Method Statement UPS (Uninterrupted Power Supply) Installation

What is the Method Statement UPS Installation?

The method statement UPS installation system is the process of implementing its proper practices in order to ensure that job execution meets project specifications, health, safety & environmental requirements and performs to a satisfactory standard.

The purpose of installing a UPS (Uninterrupted Power Supply) power supply system is to ensure that vital systems and equipment in various areas of a building or project have optimum power availability in the event of a main power failure. MDF/IDF rooms, servers, and emergency systems such as access control, fire, and smoke alarms are all connected to UPS.

The UPS power supply guarantees that these devices or appliances can be powered on UPS with the aid of its backup battery in the event of a power loss.

Delivery of Materials, Storage, and Handling

Delivery of Materials

The UPS system is factory packed for transport and should be protected as per the manufacturer’s instructions.

Batteries should be carefully delivered and properly stored in a rack.

All documents will be available with the supplied UPS system, i.e. transport/shipping documents, packing list, delivery notes, test certificates, etc.

Material delivery to the site will be inspected for approval from the engineer of the delivered equipment.

Any discrepancies, damage, etc. found to the materials will be notified and reported to QA/QC engineer.

The material found not suitable for site use will be removed immediately and placed in the quarantine zone.

No material will be permitted on the site without being inspected by the Engineer.

Storage, and Handling of Materials

UPS system and other related accessories will be handled, transported, and unloaded at the site strictly as per the manufacturer’s instruction.

UPS system and other related accessories will be stored at a dry location in the lay-down area. They will be protected and covered by polythene sheeting.

After delivery, equipment will be inspected for any damage, shortage non-compliance with project specifications & materials submittal.

The UPS system and accessories will be tagged, crated, and protected for shipping as per the manufacturer’s recommendation.

The lifting procedure will be strictly adhered to ensure the UPS system and accessories are free from damage. Manufacturers’ recommendations for lifting procedures should be followed.

All lifting equipment must be rated for the purpose and checked for damage before any attempts are made to lift the UPS system.

The equipment will be handled and stored in accordance with the manufacturer’s instructions.

Installation of UPS System

General

Prior to the commencement of any installation works associated with the UPS System, It is ensured that all the site installation pre-conditions have been satisfied.
Prior to installation, it will be ensured that:

• All relevant documentation such as (Approved Shop Drawings, Checklist and Method Statements, etc.) and material applicable to a particular section of work will be checked by the Site/Project Engineer prior to the commencement of work ensuring that they are of the correct type and as per the project specification
• The engineer in charge will ensure that approval and standard tools and tackles are available to carry out the work
• Safe access to work areas will be provided and will be approved by the competent safety person prior to the commencement of work if applicable.
• Check the work area tidy and remove flammable materials if any and ensure the safe environment
• Competent manpower will be employed to carry out the construction work.

Procedure

Work will include, but is not limited to:

• Installation of UPS complete rectifier/charger-battery-inverter system and maintenance by-pass circuit.
• Connection of normal AC power from assigned terminal/ switch circuit breaker.
• Earthing system
• The location of UPS will be installed as per the approved shop/detailed drawing

Positioning

Make sure that the floor is strong enough to withstand the weight of the UPS and battery cabinets.

The location of each UPS/Battery Charger will be verified as per approved Shop/Layout drawings before installation.

Shifting, loading, unloading, and erection of UPS will be done by using the proper capacity of cranes and lifting trolleys so as to avoid any damage.

Lifting will be carried out by using designated lifting points, cabinet eyebolts, etc.

Prior to installation, the location will be inspected in accordance with the equipment layout drawing. Also, civil work completion & clearance will be obtained before panel installation.

All preparatory work like drilling on mounting frames, anchoring, etc will be completed as per the approved panel layout drawing.

UPS / Battery charger and other related panels, cabinets, and devices will be installed as per the approved construction drawing.

Panels, cabinets, and other devices’ final alignment and leveling will be completed with the proper tools.

Nuts, bolts, and clamps will be tightened during the operation.

Panels, cabinets, and other devices will be inspected for proper identification labels, having relevant information and tags as per the approved shop drawing.

Battery Installation

Prior to installation, the location will be inspected in accordance with the equipment layout drawing and also civil work completion.

The person erecting the battery bank will remove the metallic objects like watches and rings before starting the erection.

The permissible storage temperature shall be maintained as per the instruction manual.
Insulation tools will be used.

Flooring, cable entries, and floor-supporting steelwork (if needed) will be checked before the installation of batteries and other accessories. The instruction manual will be referred to.

Battery racks will be assembled as per the approved shop drawing.

