Telecom Power System Cutover Service Training

22/1/16 Security Level:
Telecom Power System

Cutover Service Training
Network Energy Product Technology Dept

(Liaqat Ahmad Awan) www.huawei.com
HUAWEI TECHNOLOGIES CO., LTD. Huawei Confidential

Objectives
After this training, you will be able to learn the items
as below.
 Understand why the legacy telecom power systems

should be replaced.
 Learn the definition and scenarios of Power cutover.
 Learn the Key survey points for Power cutover.
 Learn power cutover solution, operation procedure and

attention points.

Contents
1. The trend of telecom power cutover
2. Definition and procedure of power cutover
3.Typical scenarios of telecom power cutover
4. Key survey points for power cutover
5. Operation procedure of power cutover
6. Telecom power cutover cases introduction
7. Telecom power cutover attention points

FAQ
Q1.Why shall we need to replace existing legacy power ?
 High maintenance cost.
 Difficult expansion.
 Difficult management.
 Low efficiency, big redundancy configuration.
 Risk for network stability.
Q2. What’s the importance for the legacy power replacement ?
 Stable network needs reliable power supply.
 The quantity of legacy power sites takes up only 8.5%, but the energy
consumption takes up 20%.
 Energy saving challenge and Trend of high efficiency power use.
 It’s a trend to replace legacy power in the world for energy saving and high
reliability.
Contents

The definition of power cutover
DC power system cutover is an action to replace, rebuild or expand existing
legacy DC power system. Then we can achieve the replacement, upgrade or
expansion for original DC power system to improve or re-establish DC power
system’s capacity and function.
市电 UPS
Mains ATS DCDB
Mains
Old power
Old power Load DC Load
ACDB 老电源系统设备负载
油机
Load DC Load
D.G.
D.G.
New power
新电源系统
New power Load DC设备负载
Load
Load DC Load

Basic power cutover types
1. Cutover with power interruption
If it’s allowed, power cutover operation can be done with load
power off. It’s very safe for the people and the equipment.
2. Cutover without power interruption

The load interruption is not allowed, and the business should be
on line all the time. This means the power cutover operation is
alive, and it has some risks for people and equipment.
Any operation mistake may cause some accident, so the
operation procedure should be specified, and everything should
be in control.
Notes:
Because the cutover with power interruption is easy and similar somehow
like new build, we can refer to power new setup process. This PPT only
focus on the power system cutover without power interruption.

Power cutover project delivery process
Site Survey and Cutover solution

Customer need Customer approve
customer
for power (Proposal/BOQ/ and Cargo
requirement
replacement inquiry SOW/Plan) preparation
Cutover
Cutover preparation Implement solution
Acceptance (Review/Customer
Operation (Operators/work
field/Training) approved)
Notes:
The power cutover solution should be based on the site survey result for operation
feasibility. And the solution should be approved by customer in advance.

Contents

Rebuild the legacy power system
Keep existing cabinet structure of power system, just change some
parts such as rectifier modules, monitor units and AC/DC distribution
units, but reuse the cabinet and existing battery strings, just like the
case as below.

Power expansion scenario
Keep existing power system structure, but add some parts to expand
existing power capacity.
For example, we try to expand existing power system with one more
rectifier cabinets, DC output cabinets or extended DCDU.
As shown below, one more rectifier cabinet is added for existing power
system expansion.

Replacement scenario
Decide the replacement solution based on room condition and customer’s
requirements.
Whole system replacement
Reuse AC&DC AC 整流柜直流柜

Cabinet Reuse AC Cabinet
Cabinets
AC 整流柜 DC 整流柜 DC
AC
Cabinet Cabinet Cabinet
Cabinet
AC Rec DC
Cabinet Cabinet Cabinet
Existing power system

Replacement scenarios continue
Replace the whole system or some parts at the original position.
Replace the whole system or some parts at other position.
For example, we try to replace the whole power system , or only
the rectifier cabinet, AC/DC distribution cabinet, battery strings etc. at
original position or other position.
Original position Other position

replacement Old system replacement
New system New system

Contents

Location and room condition survey
Survey on site: Survey in the core room:

Site name, Location, Environment. Room layout.
Transportation road condition. Equipments layout.
Distance from unload place to site. Room floor loading capacity.
Doors, elevators, stairs space, ESD floor or not.
Freight elevator loading. Cable tray/ladder layout.
Site access. Ground bus bar location.
Room air conditioning, air flow
vent area.
Room temperature.

