GIS 12-351 19 December 2003

Document No.

GIS 12-351

Applicability

Group

Date

19 December 2003

Guidance on Industry Standard for Uninterruptible Power Systems, UPS (IEC)

GIS 12-351

BP GROUP

ENGINEERING TECHNICAL PRACTICES

19 December 2003

GIS 12-351 Guidance on Industry Standard for Uninterruptible Power Systems, UPS (IEC)

Foreword This is the first issue of Engineering Technical Practice (ETP) GIS 12-351. This Guidance on Industry Standard (GIS) is based on parts of heritage documents from the merged BP companies:

Amoco (ACES) A EL-UPS-00-P

Electrical Uninterruptible Power Supply Specification

ARCO (APCES) ES 317 91F

Instrument Power Supply Systems.

BP GOMDW EL-SP-4050

Uninterruptible Power Supplies

BP Chemicals CP 17-17-1

Uninterruptible Power Supply

BP (RPSE) RP 12-5 GS 112-10

Electrical Systems and Installations – Power Supplies for Control Systems Secure Static AC Power Supplies for Control Systems

Copyright  2003, BP Group. All rights reserved. The information contained in this document is subject to the terms and conditions of the agreement or contract under which the document was supplied to the recipient’s organization. None of the information contained in this document shall be disclosed outside the recipient’s own organization without the prior written permission of Manager, Standards, BP Group, unless the terms of such agreement or contract expressly allow.

Downloaded Date: 6/17/2008 10:19:58 PM The latest update of this document is located in the BP ETP and Projects Library

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Table of Contents ............................................................................................................................................. Page Foreword .............................................................................................................................................. 2 1.

Scope.......................................................................................................................................... 5

2.

Normative references ................................................................................................................. 5

3.

General requirements................................................................................................................. 5 3.1. Governing standards....................................................................................................... 5 3.2. Ambient conditions.......................................................................................................... 5 3.3. Reliability, service life, and operation ............................................................................. 5 3.4. Acoustic noise ................................................................................................................. 6

4.

System design ............................................................................................................................ 6 4.1. General............................................................................................................................ 6 4.2. Incoming power supplies ................................................................................................ 6 4.3. Output power supplies .................................................................................................... 7 4.4. System configuration....................................................................................................... 7 4.5. System operation ............................................................................................................ 8

5.

Rectifier/battery chargers ........................................................................................................... 8

6.

Batteries and battery enclosures................................................................................................ 9 6.1. Batteries .......................................................................................................................... 9 6.2. Battery enclosures .......................................................................................................... 9

7.

Inverters ...................................................................................................................................... 9

8.

Static transfer switches ............................................................................................................ 10

9.

Manual maintenance bypass switches .................................................................................... 11

10.

Isolation transformers ............................................................................................................... 12 10.1. General.......................................................................................................................... 12

11.

Metering and alarms and indicators ......................................................................................... 12 11.1. Metering......................................................................................................................... 12 11.2. Alarms and indicators.................................................................................................... 12

12.

UPS system isolation and protection ....................................................................................... 13 12.1. Isolation for maintenance .............................................................................................. 13 12.2. Circuit protection ........................................................................................................... 13 12.3. Fuse protection.............................................................................................................. 14 12.4. Reversed polarity protection ......................................................................................... 14

13.

Enclosures ................................................................................................................................ 14 13.1. General.......................................................................................................................... 14 13.2. Manual maintenance bypass switch enclosures .......................................................... 15 13.3. Special tools .................................................................................................................. 15

14.

Identification and marking ........................................................................................................ 15 Downloaded Date: 6/17/2008 10:19:58 PM The latest update of this document is located in the BP ETP and Projects Library

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15.

Inspection and testing............................................................................................................... 16 15.1. General.......................................................................................................................... 16 15.2. Type tests ...................................................................................................................... 17 15.3. Shop tests...................................................................................................................... 17 15.4. Routine tests ................................................................................................................. 17 15.5. Test certificates ............................................................................................................. 17

16.

Documentation.......................................................................................................................... 17

17.

Preparation for shipment .......................................................................................................... 18 17.1. General.......................................................................................................................... 18 17.2. Shipping tags................................................................................................................. 18


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1.


