ESMA

Power Audit Summary

Idea Delhi/ NCR/ Andhra Pradesh
1

Contents
Operational Specifications
Operational Specifications
Operational Specification Implications
Operational Specification Implications
Audit Summary & Findings
Audit Summary & Findings
Failure Data Analysis
Failure Data Analysis
Final Recommendations.
Final Recommendations.

Operational Specifications :

ESMA module has built-in protection for low and high operating line-voltages, as below

Input VDC

FEPD Unit Status

LED

Outputs

=< 31.0

Not Operational

Off

Off

31.5 38.0

Transitional Shutdown & Startup

Red

ON

38.5 40.0

Operational transition range

Green

ON

40.5 57.0

Rated operation

Green

ON

57.5 59.5

Operational transition range

Green

ON

60.0 61.5

Transitional Shutdown & Startup

Red

ON

=>62.0 **

Not Operational

Off

Off

Operation Specification :

Voltage

Temperature

Environment
al

Ventilation

Nominal System Voltage 48 V dc

Input operating voltage 40.5 to 57 V dc
Leakage current should be less than 7.78 mA

Low temperature -40deg C / -40deg F

High temperature with guaranteed performance -50deg C / -122deg F
High ambient temperature limited (temporarily) -55deg C / -131deg F
maximum of 24 hours continuously, or 8 hours in consecutive days up to a total of 360 hours/year

Maximum permissible limits for humidity ~95%

Heat and moisture may cause damage
Protect the BTS from direct rain, splash water, dust & high humidity combined with air pollution

Back air intake & Front exhaust

Cables be routed on the module sides to prevent the obstruction of airflow from the BTS

Operational Specifications :

DC input Voltage Vs Site Alarms.

Operational Specifications Implications :

Higher voltages outside specified range (voltages surges / transients) can cause damage due to exceeding component
ratings .
The ESMA though has been tested to withstand the usual IEC defined surges and transients standards:
Tested for 1kV line-ground and 500V line-line, with 8/20us peak : Poor site grounding and earthing can reduce the effectiveness of ESMA internal protection.
Cables which are not earthed or screened properly can be a source of transients, effectively bypassing the in
built protection.
There are higher chances that repeated overvoltage peaks (60V 63V) could be causing damage over time.
Grounding looping is dangerous , it create leakage of neighbors to affect equipment modules.
The ESMA should not be damaged by operating voltages within the range stated above.
The burn position represents the weakest point and the first component to be damaged when an low voltage / overvoltage/surge condition occurs.
Missing IP seal or cracks may cause issue at longer run
Mandatory usage of ESD wrist band required at site.
6

Temperature Requirement : ESMA

Basic Cooling
The recommended constant ambient temperature for modules installed inside the
cabinet must be -40 C to +50 C (-40 F to +122 F).
Ambient temperature is allowed to exceed +50 C (+122 F) up to +55 C (+131
F),
for a maximum of 24 hours continuously, or eight hours in consecutive days up
to a total of 360 hours per year.
Cooling requirements for Flexi BTS modules
In the rear side of the cabinet, the minimum distance between the Flexi BTS
cooling fans to any obstacle is 90 mm (measured from the fan plate)
The air volume flow requirement for one Flexi BTS module is 200 m3/h.
The pressure drop caused by the rear side wall and front door (wall) for one module fan
can at the maximum be 51 Pa (including the combined pressure drop for both walls) with
an air volume flow of 200 m3/h.
All modules must receive cool ambient air,
The circulation from the front of the module to the rear side of the module must be
prevented. There must be a long enough distance to the wall (or any other obstacle) in
the rear side of the cabinet, so that the required airflow rate (200 m3/h) is reached in all
modules used.

Monthly Return Trends and Repair analysis review

Part Name as Per SAP: ESMA EDGE SYSTEM
MODULE

Network Element: BTS

Part Code as Per SAP: 470246A

BL: RA-GSM/EDGE BSS

Repair Analysis

6 monthly rolling average monthly return rates

above design goal. Excluding only the fault code 40,
returns hovering around the goal
8

Fault code 36, i.e. component failures is the

top cause followed by returns those could
not be repaired. We analyzed the top 2
causes forming 93.3% of total failures

Deep dive of repair analysis

Repair
Category

Analysis

%
share

Fault code
36

Miscellaneous
components

20.3%

LMU / Rectifier

32.2%

MOSFET/ FECB

9.9%

Fan damage

8.3%

FECB damage
due to
electrical
overstress
causing thermal
damage

9.9%

Water damaged

5.8%

Miscellaneous

6.9%

Fault code
40

60.3%
failures
due to
damage in
power
distributio
n
elements

These failures can happen due to:

Power-line surges or transients; which ripple
through the power-line and potentially also
damaging the Fan units
Frequent power feed instability (voltage
dips, brown outs and spikes) may have a
wear out effect on affected internal circuitry
Electrical environment at the site of failure
may be worse than the designed ETSI
Susceptibility standards
Water leakage is predominately due to IP
seals not properly installed

