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PROJECT NAME : BDx CGK2 DATA HALL DC1D

DOCUMENT NUMBER : CGK2‐Eaton‐RFA‐MOP‐E‐001
REVISION LOG : 1

Method of Procedure for

Remove Batteries of UPS 2x600kVA

Prepare By:
PT. Eaton Industries

Proposed by Eaton Date: 11 JULY 2024

Mariston Frans P
Acknowledge by
BDx FMT/OPS CGK 2

Approved by
BDx Project
Reynaldi Aditya 12 July 2024

Approved by
HSE BDx
Project

E01‐P‐MOP‐EE‐001_ MOP Remove Batt of UPS 600KVA – CGK-2

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Methode of Operation Procedure

BDx – UPS CGK‐2 TKP

Remove Batteries of UPS 2 x 600kva

Doc. ID: E02‐P‐MOP‐EE‐201
Document Name: MOP Remove Batt of UPS 600KVA – CGK‐2 BSD
Document Version No.: 1
Document Effective Date:
Document Ownership:
Version No Revised By Description and Reason for Change Version Effective
Date
1.0 EN Remove Battery to Temporary Room Jun2024
2.0 MFP Remove Battery to Temporary Room Jul 2024

Session 1 – Initiating condition(s)

Existing Power room has 2 units of UPS 600KVA working in parallel system’s, remove the batteries
existing to temporary Batteries room is required.

Session 2 – Purpose of this document

 To provide temporary room in the area loading room with make a gypsum partition room
 To provide temporary cooling with install 2 units standing Air cool include installation piping
until outdoor unit
 To provide temporary tray cable ladders between UPS room to Battery temporary room
 To explain the procedure for removing the 2x600KVA UPS battery while online then moving the
battery to the temporary battery room in the Loading dock area.
 To clarify the risk of work and classify the mitigation plan required.
 To ensure that during replacement’s work is run smoothly and eliminated the risk (no downtime
occur)

Session 3 – Number of persons required to execute this procedure.

Executor Nos. of Contact number

workers
Eaton’s engineer 1
Technical 2
Technician 2
Helper 5
E01‐P‐MOP‐EE‐001_ MOP Remove Batt of UPS 600KVA – CGK-2
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Session 4 – Special tools and equipment required for this procedure.

1. Multimeter
2. Clamp meter
3. Rotary Phase Tester
4. Insulation Resistant Tester
5. Torque Wrench
6. Vaccum Cleaner
7. Cable Cutting
8. Hand Press Hyodrolic Scun
9. Hand Drill
10. Weld Trafo
11. Hand Cutting wheel

Session 5 – Personal Safety Equipment (PPE) required to execute this procedure

1. Insulation gloves
2. Safety Shoes
3. Helmet
4. Dust Cloth
5. Goggle weld
6. Hand gloves
7. long sleeved shirt
8. Safety Glasses
9. First Aid Equipment
10. Baricade Line

E01‐P‐MOP‐EE‐001_ MOP Remove Batt of UPS 600KVA – CGK-2

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Section 6 – Supporting Documentation

1. Existing Configuration
Layout UPS Room, Battery Room (EXISTING)

2. SINGLE DIAGRAM ELECTRICAL (EXISTING)

3. CGK‐2 BSD is supplies to power as follows:

a. Server room
b. Battery room
c. BCB Panel

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4 Layout for UPS EATON 600KWA & Battery

Batt. Lith-Ion
UPS L1.A4
Batt. Lith-Ion
UPS L1.A5

UPS
1

UPS
2

Panel BCB
Batt UPS L1.A5
Panel BCB
Batt UPS L1.A4

Equipment’s data :
Battery Dimension : 600 x 1000 x 2000 (mm) : 8 Rack
BCB Panel Dimension : 600 x 800 x 500 (mm) : 2 Unit