Scope This GIS document provides guidance on industry standard for the design, materials, fabrication, inspection, testing, documentation, and preparation for shipment of uninterruptible power supplies

2.

Normative references The following normative documents contain requirements that, through reference in this text, constitute requirements of this technical practice. For dated references, subsequent amendments to, or revisions of, any of these publications do not apply. However, parties to agreements based on this technical practice are encouraged to investigate the possibility of applying the most recent editions of the normative documents indicated below. For undated references, the latest edition of the normative document referred to applies.

BP Engineering Technical Practices (ETP) GIS 12-354 GIS 12-356

Guidance on Industry Standard for Station batteries (IEEE) Guidance on Industry Standard for Battery chargers

International Electrotechnical Committee (IEC) IEC 60146-1-3

Semiconductor convertors: General requirements and line commutated convertors – Part 1-3: Transformers and reactors Low voltage fuses – Part 1: General requirements Low voltage fuses – Part 2: Supplementary requirements for fuses for use by authorized persons (Fuses mainly for industrial application) Graphical symbols for use on equipment – Part 1: Overview and application Classification of degrees of protection provided by enclosures Uninterruptible power systems (UPS) – All Parts

IEC 60269-1 IEC 60269-2 IEC 60417 IEC 60529 IEC 62040

3. 3.1.

General requirements Governing standards UPS systems shall be in compliance with relevant parts of IEC 62040.

3.2.

Ambient conditions UPS systems will be located indoors and shall be suitable for continuous duty under the ambient conditions specified in IEC 62040-3 and any more onerous conditions as specified in the enquiry documents.

3.3.

Reliability, service life, and operation a.

The manufacturer shall provide information on MTBF (mean time between failure) and MTTR (mean time to repair) data for the UPS system. The means of deriving this data shall also be provided.

b.

Components used in UPS systems, excluding batteries, shall have a 20-year life under specified operating conditions. Batteries supplied as part of the UPS system may be designed with a much shorter life expectation than 20 years. Planté and nickel cadmium pocket plate batteries should have a Downloaded Date: 6/17/2008 10:19:58 PM The latest update of this document is located in the BP ETP and Projects Library

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20-year life expectation but tubular lead acid and VRLA (valve regulated lead acid) types could have a 10-year life expectation or less. c. 3.4.

UPS systems and component parts, with the exception of batteries and ventilation air filters, shall be designed to operate continuously maintenance free for at least 104 weeks.

Acoustic noise a.

The maximum sound pressure level at or beyond 1 metre from the UPS system surface shall not exceed 60 dB(A) or a more onerous condition if specified in the enquiry documents.

b.

The manufacturer shall provide an octave-band spectrum for the UPS system at 1 m over the range 31.5 Hz to 8 kHz Noise measurement requirements can be found in EEMUA Standard 140. ISO 3740-3746 also contains advice on precision methods for determination of sound power levels for broad-band sources in reverberation rooms.

4. 4.1.

System design General a.

4.2.

UPS systems shall consist of the following components: 1.

A.C. to D.C. rectifier/battery charger

2.

Storage battery bank

3.

D.C. to A.C. inverter

4.

Static transfer switch (if required)

5.

Maintenance bypass switch (if required)

6.

Isolation transformer(s) (as required)

7.

Controls and instrumentation

8.

Metering alarms and indicators

b.

Standby circuits shall have a static switching device to transfer a.c. output loads. This circuit shall be fully rated for both continuous and short circuit duties.

c.

Equipment and components shall be arranged so discrete parts of system can be isolated and made safe for maintenance to be performed without disrupting service of other apparatus.

d.

Active components shall be solid state.

e.

Inverter standard design shall use pulse width modulated (PWM) technology.

f.

Semiconductor devices and relays shall be sealed.

g.

Power semiconductors shall operate at: 1.

60% maximum of manufacturer’s current rating at full load

2.

80% maximum of manufacturer’s temperature rating at full load

Incoming power supplies a.

Incoming a.c. main and by-pass supplies will be three-phase or single-phase as specified in the enquiry documents and, unless otherwise specified will have a solidly earthed neutral.

b.

