POW E R S U P PLY PROTECTION
TABLE OF CONTENTS Introduction
1
Customized power supply protection (UPS) solutions
UPS Basics
2
UPS system and main functions
UPS system applications
3
The different industrial applications and requirements
GUTOR UPS technology
4 – 15
The concept AC UPS system description AC Inverter system description DC system description Bypass – transformer and stabilizer System design, features and benefits Man-Machine Interface Intelligent system ventilation UPS system configurations – Single unit AC& DC – Parall Parallel el Redundant Redundant AC& DC – Ful Fulll Dual AC& AC& DC Battery configurations – Common versus single configuration
Complete system solutions
16
More than just a product
Standards & Quality
17
Worldwide recognised standards
Planning & Installation
18
System expertise and support
Batteries Getting the suitable battery type for your requirements Sizing of batteries Battery Monitoring
19 – 20
INTRODUCTION CUSTOMIZED POWER SUPPLY PROTECTION (UPS) SOLUTIONS
GUTOR is a leading worldclass industrial UPS Company. The depth of our technical understanding combined with the experiences gained by working closely with customers from various industrial sectors, qualify us to provide customized solutions for uninterruptible power supply protection (UPS) of superior technical quality standards.
The objective of this brochure is to guide you through the world of GUTOR UPS technology. In addition to a general overview of the main functions and important aspects of UPS systems, this brochure highlights some of the main GUTOR UPS features and benefits. We are pleased to discuss your power supply protection needs and evaluate the best possible solution. Our ultimate goal is to provide a full range of comprehensive services for as long as you require.
UPS BASICS UPS SYSTEM AND MAIN FUNCTIONS
The continuous supply of quality power is critical to commercial and industrial process installations. A power failure, or even minor disturbances in the power supply, will interrupt the process chain and eventually result in system shutdown. This could cause substantial financial losses or even jeopardizing the safety of human lives.
The key function of UPS systems is therefore the protection of electrical power supplies to installations (also called consumers or loads), which cannot tolerate even the slightest voltage interruption or inconsistencies. Unfiltered electrical power supplied by utilities may contain harmonics, sags, spikes or other noise. Introducing one or more UPS systems along the power supply chain will effectively eliminate these kinds of disturbances.
Additionally, UPS systems Additionally, are often installed to support the safe shutdown and reboot of critical process installations. Modern UPS systems provide auxiliary functions such as automatic monitoring, system performance testing and alarm displays.
Custom single line diagramm Most importantly, during power failure conditions, the UPS will bridge the critical power supply gap. In these instances, the system automatically switches to large battery banks to draw the required electrical power until mains is again available. This occurs without affecting the load performance. The size of the battery banks and eventual alternative power source (bypass, diesel power generator), depend on system and battery configurations.
UPS SY SYSTE STEM M APPL APPLICA ICATIO TIONS NS THE DIF DIFFER FEREN ENT T IND INDUS USTRI TRIAL AL APP APPLICA LICATIO TIONS NS AND REQUIREMENTS
Many factors must be considered when choosing a UPS system. Cost-benefit considerations oftentimes outweigh the ability to undertake the task for which the system is required. While it may be acceptable to make compromises in non-critical applications, in critical ones this could have catastroph catastrophic ic consequences.
GUTOR UPS systems are primarily designed to meet requirements for applications in the Oil & Gas, Petrochemical, Chemical, and Power Generation industries.
Our systems are typically designed for production process plants, offshore installations, refineries, pipeline control centres, gas-gathering plants, LNG and GTL plants, or storage tanks. UPS systems ensure quality power supplies for pumps, control devices, fire-fighting systems,
emergency lighting, air conditioning and other essential equipment. We further specialize in the design of power protection solutions applied in conven-
tional and nuclear tional nuclear power plants, or substations. In installations such as thes these e UPS systems guarantee quality power supply for switchgear controls, shaft-turning devices, or protection drives.
Safety qualifications For certain applications, such as in Nuclear Power Station it is imperative that UPS systems meet strict safety regulations. The GUTOR system design complies with IEEE standards for the qualification of Class 1E equipment. Where seismic qualification of our systems is required we follow the recommended practice.