It is ensured that the installed battery rack alignment is correct.

The battery cabinets shall feature valve-regulated, high-rate discharge, lead-acid batteries which provide energy to support the critical load during a momentary loss of input power to the rectifier. The batteries shall be flame retardant in accordance with the relevant IEC and BS requirements. The battery cabinets shall have the following features.

Battery Capacity Protection Time (at 25°C): Autonomy 30 minutes at full KW output rating of the UPS system.

The battery cabinets shall be at the same depth and height as the UPS module. The battery cabinets shall not exceed the floor space footprint as indicated on the Design Drawings.

Each battery cabinet shall require front access only for service and maintenance. The battery cabinets shall provide top and bottom cable entry.

Each battery cabinet shall feature battery trays that can be individually disconnected from the battery cabinet power wirings with quick disconnect devices. Each battery tray shall be firmly secured to the battery cabinet frame with fasteners. Each battery tray shall be removable from the front of the battery cabinet.

The battery cabinets shall each feature a DC-rated circuit breaker. The circuit breaker within an individual battery cabinet shall only provide protection to the battery string with that battery cabinet. For battery configurations involving multiple battery cabinets, a battery string in one battery cabinet may be isolated from the DC link via its circuit breaker without removing other battery strings from the DC link and the UPS module.

DC fuses are not an acceptable alternative to DC-rated circuit breakers.

The circuit breaker in each battery cabinet shall feature an A/ B auxiliary switch. The UPS module shall be capable of monitoring and alarming an open battery cabinet circuit breaker condition.

The circuit breaker in each battery cabinet shall feature a 24VDC shunt trip.

Final Discharge Voltage Full Load: 1.66 volts per cell (adjustable)

No Load: 1.75 volts per cell (adjustable)
1. Nominal Float Voltage: 2.25 volts per cell.
2. Maximum Equalizing Voltage: 2.40 volts per cell.

Battery cabinets will be provided with spill-containment equipment.

Battery cabinets will be installed remotely from the UPS system cabinet, and the Electrical Subcontractor will provide the DC conductor cables and conduits to connect the battery cabinets to the UPS modules.

The battery cabinets will be equipped with DC circuit breakers that will provide a manual means of disconnecting a battery from the UPS module.

The battery rack will be positioned as per the approved shop drawing.

Battery cells will be placed on the rack suitably in order to allow the connection of the positive and negative terminals according to the wiring diagram.

Cells will be numbered as per the drawing.

Install an external isolator for the bypass supply.

The isolation transformer will be installed as approved Material Submittal.

External fuse enclosures will be installed as per the approved drawing.

A cable connection will be verified between the battery cabinet and fuse boxes.

External bypass isolators switch for bypass line will be installed.

An isolator switch will be installed between UPS outgoing and the respective load

Uninterruptible Power Supply (UPS) Ratings and Operating Characteristics

UPS Continuous Ratings:

The UPS shall be rated at the KVA size as indicated on the Design Drawings or indicated in the scope of work section for a load power factor range of 0.8 lagging to 0.9 leading.
The UPS capacity shall be field upgradeable to the KVA size as indicated on the Design Drawings to accommodate future load growth.

Rectifier/ Charger Input:

Nominal Input Voltage: As indicated on the Design Drawings.

Operating Input Voltage Range: +10%, -15% of average nominal input voltage without battery discharge.

Operating Input Frequency Range: within 3Hz of the nominal input frequency. UPS shall operate normally from this range of input without going to battery discharge operation.

The input Power Factor shall be 0.99 lagging (the UPS system shall not present a leading power factor).

Rectifier/ Charger Input Current Limit: This shall be adjustable from 50% to 125% of full-load input current.

Battery Input Current Limit: The battery charge current limit shall be adjustable from 10% to 25% of the UPS module’s full load input current regardless of the actual load on the UPS module.

Rectifier/ Charger Input Current Limit: This shall be adjustable from 50% to 125% of full-load input current.

Battery Input Current Limit: The battery charge current limit shall be adjustable from 10% to 25% of the UPS module’s full load input current regardless of the actual load on the UPS module.

Input Current Total Harmonic Distortion shall be less than 4.5% without the use of an input filter.

Bypass Input:

• Synchronizing Bypass Voltage Range: ±10% of the average nominal input voltage.
• Synchronizing Bypass Frequency Range is centered on the nominal 50Hz frequency.
• Magnetizing Inrush Current: Typically, 500 – 800% of the largest model’s full load input current.

Rectifier/ Charger Output:

Steady State Voltage Regulation: ±0.5%

Voltage Ripple: less than 0.5% (peak to peak).