Equipment shall be suitable for continuous operation at rated load within the following supply tolerances: Downloaded Date: 6/17/2008 10:19:58 PM The latest update of this document is located in the BP ETP and Projects Library

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4.3.

1.

Voltage

±10%

2.

Frequency

±5%

c.

Equipment shall be suitable for continuous operation if the THD (total harmonic distortion) of the supply does not exceed 10%.

d.

Equipment shall be able to withstand, without damage and subsequent malfunction, input voltage depressions of up to 20% for 10 seconds and transient voltage spikes of up to 2 kV.

Output power supplies a.

The phase configuration, rated duty, voltage, power factor and frequency of the output supply shall be as specified in the enquiry documents.

b.

Equipment shall be capable of uninterrupted operation if delivering maximum continuous RMS rated current with the following harmonic content:

c.

4.4.


1.

3rd harmonic

40% of fundamental

2.

5th harmonic

30% of fundamental

3.

7th and higher odd harmonics

7% of fundamental

The THD of the output voltage waveform shall not exceed: 1.

5% at the fundamental frequency if supplying a linear load

2.

10% at the fundamental frequency if supplying the non linear load as specified above

d.

The output load shall not be subject to a rate of change of frequency greater than 0.5 Hz per second if the inverter is in service unless otherwise specified in the enquiry documents.

e.

Inverters shall have: 1.

Capability of supplying loads up to 125% of rated load for 1 hr, 150% of rated load for 10 s, and 400% of rated load for 1 second.

2.

Frequency stability of ±0.5% no load to full load

3.

Specified output voltage with ±5% manual output voltage adjustment.

4.

Specified output voltage controlled within 1% from no load to full load, over full input and battery voltage ranges, and over load power factor ranges of 0,8 lagging to unity.

5.

Transient voltage regulation for a 100% load application or removal shall be within ±10%, recovering to ±2% within one cycle.

f.

Inverters shall maintain output frequency within ±1% of specified operating frequency.

g.

Phase displacement shall be ±2% over the full battery operating range, no load to full load, with 0,8 power factor lagging.

h.

Output voltage unbalance shall be as follows: 1.

±2% for balanced linear loads

2.

±4% at 50% for unbalanced linear loads

3.

±5% for 100% unbalanced linear loads

System configuration

The UPS system configuration shall comply with the schematic diagram included in the enquiry documents.


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4.5.

5.


System operation a.

It shall be possible to operate the inverter, including during start-up, with either the mains supply or the battery unavailable. Under normal conditions the mains shall form the source of supply and changeover to battery supply on mains failure shall occur without break in the output.

b.

If a mains bypass unit is specified in the enquiry documents, this shall be used as standby to the inverter supply. Changeover of a.c. output to mains bypass on inverter fault shall be arranged automatically by means of a static switching device. Manual changeover facilities shall also be available.

c.

The inverter shall operate in synchronism with the bypass provided that this remains within the specified frequency tolerance.

d.

Transfer from mains by-pass to inverter shall be manually initiated but shall be inhibited should the inverter be outside the specified operating tolerances.

e.

If a standby inverter system is specified in the enquiry documents, this shall operate in an on load parallel redundant mode, normally synchronised and operating in parallel with the duty system. Sharing of load between the inverter circuits shall be by fully redundant control systems and in the event of failure only one inverter shall shutdown. Each inverter shall be connected to the output system by means of a static switching device.

Rectifier/battery chargers a.

Battery chargers shall comply with GIS 12-356.

b.

Input current THD and power factors shall be as shown in Table 1. Table 1 - Input current THD and power factors Design type

Total harmonic distortion (THD)

Power factor

25%, or less

80%, nominal

12%, or less

95%, or greater

Six pulse phase controlled TR full wave Diode type

c.

After a primary a.c. power outage, rectifiers/chargers shall: 1.

Automatically restart.

2.

Start up gradually assuming the inverter and battery recharge loads.

d.

Battery chargers shall be rated to continuously supply 100% of rated load under the most severe variation of ac supply input.

e.

Battery charging shall ensure an acceptable rate of water loss from the battery, while battery capacity is maintained. The charge rate shall provide sufficient battery capacity for rated duty within a time period specified.

f.

Incoming a.c. power shall be converted to regulated dc output by a rectifier charger.

g.

