O&M Doc for Telecom Sites
- 1. O&M Doc Ref: Rev: 1.0 Date: 15-10-14 Page: 1 of 13 O&M Doc for Telecom Sites By: Muhammad Javed Iqbal
- 2. O&M Doc Ref: Rev: 1.0 Date: 15-10-14 Page: 2 of 13 Contents 1. PREVENTIVE, CORRECTIVE OR BREAKDOWN CONDITION -BASED MONITORING (CBM) MAINTENANCE .............3 1.1 PREVENTIVE MAINTENANCE (PM):......................................................................................................3 1.2 CORRECTIVE MAINTENANCE (CM) OR BREAKDOWN MAINTENANCE (BM): ...............................................................3 1.3 CONDITION-BASED MONITORING (CBM):...............................................................................................3 1.4 WARRANTY MANAGEMENT ..............................................................................................................3 1.5 SPARE PARTS INVENTORY MANAGEMENT ................................................................................................3 1.6 ON NORMAL BTS SITE REQUIRED MAINTENANCE.........................................................................................3 2. ON HYBRID BTS SITE ADDITIONAL REQUIRED MAINTENANCE ...............................................................3 2.1 ON SOLAR POWER BTS SITE ADDITIONAL REQUIRED MAINTENANCE ......................................................................3 2.2 OTHER CHALLENGES....................................................................................................................4 3. ON NORMAL BTS SITE REQUIRED MAINTENANCE...............................................................................4 3.1 DG MAINTENANCE......................................................................................................................4 4. DG PREVENTIVE MAINTENANCE....................................................................................................5 5. GENSET MAINTENANCE REPORT (FOUR COPIES)...............................................................................7 6. GENSET REFUELING REPORT (FIVE COPIES) ....................................................................................8 7. AMF & ATS PANEL ....................................................................................................................9 8. BTS SITE AND ENVIRONMENTAL ALARM SYSTEM...............................................................................9 9. RECTIFIER AND BBU..................................................................................................................9 10. SHELTERS & FENCES ............................................................................................................... 10 11. EARTH PITS .......................................................................................................................... 10 12. ON HYBRID BTS SITE ADDITIONAL REQUIRED MAINTENANCE ............................................................. 10 13. BATTERY BACKUP (CYCLE) AND GENERATOR CONTROLLER .............................................................. 10 14. STANDBY GENSET INSURANCE ................................................................................................... 11 15. ON SOLAR POWER BTS SITE ADDITIONAL REQUIRED MAINTENANCE .................................................... 11 15.1 DIFFERENT O&M SKILL SETS ....................................................................................................... 11 15.2 PV MODULES ...................................................................................................................... 11 15.3 INVERTER AND AC LOAD WIRING ................................................................................................... 11 15.4 STRUCTURES....................................................................................................................... 12 15.5 MOUNTING ........................................................................................................................ 12 15.6 GROWTH OF SHRUBS, TREES AND OTHER VEGETATION.............................................................................. 12 16. COMMUNICATION ................................................................................................................... 12 17. OTHER CHALLENGES............................................................................................................... 12 17.1 O&M BUDGET..................................................................................................................... 12 17.2 SKILLED MANPOWER ............................................................................................................... 12 17.3 LOCAL LABOUR .................................................................................................................... 12 17.4 AVAILABILITY OF WATER ON BTS SITE.............................................................................................. 12 17.5 THEFT ............................................................................................................................. 13 18. DOCUMENTATION................................................................................................................... 13 19. CONTACTS ........................................................................................................................... 13
