STANDARD OPERATING PROCEDURE

Form No.: Form Rev. No.: 01 Effective date: 01.08.2015

SOP No. MUEM/CRM/BAF/SOP/4 Effective Date 01.4.2019 REVISION No 00

SOP DESC Maintenance of BAF Emerson UPS Section BAF/SPM/ECL/IEM

DEPARTMENT Mills & Utility Electrical Maintenance Page 1 of 12

Step Activity Associated Responsibility Process / tools / PPEs (HOW) Remarks / Reference
No. (WHAT) Requirements/ (WHO)
Hazards/ Impacts

1 General safety SAFETY : Safety Sr. Associate/ 1- Written clearance to be taken before starting the job from Refer to ESI document of
activities before appliances Associate/ JE/ appropriate authorities. respective area---
starting of job Unawareness Maint & 2- Safety induction training to be given to all workmen. BAF/SPM/ECL/MN
contractor 3- Brief description about hazards/safety measure to be given to BAY/CRM LAB/CTTS
supervisor all workmen at every morning before starting the job. MN BAY-
4- First aid box & display board to be kept at site. For UPS1-
5- Crane movement will be followed in site works. MCC1(A1)FDR#2F3
ENVIRONMENT: 6- All workmen will be use safety helmet, safety boot, safety For UPS2-
Dusty, CO gas,
Charged panel
P
goggles and other safety appliances properly.
7- Constant supervision will be there at site by the supervisor of

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cleaning contactor
PLTCM Aux Hyd MCC
FDR#9C

QUALITY: Carbon
copy should be

d S Follow Safety standards:

For foot protection

clear and 6-
directional Hazard
inform.
a l i -SS/GEN/04
For hand protection
-SS/GEN/05

V For eye protection

-SS/GEN/06
For head protection
-SS/GEN/07
For loose clothing
-SS/GEN/02

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PREPARED BY APPROVED BY

d S
Name and Desig.: D.K.MISHRA SR.ASSOCIATE CRM Name and Desig.: R.K.Sachan. Sr. Manager CRM

a l i
V
Signature with Date: Signature with Date:

Printed By -NEERAJ KUMAR(506757) Print valid till - 28-Jun-2020 Printed on - 18-Jun-2020 SOP Valid Till - 01-Jul-2020
STANDARD OPERATING PROCEDURE
Form No.: Form Rev. No.: 01 Effective date: 01.08.2015
SOP No. MUEM/CRM/BAF/SOP/4 Effective Date 01.4.2019 REVISION No 00

SOP DESC Maintenance of BAF Emerson UPS Section BAF/SPM/ECL/IEM

DEPARTMENT Mills & Utility Electrical Maintenance Page 2 of 12

Step Activity Associated Responsibility Process / tools / PPEs (HOW) Remarks / Reference
No. (WHAT) Requirements/ (WHO)
Hazards/ Impacts

2 Taking work permit SAFETY: Without Sr. Associate/ Obtain work permit from Deptt. in form
from Departmental work permit job Associate/ JE/ EHSMSM/WORKS/446/4007 and return the permit after leaving
maintenance should not start. Maint. & the job in daily basis.
authority See & check all six contractor
direction of the supervisor
maintenance field
area
ENVIRONMENT: Sr. Associate/ Give field training and awareness of safety of the job to all people
Live panels around
UPS panel
Associate/ JE/
Maint. &
contractor
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involved in the job. Six direction form should be filled up.

supervisor

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i
QUALITY: All Sr. Associate/ Work permit should be filled up correctly and signed by authorized
permit form should Associate/ JE/

a l
be filled up properly Maint. Assit. &
contractor
person.

3 Checking
condition of
UPS
SAFETY:
a.Electric shock
b. Falling from
V
supervisor
Sr. Associate/
Associate/ JE
& contractor
1- inform the respective area electrical Sr. Associate/
Associate/ JE to take permission from him.
2- Use safety shoe and always it should be in dry condition.
staircase supervisor 3- Do not touch any switch or open wire of that Panel.
c. Slip/Trip/Fall 4- Use safety goggles

P
d. Finger Injury 5- Both UPS must be running in Normal operation.
ENVIRONMENT: 6- Check the input voltage using multimeter and current for
Dusty

PREPARED BY
balance check using clamp meter.

