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ENGINEERING SPECIFICATION

UNINTERRUPTIBLE POWER SUPPLY

DOC NO. : 6261-N-137

TOYO ENGINEERING INDIA LTD. JOB NO.: 6261

ISSUED DATE: 18/02/2009 A DHT PROJECT PAGE NO 2 OF 21

N-137

C O N T E N T S PAGE NO. 1.0 General 3 1.1 Scope 3 1.2 Specific Job Requirements 3 1.3 Codes and Standards 3 1.4 Order of priority 4 2.0 Equipment Specifications 4 2.1 Technical Requirements 4 2.2 Classification 5 2.3 Design and characteristics of units with Non-Redundant 5 Configuration. 2.4 Design and characteristics of units with Redundant 6 Configuration 2.5 Synchronisation with Mains 7 2.6 System Component Characteristics 7 2.7 Battery 10 2.8 Construction 11 2.9 Internal Wiring 13 2.10 Terminal Blocks 13 2.11 AC Distribution Boards 13

2.12 Mimic Diagram, Metering, Indication and 14 Alarm Details 2.13 Nameplates 16

2.14 Painting 17 3.0 Inspection and Testing 17 4.0 Fault diagnostic unit 20 5.0 Packing and Transport 21




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1.0 General 1.1 Scope This specification covers the general requirements for design, manufacture, inspection and

testing at vendor’s works of the Uninterruptible Power Supply system (UPS system) . Each UPS system shall comprise of following :- - 100% Float cum Boost Charger

- 100% Battery Bank

- 100% Static Inverter

- 100% Static bypass switch

- Manual bypass switch

- Voltage stabilizer for bypass line.

- Stepdown transformer

- AC distribution board

- Interpanel cabling

- Any other equipment required for completeness of the system

Components shall be capable of withstanding the thermal and dynamic stresses resulting from internal and external short circuits and circuit switching operations etc.

The design of UPS shall be such as to minimise the risk of short circuits and shall ensure personal and operational safety.

The UPS shall be three phase or single phase system as indicated in data sheet.

The UPS shall be suitable to feed all loads connected to output which are primarily instruments, DCS, computers, disk drives and other SMPS equipment leading to high crest factor of the load.

1.2 Specific Job Requirements Specific job requirements which are herewith attached cover modifications/additions to this

specification, Purchaser’s special and/or local requirements as well as specific job requirements pertinent to this specification.

1.3 Codes and Standards The design, manufacture, testing and performance of equipment shall comply with the

provisions of all currently applicable statutes, regulations and safety codes in the locality where the equipment will be installed.




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Equipment shall comply with following standards.

IS:5 : Colours for ready mixed paints and enamels. IS: 1248 : Direct acting indicating analogue electrical measuring (Part 1, 2. 4

and 9) instruments and their accessories. IS:2147 : Degree of protection provided by enclosures for low voltage

switchgear and control gear. IS:3700 : (Part 1 to 11)

Essential ratings and characteristics of semiconductor Devices.

IS:3715 : (Part 1 to 4)

Letter symbols for semi-conducting devices.

IS:4411 : Code for designation of semi-conductor devices. IS:5001 : (Part 1 & 2)

Guide for preparation of drawings of semi-conductor devices and integrated circuits.

IS: :5469 : (Part 1 to 3)

Code of practice for the use of semi-conductor junction devices.

IS:7204 : (Part 1 to 4)

Stabilised power supplies D.C. output

IS:12021 :

Control transformers for switchgear and control gear for voltages not exceeding 1000V AC

IS:13314 :

Solid state inverters run from storage batteries

IS: 13703 : (Part I to 4)

Low voltage fuses for voltage not exceeding 1000V AC or 1500V DC

IS: 13947 : (Part-4/ Sec- 1)

Specification for low voltage switchgear and control gear.

1.4 Order of Priority

The Bus duct shall conform to the provisions of Indian Electricity Rules and other statutory regulations, as applicable. In case of any contradiction between various referred standard/ specification/data sheet and statutory regulations, the following order of priority shall govern: Statutory Regulations Specific Job Requirement Data Sheet This Specification Codes and Standards

2.0 Equipment Specifications 2.1 Technical Requirements 2.1.1 The UPS shall be suitable for input power supply as defined in the data sheet. In addition ,

the input voltage may be subject to transient comprising voltage dip to 20% of normal voltage during motor start-up and voltage interruption during short circuit. UPS shall be designed to




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operate satisfactorily while driving the input power from an emergency DG set. 2.2 Classification The required system shall have one of the following basic configuration as specified in data

sheet. (a) Non-Redundant

This configuration consists of a single-feed line comprising static battery charger, battery bank and inverter operating with mains “back up”(stabilised bypass supply).