GUTOR GUT OR UPS TECH TECHNOLOGY NOLOGY THE CONCEPT
GUTOR UPS technology is based on the following key technical criteria:
Double Conversion: AC to DC current, by means of a 6- or 12-pulse thyristor, and DC to AC current by means of an IGBT – pulse width modulated (PWM) inverter module.
Modular Design: Consists of galvanic isolated transformers; inverter-, rectifier-- and static switch rectifier modules. This design offers the highest flexibility in terms of configuring input-, DC- and output voltage parameters, and power ratings (kVA). Most importantly,, rectifier and inverter tantly modules can individually be sized according to requirements. This also allows the oversizing of rectifier and inverter, on the one hand for re-charging larger batteries, or the supply of DC loads, and on the other hand to deal with any overload profile and increased short circuit current.
Highlights: • Automatic monitoring and testing of system performance.
• No switchover time (bypass (byp ass / inve inverte rter). r).
• Galvanic isolation.
• Highest technical flexibility.
Benefits: • Ultimate protection of critical load. • Possible paralleling of UPS systems. • Extended lifetime. • Ultimate security and functionality.
On-Line: By contrast to off-line technology,, where the load technology is supplied through the bypass and only in the event of a power failure the inverter is activated the GUTOR UPS inverter is continuously supplying the load. This is an important aspect especially for critical loads where even 5 – 10 ms switchover time from bypass to inverter could be critical.
Parallel Redundant / Active Load-Sharing: Allows paralleling of two or more units whereby each unit supplies its own share of the required output power. This provides ultimate security and functionality.. Consequently the tionality lifetime is extended due to lower operation temperature.
50%
50%
Load
Load
Loads
AC UPS SYSTEM DESCRIPTION
Inverter Modules
UPS Main Cabinet Main Controller
External Connections Alarm Relay Board
AC UPS system main components include rectifier-, rectifier -, inverter- and static switch modules, a manual bypass switch, transformers, controller, and a man-
machine interface (front panel) with display.
Manual Bypass Switch Static Switch Charger Module
Main Switches Bypass / Incoming Cabinet Terminals
AC INVERTER SYSTEM DESCRIPTION
AC Inverter system main components include inverter-, static switch modules, and a manual bypass switch, transformers, a controller controller,, and a man-machine interface (front panel with display).
Inverter module GUTOR uses pulse-widthmodulated (PWM) inverter technology with IGBT’ IGBT’s. This inverter type can be run in parallel of up to 9 inverter units, with active load sharing.
PWM IGBT Inverter +
DC Input from Rectifier and/or Battery +
Output
Manual Bypass Switch Inverter Modules
Static Switch
Main Switches Inverter Main Cabinet
Bypass / Incoming Cabinet
Main Controller
Terminals External Connections
DC SYSTEM DESCRIPTION
DC Rectifier / battery charger system main components include, transformers, charger module, a controller c ontroller,, and a man-machine interface (front panel with display).
Re c t i fi e r 6 -P u ls e C on fi g ur a ti on
6-pulse 6-puls e / 1212-pul pulse se rectifier module Its function is to rectify AC to DC current. It is designed in such a way that it can achieve boost voltage for a fast charging of the batteries and finally supplying the necessary
current to the inverter, even if the mains input voltage is at a minimum of –10% of the nominal value. By applying a 12-pulse unit the mains current distortion can be reduced by more than 60%.
Re c t i fi e r 1 2- P ul s e C on fi gu ra t i on
+
0o
30o
Mains
DC-Load/Inverter +
Mains current distortion distort ion ~28%
Charger Module
Ventilation
Charger Main Cabinet
Distribution Cabinet Distribution
BYPASS
When a system is in bypass mode, the load is supplied directly by the bypass mains. The switchover from normal to bypass operation could be performed manually, or in case the power supplied by the inverter becomes
insufficient, it would occur automatically without disturbing the loads.
BYPASS – TRANSFORMER AND STABILIZER
When differences exist in input and output voltage in the bypass mains, some systems may contain a bypass transformer or stabilizer.. The transformer stabilizer adapts the input to the output voltage; the stabilizer
compensates the input mains variations and keeps the output voltage stable.