Capacity: The Rectifier/ Charger shall support a fully-loaded Inverter and recharge the battery to 95% of its full capacity within 10 times the discharge time when the input current limit is set at maximum.

Low Line Operation: The Rectifier/ Charger shall be capable of sharing the DC load with the Battery when the input voltage falls below the specified operating input voltage range, the On-Battery indicator shall enunciate operation in this mode.

Battery Equalize: Automatic and manual means shall be provided for battery equalization.

DC Sensing: Redundant DC voltage sensing methods shall be incorporated for providing battery overvoltage protection.

UPS Output in Normal Mode:

• Nominal Output Voltage: As indicated in the Design Drawings.
• Steady-State Voltage Regulation (on Inverter): Within ±1% average from the nominal output voltage.
• Transient Voltage Response: Within ±5% from nominal voltage for a 100% load step, full load re-transfers, and full load drop on battery.
• Transient Voltage Recovery: 25ms to within ±1% of steady-state.
• Transient Voltage Recovery: 25ms to within ±1% of steady-state.
• Manual Output Voltage Adjustment: ±5% from nominal.
• Line synchronization Range: ±0.5Hz, adjustable to ±5Hz.
• Frequency Regulation: ±0.005Hz free running.

Phase Angle Control:

• Balanced Linear Loads: ±1° from nominal 120°
• Unbalanced Linear Loads: ±3° from average phase voltage for 100% load unbalance.

Phase Voltage Control:

Balanced Linear Loads: ±1% from average phase voltage.

Unbalanced Linear Loads: ±3% for 100% load unbalance.

Overload Current Capability (with nominal line and fully charged battery): The unit shall maintain voltage regulation for 125% for 10 minutes and 150% for 10 seconds.

Fault Clearing Current Capability: 160% phase-to-phase for 10 cycles; 300% phase-to-neutral for 10 cycles.

Static Transfer Time: make-before-break transfer completed in less than 4ms.

Common Mode Noise Attenuation: -65dB up to 20kHz, -40dB up to 100kHz.

UPS Output in Bypass Mode:

Nominal Output Voltage: As indicated in the Design Drawings.
Static Transfer Time: make-before-break transfer completed in less than 4ms.
Common Mode Noise Attenuation: -65dB up to 20kHz, -40dB up to 100kHz.
Mechanical Design

Enclosures: The UPS module shall be housed in free-standing, double-front enclosures (safety shields behind doors). The enclosures shall be designed for industrial or computer room applications in accordance with the environmental requirements. The enclosures shall line up and match up in style and color for an aesthetically pleasing appearance.

Each of the enclosures shall be shipped separately with joining hardware to be bolted together at the time of installation.

Ventilation: The UPS module shall be designed for forced air cooling. Air inlets shall be in the lower front. Air outlets shall be in the rear of the top. Twelve inches of clearance over the UPS air outlets shall be required for proper air circulation. Air filters for the UPS module shall be in commonly available sizes.

No back or side clearance or access shall be required for any enclosure. The back and side enclosure covers shall be capable of being located directly adjacent to a wall. This does not include potential considerations for electrolyte spill containment as it applies to the battery cabinets.

Cooling Fans: The modular design of the UPS module shall permit the removal of each fan without the removal of any other assembly. Fan replacement shall be accomplished by removing no more than one fastener per fan and shall not require the removal of another subassembly.

Cable Entry: Standard cable entry for the UPS module shall be through either the enclosure bottom or top. A dedicated wireway shall be provided within the UPS module for routing user input and output wiring.

Mounting: Provide a 457mm floor stand designed to support the weight of the UPS, Battery, and IDC cabinet sections, such that the enclosure bottoms are flush with the computer-room raised floor. Floor stand leg supports shall include 150mm of adjustment.

Start-ups and transfers shall be automatic functions.

Multiple microcontrollers shall be used, so no single controller is in a mission-critical application.

All configuration, setup, and calibration information shall be stored in non-volatile memory that does not require a control battery for data storage.

Emergency transfers to Bypass due to UPS module failure shall be independent of the control logic controlling the Rectifier/ Charger, Inverter, and Monitor panel. Emergency transfer circuitry shall contain all the necessary circuitry to perform an emergency transfer without any other functioning logic.

The UPS module shall be programmable to optionally provide automatic restart capability following the loss of utility and a complete battery discharge. When utility power returns, the UPS module shall automatically energize the output terminals and subsequently transfer to Normal mode.

Monitor Panel Indicators: The UPS module shall be equipped with a monitor panel providing the following monitoring functions and indicators (each alarm and notice condition shall be accompanied by an audible alarm):

BYPASS: This shall indicate that the UPS has transferred the load to the bypass circuit.