(b) Redundant

This configuration consists of two feed lines each consisting of a static battery charger, and inverter, with common mains “back-up” (stabilised bypass supply). Both the feed lines will have a common battery bank or one battery bank per feed line with 100% or 50% battery capacity as specified in data sheet.

2.3 Design and characteristics of units with Non-Redundant Configuration The static uninterruptible A.C. power system corresponding to a design configuration using a

single inverter in continuous operation with mains back up (i.e. ON LINE UPS) is made up basically of transformers, battery charger, battery bank, inverter, static switch, manual bypass switch and a servo controlled voltage stabilizer. The detailed operation is described in following clauses.

2.3.1 Under Normal Conditions, the load will be fed from the inverter by way of the static switch

and the battery charger will supply the power output necessary to the inverter and at the same time, maintain the batteries in their charged condition.

2.3.2 When the mains supply is not available, or the battery charger is out of service, the batteries

shall supply sufficient power to the inverter, at the D.C. Voltage anticipated, so that the inverter can supply the maximum power for the period specified.

2.3.3 When the mains voltage is recovered, the battery charger must recharge the batteries to the

required voltage within the time limit specified and simultaneously supply the entire power necessary for the inverter.

2.3.4 When one of the under-mentioned conditions arises :- (a) Inverter out of service / Inverter overloaded (b) Lack of supply to inverter. (c) Output voltage of inverter has a value less than 85%-90% of the nominal value. A static switch, with high transfer speed shall transfer the whole load automatically from

inverter to the back-up system. 2.3.5 In order to resume the supply through the inverter, the static switch shall be repositioned

automatically.




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2.3.6 A manual by-pass switch must be provided, thus permitting manual transfer of load from the inverter to the mains and vice versa, without interruption in the supply to load. 2.4 Design and characteristics of units with Redundant Configuration This configuration is further sub-divided as

(a) Hot standby system (b) Parallel system

2.4.1 Hot Standby System In this system there are basically two feeding systems. (a) Feed 1 being operational feed. (b) Feed 2 being the standby feed. The dual feeds are coupled through the static switch. 2.4.1.1 In normal operation the load shall be fed from feed 1 with feed 2 on standby. The battery

charger and battery bank shall function in the same manner as described in cl.no. 2.3 (Non- Redundant configuration) for temporary loss of mains supply or other transient conditions.

2.4.1.2 If, however, should any of the undermentioned conditions arises :-

(a) Inverter out of service (b) Lack of supply to the inverter (c) Output voltage of inverter has a value less than 85%-90% of the nominal value.

The static switch must switch the entire load to the stand-by inverter 2. 2.4.1.3 When feed 2 is supplying output and if the mains supply is not available or the battery

charger is out of service the batteries must supply sufficient power, at the D.C. voltage anticipated to the stand-by inverter 2 for the period specified.

2.4.1.4 When both inverter 1 and 2 are out of service, the static switch 2 must transfer the entire

load to the back-up mains. 2.4.1.5 In order to resume the supply through inverter 1 or 2, the static switch must be repositioned

automatically. A manual by-pass switch must be provided for manual transfer of the load from the inverters to the mains and vice versa without a break in the supply to the load.

2.4.2 Parallel System In this system there are two feeding systems, both being in operation. (Refer attached

sketch no. B-6261-086004)

2.4.2.1. Both feeds will operate simultaneously and supply 50% of the load. Both the battery chargers will supply the power output necessary for the respective inverters and at the




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same time, maintain the batteries in the charged condition. 2.4.2.2 In case of failure of one battery charger, the other charger shall feed the complete load and

the battery without any interruption. When both the battery chargers are out of service or if mains supply is not available, the batteries must supply sufficient power to both the inverters for a period specified in data sheet. Each battery charger shall be equipped with automatic ‘On Line’ as well as manual charging facility.

2.4.2.3 Normally both inverters will be synchronised with each other and with the stabilised

bypass supply. The two inverters shall operate in parallel and share the load equally. If however a disturbance or fault occurs in any of the inverters as specified in cl. 2.4.1.2 the faulty unit shall automatically be separated out and the entire load shall be fed from the other healthy inverter. Each battery charger and inverter shall be capable of supplying the entire load of the system and maintain the batteries in charged condition.

2.4.2.4 When both inverters 1 and 2 are out of service, the static switch must transfer the entire

load to the back-up mains. Retransfer of load from stabilised bypass supply to the inverter shall only be in manual mode.

2.4.2.5 A manual by-pass switch must be provided for manual transfer of the load from the

inverters to the backup mains without an interruption in the supply to the load. 2.5 Synchronization With Mains The inverter output frequency must be synchronized with that of the mains, provided the

latter does not vary by more than +/-4% with respect to its nominal value. The facility shall be provided for adjustment of synchronizing frequency from ±1% to ±4%

in steps of 0.5%. Outside these limits the inverter operates at its own frequency. Free running frequency tolerance limit shall not exceed + 1%.