Typ ypic ical al in inst stal alla lati tio on of of hig high h pow power er st stab abil iliz izer er
Typ ypic ical al in inst stal alla lattio ion n of of sm smal alll po powe werr st stab abil iliz izer er
SYSTEM DESIGN, FEATURES AND BENEFITS
• Clear system operation and controlling of system function.
GUTOR UPS technology is designed to respond to system functionality, safety and reliability – our customers’’ main concerns. tomers It offers a lot of flexibility in system designs and in complying with customer’ customer’s
• Safe operation and maintenance.
specific technical specifications. We build all our products in accordance with international and national recognized standards and guarantee top quality standard with ISO 9001:2000.
• High protection against weather influences and harsh environment.
Some of the main system design features and benefits are as follows:
• Highest system availability and reliability.
Modular design
System design that allows access to all components from the front and top of the cabinet. In typical GUTOR system designs, a separate safety disconnect cabinet houses the input circuit breaker and the manual bypass switch. For easy maintenance some of the components are mounted on sliding drawers, or hinged structure parts.
High integrated control logic
All systems are equipped with microprocessor electronics (controller), which offer digital processing and setting of all parameters. To ensure a reliable operation, two independent sources, the mains and the battery power the controller.
MAN-MACHINE INTERFACE
1
GUTOR AC and DC systems are equipped with a comprehensive front panel, a flexible manmachine interface, which displays and facilitates the system’’s parameter settings system and monitoring. This front panel is divided into four main sections:
2
3
4
1. The user-specific mimic
2. Operation for turning
INTELLIGENT SYSTEM VENTILATION
Independent of requirements, we offer «N+1 N+1» » redundant ventilation concept. In case one fan fails the remaining fans are sufficient suffi cient for for the cooling cooling of the entire system. Additionally,, by means of Additionally an internal speed sensor, the rotation of each individual fan is monitored. In the event the number of rotations falls below the pre-set value, an alarm is signaled. The fans can be exchanged during normal operation without any danger to personnel and load.
diagram showing the system’’s current operation system status, indicating which system part is supplying the load at the moment and which is in standby mode.
on and off the system and a lamp test button.
3. The display unit
consists of a LC display showing Event log – Alarm list – Measurement – Operational modes, an alarm LED, an acoustic alarm and a keypad.
4. The alarm indication
panel contains LED’ LED’s which signal specific alarm occurrences.
UPS SYSTEM CONFIGURATIONS
Typical load types:
GUTOR provides a range of UPS system configurations that suit the respective load types. We group the various load types into three major categories.
AC Linear
Unlinear
Type A
Type B
Type C ~ =
~ =
~
M
• AC 1 or 3 phase motors • Passive load • Various
Typical load types:
• Power supply with one single input • Drives
=
• Power supply with dual inputs for AC
DC Linear
Unlinear
Type A
Type B
Type C = =
= =
• DC motors • DC loads
Total reliability of an installation depend on:
• Up-stream configuration, meaning the number of up-stream sources.
= =
M
• Power supply with one single input
• UPS system configuration.
• Power supply with dual inputs for DC
• Down-stream design, meaning the redundancy of the consumer side.
Lets look at some specific UPS system configurations and their characteristics in relation to the respective load types.
AC
Single Unit Configuration
Unit basic components: • Rectifier- and Inverter modules. • Batteries. • Static bypass switches. • Manual bypass.
LOAD
Characteristics: • Preferable for A+B load types.
MANUAL BYPASS SWITCH Q050
BYPASS MAINS
A
BYPASS TEST
STATIC SWITCHES
AUTO
B
EN
RECTIFIER RE CT CTI FI FI ER ER
I NV NVE RT RTER
MAINS
C
MAINS EA
BATTERY BATTERY
DC
Single Unit Configuration
Unit basic components: • Rectifier module. • Batteries.
LOAD
Characteristics: • Preferable for A+B load types.
A
B RECTIFIER
MAINS
C BATTERY
AC
Parallel Redundant Configuration
Unit basic components: • Rectifier- and Inverter modules. • Common, or individual batteries. • Static bypass switches. • Common manual bypass.