BATTERY: This shall indicate that the commercial AC utility or generator source has failed and the battery is supplying power to the inverter, which is supporting the load. A text message shall indicate if the battery charge is low or if the battery is installed but disconnected.

ALARM: This shall indicate that the UPS detects an alarm condition, outlined in detail in the operator’s manual.

Control Panel Controls: The UPS control panel shall provide the following functions from front panel pushbuttons:

Alarm contact: A dry contact for annunciating a summary alarm shall be provided for customer use. This contract shall be Form “C” capable of supplying both NO and NC contacts.

Work Permits

Before the commencement of work, a “Permit to work” indicating the activities to be performed will be obtained from concerned authorities as per HSE policy and procedures.

The site supervisor/site engineer is the authorized person to issue and control work permits.
Make sure that every worker to perform the work has attended the specific safety
training before commencing work.

The result of the inspection with the permit to work will be communicated to all persons who Will be involved in the execution of the work.

Electricity

Before using an electric tool, check the tool and its plug and connecting cable.

Do not use damaged tools.

Do not use an electric tool unless its connecting cable is well protected.

Fire Risk

There is always a fire risk however the chances of fire can be reduced and you will know what to do when a fire breaks out.

Always keep the workplace clean and tidy.

Handle machinery and tools that may generate sparks or hear carefully.

Know where fire extinguishers are located and how to use them.

Know the place of assembly for fire evacuation.

Load Shifting Machinery

Unless you are a worker concerned, do not work in an area where a Lifter, Crane (Mobile/ Tower), etc. is in operation.

Do not operate any load-shifting machinery without training and approval.

Operators of forklift trucks, scissor lifts, etc. will possess appropriate certificates/passes.

Scaffolding (Mobile)

Do not use scaffolds unless they have been erected by trained workmen and under the supervision of a Certified Supervisor.

Do not use a scaffold unless it has been inspected and certified safe (A Green Tag to visibly hoist on the scaffolds) by a Certified Supervisor before use.

Strictly follow the instructions of a Certified Supervisor. Do not alter the scaffold unless authorized to do so.

When it is necessary to work on a mobile scaffold, lock the wheels of the scaffold before you start working.

Ladders will be used where no other means of access is possible. Seal trench with 50mm concrete pours for pipe below basement slab.

Methodology-The procedures for the Installation of the UPS System are as detailed below.

Pre-requisites

Check the actual condition for installation of MV Cable as per the IFC / Approved shop drawings.

Provide all necessary work permits; indicate all the activities prior to work execution. Ensure the permit has H&S approval.

The area to be excavated will be scanned using a CAT (Cable Avoidance Tool) scanner prior to the excavation process.

All materials and documentation relevant to this particular work will be checked to confirm adequacy and compliance with the requirements prior to the commencement of the works.

The supervisor will also check that the tools and equipment available are correct for the work to be carried out.

Standard manufacturer fittings will be used throughout.

Site Access

Prior to the commencement of the works inspect the areas for safe access and confirm they are in a suitable condition for the works.

Provide sufficient safety signage and barricade the work area if needed.

Clearly designated walkways will be established to allow persons to access the site safely.

Walkways will be maintained free from obstruction and any debris.

Adequate illumination will be provided for access routes and walkways.

Signs will be displayed to indicate the routes to be taken by persons, and changes in routes will be clearly communicated.

All safety measures will be taken care of as per the instruction of the HSE Department.

Pre-Installation

Before the commencement of installation, the following are required to be carried out. All protective earth connections are to be checked.

Shop drawings for MV Cable laying will be approved and will be coordinated with other services.

Proper access will be provided as per the approved program.

The location/area will be ready for site installation.

Prior to the installation, the area where the items are to be installed will be inspected.

Mark the location of the panels and leave enough length of cable at both ends for termination.

Manpower Required

Project Manager
Construction Manager
QA/QC Manager
Electrical QA/QC Engineer
Safety Manager
Safety Engineer
Electrical Site Engineer
Surveyor
Electrical Site Supervisor/Electrical Foreman
Skilled Labor as per the required work

Equipment and Tools

Crane
Fork Lift
Measuring tape and setting out markers
Hammer and screwdriver
Electric drill hammer
Electrician toolbox
Multi-tester/Megger tester
Approved test equipment
Laptop computer
Rated load and cables

Electrical Inspection-Method Statement UPS

The UPS input, output, bypass, and battery cabinet control cable size.

UPS input, output, and bypass voltage measurement.

Procedure for UPS Testing (Load Bank Test).

