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Hitec QPS

Tender Specification

September 2012, rev. 01

Hitec QPS

1.

2.

3.

4.

Tender Specification

INTRODUCTION.......................................................................................................... 3
1.1 General............................................................................................................. 3
1.2 Scope of works and supply................................................................................3
1.3 Regulations and standards................................................................................4
1.4 Quality assurance............................................................................................. 4
1.5 Submittals......................................................................................................... 4
1.6 Manuals............................................................................................................. 4
1.7 Test and inspection...........................................................................................4
1.8 Maintenance and spare parts............................................................................5
1.9 Shipping and packing........................................................................................5
1.10 Training............................................................................................................. 5
1.11 Warranty........................................................................................................... 5
1.12 Information....................................................................................................... 5
GENERAL SPECIFICATIONS......................................................................................... 7
2.1 General requirements.......................................................................................7
2.2 System design................................................................................................... 7
2.3 Operation principals..........................................................................................7
2.3.1
Mains supply available.........................................................................7
2.3.2
Mains failure or out of normal limits.....................................................8
2.3.3
Mains restored or back into normal limits............................................8
2.3.4
Automatic Bypass facility.....................................................................8
MAIN UPS COMPONENTS............................................................................................ 9
3.1 Power module................................................................................................... 9
3.1.1
Diesel engine.......................................................................................9
3.1.2
Generator..........................................................................................10
3.1.3
Energy transfer module (ETM)...........................................................11
3.1.4
Flywheel............................................................................................. 12
3.1.5
Clutch................................................................................................ 12
3.1.6
Base frame........................................................................................12
3.1.7
Finishes..............................................................................................13
3.1.8
Batteries and starting........................................................................13
3.1.9
Black starting.....................................................................................13
3.2 Electrical Panels.............................................................................................. 14
3.2.1
Control Panel......................................................................................14
3.2.2
Bypass Control Panel.........................................................................15
3.2.3
Choke Panel.......................................................................................16
3.2.4
Switch board panels...........................................................................17
3.2.5
Medium Voltage transformer panel (only for MV systems).................17
3.2.6
Wiring................................................................................................18
3.2.7
Protection..........................................................................................18
3.3 Auxiliary Equipment........................................................................................19
3.3.1
Radiator cooler..................................................................................19
3.3.2
Daily fuel tank....................................................................................19
3.3.4
Exhaust silencer.................................................................................19
3.4 Testing............................................................................................................. 19
3.5 Documents and manuals.................................................................................20
TECHNICAL SPECIFICATIONS....................................................................................21
4.1 Electrical characteristics.................................................................................21
4.2 Environmental conditions................................................................................22

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1.

Tender Specification

INTRODUCTION
1.1 General
The extent of the work associated with the supply and installation of a Diesel Lineinteractive UPS system is described in this Tender Specification.
All equipment supplied under this contract shall be suitable for working at the
specified criteria. Additionally, the Supplier shall ensure that design, construction
or grading of all circuit breakers, controls, cables or other items of equipment in
the installation is such that it will operate with the design criteria set down
hereunder.
The Supplier is required to provide all material, equipment, labor and services and
to perform all operations required for the installation to be complete and
operative.
1.2 Scope of works and supply
The Supplier shall design, manufacture, deliver to site, test and commission all
materials and equipment to provide a complete diesel UPS installation.
The diesel UPS installation shall include, but not limited to the following:
Power Module with base frame comprising of:
o Diesel Engine,
o Freewheel Clutch,
o Synchronous generator,
o Energy Transfer Module (ETM),
o Flywheel,
Control panel(s) and Choke panel,
Low and/or medium voltage switchgear panel(s),
Each UPS unit shall be assembled at Manufacturers factory and tested at their
testing facilities prior to delivery on site for installation. Factory testing will be
executed with necessary control and low voltage (dummy) panels. Possible
medium voltage panels in the project will be separately tested at the medium
voltage Manufacturers test facilities.
The extent of the delivery associated with the diesel UPS system shall include but
not be limited to:

The design, manufacture, factory testing, delivery ex-works, site


commissioning and testing of the complete diesel UPS system, control
panel(s) and switchgear panel(s).
Delivery of radiator, fuel tank and exhaust silencer.
All necessary labor, tools, mechanical aids, appliances and testing
equipment required to complete the acceptance testing of the diesel UPS
system and recording of test results.
Liaison with other sub-contractors and the Purchaser in the planning of the
installation and preparation of workshop drawings.
Provisions for comprehensive operation and maintenance manuals.
Set of recommended spare parts.
Operational training on site to the Client's personnel in operation and
maintenance procedures.

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Comprehensive maintenance proposal for system long-term maintenance.