2.6 System Component Characteristics 2.6.1 Incomer of UPS system :- There should be an incoming Isolator, Fuses, RYB indicating lamps, Ammeter, Voltmeter,

Frequency meter on the incoming side. Incoming supply details shall be as per data sheet. 2.6.2 Transformer:- Transformer must be sized for continuous operation. It must be complete with protection

system i.e. isolator, fuses etc on both primary and secondary side. The UPS system including the stabilised by pass shall be galvanically isolated from input

power supply system and from load by providing double wound transformers. All transformers shall be dry type and air cooled and suitable for location inside panel. UPS system shall be suitable both for floating output and earthing of one leg in case of single phase system or star point in case of three phase system.

2.6.3 Battery charger :-




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Under normal operating conditions with the system voltage variation within the limits specified the battery charger shall simultaneously supply:-

(a) The entire power necessary to the inverter for supplying load. (b) Float - charging current to batteries. If for whatever reasons, the batteries discharge excessively, the battery charger shall

recharge them automatically within 10 hours and also supply power to the inverter for feeding load. After the boost charging is complete it should automatically switchover to trickle charging. This must include the dual possibility of manual charging as well as automatic charging in all charging conditions. An auto charging sequence shall be provided for rapid and float charging based on current sensing. Also, the charging shall be transferred from rapid to float mode after preset time adjustable through 0-24 hour timer.

The rectifier shall be sized based on maximum inverter input load when inverter is

delivering its rated output at 0.8 p.f. lag and recharge the battery to nominal rated capacity of the battery. The DC load imposed by the inverters shall be considered under the worst case where only one rectifier is operating but the UPS load is equally shared by all the inverters.

The DC rectifiers shall sense the battery charging current and adjust the DC bus voltage to

maintain the charging current to preset level. A separate current limit circuit shall also be provided for adjustment of battery current. The rectifiers shall be protected against reverse battery connection at DC link voltage bus. Subsequent to a discharge cycle when battery is connected to rectifier, the battery current shall be monitored, controlled and limited to set value automatically irrespective of the inverter input current.

Battery charger must be provided with all the necessary protection to ensure regular

operation and tripping under critical conditions. Battery charger shall have output current / voltage metering, indicating lamps showing

condition of charging of batteries, earth fault relays, undervoltage/overvoltage relay etc. 2.6.4 Inverter :- Each inverter shall be of static type, single phase for single phase loads, three phase for

three phase loads. The inverter shall be suitably designed to withstand the transient voltage surges generated because of starting of motor, fault etc.

The inverter shall have Switches, Fuses, current / voltage / frequency metering on output side and also includes necessary protection devices to protect from overload, short circuit and 100% loss of load. Current limiting features like DC filters on incoming side to remove ripples, A.C. filters on outgoing side to nullify harmonics shall be provided. Buffer capacitors to protect from voltage dips shall be provided.

The inverter shall operate satisfactorily for variation of DC bus voltage from fully discharged condition of the battery to rapid charge voltage of battery and inverter output load current waveform having a relative harmonic content varying between 0 & 50%, the latter waveform having a crest factor not exceeding 2.5 and individual harmonics not exceeding the following values:

- 3rd : 44% of fundamental - 5th : 33% of fundamental




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- 7th : 18% of fundamental - 9th : 07% of fundamental - 11th : 10% of fundamental

(a) Performance under static conditions

The maximum admissible output voltage should be within ±1% for load variation

between 0-100% of the nominal load & load power factor from 0.6 lag to 1.0 for single phase inverters. The same performance is required, in case of three phase inverters with balanced loads. For unbalanced loads upto 100%, the phase voltage with respect to neutral must be kept within ±5% of the nominal value.

The maximum admissible variation of output frequency is ±1% of the nominal value. The wave shape of the output voltage must be sinusoidal. The Total Harmonic distortion of voltage waveform at inverter output shall not exceed

4% of the RMS value of the fundamental considering any linear load upto maximum rated output of UPS system at rated power factor and not exceeding 15% under non-linear load.

The above mentioned performance must be maintained for mains voltage variation as

specified in data sheet. for loads between 5 to 100% of the nominal load and power factor within the range shown on the data sheet.

It shall be possible to vary the output voltage steplessly within ±5% of the specified

output voltage. This adjustment shall be possible to be made when the inverter is in operation.

(b) Performance under dynamic conditions Each inverter must be capable of withstanding an instantaneous variation of 100% in

the nominal load without its output voltage (mean value in one half wave) reducing by more than 5% of the mean value. Within 10 milliseconds of the above mentioned load variation, the mean value of the unit output voltage shall be maintained within ±1%.