If required, barriers or signs will be erected to ensure that everyone entering the work area is well-informed about what is going on.

The load must be supported by cables of adequate capacity.

If it has been determined that the UPS is dead and secure to do so, the final connection to the UPS should be made at the output stage.

The load bank must be energized with zero loads and functionally checked. If all checks out, the UPS will be turned on and switched to help the load bank.

To simulate mains failure, the mains should be disconnected at the closest isolation point upstream of the UPS before beginning the battery discharge test. The UPS monitor will be used to record battery voltage and current at 60-second intervals until the cut-off voltage is reached.

The UPS’s kW rating will be loaded (supposing a unity power factor load bank) and the UPS will be allowed to run for 15 minutes.

The mains supply must be reconnected, and the UPS must be restarted. The voltage and current of the recharge should be registered, and the battery should be able to be recharged.

It must be allowed to cool down before disconnecting the load bank and then turning it off.

To allow the load bank to be disconnected, the UPS output will be isolated.

After the load bank inspection, all power and control connections must be remade and tested.

If the battery still needs to be recharged, the UPS should be turned on and left to recharge while supplying or isolating the load.

The load bank must be prepared and securely stored before it is dispatched.

Remove all obstacles and signs, leaving the office in the same state as when you arrived.

The results will be compiled into a report, and a completion certificate will be issued.

Related Article: UPS Commissioning

Quality of Method Statement UPS Installation

The Inspection and Test Plan (ITP) for this Method Statement UPS installation summarizes various characteristics to be checked. The concerned Site Engineer or Site Supervisor will be responsible to ensure compliance for these operations and the site QA/QC Engineer will carry out quality control checks and report the inspection results.

Quality Records

Quality records will be provided as identified in the ITP and maintained as per ISO 9001 Standard form of records, quality checklists, and QA/QC reports requirements are defined in the Inspection and Test Plan. Submission of as-built records will be done after completion.

Specific Quality Measurement

All works will be undertaken in compliance with the quality requirements of the Contract and “Project Quality Plan”.

Where non-conformances are found /identified to demonstrate their conformity. All works requiring inspection and testing to demonstrate conformity with requirements will be undertaken in accordance with the “Control of Inspection and Testing”.

Where non-conformities are found/identified; they will be addressed in accordance with the “Procedure for Control of Non-Conformances”. The quality control activities associated with the works will be conveyed to all personnel involved in the execution of the works by the Project QA/QC Manager prior to the commencement of the work.

The equipment and instruments used for measurements on-site will be calibrated and certified. The relevant documents will accompany the corresponding equipment and instruments. Necessary internal and external training is provided to the staff carrying out the job to ensure that the quality standards required on the project are met.

Health, Safety, and Environmental Provisions

The health and safety activities for Method Statement UPS Installation are to be in accordance with the relevant Health, Safety, and Environmental requirements
Make sure all employees are Safety inducted before they can work on-site.

Make sure employees stake the right equipment with them on visits. Check they have been trained and know how to use it.

Keep available, records of hazards on particular sites. Make sure all relevant people are notified.

Make sure a supply of the right equipment is available.

Helmets, steel-capped high-angle shoes, safety goggles, high visibility jackets, face masks, and overalls should be appropriate and in good condition.

Assess the risks of manual handling before going to the site and look at the materials being used or stored.

The lifting area should be barricaded and appropriate signboards to be fixed to warn and avoid unauthorized entry.

Copies of the drivers/operator’s license vehicle registration and security passes are to be submitted to the Company safety department before commencing the work.

All moving cranes/equipment will have a reverse horn. All major equipment and the crane will be tested and certified by Third Party prior to mobilization to the site.

Ample and unobstructed passage will be maintained at all times in and around the truck loading and lifting space.

All equipment movement at the site must be controlled by a third-party certified rigger/bank man.

Trained, competent, and Authorized Supervision present at all times to ensure workers are safely working on site.

Personal Protective PPE Requirements

PPE is the last line of defense not the first: however, every contractor should provide adequate suitable, sufficient PPE to protect the workforce wherever possible.

As a minimum for all personnel during the abutment works will be the hat, safety boots, coveralls, goggles, and gloves will be provided and used at all times.

Additional task-specific PPE will be provided and worn in line with risk assessments.

Emergency Response

Emergency response will be initiated by Authorized Person. The emergency response section in the HSE plan will be followed.

In case of an emergency, the following actions will be activated:

• Stop the activity.
• Call the emergency number for help.
• Provide first aid and call an ambulance.
• Alert site clinic / Nurse/ First aider.

This might interest you: Testing and Commissioning of UPS

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