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PRESENTATION ON
INTEGRATED POWER SUPPLY
G.K U M A R A NA D S T E .BPA
Present system of power supply arrangement in signaling.
In signaling we use two different types of sources i.e. DC & AC supply
DC-supply All the interlocking circuits are powered
with DC supply. Every DC circuits are provided with
individual chargers and Batteries During power failures DC circuits are
continuously powered with individual battery bank backup
AC SUPPLY All the line side signals are fed through AC supply During AC supply failure all the line side signals
will become blank. No solution is available to avoid blank signals in
the present signaling arrangement. As a rule if signals become blank treated as
defective signals. Which implies non-interlocking of signaling system. Though the interlocking is well intact.
During blank signals due to AC supply failures in the face of an approaching train can create panic among the crews to control the high speed trains
CONVENTIONAL POWER SUPPLY ARRANGEMENT OF
RAILWAY SIGNALLING
110V AC SIGNALS
SP SP SPBATTERY
CHARGER
110V
BATTERY
CHARGER
24V
BATTERY
CHARGER
12V
CVTINV. INV.
CVT
230V AC 230V AC 110V DC
110V AC 110V AC TRACK CIRCUITS
110V AC
110V BATTERY BANK
24V BATTERY BANK
12V BATTERY BANK
230V AC 230V AC230V AC
SIGNALS
NEED FOR IPS.
To avoid these contingencies- Un – interrupted power supply is required.By this principle integrated power supply system was developed i.e. complete power solutions from one system to all signaling circuits for a station
What is in Integrated power supply system
1
•Single battery bank is used
•110V (55 nos of cells)/200 AH in RE ,300 AH in NON - RE
•To replace defective cells in the battery bank additional 05 Nos of cells are kept as spare cells.
2
•To charge the batteries SMPS based switch mode rectifiers are used in parallel redundancy.
3
•To feed DC- supply to various circuits different ranges of DC-DC converters are used.
4
•All the signals are powered by AC supply derived from inverters with hot standby.
•All the field track circuits supply taken from main source through CVT.
1. Ensure the availability of stable grid supply minimum voltage of 200V-AC.
2. In RE-AREA ensure that 70sq.mm cable is available between 10kVA AT transformer to CLS panel to keep minimum voltage drop on cable (Ref: TI/PSI/Project/CLS/01 dt. 04.01.2002)
3. Measure the load currents of various DC & AC circuits.
4. Pre-commissioning check list for IPS should be followed .
Pre-request items before planning for IPS at stations
Standard rating of IPS components approved by RDSO
SMR DC-DC converter
Inverter CVT Transformer
110V-20A
24V - 32V/5A,12V-28V/ 5A12V-28V / 1A, 60V-66V/5A12V-40V / 1A, 60V-110V/1A3V-6V / 0.1A, 2V-12V / 5A24V-32V/10A, 12V-28V/10A24V-40V/10A, 12V-40V/10A
1.5kVA2.0kVA3.0kVA
1.5kVA2.0kVA3.0kVA
500VA1kVA
9
IPS Specifications – Revision History and Improvements
Sl. NoSpecification
N0 Features Added /Modified Advantages
1 Amendment – 1 (Ver.1)
Introduction of SMPS based IPS
2 Amendment - 2Introduction of LPD & SPD protections at the I/P stage of IPS.
Achieved protection of IPS from heavy lightning & surges during raining season & improves the system reliability.
3 Amendment - 3 New clause has been added to provide ventilation for individual modules.
1) Better heat dissipation . 2) Reliability improvement.
4 Amendment - 4 * IPS cabinet dimensions have been standardized.
* Ear thing guidelines are formalized. * Can avoid ear thing related issues and improves overall system reliability
* Pre-commissioning check list for installation & commissioning of IPS has been added.
Proper installation & commissioning can be ensured.
* Over load & Over voltage protections, have been added for IPS system.
Improves module and load reliability as well.
5 Amendment - 5 *Class-’C’ protection is added in Data & Signaling lines.
Improves data & signaling loads reliability and power interruption to the load is avoided.
