Uninterruptible UPS Power Supply System Installation Testing & Commissioning Method Statement

Below document covers the uninterruptible power supply UPS system installation, testing and commissioning method statement.

Before starting the UPS installation work, user manual must be thoroughly read and understood.

Applicable safety instructions and warnings must be discussed and appropriate measures must be taken.

It is strictly recommended that trained service engineer from manufacturer or authorised agent must be present for supervision of ups power system testing and commissioning.

Absolute precautions must be taken while working inside UPS panel boards, handling batteries, live wires, open circuits, shifting and placement of equipment.

Site Delivery check, unpacking and visual inspection

Equipment are delivered on specifically designed pallets, keep the UPS always in uprights position.

Weight limits of the raised floor if applicable must be in accordance so as to carry UPS and other equipment load.

Unpacking must be done with care so that there will be no damage to equipment.

Visual inspection is always advised before and after unpacking to make sure that all the equipment and accessories are in specified shape without any damage.

Placement of equipment

Placement of all the equipment must in upright or in recommended positions to avoid any damage.

Small tools and accessories like nuts and bolts accompany UPS which must be counted and placed either in designated area / place to avoid losses or damage to anyone or anything.

Check Clearance space

Ventilation in UPS room is must and incoming air must not contain any kind of flammable gases or fumes.

All equipment require clearance space for 2 reasons :

(a) accessibility for service and maintenance – specified minimum clearance space is must to ensure that service personnel can access all parts of equipment for repair / maintenance / replacement etc.

(b) proper ventilation – electrical equipment generate heat while operation which must be removed for efficient and safe operation.

HSE Control Measures

• Conduct TOOL BOX TALK with foremen and workers before starting job.
• Use mandatory personal protective equipment (PPE)
• Ensure proper room ventilation and room temperature.
• Necessary measures to be taken to avoid electrical shock, short circuit and burns etc.
• All packaging materials will be removed from the site to maintain safe and tidy workplace.

Installation of UPS, battery bank and isolation transformer

UPS will be placed at designated area, cabinet cover will be removed to make internal wirings and connection.

Placement of transformer and battery bank will be adjacent to UPS.

Inter-connection between above 3 using Power cables, Fuses, Lugs, Wires, etc.

Specified wires and cables with sufficient ratings must be used to avoid any electrical hazard.

Proper size lugs, nuts, and bolts must be used to make connections.

Clamp meters and screw drivers should be used for measurement and tightening.

Installation must be done under expert supervision of trained engineers. Strict guidelines must be followed for placement, positioning and electrical connections.

Connection of communication cables and cards

To communicate with UPS required cards must be fixed with proper cables and wires to send and receive signals.

Check display function and user settings

Trained engineer will check all display functions and settings.

Configurations will be done as per the project requirements.

Start up of Uninterruptible Power Supply

It is mandatory to start UPS in presence of service engineer with all precautions and measures taken.

Engineer will assure that all connections are made properly, supply line is in place, load connected as required, grounding and earthing are done and intact.

Testing (on load, EPO & other features)

Testing can be done on load and no load.

Emergency power off must be tested, all other features will be checked, measured, tested against given or required parameters as per project specifications and manufacturer specifications.

All testing and commissioning test reports shall be in accordance with testing and commissioning agent’s formats.

UPS load test and battery discharge test readings shall be recorded on standard testing and commissioning formats as per client/consultant requirements.

Following shall be followed where applicable for UPS testing and commissioning as mentioned in the electrical general specifications.

The following procedures and tests shall be performed by certified, factory trained field service Engineers during the UPS startup:

Visual Inspection:

Visually inspect all equipment for signs of damage or foreign materials.

Observe the type of ventilation, the cleanliness of the room, the use of proper signs, and any other safety related factors.

Mechanical Inspection:

Check all the power connections for tightness.

Check all the control wiring terminations and plugs for tightness or proper seating.

Electrical Pre-check:

Check the DC bus for a possible short circuit.

Check input and Bypass power for proper voltages and phase rotation.

Check all lamp test functions.

Check overloads protection.

Provide facility to thermal image connections while under test loads.

Provide heat run testing at factory under 100% load.

Initial UPS Startup:

Verify that all the alarms are in a “go” condition.

Energize the UPS module and verify the proper DC, walkup, and AC phase on.

Check the DC link holding voltage, AC output voltages, and output wave forms.

Check the final DC link voltage and Inverter AC output. Adjust if required.

Check for the proper synchronization.

Check for the voltage difference between the Inverter output and the bypass source.

UPS Power System Verification Testing

After UPS start-up has been completed by the factory service engineer, the UPS supplier shall conduct a series of verification tests and checks that shall include but not be limited to the following:

Verify and confirm that the physical location and placement of the UPS is acceptable.

Verify and confirm that the electrical installation of the UPS and Maintenance Bypass is correct and acceptable.

Confirm proper voltage and phase rotation as it applies to the UPS and Maintenance Bypass (all inputs and all outputs).

Test correct operation of the Maintenance Bypass including verification of the UPS-to-Maintenance Bypass interlock.

Perform a battery discharge test by interrupting incoming power to the UPS rectifier input.

Confirm proper battery operation.

For sites that are fed by an emergency generator, perform a full transfer to emergency generator power, run on generator for 5 minutes, and transfer back to normal utility power.

Verify that UPS operates and interfaces with Emergency generator and ATS without errors / problems.

Training to end user

Training to end user will be given by service engineer so that future operations can be done effectively. Equipment will be handed over with due diligence to the end users / clients.