Inspection of AC UPSCheck List - Inspection for AC UPSForm: PEC-BMS-EN-FRM-E-0548 Rev 0Notes:1. Select check box, when applicable. Leave check box blank, when not applicable.2. Comment / Remark may be inserted in Cells (e.g. Not Applicable), where required.Sr. No.Check PointsChecker1.0GENERAL1.1"Inspection Check List- Preambles"(Document No: PEC-BMS-EN-FRM-E-0540) checked for general guidelines.1.2Dwgs/ Documents in the Vendor Data Requirement attached with the PO shall be referred. However the following approved drawings / documents as a minimum are to be refered prior to inspection:- ITP & FAT procedure- Dimensioned GA drawing of the UPS with floor plan, Mounting /Fixing details.- Single line diagrams, Schematic Diagrams & BOM- Project Specifications and Data sheets for UPS- IEC-62040-3, IEC-60146-1-1, IEC 60146-22.0DESIGN, VISUAL & GENERAL ARRANGEMENT INSPECTION2.1Visual GA & Dimensional Checks:2.1.1Check for surface finish/ painting (shade and thickness per PO), uniformity of shade across panels.2.1.2Check if the overall and shipping section dimensions are as per approved drawings.2.1.3Check floor plan, fixing arrangement & gland plate dimension for cables are as per approved drgs.2.1.4Check nameplate, rating plate, mimic diagram, component & warning labels as per approved documents.2.1.5Verify adherence to IP rating and gaskets provided to maintain the IP ratings.2.1.6Check the assembly of components on the panel front door and inside the panel as per approved drawings.2.1.7Check alignment of the doors and shall be without any sag.2.1.8Check component labels in line with agreed tagging philosophy for both front door and inside components.2.1.9Check terminals and terminal block arrangement and its identification against approved drawings.2.1.10Check the colour and size of internal wiring against PO specifications.2.1.11Check wire identification (ferrules/ tagging) against termination drawings & ferrules/ lugs as per spec.2.1.12Check dressing of wires: Wires shall be neatly bunched & routed in cable troughs, protected against sharp edges. Wires for the door mounted devices shall be routed in flexible conduit or similar arrrangement.2.1.13Check that no more than one wire is terminated in any terminal and wires are properly terminated.2.1.14Ensure that all components are easily accessible with enough space for maintenance.2.1.15Check that shrouds are provided for all accessible live parts.2.1.16Check cubicle lighting operated through door switches, if shown in drawing.2.1.17Check for panel front door grounding and earthing points for the UPS.2.1.18Check earth bus size and external earthing terminals against drawings.2.1.19Check tin-plating is provided for earth busbar, if specified.2.1.20Check for drawing pockets / document holder on the rear side of panel door.2.2Cable Termination Checks:2.2.1Check space for easy termination of specified incoming & outgoing cables & in particular battery cables.2.2.2Check power terminals size for its adequacy to accept specified number / size of cables.2.2.3Check cable termination arrangement including termination height from gland plate.2.2.4Check gland plate material & verify the thickness of gland plate( 3/4mm thick) for proper glanding.2.2.5Check gland plates are removable and supplied undrilled.2.2.6Check the provision of safety shrouds to prevent inadvertent contact with cable side live terminals.2.2.7Check that cables after termination do not affect accessibility of components from front (if front access).2.3Bill of Material Checks:2.3.1Check major items- thyristor, diodes, transformer, MCCB, MCBs, switches, fuse, contactor, relays, meters, RS 485/Ethernet serial link adaptor, Push buttons, etc per approved component list- rating, part no, make.2.4Checks on auxiliary devices & component rating verification:2.4.1Check anticondensation heater location, rating incl. watts, voltage. Check heater control (Thermostat).2.4.2Check functioning of the cubicle lighting circuit (if cubicle lighting is indicated in drg.)2.4.3Check the rating of the fuse, MCCB, MCB's etc., as per approved drg.2.4.4Check number of outgoing feeders in the UPS distribution board as per SLD (if in vendor scope).2.4.5Check for the provision of earth leakage devices and / or auxiliary contacts for ON/OFF position indication for the outgoing feeders in DBs (if specified). Also verify the sensitivity of the earth leakage device.2.5Checks on Battery Isolation Switch Enclosure:2.5.1Verify hazardous area certification for battery isolation box & ensure certificate number is marked on it.2.5.2Check material (Cast Iron / Cast Aluminium) of battery isolation box against PO spec / approved drawings.2.5.3Check Battery isolation switch operation is possible without opening cover. Ensure ON/OFF position marked on cover. Check if switch is pad lockable in OFF condition.2.5.4Check if shunt trip & undervoltage release are provided in battery isolation