1.3 Regulations and standards


The following standards, quality of materials and standards of workmanship shall
apply, where applicable, for the various sections of the works. It shall be the
Supplier's responsibility to comply with all relevant standards and with all
applicable legal standard and regulations. In all respects the work shall be carried
out in accordance with IEC, EN and ISO standard.
Where no appropriate standard is available, tests shall be carried out in
accordance with the manufacturer's standard practice, which shall be subject to
approval by the Purchaser.
1.4 Quality assurance
The Works shall only be contracted to companies with an effective Quality
Assurance System. The Manufacturer shall be certified according to ISO
9001:2008.
1.5 Submittals
The Purchasers drawings for the Contract shall be those issued at the times of the
application together with any others issued to cover the variations to the Contract.
As part of the Contract the Manufacturer shall provide the following drawings after
a Contract is issued:

Manufacturing and Installation drawings


Wiring Diagrams

In addition to the drawings listed above, the Manufacturer shall provide all
drawings necessary for the execution of the Contract and shall submit details and
drawings of all major items of equipment to approve construction of the system.
All required drawings shall be submitted to an agreed time schedule to suit the
construction of the system. This time schedule shall clearly indicate the latest
submission and approval date for those drawings that are essential for the
continuation of the Works.
1.6 Manuals
The Manufacturer shall provide a User Guide and a Service Manual for the systems
supplied one month after the Factory Acceptance Test (FAT). These guides also
shall be available in electronic format on CD-ROM. Manuals shall be in English.
The User Guide and Service Manual shall be bound in book form with hard plastic
covers to withstand constant use and shall be properly indexed to facilitate easy
reference.
1.7 Test and inspection
The Purchaser reserves the right to arrange for the inspection of all goods forming
the subject of this contract or order, at any stage before final acceptance and by
any means it may seem necessary.
When inspecting the diesel UPS system at the Manufacturer's works or warehouse,
the Purchasers authorized representative shall have free access to the premises of
the Manufacturer at all times during working hours, shall have the right to inspect
work which is the subject of the contract or order, at any stage of manufacture,
and may reject any goods which are found to incomplete, defective or in any way
not in conformity with the terms of the contract or order.

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Tender Specification

All parts of the diesel UPS system shall be inspected and tested before being
delivered to site. The Manufacturer shall conduct all tests necessary in the factory
and in the presence of the Purchaser to prove that the diesel UPS system complies
in all respects to the specification. The Manufacturer shall conduct all tests
necessary on site and in the presence of the Purchaser to prove that the diesel
UPS system functions properly.
1.8 Maintenance and spare parts
Manufacturer shall include in his offer spare parts and special tools for
maintenance sufficient to cover proper maintenance of the entire works for a
period of one year starting from the acceptance date. The manufacturer shall
guarantee the availability of spare parts for a minimum period of ten years
The Manufacturer shall provide a detailed description of the required maintenance
work during the first 5 years of operation. Manufacturer shall include in his
quotation a detailed proposal for a maintenance contract, which includes for all
required maintenance work as described.
The proposal shall include, but not be limited to:

detailed description of the maintenance works required,


description of the local service organization.

1.9 Shipping and packing


All equipment shall be suitably packed for the way of shipping and for the storage
period and environmental conditions as indicated in the contract. All parts shall be
suitably treated to prevent corrosion. The supplier shall be responsible for any
damage arising from inadequate or careless packing.
The construction of the diesel UPS power module shall enable partial shipment.
1.10

Training

On completion of the start-up and commissioning the Manufacturer shall provide a


local training directly after commissioning and before Site Acceptance. In this local
training, instructions shall be given to the Purchasers staff of the proper operation
and maintenance of the plant, the training will last a maximum of three days. The
cost for such training shall be included in the offer.
1.11

Warranty

The Diesel UPS system shall be warranted during twelve months after the
commissioning with a maximum of eighteen months after delivery ex-works
whichever is the sooner.
1.12

Information

A detailed specification list of the UPS system and secondary equipment will be
attached to the offer. Especially items are:

UPS power rating per unit


Mains voltage
Mains frequency
Power Module dimensions
Power Module weight
Make and Type generator
Make and Type Induction Coupling

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Make and Type Diesel engine, also:


o
Output power
o
Speed
o
Bore
o
Stroke
o
Number of Cylinders
o
Piston displacement
o
Compression Ratio
o
Governor
o
Fuel Consumption
o
Combustion air
o
Exhaust flow
o
Exhaust temperature
o
Max. Exhaust back pressure
o
Lubrication oil content
o
Lubrication oil consumption
o
Cooling water content diesel engine
o
Max. outlet temperature
o
Pump capacity
o
Heat rejection through cooling system
Heat rejection of Power Module to room at normal operation
Heat rejection of Power Module to room at diesel operation
Noise level at normal and diesel operation
Installation Height
Humidity
Minimal and maximal ambient temperature

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Tender Specification

GENERAL SPECIFICATIONS
2.1 General requirements
The diesel UPS system shall be capable of supplying unattended continuous clean
A.C.-power to critical loads. The diesel UPS system shall be of an established
proven design and have a design lifetime in excess of 25 years.
The diesel UPS system shall include all mechanical and electrical devices
necessary to automatically effect continuity of clean power supply to the load, and
to isolate all transient and longer-term disturbances in the incoming mains supply
within the specified power supply requirements.
The diesel UPS system shall be designed to facilitate servicing, testing and
monitoring.
The design shall be so that all parts can be reached and replaced easily. It shall be
possible to electrically isolate any part of the plant to permit safe servicing.
2.2 System design
The diesel UPS system shall be built with proven rotary components. It basically
consists of a generator operating parallel to the mains supply, connected through
a tapped reactor. In case of mains failure, the generator will be driven from the
kinetic energy storage and/or the diesel engine.
The rotating components shall be mounted on a single frame. The use of a battery
based energy storage system, as an alternative for the above mentioned rotary
energy storage device shall not be accepted. Also the use of solid-state converters
for energy conversion shall not be accepted.
The system shall provide following main functions:

supply of clean and constant electrical power to critical load,


short-term back-up for mains failures,
long-term back-up for mains failures,
capability to sustain repeated mains failures in short periods of time,
filtering of mains distortion from mains to load,
filtering of current distortion from non-linear load to the mains,
power factor correction from load (leading or lagging) to mains.

