Guidelines for standard of workmanship for printed boards.
6. / QM-206 / Guidelines for standard of workmanship for printed boards assemblies
7. / QM-207 / Guidelines for soft solder and fluxes for Telecom Equipments.
8. / QM 210 / Guidelines for standard of workmanship for surface Mounting Devices.
9. / QM-333 / Specification for Environmental Testing of Electronic Equipments for Transmission and Switching use.
10. / ITUT Rec. O.41 / Psophomeric noise requirements.
11. / IS: 5 / Standard on colours & shades.
12. / IS: 101 / Methods of Sampling & Test for Paints, Varnishes & Related Products.
13. / IS: 168 / Ready Mixed Paint, Air Drying, For General Purpose-Specification
14. / IS: 613 / Standard on Bus-bars
15. / IS: 1248 / Standard on Shunts.
16. / IS: 1359 / Specification for Tinning requirements.
17. / IS:1554 with Amend. -1 (June 1994) / Standard for Cables & Wires.
18. / ISO-9001-2000 / Quality Management Systems Requirements.
19. / EN 61643 - 11 / A11 / Low Voltage Surge Protective Device – Part 11: Surge Protective Device connected to low voltage power system – Requirement and Tests
20. / IEC 62305 - 1 / Protection Against Lightening – Part 1: General Principle
21. / IEC 62305 - 2 / Protection Against Lightening – Part 2: Risk Management
22. / IEC 62305 - 3 / Protection against lightning – Part 3: Physical damage to structures and life hazard
23. / IEC 62305 - 4 / Protection Against Lightening – Part 4: Electrical & Electronic System Within Structure
24. / IEC 60364 - 5 - 53 / Electrical Installation Of Building – Part 5 - 53: Selection & Erection of Electrical Equipments
25. / IEC 61643- 1 (Second Edition 2005 – 03) / Low-voltage surge protective devices – Part 1: Surge protective devices connected to low-voltage power distribution systems – Requirements and tests
26. / IEC 60364-5-53: 2001 Amendment-1 2002 – 04 / Electrical installations of buildings - Part 5-53: Selection
and erection of electrical equipment - Isolation, switching
and control
PART 1
TECHNICAL REQUIREMENTS
No. : BSNL/Specification/SMP – 001/01/March.2014
1.0Scope
1.1This document contains the generic requirements of Power Plants, based on High Frequency Switch Mode Techniques, using switching frequencies of 20KHz and above, for the use in Indian Telecom Network. The Power Plant as per thisGR shall be compatible with either VRLA or both VRLA as well as Conventional Lead Acid batteries. The power plant compatible with VRLA batteries only shall be certified as "SMPS power plants compatible with VRLA battery only". The Tendering Authority will indicate the type of power plant required in the Tender.
1.1.1The DC Distribution cabinet does not form part of this GR.
1.1.2The system shall be capable of meeting the load requirements of various telecom equipment and battery bank in Telecom Network. The system should be expandable at rack level itself or by additional racks using the basic FR/FC and/ or FR/BC modules of the same rating. The prescribed FR/FC and FR/BC ratings are25A, 50A, 100A and 200A. These power plants may be mainly classified in two categories:
1.1.2.1Large capacity Power plants systems:
These types of power plants are envisage for large or very large telecom systems. Power plant systems with ultimate capacity of 600A/1000A/1500A and above are envisaged for this application. Battery back-up for these systems shall be as per Annexure – I letter No. 7-1/2013-NWO-CFA/MSE (Ch.II) Dated: 14.03.2014 Issued by BSNL C.O, New Delhi – 110 001. SMPS power plants based on 100Abasic modulesare envisaged for 600A/1000A/1500A and 100A/200A basic modules for above 1500A for these application. All these power plants use three phase supply.
1.1.2.2 Small capacity Power plants systems:
These type of power plants are envisage to serve small telecom systems in rural and semi-urban areas. Battery back-up for these systems shall be as per Annexure – I letter No. 7-1/2013-NWO-CFA/MSE (Ch.II) Dated: 14.03.2014 Issued by BSNL C.O, New Delhi – 110 001. This type of power plant may also be used withsmall telecom systems such as mobile base stations etc. in the urban and metros areas. SMPS power plants with ultimate capacity of less than 150A (single phase) based on 25A/50A single phase module are envisaged and these power plants shall operate on single or three phase / 4 wire A.C input power distribution.
The power plants with ultimate capacity 150A/300A/450Abased on 50A basic modulesshall operate on three phase / 4 wire A.C input power distribution. Higher rated modules in place of 50A basic modules (60A/75A) is also permissible, but counting of modules will be as per the ultimate capacity fixed for 50A basic module (i.e 150A/300A/450A).
1.1.3The power plant system shall consist of a Distribution, Switching, Control, Alarm and Monitoring arrangement (DSCA) and Float Rectifier-cum-Float Chargers (FR/FCs) and Float Rectifier-cum-Battery Chargers (FR/BCs) in a rack. It shall employ modular configuration for flexible provision of DC power.
