Uninterruptible Power Supply (UPS) and DC Systems Installation Procedure

1 SCOPE
2 REFERENCE DOCUMENTS
3 AUTHORITIES AND RESPONSIBILITIES
4 MATERIALS CONTROL
5 INSTALLATION OF BATTERIES, DC, AND UPS SYSTEM
6 INSPECTION

Uninterruptible Power Supply (UPS) and DC Systems Installation Procedure

1 SCOPE

This procedure covers the Method Statement for UPS system including batteries, DC and UPS panel/equipment/material assembly and installation activities. This procedure will be applied to  the inspection, method and criteria for installation work carried out by the Electrical Department. Construction shall review the feasibility of methodology in reference to actual site condition, Project specification and standard and approved construction drawing.

2 REFERENCE DOCUMENTS

a) Applicable / Approved International Standards
b) Issued For Construction Drawings
c) Manufacturer Instructions

3 AUTHORITIES AND RESPONSIBILITIES

Site Manager — Determine all requirements needed in order to comply with contractual requirements and safety standards.

Construction Manager- Lead all construction activities and enforce strict adherence to all project requirements.
Electrical Superintendent – Ensure that work once started is carried out as planned and that the applicable standards are complied with. Check working methods and precautions to be taken by the supervisors/foreman before commencing work.
Field Engineer — Ensure that all related works are carried out in accordance with approved Released for Construction drawings, specifications, schedule, quality and safety. Report to Construction Manager.
Safety Officer — Ensure that “Safety, Fire, Loss Prevention” program or Safety Plan was been implemented and monitored.
Supervisor/ Foreman – Supervise all field installations Reports to Electrical Superintendent.
QC Inspector- He shall be responsible for conducting surveillance and inspection duties for work and ensuring quality compliance and efficient recording and reporting of results as required. He shall review all relevant documents, material conformance certificates and non-conformance reports and shall receive all internal requests for inspection from various sections of implementing work and prepare (RSI) Request for Site Inspection as per schedule work priorities and proceeds the Quality inspection with the client, owner representative as required.

4 MATERIALS CONTROL

a) Ensure that materials and equipment are stored and handled in accordance with project and vendor requirements. Batteries and other equipment must be stored in an environment condition required by the manufacturer.
b) Check if all supplied materials are in conformance with Purchase Order or Specifications or Drawings. Any discrepancies to be reported immediately to CGA Materials Department.
c) Check that internal devices and components’ nameplates and abbreviations are matching the description shown on the UPS schematic drawings.
d) Verify Factory Test Result and Certification for equipment and its accessories.
e) Check if equipment is durably marked by the manufacturer with the voltage and the current rating, and the number of phases for which they are designed and with the manufacturer’s name or trademark in such a manner so as to be visible after installation, without disturbing the interior parts or wiring.

5 INSTALLATION PROCEDURE OF BATTERIES, DC, AND UPS SYSTEM

1. Ensure that the environmental conditions are suitable for the installation of Panels,
   Cubicles, and Cabinets. The following points can be checked:
   • Access ways free of excess civil materials and civil debris.
   • Floors, walls and ceilings dried with adequate sealing to ensure no new ingress of water.
   • All civil works completed and clear, clean area.
   • All apertures closed to minimize ingress of dust.
2. Batteries and battery chargers shall be connected and installed upon arrival to site as per recommendation of the Vendor. The assembly of each battery and battery rack will be carried out in accordance with the Vendor’s recommendations and assembly instructions.
3. Temporary power supply will be connected to each battery charger and maintained to be in service until the completion of permanent power supplies and being ready for continuous energization. The source for the temporary power supply needs to be reliable. A freshening charge will be provided to each battery upon its shipment from the factory to site and as per Vendor’s requirements.
4. The individual cells or modules to be lifted using the lifting equipment recommended by the Vendor. Cells or modules to be lifted by the channels or the bottom of the case and not by the cell posts. Cell polarity will be checked for positive to negative connections throughout the battery.
5. Battery to be handled and fill each battery cell with acid.
6. Inspect all terminal posts and connecting hardware prior to installment of intercell connectors. Any area showing evidence of corrosion, dirt or acid shall be cleaned, exercise care to prevent removal of lead plating. A thin film of corrosion inhibiting grease to be applied to all contact surfaces lntercell connections to be completed with connectors and associated hardware supplied by the Vendor. Where more than one intercell connector per cell post is required, the connectors to be mounted on opposite sides of the post for maximum surface contact. Both ends of the connection bolts will be tightened as per the torque values recommended by Vendor.
7. All cell covers and containers to be cleaned. A water moistened clean wipe will be used for the removal of dust and dirt. A bicarbonate of soda and water moistened wipe shall be used for the cleaning of electrolyte spillage. Use wipes free of oil distillates. Explosion resistant vent plugs to be installed where provided. Individual cell numbers in sequence with No. 1 at the positive end of the battery will be applied for permanent identification The voltage of the battery to be measured to ensure that individual cells are connected correctly. Should the measured voltage is less than approximately the number of cells multiplied by the measured voltage of one cell; the individual cell polarities will be rechecked.
8. lntercell connection resistance to be measured and recorded. Any connection with a resistance measurement exceeding 10 percent above the average will be remade and re­ measured.
9. Final connections from the battery to the charger and DC system will be installed after assembly of the battery.
10. Battery racks installations must meet the bonding and grounding specific requirements. Battery racks will be bonded at both end points to a local supplementary grounding electrode as per approved construction drawing. Install lug and cable on the steel rack and tighten to ensure ohmmeter reading between each component and a common point on rack frame indicates continuity for proper grounding.
11. Positive and negative battery cables will be run in the same conduit to prevent inductive heating.
12. The positive and negative buses of batteries to be isolated from earth ground
13. After the battery assembly is complete to the stage of intercell connections, the battery to be protected from construction dirt and debris. Batteries discharge test to be conducted in accordance with the Vendor’s instructions and recommendations.
14. For DC and UPS panel installation.
    DC charger panels, battery fuse panel, DC and UPS distribution panels, UPS inverter panels, bypass transformers to be received, handled, loaded, unloaded, lifted (incl. any crane etc.), installed and pre-commissioned as specified herein and as per the Vendor’s drawings, IFC Drawings and local code requirements.
    • A workspace recommended will be allowed in front of the UPS cabinets. If rear access or side access is required for UPS maintenance, a clearance is needed.
    • Cables for the primary AC input, output, and the alternate AC source to run in separate raceways.
15. Panels, cubicles and cabinets must then be erected and interconnected as described in the manufacturer / vendor erection instructions’ and approved construction drawing. Check alignment of installed equipment.
16. Reconnect all auxiliary wirings removed during transportation.
17. Incoming cables and ground cable to be connected in accordance with schematic diagram and wiring connections as per construction drawing.

6 INSPECTION

All equipment will be checked for completeness and compliance to technical drawings prior to
successive tests. Cable connection, controls, protection and metering system and circuitry will
be generally checked-out. Detailed check out will be conducted during pre-commissioning and
test activities.
RSI for erections and mounting of equipment to be coordinated by CGA QA/QC Inspector, who
will implement the inspection program and notify all parties involved in advance of the scheduled
dates of inspection to enable them to participate. All relevant records must be signed by the
required parties and documents must be properly controlled and filed. Any approved changes in
the technical drawing and document must be as-builted.