(c) Overload - The inverter must be capable of withstanding an overload of 150% for at

least 60 seconds, 125% for at least 10 minutes. The overloading shall be based on nameplate rating and not the nominal load. UPS shall be provided with a current limit circuit to avoid excessive loading beyond its permissible overload withstand capability.

In case of excessive overload or inrush exceeds the capability of inverter, the static

switch shall transfer the load to the mains by pass..

(d) Return to normal (inverter) source shall be automatic for all externally caused transfers such as overload etc, but shall be manual for all internally caused transfers such as inverter failure etc. Undervoltage and overvoltage sensing levels to initiate transfer shall be adjustable.

(e) The maximum transfer time between inverters and bypass supply shall not exceed

4ms and 20ms in synchronous and asynchronous mode respectively.




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(f) Each inverter shall be designed to clear a fault in any of the branch circuits upto a

maximum rating of 25% of the system capacity without the assistance of the stabilized bypass supply. In case of any fault in branch circuits, the load connected to the healthy circuits shall not get affected. The fault clearing time shall be less than 4 msec.

2.6.5 Static Switch The Static switch shall comprise of silicon controlled rectifiers and other static devices

required to automatically transfer loads from normal source to the standby source and vice versa. Static switches shall have following characteristics.

(a) Continuous capacity equal to the continuous full load capacity. (b) Short time rating of all the static switches shall be at least ten times the rated output

for the duration more than the fault clearing time of the type of fuse provided. (c) Maximum transfer time including sensing shall be ¼ cycle. Transition shall be make

before break. (d) Overload capacity rating shall be 150% of the rated current for 60 seconds.

(e) Switch shall withstand transient voltage upto 150% of rated voltage.

Necessary protections shall be provided on both incoming and outgoing side and indicating lamps shall be provided for different positions of the switch as well as for mal-operation. Annunciation facility shall be provided for voltage variation and frequency variation outside prescribed limits.

2.6.6 Stabilizer All the conditions specified in cl. 2.6.4 (a) & (b) shall be applicable. A manual switch shall

be provided to bypass the stabilizer. The stabilised bypass supply shall have a continuous current rating equivalent to the rated

output of the UPS unit and be capable of conducting a current ten times the rated output for the duration more than the fault clearing time of the type of fuse provided. The load transfer devices may comprise either continuous rated static elements in both inverter and stabilised bypass supply.

2.6.7 Manual By-pass Switch

Manual by-pass switch is used to isolate any static switch transfer for maintenance or repair without interruption to the UPS load. It shall also have facility of bypassing both the static transfer switches during start-up or any other time at the option of the operator. The switch contact shall be make before break type. It shall have current rating equal to the full load inverter current and necessary short time load carrying and interrupting capacity to meet the requirement of UPS System.

In case of larger rating UPS, where it is not possible to provide one power switch with

make before break feature, combination of breakers with the control scheme having make




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before break logic may be provided which ensures momentary paralleling before tripping of selected breaker.

2.7 Battery The type of battery (Ni-cad, sealed maintenance free lead acid or vented lead-acid) shall

be as specified in the data sheet. It shall be the vendor’s responsibility to size the battery bank as per the UPS rating and

backup time specified in the data sheet. Make of the battery shall be as mentioned in Data Sheet attached with this specification.

Battery shall be complete with all accessories and devices including, but not limited to the following (for each battery):

1 lot - Battery stand in double row, double tier formation made of treated teakwood assembled without the use of any metal fastenings for lead acid battery.

1 lot – Intercell, interrow and interbank connectors and end take-offs of lead plated/PVC sleeved copper.

1 lot – Porcelain cell insulators. 1 lot – Stand insulators 2 nos. – Hydrometers suitable for specific gravity readings along with wall mounting

teakwood stand. 1 lot – Cell number plates and fixing pins as required. 2 nos. – Thermometers with specific gravity correction scale along with wall mounting

teakwood stand. 1 no. – Cell testing voltmeter complete with 1M long leads. 4 nos. – Level testers. 2 pairs of rubber gloves, eye penetration goggles 2 nos. rubber aprons. 1 set – Acid/Alkali resistant jugs and funnels. 1 set – Spanner set. 1 lot – Catalytic caps (for lead acid batteries) - Required quantity of electrolyte for initial filling of the battery set plus 10% extra in non-returnable containers. 1 No – Cell booster 2.8 Construction 2.8.1 All equipment except battery shall be housed in floor mounted, free standing enclosure.

The cable entry shall be as mentioned in the data sheet. The panel shall be single front type having rear access for maintenance. The panel shall

be fabricated from 1.6mm/2mm thick cold rolled sheet steel and structural steel. Degree of protection shall be minimum IP-31. Hinged doors shall be provided at front and back with dust tight gasket. Interpanel sheet steel barriers shall be provided.

