ES.2.14.0040 Revision A Page 2 CONTENTS 1.0 Introduction 2.0 Custodian 3.0 Purpose 4.0 Application 5.0 Service and Environment 6.0 Codes and Standards 7.0 General Requirements 8.0 Scope 9.0 Electrical Characteristics 10.0 Design and Construction 10.1 General 10.2 Rectifier/Charger Unit 10.3 Inverter Unit 10.4 Battery Bank 10.5 Static By-Pass Transformer 10.6 Static By-Pass Transfer Switch 10.7 Maintenance By-Pass Circuit 10.8 Indication Lights, Meters, Protection and Control 10.9 UPS Enclosure 10.10 Earth Bus 10.11 Noise Limitation 10.12 Radio Frequency Interference Limits 10.13 Additional Requirements ES.2.14.0040 Revision A Page 3 11.0 Labelling 12.0 Inspection and Testing 12.1 General 12.2 Factory Testing 13.0 Painting and Finish 13.1 General 13.2 Exterior 13.3 Interior 14.0 Special Tools 15.0 Shipping, Handling and Storage 16.0 Drawings and Data 17.0 Spare parts 18.0 Guarantee and Warranty 19.0 Deviations 20.0 Bibliography 20.1 International Reference Standards 20.2 QP Standards ES.2.14.0040 Revision A Page 4 1.0 Introduction This is an engineering specification that gives details of AC Uninterruptible Power Supplies (UPS’s) for QP operations. Note that any changes to this document from the last revision are highlighted by a bold vertical bar to the left of the area of change. Should there be a need to consult this document’s change history log, refer in the first instance to its custodian (EE). References made throughout this specification are numbered inside the square brackets [ ] and may be found in the Bibliography of Section (20). Cross references between sections and sub-sections within this specification are numbered inside round brackets ( ) 2.0 Custodian The custodian of this specification is EE, who is responsible for the accuracy and quality of its contents and for its future revisions, where these changes are required to reflect industry trends or changes to QP business practices. 3.0 Purpose The purpose of this specification is to provide guidance to QP, their Consultants and Contractors on the AC Uninterruptible Power Supply Systems utilised by QP throughout its operations both onshore and offshore. 4.0 Application The application of this specification is to provide reliable power supplies to various control systems, shutdown and safety equipment for oil and gas facilities both onshore and offshore. For all QP onshore and offshore facilities except PS-4 complex the power supply is: - 415 Volts, 3 phase and neutral, 50Hz with the neutral solidly earthed. For PS-4 complex offshore, the system power supply is: - 440 Volts, 3 phase and neutral, 60Hz with the neutral solidly earthed. Any reference herein to 440 Volts and 60Hz shall not be taken as an alternative to 415 Volt and 50 Hz but rather specific to PS-4 and associated platforms supplied from it. 5.0 Service and Environment The atmosphere throughout all QP plants shall be considered to be corrosive, as normally associated with oil and gas processing plants, refineries, chemical plants, LNG plants, offshore platforms, industrial sites and the like. In addition for offshore and coastal locations, the atmosphere shall be considered to be salt laden. ES.2.14.0040 Revision A Page 5 High humidity is experienced in all areas and condensation will occur on all equipment during some period of its lifetime and therefore all components, nuts, bolts and washers etc. shall be of corrosion resistant material except where specifically stated otherwise and shall be tropicalised. The equipment shall, in all respects be suitable for operation in service condition as defined in ES.2.03.0001 Appendix E, Electrical Engineering Philosophy [27]. The AC UPS system will be installed in an air-conditioned room. This room is classified as a non-hazardous area. The UPS battery shall be located in the battery room which is force ventilated and cooled from the HVAC system During certain periods of abnormal operation, the indoor conditions may be the same as the outdoor environment. As such all materials used shall be suitable for these transient conditions. The Supplier shall refer to Appendix E of ES.2.03.0001 [27] for more information on climatic conditions on site. The system shall be designed for a service life of at least twenty years in the environment and for the duty specified. All equipment shall be tropicalised. There shall be no exposed copper, all copper must be tinned or covered with insulation. All materials shall be of the self-extinguishing type. 6.0 Codes and Standards See Section (20) Bibliography for a complete list of reference documents The IEC Standards shall take preference over all other preferred standards. 7.0 General Requirements 7.1 Suppliers Product Range It is a general requirement that the Supplier offers only equipment that is within his standard range. The equipment shall not be a proto-type or a new product line that has not been sold in reasonable numbers to similar users to QP. The supplier shall include in his tender documentation a list of users in the Middle East that have purchased the same equipment being offered. 7.2 Origin of Main Power Components Main components in general shall be from the country where the UPS is supplied. Test certificates for all the main components shall be in the name of the Supplier for the UPS and not in the name of the third party manufacturer or vendor. ES.2.14.0040 Revision A Page 6 7.3 Project Management The Supplier shall nominate a single person to manage the project and this person shall be the “focal point” for all discussions, meetings, communications, correspondence, and the like, between the Supplier and QP, the Principal. 