Scope of Works :
1. Rack Batteries UPS L1.A4 and Panel BCB Battery UPS L1.A4 dismantle and move to
temporary battery room
2. Rack Batteries UPS L1.A5 and Panel BCB Battery UPS L1.A5 dismantle and move to
temporary battery room
3. Make the room place a temporary battery by installing partitions and door

Make new partition for temporary battery

room

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5 Proposed the Potition of Rack Batteries and P.BCB

Area Batt. Lithium

UPS EATON

Partition and Door

Temporary

6 Proposed the Potition of Rack Batteries and P.BCB

Cable DC Power
UPS to Batter
NYAF 4Cx240mm

make a hole in the wall under the

raised floor for the hole

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7 Proposed Equipment dimension and section view of UPS EATON

UPS Dimension : 1200 x 1100 x 2059 (mm)

UPS Weight Frame : 779 Kg
UPM Weight : 39 Kg /Module

9 Proposed Equipment dimension and section view of Battery

Battery Dimension : 600 x 1000 x 2000 (mm)

Weight Frame : 329 Kg
Weight Battery : 62 Kg /Module

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10 Installation new cable DC power from UPS to BCB Panel and BCB Panel to Battery Bank
Temporary Room
11 Genset Running during the gradual replacement of ups units exiting
12 Mobilization of battery and rack Battery exisiting to storage BDX
13 Positioning Rack Battery with placement Modules Battery in the Rack
14 Termination, startup Battery and Power On

Impact on
Engineering System
Section 7 – Engineering Assessment of Risk Control
Standard

Moderate

Major
Minor
2
1 2 3

High 3 3 6 9

Likelihood of Incident
Medium 2 2 4 6

The Operational risk score should be determined using the Low 1 1 2 3

matrix set out on the right. Insignificant 0.33 0.33 0.66 1

Potential incidents with a risk score greater than 2 must have mitigation measure and / or controls
identified that reduce the revised risk score to no more than 2 so far is as this is practicable.

Once the final Risk Rating has been established the rules set out below MUST be applied.

1.
Potential Incidents related to work effort:
Electric shocks, short circuits, stops phase lines, falls and squish
Impact Score: 3 Likelihood Score: 3 Risk Score: 9
Mitigation Measure:
use personal protection, including the following :
1. busbars are covered with insulation
2. wearing electric gloves
3. used wear long sleeves
4. Take measurements before starting work

Revised Likelihood Score 1 Revised Risk Score: 1 Overall OPERATIONAL 1

RISK SCORE
2.
Potential Incident related to the work effort:
Shock Electrical and heavy object impact during Installation and termination cable Input UPS
E01‐P‐MOP‐EE‐001_ MOP Remove Batt of UPS 600KVA – CGK-2
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Impact Score: 3 Likelihood Score: 2 Risk Score: 6

Mitigation Measure: PPE during process Replacement UPS activity
Revised Likelihood Score 1 Revised Risk Score: 2 Overall OPERATIONAL 2
RISK SCORE
3.
Potential Incident related to the work effort:
The work of lifting has the potential to be squeezed, damage to the path that is traversed due to the
weight of the goods being lifted
Impact Score: 3 Likelihood Score: 2 Risk Score: 6
Mitigation Measure: make safety by using a pedestal on the path that will be traversed, workers use
personal protective equipment
Revised Likelihood Score 1 Revised Risk Score: 2 Overall OPERATIONAL 2
RISK SCORE
4.
Potential Incident related to the work effort:
The work when cutting iron material and iron connection work using welding equipment, which will
create a spark
Impact Score: 3 Likelihood Score: 2 Risk Score: 6
Mitigation Measure: make sure there is a fire extinguisher, workers use eye protection, hand protection
Revised Likelihood Score 1 Revised Risk Score: 2 Overall OPERATIONAL 2
RISK SCORE

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Section 8 – Full Procedure Details

