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Battery container + 800kw PCS annual Inspection Template
Battery container + 800kw PCS annual Inspection Template
Zhirui Chen

Battery container + 800kw PCS annual Inspection Template

Scope This manual is for BYD Engineers attending operational battery sites, operational sites are ones where Site Acceptance Test (SAT) have been completed and signed off by both Customer and BYD. BYD deputes Engineers to maintain, service and repair Battery Energy Storage Systems (ESS) operating at site, such Engineers need to follow this manual to ensure safety and contractual requirements that Customer has with asset owners under EPC and O & M. Maintenance activity Procedures to be followed 1. As far as possible, Engineers site visit plans are to be communicated to Customer as early as possible, as a minimum weekly plan to be provided before 3pm of previous Friday. 2. When site visits are required at short notice, prior notification will still be required, this could be through email or phone call to Customer. 3. On arriving at the site and before leaving sites, customer need to be informed, this could be through an update on phone or group WeChat. 4. Vehicles should be parked at designated areas only. 5. Codes for opening gates and disabling alarms are to be obtained from Customer, these should not be disclosed to anyone. 6. Security alarm is to be disabled before entering site and it should be armed before leaving site followed by a phone call to Customer. 7. If any damage to gate, lock or alarm is noticed, these should be reported to Customer immediately. 8. If Engineers need to take control of the ESS, Customer need to be contacted for permission by phone or through Group WeChat and wait for permission to be granted. After completion of work Customer will need to be contacted on the same number and ensure that Customer has full control of the ESS before leaving site. Permit to Work 1. BYD Engineers are only permitted to work on equipment provided by BYD RAMS (Risk Assessment and Method Statement) Battery sites include solar PV Farms and stand-alone locations, BYD provide RAMS (to be agreed beforehand) to work at such sites for review by customer. When at sites, Engineers will be required to evaluate site specific risk assessments. PPE 1. Mandatory five part PPE are required to be worn when entering sites, these are Safety Shoe, Hi Viz Jacket, Hard Hat, Safety Gloves and Safety Glasses. 2. If access to battery compartment of ESS is required, additional PPE will need to be worn, these are Flame Proof Vest, Visors and High Voltage Gloves. Tools and Equipment 1. All tools used at sites will need to fit for purpose. 2. Hand tools must be insulated 3. Meters and Test Equipment will be fit for purpose and Engineers should have valid calibration certificates. Emergency Arrangement 1. Operatives must be aware of location coordinates and ESS escape routes prior to starting work. 2. If working alone a line manager must be notified before and after work has finished. 3. All operatives must be aware of the emergency services number before starting work and where applicable review the ESS site H&S file. 4. First aid kit should be accessible either kept on site or on vehicle. Capacity Test Notes: 1. Prior to conducting System Capacity Check, conduct many short duration charge/discharge cycles to ensure that the ESS and Import/Export meters are working correctly. 2. Make sure that the batteries has been equalized and have similar voltage and temperature level. 3. Discharge the ESS fully till the Controller stop the system automatically on reaching lowest charge before carry on capacity test. 4. During the capacity test, the ESS need to be operated at the rated power unless the site restrictions do not permit this. 5. Provide photographs to show all key information. 6. Wait 1hrs between charge and discharge cycles for batteries cooling.

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Free Battery container + 800kw PCS annual Inspection Template Checklist

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Title Page

  • Which Site

  • Which ESS

  • Service Date

  • Participant Details

  • Report Prepared by

PCS Inspection

    PCS Checklist

  • Which?

  • Visual check: Visual check all PCS components especially bolts and power cable if any obvious damaged or burnt.

  • SPD : Check if the SPD willow colour is green.

  • PCS HVAC dustproof screen : Clean the dustproof screen if any dust on it.

  • PCS door lock : Check if door lock can be open smoothly.

  • PCS inner dust clean: Use dust collector to clean the PCS inner if any dust inside PCS.

  • PCS indicator: Visual check if the Power/Running/Fault indicator are working well.

  • PCS screen: Check if any current alarm on screen.

Battery Inspection

    Battery

  • Which?

  • Battery DC cable : Visual check if any obvious damaged or burnt.

  • Battery appearance: Visual check if there is shape change or liquid leakage on battery appearance.

  • Battery pole: Visual check if any obvious damaged or burnt.

  • BMS: Check if the indicator and maintenance switch in normal status

  • Fan control box: Check if the indicator switch in normal status

    • DC Junction Box

  • Which?

  • Visual check: Visual check all junction box components if any obvious damaged.

  • DC cable/Busbar: Visual check if any obvious damaged or burnt.

    • PDC

  • Which?

  • Visual check: Visual check all PDC components if any obvious damaged.

  • SPD : Check if the SPD willow colour is green.

  • UPS : Check if it is working normally.

  • PDC inner dust clean: Use dust collector to clean the PDC inner if any dust inside PDC.

  • PDC indicator: Visual check if the Power indicator are working well.