*Guidelines given for Installation of LPD & SPD Devices.
Proper LPD & SPD co-ordination can be achieved,
TYPICAL BLOCK SCHEMATIC OF IPS AS PER RDSO/SPN/165/2004
REMOTEASM
PANEL
INCOMING230V AC SUPPLY
SMR110V/20A
SMR 110V/20A
BY PASS CVT1000VA
INV 11500VA
INV 21500VA
FUSE FUSE
FUSE
C7 CVT
1500VA
TX500VA
C7
C5
C6
110V ACTRACK CKT.
230V AC BUS
110 V DC BUS
FUSE
110V DCTO POINT MACHINE
TX500VA
110V ACSIGNAL UP
TX500VA
110V ACSIGNAL
DNFU
SE
SICK CELL CHARGER
2-12V
DC-DCCONV
DC-DCCONV
DC-DCCONV
DC-DC CONV
RELAY EXTERNAL24-32V/5A X 2
BLOCK LINE (BLOCK LOCAL)12-40V/1A X 2
DC-DCCONV
DC-DCCONV
DC-DC CONV
DC-DCCONV
BLOCK LINE (DN)12-40V/1A X 2
DC-DCCONV
DC-DC CONV
BLOCK LINE (UP)12-40V/1A X 2
DC-DC CONV
PANEL INDICATION & HKT
12-28V/5A X 2
DC-DCCONV
RELAY INTERNAL24-32V/5A X 2
DC-DCCONV
DC-DC CONV
SMR 110V/20A
Battery 1 Set
110V/300AH
LM LA
C11
FUSE
C
SMR 110V/20A
COLD STANDBY
150- 275V AC
Typical Block Diagram of IPS as per RDSO / SPN / 165 / 2004
110V/20A1.5 KVA
110 V DC BUS
TRACK CIRCUIT UP
DC-DC CONV
DC-DC CONV
DC-DC CONV
DC-DC CONV
24-32V/ 5A-4Nos RELAY INT.
DC-DC CONV
DC-DC CONV
DC-DC CONV
DC-DC CONV
DC-DC CONV
DC-DC CONV
DC-DC CONV
DC-DC CONV
DC-DC CONV
DC-DC CONV
230V AC BUS
SMR
1.0 KVA
1.5 KVA
TRACK CIRCUIT DN
SIGNAL UP
SIGNAL DN
COLD STAND BY
AVR
110V/20A
110V/20A
110V/20A
SMR (FRBC)
110 V DC BUS
1.5 KVA
INVERTER
ASM INDICATION PANEL
230/110V,500VA
230/110V,500VA
230/110V,500VA
230/110V,500VA
230V AC BUS
STEP DOWN TRANSFORMERS
230/110V,500VA
230/110V,500VA
110 V BATTERY
230V AC BUS
TO POINT MACHINE
DC-DC CONV
DC-DC CONV
DC-DC CONV
DC-DC CONV
DC-DC CONV
DC-DC CONV
DC-DC CONV
DC-DC CONV
DC-DC CONV
DC-DC CONV
DC-DC CONV
DC-DC CONV
DC-DC CONV
DC-DC CONV
DC-DC CONV
DC-DC CONV
AVR
LPD PANELCLASS -B&C
DC-DC CONV
24-32V / 5A-1NoRELAY INT.
(COLD STANDBY)
24-32V/ 5A-2Nos RELAYEXT-1.
24-32V/ 5A-2Nos AXLE COUNTER
12-28V/ 5A-2Nos PANEL IND.
12-28V/ 5A-2Nos BLOCK LOCAL.
12-28V/ 5A-2Nos Datalogger
12-40V/ 1A-2Nos BLOCK LINE UP.
12-40V/ 1A-2Nos BLOCK LINE DN.
3-6V/ 0.1A-2Nos BLOCK TELE UP.
