Malaysia Mab Klia

Home / Malaysia Mab Klia

Malaysia Mab Klia

A study of the MAB Satellite Equipment Room (SER) is attached below. This paper was prepared by MAB KLIA Management and maintenance division for submission to the Board for Tender and committee approval.

1. Existing SER rooms power distribution system and the monitoring devices.

Most of our power distribution system in the SER rooms are three (3) phase with 415Vac/40A/300mA power supply derived from the TNB and the alternative power source – generator. The related power supply will be terminated at the “Main Distribution Board (MDB)” and distribute to the UPS/rectifier for power back-up (approximately 30~60 minutes according to original technical specifications and requirement) in case of any power interruption before it is terminated to the end-point devices.

Some of the equipment’s status can be remotely monitor (NOT CONTROL and MANAGE) by the technical personal at the BMS Workstation through the “Direct Digital Controller (DDC)” to the server. The existing monitoring features of the power interruption event ONLY available manually for “MDB” failed and “UPS/Rectifier” status.

2. Problems received at the BMS center

With the statistics as shown in the “BMS SYSTEM EVENT REPORT” of some incident occurred at the following locations:-

1.1 Event date: 09/09/2005

1.2 TT number: 113394

1.3 Location: MDF G07 Ground Floor, SAT

1.4 Down time: 02: 00: 00

1.5 Incident arises: MDF G07 incoming power supply off at 12:50pm until 14:50pm

2.1 Event date: 28/12/2005

2.2 TT number: 121337

2.3 Location: MDF room Ground floor, SAT

2.4 Down time: 00: 56: 00

2.5 Incident arises: MDF G07 incoming Power supply off at 8:26am until 9:22am

3.1 Event date: 13/09/2006

3.2 TT number: NA

3.3 Location: MSBC1B1 and B2, Ground floor, CP

3.4 Down time: 00: 25: 00

3.5 Incident arises: MSBC1B1 and B2 Power tripping at 1:05am until 1:28am

3. Event Reports

In-conjunction to the incident and report 1, although the incident occurred not resulted from the power supply failure but it was no contact relay information and caused all related departments and technical personals must attend to the “suspected” remote site (MDF G07) and carry-out trouble-shooting, fault diagnostic and analysis of the event; thus, causes them approximately two (2) hours of downtime before the problem had been rectified. In this incident, parties involved in site attending were: Service desk, UTW and UPS contractor.

In-conjunction to the incident and report 2, it was shown that the incident happened worst than incident 1. The technical personal found that the power supply to the network and end-point devices were down at the same time due to the incoming circuit breaker had been isolated. The result also indicated that an earth fault, nuisance, lightning or a short-circuit surge was strike at the MDB/power line which caused the circuit breaker to tripped off the outgoing power source to the end-point devices and the DDC controller, thus, resulted to the controller unable to send the alarm event data to the workstation. The incident caused a down time of one (1) hour.

In-conjunction to the incident and report 3, improvement of the MDB power supply and the DDC were found to be highly critical in an operation. The DDC found to be faulty as it may be strike by surges from the power line and as stated in the report, 16 units of controllers were down due to a power change over from TNB to Generator which believed that the circuit breaker was tripped due to some surges or nuisance interruption. The incident caused a down time of half an hour.

In summary, all the incidents happened above were due to the power supply disruption and the DDC working conditions. As shown in the reports, the power supply source from the “Main Distribution Board (MDB) found to be manually access and easily tripped which caused by power interruption at the circuit breaker (if any of the fault strike at a sudden). Those power faults shall inclusive of: power/lightning surge, earth fault, nuisance, transient or harmonic discharge.

With the power interruption scenario, manual reporting to the BMS is a must if the DDC was down, personal site attending, site security clearance, site trouble-shooting and manual resetting shall be carry-out, which causes them a high down time, service interrupted, revenue losses and high service OPEX.

4. Reason/purpose for the development project to be carried out.

The problems happened in the SER rooms were due to power supply disruption at the related circuit breaker in the MDB by either power/lightning surge, earth fault, nuisance, transient or harmonic. The disruption also affected the controller and the intercom responding to the BMS control centre. Thus, resulted to a negative impact to the management of the following:

  • High on CAPEX/OPEX in service and maintenance expenses, downtime losses on power tripped/failure, service interrupted, revenue losses unpredictable,
  • The DDC did not provide retrieve event report capability.
  • Battery aging is high as the lifespan is short due to the numbers of cycle in charge/discharge (European standard of battery fully charge/discharge life span cycle should be approx. 800~1,200 times)
  • Territory restriction on service & maintenance, unnecessary time spend on security clearance and approval;
  • Mobilization cost is high, unmanageable and unreliable
  • At the DDC, no remote access control capability if the power supply is down and no proper power surge event logging report on historical record (like happened on incident 1).

