g3ir-1050-65-sp-9017_r1

Client Name : BASF India Limited Project Name : Project GIR Project Number : G3IR

Document No. : G3IR-1050-65-SP-9017 Date 28-Jun-12

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Rotary UPS System Package

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Project Document No: G3IR-1050-65-SP-9017

Unit: General Discipline: Electrical Document Type: Specification Document Title: SPECIFICATION FOR ROTARY UPS

DISCLAIMER

THIS DOCUMENT DEVELOPED BY FLUOR DANIEL INDIA PRIVATE LIMITED, IS THE PROPERTY OF BASF INDIA LIMITED AND THIS DOCUMENT CANNOT BE REPRODUCED, COPIED, DISTRIBUTED

DIRECTLY OR INDIRECTLY OR OTHERWISE USED WITHOUT EXPRESS WRITTEN PERMISSION OF BASF INDIA LIMITED FOR ANY PURPOSE OTHER THAN FOR THE PROJECT FOR WHICH IT IS

FURNISHED.

1 30-Jul-12 Issued for Design HS NG VP

0 28-Jun-12 Issued for RFQ HS NG VP

Fluor BASF Revision Date Purpose Prepared By Checked By

Approved By

ISSUED FOR DESIGN06 Aug 2012



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Record of Revisions

This specification has been revised as indicated below and described in the revision record on the following page. Please destroy all previous revisions. Revision No.

Date Description

0 28-Jun-12 Issued for RFQ

1 30-Jul-12 Issued for Design



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TABLE OF CONTENTS

1. GENERAL ...........................................................................................................................................................4

2. SCOPE OF WORKS AND SUPPLY.................................................................................................................4

3. CODES & STANDARDS....................................................................................................................................6

4. SYSTEM DESIGN ..............................................................................................................................................6

5. ELECTRICAL & CONTROL PANELS: .......................................................................................................10

6. TECHNICAL SPECIFICATIONS ..................................................................................................................12

7. ENVIRONMENTAL CONDITIONS ..............................................................................................................12

8. DRAWINGS & DOCUMENTS .......................................................................................................................14



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1. GENERAL

1.1. This specification is intended to cover the design, engineering, manufacture, assembly/pre-assembly, tests at manufacturer’s works, shop painting, packing, ocean shipment if applicable, insurance and clearance through Indian Port in case of imported plant and equipment, inland transportation, transit insurance, delivery to site, erection, testing and commissioning for Rotary Diesel UPS system , which shall be used to provide uninterrupted power to one of the unit (net continuous output load of 1720 kVA at 0.8 p.f at 45 deg C), complete with all accessories, auxiliaries and ancillaries as specified hereinafter and as required for safe and trouble free continuous commercial operation, in a manner acceptable to the Owner.

It is understood that the net power output can be supplied through a variety of engine /alternator capacities, supplier to note that the selected engine shall be such as to deliver the minimum output of 1375 kW. Supplier shall take care the fact that any price implications on account of higher engine/alternator size shall not be acceptable.

2. SCOPE OF WORKS AND SUPPLY

The diesel rotary UPS supply shall include, but not limited to the following:

2.1. Power Module with base frame comprising of:

Diesel Engine,

Kinetic Power Source,

Synchronous generator,

Electric and control panels

Spare parts and accessories

All electrical switchgear including static switches as required between Rotary UPS with automatic by-pass and Manual by-pass feeder, electrical and control panels etc.

2.2. Each UPS unit shall be assembled at Manufacturer’s 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.

2.3. Civil Scope of work

All the design for foundation, cable trench, steel design, including required calculations shall be in supplier’s scope

Supply of anchor bolts



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2.4. 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 rotary diesel UPS system and control panel(s).

-Delivery of radiator, fuel day tank and exhaust silencer and other auxiliaries to make the installation complete.

-All necessary equipments, labour, tools, mechanical aids, appliances and testing equipment required to complete the installation and acceptance testing of the rotary diesel UPS system and recording of test results shall be supplied by Bidder.

-Liaison with other sub-contractors and the Purchaser in the planning of the installation and preparation of workshop drawings.

- Earthing of Rotary UPS & auxillary equipments (including dedicated earth pits)

-Provisions for comprehensive operation and maintenance manuals.

-Set of recommended spare parts and operational spares for 2 years

-Operational training on site to the Client's personnel in operation and maintenance procedures.

-Comprehensive maintenance proposal for system long-term maintenance.

2.5. It is not the intent to specify completely herein, all aspects of design and construction of equipment. Nevertheless, the equipment shall conform in all respects to high standards of engineering, design and workmanship and shall be capable of performing in continuous commercial operation in compliance to the requirements mentioned in various documents.