  • PDC screen: Check if any current alarm on screen.

HVAC Inspection

    HVAC

  • Which?

  • 1 Air Cooled Condensor Coils and Comb Fins

  • 2 Condenser Fan Blades and Air Handling Impellers

  • 3 Condenser Fan Motors

  • 4 Air Circulation Fan Motors

  • 5 Cooling/Heating Coils

  • 6 Condition of Compressor

  • 7 Compressor Motors

  • 8 Compressor Oil Level

  • 9 Air Fan V Belts for Alignment and Wear

  • 10 Air Handling Pre-Filters and Main Air Filters

  • 11 Thermostatic Expansion Values

  • 12 Liquid Line Solenoid Values

  • 13 All Safety Pressure Switches

  • 14 Temperature Cut-Outs

  • 15 Pressure Regulating Value

  • 16 Filter Indicator

  • 17 Operation of Condensate Drains and Pump

  • 18 Inspect Control Panels and Wiring

  • 19 Calibration of Gauges

  • 20 Leak Test System

  • 21 Refrigerant Charge

  • 22 Crankcase Heaters

  • 23 Pipework Insulation

  • 24 Filters and Driers

  • 25 Fixings and Mountings

  • 26 Fascias and Grills Cleaned

  • 27 AHU Coils, Drip Pans and Drains Sanitised

  • 28 Condensing Units Cleaned

Fire System Inspection

    Fire Extinguisher System (Before any test, must remove the trigger from fire cylinder to avoid erroneous gas discharge.)

  • Which?

  • Fire cylinder pressure : Check if the fire cylinder pressure pointer is in normal range.

  • 1) Fire Controller Panel<br>Check if the Fire Controller Panel show "All normal"

  • 2) All heat sensor<br>1. Use heat detector tester to activate heat sensor.<br>2. The bell will alarm, and the ESS and HVAC will shut down right now.<br>3. Press the reset button on fire panel to clear the alarm.

  • 3) All smoke sensor<br>1. Use smoke detector tester to activate smoke sensor.<br>2. The bell will alarm, and the ESS and HVAC will shut down right now.<br>3. Press the reset button on fire panel to clear the alarm.

  • 4) Level 1 fire alarm<br>1. Activate one of smoke or heater sensor.<br>2. The bell will alarm, and the ESS and HVAC will shut down right now.<br>3. Press the reset button on fire panel to clear the alarm.

  • 5) Level 2 fire alarm<br>1. Activate both smoke or heater sensor.<br>2. Both bell and strobe will alarm, and the ESS and HVAC will shut down right now. The fire controller panel will go into countdown status, and the fire cylinder trigger will be active after countdown 30s.<br>3. Press the reset button on fire panel to clear the alarm and back the trigger pin to original position.

  • 6) Function test-Manual/Auto switch<br>1. Turn the key to position "Auto" on the Manual/Auto Switch, and the fire controller panel show "ALL NORMAL".<br>2. Turn the key to position "Manual" on the Manual/Auto Switch, and the fire controller panel show "ABORT RELRASE SW NO PENDING RELEASE NO ACTION".

  • 7) Function test-emergency start<br>1. Push the emergency start handle to activate the emergency start signal.<br>2. Both bell and strobe give alarm, and the ESS and HVAC will shut down right now. The fire cylinder trigger will be active right now.<br>3. Recover the emergency start handle,reset the fire controller panel and back the trigger pin to original position.

  • 8) Function test-emergency stop<br>1. Make the fire extinguisher system going into level 2 fire alarm.<br>2. Press down the emergency stop button, and the fire controller panel countdown will stop at last 10s of the 30s countdown process.<br>3. Release the emergency stop button, the countdown will go on. The trigger will be active when 30s countdown process finish. When the 30s countdown finish, the emergency stop function will be disabled.<br>4. Reset the fire controller panel and back the trigger pin to original position.

  • 9) Test fire alarm under Manual mode <br>1. Turn the key to "Manual" position on the Auto/Manual Switch.<br>2. Make the fire extinguisher system going into level 2 fire alarm.<br>3. Both bell and strobe will alarm, and the ESS and HVAC will shut down right now.<br>4. The fire controller panel countdown will stop at last 10s.5. Reset the fire controller panel and back the trigger pin to original position.

  • 10) Fault function-heat/smoke sensor<br>1. Take down any one heat or smoke sensor, the fire controller panel will give buzzing and fault message.<br>2. All heat or smoke sensor are required to be checked.

  • 11) PCS fire trace system linkage function<br>1. Short connect the two pin of the fire trace system signal plug on fire controller panel, to simulate the PCS fire trace system active signal.<br>2. Both bell and strobe give alarm, and the ESS and HVAC will shut down right now.3. The fire controller panel will give related fault message.

Other Inspection

    Lighting System

  • Which?

  • General lighting : Check if it is working normally.

  • Emergency lighting : Check if it is working normally.

    • Container

  • Which?

  • Container appearance : Check if any damage or rust.