The enclosure shall be epoxy painted shade 631 as per IS:5. All the panels of UPS system including ACDB shall have symmetrical dimensions, height

and colour of all panels i.e. UPS-1 , UPS-2, Input isolation transformer panel, Output ACDB shall be similar.




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The maximum and minimum operating height of switches shall be 1800mm and 300mm

respectively. 2.8.2 Cooling fans shall be provided to restrict the temperature rise. Louvres if provided, shall be

covered with fine wire mesh. Forced ventilation of the panel shall be supplemented by 100% redundant cooling fans. In

normal operation, normal and redundant fans shall run together. Each cooling fan shall be provided with an air flow switch having an alarm contact that closes upon failure of air flow. The power supply for the fans shall be tapped from the inverter output. However, the rating of the UPS as specified in the data sheet shall be the net output of UPS after deducting power consumption for fans etc. However, in case of non-operation of 50% of running fans, the UPS output shall not be affected. The fans shall be arranged to facilitate removal of faulty fan for maintenance without taking system shutdown.

2.8.3 Grounding bus of suitable material/size shall be provided throughout panel including ACDB

with provision for earth connection at both ends to Purchaser’s main earth grid. All non-current carrying metallic parts shall be connected to ground bus. Type and size of external earthing conductor used shall be specified in the data sheet.

2.8.4 Bus bars shall be colour coded and live parts shall be shrouded to ensure complete safety to

personnel intending routine inspection by opening the panel doors. All the equipment inside the panel and on the doors shall have suitable name plate and device tag numbers as per the schematic diagram.

2.8.5 All power and control switches shall be rotary type, mounted on the door and shall be

externally operable. All instruments shall be switchboard type, back connected, 72 x 72 mm, square of reputed make & analog/digital type. Analog instruments scale shall have red mark indicating maximum permissible operating rating. Separate test terminals shall be provided for measuring and testing of equipment to check the performance.

2.8.6 40W fluorescent lamp/CFL and 15A SP socket outlet with MCB shall be provided inside

the panel for carrying out maintenance. Panel shall be provided with anti-condensation heaters complete with heating element,

MCB and thermostat. 2.8.7 All electronic control and monitoring printed circuit cards shall be modular plug in type.

Monitoring points shall be provided on each of the PCBs and the PCB shall be firmly clamped in position so that vibration or long usage do not result in loose contacts. All PCBs shall be placed in a manner to avoid the replacement of PCB by a wrong spare PCB. Failure of each PCB shall be indicated by visual alarms. The visual fault diagnostics shall preferably indicate fault upto various sections in the card. All PCBs shall be provided with transparent epoxy coating for environmental protection and tropicalisation & they shall be suitably located away from heat sources.

2.8.8 A removable bolted gland plate shall be provided along with double compression type

nickel plated brass cable glands for external cable connections. Clamp type terminals shall be used for connection of all wires upto 10 mm2. Bolted type terminals suitable for cable lugs shall be provided for wire size above this. Copper lugs for all external connections




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shall be provided with the panels. Suitable slotted angles shall be provided upto the respective terminal blocks for supporting

and clamping cable cores at regular intervals inside the cable alley. 2.9 Internal Wiring 2.9.1 Internal wiring shall be carried out with 1100/650V grade, PVC insulated, multistrand

copper conductor wires with minimum size of 4 sq.mm. for power circuits. Control circuits shall be wired with copper conductor of atleast 2.5 sq.mm. for CT circuits and 1.5 sq.mm. for other circuits. All control wiring shall be enclosed in plastic channels or neatly bunched together.

Ferrules for identification shall be provided according to the wiring diagram. The ferrules

shall be of yellow colour and engraved with black numbers and shall be fitted to each wire. Spare auxiliary contacts of all equipments shall be wired upto the terminal block. Spare or

unassigned modules shall be complete with internal wiring. 2.9.2 A removable bolted gland plate shall be provided along with double compression type

nickel plated brass cable glands for external cable connections. Clamp type terminals shall be used for connection of all wires upto 10 mm2. Bolted type terminals suitable for cable lugs shall be provided for wire size above this. Copper lugs for all external connections shall be provided with the panels.

Suitable slotted angles shall be provided upto the respective terminal blocks for supporting

and clamping cable cores at regular intervals inside the cable alley. 2.10 Terminal Blocks 2.10.1 Terminal blocks shall be of reputed make complete with hardware such as brass studs,

links, washers, nuts, locknuts etc. Each terminal shall not have more than two connections. A minimum of 20% spare terminals shall be provided.