3-6V/ 0.1A-2Nos BLOCK TELE DN. 2-12V/ 5A-2Nos
FOR SPARE CELLS
24-32/ 5A-2Nos BPAC North
24-32V/ 5A-2Nos
BPAC south
FUSE(20A)
LVDS
ST
AT
IC S
WIT
CH
24-32/5A02 Nos
Relay Ext-2
MANUFACTURES OF IPS
RDSO APPROVED FIRMS ARE
M/S AMARA RAJA POWER SYSTEM
STATCON POWER CONTROL SYSTEM
HBL NIFE POWER SYSTEM
INSTALLATION OF IPS IPS comes with three panels namely1. FRBC or SMR panel Five rectifier modules Rated modules 110V-20A, 2.7kW output of the panel is connected to battery
bank and other panels2. DC distribution panel It can accommodate Max. of 39 converters it consists of different rating of DC-DC
converters3. AC distribution panel Combinations of inverters, step-down
transformers and CVT
Layout of 3 Panels, Class ‘B’ Protection Box & ASM Box
Class ‘B’Protection
SMR PANEL DC PANEL AC PANEL
ASM BOX
ALL FAIL SIGNALSI/P SUPPLY FROM
PANEL
AUTO C/O
LOADS
Battery
INSTALLATION PROCEEDURES System should be installed with
sufficient space at rear and front side minimum of one meter.
Keep the cabinets side by side with a spacing about one foot between them
Grout the cabinet to floor Draw the 10sq.mm copper wires from
IPS panels to power panel. Earthing of IPS
The Earthing Value should be less than 2 Ω as measured by megger.
Earthing of IPS panel
If the Megger is not available at site, then we should measure the N-E Voltage of Mains Supply on class B protection Box. It should be less than 5V.
TYPICAL PROTECTION SCHEME SHOWING LIGHTNING &SURGE PROTECTION AT INPUT OF POWER SUPPLY
X4
TOIPS
X1
FUSE32A/63A
X3
DC PANEL SMR PANEL
NL
FROMMAINS
AC PANEL
N L
MCD50-B VDE
X2
MCD125-B NPE
CUSTOMER EARTH
Before connecting the load to the IPS
DC-DC converters, signal transformer voltages should be adjusted to required voltages.
According to load current, number of DC-DC converters should be selected as N+1 redundancy. It means if any one converter fails our circuit should not go to failure mode.
COLOUR SCHEME FOR WIRING PRACTICE
DC CIRCUITS POSITIVE : RED ,
NEGATIVE :BLACK AC CIRCUITS PHASE : BLUE ,
NEUTRAL :YELLOW EARTH :GREY/GREEN
TYPICAL INSTALLATION OF BATTERY ROOM
IPS ROOM
STATUS MONITORING PANEL
FIXED AT ASM OFFICE. INDICATES HEALTHY OF COMPLETE IPS
SYSTEM. AFTER COMMISSIONING OF IPS. LETTER
TO BE SERVED TO ASM ,REGARDING SMP WORKING TILL CORRECTION IS MADE IN SWR.
IN PANEL BLOCK TELE PHONE SUPPLY FOR CONVERTERS ARE AVAILABLE.
Start generator: 50% DOD or Approx. 109V Emergency start generator: 60% DOD or Approx 107V System shut down: 70% DOD or Approx 105V Call S&T staff: Failure of FRBC, Converters, Inverters,
CVT’s & Transformers. PF contacts are available for DATA
LOGGERS.
MONITORING PANEL
MAINTANANCE OF IPS SMR Maintenance SMRs are fully alarmed and operate in an active loop
sharing arrangement. However , some regular checks can be an early warning of problems waiting to happen.
Current sharing (Applicable , when number of modules is
more then one number) Under normal conditions the currents contributed by every
rectifier should be within +/-2 Amps of each other. It is possible however, for internal loop parameters to change to such an extent that a unit does not share to the extent that it should.
Maintenance check for DC-DC converters
S No CHECK POINT ACTION REQUIRED FREQUENCY
1. Converter O/P voltage
Check if the O/P voltages are set as per requirement. If not, correct them
Once in 15 days
2. Paralleling of Converters
Switch OFF main Converter and observe if the stand-by is taking the load.
