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Document Title:
Power Distribution Panel - Maintenance Manual
Doc No: NS01-R-SIG-14-0009 Title: Power Distribution Panel - Maintenance Manual Page 1 of 57
Revision: 02
NOIDA - Greater NOIDA Metro Rail Project
20-03- Anurag
00 2018
Chandrasekaran.R.M
Aggarwal
R.E.Baker First Issue
Doc No: NS01-R-SIG-14-0009 Title: Power Distribution Panel - Maintenance Manual Page 2 of 57
Revision: 02
NOIDA - Greater NOIDA Metro Rail Project
Table of Contents
1 INTRODUCTION .......................................................................................................... 7
1.1 Purpose ................................................................................................................. 7
1.2 Applicability............................................................................................................ 7
1.3 Document References ........................................................................................... 7
1.3.1 Project Submittals .......................................................................................... 7
1.3.2 Other References ........................................................................................... 7
1.4 Description Of Changes From The Previous Revision .......................................... 8
1.5 Terms, Acronyms and Abbreviations ..................................................................... 8
1.5.1 Acronyms ....................................................................................................... 8
1.6 Symbol Description.............................................................................................. 10
2 SAFETY AND HEALTH REQUIREMNETS ................................................................ 11
2.1 General Safety and Health Requirement ............................................................. 11
2.2 Work Permit System ............................................................................................ 12
3 POWER DISTRIBUTION PANEL PDP-1.................................................................... 13
3.1 PDP-1 .................................................................................................................. 13
3.2 PDP-1 Rack and Sub-Systems............................................................................ 13
3.3 Isolation Transformer........................................................................................... 14
3.4 Step Down Transformer ...................................................................................... 14
3.5 PDP-1 AC Power Distribution .............................................................................. 14
3.6 PDP-1 Rack Sub – Assembly Modules: .............................................................. 15
3.7 PDP-1 Rack Front View ....................................................................................... 16
3.8 General................................................................................................................ 16
3.9 PDP-1 Front View ................................................................................................ 16
3.10 PDP-1 Rear View ................................................................................................ 18
4 POWER DISTRIBUTION PANEL PDP - 2.................................................................. 20
4.1 PDP-2 .................................................................................................................. 20
4.2 AC Power Distribution Panel - 230 V AC ............................................................. 20
4.3 AC Power Distribution PANEL - 415 V AC .......................................................... 21
4.4 AC to DC Convertors ........................................................................................... 21
4.5 AC to DC Convertors and Power distribution ...................................................... 21
4.6 Power Distribution panel PDP-2 FRONT View .................................................... 22
4.7 General................................................................................................................ 22
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Revision: 02
NOIDA - Greater NOIDA Metro Rail Project
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NOIDA - Greater NOIDA Metro Rail Project
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NOIDA - Greater NOIDA Metro Rail Project
List of Tables
List of Figures
Doc No: NS01-R-SIG-14-0009 Title: Power Distribution Panel - Maintenance Manual Page 6 of 57
Revision: 02
NOIDA - Greater NOIDA Metro Rail Project
1 INTRODUCTION
1.1 PURPOSE
The purpose of this document is to provide the Maintenance Manual for AC Power
Distribution Panel and AC-DC Power Distribution Panel deployed in Noida Metro Rail
Project.
1.2 APPLICABILITY
This document is applicable to the Power Distribution Panel that is supplied for Noida
Metro Railway system.
1.5.1 Acronyms
The following table provides definitions for terms, acronyms and abbreviations relevant to
this document.
Terms Definition
AC Alternate Current
AC PDP Alternate Current Power Distribution Panel
AC–DC PDP Alternate Current & Direct Current Power Distribution Panel
ASTS Ansaldo STS
AXC Axle Counter
ATS Automatic Train Supervision
CBTC Communication Based Train Control
DC Direct Current
DMRCL Delhi Metro Rail Corporation Limited
ELD Earth Leakage Detector
EXT External
HV High Voltage
INT Internal
IR Insulation Resistance
LED Light Emitting Diode
MCB Miniature Circuit Breaker
Terms Definition
MCCB Moulded Case Circuit Breaker
MLK Microlok
MOHM Mega ohm
N/A Not Applicable
NR Not Required
NS01 NOIDA-Greater NOIDA Metro Rail Project
OCC Operational Control Centre
PDB Power Distribution Box
PDP Power Distribution Panel
PS Power Supply
SCR Station Control Room
SER Station Equipment Room
SMR Signal Maintenance Room
SPD Surge Protection device
SYS System
UPS Uninterruptible Power Supply
V Voltage
Symbols Description
DANGER
Death or Serious injury will occur if you do not take the precautions
described.