2.10.2 Terminals shall be shrouded. Terminal blocks shall be grouped depending on the circuit

voltage. Terminal blocks of different voltage groups shall be segregated. A minimum 100mm clearance between two sets of terminal blocks shall be kept. 2.10.3 Terminals shall be adequately rated to carry the current of associated circuits. The

minimum rating of the terminal block shall be 10A. Terminals shall be numbered as per the wiring diagram. 2.11 A.C.Distribution Boards

Sheet steel enclosed A.C. distribution board shall be provided as part of the complete UPS package. It shall accommodate feeders as mentioned in the data sheet. The distribution board shall be floor mounted, fixed type, compartmentalised construction having horizontal & vertical busbars. All busbars shall be PVC sleeved. It shall be possible to operate the switches without opening the doors. Switches shall be provided with door interlock. Vertical




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cable alley shall be provided for termination of outgoing cables. Cable alley width shall be min 250 mm. Suitable supports shall be provided for supporting outgoing cables. Switch fuse units or MCBs shall be provided in the outgoing circuits as specified in data sheet. Incomer of the ACDB shall have ammeter, voltmeter and ON/OFF LED type indication lamp. Output feeders of ACDB shall have ON/OFF LED type lamp. Minimum 50 x 6 mm size Cu earth busbar shall be provided. Cable entry shall be from bottom, if not specified otherwise in the data sheet. The bottom gland plate of the distribution board shall be of non-magnetic material where single core cables are used.

2.12 Mimic Diagram, Metering, Indication And Alarm details :- 2.12.1 Mimic Diagram Mimic diagram shall be provided on front face of UPS, depicting the status of various

components of the UPS system using LEDs. Any additional devices/features considered necessary for reliable operation and maintenance shall also be included in various panels and the same shall be highlighted separately.

2.12.2 Metering Following metering shall be provided for UPS system. 2.12.2.1 Battery Charger (a) Incoming voltage (for all line voltages)

(b) Incoming current (for all phases)

(c) Incoming frequency

(d) DC voltage at each battery charger output (e) DC current at each rectifier output.

(f) Battery current for rapid and float charging/discharging.

2.12.2.2 Inverter

(a) DC input current at each inverter.

(b) AC voltage at each inverter output.

(c) AC current at each inverter output.

(d) Frequency meter at each inverter output.

2.12.2.3 Stabilised bypass/backup mains

(a) Frequency meter for incoming supply.




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(b) Voltmeter with selector switch for incoming supply.

(c) Ammeter with selector switch for incoming supply.

2.12.2.4 ACDB

(a) Voltmeter ( with voltmeter selector switch for 3 phase output).

(b) Ammeter ( with ammeter selector switch for 3 phase output).

(c) Power factor meter.

(k) Frequency meter (Note:- Meters shall be of 96 x 96mm size and shall have accuracy class-1.) 2.12.3 Indication 2.12.3.1 (a) AC mains ‘ON’ – Battery charger (b) AC mains ‘ON’ - Bypass 2.12.3.2 Battery charger (for each charger)

(a) Charger output ‘ON’ (b) Battery on float (c) Battery on boost

2.12.3.3 Inverter (for each inverter)

(a) DC input ‘ON’

(b) Load on inverter (c) AC output normal

(c) Inverter synchronized with mains

2.12.3.4 Static switch inhibited (on a/c of poor quality of bypass line) 2.12.3.5 Load on Bypass 2.12.4 Audio-visual Alarm (Complete with Accept / Reset / Test facilities) (a) Mains failure




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(b) Rectifier failure

(c) Battery discharging

(d) Battery discharged (e) Battery C.B. open – battery fault (f) Inverter high temperature (g) Inverter failure- Inverter bypassed (h) Low voltage from inverters (i) No synchronization with mains (j) Static switch faulty (k) Fuse failure - Inverter fuse failure - Rectifier fuse failure (l) UPS output failure (m) Fan failure

(n) High/Low D.C.Voltage

(o) Inverter overloaded

(p) D.C.Ground fault (q) Static bypass inhibit (r) Load on static bypass

(s) Load on manual bypass

(t) All power fuse failures Note:- In case of redundant UPS system the above alarms shall be provided for each rectifier-inverter unit. 2.12.5 Controls

(a) All the switches for starting, shutdown and testing sequence.

(b) Primary input circuit breakers for feeding chargers, bypass line and dc bus from Battery including backup protection.

(c) Inverter ON/OFF switch (to initiate inverter operation)




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(d) Static switch transfer test Push button.

2.13 Nameplates Nameplates made of stainless steel/anodised aluminium shall be fixed to all feeder

compartments, instruments, meters, relays, fuses at their non-removable parts. The name plates shall have adequately sized lettering.

2.14 Painting 2.14.1 All sheet steel work shall be phosphated by removing oil, grease, dirt etc by emulsion

cleaning. This shall be followed by pickling with dilute acid for removing rust and scale. Further, it shall be washed with running water, rinsed with slightly alkaline hot water and dried. This shall be followed by phosphating and thorough rinsing with clean water and final rinsing with dilute dichromate solution and oven drying.