Proposed the Potition of Rack Batteries and P.BCB UPS L1.A5

Cable DC Power
UPS to Batter
NYAF 4Cx240mm

make a hole in the wall under the raised

floor for the hole

make a hole in the wall under the raised

floor for the hole

Date:

Stages of Installation Cable UPS L1.A5

NO ACTIVITY DURATION OUTCOME RISK IMPACT ACTION

Conduct briefing before work to

1 Job briefing 10 Minutes N/A N/A Eaton
fit the SOP & MOP

Prepare the equipment to be

2 Prepare tools and special tools 20 Minutes N/A N/A Eaton
used before doing the job

Laying new cables and pull the Arrange a pile of cables on the
3 4 hours N/A N/A Eaton
cables are form UPS to BCB than to tray or ladder line that has been

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the rack battery bank provided

Make sure power source to UPS

L1.A5 before the rack Battery UPS to prepare dismantle rack
4 L1.A5 will be shutdown and 6 hours N/A N/A Eaton
dismantle, Power Source has batteries
supply for Genset

UPS L1.A5 set to mode bypass

static, than panel go to External
Bypass with Breaker Bypass Close. Place and arrange the new
DC High Short
5 Breaker panel BCB should be 3 hours battery in the rack that is Eaton
switch Open Voltage Circuit
already available
Take Out interconnection in the
rack battery and panel BCB

Handling
Moving all Rack Battery and panel fell and
moving
6 BCB UPS L1.A5 to Temporary 2 hours battery circuit is ready to use was Eaton
moduls
Room Battery crushed
battery

Remove the cables battery in the DC High Short

7 1 hour Cable power DC to battery Eaton
terminal busbar UPS L1.A5 Voltage Circuit

Termination the cables battery to

panel BCB UPS L1.A5, than Check connection and tighten DC High Short
8 1 hour Eaton
termination all inter‐rack battery the bolt with torque tools Voltage Circuit
to panel BCB

ensure the connection is good and Check connection and tighten DC High Short
9 1 hour Eaton
correct the bolt with torque tools Voltage Circuit

UPS L1.A5 Should be to start up,

Battery can to connection with the
breaker switch to Close.
UPS L1.A5 has running normal,
10 Make sure UPS has run and no 2 hour N/A N/A Eaton
alarm indication Genset should be to Stop

Make Sure UPS has supply power

to LOAD

11 Finish

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Proposed the Potition of Rack Batteries and P.BCB UPS L1.A4

Cable DC Power
UPS to Batter
NYAF 4Cx240mm

make a hole in the wall under the raised

floor for the hole

make a hole in the wall under the raised

floor for the hole

Date:

Stages of Installation Cable UPS L1.A4

NO ACTIVITY DURATION OUTCOME RISK IMPACT ACTION

Conduct briefing before work to

1 Job briefing 10 Minutes N/A N/A Eaton
fit the SOP & MOP

Prepare the equipment to be

2 Prepare tools and special tools 20 Minutes N/A N/A Eaton
used before doing the job

Laying new cables and pull the Arrange a pile of cables on the
3 cables are form UPS to BCB than to 4 hours tray or ladder line that has been N/A N/A Eaton
the rack battery bank provided

Make sure power source to UPS

L1.A4 before the rack Battery UPS to prepare dismantle rack
4 L1.A4 will be shutdown and 6 hours N/A N/A Eaton
dismantle, Power Source has batteries
supply for Genset

5 UPS L1.A4 set to mode bypass 3 hours Place and arrange the new DC High Short Eaton
static, than panel go to External
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Bypass with Breaker Bypass Close. battery in the rack that is Voltage Circuit
Breaker panel BCB should be already available
switch Open
Take Out interconnection in the
rack battery and panel BCB

Handling
Moving all Rack Battery and panel fell and
moving
6 BCB UPS L1.A4 to Temporary 2 hours battery circuit is ready to use was Eaton
moduls
Room Battery crushed
battery

Remove the cables battery in the DC High Short

7 1 hour Cable power DC to battery Eaton
terminal busbar UPS L1.A4 Voltage Circuit