LOAD MANUAL BYPASS SWITCH Q050
BYPASS MAINS
• Preferable for A+B load types. • Highest reliability and system availability avail ability.. • Load sharing facility facility,, meaning that each unit supplies its own share of total output. • Redundant. • High MTBF. • High overload capability c apability.. • Up to 9 units in parallel operation for higher performance.
DC
A
BYPASS
Characteristics:
STATIC SWITCHES
TEST AUTO
EN
R E CT IFIE R 1 MAINS 1
RECTIFIER BATTERY 1
BATTERY 2
MAINS
R E CT IFIE R 2
B
IN VE R TE R 1
EA
EN
C
IN VE R TE R 2
MAINS 2
EA
BATTERY
Parallel Redundant Configuration
Unit basic components: • Rectifier module. • Common, or individual batteries.
LOAD
Characteristics: • Preferable for A+B load types, in particular for ultimate reliability and availability requirements. • Load sharing facility facility,, meaning that each unit supplies its own share of total output. • More units in parallel operation for higher performance.
RECTIFIER RECTIFIE R1
MAINS 1
A
BATTERY 1
B
RECTIFIER RECTIFIE R2
MAINS 2
C BATTERY 2
AC
Full Dual Configuration
Unit basic components: • Rectifier- and Inverter modules. • Common, or individual batteries. • Static bypass switches. • Manual bypass.
Characteristics:
MANUAL BYPASS SWITCH Q050
BYPASS MAINS
BYPASS TEST
STATIC SWITCHES
AUTO
EN
RECTIFIE RECT IFIER R
A B
INVERTER INVE RTER
C
MAINS EA
• Preferable for C load load types.
LOAD
BATTERY MANUAL BYPASS SWITCH Q050
BYPASS MAINS
BYPASS TEST
STATIC SWITCHES
AUTO
A EN
RECTIFIE RECT IFIER R
INVERTER INVE RTER
B MAINS EA
C BATTERY
DC
Full Dual Configuration
Unit basic components:
LOAD
• Rectifier module. • Individual batteries.
A RECTIFIER
Characteristics: • Individual, separate unit set-up. • Prefe Preferable rable for C load load types.
B
MAINS
C
BATTERY
MAINS RECTIFIER
A
MAINS
B BATTERY
C
BATTER BA TTERY Y CONFIG CONFIGURA URATIONS TIONS
Mains
Load +
Short-circuit in the DCcircuit in one unit has an influence in the DC-circuit of the second unit unit
Load
Mains +
For Parallel / Redundant and Full Dual UPS system configurations, where two and more units are combined, a common battery configuration is possible. While on one hand this configuration offers space and cost advantages, on the other, the same could be a common failure point. A breakdown of the DC circuit in one UPS unit influences the DC circuit of the combined unit.
Shortcircuit Common Batteries
Mains
Load +
Short-circuit in the DCcircuit in one unit has no influence in the DC- circuit of the second unit
Load
Mains +
Shortcircuit Individual Batteries
With this configuration the same arguments like those mentioned above, such as higher battery costs, apply apply.. In this way, the risk of a common failure point in the DC circuit can be avoided.
COMPLETE SYSTEM SOLUTIONS MORE THAN JUST JUS T A PRODUC PRODUCT T
GUTOR provides complete power supply protection solutions. These include consulting during early stage of a project, engineering, assembly, testing, commissioning of the system(s) and batteries. Most importantly, we are
committed to a reliable long term after sales service.
STAN ST AND DARD ARDSS & QU QUAL ALIT ITY Y WORLDWIDE RECOGNISED STANDARDS
GUTOR supplies products that are designed and manufactured based on recognised worldwide technical and safety standards, such as EN, IEC, IEEE, VDE, SEV, NEMA, ANSI, CSA, UL, FCC. We guarantee quality assurance by means of internal and external controls conducted by our quality management and Bureau Veritas our external auditor. In addition, our systems and processes have undergone customer assurance programs to assure qualification for special applications. Available reports are accessible to our customers and inspectors.
PLANNING & INSTALLATION SYSTEM EXPERTISE AND SUPPORT
When planning or installing an UPS system, GUTOR’ GUTOR’s Sales, Engineering and Service teams offer their expertise and support.