The use of separate input and/or output filters to obtain one or more of above
mentioned main functions shall not be accepted.
2.3 Operation principals
2.3.1 Mains supply available
Under normal operating conditions the site power supply system feeds the UPS
system and provides power for the UPS system full output load plus any auxiliary
requirements of the UPS system.
The UPS system shall stabilize the mains voltage to within the acceptable
tolerances as specified in the electrical characteristics and improve the general
power factor of the system. The UPS system shall run continuously synchronized
with the mains.

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2.3.2 Mains failure or out of normal limits


Should the primary power supply to the UPS system fail to be within the
acceptable limits for voltage and frequency, the UPS system shall continue to
supply full output load without interruption. Simultaneously the incoming mains
shall be disconnected from the system. The rotary energy storage device shall
ensure continuity of power during the diesel run-up period.
2.3.3 Mains restored or back into normal limits
Upon restoration of the incoming mains to within the set limits, the generator shall
be synchronized to the mains, the mains reconnected to the system and the diesel
engine signaled to be disconnected from the generator and shut down. An
adjustable period shall be provided upon restoration of mains supply to run the
engine on no-load for cooling down purposes before the engine is shut down.
The transition of power from mains to diesel or visa versa shall be smooth and the
generator output voltage and frequency shall during this stage stay within the
acceptable tolerances as specified in the electrical characteristics.
2.3.4 Automatic Bypass facility
Each supply system shall be equipped with an automatic bypass facility. The
switching procedure from and to bypass shall enable an uninterruptible transfer.
This bypass facility shall have provisions to inhibit the initiation of the UPS system
starting cycle during intended power shut downs for maintenance purposes.

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Tender Specification

MAIN UPS COMPONENTS


3.1 Power module
The diesel UPS Power module shall be a skid-mount, single shaft, assembly of
rotating machines, basically comprising a diesel engine, a free-wheel clutch, a
generator, an energy transfer module and a flywheel. On the base frame all
auxiliaries for the power module are fixed. All these part are described in detail
below.
All connections between diesel engine, induction coupling and generator shall be
flexible to allow unrestricted movement and to obviate vibrations being
transferred to the building or other elements of the installation.
3.1.1 Diesel engine
The engine shall be a diesel fuelled, water-cooled, compression ignition, direct
injection industrial type. The diesel engine shall operate at a nominal speed.
The engine shall be rated to match the stated electrical output, load
characteristics and power factor as specified in the schedule of requirements,
subject to the specified site environmental conditions. The output of the engine
under the specified site conditions shall be the Nett available output after
allowance for all auxiliary equipment including but not limited to air filter, radiator
fan, pre-heating elements, oil pump, water pump, battery charging alternator, UPS
control electronics etc. The output-rating of the engine shall be in accordance with
ISO 3046.
The engine shall be equipped with an electrical starting system. An overrunning
type of clutch shall be used without the needs of external controls. The clutch shall
be virtually maintenance free with internal lubrication.
The diesel engine shall be water-cooled by means of a vertical mounted radiator
cooler, equipped with one or more electrical fans. The diesel engine shall be
equipped with a water pump. Coolant temperature shall be regulated by means of
modulating by-pass thermostats. Temperature sensors shall be provided to detect
over temperature and pre-heating failure.
The engine shall have a forced-feed lubrication system adequately rated to supply
circulating lubrication oil to all bearings, gear trains and important moving parts.
The engine shall be equipped with thermostatically controlled oil cooler.
Spin on, paper element for full flow lubrication, oil filters shall be provided. The
filter shall be located for easy replacement. A low oil pressure cut-out device shall
be provided to operate a shut-off of the engine and to provide a visual and audible
indication on the control panel. An oil pressure gauge shall be provided. The
gauge shall be independent of the low oil pressure protection system.
The engine shall be provided with a pre-lubrication pump with interval control to
maintain an oil film on all running parts. For maintenance purposes this pump
must also be usable for draining the sump.
The speed of the engine shall be controlled by an electronic governing system with
control box, pick-up mounted at fly-wheel and actuator to control the fuel pump.
The precise frequency control shall be done from the UPS controller. The governor
shall be fully compatible to be operated in conjunction with the UPS synchronizing
and control equipment. The permanent speed fluctuation shall not exceed 0,5% of