Legacy DC power system survey
Legacy DC power system survey
The power equipment/cabinet dimension.
Cable routing type to the cabinet.
How the cabinet is fixed on the ground / floor.
Power system model, rated capacity.
AC input lines (dual or single).
Rated capacity of AC input and DC output.
The total DC load current.
Quantity of DC load cables and DC current of each cable.
Rectifier model, capacity and quantity.
Location of AC/DC connection point, spec of the terminals.
Quantity and spec of MCBs (fuses) in DCDU.
The class of AC/DC surge protection inside power cabinet.

AC input & DC output survey
AC Input survey DC output survey
Location of ACDB. The quantity of DC distribution cabinets;
Total capacity of ACDB ； Dimension of DC distribution cabinet ；
Mains input type, rated AC voltage The ways of power cables inlet and outlet
and frequency. of DC distribution cabinet;

Total number of AC output Distribution cabinet model and rated total
breakers, the number & spec of free capacity (current).

Number and spec of DC distribution output
breakers.
Layout of AC cables routing, spec of terminals, the number & spec of free fuses /
pipe and cable slot. breakers.
Spec and length of AC input cables. The layout of DC output cables or bus
bars between existing power system and

DC distribution unit or PDF.
Max DC voltage drop allowed by the
regulation of DC load.

Battery and monitor survey
Battery Monitor
The max allowed battery strings inside Layout of communication cables inside
the cabinet, and the actual quantity of power system.
battery strings inside; Layout of communication cables outside
Battery capacity and spec. power system.
Battery cabin dimension. Alarm cables connection type.
Battery cables spec and color. Environment sensor model and layout of
Battery rack dimension (Open rack). signal cables related.
The cables layout and length from Battery current, load current detective
battery racks/cabinets to power system. sensor and the spec.
Ground connection for battery Terminals definition, spec of signal cables.
cabinets/racks; Communication protocol.
Spec of battery cables and terminals Alarm list of legacy power monitor unit.
Battery room temperature.

Core room power cutover survey guide
DC power
cutover survey template

Contents

Same position cutover steps –Dual lines
Confirm the old Install and test the Connect one Set the temp
power system is temp power battery string to power DC output
working normally nearby temp power voltage
Set the temp Migrate the DC

Shut down and Confirm the two
power DC output load dual lines to
dismantle the old voltage to carry all temp power one power systems are
system load current by one cable working normally
Installing and Confirm the two

Connect the Power on the new
commissioning the power systems
new system at battery to the new system and adjust are working
original position system the output voltage normally
Set the new Migrate the DC

Shut down and
Clean up and power DC output load dual lines to
dismantle the
Acceptance voltage to carry new system one
temp system all load current by one cable

Different position cutover steps –Dual lines
Confirm the old Install and test the Connect one
Set the new power
power system is new power system battery string to
DC output voltage
working normally nearby new power
Shut down and Set the new Migrate the DC

power DC output load dual lines to Confirm the two
dismantle the old power systems are
voltage to carry all new power one by
system load current one cable working normally
Single line cutover solution without

Check and confirm
the new power Clean up and power interruption
system is working Acceptance
fine
Cable clamp tools is used for single

line load cutover solution, if it’s
approved by customer.
However, it’s proposed to power off
load for single line load cutover first if
it’s allowed by customer.