Once in a month
3. Paralleling of Converters
Switch OFF Stand-by Converter and observe if the main is taking the load.
Once in a month
4. Converter Mechanical Alignment
Check if all the converters are inserted properly
Once in 3 months
5. Converter Cleaning Remove one by one and clean the converter using a soft cloth . Gently blow some air from top or Bottom to remove the dust inside.
Once in 3 months
Maintenance Check Points for ACDP
SNo Check Point Action Required Frequency
1. O/P voltages of Inverters, CVTs Step- Down Transformers as per requirement
Check if the O/P voltages are set as per requirement. If not , check for fusescontactors.
Once in 15 days
2. Inverter O/P current Check if the DPM is showing the signal current as per original settings.
Once in 15 days
3. Auto changeover between Inverters and Bypass CVT
Check for this changeover operation as described in instruction manual
Once in a month
4. Connector Mechanical Alignment
Check if all the connectors of various sub systems are inserted properly
Once in amonth
5. Sub System Cleaning Remove one by one and clean them using a soft cloth . Gently blow some air to remove the dust inside.
Once in 3months
BATTERY MAINTANANCELow Maintenance Battery IRS 88/93
Cleaning of all cells around top cover and terminals periodically. Applying petroleum jelly over the terminals. Periodically recording of all cell voltages and their specific gravity. Periodically checking of electrolytic level of cells. Periodically recording of all cell voltages with Battery Charger
switched OFF. Boosting of Sick cell using Sick cell Charger. Replacement of non-reparable cell in a bank by fresh charged
cell.
Cleanliness Apart from these instructions regular cleaning of IPS and battery
room should be done. Cleaning of dust collected inside the IPS panels (SMPS, DCDP & ACDP) should be done with the help of blower once in a month.
EFFECT OF DUST ON WORKING OF IPS
Since IPS uses double side PTH PCB’s having high component density and compact module construction
It needs clean environment around it. It is true for any modern electronic equipment.
• The floor should be pucca with mosaic/tiles or with PVC flooring.
• There should be windows with glass doors so that they can be closed.
• Doors and windows should have gaskets.• There should be provision for exhaust fan and
dampers on outside.• The windows should preferably have wire mesh or
Netlon type jali.
Equalizing charge Measure the voltage of each individual
cell while the battery is at REST. Variation of 0.05V between cells and
variation of 20 points in the specific gravity indicates imbalance in the bank. Battery bank needs equalizing charge.
In IPS equalizing charging can be done by operating manual start EQ in CSU.
LOW VOLTAGE DISCONNECT SWITCH
HOUSED IN SMR PANEL
LVDS TRIP; 98 V TERMINALS SHOULD
BE SHORTED DURING THE CONTACTOR RELAY FAILURE
Problems faced in IPS after commissioning
SLNO PROBLEMS ACTION TAKEN
1 CLS PANEL MCB TRIPPING SMR CURRENT LIMITED TO MAX 10A
2 LVDS OPEN LVDS SHOULD BE IN AUTO
3 BLOCK TELEPHONE HEAVY HUMMING
DISCONNECTED BLOCK TELEPHONE CONVERTER
4 D2 SIGNAL BLANK,AND HOME SIGNAL FOR LOOP LINE NOT OBEYED ON IPS SUPPLY BACKUP
AC SUPPLY FEEDING TO SIGNALS WERE EXTENDED TO D2’s AND HOME SIGNAL ROUTE INDICATORS.
IMPROVEMENT NEEDS IN IPS
ELECTRONIC SWITCH MAY BE AVAILABLE PARALLEL WITH LVDS TO MAKE USE IN EMERGENT CONDITIONS.
UNIFIED CAPACITY OF CONVERTERS 12V – 32V/5 AMP
HIGHER CAPACITY TRANSFORMER ,CVT REMOTE DIALINIG FEATURE MADE COMPULSERY. SUFFICIENT LENGTH OF CABLE TO BE MADE
AVAILABLE BETWEEN SMR TO BATTERIES. Cable entry hole to be provided on top of modules. Extra converter slot made available in dcdp for
circuit expansion.
THANK YOU
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