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the nominal engine speed. External facilities shall be provided on the engine to
adjust the nominal speed setting.
An engine mounted fuel pump shall be provided in the main fuel line. The injection
pump and injectors shall be easily accessible for maintenance purposes and shall
be suitable for operation with the commercial brands of diesel fuel normally
available. A micro filter with a replaceable element suitable for the full flow rate of
the injection pump(s) shall be provided between the fuel pump and the injection
pump. The filter shall be easily accessible.
An additional heavy-duty primary filter (sludge filter) of the washable screen mesh
type shall be fitted in the fuel line between the fuel tank and lift pump. The filter
bowl shall serve as a water trap.
Interconnecting fuel piping shall be copper and shall neatly run from the sludge
filter to the other parts of the fuel system. All piping shall be securely fixed by
means of saddles and clamps. The fuel line shall be connected directly to the daily
fuel tank. Excess fuel from the injection pump shall be returned directly to the
daily fuel tank.
The engine shall be equipped with dry air intake filters suitable for protecting the
engine against the worst climatic conditions specified. A dry type air cleaner with
replaceable filter elements, mounted on the diesel engine and with flexible
connections mounted on the intake manifold and a visual indicator on each filter,
is to be provided.
The engine shall be equipped with a charging alternator of suitable voltage with
current rating of not less than 30 A to charge the starter battery. The alternator
shall be fitted with a regulator to maintain the starter battery at the correct
voltage.
3.1.2 Generator
The generator shall be a three phase, brushless, self-excited, self regulating,
synchronous machine which can deliver the specified output continuously without
exceeding the temperature and other limitations specified.
The generator shall be designed and suitably rated to comply with the specified
electrical characteristics of the diesel UPS system, and the following particular
requirements:
Nominal voltage
Nominal frequency
Nominal speed
Degree of protection
Insulation class

400/480 V
50/60 Hz
1500/1800 rpm
IP 21
H

The output voltage shall be adjustable over a range of 5% of the nominal value.
The alternator shall be wired for a 3-phase, 4-wire system. Each phase shall be
brought out separately into a terminal block.
The generator shall be suitable for supplying non-linear loads like computers,
rectifiers and/or 6 pulse, 12 pulse controlled thyristors.
A good sinusoidal waveform free of slot ripple is essential. At no-load the
waveform distortion shall be less than 2 % THD. At full nominal load, the total
waveform distortion shall be less than 3.5 % THD with no individual harmonic
exceeding 3 %.

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The design of the generator and regulator system shall be such that it will
maintain machine excitation for a period to clear protection circuits, under any
output short-circuit condition. The generator shall be capable of withstanding short
circuit fault conditions without damage and shall also be capable of withstanding
short time overloads such as the starting of motors.
The generator shall be capable of withstanding an overload of 10% for one hour in
a 12-hour period under the specified environmental conditions.
The generator shall be equipped with an electronic voltage regulator. The
generator and voltage regulator components shall be protected against voltage
transients induced by switching or lightning surges. The requirements laid down in
IEC publication 60.1 shall be adhered to. The generator, voltage regulator and
control system shall be designed to ensure a quick voltage recovery after the
sudden application or rejection of full load. The transient voltage drop shall not
exceed the limits as specified in the diesel UPS system electrical characteristics
after the sudden application of full load. Only 3-phase sensing regulator systems
which take their input supply from either an auxiliary winding contained within the
alternator or from a directly coupled permanent magnet pilot exciter shall be
accepted. The voltage regulating system shall monitor average values and not
peak values.
The generator shall be equipped with re-greasable double sealed ball or roller
bearings capable of operating for at least 100.000 hours continuously. A flexible
coupling between the generator and the induction coupling shall be designed to
transmit torque smoothly and to take up any angular or axial misalignment which
may occur due to generator running clearances. There should be no free
movement in the coupling.
A cable terminal box with a removable cover shall be provided on the generator.
The box shall be suitably sized to accommodate all the cables, glands or overhead
busbars.
3.1.3 Energy transfer module (ETM)
The Energy Transfer Module (ETM) shall be an electrical machine, rated to deliver
the specified output power during diesel start-up without exceeding the limitations
specified. The required energy will be taken from the Flywheel, to which the ETM is
connected.
The ETM is equipped with two axial shafts. One shaft is connected to the outer
rotor, while the other shaft is connected to the inner rotor. The outer rotor is
connected to the generator. The inner rotor is connected to the Flywheel.
The ETM shall be manufactured by the manufacturer of the UPS system and shall
be designed and suitably rated to comply with the specified electrical
characteristics of the diesel UPS system, and following particular requirements:
Outer rotor
Inner rotor
Brushless exciter
Degree of protection
Insulation class

1500/1800 rpm
~2900 rpm
for DC winding
IP 21
F

The ETM shall be equipped with an electronic controller. The ETM and control
system shall be designed to ensure a quick frequency recovery after the sudden
application or rejection of full load. The transient frequency drop shall not exceed
the limits as specified in the diesel UPS system electrical characteristics.

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The ETM shall be equipped with double sealed ball or roller bearings for the outer
rotor, and double sealed ball or roller bearings for the inner rotor, all capable of
operating for at least 100.000 hours continuously. Precautions by means of a
labyrinth seal shall be taken to ensure that pollution from outside the machine
cannot enter the bearings.
A flexible coupling between the induction coupling and generator resp. Flywheel
shall be designed to transmit torque smoothly and to take up any angular or axial
misalignment which may occur due to generator running clearances. There should
be no free movement in the coupling.