Contents

Case1 xx power swap trail project
 Background
Existing power system has been running more than 10 years, low efficiency and difficult maintenance service.
Customer wished to replace existing rectifier with new one, and the business should be “zero” outage.
 Solution Overview
1. Parallel connection for old and temp rectifiers to PDF, migrate the load current from old to temp rectifier.
2. Parallel connection for new and temp rectifiers to PDF, migrate the load current from temp to new rectifier.
Old Rect. PDF Temp Rect. New Rect. PDF Temp Rect.
DC Load DC Load
Case1 xx power swap trail project
 Operation Procedure
1. Install the Temp. rectifier nearby the old system. Power on the temp. rectifier and commissioning.
2. Adjust the temporary rectifier’s output voltage to be 0.2V lower than the old system. The path is Settings > VRLA Battery
> Basic > Float Charge.
3. Connect the temp. DC cable (RTN,-48V) from temp. rectifier to bus bar of PDF cabinet.
4. The two systems are parallel working, but all the loads are fed by the old system.
5. Adjust the Temp. system voltage to be 0.2V higher than old system. Check whether the temp rectifier provides full load
currents. If not, raise the output voltage of the temp rectifier by 0.2 V in each step until the temp power system provides
full load currents
6. Dismantle the old system and recover the temp. rectifier‘s voltage to default value;
7. Install the new ETP48360 module in old cabinet , connect all cables and battery, then power on and commissioning,
make sure the new rectifier work normally;
8. Adjust the temp. system ‘s output voltage to be 0.2V higher than the new system.
9. Reconnect the original DC cable(RTN,-48V) from DC busbar of PDF to new rectifier. Then the two systems are parallel
working, but all the loads are still fed by the temp rectifier.
10. Adjust the temp rectifier’s voltage to be 0.2V lower than new system, decrease the voltage of temp rectifier by 0.2 V in
each step until all loads are fed by new ETP48360 system.
11. Shut down the temp rectifier and dismantle the cables, remove the temp rectifier cabinet.
12. Check and confirm the new system is working fine with all loads.
13. Clean the site and acceptance with customer.

Case2 XX railway power swap project
 Background
The old power system has been running for over 15 years in the central room, some rectifier modules
are broken, and customer wished to replace existing rectifier cabinet without power interruption.
1. Install a new rectifier cabinet next to existing power cabinet to replace the legacy rectifier cabinet.
2. Reuse existing DC cabinet but replace the monitor door with new voltage/current detective system.
3. Connect new signal cables for DC cabinet fuses to rebuild the monitor system and finish
commissioning.
Before Migration After Migration

Case2 XX railway power swap project
 Operation Procedure:
1.Install the Huawei rectifier cabinet next to existing rectifier cabinet, connect the AC power cable, grounding cable, and
make sure existing battery is fully charged.
2.Adjusted Huawei Power DC output voltage to 53.2V (0.2V lower than the old system).
3.Connect the new DC cable between the Huawei rectifier and existing DC cabinet positive and negative bus bar.
4.The two systems are parallel working, but all the loads are fed by the old system.
5.Adjust the Huawei rectifier voltage to be 0.2V higher than old system. Check whether Huawei rectifier provides full load
currents. If not, raise the output voltage of Huawei rectifier by 0.2 V in each step until Huawei rectifier provides full load
current.
6.Shut down the old rectifier and dismantle related cables. Recover Huawei rectifier‘s voltage to default value 53.5V.
7.Remove the DC distribution cabinet door and associated cables.
8.Install the new DC cabinet door, connect the detective cables for battery fuse and DC load fuses.
9.Commissioning the communication between the existing DC cabinet and Huawei rectifier cabinet, and make sure the
Huawei rectifier can normally monitor the DC distribution cabinet.
10.Confirm the new power system is working normally with loads, make sure DC distribution monitoring and management
system is working fine for the new system.
11.Clean up and Acceptance with customer.