7.4 Abbreviations and Definitions For the purpose of this specification the following abbreviations and definitions shall apply: Abbreviations A.C. or a.c Alternating Current or voltage BSI British Standards Institute DB Distribution Board D.C. or d.c. Direct Current or voltage Deg. C Degrees Celsius DFT Dry Film Thickness EMI Electromagnetic Interference FAT Factory Acceptance Testing HVAC Heating, Ventilation and Air Conditioning Hz Frequency of Alternating Current or Voltage, cycles per second (Hertz) IEC International Electrotechnical Commission LED Light Emitting Diode LV Low Voltage - up to 1000 V A.C. or 1500V d.c. MCB Miniature Circuit Breaker MCCB Moulded Case Circuit Breaker RMS Root Mean Square value of current or Voltage SCADA System Control and Data Acquisition SI System International VDE Verbrand Deutscher Elektrotechniker General Definitions For the purposes of this specification, the following definitions shall apply: - Shall and Should – The word ‘shall’ is to be understood as mandatory and the word ‘should’ as strongly recommended to comply with the requirements of this specification. The Principal is the party, which initiates the project and ultimately pays for its design and construction. The Principal will generally specify the technical requirements. The Principal may also include an agent or consultant, authorized to act for the Principal. The Contractor is the party which carries out all or part of the design, engineering, procurement, construction and commissioning of the project. The Principal may sometimes undertake all or part of the duties of the contractor. The Manufacturer/Supplier is the party, which manufactures or supplies equipment and services to perform the duties specified by the Contractor. ES.2.14.0040 Revision A Page 7 The Purchaser is the party, which buys the UPS units for its own use or on behalf of the Principal. Technical Definitions Vital Service is a service which, when failing in operation or when called upon, can cause an unsafe condition of the process and/or electrical installation, jeopardise life, or cause major damage to the installation. Rated Output is the apparent power expressed in kVA, which can be continuously delivered by the unit over the range of conditions of service and electrical loading specified in this document without exceeding component ratings and any of the required output tolerances. Power Factor is the power factor of the fundamental wave, cos φ, (sometimes referred to as the displacement factor). Active power of the fundamental wave i.e. cos φ = apparent power of the fundamental wave Relative Harmonic Content is the ratio of the r.m.s. value of the harmonic content to the r.m.s. value of the total non-sinusoidal periodic waveform. i.e. relative harmonic content = √ 1- (g1/g) 2 where g1 = r.m.s. value of the fundamental component of current or voltage. and g = r.m.s. value of the total waveform of current or voltage. Crest Factor is the ratio of the peak value to the r.m.s. value of the total non-sinusoidal periodic waveform. Partial Discharged Condition of a battery is the condition reached when the battery has been discharged to the point that the inverter can no longer deliver its rated output within the permissible tolerances. Float Charging is the passing of an electric current through a battery by applying a constant voltage from a charger such as to maintain the battery in a state of charge. Rapid Charging is the passing of an electric current through a battery by applying a controlled voltage from a charger, such as to restore the battery to a predetermined state of charge in a limited time span. Starting Voltage is the voltage present at the battery terminals when it starts to discharge. Final (or end of discharge) Voltage is the voltage at which battery discharge is terminated. ES.2.14.0040 Revision A Page 8 Nominal Capacity of a battery is a battery cell rated capacity, selected and declared by the Manufacturer, based on a specific discharge time, final voltage and reference temperature. Mean Time Between Failure (MTBF) represents the predicted duration of trouble free operation and is calculated as follows: - operating time MTBF = hours Number of faults resulting in outage Non-Flame Propagating Material is one, which will not, when ignited, continue to burn nor cause other material, in contact with or adjacent to it, to ignite. Non-Toxic Substance is one which causes no harm to the environment or to a person exposed to it , except only if exposed to or ingested in an overwhelming dose or unusual conditions. Switch Mode Power Supply (SMPS) is a power supply where the output D.C. voltage and current are pulse-width controlled by means of switching, at high frequency, an unregulated D.C. voltage converted from A.C. mains. Valve Regulated (or Sealed) Cell is a cell or battery in which the venting of electrolysis gas is controlled by a re-closing valve. Provision is not made for water additions. The electrolyte may be immobilised, absorbed, or limited in volume. 8.0 Scope This specification covers the design, manufacture, and testing of factory assembled AC Uninterruptible Power Supply (UPS) system to be installed for various projects of Qatar Petroleum. 9.0 Electrical Characteristics An A.C. single phase and neutral 50/60 Hz vital supply shall be provided from the UPS system to power the Instrumentation and Controls, Distributed Controls System (DCS), Fire and Gas (F&G) and Emergency Shutdown Systems (ESD). During failure of normal supply, the UPS system shall provide continuous power supply to all vital loads. The UPS system supply feeds shall be from the Emergency Bus and from 415/440 Volt Switchboard Normal Bus as indicated in the Single Line Diagrams. The UPS system shall be suitable for operation in accordance with the following service requirements indicated below. Any Derating Factor applied shall be clearly indicated in the tender. Supply Voltage 415V, 3 phase or 240V, 1 phase or 440V, 3 phase Solidly grounded, as specified in the Data Sheet Voltage Tolerance + 10% Supply Frequency 50Hz + 5% or 60Hz + 5% Output Voltage 240V + 5%, or 110V + 5%, 1 Phase & Neutral, Sinusoidal Waveform. ES.2.14.0040 Revision A Page 9 Output Frequency 50Hz + 1% Load As Specified in the Data Sheet Battery Recharge Time From Partially Discharged to Capacity that will enable it to fulfil the inverter input Power requirements within 8 hours. Battery Type Vented, Pocket Plate, Nickel Cadmium or Recombination Type [13] Neutral Earthing Solidly Earthed Transient voltage depressions down to 80% of rated voltage shall not affect the performance of the equipment. The UPS offered shall be capable of riding through power system frequency depressions. System voltages and frequencies for QP locations are given in section 8.3 of ES.2.03.0001 Engineering Philosophy [27]. 