To resolve and overcome these problems, we would like to propose an innovative Central Power Management System fully developed in Malaysia known as “IBES Centralized Management System (IBES CMS)”. The solution has been tested and deployed within many prominent organization and companies in Malaysia such as KLIA, Telekom Malaysia, MAXIS Berhad, SIRIM, MARDI, UKM, UPM, JKR, KLCC Twin Tower, Petronas data centre, Jabatan Perdana Menteri and even in Maybank Data Centres and many others.

The track records in the above territories proved that: inculcate

  • power failure or interruption to the SER rooms will be eliminated/minimized;
  • instant remote access and in-touch ONLINE of the SER rooms condition in the scenario of any unforeseen problem arises;
  • the system is fully functioning during all adverse condition for the past three (3) years (rain, lighting etc)
  • the performance and reliability of the end-point devices improved by more than 80%, whereby any failure (power) was fully recovered or remote access within a stipulated time (less than 5 second)
  • pro-long battery life-span when the numbers of cycle in charge/discharge is minimize/reduce (European standard of battery fully charge/discharge life span cycle should be approx. 800~1,200 times)
  • There are obvious savings on manpower (time), < 5 second of respond time, minimize mobilization expenses, reduce resources and costs.
  • the up-time of the SER room deliver better value to Customer Services (and enhanced revenue for MAB)

In KLIA, we have tested two pilots TRIAL-run at SDF 01 and MDF G07 since August 2007, with the proposed CMS ONLINE. The purpose of the TRIAL-run is to justify how the system benefits KLIA and MAB in long run. After a period of 1 year, with the statistic report recorded at the CMS workstation, we found that the IBES CMS system achieved great saving in:-

  • minimize power tripping in the above SER rooms,
  • instant and automatic reboot the power supply without personal attending,
  • minimize UPS battery charge and discharge cycles, pro-long battery life-span.
  • instant reporting to the technical personals via SMS and CMS workstation.
  • reduce revenue and time losses.
  • enhance MAB image with high operation efficiency and provides professional services to our valuable customers.

5. Propose enhancement to the incident 1, 2 and 3

With the incident 1, 2 and 3 above, we concluded into five (5) uncontrollable problems that need enhancement in our daily operation. The new proposed system has the advantages and value added of the following:-

  • failed to remote ON/OFF/reset control of the existing circuit breaker by means of GSM/LAN/WEB backbone;
  • minimize nuisance interruption to pro-long battery life-span;
  • detect power fault event and automatic provides fault diagnostic logging with pre-programmed software driven operation;
  • Eliminates nuisance interruption in the “MAIN DISTRIBUTION BOARD (MDB)”, and
  • Provides alternative monitoring and control incase DDC failure.

Need of improvement description

a) Failed to remote ON/OFF/reset control of the existing circuit breaker by means of GSM/LAN/WEB backbone;

The conventional circuit breaker is a manually operated device with no intelligent features and mechanism to be monitored and controlled by external devices, like BMS and DDC. It is also unable to detect any power fault and convert to communication data, like SMS/LAN/WEB for remote access by means of a hand-phone or PC workstation.

b) Minimize nuisance interruption to pro-long battery life-span

The existing circuit breaker always tripped off by nuisance or surges interruption in most of the operation. It leads to more often of charging/discharging of the battery As recorded in the European standard of battery fully charge/discharge life span cycle should be approx. 800~1,200 times.

c) Detect power fault event and automatic provides fault diagnostic logging with pre-programmed software driven operation;

The existing circuit breaker designed with no software communication backbone which resulted to the BMS and DDC not able to enhance remote monitor and control of the manually operated circuit breaker.

d) “MAIN DISTRIBUTION BOARD (MDB)”