Rectifier chargers shall be full wave bridge diode type or phase controlled, 6-pulse, solidstate type with constant voltage/constant current control circuitry.

h.

Battery charger output voltage ripple shall not exceed 2% RMS with batteries disconnected.

i.

Rectifiers/chargers shall have: Downloaded Date: 6/17/2008 10:19:58 PM The latest update of this document is located in the BP ETP and Projects Library

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6. 6.1.


1.

Automatic voltage regulating capability, with d.c. bus voltage between no load and full load maintained to within ±1% if A.C. input voltage is within ±10% of rated input voltage and input frequency is within ±5% of rated input frequency.

2.

Temperature compensation capability to reduce effects of higher temperatures, excess hydrogen emissions, and thermal runaway of battery

3.

Automatic protection against reversal of current

4.

Sufficient capacity to support total connected load and recharge the battery at float condition to 90% of full capacity within a recharge time specified in the enquiry documents.

5.

Battery recharging capability from discharge to 95% charge within 10 times rated discharge time of battery plant.

j.

Control circuitry shall automatically boost the equalize voltage after failure of normal ac power. This feature shall be switch selectable and provisions shall be made to manually initiate it.

k.

If VRLA batteries are used, a charger shall be provided with automatic charge variation to compensate for changes in the battery’s ambient temperature.

Batteries and battery enclosures Batteries Battery types shall be specified in accordance with GIS 12-354.

6.2.

7.

Battery enclosures a.

Batteries shall be supplied either stand mounted or cubicle mounted and follow the recommendations specified in section 7 of IEC 62040-1.

b.

Mounting arrangement shall allow easy and unrestricted access for routine maintenance.

c.

If vented flooded cell batteries are used, enclosures shall have adequate ventilation for exhausting battery off gas.

Inverters a.

Inverter output shall be inherently current limited to continue operation undamaged with any fault on load side terminals.

b.

Inverters shall withstand, and automatically recover from, momentary or sustained singlephase or three-phase output power short circuit.

c.

Inverters shall deliver power sufficient for cold start of UPS powered equipment without transfer to an alternate source.

d.

Inverters shall provide the following protection: 1.

Automatic disconnection from d.c. bus if voltage falls below the minimum inverter operating dc voltage

2.

Fast acting, current limit type fuses in power modules to protect semiconductors.

e.

Inverter output circuits shall generally be magnetically isolated from input circuits and have a means of earthing output.

f.

Neutral conductor on the inverter output and the neutral conductor on the mains bypass circuit output or isolation transformer secondary shall be connected together and earthed in the UPS enclosure. Downloaded Date: 6/17/2008 10:19:58 PM The latest update of this document is located in the BP ETP and Projects Library

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g.

8.


Removable link shall be installed in the neutral conductor of the inverter output to allow isolation of UPS for maintenance.

Static transfer switches a.

Static transfer switches shall function as follows: 1.

Be high speed, "zero break" transfer devices that are an integral part of UPS systems.

2.

Provide automatic or manually initiated uninterrupted transfer of load to the bypass source.

3.

Operate with a "no break load transfer". This is defined as no break in continuity of sinusoidal voltage waveform to load connected to UPS.

b.

Static switch transfer time, including sensing, shall be 1/4 cycle maximum.

c.

UPS output load demands over 125% of UPS full load current rating shall result in automatic transfer to an alternate source.

d.

Transfer time shall be essentially zero (within 1/4 cycle) to ensure uninterrupted flow of power to system loads.

e.

Upon cessation of an overload, retransfer to the UPS inverter shall be fully automatic (output current demand less than 100% of full load rating).

f.

Automatic solid state (static) transfer switches shall transfer UPS loads to an alternate ac source under the following conditions:

g.

h.

1.

Inverter load capacity is exceeded (steady state load, transient loads, or faulted load condition).

2.

Battery output capability is exceeded.

3.

UPS fault condition occurs.

4.

Inverter fails or is outside tolerance voltages.

5.

During a manually initiated transfer

Automatic and manual (static) switch transfers to or from an alternate source shall be inhibited under the following conditions: 1.

Inverter output is out of sync with alternate (bypass) sources.

2.

Quality of transfer source is poor.