- 3. O&M Doc Ref: Rev: 1.0 Date: 15-10-14 Page: 3 of 13 1. Preventive, Corrective or Breakdown Condition -Based Monitoring (CBM) Maintenance 1.1Preventive Maintenance (PM): Preventive or routine Maintenance (PM) which includes routine inspection and servicing of equipment which help prevent breakdowns and reduce energy yield losses. PM is usually a scheduled activity. 1.2Corrective Maintenance (CM) or breakdown Maintenance (BM): Includes repair of broken down equipment and is usually reactive. 1.3Condition-Based Monitoring (CBM): Involves monitoring of equipment condition and site operations on a real-time basis and addresses a potential problem at a very early stage to prevent downtime. This requires a robust site performance monitoring system. 1.4Warranty Management The O&M personnel should have a very clear understanding of the warranty terms from the suppliers. They also need to know the type of defects or problems that are covered under warranty. The duration of the warranty and also the key personnel from the supplier with who warranty claims can be taken up and enforced in a timely manner. 1.5Spare Parts Inventory Management The inventory management is critical because this could increase or decrease the cost of the O&M as well as the working capital requirement. It is also essential for the timely completion of the different types of maintenance. The O&M personnel should know very clearly the list of the spare parts available, their quantity at the site warehouse and the lead times for delivery of spare parts from the suppliers. 1.6On Normal BTS site required maintenance 1. DG Maintenance 2. AMF & ATS Panel 3. BTS site and Environmental Alarm System 4. Shelters & Fences 5. Earth Pits 2. On Hybrid BTS site additional required maintenance 1. Battery backup (cycle) and Generator controller 2. Standby Genset Insurance 2.1On Solar power BTS site additional required maintenance Maintenance is important for improving the performance of the solar power plant. Different O&M skill sets PV Module Inverter and AC load wiring Structure Mounting Growth of shrubs, trees and other vegetation Communication
- 4. O&M Doc Ref: Rev: 1.0 Date: 15-10-14 Page: 4 of 13 2.2Other Challenges O&M Budget Skilled manpower Local labour Availability of water on BTS site Theft Documentation 3. On normal BTS site required maintenance 3.1DG Maintenance First level maintenance for DG Diesel filling Battery charger(Electrical & Mechanical) Battery voltage Level of distilled water in the secondary cells Battery terminals grease lubrication coating. Running hours reading meter Oil filter Fuel filter Air filter DG inside wiring DG belt status Radiator leakage Radiator water level Cooling fan All lock in Genset like Door locks, Fuel tank lock Built in AMF Emergency stop switch Fuel solenoid Fuel pump and nozzles Frequency and speed adjust system AVR card
- 5. O&M Doc Ref: Rev: 1.0 Date: 15-10-14 Page: 5 of 13 4. DG Preventive Maintenance Maintenance Items Service Time Serial Number Name On refueling/ per visit Monthly /After 240 hours After 6 months After 1 year 1 General inspection & cleaning * 2 Radiator leakage * 3 Radiator Water level * 4 DG Temperature * 5 Cooling fan & cooling system * 6 Air filter cleaning * 6 DG exhaust system and thermo pore insulation * 7 Battery charger(Electrical & Mechanical) * 8 Battery voltage * 9 Level of distilled water in the secondary cells * 10 Battery terminals & insulation * 11 Oil level * 12 Oil filter * 13 Oil thickness and color * 14 Oil change * 15 Fuel level * 16 Fuel filter * 17 Fuel solenoid Test Test Test * 18 Fuel pump and nozzles Test Test Test * 19 Manual or lifting fuel pump Test Test Test * 20 Emergency stop switch Test Test Test Test 21 Frequency and speed adjust system Test Test Test Test 22 AVR card and field control Test Test Test Test 23 Phase to phase and neutral to phase voltages *
- 6. O&M Doc Ref: Rev: 1.0 Date: 15-10-14 Page: 6 of 13 24 Alternator and Alternator three pole breaker * 25 DG Earth & grounding Housing , Engine * 26 Fuel tank leakage * 27 Water in fuel tank Test Test * 28 Built in AMF /LCD/Fuses /connecters * 29 Control wiring & Alarm and safeties ,Not joint always use new wire * 30 Ignition and starter Test Test Test * 31 Remote start and stop *