Note: FR/BC is only used for conventional flooded Lead Acid batteries only. Power plants compatible with VRLA batteries only, do not require FR/BC modules and as such only FR/FC are used in such power plants.
1.1.4The system shall be sufficiently flexible to serve any load from 6.25A onwards, depending on manufacturer's design, rating, number of FR/FC modules used in a rack and system configuration.
1.1.5Tocater to higher load requirements, same type of FR/FCs mounted in the same rack or different racks shall be capableof workingin parallel load sharing arrangement.
1.2 Functional and Technical Requirements
1.2.1Functional Requirements
1.2.1.1Lightning & Surge Protection:
The protection of Telecom Site against the lightening and high voltage surges shall be as per GR of Lightening and Surge Protection of Telecom Site (GR No. TEC/GR/FLA/LSP-001/01/June 2010).
1.2.1.2 Stage–2 Protection:
This protection against, low voltage surges of up to 1.5 KV, shall be provided at the power plant level. This protection shall be equipped with thermal disconnection and potential free contact for arrestor(s) connected between live & neutral and neutral & earth. This protection shall be in compliance of IEC 62305 60364-5-53 for the following values of current:
Between / Protection RequirementR, Y, B & N / Greater than or equal to In: 10KA, 8/20S for each phase
N & PE / Greater than or equal to In: 20KA, 8/20S.
Where In: Value of nominal discharge current 8/20S.
Note: Voltage rating of MOVs shall be 320V minimum.
1.2.1.3 Response time of the Stage II device shall be ≤ 25 nano seconds.
1.2.1.4Installation procedures of SPDs
The power plant shall contain Stage-II protective device for protection against low voltage surges of voltage up to 1.5 KV.
1.2.2Technical Requirements
1.2.2.1 System Applications
SMPS is intended to be used in Auto Float-cum-Charge mode as a regulated D.C. Power Source.
1.2.2.1.1 Switching frequencies of these power plants shall be 20 KHz and above.
1.2.2.1.2 The system shall only be based on menu driven Microprocessor Controlled Techniques (both DSCA as well as FR/FC, FR/BC module) for control, monitoring & alarms. DSCA shall display the Software version and checksum number for DSCA and FR/FC, FR/BC. Setting of all the parameters shall be through menu-driven microprocessor control only. The failure of Micro processor or DSCA shall not affect the setting of individual FR/FC, FR/BC. No parameter of FR/FC, FR/BC modules shall be disturbed on the failure of DSCA. In this condition all the FR/FC FR/BC modules shall take care of the load on default settings and share the load collectively. Only the setting of new parameters from DSCA shall be affected. In case of failure of microprocessor of FR/FC, FR/BC module its last settings shall not be affected.
The system shall be RS485/RS232/Ethernet compatible, if remote monitoring is required.It shall be feasible to set any monitoring control parameter from a remote site through RS 485. All the information regarding Control and monitoring of Power Plant data shall be accessible on demand from the remote site. The exchange of information and protocol format shall be as given in the Annexure -1.
1.2.2.2 The DSCA shall be provided for the ultimate capacity of the Power Plant. However, it shall preferably be provided either in the first rack or in a separate rack. The DSCA, in addition to control, monitoring and alarms, shall provide for the following:
a) Termination for the batteries*.
b) Termination for the exchange load.
c) Interconnecting arrangement for power equipment.
d) Battery Switching arrangement (Connection to / isolation from system)**
e) Termination for AC input to the rack shall be finger touch proof, flame retardant, insulated. Use of bus-bars for the purpose is precluded. However, for terminating cables of large cross sectional area, especially in high ultimate capacity power plants, copper bars may be provided as terminal blocks to handle such high currents.
f) Termination for AC and DC to FR/FC modules.
g) Circuit Breakers/ fuses etc.
* The capacity and number of batteries shall be as per order. For the purpose of Type Approval, it shall be taken as three batteries.
** Only CACT approved DC contactor or `MCBs’ (which do not produce spark while cutting in or out) for manual isolation and reconnection of the battery. Themanual isolation/reconnection of the battery by tripping the contactor through an external switch is not permitted.
Note-1: For AC input supply, AC contactor with AC Coil shall preferably be used. AC Contactor with DC coil (if used) shall have its own power supply and shall not be fed from Exchange battery.
Note-2: Battery shall be protected against the short circuit from any source, including switching equipment such as contactor, MCB coil and their control and sensing circuitry.
Note-3: Solid state switching device maypreferably be used. Relays, if used, shall be UL or CE compliant.
1.2.2.2.1 Interlocking of batteries: Necessary interlocking arrangement for batteries shall be provided so as to ensure that at-least one battery remains floated across the load under all working conditions.
1.2.2.3Power Plant compatibility with Engine alternator: The power plant system (including FR/FCs, FR/BCs and DSCA), shall be suitable for operation from A.C mains or a DG set (of capacity 1.25 times AC load of power plant).
1.2.2.4Load Sharing (Parallel operation):FR/FC modules shall be suitable for operating in parallel withone or more modules of similar type, make and rating, other output conditions remaining within specified limits.