  • Container nameplate : Check if container nameplate are fixed tightly.

  • Container door lock: Check if container door can be open smoothly.

  • Container inner cleaning: Clean the container inner if any rubbish stay on the escape routine.

    • Firmware Version

  • UC

  • PCS HMI

  • BSMU

  • BECU

  • ACDC

  • ADAS

  • EMCU

  • Master

  • RTU

  • DMC HMI

Capacity Test

    Capacity Test

  • Which PCS？

  • Time

  • Initial SOC 0% Meter Reading Import/kWh

  • Initial SOC 0% Meter Reading Export/kWh

  • Time

  • Full Charge to SOC 100% Meter Reading Import/kWh

  • Full Charge to SOC 100% Meter Reading Export/kWh

  • Time

  • Wait 1 hour Initial SOC 100% Meter Reading Import/kWh

  • Wait 1 hour Initial SOC 100% Meter Reading Export/kWh

  • Time

  • Full Discharge to 0% Meter Reading Import/kWh

  • Full Discharge to 0% Meter Reading Export/kWh

  • Calculations-Charge Energy /kWh

  • Calculations-Discharge Energy /kWh

  • Calculations-Battery Effiency /%

Completion

  • I confirm that the performed work, issues encountered, corrective actions, and follow up action items as stated in this report are accurate.

  • Technician Full Name and Signature

  • Client / Owner Name and Signature

Battery container + 800kw PCS annual Inspection Template
Zhirui Chen

Battery container + 800kw PCS annual Inspection Template

Scope This manual is for BYD Engineers attending operational battery sites, operational sites are ones where Site Acceptance Test (SAT) have been completed and signed off by both Customer and BYD. BYD deputes Engineers to maintain, service and repair Battery Energy Storage Systems (ESS) operating at site, such Engineers need to follow this manual to ensure safety and contractual requirements that Customer has with asset owners under EPC and O & M. Maintenance activity Procedures to be followed 1. As far as possible, Engineers site visit plans are to be communicated to Customer as early as possible, as a minimum weekly plan to be provided before 3pm of previous Friday. 2. When site visits are required at short notice, prior notification will still be required, this could be through email or phone call to Customer. 3. On arriving at the site and before leaving sites, customer need to be informed, this could be through an update on phone or group WeChat. 4. Vehicles should be parked at designated areas only. 5. Codes for opening gates and disabling alarms are to be obtained from Customer, these should not be disclosed to anyone. 6. Security alarm is to be disabled before entering site and it should be armed before leaving site followed by a phone call to Customer. 7. If any damage to gate, lock or alarm is noticed, these should be reported to Customer immediately. 8. If Engineers need to take control of the ESS, Customer need to be contacted for permission by phone or through Group WeChat and wait for permission to be granted. After completion of work Customer will need to be contacted on the same number and ensure that Customer has full control of the ESS before leaving site. Permit to Work 1. BYD Engineers are only permitted to work on equipment provided by BYD RAMS (Risk Assessment and Method Statement) Battery sites include solar PV Farms and stand-alone locations, BYD provide RAMS (to be agreed beforehand) to work at such sites for review by customer. When at sites, Engineers will be required to evaluate site specific risk assessments. PPE 1. Mandatory five part PPE are required to be worn when entering sites, these are Safety Shoe, Hi Viz Jacket, Hard Hat, Safety Gloves and Safety Glasses. 2. If access to battery compartment of ESS is required, additional PPE will need to be worn, these are Flame Proof Vest, Visors and High Voltage Gloves. Tools and Equipment 1. All tools used at sites will need to fit for purpose. 2. Hand tools must be insulated 3. Meters and Test Equipment will be fit for purpose and Engineers should have valid calibration certificates. Emergency Arrangement 1. Operatives must be aware of location coordinates and ESS escape routes prior to starting work. 2. If working alone a line manager must be notified before and after work has finished. 3. All operatives must be aware of the emergency services number before starting work and where applicable review the ESS site H&S file. 4. First aid kit should be accessible either kept on site or on vehicle. Capacity Test Notes: 1. Prior to conducting System Capacity Check, conduct many short duration charge/discharge cycles to ensure that the ESS and Import/Export meters are working correctly. 2. Make sure that the batteries has been equalized and have similar voltage and temperature level. 3. Discharge the ESS fully till the Controller stop the system automatically on reaching lowest charge before carry on capacity test. 4. During the capacity test, the ESS need to be operated at the rated power unless the site restrictions do not permit this. 5. Provide photographs to show all key information. 6. Wait 1hrs between charge and discharge cycles for batteries cooling.

Use this Template
The templates available in our Public Library have been created by our customers and employees to help get you started using SafetyCulture's solutions. The templates are intended to be used as hypothetical examples only and should not be used as a substitute for professional advice. You should seek your own professional advice to determine if the use of a template is permissible in your workplace or jurisdiction. You should independently determine whether the template is suitable for your circumstances.

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