10.0 Design and Construction 10.1 General 10.1.1 The UPS System shall be designed to provide a continuous and uninterruptible source of conditioned AC power to the critical loads as stated. During any interruption of normal mains power supply the battery bank shall provide DC input power to the inverter without interruption to AC power to the critical loads for specified duration (also known as the ride through). The load cycle is attached. 10.1.2 The UPS system shall be designed to operate under the following modes: - a) Normal: The healthy supply from the Power system bus is rectified into regulated DC voltage to float charge the battery banks and supply the critical loads via the inverter. b) Emergency: In the event of failure or disturbance on the normal mains supply the battery bank shall, without interruption, take over supply to the load via the inverter for the specified time. When the AC mains supply is restored, the UPS shall revert back to mode (a) above without any interruptions. c) By-Pass Mode: In the event of external overload/short circuit condition or inverter fault, the load is automatically transferred to the main by-pass supply by the static switch. When the overload condition/short circuit condition, or inverter fault is cleared, the load shall be automatically transferred back to the original mode of operation. ES.2.14.0040 Revision A Page 10 d) Maintenance By-Pass: This is effected when the load is manually transferred to the by-pass source via a maintenance by-pass moulded case circuit breaker (MCCB) for total isolation of the load from the UPS. e) Two units of such UPS systems (redundant) shall be used to provide the most reliable output. If one unit is needed, this shall be clearly specified in the project drawings and datasheets. 10.1.3 Overall UPS efficiency shall be at least 85% for operational mode. 10.2 Rectifier/Charger Unit 10.2.1 Under normal conditions, the AC thyristor power rectifier section shall convert the incoming line voltage to DC, which shall feed the inverter. The inverter shall supply power to the load through a static switch. 10.2.2 The rectifier/charger unit shall be of constant voltage, current limiting type and shall incorporate a soft start feature to gradually accept load on initial energising. 10.2.3 The rectifier/charger unit shall be adequate for charging the battery bank from partially discharged state to a state of sufficient charge which will provide for a complete repetition of the duty described in section 10.1.1 after 8 hours of charging. The power rectifier shall be capable of supplying the entire DC load requirement while simultaneously charging the battery bank as described above. 10.2.4 The rectifier/charger unit shall perform battery charging at float charge mode and rapid charge mode. 10.2.5 The rectifier/charger unit steady DC output voltage variations shall be within + 1% of the set charging value during load variations from zero to rated rectifier output, and during steady state input voltage and frequency variations as stated in section 9.0 above. 10.2.6 Short time AC supply voltage depression of 20% due to motor starting and frequency dips shall not result in tripping of the rectifier/charger unit or the initiation of battery discharge. The UPS output shall not be adversely affected. 10.2.7 On-line adjustment of the set value of battery charging voltage shall be possible by means of a setscrew type rheostat potentiometer on the relevant control card. 10.2.8 A moulded case circuit breaker with releases or trip unit (for short circuit protection) and thermal release or trip unit (for overload protection) shall be used for overcurrent protection of the rectifier/charger unit. 10.2.9 The rectifier/charger unit shall be designed to prevent current from the inverter unit from flowing back into the rectifier/charger. The circuitry shall be such that no current will back-flow into the battery bank from the inverter section. 10.2.10 The rectifier/charger unit shall be provided with facilities to boost charge the battery by automatic and manual means. Automatic boost charge shall occur following any period of battery discharge exceeding 10 seconds. Battery boost charge operation shall be controlled automatically according to the constant current/constant voltage characteristics. ES.2.14.0040 Revision A Page 11 10.2.11 A timing relay shall be provided to control the boost charging operation. The timing relay shall be activated on detection of battery voltage and current conditions, which indicate the restoration of the battery to an appropriate state of charge. 10.2.12 A suitable interlock shall be provided to ensure that boost charging shall not be carried out on failure of the ventilation system of the room. 10.2.13 A suitable arrangement shall be provided to charge any of the batteries from any of the rectifier/charger unit. 10.3 Inverter Unit 10.3.1 The inverter shall be of the current limiting type and shall invert the DC input to 240 volts or 110 volts, 50Hz (60Hz), single phase and neutral, 2 wire system. The inverter shall remain operable even when the batteries are disconnected from the system. 10.3.2 The inverter shall be of the pulse-width-modulated type operating at a switching frequency of 50Hz (60Hz). The output frequency shall be synchronised to the input frequency within + 0.5% and the rate of change of frequency shall not exceed 0.2Hz a second. Frequency stability shall be +2% when free running, and shall normally be locked on to the AC power system. In the event of the mains frequency deviation being greater than +2%, the inverter shall lock-out and drive the 50Hz (60Hz) reference frequency from an internal oscillator. 10.3.3 The inverter shall have minimum overload ratings as follows while maintaining its rated output: • 125% of rated output for 15 minutes • 150% of rated output for 1 minute 10.3.4 The inverter shall be able to sustain surge currents of at least ten times normal current, so as to operate the circuit breakers within 30 milliseconds in the event of a short-circuit and shall be capable of switching an inrush current onto a steady load. It shall be suitably sized such that the start-up load does not exceed the crest factor of the UPS system. 