Case 3 XX telecom power swap project
 Background
Existing power system has been working for 15 years in the central office, and the power supplier no
longer provide the maintenance service. So, the customer need to replace the whole legacy power system
at the same position without business outage.
1. First swap all load cables to the temp rectifier cabinet, then dismantle the old system.
2. Install the new system at original position and swap all loads to the new system back.
Temp
power
INVERTER
ACDU DCDU RECT
ACDB
Before Migration After Migration

Case 3 XX telecom power swap project
 Operation Procedure:
1.Install the temp rectifier cabinet nearby the existing power system, connect the AC power cable, grounding cable, one
battery string and power on & commissioning for temp rectifier system.
2.Adjust temp rectifier’s float charge voltage to be 0.2V lower than the old power system, then connect the parallel
connection DC cable between them, and the old rectifier provide power for all loads.
3.Migrate the dual load cables from old rectifier to temp rectifier one by one cable , and make sure all load cables are
done for migration.
4.Adjust the temp rectifier’s float voltage to be 0.2V higher than old system, Check whether temp rectifier provides full load
currents. If not, raise the output voltage of temp rectifier by 0.2 V in each step until temp rectifier provides full load.
5.Shut down and dismantle the old power system ;
6.Install the new power system at original location and power on, & commissioning , connect to one battery string for
power back up.
7.Adjust the new rectifier’s float voltage, then connect the parallel connection DC cable between temp and new power
system;
8.Migrate the dual load cables from temp rectifier to new rectifier system one by one cable;
9.Adjust the new rectifier’s float charge voltage higher than temp system, and then new system provide the power for all
loads;
10.Shut down and dismantle the temp power system.

Contents

Operator and cutover time requirement
Operator requirement
Partners should have the qualification to do the electrical project.
Staff should have local skill qualification, and finish fire/first aid training.
Staff should be familiar with power system structure, principle, operation
and the cutover procedure.
There should be an experienced staff doing supervision on site.
Operation time requirement

Cutover operation should be arranged during non-business peak hours, non-
major holidays, or non-major special protection period.
Cutover should not be arranged at planed power outage period.
Avoid the period of thunderstorms and grid instability.
At mid-night, need to consider possible noise problems.

Labor protection and tools required
Labor protection
During the operation that can touch live parts, the people need to stand
on an insulating pad;
Remove metal objects such as watches, rings, necklaces, job cards,
etc.
If possible, please wear insulated gloves;
If necessary, please wear protective glasses;
Tools required
Special insulated tools, or the tools insulated
by insulation tape.
The wooden ladder should be used.

Preparation before cutover operation
Cutover preparation
Site lighting and emergency lighting equipment should be ready.

Fire equipment and emergency rescue equipment should be ready.
Skilled and professional partners are ready.
The operators should be healthy and in good state.
Before operation, the cutover solution should be approved by customer,
and get the work permit from customer.
Before the operation, do check and make sure the backup power/ D.G./ATS/
batteries are in good condition.
Items should be labeled , such as switches fuses / MCBs and cables etc.
Keep the work area clear.

Requirements for cutover operation
Cutover operation requirements
The operation should follow the approved SOP. If it’s possible, it’s better to
power off the load for cutover.
During the implementation, all equipments should be grounded securely.
The new equipment should be grounded before installation, and the grounded
connection should be removed at last for the old equipments.
The live parts should be insulated securely.
If possible, it’s better to disconnect the live parts before cutover, and the tools
use should be safe and in order.
The operation of DC load cables removal and connection should follow “ first
negative and then positive for removal, first positive and then negative for
connection”.
Before removing the old parts, fuses/MCBs related should be disconnected first.
When remove cables and fuses ,the cables and fuses should take no load .
When install live cables and fuses, the voltage gap between the terminals and
the live connection should be no more than 0.2V.