The MDB is a protection gadget, serves to protect & supply power source to the UPS/Rectifier and end-point devices. The MDB contains of MCCB, ELCB/RCCB/ELR/MCB which serve to protect equipment against earth fault, surge, short-circuit and over-current during a power transmission to the end-point devices/equipment. Most of the time, the ELCB/RCCB/ELR tripped the power source which caused by nuisance, transient, lightning strike or harmonic surges and resulted to the following tragedies:-

  • Personal attending to site a must, mobilization cost is high;
  • Service interrupted & revenue losses;
  • The power source to the devices like DDC, BNA or servers is not fully protected;
  • Huge investment on UPS battery standby time;
  • Manual trouble-shooting or intervention is a must, down time period is longer;
  • No proper automatic event logging management report;
  • Borderless restriction, huge manpower in area coverage; and
  • High yearly OPEX and CAPEX.

e) Provides alternative monitoring and control incase DDC or BNA devices failure

The DDC is a dry-contact controller serves to provide signal either “OPEN CONTACT (OFF)” or “CLOSE CONTACT (ON)” to the service desk or the BMS centre. Although this dry-contact has been designed and integrated with the power output source from the MDB but it didn’t mean that the signal detected was 100% true as in this event, the availability of the power supply output from the MDB did not “ONLINE” with a proper power detection device; more ever, like this incident 1, the BMS also can generate a “FALSE” signal due to the fault of electrical devises.

In this event, the reliability and efficiency of the incoming and outgoing power supply and the end-point devices operation conditions are highly critical. To enhance the efficiency of an operation and improve the services, we request the proposed IBES CMS system to be the alternative monitoring and control device system which able to perform the following:-

  • To detect “ONLINE” of the power source from the MDB, with some real generated digital data;
  • The status of the TNB/Generator incoming and outgoing power supply with fault digital data shall be “ONLINE” with the Service Desk via LAN/WEB/GSM backbone;
  • Provides self intelligent automatic power reset of the power supply to the end-point devices in the event of earth leakage and power/lightning surges; and further provides fault diagnostic digital data report “ONLINE” with the Service Desk via LAN/WEB/GSM backbone;
  • The unique system must be able to identify any fault event in an operation. For example, if an earth fault is detected, the system shall performs clause (c) above and if it is a short-circuit event arises at any of the power line/UPS/end-point, the intelligent system must shut-down immediately and permanently, and further provides fault diagnostic digital data output report which to be “ONLINE” with the Service Desk via LAN/WEB/GSM backbone. In this scenario, a site visit and trouble-shooting is a must.
  • With the above (a), (b), (c) and (d) solutions, the downtime occurred in the “EVENT REPORT” stated on the above can be minimized. By providing this solution, all data can be collected and centralized at a CMS control centre (like BMS). Any fault complaint shall be software driven with pre-programmed reports and command operation.

In most of the fault operation (except short-circuit scenario), the unique system shall performs intelligent operation (with event reporting through the LAN/WEB/GSM) and power supply will be automatic reset to the end-point devices which resulted to the technical personal at the Service Desk shall only study the report from the PC workstation and not wasting unnecessary time and effort to attend the problematic remote site.

6. Why it needs to be carried out now?

Currently BMS system and DDC are designed to monitor all end-point devices and alarm operation status but exclusive of remote monitoring and auto control of power distribution and fault operation to the end-point devices with the disadvantages in the following:-

  • The BMS system does not have the function of neither to auto reset the existing power circuit breaker (ELCB, ELR, RCCB … etc), nor to provide diagnostic power fault event and self intelligent to set/activate for an operation after a power tripping scenario;
  • Historically, as recorded in the BMS system, the impact of power failures/disruption on BHS, FIDS, POS and Door access resulted to great losses inclusive of delayed on gate opening, daily OPEX and down time.
  • The BMS system is designed to monitor indirectly of the power supply status to the end-point devices through the DDC. The DDC is an indirect controller (not a detector/sensor) to collect data/information of the power supply working condition by a dry-contact signal; and yet, sometime, the mechanical devices will mis-triggering an alarm to the BMS centre as we had seen in the incident 1 above;
  • Delay of power recovery in SER room may impact on the network disruption in a particular coverage area. The disruption of services shall inclusive of flight information, revenue losses, BMS operation, baggage system, security system etc., and mostly, jeopardize MAB and Malaysia reputation and image as one of the world class service provider;
  • Frequent of power tripping will shorten the life-span of the UPS battery is also one of the worry.
  • Although the management has engaged UTW and UPS contractor to attend a problematic SER room, but sometime due to unforeseen circumstances and unexpected scenario, some incident happened was beyond our reach and always the down time was more than an hour (as attached in the report), which resulted to the impact as mentioned above. As the existing BMS is having some shortage of performance on the power monitoring and remote control that as an operator, we think need to improve and enhance the power reliability by implementing the proposed IBES CMS system, so to complementary the BMS system and to provide 100% assurance of a reliable power system in all the SER room.