CAUTION
Symbol and text indicate important instructions and /or user
information. Failure to comply with these instructions may impair
the availability of the system and, as a direct result and/or
combined with noncompliance with other instructions or errors have
a negative impact on safety.
WARNING
Symbol and text indicate important instructions to be followed.
Failure to comply with these instructions may impair the availability
of the system and, as a direct result and/or combined with
noncompliance with other instructions or errors have a negative
impact on safety
NOTICE
Damage or an undesirable result or state may occur if you do not
take the precautions described.
ELECTRICAL HAZARD
Electrocution or shock due to electrical live component.
DANGER
Death or Serious injury will occur if you do not take the precautions
described.
3 POWER DISTRIBUTION
DISTRIBUTION PANEL PDP-
PDP-1
3.1 PDP-1
The PDP (Power Distribution Panel) is the source of supply for all signalling and Train
control systems in Noida Metro Railway System. The Input Power supply to PDP-1 is
drawn from two independent power supply sources from state Grid. The State Grid Power
Supply is from two independent feeders and the power supply from supply feeders are
connected to the UPS-1 and UPS-2. The PDP-1 input Power supply is from two
independent UPS systems. The PDP-1 Rack is installed at the UPS Room. This Rack
PDP-1 is also referred as AC-PDP.
The PDP-1 rack installation locations at Noida Metro Railway are given below.
• Depot
• Depot Station
• Parichowk
• Sector 144
• Sector 142
• Sector 81
• Sector 71
It is to be noted that AC-PDP installed at the stations mentioned above may varry in PDP
lay out and ratings of the transformers used. The PDP Maintenance Manual covers and
explains the common engineering principle adopted through out the Noida Metro Project.
For restoration of PDP failures NMRC Maintenance Personal are advised to Refer Station
based PDP Layout drawings.
• AC – DC Convertor Modules
• Fuse Links
The Isolation Transformer provides isolation of common neutral return path to state grid.
The Isolation Transformer is mounted at the bottom of the PDP-1 rack.
Sub-assembly Description/Function
A circuit breaker is an automatically operated electrical switch
Circuit Breaker designed to protect an electrical circuit from damage caused
by overload and short circuit.
A surge protector device is used to protect electrical and
Surge Protection Device electronic devices from high voltage spikes entering the power
supply.
A current transformer can be used to provide an isolated lower
current in its secondary which is proportional to the current in
Current Transformer the primary circuit. It is used to Monitor current flow in the
electrical circuit. There are three current transformers in the
rack
Isolation Transformer 415 V / 415 V for Point Machine
To eliminate common Neutral in Electrical Connections, and to
Isolation Transformer
establish BX 230 and NX 230, BX 110 and NX 110.
3.8 GENERAL
Various general views of Power Distribution Panel PDP-1 cabinets are shown below. The
reference drawing is Depot PDP-1 Layout Drawing Number: NS01-G –SIG-9-0033 Sheet:
AC 2. The actual architecture of PDP may vary for different locations and stations as per
the requirement.
4.1 PDP-2
The PDP-2 rack also referred as AC-DC PDP (AC-DC Power Distribution Panel) is the
source of supply for all signalling and Train control systems. The Input supply to PDP-2
rack is extended from PDP-1 rack.
The PDP-2 rack is installed at the following interlocking station locations listed below.
• Depot
• Depot Station
• Pari Chowk
• Sector 144
• Sector 142
• Sector 81
• Sector 71
AC-DC PDPs are installed at SER (Station Equipment Room). The arrangement in the AC-
DC PDP can be sub dived into two major areas in power supply distribution. This break up
is for our better understanding of the PDP.
• AC Power Supply Distribution.
• AC to DC conversion and DC Power Supply Distribution
It is to be noted that PDP-2 installed at the stations mentioned above May vary in PDP lay
out. The PDP Maintenance Manual covers and explains the common engineering principle
adopted throughout the Noida Metro Project.
For restoration of PDP-2 failures NMRC Maintenance Personal are advised to refer Station
based PDP-2 Layout drawings.
4.4 AC TO DC CONVERTORS
The AC to DC convertors is of modular type Dc power supply units, and the input voltage
to the unit is 230 V AC and the output is DC. The units are of Plug in Type and the
modules can easily be replaceable without disconnecting the running power of working
equipment.
4.7 GENERAL
Various general views of Power Distribution Panel PDP-2 cabinets are shown below. The
reference drawing is Depot PDP-2 Layout Drawing Number: NS01-G –SIG-9-0033 Sheet:
AC 12.The actual architecture of PDP may vary for different locations as per the
requirement.