1.2.2.4.1 The current sharing shall be within +/- 10% of the average current per rectifier module in the system (mounted in the same or different racks), when loaded between 50 to 100% of its rated capacity for all working conditions.
1.2.2.4.2 In the event of failure of DSCA, FR/FC, FR/BC modules’ parameters shall not be disturbed. All the FR/FC FR/BC modules shall take care of the load on default settings and share the load collectively.
1.2.2.5 Battery Monitoring:
1.2.2.5.1 Battery under voltage isolation: There shall be a provision for Automatic isolation/reconnection of each battery from the load. The DC contactor used for the purpose shall be of single pole only.
The operate and release voltages for the above conditions shall be as follows:
Cut-off: 1.85V/cell (44.4V+0.25V) shall be settable between 1.85V and 1.9V/cell)
Reconnect: When the FR/FC voltage has built-up fully. Shall be settable between 2.15V to 2.3V/cell)
1.2.2.5.2 Battery Health Monitoring in Auto Mode: To keep the battery in healthy state, the battery condition shall be continuously monitored. On restoration of AC mains after an interruption, depending on the sensed battery condition (depthof discharge), the system shall change over to Auto Charge mode to charge the battery at higher voltage of 55.2V till the battery is fully recouped.
1.2.2.5.3 Battery Health Check (Optional): There shall be a provision of monitoring the voltage, current, trickle current, conductance and temperature (programmable) of the batteries associated with the power plant at a set periodicity. There shall also be a provision of monitoring of each cells of the battery bank for voltage and temperature.
The provision for conducting a partial discharge (about 20%) test, of a pre-determined duration and frequency, shall be made available in the power plant (Frequency and duration of partial discharge test shall be programmable). During this test, thecurrent and voltage of the battery as well as each individual cell shall be recorded. It shall also record the conductance and temperature of each cell.
Conductance measurements/observations shall be off-line to prevent noise interference.First observations of conductance, recorded by the power plant system, for the battery shall form the base values for future comparison.
The provision of partial test discharge shall be implemented in such a way that at a time only one battery is put to discharge, so as to ensure that necessary battery reserve is available in case of power failure during or immediately after the test discharge. Provision shall be made for observing the state of charge of battery before commencing this test. In case the battery is not fully charged this test may be deferred till the battery is fully recouped.
Any abnormality observed during above observations shall be highlighted by initiating an alarm. All the above information shall be made available to the remote site through RS 485(Refer Annexure 1 for specified protocol).
Note: The Battery Health Check feature shall be optional. However, type approval shall only be accorded with the above provision. The manufacturer will give the list of hardwareequipment requiredfor the purpose in the instruction and maintenance manual. User shall clearly indicate the requirement of battery health check feature while ordering the power plant. The manufacturer shall also undertake that the above provision will become fully function by adding the hard ware (indicated in the instruction manual) for the purpose.
1.2.2.5.4 SMPS Management (Optional)
The purchaser may decide the requirements for optional SMPS Management features like Energy saving Management, DG Efficiency & Fuel Saving Management, Battery Efficiency & Management, Rectifier Control – Efficiency Management, etc.
1.2.2.5.5 Battery path Current Limiting Circuit : In Auto Mode the current in each battery path shall be settable as per the battery capacity so that the battery path current is kept at 10 % of battery AH capacity. Tendering Authority will give the capacity of the battery to be used for this purpose. For the type approval the manufacturer shall demonstrate the facility and undertake to make provision as per order.
1.2.2.5.6 Temperature Compensation for Battery: In autofloat/charge, mode there shall be provision for monitoring the temperature of battery and consequent arrangement for Automatic temperature compensation of the FR/FC, FR/BC output voltage to match the battery temperature dependant charge characteristics. The output voltage of the rectifier in Float/Charge operation shall decrease or increase at the rate of 72mV (3mV/cell, 24 cell battery) per degree increase or decrease in temperature over the set voltage. The output voltage shall decrease till the open circuit voltageof the battery is reached. The open circuit voltage range shall be settable between 2.1V/cell to 2.2V/cell. At this voltage, the power plant voltage gets locked and further increase in temperature shall not decrease the voltage any further. This voltage shall also remain locked till the temperature falls below the value corresponding to set value. When the output voltage reaches 55.8V, due to increase in the output voltage owing to decrease in temperature, it shall get locked at this voltage & any further decrease in temperature shall not lead to further rise in the output voltage of the power plant. This voltage shall also remain locked till the temperature rises above the value corresponding to set value. A tolerance +/- 5 mV may be acceptable over the specified rate of 72mV/degree C. The nominal distance between thebattery & power plant may be 20 metres. The manufacturer shall provide the necessary sensor and cord for the purpose with the power plant. Failure of temperature compensation circuit including sensors (including the open or short circuit) shall create an alarm and shall not lead to abnormal change in output voltage. Proper sign-writing shall be made in DSCA and both ends of temperature compensation cord for its easy termination.
1.2.2.6 Protections
Failure of control and sensing circuitry shall not cause any hazard. The voltages of the system shall not abnormally increase to endanger the load.