7. What are the benefits of carrying out the project and the consequences of not carrying out the project?

The benefits of carrying out the project will be as follow:-

  • Enhance and upgrade the BMS and DDC features and capability; fully utilize and value added to the BMS for highest performance in today’s technology demand;
  • Enhances distinguish service and quality shall bring great benefits and highly recognition to MAB and Malaysia image as being one of the world class service provider in the region;
  • A Forward Thinking Centralized Power Management System for all the key and strategic business system (SER rooms, ATM, BMS, Systems and Servers); to enhance and ensure quality and service continuity, delivering ultimately an unprecedented and uncompromising high quality services to all our customers.
  • The recovery of power interruption/tripping due to lightning, power surge, earth fault, nuisance, transient or harmonic in SER rooms can be eliminated or improved in within 5 second instead of one (1) hour; instant remote “ONLINE” to the SER rooms is achievable which helps to improve efficiency in daily operation;
  • Provides 24 hours ONLINE monitoring and managing equipment operation; the central workstation can generate tripping analysis report and SMS function to alert the users when power failure or problem at the end-point devices occurs.
  • Assurance is given against AC power stability, reliability and eliminates nuisance interruption during power distribution to the end-point devices; immediate reset can be done automatically or remotely by pre-designated hand-phone or at the CMS workstation.
  • Prevent or minimize personal attending to a problematic site and provides remote fault report in advance via SMS or WEB/LAN/ONLINE and helps to achieve saving on daily OPEX; Emphasizes on “instant respond and action” which moving towards zero downtime;
  • Border-less service operation with instant and remote accessible connection via GSM/LAN/WEB backbone to a hand-phone or PC workstation; achieving great saving on daily OPEX saving;
  • Minimize equipment damages which caused by lightning strike or power surges; prevent revenue losses and helps to reduce yearly CAPEX; and

If the project is not carrying out, the consequences are:

  • Delay of power recovery in SER room may impact on the network disruption in a particular coverage area. The disruption of services shall inclusive of flight information, BMS operation, baggage system, security system etc, and mostly, jeopardize MAHB and Malaysia reputation and image as one of the world class airport service provider.
  • The BMS system does not have the function of neither to auto reset the existing power circuit breaker (ELCB, ELR, RCCB etc), nor to provide diagnostic power fault event and self intelligent to set/activate for an operation after a power tripping scenario.
  • Failure to achieve to enhance and ensure quality and service continuity, delivering ultimately an unprecedented and uncompromising high quality services to all our customers;
  • The recovery of power interruption/tripping due to lightning, power surge, earth fault, nuisance, transient or harmonic in SER rooms cannot be eliminated or improved in within 5 second instead of half an hour; instant remote “ONLINE” to the SER rooms by the BMS or technical personal is not achievable which shows poor efficiency in daily operation;
  • The existing BMS at the central workstation don’t have SMS function to alert the users when power failure or problem at the end-point devices occurs.
  • The existing BMS cannot remote access to control the circuit breaker; all operation and fault trouble-shooting shall be manually operated and it is time consuming;
  • Assurance is not given against AC power stability, reliability and eliminates nuisance interruption during power distribution to the end-point devices;
  • high impact of service interrupted as normalization of power supply will take longer time as the maintenance team takes time to be informed of the incident, security clearance, attend to site, manual trouble shooting and recover the power manually;
  • Personal attending to a problematic site is a must;
  • UPS will run for less than 30 minutes (Subject to the load) before the recovery of the power supply to normal as the fault cannot be identified in such a short time (< 5 second) and site attending and normalize the power supply will take more than one (1) hour.
  • Incidents like the above may occur again at anytime as all power supply to the SER rooms.

8. What is the current practice without the existence of the development project to be carried out?

The call center will be alerted by the BMS, then to inform the duty competent engineer for the power failure. Subject to the location of SER room and engineer needs to request for access authorization to the SER room, the power will be normalized only after the competent engineer attended to the SER room and manually reset the power breaker.