There are a few important aspects that must be considered, such as:
• Safety regulations
• IP protection
• Placing of system
• Cable inlet
• Ventilation
• Earthing
• Fuse coordination (Selectivity)
• Connections
Detailed recommendations and instructions including maintenance are provided in customized operation instruction manuals.
BATTERIES GETTING THE SUITABLE BATTERY BATTER Y TYPE TYP E FOR YOUR REQUIREMENTS
Batteries are a key element in the concept of the UPS power protection solution package. They are used to store the energy required to feed the load (Inverter) during a mains failure. The choice of battery type is therefore critical.
GUTOR has many years of experience in working closely with well-known battery manufacturers, advising and sizing optimal batteries for various applications.
In case of a power failure it is crucial that the back-up batteries are in optimal working condition. Battery monitoring is an effective way to ensure their good performance and full capacity.. Ultimately monitoring ity facilities extend availability of the entire installation.
GUTOR systems provide standard built-in capacity test facility for safe discharge and load testing of the batteries. This can be manually initialised through keypad commands on the front panel. When the system is initialised, it switches to battery operation
GUTOR systems are designed for Lead Acid as well as Nickel-Cadmium battery types.
SIZING OF BATTERIES GUTOR advises and supports customers with issues related to sizing of all sorts of batteries. We size batteries for individual load profiles, according to IEEE standards.
BATTERY MONITORING
mode while the rectifier is kept on stand-by for immediate restart if necessary.. The total discharge sary time is recorded in the system for statistic purposes.
Optional GUTOR provides an (ABM) Advanced Battery Monitoring that can be integrated in all systems. Compared to above capacity test facility, ABM offers various advantages:
Built in Battery Monitoring and Testing Facilities ABM
• Performance & Capacity testing of battery.
• Manual or programmed automatic initialisation possibility possibility..
• Detailed recording for statistic purposes.
• Higher safety for the system as only 25% discharge of the total battery capacity is required.
VBAT
• More detailed monitoring – Estimated battery back-up time according to actual load – Total battery voltage.
=
Ex. 2
Ex. 1
VBAT at 25% of expected Battery back-up time
Advanced Battery Monitor
= Expected discharge curves
VBAT at 50% of expected Battery back-up time VBAT at 75% of expected Battery back-up time
At 10%load
At 10% load
Load
=
100% 90 9 0%
75%
50%
10%
Expected Battery back-up time
„ Example 1: Battery weak: V BAT falls below VBAT 25%“ time before 25% of the time is reached „ Example 2: Battery defective: VBAT falls below VBAT 50%“ time before 25% of the time is reached reached
Upon request GUTOR provides advice to customers, and installs third party battery monitoring facilities.
These offer individual, or cell monitoring (lead acid battery types only). Compared to GUTOR’ GUTOR’s ABM, these
facilities generally require additional equipment and engineering and as a result are more costly.
GUTOR offices:
Headquarters Hardstras strasse se 72 – 74 CH-5430 Wett Wettingen ingen Switzer Switzerland land GUTOR Electronic Ltd Hard Phone: Pho ne: +41 (0)56 437 34 34 Fax: +41 (0)56 437 34 44 e-mai e-mail: l: gutor gutor.info@
[email protected] apcc.com m www www.guto .gutorr.com
Asia-Pacific 6th h Fl Floo oorr, Wis Wisma ma Gen Genti ting ng Jala Jalan n Sult Sultan an Isma Ismailil 5025 50250 0 Kual Kuala a Lump Lumpur ur Ma Mala lays ysia ia GUTOR Electronic Asia Pacific Sdn. Bhd. 6t Phon Ph one: e: +6 +603 03 2161 2161 3440 Fa Fax: x: +6 +603 03 2161 2161 3441 ee-ma mail il:: gutor gutor.as .asiaia-pac pacifi ific@a c@apcc pcc.co .com m ww www w.g .gut utor or.c .com om
North America GUTOR North America 40 Catamore Blvd. 02914 East Providence RI USA Phone: +1 (401) 435 9800, ext 6638 Fax: +1 (888) 726 8448 e-mail: gutor
[email protected] [email protected] www.gutor www.gutor.com .com 1 B