After phosphating, two coats of ready mixed stoving type zinc chromate primer shall be applied. After application of primer, two coats of finishing synthetic enamel paint shall be applied. Each coat shall be followed by stoving. The second coat shall be applied after completion of tests.

The colour shade of final paint (epoxy based) shall be as specified in the datasheet. Panel

finish shall be free from imperfections like pinholes, orange peels, run off paint etc. 2.14.2 All other parts such as handles, levers and fasteners that are not stainless steel shall be tin,

cadmium, nickel or chrome plated. 3.0 Inspection and Testing Inspection and testing shall be carried out in accordance with relevant standards. Routine

and Acceptance tests shall be witnessed by a representative of TEIL/Purchaser. Test certificates for Type tests not more than 5 years old shall be submitted with quotation. Vendor shall quote unit rate for witnessing each Type test.

3.1 Routine Test The following routine tests shall be performed on the UPS. (a) Insulation Test (b) No load test (c) Checking of auxiliary devices (d) Output voltage tolerance (e) Relative harmonic content (f) Temperature Rise Test (g) Output frequency tolerance (h) Efficiency check 3.2 Acceptance Tests

(a) Insulation tests




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(b) Interconnection cable check – The interconnection cables are to be checked for

correct wiring, insulation and quality of the terminations. (c) AC input failure test – The test is performed with the test battery and carried out by

tripping ac incoming breakers or by switching off rectifiers and bypass supply at the same time. Output voltage and frequency variations are to be checked for specified limits.

(d) AC input return test – The test is performed by closing ac incoming circuit breakers or

is simulated by energising rectifiers and bypass supply. Proper operation of rectifiers starting and voltage and frequency variations of output are to be checked.

(e) Simulation of parallel redundant UPS fault – The test is applicable for UPS with

parallel redundant configuration. Fault of rectifier or inverter are to be simulated and output transients are to be recorded.

(f) Transfer test – Transients shall be measured during load transfer from inverter to

bypass supply caused by simulated fault and load manually retransfer after clearing the fault.

(g) Regulation test – The test shall be carried out by measuring input voltage, input

current, output voltage, output current, DC link voltage, output distortion, input active power, output active power and frequency at no load, 50% load and 100% load at 0.6 and 0.8 p.f. Following parameters of rectifiers and inverters are to be measured: Measurement shall be carried out in the rectifier float and rapid charge mode. Measurement shall be at nominal ac voltage and at no load, 50% load and 100% of rectifier full load. Rectifier measurement shall comprise of: - input voltage, frequency, phase current and input power. - DC output voltage and current - Ripple current at the DC link bus shall be recorded after isolating the test battery. Inverter measurement shall also be at no load, 50% load and 100% load of inverter rated output current and shall be repeated for inverter DC input voltages corresponding to battery float charge operation as well as rated inverter maximum and minimum input DC voltage. Measurement shall comprise of: - input voltage, input current. - Output voltage, frequency and waveform distortion, output power and current.

(h) UPS efficiency – This shall be determined by measurement of active power input and output at rated pf for 50%, 75% and 100% load.

(i) Current division in parallel UPS – Load sharing between UPS units shall be

measured with a dummy load under parallel redundant UPS configuration.

(j) Light load test – The test is to verify that UPS is correctly connected and all functions operate properly. The load applied is limited for economic reasons to some percentage of rated load. The following points are to be checked:

(a) Output voltage and frequency and correct operation of meters. (b) Operation of all control switches and other means to put UPS system into




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operation. (c) Functioning of protective and warning devices.

(k) Continuous full load test at 0.8 power factor with temperature rise measurement : The test is required to be performed by connecting resistive load or resistive and inductive load to the UPS system output. The load shall be placed outside the test room to avoid influences of its heat upon UPS ventilation. UPS system in this test shall undergo a complete full load test for 32 hours at 0.8 power factor. Out of these 32 hours. each invertor section shall be subjected to full load test for 8 hours, both invertors sections operating in parallel shall be subjected to full load test for 8 hours and the for remaining 8 hours; the by pass section shall be subjected to full load test. Steady state temperature of rectifier transformer, rectifier set, D.C. choke, inverter set, static switch etc. shall be recorded during the test. The temperature of all UPS panels are also to be recorded. (l) Auxiliary equipment and control circuit tests – The correct functioning of all measuring

instruments, alarms, indications, protection devices and control are to be verified. The functioning of auxiliary devices such as lighting, cooling fans, annunciation etc. should be checked.

(m) Synchronisation test – Frequency variation limits of inverter is to be tested by feeding

bypass supply incoming line by variable frequency generator and inverter synchronisation limit is to be checked as specified.