10.3.5 The UPS system has to be suitably designed for non-linear loads such as computer systems. The maximum Total Harmonic Distortion (THD) and Single Harmonic Distortion (SHD) into a linear load shall be limited to 5% and 3% respectively. For non- linear loads, the THD and SHD values shall be less than that specified for linear loads. The Supplier shall state these figures in the data sheet. 10.3.6 An electronic current limiting device in addition to the normal circuit breaker overcurrent protection shall protect the inverter output. 10.3.7 Output Regulation shall be as follows: a) Steady state output regulation shall be +5% of rated output voltage under all load conditions. b) Dynamic output voltage regulation shall be + 10% for instantaneous load change of 100% rated output, with recovery to within +5% of steady state voltage in less than 100 milliseconds. ES.2.14.0040 Revision A Page 12 c) Output voltage shall be manually adjustable by +5% of normal. 10.3.8 An adjustable timer (1 to 6 hours) shall be provided for controlling the duration of ride through (load supplied to battery) to prevent the battery bank from over-discharging. At the end of the pre-set timed duration, the inverter shall be switched off automatically to prevent continued discharge of the battery bank. Upon restoration of AC input to the UPS system, the power rectifier shall automatically initiate battery charging. The inverter shall be switched on automatically and the system shall revert to its normal operation. 10.4 Battery Bank 10.4.1 The battery bank shall consist of an assembly of high quality, heavy duty, vented pocket plate, nickel cadmium cells of adequate AH capacities, series connected to provide the required voltage fulfilling the input power requirements of the inverter when it is delivering its rated kVA output at 0.8 p.f. lagging for the specified duration. 10.4.2 The Supplier shall determine the number and capacity of cells for forming the battery bank. Detailed battery sizing calculations shall be furnished by the Supplier for the Purchaser’s review and approval. 10.4.3 The nickel cadmium cells used shall conform to the following: - a) The cell container shall be made from non-flame propagating, shock resistant and leak-proof opaque plastic. b) High and low electrolyte level lines shall be marked on the exterior of the containers by means of permanent markers. c) All cell terminals shall have adequate current carrying capacity ; cell terminal posts shall be equipped with electrolyte-resistant connector bolts. d) All cell terminal posts, bolts and associated hardware shall be corrosion resistant. e) The battery cell interconnectors shall be made with suitably sized solid links of tinned or nickel-plated copper. Special electrolyte-resistant jelly shall be applied over the solid links. Inter row connection shall be made with insulated cable complete with lugs. f) Life expectancy of the battery at 30° C shall be at least twenty years. The Supplier shall submit statistical figures to show proof of its capabilities. g) The battery shall be provided with a two-pole moulded case circuit breaker mounted on the UPS cubicle for total isolation of the battery from the rest of the UPS system. The circuit breaker shall have contacts for providing an interlock with battery room ventilation system failure. 10.4.4 Batteries shall be mounted on freestanding steel racks protected with an alkali resistant paint or epoxy finish. The racks shall be arranged to permit easy access to each row and tier of cells. Trays shall be provided for spillage of electrolyte. 10.4.5 The Supplier shall supply two diagonally opposite earthing bosses welded to the racks. ES.2.14.0040 Revision A Page 13 10.5 Static By-Pass Transformer The 415 Volt/ 240 Volt or 415 Volt/ 110 Volt static by-pass transformers shall have common mode attenuation of not less than 50dB. The transformers shall be provided with voltage stabilisers. For 440V system, primary voltage shall be 440V. 10.6 Static By-Pass Transfer Switch 10.6.1 The static by-pass transfer switch shall comprise an automatic transfer circuitry that synchronises the inverter output with that of the by-pass source before automatic by-pass is effected. The by-pass source shall be an AC stabilised supply from the secondary output of the static by-pass transformer located within the UPS system. 10.6.2 The by-pass circuit shall have a continuous current rating equal to the rated UPS output and shall be capable of conducting a current equal to ten times the rated output for not less than two seconds. 10.6.3 Automatic by-pass shall be initiated in the event of any of the following taking place: - • Inverter output voltage drops below 95% of the nominal output voltage. Transfer shall be accomplished before the voltage drops to 85% of the nominal output voltage. • Inverter output voltage exceeds 105% of the nominal output voltage. Transfer shall be accomplished before voltage reaches 115% of the nominal output voltage. • Inverter failure condition. • Load current exceeds the specified inverter overload capacity. • Battery output is below specification (battery undervoltage). • Overheating of inverter power circuitry. • Fault clearing downstream of UPS system. 10.6.4 Retransfer of the loads from the mains by-pass to the inverter shall only be possible if the following conditions exist: - • The inverter output voltage is synchronised with the mains by-pass voltage • The inverter output voltage is within +10% of the nominal output for more than 5 seconds • any of the conditions that caused the automatic transfer operation from inverter to mains by-pass has been rectified 10.6.5 The static by-pass transfer switch shall not operate in any of the following events: - • By-pass source voltage exceeds +15% of rated UPS output voltage (undervoltage or overvoltage). • By-pass source frequency is not synchronised with the inverter output frequency. • Automatic transfer/retransfer exceeds more than 4 times in 5 minutes. • The static switch operation is manually suppressed. 