3.1.4 Flywheel
The flywheel shall be a fully enclosed rotary mass, sized to store the specified
amount of kinetic energy and sized to deliver the specified amount of power to the
energy transfer module.
The flywheel shall be manufactured by the manufacturer of the UPS system and
shall be designed and suitably rated to comply with the specified electrical
characteristics of the diesel UPS system, and following particular requirements:
Flywheel speed
Stored energy

~2900 rpm
7.5/10/12.5/15 MJ

The flywheel is equipped with double sealed ball or roller bearings, capable of
operating for at least 100.000 hours continuously. Precautions by means of a
labyrinth seal shall be taken to ensure that pollution from outside the machine
cannot enter the bearings. The bearings shall be oil bath lubricated or oil
circulation lubricated with an external oil pump, oil cooler and oil storage.
A flexible coupling between the flywheel and ETM shall be designed to transmit
torque smoothly and to take up any angular or axial misalignment which may
occur due to generator running clearances. There should be no free movement in
the coupling.
3.1.5 Clutch
The diesel engine and induction coupling shall be connected by means of a
suitable mechanical clutch and flexible coupling. The clutch shall be suitably sized
to ensure reliable operation under all conditions, and shall not require neither any
electrical excitation or auxiliary supply nor any electrical or electronic control
system to engage or disengage. A clutch using friction plates shall not be
accepted. The clutch shall be a free-wheel type of a rugged, versatile design. It
shall use rollers as contact elements and shall have sufficient overload capacity. It
shall be of proven design, will not need external lubrication and be virtually
maintenance free.
3.1.6 Base frame
The diesel engine, free-wheel clutch, induction coupling, generator and
accessories shall be mounted on a suitable self-supporting base frame. The base
frame shall be adequately designed to ensure that no distortion during transport
or installation can occur. The base frame shall be designed to ensure that the
machines are installed horizontal in line and that free access to all equipment is
possible. Fuel storage in the base frame shall not be accepted.

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The power module shall be arranged to run free from excessive vibration and noise
under all conditions of load and speed. Therefore, the base frame shall be provided
with suitable anti-vibration dampers to minimize the vibration between the
machine and the building. Provision shall be made on the base to lift the complete
set for transportation purposes.
In case the base frame is designed for transportation in parts the electrical wiring
shall be provided with connectors to enable easy assembly on site, to ensure that
no wiring errors are introduced.
3.1.7

Finishes
All the metal work shall receive a finishing process of degreasing, rust-proofing
and zinc phosphate immersion grounding, followed by a double layer of synthetic
lacquer. The total paint thickness shall not be less than 100 m.
For all electrical panels an epoxy powder coating process shall be used. All metal
work shall be thoroughly degreased, cleaned and treated with an electroimmersion lacquer and finished off with one electrostatic applied layer of structure
powder coating based on polyester resin. The total paint thickness shall not be
less than 85 m. The final color shall be RAL7035. Painting of the power module
shall be in accordance with manufacturers standard colors.

3.1.8 Batteries and starting


The system should be provided with a redundant starting possibility, meaning that
starting using normal batteries is provided, but also a parallel starting unit that
is fed from the generator is implemented. Independent of the state of charge of
the batteries and their MTBF this unit provides full start-up capabilities.
A suitable rated heavy duty starting battery for powering the starter and control
circuits shall be provided. The batteries offered shall be suitable to operate
between 5 C and 40 C, and must be suitable for continuous float charge
operation. The life expectancy of the batteries under the above operating
conditions must be specified; however a minimum of 10 years is required.
The battery capacity shall be adequate for at least three consecutive attempts at
starting. The battery capacity shall be determined for the specified minimum
ambient temperature. The battery shall not be used for feeding control system(s).
The starter battery shall be mounted on a separate floor standing stand, made of
coated steel. The battery stand shall be designed to minimize electrolytic corrosion
and shall be designed to allow easy access for maintenance.
An engine driven alternator with an automatic voltage regulator shall be provided
to charge the battery with the engine running. A double powered, both mains and
output, battery charger shall be provided to charge the battery.
The charger shall be of the constant voltage type with current limiting facilities
suitable to charge the battery in accordance with the battery manufacturer's
specification. The ripple content of the output voltage shall be less than 2%.
The charger shall be of adequate capacity to charge a completely discharged
battery within eight (8) hours. The charger shall have an adjustable auto boost
facility. Boost charging shall be indicated on the UPS control panel by means of an
annunciator.

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An alarm shall be provided to indicate low battery voltage.


3.1.9 Black starting
The system shall have a black starting function. This enables it to be started in
absence of the mains. The control system shall be powered from this black starting
unit.

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3.2 Electrical Panels


3.2.1 Control Panel
A control panel containing the control equipment, protection equipment, alarms,
switchgear for auxiliary supply circuits, etc., shall be provided for each diesel UPS
power module.
As minimum following equipment shall be provided:

Auxiliary relays, time relays, fuses, terminals, wires, etc. for the control of
the UPS operation,
A Programmable Logic Controller for controlling of the system, complete
with all required interfaces,
Auxiliary transformers,
A electronic control unit for frequency regulation, voltage control and
synchronization,
A battery charger suitable for charging the starter battery,
24V distribution and power supply.