3.

Voltage difference between inverter output and alternate source exceeds a preset ±10% (adjustable).

4.

UPS major alarm/failure condition exists (inhibiting transfer from an alternate source to the normal source).

5.

Static switch failed or is unavailable.

6.

Inverter or alternate source is lost as the transfer source.

Static transfer switches shall: 1.

Contain thyristors and associated heat sinks that shall never exceed recommended ratings, even under worst-case overload and high ambient temperature condition.

2.

Have fast acting silver fuses to provide overload and fault protection from both output distribution wiring and the static transfer switch itself.

3.

Be naturally commutated. Downloaded Date: 6/17/2008 10:19:58 PM The latest update of this document is located in the BP ETP and Projects Library

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4.

i.

9.

Have two double-sided pairs of silicon-controlled rectifiers per phase (pole). Poles shall be fully rated for the inverter’s full load and overload as specified on the enquiry documents.

Static transfer switches shall be rated as follows: 1.

To carry UPS full output and 400% of rated load for 1 second for fault clearing.

2.

Under full load operation, be rated to 50% of their capability to provide long life.

Manual maintenance bypass switches a.

If specified in the enquiry documents, a manual maintenance bypass switch shall be connected to the output of UPS system to facilitate maintenance.

b.

The maintenance bypass switch shall isolate the static transfer switch from its bypass source and connect output directly to that bypass power source.

c.

If isolating the UPS and static switch for safety during maintenance, the maintenance bypass switch shall allow critical load to be supplied from an alternate power source without load power interruption.

d.

Manual maintenance bypass switches shall: 1.

Be a manually operated single switch that mechanically performs transfer isolation functions for UPS system.

2.

Provide “make before break” transfer of UPS loads to an alternate or maintenance bypass source without load interruption.

3.

Ensure isolation of UPS system, including the static switch and output transformer, from power sources and loads.

4.

Have three positions (Normal, Bypass, and Test).

5.

Be lockable in Open position.

6.

Allow transfer between two sources that are in syncronism.

7.

Be equipped with lights that indicate both sources are in syncronism or electrical interlocks.

8.

Not require assistance of the static switch to ensure a zero-break load transfer.

e.

UPS systems shall have three separate power sources: normal, alternate, and maintenance bypass.

f.

Manual maintenance bypass switches shall have an alternate source/maintenance bypass source. Alternate source input to a non-automatic circuit breaker shall be mounted on UPS front control panel, or door.

g.

Alternate sources for manual maintenance bypass switches shall: 1.

Be a separate single second source to UPS system that is not normal UPS input power source.

2.

Be both alternate source to UPS static switch and maintenance bypass source with control by a maintenance bypass switch.

3.

Have a disconnect device.

4.

Have a non-automatic disconnect switch located on the UPS front control panel, or door (for units specified with an alternate source/maintenance disconnect switch mounted local to the UPS system).


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10. Isolation transformers 10.1.

General a.

Transformers shall be continuously rated, dry type with copper windings and shall conform to IEC 60146-3.

b.

UPS a.c. power input and output supplies including bypass circuits shall be connected to electrostatically shielded isolation transformers if specified in the enquiry documents.

c.

Full isolation output transformers shall allow independent earthing of load.

d.

Isolation transformers on the input side of the rectifier shall be provided with secondary surge protection.

11. Metering and alarms and indicators 11.1.

Metering Front panel metering instrumentation shall include the following 3.5 inch scale analogue or digital meters (2% accuracy):

11.2.

a.

Inverter output voltmeter

b.

Inverter output ammeter

c.

Bypass source output ac ammeter.

d.

Inverter output frequency meter

e.

D.C. output bus voltmeter

f.

D.C. output bus ammeter

g.

Rectifier input voltage (normal source).

h.

Rectifier input ampere (normal source).

i.

Alternate source voltmeter (downstream of alternate source UPS input disconnect device)

Alarms and indicators a.

Alarms shall be provided for failures that affect overall integrity of UPS systems.

b.

Alarms shall not be initiated because of transient conditions.

c.

Minimum local alarms shall be as follows: 1.

2.