APPROVED BY S O
Name and Desig.: D.K.MISHRA SR.ASSOCIATE CRM Name and Desig.: R.K.Sachan. Sr. Manager CRM
l i d
Signature with Date: Signature with Date:

V a
Printed By -NEERAJ KUMAR(506757) Print valid till - 28-Jun-2020 Printed on - 18-Jun-2020 SOP Valid Till - 01-Jul-2020
STANDARD OPERATING PROCEDURE
Form No.: Form Rev. No.: 01 Effective date: 01.08.2015
SOP No. MUEM/CRM/BAF/SOP/4 Effective Date 01.4.2019 REVISION No 00

SOP DESC Maintenance of BAF Emerson UPS Section BAF/SPM/ECL/IEM

DEPARTMENT Mills & Utility Electrical Maintenance Page 3 of 12

Step Activity Associated Responsibility Process / tools / PPEs (HOW) Remarks / Reference
No. (WHAT) Requirements/ (WHO)
Hazards/ Impacts

QUALITY: All
cleaning
equipments
should be in good
quality and must
be in dry condition

O P
d S
a l i
V

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PREPARED BY APPROVED BY

d S
Name and Desig.: D.K.MISHRA SR.ASSOCIATE CRM Name and Desig.: R.K.Sachan. Sr. Manager CRM

a l i
V
Signature with Date: Signature with Date:

Printed By -NEERAJ KUMAR(506757) Print valid till - 28-Jun-2020 Printed on - 18-Jun-2020 SOP Valid Till - 01-Jul-2020
STANDARD OPERATING PROCEDURE
Form No.: Form Rev. No.: 01 Effective date: 01.08.2015
SOP No. MUEM/CRM/BAF/SOP/4 Effective Date 01.4.2019 REVISION No 00

SOP DESC Maintenance of BAF Emerson UPS Section BAF/SPM/ECL/IEM

DEPARTMENT Mills & Utility Electrical Maintenance Page 4 of 12

Step Activity Associated Responsibility Process / tools / PPEs (HOW) Remarks / Reference
No. (WHAT) Requirements/ (WHO)
Hazards/ Impacts

4 Cleaning of UPS SAFETY: Sr. Associate/ 1- Ensure the Section is electrically isolated before start
a.Electric shock Associate/ JE/ the job either by Shutdown or transferring the Load to
b. Falling from Maint. Assit. & other section of the UPS System. Only Trained and
staircase contractor Qualified engineers are allowed to do this activity as
c. Slip/Trip/Fall supervisor power terminal will be live.
d. Finger Injury 2- Use of dust mask, gloves, goggles and safety helmet.
3- Cleaning by Proper insulated brush.
ENVIRONMENT: 4- Use insulated body or properly earthed vacuum
Dusty

QUALITY: All P
cleaner/hand blower.

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cleaning
equipments
should be in good

d S
5 Battery
quality and must
be in dry condition
SAFETY:
a l i
Sr. Associate/ 1- Switch off the rectifier of both the ups system
backup test a.Electric shock ,
Use insulated
handgloves.
b. Falling from
V
Associate/ JE/
Maint. Assit. &
contractor
supervisor
2- Check at display of the UPS that battery is in on
load condition.
3- If battery is on load then Do battery backup test for
10/15 minutes minimum.
staircase 4- Ups operating range in dc voltage mode must be
c. Slip/Trip/Fall allowed from 405V/393V dc to 315V/305V.
d. Finger Injury

ENVIRONMENT:

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PREPARED BY APPROVED BY

d S
Name and Desig.: D.K.MISHRA SR.ASSOCIATE CRM Name and Desig.: R.K.Sachan. Sr. Manager CRM

a l i 1. Nuprin Tube
2. Roller

V
Signature with Date: Signature with Date: 3 Electrical Motor.
4. Operation of pump
Printed By -NEERAJ KUMAR(506757) Print valid till - 28-Jun-2020 Printed on - 18-Jun-2020 SOP Valid Till - 01-Jul-2020
STANDARD OPERATING PROCEDURE
Form No.: Form Rev. No.: 01 Effective date: 01.08.2015
SOP No. MUEM/CRM/BAF/SOP/4 Effective Date 01.4.2019 REVISION No 00

SOP DESC Maintenance of BAF Emerson UPS Section BAF/SPM/ECL/IEM

DEPARTMENT Mills & Utility Electrical Maintenance Page 5 of 12

Step Activity Associated Responsibility Process / tools / PPEs (HOW) Remarks / Reference
No. (WHAT) Requirements/ (WHO)
Hazards/ Impacts