switch (if specified). Check if auxiliary contacts for battery isolation switch ON/OFF and Trip status provided (if specified).2.5.5Check space inside isolation switch for termination of battery cables, considering the no. & size of cables.2.5.6Check if cable entry (top/ bottom), no. of cable entries and cable entry sizes as per approved drawings.2.5.7Check if cable entries are provided with Ex-d plugs (if specified) & verify material of the plugs.2.5.8Verify with a sample cable gland if all threads fully engage in the entries provided on the enclosure.2.6Checks on Battery Racks / Cells:2.6.1Check rack BOQ w.r.t drawings (If rack material is in packed condition then verify packing list w.r.t BOQ).2.6.2Review Internal test report furnished by battery vendor (not applicable if battery dispatch in dry condition).2.6.3Check if batteries are dispatched in electrolyte filled, charged and then discharged condition (to increase the storage time at site), as specified in PO specifications.3.0TESTS: (IEC 62040-3; Cl - 6 & Table 3, 4, 7 and IEC 60146-1-1; Section-4 & Table 4)Following list of Routine, Type & Optional tests carried out as applicable (Based on PO / final approved ITP). The test results shall be recorded and attached with the inspection report.3.1ROUTINE TEST:3.1.1Insulation test (IEC 60146-1-1; Cl - 4.2.1 and IEC 62040-3; Cl - 6.2.4)AC test voltage as specified in IEC 60146-1-1 table 5 of Cl - 4.2.1.4 is applied to power circuits.On completion of test, the insulation resistance between the system and earth shall be 1M (min).Note:Any resistors between the system and earth (for earth fault monitoring) to be disconnected; bypass all electronic components like thyristors, diodes, printed circuit boards, controlgear, etc. prior to test.The above requirement shall be clearly indicated in form of warning label on the respective components which need to be disconnected prior to dielectric test. Check if such warning labels provided.3.1.2Light Load test (IEC 60146-1-1; Cl - 4.2.2.1 and IEC 62040-3; Cl - 6.6.3 & 6.6.4(aux. device test)Light load (around 10% of rated load) is applied at rated voltage (also min. & max. input voltage for type test). Check the output voltage variations. Also verify the functioning of auxiliary devices such as lighting, fans, annunciators. For parallel redundnat design, check load sharing at this lightly loaded condition.3.1.3Functional test (IEC 60146-1-1; Cl - 4.2.2.2 and IEC 62040-3; Cl - 6.6.6 to 6.6.10)3.1.3.1Verify functioning of the control / protective devices, alarms & signaling devices (lamps / mimic displays)3.1.3.2Check the output voltage variations by simulating an AC Input failure condition (IEC 62040-3; Cl - 6.6.6)3.1.3.3Check the output voltage variations by simulating an AC Input return condition (IEC 62040-3; Cl - 6.6.7)3.1.3.4Check the parallel redundant operation of the UPS (if applicable) by simulating failure of one UPS (e.g. inverter semiconductor failure). Check output voltage transient & frequency (IEC 62040-3; Cl - 6.6.8). Measure the current division in parallel redundant units (optional test per IEC 62040-3 Table-7) prior to simulating the fault (IEC 62040-3; Cl - 6.6.14).3.1.3.5Verify the Transfer test (i.e operation of static transfer switches) of the UPS under full load condition as specified in IEC 62040-3 Cl 6.6.9. Check the output voltage variations during this test.3.1.3.6Check the correct operation of the UPS without overheating / malfunction by loading the UPS output, equivalent to rated load using dummy load (Full load test - IEC 62040-3 Cl 6.6.10). Note: If rectifier static & dynamic stability performance test (type test) are specified in PO, this test will be performed as part of static & dynamic stability test.3.1.4Check Aux. devices; control equipment; protective devices (IEC 60146-1-1 Cl 4.2.7; 4.2.9; 4.2.10)3.1.4.1Verify the wiring and functioning of auxiliary and control circuit based on approved schematics.3.1.4.2Check proper functioning of control components and indicators e.g., Push buttons, selector switches, indication lamps, MCB, auxiliary relays etc., in line with approved schematics.3.1.4.3Verify functioning of mimic panel / LCD display unit according to specification.3.1.4.4Verify functioning of the communication channels with the remote control system.3.1.4.5Check if the protocol used for remote communication is as per the specification. (if specified).3.1.4.6Check communication port based on medium of communication (RS 485 / fiber optic port) is as specified.3.1.4.7Check if all remote signals as specified in I/O list are available at the UPS communication port (if specified). Also check if all signals are stamped with corresponding event occurrence time.3.1.4.8Check the UPS time synchronization feature (can be hardwired digital input or soft signal through serial link). If soft signal is used, check the protocol used.3.2TYPE TEST: (to be conducted, if specified