At each charger a)

Mains supply failure.

b)

Charger failure.

c)

D.C. voltage low/high

d)

D.C. earth fault, if applicable

e)

Battery isolated

f)

Charger current limiter operating, if applicable.

At each inverter. a)

A.C. output high/low voltage.

b)

Overload.

c)

Inverter failure. Downloaded Date: 6/17/2008 10:19:58 PM The latest update of this document is located in the BP ETP and Projects Library

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d) 3.

Output frequency out of limits.

At each a.c. output supplies static switch: a)

Mains bypass supply frequency out of limits.

b)

Device bypassed.

c)

Standby in use.

d)

Control circuit fault.

e)

A.C. output supplies lost.

4.

High cabinet temperature.

5.

Ventilation failure.

d.

Alarm initiating devices shall automatically reset, but indicating device shall remain active until manually reset.

e.

Facilities shall allow alarms to be indicated remotely either individually or, preferably, by means of a common alarm system.

f.

Remote alarms shall be automatically reset when local alarm indication is manually reset.

12. UPS system isolation and protection 12.1.

Isolation for maintenance a.

Equipment and components shall be arranged such that discrete parts of the UPS system can be isolated and made safe for maintenance work to be carried out with the remainder of the apparatus in service. It shall be possible to isolate any part of the system without loss of a.c. power output.

b.

The minimum requirement for isolation shall be all poles, including any neutrals, of:

c. 12.2.

1.

Battery with associated charger remaining in service

2.

Charger with associated battery remaining in service

3.

Static switch

4.

Alternate source (bypass)

5.

Any control system supplies

To enable maintenance to be undertaken safely, each of the above shall be segregated and screened from other equipment that may remain live.

Circuit protection UPS systems shall have the following circuit breakers or alternatively fuse protected switches: a.

A.C. input disconnecting switch - front access MCB (moulded case breaker) or fuse protected switch for charger/rectifier disconnection and overload protection.

b.

Bypass disconnecting switch - front access MCB or fuse protected switch for bypass disconnection and overload protection.

c.

Battery input d.c. disconnecting switch, front access MCB, or fuse protected switch for d.c. input disconnection of both input lines and overload protection.

d.

UPS system non-automatic output disconnecting switch

e.

Battery connection to d.c. bus through non-automatic disconnecting switch

f.

UPS alternate source non-automatic input disconnecting switch Downloaded Date: 6/17/2008 10:19:58 PM The latest update of this document is located in the BP ETP and Projects Library

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12.3.

12.4.


Fuse protection a.

Fuses rated 600 V and less shall be supplied with disconnect blocks.

b.

Fuse holder section of block shall have a removable pullout handle that eliminates possibility of shock while changing the fuse.

c.

Fuses shall comply with relevant parts of IEC 60269-1 and 2.

d.

Fuse holders shall be black.

e.

Link holders shall be white.

f.

Unearthed poles of supplies shall be fused.

g.

Earthed poles shall be connected by a link holder

Reversed polarity protection a.

Chargers shall have reverse polarity protection on output to the battery.

b.

Inverters shall be protected against the connection of reversed d.c. supplies.

13. Enclosures 13.1.

General a.

Enclosures shall be in accordance with section 7 of IEC 62040-1.

b.

Enclosures shall be designed to prevent entrance of rodents, reptiles, birds, and insects.

c.

UPS equipment, except batteries, shall be housed in freestanding, dead front, ventilated, steel enclosures with welded steel framework rated IP 30 in accordance with IEC 60529.

d.

Doors shall be hinged and bonded to enclosure with green/yellow insulated bonding conductor.

e.

Enclosures shall be cleaned, primed, and finished to the manufacturer’s standard paint and colour.

f.

UPS enclosures shall have: 1.

Adequate space for conduit and/or cable terminations.

2.

Either top or bottom entry.

3.

Front access only for operation and maintenance, suitable for side-by-side installation.

4.

Removable lifting means.

g.

Forklift handling or top lifting devices shall not cause distortion of enclosure.

h.

UPS shall have a suitably rated copper neutral bus bar.

i.

UPS and maintenance bypass switch (MBS) enclosures shall have a 70 mm2 minimum cross section copper earth bus bar the width of the unit.

j.

Earth bars shall be as follows: 1.

Marked green/yellow

2.