Dusty
QUALITY: All
cleaning
equipments
should be in good
quality and must
be in dry condition
6 Battery bank SAFETY: Sr. Associate/ 1.Switch off the rectifier of both the UPS system
individual cell
voltage check
a.Electric shock
b. Falling from
staircase
Associat JE &
contractor
supervisor P
2. Check for UPS in battery on load condition.
3. Check individual battery terminal voltage on battery load
condition.
O
c. Slip/Trip/Fall
d. Finger Injury

d S
4.If battery voltage goes below 10.5v for SMFB or 1.1 in case of
Ni-Cd with respect to other battery then replace the faulty
battery
ENVIRONMENT:
Dusty
QUALITY: All
a l i 4. Verify the charging current for 10 % to 15% of battery ah
capacity during charging condition.

cleaning
equipments
should be in good
quality and must
V
be in dry condition

7 Changing of SAFETY: a.Electric Sr. Associate/ 1. Component /PCB changing must be done after shutdown of the
control
PCB/Component
shock
b. Falling from
Associate/ JE/
Maint. Assit. &
UPS on maintenance bypass operation.
2. Use proper tools.

O P
PREPARED BY APPROVED BY

d S
Name and Desig.: D.K.MISHRA SR.ASSOCIATE CRM Name and Desig.: R.K.Sachan. Sr. Manager CRM

a l i
V
Signature with Date: Signature with Date:

Printed By -NEERAJ KUMAR(506757) Print valid till - 28-Jun-2020 Printed on - 18-Jun-2020 SOP Valid Till - 01-Jul-2020
STANDARD OPERATING PROCEDURE
Form No.: Form Rev. No.: 01 Effective date: 01.08.2015
SOP No. MUEM/CRM/BAF/SOP/4 Effective Date 01.4.2019 REVISION No 00

SOP DESC Maintenance of BAF Emerson UPS Section BAF/SPM/ECL/IEM

DEPARTMENT Mills & Utility Electrical Maintenance Page 6 of 12

Step Activity Associated Responsibility Process / tools / PPEs (HOW) Remarks / Reference
No. (WHAT) Requirements/ (WHO)
Hazards/ Impacts

staircase contractor
c. Slip/Trip/Fall supervisor
d. Finger Injury

ENVIRONMENT:
Dusty

QUALITY: All
cleaning equipments
should be in good
O P
quality and must be
in dry condition

d S
i
8 Checking of SAFETY: Sr. Associate/ 1. Check the battery charging current in battery bank by Clamp
Battery charging
current of both
UPS
a.Electric shock
b. Falling from
staircase l
Associate/ JE/

a
Maint. Assit. &
contractor
meter in dc mode.
2. Verify the total charging current for 10 % to 15% of battery ah
capacity.
c. Slip/Trip/Fall
d. Finger Injury
ENVIRONMENT:
Dusty
V
supervisor

QUALITY: All
cleaning
equipments
should be in
good quality and

O P
PREPARED BY APPROVED BY

d S
Name and Desig.: D.K.MISHRA SR.ASSOCIATE CRM Name and Desig.: R.K.Sachan. Sr. Manager CRM

a l i
V
Signature with Date: Signature with Date:

Printed By -NEERAJ KUMAR(506757) Print valid till - 28-Jun-2020 Printed on - 18-Jun-2020 SOP Valid Till - 01-Jul-2020
STANDARD OPERATING PROCEDURE
Form No.: Form Rev. No.: 01 Effective date: 01.08.2015
SOP No. MUEM/CRM/BAF/SOP/4 Effective Date 01.4.2019 REVISION No 00

SOP DESC Maintenance of BAF Emerson UPS Section BAF/SPM/ECL/IEM

DEPARTMENT Mills & Utility Electrical Maintenance Page 7 of 12

Step Activity Associated Responsibility Process / tools / PPEs (HOW) Remarks / Reference
No. (WHAT) Requirements/ (WHO)
Hazards/ Impacts

must be in dry
condition

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9 Cleaning of
Battery bank
Safety
Electric Shock
Working
Agency

d S 1 Use all PPE& Proper insulated Tools

2 EMERSON Engineer to perform the job
Environment
Dust generation

a l i 3 Thorough cleaning of battery bank, terminals,

interconnection links, etc.
4 Use Dust mask, gloves, goggles and Safety helmet.

V
Quality
5 Cleaning by proper insulated brush
Cleanliness of the 6 Use insulated body or properly earthed vacuum cleaner
unit hand blower
7 Proper tightening of battery terminal
8 Check over heating of battery.