in PO / ITP)3.2.1Perform Input Voltage & frequency tolerance test as per IEC 62040-3 Cl 6.3.23.2.2Perform Input Inrush current test as per IEC 62040-3 Cl 6.3.33.2.3Measure the DC Components in the Output; the values shall be as specified in IEC 62040-3 Cl 6.3.4.63.2.4Perform UPS Dynamic Stability tests (as listed below) as per IEC 62040-3 Cl 6.3.6 / 7 / 8:3.2.4.1Record the transient performance of the output voltage waveform for a Change of operating mode (from Normal to stored energy mode) for a 100% resistive load by interrupting the input supply at different conditions as specified in IEC 62040-3 Cl 6.3.6.1.3.2.4.2Record transient performance of output voltage waveform for Change of operating mode (from Stored energy to normal mode) for 100% resistive load by restoring input supply as per IEC 62040-3 Cl 6.3.6.2.3.2.4.3Record the transient performance of the output voltage waveform for a Change of operating mode (from Normal mode to Bypass mode) by simulating inverter fault or overload as specified in IEC 62040-3 Cl 6.3.6.4. Verify the inhibition of transfer for frequency / votage variations beyond the specified limits.3.2.4.4Record the transient performance of the output voltage waveform for an Output Load Steps - Linear load (20% & 80% load addition & 80% & 20% load rejection) as specified in IEC 62040-3 Cl 6.3.7.1.3.2.4.5Perform Temperature rise test as per IEC 62040-3 Cl 6.6.10 & 6.2.1 (per IEC 60146-1-1 Cl 4.2.5 for rectifier) and Cl 6.2.2 (per IEC 60146-2 Cl 5 for inverter).If any specific time requirement is specified in PO / ITP, test shall be conducted for the specified duration.3.2.4.6Measure the outut voltage waveform and its fundamental & harmonic content under steady state conditions by applying the rated apparent power as specified in IEC 62040-3 Cl 6.3.8.1 Reference Non-Linear load output distortion - Normal Mode.3.2.4.7Measure the outut voltage waveform and its fundamental & harmonic content during the transition of UPS from Normal mode to Stored Energy mode when operating at 100% rated non linear load as specified in IEC 62040-3 Cl 6.3.8.2 Reference Non-Linear load output distortion - Stored Energy Mode.3.2.4.8Repeat the test under line item # 3.4.4.1 for 100% rated non linear load as specified in IEC 62040-3 Cl 6.3.8.3 Reference Non-Linear load - Change of operating mode from Normal to Stored Energy Mode.3.2.4.9For UPS rating 4kVA:Record the transient performance of output voltage waveform for Output Load Steps - Non Linear load (25% & 75% load addition and 75% & 25% load rejection) as specified in IEC 62040-3 Cl 6.3.8.4.For UPS rating > 4kVA:Record transient performance of output voltage waveform for Output Load Steps - Non Linear load (33%, 33% & 33% load addition and 33%, 33% & 33% load rejection) as specified in IEC 62040-3 Cl 6.3.8.5.3.3OPTIONAL TEST: (to be conducted, if specified in PO / ITP)3.3.1Perform Synchronization test by synchronizing the UPS output to an external source (i.e. bypass) as per IEC 62040-3 Cl 6.6.5. Verify the frequency variation limits & while synchronization verify the phase angle between the external source and the UPS inverter output against the manufacturer's specified limits.3.3.2Perform UPS efficiency test as per IEC 62040-3 Cl 6.6.113.3.3Check Battery ripple current as per IEC 62040-3 Cl 6.6.173.3.4Verify UPS Overload capability test as per IEC 62040-3 Cl 6.6.183.3.5Verify Short Circuit Test & Protection device test as per IEC 62040-3 Cl 6.6.19 & 6.6.203.3.6Perform UPS Restart test by restarting the UPS after a complete shutdown as per IEC 62040-3 Cl 6.6.21. The input inrush current and output voltage shall be checked during this test.3.3.7Check operation of overvoltage devices by simulating UPS output overvoltage as per IEC 62040-3 Cl 6.6.223.3.8Perform Output voltage variation test at various load conditions (0%, 25%, 50%, 100%) and operating conditions (nominal, min. & max. input voltage) as per IEC 62040-3 Cl 6.6.23. Verify the output voltage regulation at all conditions.3.3.9Measure the Harmonic Component of input voltage & current (THD) under rated linear load condition as per IEC 62040-3 Cl 6.6.26.3.3.10Conduct Earth fault test on UPS & measure UPS output transients as per IEC 62040-3 Cl 6.6.27.3.3.11Perform Audible noise test on UPS system as specified in IEC 62040-3 Cl 7.3.3.3.12Verify the output voltage unbalance and phase angle deviation by applying an unbalance load on UPS as per IEC 62040-3 Cl 6.6.12. (test applicable only for 3 phase UPS)3.3.13Verify the output voltage unbalance and phase angle deviation by applying a balance load on UPS as per IEC 62040-3 Cl 6.6.13. (test applicable only for 3 phase UPS)4.0PUNCH LIST POINTS:-4.1Check that punch list points noted during the inspection are recorded in the project format and vendor has understood the corrective action required for each punch list.NameDateCheckerApprover

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