Extend the length of the suite of UPS enclosures

3.

Have joints between each transport section

4.

M12 brass terminal at each end with compression lug suitable for a 70 mm2 external bonding conductor


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k.

13.1.2.

13.1.3.

13.2.

The following non-current carrying metallic parts of UPS shall be bonded to the earth bus bar: 1.

Metalwork

2.

Cable gland plates

3.

Component or subassembly chassis

Component accessibility a.

Power switching modules shall be serviceable and removable from front of UPS.

b.

Switching module weight shall allow removal by one person without aid of lifting devices.

c.

UPS shall permit ready access to power switching, control modules, and printed circuit boards.

d.

Placement of components, test points, and terminals shall be accessible without disassembly of other components for circuit checking, adjustment, troubleshooting, and maintenance from front of UPS. Removal of adjacent modules or assemblies shall not be required.

Ventilation a.

Natural convection cooling shall be used.

b.

Forced air-cooling shall be by redundant blowers.

c.

Blowers and motors shall have permanently sealed lubricated bearings.

d.

Blower unit failures shall be alarmed.

e.

Air inlets for forced air-cooled UPS systems shall have multi-pleated 40% efficiency filters that are replaceable from outside unit.

f.

Air inlet and exhaust openings shall have expanded metal guards for protection.

Manual maintenance bypass switch enclosures a.

A separate enclosure if specified in the enquiry documents, shall house manual maintenance bypass switches (MBS).

b.

Enclosure shall:

c. 13.3.


1.

Have indicator lights for source synchronization.

2.

Isolate UPS from bypass source to prevent load voltage from entering.

Bypass devices shall be lockable in any position and shall operate without interruption of supply to the distribution bus bars.

Special tools a.

Special tools required for maintenance shall be supplied.

b.

Containers suitable for wall mounting shall be included, with labels to clearly indicate the purpose for which each tool is required.

14. Identification and marking a.

Components and devices shall be identified in accordance with IEC 62040-1-1 and IEC 62040-1-2.

b.

The following information shall be given on a main nameplate, preferably stainless steel: Downloaded Date: 6/17/2008 10:19:58 PM The latest update of this document is located in the BP ETP and Projects Library

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1.

Manufacturer’s name

2.

Order Number

3.

Date of manufacture

4.

Client’s name

5.

System voltage, phases, wires, frequency, and rating

6.

Fault rating

7.

Third party certification data

8.

Item Number

9.

Cooling Method

10. Max permitted output circuit fuse rating (if appropriate) c.

Warning and caution labels shall have black lettering on a yellow background in accordance with IEC 60417.

d.

Information nameplates should have black letters on a white background. The nameplates should be engraved, embossed or otherwise formed so as to be permanent.

e.

Nameplates should be fastened to equipment by two stainless steel screws.

f.

A laminated wiring diagram of UPS system shall be included on inside of UPS door.

g.

Devices mounted on doors shall have front and rear door mounted nameplates.

h.

Rear doors of UPS systems shall have nameplates that indicate the equipment served.

i.

If there is more than one ac power source to a compartment, warning and caution labels shall be installed, if necessary, to warn or indicate safety precautions.

j.

At least 2 voltage shock safety labels shall be mounted on UPS cabinets, one on outside and one on inside.

k.

Wire marker designations shall correspond to UPS schematic and wiring diagrams.

15. Inspection and testing 15.1.

General a.

Testing shall be performed in accordance with sections 6 and 7 of IEC 62040-3.

b.

The purchaser shall retain the following rights:

c.

1.

To inspect equipment, materials, and fabrication at any time during assembly.

2.

To witness tests performed by the manufacturer.

Electrical equipment shall be assembled, wired, and tested at the factory with interconnect wiring terminated. Factory tests shall include 1.

Complete functional test of all components.

2.

Verification of circuit breaker trip settings.

d.

Equipment dimensions, construction materials, connections, ratings, and painting shall be verified to be in accordance with approved contractor drawings and this GIS.

e.

Mechanical and electrical tests shall be performed for UPS systems to verify satisfactory operation.

f.

Type and routine testing of components and the complete apparatus shall be in accordance with IEC 62040-3. Downloaded Date: 6/17/2008 10:19:58 PM The latest update of this document is located in the BP ETP and Projects Library

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15.2.