Figure 8 ELD and 230 V AC Distributions (Row-5, Row-T3, and Row –T4)
5.5 GENERAL
Various general views of Power Distribution Panel AC – DC cabinets are shown below.
The reference drawing is Sector-50 AC/DC PDP Layout Drawings NS01-G –SIG-9-0013
Sheet: AC 2.The actual architecture of PDP may vary for different locations as per the
requirement.
6 CORRECTIVE MAINTENANCE
MAINTENANCE AND TROUBLESHOOTING
TROUBLESHOOTING PROCEDURES
6.1 INTRODUCTION
The purpose of this section is to provide troubleshooting procedure for Power Distribution
Panel. This document briefly explains the methods of fault rectification during run of PDP.
It guides personal to troubleshoot errors or electrical faults in PDP, ensuring smooth run of
the unit.
DANGER
Death or Serious injury will occur if you do not take the precautions
described.
ELECTRICAL HAZARD
Electrocution or shock due to electrical live component.
2. Check availability of correct drawings, bill of material, manuals, etc. before start of
troubleshooting procedure.
3. Check the unit if it is cleaned regularly, if not clean the dust.
4. Presence of authorized personal is required in case of any shutdown needed.
Proper permission must be taken before shutdown.
5. Follow all the safety precautions and wear safety gears.
Reset MCB
MCB –on, MCB-off, MCB-on
Observe that the tripped MCB after reset operation never trips again within 15
minutes.
If you observe the MCB is stable and never trips, the Fault is restored. Record this event in
failure register and inform the concerned Authorities in your organization.
• If anything observed, shutdown corresponding switches and re-wire or refurbish Lamp wiring
• Replace it if fault observed.
Corrective • Check supply voltage at the input terminals of the Lamps. If not ok check wiring and terminations.
Action
•Power supplies are provided with LED Display indicating output voltage and current values. If any of the DC
power source is not working then,
Faults in AC-DC
Convertors
• First check complete wiring of the DC Power supply section for any damage, shorting, loose wiring, and
loose termination
•Then check input supply MCB for any tripping due to over current or overvoltage. Reset the MCBs (i.e. reset
supply power). Check output voltages of the DC power supply verify with the test reports. Check display
Corrective readings.
Action •Check output fuse if it is blown, replace it with proper ratings.
•If problem still persists (due to internal damage), contact manufacturer for replacement or repair of the unit.
Restoration
Faults in •If power to any of the workstation/equipment fails due to failure of the MCB then,
MCB/MCCB
•First check wiring of the respective workstation for any damage due to bending, loose
Corrective termination, lugging etc. If observed rewire it. Also observe if any mechanical damage.
Action •Check ratings of the MCBs matching with the specified ratings of the system.
•If the device is burn out due to excess load, replace it with higher ratings as required.
Record of changes/maintenance log should be maintained in such cases.
Restoration
7 PREVENTIVE MAINTENANCE
MAINTENANCE AND SERVICING INSTRUCTIONS
INSTRUCTIONS I
DANGER
Death or Serious injury will occur if you do not take the precautions
described.
ELECTRICAL HAZARD
Electrocution or shock due to electrical live component.
7.4 MONTHLY
Remove the dust from the cabinet with vacuum cleaner. Clean the complete equipment
Check that all the meters (Voltmeters, Ammeters, etc.) are showing appropriate values
Inspect all devices periodically to ensure that the equipment is in proper working order
Check tightness of connections and fitments
7.5 QUARTERLY
Monitor and record input voltages respective phase input currents, DC power supply
voltages and output currents of PDP.
7.7 YEARLY
a) Inspect all wiring for wear and cuts
b) Inspect power and control contacts of MCBs, MCCBs, changeover switches, Surge
Protection devices and Transformer connections, etc. Replace the worn
out/defective contacts/devices.
c) Inspect all auxiliary and control circuits for desired functioning
d) Check gasket of the door
2 Dust Cleaning √
Insulation Resistance
3 √
Test
4 Input MCCB/MCB √
5 Changeover Switches √
6 Lamps √ √
7 Meters √ √
8 Transformers √ √
9 Power Supplies √ √
10 Filters √
12 Earthing √
13 Fan Tray √
Voltage)
Voltage at 415VAC
Power OFF panel.
Power Indication
Reverse the phase
Outgoing Terminals
sequence by
is 0V AC and
23 interchanging the R with
Corresponding PAC
Y phase. (Interchange
OK Indication
any two Phases). Switch
disappears from NV
on the panel.