10.6.6 The static by-pass transfer switch shall be capable of effecting the transfer/retransfer operation within 0.5 milliseconds. A test switch shall be available for routine functional testing. ES.2.14.0040 Revision A Page 14 10.7 Maintenance By-Pass Circuit 10.7.1 A manual maintenance by-pass circuit shall be provided complete with incoming moulded case circuit breaker and a maintenance by-pass transformer to transfer the load to an alternate AC source and permit isolation of the rest of the UPS system for maintenance. The alternate source shall be a stabilised AC supply from the maintenance by-pass transformer located adjacent to the UPS cabinet. 10.7.2 The maintenance by-pass transformer shall have common mode attenuation of not less than 50dB. The transformer shall be provided with voltage stabiliser. 10.8 Indication Lights, Meters, Protection and Control 10.8.1 Status Indicators The following minimum indications, in the form of Light Emitting Diodes (LED’s), shall be provided on the panel front to enable verification of the operational status of the UPS. The indications shall be superimposed on a mimic diagram of the UPS units to identify the relevant components or circuit: • AC input supply available. • By-pass supply available. • Rectifier/charger on. • Inverter on. • Battery feeding load. • Load on inverter. • Load on by-pass. • Inverter/by-pass synchronised. • battery on boost charge. 10.8.2 Measurement The following digital or analogue displays or measuring instruments shall be provided on the panel front: • DC voltmeter to indicate charging/battery voltage. • DC ammeter to indicate battery bank charge/discharge current, zero center scale meter. • DC ammeter to indicate total current output of rectifier charger. • AC voltmeter to indicate input voltage to battery charger. • AC ammeter measuring UPS output current. • Frequency meter measuring UPS output frequency. Measuring accuracy shall not be less than Class 1.5 to IEC 60051 [3]. 10.8.3 Protection and Alarms The following alarms and protection functions shall be provided as a minimum: a) Alarm only • Charger failure/battery discharging. ES.2.14.0040 Revision A Page 15 • Battery disconnected. • DC earth fault (for normally unearthed DC system). • Inverter/by-pass not synchronised. b) Alarm and Trip rectifier Charger • AC input undervoltage. • Rectifier failure. c) Alarm and Trip Inverter • DC overvoltage. • DC undervoltage. • Inverter failure. • Inverter overcurrent. • Inverter output voltage deviation. • Inverter stack over temperature. LED indicators shall be provided at the front of the panel for the above alarms. All alarms associated with trip functions shall be hand reset. All above alarm and trip contacts shall be wired to a relay such that one common normally closed and one common normally open, potential free contacts are provided for a remote common alarm. d) Control The following control switch/circuit breaker and adjustment facilities shall be provided: • Rectifier input circuit breaker with pad-locking facility. • DC output voltage adjustment. • DC current limit adjustment. • Inverter on/off control switch. • AC output voltage adjustment. • Synchronising range adjustment. • Load transfer initiating control switch. • Battery isolating switch/circuit breaker. • Rapid charge initiating switch. • Rapid charge duration timer. • Rectifier on/off control switch. 10.9 UPS Enclosure 10.9.1 The enclosure housing the rectifier, inverter, static by-pass transformer, static switch and control circuitries shall be indoor, free standing, totally enclosed, sheet steel cabinet that shall provide a degree of protection IP 42 in accordance with IEC 60529 [12]. 10.9.2 The panel shall be fully accessible from the front and suitable for operation and maintenance from the front only. All components shall be clearly identified and easily accessible. Suitable partitions shall be provided to allow adjustment and inspection to be carried out safely. ES.2.14.0040 Revision A Page 16 10.9.3 The minimum thickness of the sheet steel shall not be less than 2mm. 10.9.4 Forced cooling of the system is not acceptable and forced ventilation of the system components shall not be considered. 10.10 Earth Bus 10.10.1 The Supplier shall install a continuous tinned copper earth bus at the bottom of the UPS enclosure, close to external cable glands to facilitate termination of the cable earth braids or armouring. The earth bus shall run through the entire length of the enclosure so that all earthing conductors have ready access to it. 10.10.2 Each end of the bus bar shall be fitted with an earth terminal for connection of an earth conductor to the earthing system. 10.10.3 The electrical continuity of all exposed non-current carrying conductive parts of the UPS units components and enclosure shall be maintained, by bonding conductors between different parts of the UPS unit, and by bonding to the earth bus bar. 10.11 Noise Limitation The Supplier shall ensure that the audible noise level generated by the UPS system shall not exceed 75 dBA at a distance of one metre and if tonal components are present, the noise level shall not exceed 70 dBA [1]. 10.12 Radio Frequency Interference Limits The production of radio frequency voltages shall not exceed level “N” as defined in VDE 0875 [26]. The performance of the UPS unit shall not be affected or in any way degraded by the use of portable radio transmitters/receivers. 10.13 Additional Requirements 10.13.1 All relay contacts and devices requiring external connection shall be wired to terminal blocks located inside the enclosure. All internal wiring, electrical components, relays, rheostats and terminal blocks shall be clearly tagged and identified. 10.13.2 Terminal blocks shall be arranged and positioned to afford easy access for carrying out external cable terminations, testing, inspection and maintenance. Terminals for different voltages shall be segregated and the voltages shall be clearly indicated. Each terminal block shall be provided with 20% spare terminals. It shall be possible to test and adjust major components or circuit, without disconnecting or removing them from the cabinet by using standard multi-meter and oscilloscope. 