- 7. O&M Doc Ref: Rev: 1.0 Date: 23-10-14 Page: 7 of 13 5. Genset Maintenance Report (four copies) 1. Site (Attached with Genset) 2. Customer copy 3. Account copy 4. Stores copy Genset Maintenance Report Site ID: Site Name: Genset Model:________ Rating : Date Genset Running hours Battery water level Battery /charger status Oil filter Fuel filter Air filter Engine Oil litter Load Balanced L1,L2,L3 Next service date DG/DG Belt Status Team lead Name & cell Number
- 8. O&M Doc Ref: Rev: 1.0 Date: 23-10-14 Page: 8 of 13 6. Genset Refueling Report (Five copies) 1. For Fuelling team 2. Customer copy 3. Account copy 4. Store copy 5. Vendor copy(Gas station or oil company) Genset Refueling Report Site ID: Site Name: Genset Model:________ Rating : Fuel average per hour :___________ Load:L1:____Amp,L2:________Amp L3:_______Amp Date Genset Running hours Fuel in tank before fuelling(Liters) Refueling (Liters) Total Liters Next fuelling date Vendor Name & cell Number Customer Name & cell Number Store Name & cell Number Team lead Name & cell Number
- 9. O&M Doc Ref: Rev: 1.0 Date: 23-10-14 Page: 9 of 13 7. AMF & ATS Panel Main power wire connection before PMT Main power wire connection After PMT Fuses before Power meter SPD RCCB for utility socket Grounding & earth level ,connection for PMT ,Power meter box, ATS, ACDB Ground and Earth bonding on PMT Neutral to ground voltages All wire connections for input/output terminal blocks , input/output breakers, MCCB, GENSET MCB ,Main MCB ,all Timers and relays, Manual bypass switches and AMF Proper setting on AMF All main on/off ,phase fail ,under voltage and over voltage .All Genset frequency, L-N voltages, Remote stop and start and automatic load shifting test Manual bypass switches Tower Light controller and tower lights Tight all screws and every wire on every visit UPS & Inverter 8. BTS site and Environmental Alarm System Order wire Follow up for alarms Low fuel DG fail DG on load DG high temp Mains fail alarm Line fail alarm Fire alarms Door open alarm Humidity and flood Smoke alarm 9. Rectifier and BBU Maximum .9 ohm resistance and .9v between neutral to ground voltages in ACDB for Rectifier cabinet No lose connection on three phase power, neutral and ground in ACDB for rectifier No joint in AC power cable for rectifier No lose connection on three phase power, neutral and ground terminal block in rectifier cabinet Clear all alarms on rectifier module and MCU Check DC grounding Check all string charging current ,almost equal required Check that the Battery voltages in every string are equal during discharging.
- 10. O&M Doc Ref: Rev: 1.0 Date: 23-10-14 Page: 10 of 13 Battery/Rectifier Performance report Site ID: Site Name : Date:_____________ Rectifiers Model/capacity: Number of Rectifiers:______________ Rectifies floating voltages :_______VDC Battery Make/capacity: __________/________Number of Battery Strings:__________ Number Name 1 2 3 4 Physical Status Test by Rectifier status Battery string 1 ____V ____V ____V ____V Battery string 2 ____V ____V ____V ____V Battery string 3 ____V ____V ____V ____V Battery string 4 ____V ____V ____V ____V Battery string 5 ____V ____V ____V ____V AC voltages /Current LI___ Vac L2____ Vac L3____ Vac L1____ Amp L2____ Amp L3___ Amp 10. Shelters & Fences Earth and grounding for shelter, fences and tower legs Lightning rods and Grounding system Shelter security lights Grease lubrication on all connections on Grounding bar Pad lock status Security of site Stop growth of shrubs a, other vegetation and Trees in site. Site cleaning for paper, wrapping cartons, cleaning clothes, used oil etc 11. Earth Pits The Conventional system of Earthing means digging of a large pit into which a GI pipe or a copper plate is positioned in the middle layers of charcoal and salt. It requires pouring of water at regular interval (every visit). On Hybrid BTS site additional required maintenance 12. Battery backup (cycle) and Generator controller Now day’s hybrid system is used frequently on BTS sites by operator companies for fuel and refuelling Genset cost saving and backup batteries utilization .This system has these major parts. Control unit For batteries status monitoring and Genset stop &start Control wiring Controller power, current sensors, Genset remote start stop control command, NOC alarms and communication cables