The control panel shall be totally enclosed and manufactured of a suitable angle
iron and 1.5 mm thick sheet metal construction, with minimal ingress protection of
IP30. The panel shall have key-lockable doors. A cable mounting frame and
removable gland plate shall be provided to accept all incoming and outgoing
control cables. Terminals shall be provided for the termination of these cables.
Panel color RAL 7035.
A copper earth bar, minimum sizes 25 mm x 6 mm, along the bottom of the panel
shall be provided. All non-current metallic components shall be effectively bonded
to the earth bar with yellow/green insulated stranded copper conductors.
The control circuits shall be designed by using solid-state devices or PLC's with all
interfaces being done with relays and contactors. All PLC in- and outputs shall be
provided with galvanic isolation. The PLC shall have a self-diagnostics checking
function with operational and supervisory conditions indicated on the front by
LED's.
Located on the control panel doors is a HMI touch panel. The touch panel shall
show a simplified single-line diagram of the relevant diesel UPS unit, and indicate
the state of the circuit-breakers.
The touch panel shall be able to display following:

battery voltage
engine speed
mains voltage
mains frequency
generator voltage
generator frequency
output current
output active power
output reactive power

The touch screen shall contain following switches to control the operational state
of the diesel UPS system:

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operational modes:
diesel engine:
by-pass mode:

on, off
automatic, diesel test, system test
normal, by-pass (only single system)

The touch panel shall contain following indicators:

green indication:
yellow indication:
red indication:

operational
warning/attention
failure

The touch panel shall be able to show following signals and alarms:

Diesel engine over speed


Oil pressure low
Cooling water temperature too high
Fuel level too low
Battery voltage low
Fuel level too high
Cooling water level low
Generator failure
Induction coupling failure
Mains supply failure
Not standby
Lubrication oil pump failure
Cooling water temperature too low
Emergency stop
Bypass closed
Maintenance required
Network error
Bearing temperature Induction coupling or Generator (optional)
Diesel oil level low
Fuel leakage
Overload (single system)
Start failure

The touch panel shall be provided with:

Audible alarm
Alarm reset button

As a standard the system shall be provided with a remote monitoring function.


Manufacturer shall offer a software tool for remote monitoring, supervision and
maintenance support of the UPS system as an option. The software program must
be able to run on a PC under Windows. All readings and data such as operating
hours, number of diesel starts, diesel running time must be available. Also an
overview of changes of state and errors of the last three months must be available
in a history log.
3.2.2 Bypass Control Panel
A bypass control panel designed to comply with the specified electrical
characteristics of the diesel UPS system, shall be provided. The bypass control
panel shall be equipped to provide the paralleling protection and control circuits
for all units within the parallel system.

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As minimum following equipment shall be provided:


Auxiliary relays, time relays, fuses, terminals, wires, etc. for the control of the
UPS operation,
Auxiliary transformers,
The bypass control panel shall be totally enclosed and manufactured of a suitable
angle iron and 1.5 mm thick sheet metal construction, with minimal ingress
protection of IP30. The panel shall have key-lockable doors. A cable mounting
frame and removable gland plate shall be provided to accept all incoming and
outgoing control cables. Terminals shall be provided for the termination of these
cables.
Located on the control panel doors is a HMI touch panel. The touch panel shall
show an output load (kW) meter and a bypass control switch.
The touch panel shall control the state of the automatic system bypass:

bypass operation:

auto, bypass

A copper earth bar, minimum sizes 25 mm x 6 mm, along the bottom of the panel
shall be provided. All non-current metallic components shall be effectively bonded
to the earth bar with yellow/green insulated stranded copper conductors.
The touch panel shall contain following indicators:

green indication:
yellow indication:
red indication:

operational
warning/attention
failure

The touch panel shall be provided with:

Audible alarm
Alarm reset button

The touch panel shall be able to show following signals and alarms:

DC Failure
Output voltage failure
Not enough units
Not redundant
One unit redundant
Two units redundant
Emergency stop
Not standby
Maintenance required
Network error
Overload

3.2.3 Choke Panel


A choke panel, containing the choke coil shall be provided. The choke shall be
designed and suitably rated to comply with the specified electrical characteristics
of the diesel UPS system, and the following particular requirements:
Nominal voltage
Nominal frequency

September 2012, rev. 01

400/480V or medium voltage


50/60 Hz

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The choke shall be constructed as a three-leg design with a common iron core and
designed with a tap at approximately 80 % of the windings. The LV-generator shall
be connected to the tapping point, while mains and load shall be connected to
either side of the choke. The choke reactance shall be calculated to match the subtransient reactance of the generator.
The choke in combination with the generator shall be designed such that the short
circuit current to the mains is limited to 2* In. Above that an input short circuit
shall not result in larger fluctuations of the secondary voltage then stated in the
technical specifications.
The choke shall be provided with 3 current transformers (one per phase), a
thermal relay in LV and no CTs. The choke panel shall be totally enclosed and
manufactured of a suitable angle iron and 1.5 mm thick sheet metal construction,
with minimal ingress protection of IP30. The panel shall have a removable cover
plate and supplied with forced cooling (cabinet fans). Panel color RAL7035.
A copper earth bar, minimum sizes 25 mm x 6 mm, along the bottom of the panel
shall be provided. All non-current metallic components shall be effectively bonded
to the earth bar with yellow/green insulated stranded copper conductors.
3.2.4 Switch board panels
A switchboard panel containing the UPS input circuit-breakers and protection
equipment, and a switchboard panel containing the UPS output circuit-breakers
and protection equipment should be provided.
As minimum following equipment shall be provided, depending of the
configuration (Single or Parallel):
One input circuit breaker per UPS module,
One output circuit breaker per UPS module,
One common input, one common output and one common bypass circuit
breaker,
One circuit breaker for the supply of the auxiliary transformer,
Current transformers,
Auxiliary equipment for protection and control,
Circuit-breakers shall be 3-pole switches, rated to match the rating of the UPS
power modules, and shall be rated for the short-circuit capacity of the mains
supply and the UPS generator. Circuit breakers shall be equipped with electricalmotorized spring charging, a closing coil, a trip coil and under voltage release. The
circuit breakers shall be equipped with shutters, push button covers and counter.
Circuit breakers shall be withdrawable to facilitate maintenance and service.
All status-, alarm- and control-contacts of each circuit breaker is to be connected
to a terminal I/O-unit. This I/O-unit is connected by data cable to the
Programmable Logic Control-unit in the unit control panel.
The switchboard panel shall be totally enclosed and manufactured of a suitable
angle iron and 1.5 mm thick sheet metal construction. The panel shall have keylockable doors.
3.2.5 Medium Voltage transformer panel (only for MV systems)
A medium-voltage transformer panel containing dry type transformer for the
connection of the low voltage diesel UPS system to the medium voltage by-pass
and distribution board shall be provided for each diesel UPS power module.