10.13.3 Wiring of different voltages shall be segregated and routed in different trunkings or trays. The voltages shall be clearly indicated on the wires and wire-ways. 10.13.4 All meters, switches, pilot lights, etc. mounted on the enclosure front panel shall be provided with permanent nameplates attached with 316 stainless steel screws. Nameplates shall be engraved on white-black-white traffolyte. ES.2.14.0040 Revision A Page 17 10.13.5 All pilot lights provided shall be of the LED cluster type and shall be mounted on the front of the panel. 10.13.6 All cable entries to the panel shall be from the bottom and suitable undrilled gland plates shall be provided for field drilling 11.0 Labelling The language for all labels shall be English unless specified otherwise by QP. 11.1 Labelling of components Labels shall be provided as follows:- • Each compartment shall be identified with a label at the front and rear on the fixed part of the assembly, marked with the cubicle reference and service description as specified in the data sheets. • Withdrawable parts shall be provide with circuit identification labels. • Label shall be provided with unique code references corresponding to the manufacturer’s schematic diagrams for the following:- i. Each control switch ii. Each indicating lamp iii. Each fuse and link iv. Selector switch positions v. Each instrument vi. Each relay • Labels shall be engraved, screwed and not fixed by adhesive. Their colouring shall be:- i. All except below, black lettering on a white background. ii. Danger labels, black lettering on a yellow background. iii. ‘Stop’ warning labels, red lettering on a white background. • Terminal label markings shall comply IEC 60445 [11]. • Lettering shall be at least 20 mm high on all external labels. 11.2 General Equipment Nameplate The following information shall be given on the general equipment nameplate:- • Manufacturer’s name or trademark. • Manufacturer’s serial and reference number of the product. • Type designation. • Purchaser’s name. • Purchase order number and date. • Year of manufacture. • Rated voltage. • Rated frequency. • Degree of protection to IEC 60529 [12]. ES.2.14.0040 Revision A Page 18 12.0 Inspection and Testing 12.1 General 12.1.1 Any unsatisfactory material, equipment, or workmanship shall be replaced or repaired to the Purchaser’s satisfaction at the Supplier’s cost. 12.1.2 The Supplier shall notify the Purchaser of their intentions of carrying out any factory tests at least four weeks prior to the commencement of such tests. 12.1.3 All pre-requisites for tests such as temporary interconnections, test instruments, etc. as well as the actual testing and documentation of tests shall be the responsibility of the Supplier. 12.1.4 The Supplier shall submit all certified test reports to the Purchaser within two weeks of the completion of such tests. 12.2 Factory Testing 12.2.1 The UPS system shall be tested in accordance with the Standards and Codes listed in Section 6. Testing shall be carried out as per the Purchaser’s approved test programme. The factory test shall comprise: - 12.2.2 Performance Tests 12.2.2.1 Insulation Tests The voltage specified in the following table shall be applied to the circuits indicated for one minute: - Table of Withs tand Voltage Control Electronics < 60 Volts Power Electronics (U n1 ) Volts Auxiliary circuits (U n2 ) Volts To earth 700V D.C. (2 x U n1 +1000)V (2 x U n2 +1000)V To Control Electronics - (2 x U n1 +1000)V (2 x U n2 +1000)V To Power Electronics (2 x U n1 +1000)V - (2 x U n1 +1000)V To Auxiliary Circuits (2 x U n2 +1000)V (2 x U n1 +1000)V - DC test voltages may be applied instead of AC. The magnitude of DC test voltages to be applied shall be √2 times the above-mentioned AC (r.m.s) values. 12.2.2.2 Load Duration Test All converters to be supplied as part of the purchase order shall be subjected to a load duration test performed at rated voltage for a period of not less than 48 hours prior to the execution of function tests. At least one converter of each group of identical converters shall be loaded to its rated output, at 0.8 power factor lagging, throughout the 48 hour test period. If an appropriate load is not available to conduct the test, then it shall be carried out using a resistive load. The load resistance shall then be such that the inverter DC input current is the rated value. ES.2.14.0040 Revision A Page 19 All other converters to be supplied as part of the purchase order may be energised under partial load or zero load current conditions throughout the test period. Manufacturer’s test report shall state the dates and times on which the load duration test was performed and shall record details of load currents and any circuit or component malfunction identified during the test period. 12.2.2.3 Functional Tests Functional tests shall be performed on all converters. If, during the execution of functional tests, an electronic component of the converter is required to be replaced, e.g. due to converter malfunction or failure of the unit to fulfil the performance requirements of the specification, then the converter load duration test shall be repeated at rated current following which the functional tests shall be carried out. The manufacturer ‘s standard test protocol will be acceptable provided it is no less stringent than that specified below. Tests and measurements marked (**) may be omitted subject to the manufacturer submitting with the tender, details of the availability of test records (including dates and location of tests) which verify the specified performance values. a) Rectifier load test at constant output voltage Measurement shall be carried out in the rectifier float-charge operating mode and in the rectifier rapid-charge operating mode. In each mode, measurements shall be carried out at nominal AC supply voltage and at zero, 50%, and 100% of rectifier full load direct current. Measurements at 100% full load current shall be repeated at 90% and 110% of nominal AC supply voltage. Measurements shall comprise: - • Input phase voltage and frequency • Input phase current • Input power • DC output voltage • DC output current b) Rectifier load test at constant output current limit Measurements shall be carried out in the rectifier float-charge operating mode and in the rectifier rapid-charge operating mode. In each mode, measurement shall be carried out when the rectifier is operating under DC output current limiting conditions with the DC output voltage between zero and the