Testing and Commissioning of UPS-Single Phase

Purpose

This defines the method for Testing and Commissioning of UPS Uninterrupted Power Supply (UPS)-Single Phase by ensuring that the execution complies with the requirements and intended satisfactory level.

This procedure aims that quality assurance and quality control activities are adopted by the contractor in a systematic manner in accordance with project requirements.

References

This procedure is subject to the requirements as stated in the following regulatory & statutory documents, applicable standards, specifications, and building codes:
Project Specifications
Project approved materials, shop drawings & IFC drawings
Manufacturer’s Installation Manual & Instructions
Approved Project HSE Plan
Approved Project Emergency Response Plan
Approved Project Waste Management Plan
Occupational Health and Safety

Definitions

MS – Method Statement
QCP – Quality Control Procedures
ITP – Inspection and Test Plan
ITA – Independent Testing Agency
UPS – Uninterrupted Power Supply

Access/Egress

Works will be started or carried out only when all associated main contractor’s procedures are completed and by ensuring safe access to work areas will be available through hoist lifts/access ladders to carry out the work where ever main contractor site engineer’s & safety officers clearance available.

Logistics

MEP subcontractor will deploy a dedicated team for the required logistics and material movement in –out of the project.

Health and Safety Hazards

Extreme heat and humidity

Extreme cold, high winds, and dusty condition

Mobile equipment- crane, forklift, etc. for material loading/offloading, transfer of materials to work locations

Temporary electrical supply for lighting, use of power tools, etc.

Manual handling/offloading & installation of PV modules.

Damaged hand tools

Unsafe working on ladders
Poor housekeeping & waste management

Information Dissemination

HSE Site Safety Inductions
Work supervisors shall ensure STARRT and RAMS are discussed with the work group prior to works commencing
Safety toolbox talks
Environmental toolbox talks
Training courses (Internal and Third Party Training)
HSE Bulletin/ HSE Site Notice Boards
Site Engineers, Site Supervisors, and Site Foreman

Permits and Certificates

Hot work permit (Cutting /grinding)

Lifting Plan

Working at heights / Working on scaffolding – Supervisor to be trained by a third party.

MEWP – Third-party certification for the operator and the equipment. Competence certification for workers.

Responsibilities

Project Manager

The project manager shall be responsible for overall project planning, procurement, technical submissions, and drawing submissions.
The project manager shall coordinate activities within the site team and with the management for the timely completion of activity in accordance with contract requirements.

Construction Manager

The construction manager is responsible for the work execution in compliance with the approved method statement, HSE Risk Assessment, and project specification, issued for construction drawings, sections, and details.

Site Engineer

The site engineer is responsible to carry out the work as per approved shop drawings and method statements. He is also responsible to ensure adequate tool kits required for the works are in place prior to the starting of work. The site engineer reports to the Construction Manager.

The site Engineer is responsible to ensure work has been done as per the specification and drawings; inspections are carried out based on ITP and quality control procedures and coordinated with QA/QC department for inspections.

The site engineer is responsible to ensure that all safety precautions are ensured in place and that all personnel on site are using the required personal protective equipment like helmets, gloves, shoes, and reflective jackets. The site engineer in coordination with safety officers will ensure all relevant permissions are taken prior to the commencement of works.

The site engineers shall ensure that the works are supervised by a competent supervisor till the completion of the task.

QA/QC Engineer

The QA /QC engineer will be responsible for overseeing the quality requirements and quality control measures for the project in coordination with the project engineer and construction manager.

Safety Engineer

The HSE officer will be responsible for the safety, health, and environmental aspects on site as per the project safety and environmental requirements/safety standards in coordination with the project engineer and construction manager.

Methodology-Testing and Commissioning of UPS

Site planning & preparation

Identify and ensure that pertinent documents are approved and manufacturer instructions.
Identify and obtain appropriate pre-commissioning and commissioning tools and equipment.

Determine the staffing/manpower required and assign tasks to team members.

Before pre-commissioning and commissioning commencement, ensure all necessary installation works are completed and approved.

The surrounding working area shall be cordoned off/ barricaded and applicable safety warning sign boards shall be provided to prevent unauthorized access.

Prerequisites to procedure or start of testing and commissioning

Ensure all input, output, battery, and control cables are connected to UPS sets and approved.

Ensure all battery inter links are connected and approved.

Ensure all cables in the battery breaker are connected and approved.

Manufacturer’s field service: Engage a factory-authorized service representative to inspect components, assemblies, and equipment installations, including connections, and assist in testing.

Factory test complete UPS system and FAT test reports will be attached.

Pre-start checks/Pre-commissioning

The pre-commissioning activities are the internal checks to be conducted on-site before the start-up and commissioning of UPS systems.

Prior to starting, the pre-commissioning checks make sure all the electrical installations are completed and the installation checklist is filled.

All the pre-commissioning activities listed below will be carried out by the specialist, witnessed, and inspected.

All foreign objects have been removed from and around UPS systems, batteries, and battery breakers by the installer after the installation completes.

Carry out the visual inspection of the UPS for any alarms before carrying out the start-up. Ensure the UPS is in normal mode. Check all the parameters on the display.