Termination the cables battery to

panel BCB UPS L1.A4, than Check connection and tighten DC High Short
8 1 hour Eaton
termination all inter‐rack battery the bolt with torque tools Voltage Circuit
to panel BCB

ensure the connection is good and Check connection and tighten DC High Short
9 1 hour Eaton
correct the bolt with torque tools Voltage Circuit

UPS L1.A4 Should be to start up,

Battery can to connection with the
breaker switch to Close.
UPS L1.A5 has running normal,
10 Make sure UPS has run and no 2 hour N/A N/A Eaton
alarm indication Genset should be to Stop

Make Sure UPS has supply power

to LOAD

11 Finish

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3. SINGLE DIAGRAM ELECTRICAL (AFTER REPLACEMET)

Section 9‐ Full Mobilization & Dismatle

LAYOUT MOBILIZATION 1st FLOOR :

Area Battery Temporary Battery will be to remover

Room

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Date:

Stages of UPS Dismantle & Mobilization

NO ACTIVITY DURATION OUTCOME RISK IMPACT ACTION

Preparation :
will damage scratched
‐ make protection on the floor using
makes it easy to mobilize the the floor on damaged
1 a plywood plinth 1 Hours Eaton
device to be taken out the way broken
‐ In the raised floor area, use a base
through vanished
in the form of an iron plate

Breaker Input UPS is OFF

‐ make sure the ups is off and there
prepared to be disassembled be cannot
2 is no power source connected 1 Hours Eaton
and can be lifted out squeezed be issued
‐ make sure the cable connection is
disconnected on each terminal

‐ do the lifting using a hand pallet

‐ pull out through the road that has
been provided protection be cannot
3 1,5 Hours ups can be taken out easily Eaton
‐ take it out carefully so as not to squeezed be issued
damage the floor on which it
passes

‐ save it in the storage space that has

cramped,
been prepared The UPS has been properly the room is
4 30 minutes does not Eaton, BDx
‐ ups protection that has been stored not enough
fit
properly stored

5 Finish All work Done N/A N/A N/A

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Section 10 – AC STANDING TEMPORARY

LAYOUT MOBILIZATION 1st FLOOR :

Outdoor Unit AC
Piping AC
Standing

Indoor Unit AC

Date:

Stages of Installation AC Standing

NO ACTIVITY DURATION OUTCOME RISK IMPACT ACTION

Preparation :
‐ Preparation of a standing indoor AC
will damage
stand 25cm high
Marking and pipe lines are floors and floors
‐ Prepare an outdoor AC Support
1 1 Hours available for installation from walls during and walls Eaton
wall mount
indoor to outdoor installation damage
‐ Prepare a 3 Phase 32 Amp Power
work
cable,
‐ Siapkan pemutus fasa 32 Amp 3

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Positioning base frame Indoor

‐ make sure the placement position
prepared to be disassembled be cannot
2 is ready 1 Hours Eaton
and can be lifted out squeezed be issued
‐ make sure the cable connection is
disconnected on each terminal

‐ install the outdoor AC mount and AC indoor and Outdoor can be be cannot
3 5 Hours Eaton
install the outdoor unit taken easily squeezed be issued

‐ Connect pipes indoors and

outdoors
‐ carry out a press test on the AC Installed AC Cooling for Battery be cannot
4 4 Hours Eaton,
pipe installation Temporary Room squeezed be issued
‐ fill the freon and turn on the air
conditioner

5 Finish All work Done N/A N/A N/A

Section 11‐ Test Scrip Check List, Sequence and Time line

separate form attachment

Section 12‐ Completion

SOP Performed by: Job Title:

SOP Approved by: Job Title:

Section 11 – Escalation

In case of system features and functional problem, please contact

Primary Support:
Secondary Support:
EATON Contact

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Section 13 – Training record

Name Job Duty Date

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