set value corresponding to constant voltage operation. Measurements shall comprise: - • DC output voltage • DC output current ES.2.14.0040 Revision A Page 20 c) Inverter static load tests (i) 1-Phase Inverters Measurements shall be carried out at zero, 50%, and 100% of inverter output current and shall be repeated for inverter DC input voltage corresponding to battery float-charge operation and the rated maximum and minimum inverter input voltage. Measurements shall comprise: - • DC output voltage • DC output current • Output voltage, frequency and waveform distortion. • Output phase current(s) • Output power (ii) 3-Phase Inverters • Balance load tests The static load test described in (i) for 1-phase inverters shall be carried out on 3-phase inverters, the load being a balanced 3-phase load. • Unbalanced load test. Measurements shall be carried out under unbalanced conditions such that the current in one phase of the inverter differs from that in the other two phases by 50% of the rated output current. Measurements shall be carried out for inverter DC input voltages corresponding to battery float-charge operation and the rated maximum and minimum inverter input voltage. Measurements shall comprise: - • Input voltage • Input current • Output voltages • Angular displacement of output phase voltages • Output currents d) Inverter dynamic load tests (**) Measurements of inverter output voltage variations shall be recorded in response to: - • Instantaneous load changes of 100% rated output • Measurements shall be recorded when the load is switched to/from the inverter via the static by-pass switch and via the load circuit switch. • Application of a short circuit to the inverter output via a slow acting (type g1) fuse link having a current rating nearest to 10% of the UPS unit rated output, the by-pass circuit being isolated. ES.2.14.0040 Revision A Page 21 e) Static by-pass switch tests Measurements shall be carried out to verify the correct functioning of the by- pass circuit voltage and frequency monitors, and the inverter/ by-pass synchronous operating controls. Measurements of the load voltage waveform(s) shall be carried out during the following load transfer tests which shall be performed with the UPS delivering any load between zero and its rated output, and with the inverter operating in synchronism with the by-pass circuit supply: • Load transfer to by-pass initiated by manual operation of load transfer switch • Load transfer to by-pass initiated by simulating inverter malfunction. • Load transfer to by-pass initiated by short-circuiting of fuse protected load circuit (**). • Load retransfers to inverter initiated automatically and manually. • Lock-out of automatic load retransfers on sustained and recurring fault. f) Auxiliary equipment and control circuit tests The correct functioning of all measuring instruments, alarm and indication, protection and controls shall be verified. g) Battery discharge test A battery discharge test shall be performed at a current corresponding to the inverter input current when the inverter is delivering its rated output kVA at 0.8 power factor lagging. The following measurements shall be recorded: - • Battery voltage after the specified discharge time. • Battery discharge duration at the instant of inverter shutdown initiated by the DC circuit low-voltage monitor. 12.2.3 The Purchaser may require additional testing if test results are unsatisfactory or marginal. Any equipment rejected shall be repaired or replaced to the Purchaser’s satisfaction and test shall be repeated at no additional cost to the Purchaser. 12.2.4 Inspection and testing shall be carried out in the presence of the Purchaser or the Purchaser’s designated representative. A minimum of 4 weeks written notice by the Supplier is required so that the Purchaser can depute his representative for witnessing the test. 13.0 Painting and Finish 13.1 General Due note should be taken of the presence of chlorides and H 2 S in the atmosphere at the site location and coatings should be such as to give protection to the base metal of construction and resist chemical attack by the corrosive atmosphere for a minimum period of five years. ES.2.14.0040 Revision A Page 22 The Manufacturer may propose alternative paint systems which are equal, or superior to, the below mentioned for the Purchaser’s approval. 13.2 Exterior All exterior surfaces of panels and boxes shall be cleaned, filed, primed and finish painted with a synthetic stove enamel, of shade light grey to BS 381C [18], semi gloss, to total DFT of not less than 150µm. It shall be the Manufacturer’s responsibility to ensure that no substrate flaws are visible on any exterior surface. The Manufacturer shall supply 250ml of the paint used for final coat of exterior surfaces to allow for future touch-up. 13.3 Interior Internal surfaces shall be cleaned, pr imed, and finish painted matt white to the Manufacturer’s Specification (to be submitted for approval). They shall be free from holidays or significant paint blemishes. The Manufacturer shall inform the Purchaser of the paint system used, such as to allow him to make compatible repairs, should they become necessary. 14.0 Special Tools 14.1 A complete set of special tools and tackles required for operation, maintenance and testing shall be provided. The Supplier shall provide a list of special tools, individually priced with his quotation. 15.0 Shipping, Handling and Storage 15.1 The equipment shall be shipped in sections to suit ease of handling for transportation and installation 15.2 Each shipping container shall be provided with supports in the form of suitable steel sections, lifting eye bolts etc to maintain alignment of parts during shipping, handling, hoisting and installation. Location of lifting points shall be clearly marked on shipping containers and drawings. Each shipping section shall have its weight clearly marked on the container. 15.3 Battery cells shall be packed separately from other equipment 15.4 Battery cells shall be shipped in the manner recommended by the battery manufacturer. 15.5 Withdrawable circuit breakers shall be shipped separately from their housings. 