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The medium voltage transformer panel shall be totally enclosed and manufactured
of a suitable angle iron and 1.5 mm thick sheet metal construction, with minimal
ingress protection of IP21. The panel shall have key-lockable doors.
The transformer panel shall be equipped with lifting lugs.
The magnetic circuit shall have a low loss laminated core, the core lamination shall
be insulated with an oxide or equivalent layer.
The transformer shall have separated high-voltage and low-voltage windings. The
insulation of the windings shall consist of approved materials which do not
deteriorate when the transformer will be operated continuously at the maximum
permissible temperatures.
The temperature protection system shall give a warning signal for thermal
protection of the medium voltage transformer.
The average winding temperature rise for both high voltage (at the rated tapping
position) and low voltage windings at full load shall not exceed the specific
temperature rise limits.
A factory test shall be carried out by Manufacturer in accordance with the relevant
clauses in EC 726, section five.
3.2.6 Wiring
Color coding for the wiring of control and protection circuitry shall be such as to
avoid confusion with power circuits. Black or grey control wiring is preferred.
Halogen free wiring is mandatory.
Busbars shall be manufactured of solid copper bars and the neutral busbar shall
have the same cross sectional area as the phase busbars. Busbars shall be
suitably supported to withstand the force during short circuit conditions.
Each wire shall be clearly marked at both ends with numbered ferrules and these
numbers shall appear on the wiring diagram of the panel. Adhesive strips are not
acceptable.
Cabling connected to incoming or outgoing circuits shall be terminated on gland
plates supplied for this purpose. Both external and internal wiring for low voltage,
control, interlocking, alarm, measuring and DC circuits shall terminate on
numbered wiring terminals. Not more than two conductors shall terminate on the
same terminal and each conductor shall have its own lug. All terminals shall be
clearly marked.
The correct terminal size as recommended by the manufacturer for each
conductor to be connected shall be used throughout. The terminal numbers shall
appear on the wiring diagrams of the switchboard.
The current rating of conductors for the internal wiring shall be sufficient for the
maximum continuous current that can occur in the circuit. This value shall be
determined from the circuit-breaker or fuse protection of the circuit. The smallest
conductor size to be used for power wiring in switchboards shall be 1.5 mm.
Flexible cord minimum AWG 22 may be used for control wiring. Wiring shall be
arranged in horizontal and vertical rows and shall be bound with suitable plastic
straps or installed wiring channels. Terminals for power wiring shall be separated
from other terminals.

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Where heat generating equipment is present and the internal temperature of the
board is likely to exceed 50 C, silicon-rubber insulated stranded conductors shall
be used.
3.2.7 Protection
Adequate provision shall be made to protect the circuits against voltage transients
induced by switching or lightning surges. The requirements laid down in IEC 10002-9 and IEC 1000-2-10 shall be adhered to.
All metal work, including the cabinet shall be electrically bonded to the earthing
terminal. Earth continuity conductors shall not be less than half the cross sectional
area of mains cables to the cubicle, with a minimum of 4 mm.
All circuits shall be protected via suitably miniature circuit breakers or suitably
rated fuses. The star point of the generator shall be connected to the neutral
busbar and the neutral busbar shall in turn be connected to the earth bar via a
removable connection. The earth bar shall be bonded to the main distribution
system earth. TN-C, TN-S or TN-CS earthing systems should be supported and the
input earthing bar should be bonded to the output earthing bar.
3.3 Auxiliary Equipment
3.3.1 Radiator cooler
A radiator cooler shall be provided for each diesel UPS power module. The radiator
cooler shall be free-standing, vertical mount type, and suitable for indoor use. The
radiator cooler shall be equipped with one or more electrical fan(s).
The fan shall be suitably rated to transport the heat rejection from the UPS power
module in normal operation and diesel operation. During diesel operation the
radiator will suitably rated to cool the cooling water circuit of the diesel engine.
The radiator cooler fan shall be controlled by the PGM control panel.
The radiator cooler shall be equipped with an expansion tank, cooling water level
indicator and cooling water temperature gauge.
3.3.2 Daily fuel tank
Each diesel UPS power module shall be equipped with a daily fuel tank, which shall
be mounted in the diesel UPS plant room. Total capacity shall be sufficient for at
least four hours diesel operation at full load. The tank shall be made of 2 mm thick
sheet metal construction, and be mounted on a floor mounted frame. A drip-tray
sized for the complete fuel tank contents and equipped with a drain cock and fuel
sensor shall be provided below the fuel tank.
Fuel level float switches shall be provided on 4 levels to control the electrical fuel
pump and for signaling purpose. A low level alarm operated by a float switch shall
be provided to give an audible and visual alarm on the control panel when the fuel
level drops below 30% of the capacity. A high level alarm operated by a float
switch shall be provided to give an audible and visual alarm on the control panel
when the fuel level exceeds90% of the capacity.
A level gauge glass shall be provided on the outside of the tank for visual
indication of the fuel level. An electrical pump shall be provided to fill the daily fuel
tank automatically from a main storage tank. Additionally a semi rotary hand
pump, complete with the necessary gate and non-return valves, shall be provided.
The tank shall be equipped with a suitable breather. The tank shall be provided
with a drain cock to allow the tank to be completely drained.
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3.3.4 Exhaust silencer