(n) Overload capability test – Specified values of short time overload are to be applied for

specified time interval. Values of output voltage and current are to be recorded.

(o) Short circuit current capability test – Specified short circuit current capability is to be tested by application of a short circuit to UPS output if necessary via a suitable fuse. Short circuit current is to be recorded.

(p) Short circuit fuse test – Fuse tripping capability of UPS is to be tested by short

circuiting the UPS system output via a specified rating fuse. The test shall be repeated to ensure against fuse non-conformity. The test is carried out at an appropriate UPS load under normal operation.

(q) Restart – Manual restart to be tested after complete shut down of UPS system. (r) Output over voltage – Operation of output overvoltage protection is to be checked. (s) Periodic output voltage modulation – Output recording at different loads and

operating condition to be done.

(t) Harmonic components – Harmonic components of output voltage are to be recorded at no load, 50% load and 100% load conditions. Harmonic currents caused by UPS system components in the AC incomer side shall also be recorded.

(u) Earth fault test – An earth fault is to be applied to the output terminal of UPS system.

UPS output transients are to be measured. An earth fault is also to be applied to the




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battery terminal and UPS system output transients shall be measured.

(v) Audible noise test – The audible noise is required to be measured at 1m distance from UPS system in at least 4 to 5 locations and its value shall be within permissible limits.

(w) Following simulations shall be carried out (a) Battery circuit breaker open (b) Inverter failure - In this the time required for transfer of load to mains shall be noted. (c) Manually return the load to inverter. (d) Sudden addition/deletion of rated load. (e) Fault clearing time required when there is short circuit across inverter output. (f) Apply 150% of rated load and measure the time required for inverter protective

device to operate. (g) Automatic switch over to mains in case of overload of inverter and return to

normal (inverter) for all externally caused transfer and manual transfer for internal faults.

(h) Arrangement of manual charging of batteries in all 3 modes (trickle / boost / equalizer charging).

(x) Final acceptance testing of UPS along with batteries shall be carried out at site. UPS

and its battery shall be tested on full load condition along with transfer time measurement and battery load test (charge/ discharge) at site. Water load is acceptable and shall be arranged by Vendor. It shall be the responsibility of the Vendor to arrange instruments and tools as required by their commissioning engineer for these tests.

3.3 Type Test The following type test shall be carried out if called for in the data sheet. (a) Temperature dependant frequency variation test (b) Current division (c) Voltage division (d) Hold off interval 3.4 In addition to above UPS tests, the battery shall be tested as per applicable standards

including duty cycle tests at battery manufacturers works 3.5 The test schedule and procedure shall be formulated in line with above. Before giving call for

witness of the tests, Vendor shall get TEIL’s approval on the test procedures. Vendor shall also indicate the max. allowable tolerance for each test result along with the test procedures. If tests show that certain requirements of the specifications are not met, Vendor shall make necessary corrections to the equipment so that it satisfies all the requirements before acceptance is made.

4.0 Fault Diagnostic Unit lf specified in the data sheet, each UPS set shall have provision for adding microprocessor




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based ‘ON line fault diagnostic unit. This shall supervise the UPS operation continuously. It shall identify and locate faults immediately so that corrective action can be taken. Fault Diagnostic

unit shall he compatible to hook up with owner’s PC through RS232/RS485 interface. The software shall be provided on a CD ROM.

The fault diagnostic unit shall have provision for automatic print out facilities for time.

Input/output voltages, currents, frequency as a minimum under the following conditions. - UPS power source changeover from mains to battery.

- UPS power source changeover from battery to mains.

- Changeover from inverter to stabilized bypass supply and vice versa.

- Changeover from one inverter to other inverter.

- Changeover time in case of inverter to stabilized bypass supply and from one inverter to other inverter.

- UPS failure.

- Type of failure incident along with diagnostic report. In addition to the above, any other feature which vendor feels may be useful shall he provided and highlighted separately. If any additional equipment (e.g. bin connector, adaptor cards etc.) are required for

connecting this unit with UPS system as well as with owner’s PC. the same are also to be included in the vendor’s scope.

5.0 Packing and Transport

All the equipment shall be divided into required transport sections for protection and ease of handling during transportation. The packing should be suitable for outdoor storage and shall be suitable for transportation by ship/ rail or road. The panel shall be wrapped in polythene sheets before being placed in crates to prevent damage to finish. Crates shall have skid bottom for handling. Special notations such as ‘This side up’, ‘Fragile’, ‘Centre of gravity’, ‘Weight’ etc. shall be clearly marked on the package together with Tag nos., P.O. nos. etc.

Documents

< Security Level 2 > - HPCLtenders.hpcl.co.in/tenders/tender_prog/TenderFiles/1896/Tender... · Alarm Details 2.13 Nameplates ... inverter to the mains and vice versa,