Check input and output supply voltage. Ensure that supplies are within the specified limits of the local regulation.

Check the individual battery voltage.

Clean UPS and batteries for any dust.

Check all the terminals are properly tightened.

Check UPS load level and Load on batteries testing

Ensure that the UPS is back to normal on display.

Record all readings and result in testing and commissioning report.

Start-up of UPS systems.

Switch “ON” input power/bypass power to the UPS system.

Set the date and time on display.

Program the UPS systems by feeding battery, output, and paralleling parameters through laptop/display.

After confirmation of set up wizards switch “ON” battery breaker.

Check the battery charging voltage and current on the display.

Switch on the UPS inverter from the display option/front panel.

After confirmation of the inverter function switch “OFF” the inverter.

Switch on the output breaker of the UPS system.

Check the Paralleling of UPS systems.

Automatic operation includes the following:

Normal conditions: load is supplied with power flowing from the normal battery connected in parallel with the rectifier-charger output.

In redundant UPS configurations, both the UPS systems shall share the load at 50% capacity.

Abnormal supply conditions: If normal supply deviates from specified and adjustable voltage, voltage waveform, or frequency limits, the battery supplies energy to maintain constant, regulated inverter power output to the load without switching or disturbance.

If normal power fails, energy supplied by the battery through the inverter continues supply-regulated power to the load without switching or disturbance.

When power is restored at the normal supply terminals of the system, controls automatically synchronize the inverter with the external source before transferring the load. The rectifier-charger then supplies power to the load through the inverter and simultaneously recharges the battery.

If the battery becomes discharged and a normal supply is available, the rectifier-charger charges the battery.

On reaching full charge, the rectifier charger automatically shifts to float-charge mode.

In redundant UPS configurations, if any UPS system fails, the automatic load shall be transferred to the redundant UPS.

If any element of the UPS system fails and power is available at the normal supply terminals of the system, the static bypass transfer switch switches the load to the normal ac supply circuit without disturbance or interruption.

If a fault occurs in the system supplied by the UPS, and current flows in excess of the overload rating of the UPS system, the static bypass transfer switch operates to bypass the fault current to the normal ac supply circuit for fault clearing.

When the fault has cleared, the static bypass transfer switch returns the load to the UPS system. If the battery is disconnected, the UPS continues to supply power to the load with no degradation of its regulation of voltage and frequency of the output bus.

Manual operation includes the following:

Turning the inverter off causes the static bypass transfer switch to transfer the load directly to the normal ac supply circuit without disturbance or interruption.

Turning the inverter on causes the static bypass transfer switch to transfer the load to the inverter.

Maintenance Bypass/Isolation Switch Operation

The switch is interlocked so it cannot be operated unless the static bypass transfer switch is in the bypass mode.

The device provides manual selection among the three conditions in subparagraphs below without interrupting supply to the load during switching:

Full Isolation: Load is supplied, bypassing the UPS. Normal UPS ac input circuit, static bypass transfer switch, and UPS load terminals are completely disconnected from external circuits.

Maintenance bypass: Load is supplied, bypassing the UPS. UPS AC supply terminals are energized to permit operational checking, but system load terminals are isolated from the load.

Normal: Normal UPS ac supply terminals are energized and the load is supplied through either the static bypass transfer switch and the UPS rectifier charger and inverter, or the battery and the inverter.

Monitor the UPS through the network card as attached in the operation manual.

Built-in alarms point in the UPS system to interface with BMS.

Training

All required training for stipulated installation activities is provided to all technical staff for ensuring quality workmanship.

Working Hours

Site operational time shall be followed as per project progress requirements, and all relevant local authority schedules of holidays are to be observed. Comply with regulations regarding summer working hours (Working in direct sunlight during hot weather conditions).

Housekeeping

Working areas will be kept clean by disposing of the waste materials in the designated areas.

At the end of the day’s work, the installation supervisor will ensure that the debris is disposed of during the course of the activity on regular basis. Dust created by work e.g. drilling, of the slab, grinding, and polishing.)

The area must be isolated/protected by a green net and required additional PPE for the operatives. Any materials stacked on the site shall neither obstruct the emergency evacuation route.

Manpower

Subject to main contractors’ programmer and scope/area available for MEP activities, but not limited to below:

Site Electrical Engineer
Site Supervisor
Site QC Inspectors
Safety Officer
Foremen
Electricians

Equipment and Material

Spanner
Multimeter
Torque wrench
Crane
Fork Lift
Insulation resistance tester
Measuring tape and setting out markers
Hammer and screwdriver
Multi-tester/megger tester
Electrician toolbox
Electric drill hammer
Approved test equipment
Laptop computer
Rated load and cables

Personal Protective Equipment

Safety helmet
Safety goggles
Safety boots
High visibility vest
Hand gloves
Ear plugs
Respiratory protection
Full body harness

Notes:
Third-party certification (competence certificates) for workers, operators, equipment valid registration, insurance & fitness certificates, and operator daily inspection checklist should be available for safety officer validation before commencing the works.

tag: Testing & Commissioning of UPS-Single Phase

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