Type tests Type tests shall be applied to at least 1 complete apparatus of each type or design. Certification of type test results shall be provided in advance of placing the order.

15.3.

Shop tests Instrument power supply systems, including inverters, ac or dc voltage stabilizers, transfer switches, and alternate source devices shall be shop tested as follows:

15.4.

a.

Full load heat run for 48 hours with determination of efficiency and losses. Efficiencies shall be measured and recorded at 50%, 75%, and 100% of full load rating of UPS system. This test data shall meet the quoted guarantee for acceptance.

b.

Transient voltage response with step load changes up to 100% load.

c.

Measurement of total transfer time, including failure detection period.

d.

Check and record voltage and current wave shapes at no load and loadings, in accordance with this clause.

e.

Simulation of mains, inverter, and battery failure that would cause transfer of load from inverter output to bypass supply and return transfer tests.

f.

Functional check of alarm relays and indicating lights.

g.

Manual return to inverter output from bypass supply.

h.

Frequency out of limits test and synchronization test.

i.

Static switch transfers and permissives verification.

j.

Overload test, to verify various loading requirements of this GIS and quoted short time overload capabilities until the unit current limits. Static switch transfer at current limit values shall also be verified. The test current limit and time values shall be stated in the quotation as guaranteed values to be verified during test.

k.

Total harmonics distortion (THD) input current test, under rated linear load conditions. Input source voltage shall be set to the nominal value and THD shall be in compliance with the quoted guaranteed values.

Routine tests Routine soak tests shall be applied on each complete apparatus, under full design load for 100 hours involving:

15.5.

a.

Inverter and static switches.

b.

Rectifier/charger units.

Test certificates a.

The manufacturer shall provide certificates for all tests performed, whether or not witnessed by the purchaser or their representative.

b.

Test result values shall be stated on certificates.

c.

For tests witnessed by the purchaser or their representative, certificates shall be available for signature by the purchaser or their representative on the day of tests.

16. Documentation The following information shall be submitted to the purchaser for approval after receipt of order: Downloaded Date: 6/17/2008 10:19:58 PM The latest update of this document is located in the BP ETP and Projects Library

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19 December 2003

a.


Complete certified drawings shall show: 1.

Panel and internal arrangement (location of equipment and controls).

2.

Dimensional plan and elevation, front view, and other elevations, if pertinent. Conduit entrance location and dimensions for both top and bottom entrance.

b.

4.

Incoming and outgoing cable connection locations.

5.

Grounding and neutral connections.

6.

Weight of equipment.

7.

Vendor model numbers, trip units, withstand ratings, and interrupting ratings of moulded case breakers provided.

Detail connection (wiring) diagrams shall show: 1.

All wiring within unit down to board level.

2.

All interconnecting wiring between units.

3.

Identification of terminals and terminal blocks.

4.

Clear identification, by some distinguishing method, of wiring that is to be installed by the purchaser or their contractor.

5.

Detailed schematic diagrams for unit ordered.

17. Preparation for shipment 17.1.

17.2.

General a.

UPS systems shall have lifting facilities for easy loading, unloading, and handling by a crane or forklift. Shipping splits shall also be suitable for positioning via pipe rollers.

b.

Instruments, relays, and meters shall be prepared for shipment in accordance with manufacturer’s recommendations. Device fronts and UPS front shall be protected from damage.

c.

Blocking, binding, and desiccant shall be clearly marked to ensure removal.

d.

Special cautions that must be observed in removal of shipping restraints shall be clearly marked on shipping container and/or crate.

e.

All parts shipped separately shall be clearly tagged to indicate their association with other tagged item(s).

f.

Complete installation instructions for parts shipped separately from the main assembly shall accompany the main assembly shipment.

Shipping tags a.

A shipping tag shall be attached to each piece of equipment. This tag shall show purchase order number and equipment item number.

b.

If an enclosed container is required for shipping, this container shall show equipment tag information.

c.

Items/parts ancillary to equipment shall be tagged with equipment item number.

d.

Tags shall be attached with stainless steel wire or stainless steel screws.


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GIS 12-351 19 December 2003

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