Board.
Voltage at 415VAC
Power Indication
Power OFF panel. Outgoing Terminals
Remove R phase wire is 0V AC (and
24
from L1 terminal of VMR. Corresponding PAC
Switch ON the panel. OK Indication
disappears from NV
Board.)
Voltage at 415VAC
Power Indication
Outgoing Terminals
Repeat Test 3.22 for Y & is 0V AC (and
25
B phase also. Corresponding PAC
OK Indication
disappears from NV
Board.)
Voltage at the
Check Voltage at PD Output of PD
26
terminals of ELD Terminals of ELD is
110 ± 8%.V AC.
Check Voltage at
Voltage at the
Outgoing 230V AC power
27 output Terminal is
Alarm Indication
230 ± 5%. V AC
Terminals.
Open Corresponding
Fuse or Negative link of Voltage at the
supply feeding to 110V output Terminal is
28 AC power Alarm 0V AC. ( BX AC OK
Indication Terminals. bit at NV Board
(Restore after noting Disappears)
down the voltage)
Check Voltage at Voltage at the
29 Outgoing 110V DC power output Terminal is
Alarm Indication 110 ± 8%.V DC.
Terminals.
Open Corresponding
Fuse or Negative link of Voltage at the
supply feeding to 110V output Terminal is
30 DC power Alarm 0V DC. ( BX DC OK
Indication Terminals. bit at NV Board
(Restore after noting Disappears)
down the voltage)
Switch off Power supply Voltage at the
1. Check Voltage at output Terminal is
31 Outgoing 110V DC power 0V DC. ( BX DC OK
Alarm Indication bit at NV Board
Terminals. Disappears)
Restore supply at PS1
and Switch off Power
supply 2&3 one by one &
Voltage at the
Check Voltage at
output Terminal is
Outgoing 110V DC power
32 0V DC. ( BX DC OK
Alarm Indication
bit at NV Board
Terminals. ( Restore the
Disappears)
power supply
connections after noting
down the voltage)
Measured voltage is
Check Voltage at PD expected as 415V
terminals feeding supply AC ±2%V AC (3-
33
to Power Distribution Box phase) 230V
in SMR AC±5%.(Phase
Voltage)
Measured voltage is
Check Voltage at PD expected as
terminals feeding supply 415VAC ±2%V AC
34
to Power Distribution Box (3-phase) 230V
in SCR AC±5%.(Phase
Voltage)
8 PREVENTIVE MAINTENANCE
MAINTENANCE AND SERVICING INSTRUCTIONS II
8.3 MONTHLY
a) Remove the dust from the cabinet with vacuum cleaner. Clean complete equipment.
b) Check that all the meters (Voltmeters, Ammeters, etc.) are showing appropriate
values.
c) Inspect all devices periodically to ensure that the equipment is in proper working
order.
d) Check tightness of connections and fitments
e) Clean filters
8.4 QUARTERLY
a) Monitor and record input voltages and respective input currents, DC bus voltages
and output currents of PDP
8.6 YEARLY
a) Inspect all wiring for wear and cuts
b) Inspect power at all the MCBs and replace warn out contacts
c) Inspect all auxiliary and control circuits for desired functioning
d) Check gasket of the door
e) Check functioning of Earth Leakage Detector (ELD)
Half
Sr. No Checkpoints Monthly Quarterly Yearly
Yearly
1 Visual Checks √
2 Dust Cleaning √
Insulation Resistance
3 √
Test
4 Meters √ √
5 DC-DC Converters √
6 Filters √
8 Earthing √
10 Fan Tray √
Measured
Test Activity Expected Results Pass /Fail Remarks
Results
Check the continuity The buzzer should
between the earth stud Beep in the Multi-
1
at AC-DC PDP Rack and meter.
room earth
Check the potential The potential
difference between the difference between
earth and neutral of the earth and neutral
2
AC-DC PDP Rack of AC-DC PDP
Rack should be
less than 1 volt.
Locate the incoming
circuit breakers of the
Power Circuit breakers
3 Distribution Panel (PDP). are in the off
Ensure that all circuit position.
breakers are in the off
position.
With the circuit breakers
in the off position,
Measure and verify the Measured voltage
4 input voltage at all input is expected as 415
circuit breaker of the AC V AC.
Power Distribution Panel
(PDP).
Turn on all the Input
circuit breakers of the
Measured voltage
Power Distribution Panel
5 is expected as 415
(PDP)
V AC.
Measure Voltage at the
Output of Circuit breaker.
Check Readings at Voltmeter and
6
Voltmeter & Ammeter Ammeter Displays