Requirements for cutover operation continue
 Prohibit welding and drilling operation in live bus bar.
 The cables terminal should be insulated immediately after removal.
 The cables laying and connection should be with enough bend radius.
 Make sure there is no risk caused by mechanical stress for thick cables layout.
 Arrange the operation reasonably, the operation of cable frame build / cable layout
/cabinet installation etc. can be done during no-cutover period.
 Before cutover operation, the new power or temporary power should be set to
“manual model” to avoid a sudden voltage change caused by charging model or
battery temperature compensation.
Adjust the output voltage of new system to 0.2V lower than the old system before
parallel connection, and adjust the voltage of old system to 0.2V lower than the new
system before quit.
 When the operation is finished, clean the operation area. The dismantled
equipments parts and devices should be put on the position required by customer.

Cutover accident handling
Cutover accident handling

If there is a personal injury during cutover operation, you must stop the cutover
operation and do the personal safety first aid immediately.
If the cutover operation fail, you must stop cutover and perform the recovery
process.
The parts removed from old system should be kept properly in order to be
reused when the cutover fails.

Thank you
www.huawei.com

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22/1/16 Security Level:

Telecom Power System

Network Energy Product Technology Dept

HUAWEI TECHNOLOGIES CO., LTD. Huawei Confidential

 Understand why the legacy telecom power systems

 Learn the definition and scenarios of Power cutover.

 Learn the Key survey points for Power cutover.

 Learn power cutover solution, operation procedure and

HUAWEI TECHNOLOGIES CO., LTD. Huawei Confidential

2. Definition and procedure of power cutover

3.Typical scenarios of telecom power cutover

4. Key survey points for power cutover

5. Operation procedure of power cutover

6. Telecom power cutover cases introduction

7. Telecom power cutover attention points

HUAWEI TECHNOLOGIES CO., LTD. Huawei Confidential

2. Definition and procedure of power cutover

3.Typical scenarios of telecom power cutover

4. Key survey points for power cutover

5. Operation procedure of power cutover

6. Telecom power cutover cases introduction

7. Telecom power cutover attention points

HUAWEI TECHNOLOGIES CO., LTD. Huawei Confidential

HUAWEI TECHNOLOGIES CO., LTD. Huawei Confidential

2. Cutover without power interruption

HUAWEI TECHNOLOGIES CO., LTD. Huawei Confidential

Site Survey and Cutover solution

HUAWEI TECHNOLOGIES CO., LTD. Huawei Confidential

2. Definition and procedure of power cutover

3.Typical scenarios of telecom power cutover

4. Key survey points for power cutover

5. Operation procedure of power cutover

6. Telecom power cutover cases introduction

7. Telecom power cutover attention points

HUAWEI TECHNOLOGIES CO., LTD. Huawei Confidential

HUAWEI TECHNOLOGIES CO., LTD. Huawei Confidential

HUAWEI TECHNOLOGIES CO., LTD. Huawei Confidential

Reuse AC&DC AC 整流柜 直流柜

Existing power system

HUAWEI TECHNOLOGIES CO., LTD. Huawei Confidential

Original position Other position

New system New system

HUAWEI TECHNOLOGIES CO., LTD. Huawei Confidential

2. Definition and procedure of power cutover

3.Typical scenarios of telecom power cutover

4. Key survey points for power cutover

5. Operation procedure of power cutover

6. Telecom power cutover cases introduction

7. Telecom power cutover attention points

HUAWEI TECHNOLOGIES CO., LTD. Huawei Confidential

Survey on site: Survey in the core room:

HUAWEI TECHNOLOGIES CO., LTD. Huawei Confidential

HUAWEI TECHNOLOGIES CO., LTD. Huawei Confidential

Total capacity of ACDB ； Dimension of DC distribution cabinet ；

and frequency. of DC distribution cabinet;

breakers, the number & spec of free capacity (current).

bars between existing power system and

HUAWEI TECHNOLOGIES CO., LTD. Huawei Confidential

HUAWEI TECHNOLOGIES CO., LTD. Huawei Confidential

Reuse AC&DC AC 整流柜直流柜