We did sample site assessments including advanced power audits using oscilloscope to test
this analysis

Audit Summary Delhi / NCR / AP

Sites Audited: 10*
NCR=5 & AP=5

Cluster covered: Delhi / NCR / AP

Module Audited: ESMA
Objective: To investigate RCA for frequent ESMA failures.
Tools Used :

*
10

Fluke power meter ,

Fluke IR thermometer,
Fluke earth tester &
Environment Probe

Identified as repeated ESMA failure Sites

Audit Summary Idea,

Delhi /NCR

High severity issue

Low severity issue
Good

Observations
BTS - Site
System Module

Samalkha
Indoor
ESMA

Amity School
Indoor
ESMA

NEPZ
Indoor
ESMA

Sahapur
Indoor
ESMA

Loni
Indoor
ESMB

BTS Grounding

Resistance ~ 0.072
ohm Loop Suspected

Resistance ~ 0.165 ohm

Loop Suspected

Resistance ~ 0.289 ohm

Loop Suspected

Resistance ~ 0.047 ohm

Loop Suspected

Resistance ~ 0.069 ohm

Loop Suspected

Grounding Pit

High resistance 5.67

ohm at earth pit

Resistance value was 0.79

ohms

High resistance 4.504 & Resistance value was 1.31

6.207 ohms near to earth
ohms
pit)
Surge & Spikes in Surge observed 63.5
Power observation not
Surge observed 74.4 Vdc
No DC Voltage Surge,
DC Power Supply
Vdc
allowed due to Dushera break
although THD between
Current & Voltage is > 5%
Leakage Current
(Value < 7.78mA
Battery Bank

29.27 mA

3.75 mA

OK

6 cells are suspected faulty

28.62 mA

17 cells are suspected 6 cells are suspected faulty

faulty in two battery banks

PCM/E1/Alarm Alarm cable shield not

Alarm cable shield not
Alarm & PCM cable shield
Cable Shield
grounded
grounded
not grounded
grounding
Installation of
Modules are not fixed
Modules are not fixed
Modules are not fixed
Modules inside
properly
properly
properly
cabinet
IP Seal on unused IP Seal missing at IP Seal missing at unused
IP Seal missing at
port
unused ports
ports
unused ports
Dust
NOK
NOK
NOK
11

Resistance value was 0.4 ohms

Surge observed 60 Vdc

0
OK

Alarm cable shield not

grounded

Alarm & PCM cable shield not grounded

Modules are not fixed

properly

OK

IP Seal missing at
unused ports
NOK

IP Seal missing at unused ports

~ OK

High severity issue

Low severity issue
Good

Audit Summary: Idea, Delhi / NCR

Observations

Samalkha

Amity School

NEPZ

Sahapur

Loni

Ambient Temperature

Moderate High
Ambient

High Ambient

High Ambient

OK

High Ambient

Neutral & Ground

Neutral disturbance
observed

4 V between Neutral &

Ground

0V, NG connected

0V, NG connected

0V, NG connected

Temperature @
ESMA /ESMB

Moderate High

High

High

High

High

Operating DC Voltage
( Value: -40.5 to
-57.7)

EB Supply

12

-53.9 V

-51.6 V

-54.2 V

-54.1 V

-53.8 V

L1 & N = 232
L2 & N = 235
L3 & N = 238
L1& G = 234
L2 & G = 233
L3 & G = 236
N&G=2

L1 & N = 228
L2 & N = 230
L1& G = 232
L2 & G = 233
N&G=5

L1 & N = 237
L2 & N = 239
L3 & N = 240
L1 & G = 237
L2 & G = 239
L3 & G = 240
N&G=0

L1 & N = 240
L2 & N = 238
L3 & N = 232
L1 & G = 239
L2 & G = 235
L3 & G = 233
N&G=0

L1 & N = 231
L2 & N = 231
L1& G = 232
L2 & G = 231
N&G=0

Audit Summary: Idea, AP

Observations
BTS - Site
Systeme Module
BTS Grounding

High severity issue

Low severity issue
Good

Allwyn Colony
Outdoor
ESMB*
Resistance ~ 0.164Ohm
Loop suspected

Jagadgirigatta 2
Indoor
ESMB*
Resistance ~ 0.159Ohm
Loop suspected

Earth Pit not accessible

Resistance ~ 0.720 Ohm

Earth Pits are not maintained

Resistance ~16.20 ohm

Power Test not done

Full of Surges ~57.2V

Surge observed max 56V

No surge observed

Surge observed max 56,2V

0A

29.45 mA

85.7 mA

53.88 mA

5.372mA

Some cells were found

bulged, 3 cells are
suspected faulty

Voltage dips from 54.3 V to 50.3

V in 10 mins

Voltages dips from 53.8 V to

48.4 V in 10 mins

Voltages dips from 54.7 V to

49.4 V in 10 mins

Voltages dips from 54.7 V to 47.5 V for

first set & 54.2 V to 46.7 V for second set
in 10 mins. 13 cells are suspected faulty.