An exhaust silencer shall be provided, specifically designed to reduce noise
created by the engine exhaust with a minimum of 30 dB.
3.4 Testing
A Factory Acceptance Test (FAT) shall be carried out at Manufacturers factory prior
to delivery to determine the proper function of the equipment in accordance with
the specification. A maximum of three persons of Purchasers personal shall be
present in the factory during the FAT. All expenses for lodging, boarding and local
transport are to be paid by the Manufacturer with a maximum of three days. A
program will be submitted at least four weeks prior the actual test date.
A Site Acceptance Test (SAT) shall be carried out on site after completion to
determine the proper function of the diesel UPS system in accordance with the
specification.
The Purchaser shall be given the option of witnessing all tests and notice shall be
given when the system or equipment is ready for inspection or test to enable the
necessary arrangements for attending the test to be made. The Manufacturer shall
issue for approval a list of all tests which are part of the FAT and will be witnessed
by the Purchaser. The Manufacturer shall also issue for approval a list of all tests
which are part of the SAT and will be witnessed by the Purchaser.
Before shipment all electrical equipment shall be subjected to but not limited to
the following tests, as appropriate:
Inspection and functional tests to prove correct operation of controls, interlocks,
tripping devices and closing circuits, indications etc.
Load test on each UPS unit in both normal and diesel operation, including load
transfer and retransfer tests with 50% and 100 % nominal load at p.f. 0.8,
Load sharing test with two UPS units in parallel in both normal and diesel
operation, including load transfer and retransfer tests with full nominal load
at p.f. 0.8 for two UPS units (i.e. twice the UPS unit rating),
Vibration test on all power modules,
Measurement of harmonic voltage distortion for individual harmonics and the
total harmonic distortion.
Measurement of input power factor at 50% and 100% load,
Measurements shall be demonstrated with proper recording equipment with an
appropriate sample rate.
All tests shall be recorded properly by the Manufacturer and included in the
manuals for future reference.
3.5 Documents and manuals
After a maximum of one month after the FAT, the Manufacturer shall submit copies
in English of the following documentation to the Purchaser:
Operating and maintenance instructions,
Detailed description of the functioning of the purchased equipment,
Detailed documentation of the equipment as-built, including:
-

Electrical and mechanical drawings,


List of cables and terminals.

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Manuals of the main sub-assemblies in the purchased equipment, including but


not limited to:
-

diesel engine,
generator,
circuit breakers.

Test records of Factory Acceptance Tests,


Certificates, documentation of tests, etc. of purchased material and goods
mentioned in the specification,
Documents verifying that inspection control and tests performed are in
accordance with the specification.

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4.

Tender Specification

TECHNICAL SPECIFICATIONS
4.1 Electrical characteristics
The diesel UPS system shall meet the following general operating criteria:
System specification:
System Power
Allowable Power Factor

2500/3000/3600 kVA
between 0,9 ind and 0,8 cap

Rated Power

2000/2400/2880 kW

Rated Power Factor

1,0

Nominal voltage:

400/480V

Nominal frequency:

50/60 Hz

Input specifications:
Input mains-voltage fluctuations:

10 %

Input frequency tolerance:

1%

Input power factor under nominal conditions:

0.98

Harmonic filtering under nominal conditions:

99 %

Max. reverse current during up-stream short circuit:

up to 2 * In

Output specifications:
Output voltage steady state:

1%

Output voltage dynamic (during mains interruption):

5%

Output voltage dynamic (during mains short circuit):

within ITI(CBEMA)

Output frequency mains operation:

as mains frequency

Output frequency diesel operation steady state:

0,5 %

Output frequency dynamic:

2.0 %

System voltage symmetry:

2%

Radio interference level (EN 55.011):

Class A

Diesel engine:
Operating with diesel fuel corresponding:

Grade No.2D per ASTM D975

Engine power (standby power) corresponding:

DIN/ISO 3046

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Tender Specification

4.2 Environmental conditions


The diesel UPS system shall be designed to operate under following continuous
environmental conditions:
Ambient temperature:

min. 5 and max. 40 C

Humidity:

max. 85% non-condensing

Altitude:

max. 400 m

September 2012, rev. 01

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