- 11. O&M Doc Ref: Rev: 1.0 Date: 23-10-14 Page: 11 of 13 Communication Communication through GPRS or data modem, SIM activation, modem antenna 13. Standby Genset Insurance Hybrid control sites are very difficult to maintain and 100% uptime comparatively non hybrid site because if Genset fail to site to start after BTS back battery utilization than site must down before team arrival on site. A fully fit Genset is only solution Check remote start and stop cable Genset battery charger Fuel solenoid AMF auto mode ATS in auto mode All breakers for rectifier AC power will be on 14. On Solar power BTS site additional required maintenance 14.1 Different O&M skill sets A solar PV power plant has several components and each of the sub-system requires different O&M skill sets. A few of the sub-systems and their O&M requirements are mentioned below. 14.2 PV Modules The PV module yield from the module is highly dependent on the cleaning of the panels. In the dusty environments of country the cleaning frequency has to be quite high. Cleaning with house water pipes No clean or duster allow No detergent and other clean chemical is allow 14.3 Inverter and AC load wiring PV plant is a DC power source so there need to use inverter to drive AC load on BTS site like board (tower) light, security lights etc. Inverter is a major part of PV plant and it based on pure electronics and expansive components, so they need protection from: Extreme hot Humidity dusty conditions There many factors involve to burn or damage an inverter like: short circuit in load overload Reverse polarity on input So team need to check on every visit: Cooling fans Cabinet air filter Battery connections Inverter Input breaker Load status Load wiring test carefully Earthing protection
- 12. O&M Doc Ref: Rev: 1.0 Date: 23-10-14 Page: 12 of 13 Luckily there is no outage chance on BTS site due to inverter failure because BTS load run on DC batteries directly through rectifier MCU. 14.4 Structures Bending of the structures can happen due to the improper design, losing, rust, unaddressed wires. This bending can damage the modules. 14.5 Mounting Rain is the reason to wash away top soil due to improper drainage system or poor foundation of structure. Caving of the foundation and the structures caused by improper compaction of the ground has also been observed. A pro- active O&M team can address this by visual inspection and take preventive action on every visit especially before rains. 14.6 Growth of shrubs, trees and other vegetation They will grow very tall and will cause shadowing effect on the panels. Snakes and other poisonous reptiles might make these shrubs their home and can cause safety hazard to the workers. 15. Communication For solar power plant working, efficiency, batteries charging, backup, load current, remote start & stop, Genset running and other parameters NOC always need reliable communication infrastructure known as Remote monitoring system (RMS) .Now days RMS is the backbone of O&M for early alarms to save the BTS site from outages. Remote monitoring systems need an internet or GPRS connection and in the absence of a reliable connection, there could be problems of lack of data logging for long periods of time. This makes it very difficult to diagnose and rectify problems in a timely manner. It is need to check on every visit. GPRS Antennas Communication ports Dry contacts Transducers Power supplies and backup batteries 16. Other Challenges According to our experience and which we learnt and in telecom industry, we have come across some of the problems which are very severe. 16.1 O&M Budget Typically, the O&M budgets are very limited for various reasons. 16.2 Skilled manpower Since the O&M involves people who have the skills in electrical and electronics engineering, it is a challenging task to get people to move to such remote locations to work. 16.3 Local Labour In regions, local teams need to be employed for O&M. While this is a noble objective and also is important for the economic development of local communities, in some cases the locals form unions and demand wages that make the O&M cost to go very high .Continuously shuffling of team members and deployment of team leads from other part country is a solution. 16.4 Availability of water on BTS site For PV panels require cleaning. In case of the Site is located in arid regions with very little availability of water.
- 13. O&M Doc Ref: Rev: 1.0 Date: 23-10-14 Page: 13 of 13 16.5 Theft Theft of materials (even PV panels) is rampant. This can be prevented by having a good security system and a good inventory management system. 17. Documentation Log books for the events, alarms, another maintenance issues and complete detail of site maintenance with every team can help the O&M personnel to identify, diagnose and trace the problems. 18. Contacts NAME ROLE NUMBER EMAIL ADRESS O&M TEAM Customer TEAM