15.6 Preparation for shipment shall protect the auxiliary devices, accessories, etc. against corrosion, dampness, breakage or vibration damage during transportation and handling. 15.7 Each shipping container shall be identified with the contents, purchase order number and item number. ES.2.14.0040 Revision A Page 23 15.8 The manufacturer shall advise the Purchaser of any special storage requirements prior to shipment. 16.0 Drawings and Data 16.1 Drawings and data shall be provided in accordance with the standard forms attached to the material requisition. This data shall include all the protection and overload relay performance curves. 16.2 In addition to the instructions in the standard forms the Supplier shall comply with the following additional requirements for the installation, operation and maintenance manuals: 16.2.1 The front cover, spine and inside page shall state the purchase order number and Suppliers reference number. 16.2.2 The inside front page shall carry an index listing the contents of each section of the manual. 16.2.3 Individual sections shall be complete and shall refer to equipment actually supplied. 16.2.4 Published data shall be included, including published data for bought out items. 16.2.5 Full details of any special equipment shall be clearly set out in separate sections. 16.2.6 Details of protective devices shall be fully documented. 16.2.7 A punch list of “do’s” and “don’ts” shall be included. 16.2.8 Full details for installation and setting up shall be included. 16.2.9 Recommended test data shall be stated covering initial and regular testing. i.e. values for high voltage, AC or DC etc. shall be given. 16.2.10 Items requiring regular inspection, checking, testing and maintenance shall be listed and the time scale clearly indicated. 16.2.11 Important items shall be cross-referenced to other parts of the manual as necessary. 17.0 Spare Parts 17.1 The Supplier shall furnish a completed SPIR form indicating the Spare Parts required for two years operation. 18.0 Guarantee and Warranty 18.1 The package shall be guaranteed to meet the specified requirements of the UPS system. 18.2 The Supplier shall guarantee all equipment and component parts against defective material, design and/or workmanship for one year after placement in service, or for 24 months from date of shipment, whichever occurs first. ES.2.14.0040 Revision A Page 24 18.3 If any defects or malperformance occur during the guarantee period, the Supplier shall make all necessary alterations, repairs and replacement immediately and free of charge to the Purchaser. 19.0 Deviations 19.1 Deviations from this specification are only acceptable where the Supplier has listed in his requirements that he cannot, or does not wish to, comply with, and QP has accepted in writing the deviations before the order is placed. 19.2 In the absence of a list of deviations, it will be assumed that the Supplier complies fully with this specification. 20.0 Bibliography 20.1 International Reference Standards The equipment shall comply with the latest edition of the International Eletrotechnical Commission (IEC) recommendations, including the following: - Standard Compliance [1] EEMUA Noise procedure specification [2] IEC 60050 International electrotechnical vocabulary [3] IEC 60051 Direct acting indicating analogue measuring instruments and their accessories [4] IEC 60146 Semiconductor converters [5] IEC 60157-1 Low voltage switchgear and control gear Part 1: contactors [6] IEC 60158-1 Low voltage control gear Part 1: contactors [7] IEC 60269 General requirements – cartridge fuses for voltages up to and including 1000V ac and 1500V dc [8] IEC 60332 Tests on electric cables under fire conditions Part 3: Tests on bunched wires or cables [9] IEC 60337 Control auxiliary switches, relays and pushbuttons [10] IEC 60408 Low voltage air break switches, air break disconnectors, and fuse combination units [11] IEC 60445 Identification of equipment terminals and of terminations of certain designated conductors, including general rules of an alphanumeric notation [12] IEC 60529 Classification of degrees of protection by enclosures ES.2.14.0040 Revision A Page 25 [13] IEC 60623 Vented Nickel Cadmium Prismatic Rechargeable Single Cells [14] IEC 60664-1 Insulation Co-ordination for equipment with Low-Voltage Systems – Part 1: Principles, Requirements and Tests [15] IEC 60801-3 Electromagnetic compatibility for industrial process measurement and control equipment. Part 3: Radiated electromagnetic field requirements [16] IEC 60947 Low voltage switchgear and control gear [17] IEC 61000 [18] BS 381C Electromagnetic Compatibility (EMC) Specifications for colours for identification, coding and special purposes [19] BS 6231 Specification for PVC Insulated Cables for Switchgear and Control gear wiring [20] BS 7671 Requirements for Electrical Installations, IEE wiring Regulations 16 th . Edition [21] ISO 9000 Quality management and quality assurance standards – guidelines for selection and use [22] ISO 9001 Quality systems. Model for quality assurance in design, development, production, installation and servicing [23] ISO 9002 Quality systems. Model for quality assurance in production, installation and servicing [24] ISO 9003 Quality systems. Model for quality assurance in final inspection and test [25] ISO 9004 Quality management and quality system elements [26] VDE 0875 Specification for radio interference suppression of electrical appliances and systems Equipment shall comply with any statutory regulations, bylaws and orders enforced in the State of Qatar. The recommendations listed in the above table are supplemented by this specification, which states additional requirements to those stated in these recommendations. This specification shall also be read in conjunction with all other specifications, data sheets and single line diagrams attached to the material requisition. ES.2.14.0040 Revision A Page 26 20.2 QP Standards [27] ES.2.03.0001 Electrical Engineering Philosophy [28] ES.2.06.0001 Electrical Installation Practices [29] ES-D-10 Engineering Standard Draughting [30] ES-Q-12 Standards Specification for Painting and Wrapping [31] EP-S-01 Corporate Fire and Safety Philosophy The following shall form part of this Specification: UPS data sheet Single Line Diagrams Load Cycle