O P
PREPARED BY APPROVED BY

d S
Name and Desig.: D.K.MISHRA SR.ASSOCIATE CRM Name and Desig.: R.K.Sachan. Sr. Manager CRM

a l i
V
Signature with Date: Signature with Date:

Printed By -NEERAJ KUMAR(506757) Print valid till - 28-Jun-2020 Printed on - 18-Jun-2020 SOP Valid Till - 01-Jul-2020
STANDARD OPERATING PROCEDURE
Form No.: Form Rev. No.: 01 Effective date: 01.08.2015
SOP No. MUEM/CRM/BAF/SOP/4 Effective Date 01.4.2019 REVISION No 00

SOP DESC Maintenance of BAF Emerson UPS Section BAF/SPM/ECL/IEM

DEPARTMENT Mills & Utility Electrical Maintenance Page 8 of 12

Step Activity Associated Responsibility Process / tools / PPEs (HOW) Remarks / Reference
No. (WHAT) Requirements/ (WHO)
Hazards/ Impacts

10 Checking SAFETY: Sr. Associate/ 1. Visually Check the leakage from battery.
leakage of a.Electric shock Associate/ JE 2. If found replace the battery with new one of same capacity.
battery b. Falling from & contractor 3. If battery is to be replaced then follow following
staircase supervisor steps/Procedure
c. Slip/Trip/Fall 3.1 The job will be started after proper shutdown & proper
d. Finger Injury positive isolation of power in dc path by switching of the battery
Ckt breaker of both the UPS.
ENVIRONMENT:
Dusty

P
3.2. Use proper insulated tools
3.3 After installation of battery check the positive and negative

O
polarity of battery bank and rectifier for same polarity.
QUALITY: All
cleaning
equipments

d S
3.5 Switch on the battery breaker.

should be in good
quality and must
be in dry condition
a l i
V

O P
PREPARED BY APPROVED BY

d S
Name and Desig.: D.K.MISHRA SR.ASSOCIATE CRM Name and Desig.: R.K.Sachan. Sr. Manager CRM

a l i
V
Signature with Date: Signature with Date:

Printed By -NEERAJ KUMAR(506757) Print valid till - 28-Jun-2020 Printed on - 18-Jun-2020 SOP Valid Till - 01-Jul-2020
STANDARD OPERATING PROCEDURE
Form No.: Form Rev. No.: 01 Effective date: 01.08.2015
SOP No. MUEM/CRM/BAF/SOP/4 Effective Date 01.4.2019 REVISION No 00

SOP DESC Maintenance of BAF Emerson UPS Section BAF/SPM/ECL/IEM

DEPARTMENT Mills & Utility Electrical Maintenance Page 9 of 12

Step Activity Associated Responsibility Process / tools / PPEs (HOW) Remarks / Reference
No. (WHAT) Requirements/ (WHO)
Hazards/ Impacts

10 Battery SAFETY: Sr. Associate/ 1. Check new battery voltage and condition.
replacement a.Electric shock Associate/ JE/ 2. Check UPS indications for healthiness before starting the
b. Falling from Maint. Assit. & job.
staircase contractor 3. Arrange loops beforehand.
c. Slip/Trip/Fall supervisor 4. Disconnect and isolate battery bank and remove batteries
d. Finger Injury from stand.
5. Check power in the cables which are disconnected.
ENVIRONMENT: 6. Arrange and connect new batteries and check battery bank
Dusty

P
voltage before putting to service. Battery voltage will be
between 13.8V – 10.5V in the case of SMFB (12V), 2.25V--

O
1.75V in the case of VRLA (2V) and 1.41V --1.10V in the case
QUALITY: All
cleaning
equipments

d S
of NICD (1.2V) on discharging.
7. Dispose removed batteries and box-up battery bank.
8. Put into service and check charging current that it is
should be in good
quality and must
be in dry condition
a l i reducing.
9. After appropriate charging of battery check it by putting on
load.

12 Restart UPS after SAFETY: a.Electric

repairing. shock
V 415V LIVE PANELS AROUND THE UPS
USE TSL STANDARD TOOLS, MEASURING INSTRUMENT,
1. Skilled person will check the system before power switch ON
2. All PPE, Goggles, safe tools etc will be used.
b. Falling from 3. Only authorised service personal can switch ON the UPS.
staircase 4. CO2 type fire extinguisher will be kept ready near UPS
c. Slip/Trip/Fall
d. Finger Injury Return the clearance to the issuer

O P
PREPARED BY APPROVED BY

d S
Name and Desig.: D.K.MISHRA SR.ASSOCIATE CRM Name and Desig.: R.K.Sachan. Sr. Manager CRM

a l i
V
Signature with Date: Signature with Date:

Printed By -NEERAJ KUMAR(506757) Print valid till - 28-Jun-2020 Printed on - 18-Jun-2020 SOP Valid Till - 01-Jul-2020
STANDARD OPERATING PROCEDURE
Form No.: Form Rev. No.: 01 Effective date: 01.08.2015
SOP No. MUEM/CRM/BAF/SOP/4 Effective Date 01.4.2019 REVISION No 00

SOP DESC Maintenance of BAF Emerson UPS Section BAF/SPM/ECL/IEM

DEPARTMENT Mills & Utility Electrical Maintenance Page 10 of 12

Step Activity Associated Responsibility Process / tools / PPEs (HOW) Remarks / Reference
No. (WHAT) Requirements/ (WHO)
Hazards/ Impacts

ENVIRONMENT:
Dusty

QUALITY: All
cleaning equipments
should be in good
quality and must be
in dry condition

O P
d S
a l i
V

O P
PREPARED BY APPROVED BY

d S
Name and Desig.: D.K.MISHRA SR.ASSOCIATE CRM Name and Desig.: R.K.Sachan. Sr. Manager CRM

a l i
V
Signature with Date: Signature with Date:

Printed By -NEERAJ KUMAR(506757) Print valid till - 28-Jun-2020 Printed on - 18-Jun-2020 SOP Valid Till - 01-Jul-2020
STANDARD OPERATING PROCEDURE
Form No.: Form Rev. No.: 01 Effective date: 01.08.2015
SOP No. MUEM/CRM/BAF/SOP/4 Effective Date 01.4.2019 REVISION No 00

SOP DESC Maintenance of BAF Emerson UPS Section BAF/SPM/ECL/IEM

DEPARTMENT Mills & Utility Electrical Maintenance Page 11 of 12

Step Activity Associated Responsibility Process / tools / PPEs (HOW) Remarks / Reference
No. (WHAT) Requirements/ (WHO)
Hazards/ Impacts

CHECKLIST
S.NO OBSERVATION UPS-1 UPS-2 AUX STATUS REMARKS
1 INSPECTION (CLEANING & PHYSICAL CONDITION)
2
3
COOLING FAN, SENSING & ELECTROMICHANICAL DEVICES
INDICATING AND MEASURING METERS

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4
5
INDICATION LAMP AND HOOTER
MIMIC INDICATIONS

d S
6
7
8
SMPS VOLTAGE
SYNC STATUS
MAIN INPUT VOLTAGE AND CURRENT
a l i
9
10
11
BYPASS INPUT VOLTAGE
CHARGER VOLTAGE
OUTPUT VOLTAGE AND CURRENT
V
12 NEUTRAL-GROUND VOLTAGE
13 BATTERY CHARGING/DISCHARGING CURRENT
14
15
BATTERY VOLTAGE AND CURRENT (MAIN SUPPLY IN OFF CONDITION)
BATTERY VOLTAGE AND CURRENT AFTER 15MIN(MAIN SUPPLY IN OFF CONDITION)
O P
PREPARED BY APPROVED BY

d S
Name and Desig.: D.K.MISHRA SR.ASSOCIATE CRM Name and Desig.: R.K.Sachan. Sr. Manager CRM

a l i
V
Signature with Date: Signature with Date:

Printed By -NEERAJ KUMAR(506757) Print valid till - 28-Jun-2020 Printed on - 18-Jun-2020 SOP Valid Till - 01-Jul-2020
STANDARD OPERATING PROCEDURE
Form No.: Form Rev. No.: 01 Effective date: 01.08.2015
SOP No. MUEM/CRM/BAF/SOP/4 Effective Date 01.4.2019 REVISION No 00

SOP DESC Maintenance of BAF Emerson UPS Section BAF/SPM/ECL/IEM

DEPARTMENT Mills & Utility Electrical Maintenance Page 12 of 12

16 BATTERY CHARGING CURRENT (MAIN SUPPLY IN ON CONDITION)

17 CONDITION OF AC FILTER CAPACITIOR
18 CONDITION OF DC FILTER CAPACITOR
19 RIPPLE VOLTAGE OD DC BUS

O P
d S
a l i
V

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PREPARED BY APPROVED BY

d S
Name and Desig.: D.K.MISHRA SR.ASSOCIATE CRM Name and Desig.: R.K.Sachan. Sr. Manager CRM

a l i
V
Signature with Date: Signature with Date:

Printed By -NEERAJ KUMAR(506757) Print valid till - 28-Jun-2020 Printed on - 18-Jun-2020 SOP Valid Till - 01-Jul-2020