Alarm & PCM cable

shield not grounded
Rusted Bolt & multiple
connection on single
Clamp on cable ladder

Alarm cable shield not grounded

Alarm cable shield not

grounded.
No grounding at near EGB

Grounding Pit

Surge & Spikes in DC

Power Supply
Leakage Current
(Value < 7.78mA)
Battery Bank

PCM/E1/Alarm Cable
Shield grounding
Feeder Grounding

Installation of Modules
inside cabinet
IP Seal on unused port

Dust

Siddiamber Bazar
Bibi Nagar
Indoor
Indoor
ESMA
ESMA
Resistance ~ 0.181Ohm
Resistance ~ 0.222 Ohm
Loop suspected
EGB is not installed
Rusted ground connections
,temporary & loose connection @EGB
@IGB
Well maintained.
Resistance ~ 0.094 Ohm

Mansoorabad
Outdoor
ESMA
Resistance ~ 0.154Ohm
Loop suspected

High resistance value near to earth pit i.e.

19.20 ohm.

Outdoor Site, safety of tester

NA
IP Seal was missed at
unused ports
New BTS installed

Rusted Bolt on cable ladder

Modules are not fixed properly Modules are not fixed properly
***** Power connection at ESMB
were loose
IP Seal missing
IP Seal missing

NOK

13

* Instead of ESMA , ESMB was found at site during audit

NOK

Alarm & PCM cable shield not Alarm & PCM cable shield not grounded,
grounded
OK
No grounding at near EGB

Modules are not fixed

properly

Modules are not fixed properly

IP Seal missing

IP Seal is not used

IP Rubber boot bursted @ ESMA
power supply
NOK

~OK

High severity issue

Low severity issue
Good

Audit Summary: Idea, AP

Allwyn Colony

Jagadgirigatta 2

Siddiamber Bazar

Bibi Nagar

Mansoorabad

Ambient Temperature

Observations

OK

OK

OK

OK

OK

Humidity
( Value < 95 %)

OK

Low humidity RH 35 %

Low humidity RH 36-39 %

Low humidity RH 36-39 %

Low humidity RH 36-39 %

No corrosion observed OG3000

No corrosion observed OG3000

No corrosion observed OG3000

No corrosion observed OG3000

0V , NG connected

0V , NG connected

0V , NG connected

0V , NG connected

OK

OK

OK

OK

Environmental condition
Neutral & Ground
Temperature @ ESMA
/ESMB
Operating DC Voltage
( Value: -40.5 to -57.7)
EB Supply

No corrosion observed
OG3000
8 V between Neutral &
Ground
OK

-49.9V
L1 & N = 230
L2 & N = 247
L1& G = 240
L2 & G = 245
N&G=8

14

-54 V
L1 & N = 236
L2 & N = 234
L1& G = 236
L2 & G = 236
N&G=0

-53.7 V
L1 & N = 236
L1 & G = 237
N&G=0

-54.9 V
L1 & N = 247
L2 & N = 241
L3 & N = 236
L1 & G = 247
L2 & G = 241
L3 & G = 236
N&G=0

-53.9 V
L1 & N = 217
L1& G = 226
N&G=0

Audit Findings: Delhi/NCR/AP , Idea

15

Audit Findings:
Site Name : Samalakha , Delhi

Fluctuations in EB phase and Neutral is being transferred to DC load

16

Audit Findings:
Site Name : Samalakha , Delhi

61.2 V High Voltage observed at DC load.

17

Audit Findings:
Site Name : Samalakha , Delhi

18

63.5 V High Voltage observed at DC load.

Audit Findings:
Site Name : Loni , Delhi

19

Audit Findings:
Site Name : Loni , Delhi

20

DC voltage Surges & whiskers

Audit Findings:
Site Name : NEPZ , Delhi

21

Audit Findings:
Site Name : NEPZ , Delhi

22

Input AC Disturbances create unbalance & Pollute Output DC

Audit Findings:
Site Name : NEPZ , Delhi

23

Input AC Disturbances transferred to Output DC 74.4 V

Audit Findings:
Site Name : NEPZ , Delhi

24

Big Volume of Surges

Audit Findings:
Site Name : Jagadgirigutta , AP

25

Full of surges & Spikes

Audit Findings:
Site Name : Jagadgirigutta , AP

26

Full of surges & Spikes

Audit Findings:
Site Name : Samalakha , Delhi

27

Audit Findings:
Site Name : Mansoorabad , AP

Earth pits are not maintained & Earth Value is 19.3 ohm near to earth pit

28

DG Grounding is not connected