2.6. Any deviation or variation from the Scope requirement and/or intent of the specification shall be clearly defined under Deviation Schedule of the Bid Proposal Sheets irrespective of the fact that such deviation/variations may be standard practice or a possible interpretation of the specification by the Bidder. Except for these deviations/variations covered under Deviation Schedules which are accepted by the Owner’s before the award of the Contract, it will be the responsibility of the Bidder to fully meet the intent and the requirements of the specification within the quoted price. No other departure of the specification whatsoever except for the declared deviation submitted by the Bidder with his proposal shall be considered. Bids not complying with requirement shall be treated as non-responsive and hence liable for rejection. The interpretation of the Owner in respect of the scope, details and services to be performed by the Bidder, shall be binding, unless specifically clarified otherwise by the Owner in writing before the Award of Contract.

2.7. Battery Limit

Supplier provided incoming & outgoing circuit breaker panel of the rotary diesel UPS set. Incoming power cables from Owner provided switchboard to rotary UPS panel and outgoing power cables from this panel to owner provided MCC will be in owner’s scope. All inter-cabling (power, control and instrumentation) between supplier provided panels and UPS shall be in supplier’s scope.

Supplier to refer attached sketch G3IR-0000-65-SK-0002 & 0003 for details of battery limit of the work falling under supplier’s scope . Cable trays and support structure for the cable routes shall be in supplier’s scope.



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2.8. Exclusion of Work

Construction of all civil works foundation, concrete cable trench, etc

3. CODES & STANDARDS

3.1. All standards, specifications and codes of practice referred to herein shall be the latest editions including all applicable official amendments and revisions as on date of opening of bid. In case of conflict between this specification and those (IS: codes, standards, etc.) Referred to herein, the former shall prevail. All the equipment shall conform to the requirements of the following standards and codes:

Diesel Engine IS -10000, BS- 5514 and As Per Standard Practice Of Diesel Engine Manufacturer’s Association Of USA.

Generator IS-4722/ IEC-60034, IS-12065, IS-12075

Fuel oil for DG Set IS-15217

Diesel fuels IS-1460.

Recommended practice for hot-dip galvanizing of iron and steel.

IS-2629

Methods for testing uniformity of coating of zinc coated articles

IS- 2633

Rotary UPS-Performance and requirement

IEC-88528 Part 11

3.2. The installation work shall conform to Indian Electricity Act and Indian Electricity Rules as amended up to the date this specification is issued. Any approval required from statutory authorities shall be obtained by the Supplier. Nothing in this specification shall be construed to relieve the Contractor of this responsibility.

3.3. In case of any contradiction between various referred standard/ specification/data sheet and statutory regulations, it shall be brought to the notice of Client for resolution and no assumptions shall be made. Generally the following order of priority shall govern:

Statutory regulations

Data Sheets

This specification

Codes and standards

Note: All necessary approvals and compliance with CPCB shall be in Supplier’s scope.

4. SYSTEM DESIGN

4.1. The diesel UPS system shall be built with proven rotary components, and basically consist of a diesel engine, a mechanically/electrically coupled rotary energy storage device, a generator and a choke with all required electrical & control panels. The rotating



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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.

Note: The system shall be suitably designed for powering VFD loads which shall constitute 20% of the total load. Also, supplier to ensure the required power output in all conditions (i.e even during failure of fans provided in acoustic panel)

4.2. In general, the system shall provide following main functions (but not limited to):

Supply of clean and constant electrical power to critical load

Short-term back-up for utility failures

Long-term back-up for utility failures

Capability to sustain repeated utility failures in short periods of time

Filtering of utility distortion from utility to load

Filtering of current distortion from non-linear load to the utility

Power-factor correction from load (leading or lagging) to utility

4.3. Performance Requirement

The combined system shall be capable to provide clean power output irrespective of change-over between supply sources (kinetic energy storage to DG power, DG power to normal power)

The Diesel UPS system shall be designed with capability to handle highly distorted load without de-rating and to provide high overload & fault clearance capacity.

The design of flywheel shall be such that it shall be capable of taking critical load without interrupting the supply till the DG engine back-up available. Vendor shall furnish calculations for the same for Owner’s approval.

By-Pass System:

A no break transfer of load to mains shall take place automatically in the event of system/module failure or manually for maintenance.



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4.4. 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 net 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 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.

4.5. 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. The performance of generator shall be in accordance with ISO-8528 Part-1.

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.

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 %.

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.

Note: The rotary UPS set shall be capable of generating minimum 1720 kVA (net power output excluding its own auxiliary power consumption) at 0.8 p.f. power at generator terminals under specified site condition. Contractor to provide documentary proof to prove that the suggested model can deliver the required power.

4.6. Starting System:

The engine shall be equipped with a 24 volt DC electric start system of sufficient capacity to crank the engine at a speed that will assure reliable starting. Two starters and two starting battery with charger shall be furnished.



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4.7. Base Frame:

The diesel engine generator and other applicable accessories (as per type of coupling) shall be mounted on a suitable self-supporting base frame and shall be located inside the acoustic enclosure. The contractor shall recommend his own layout and indicate the space requirement along with the proposal.

The acoustic enclosure shall be fabricated from CRCA sheet with steel section & frame of suitable size. The construction shall be modular type to facilitate dismantling as required for maintenance. The frame shall be of sufficient stiffness and rigidity.

The enclosure shall be suitable for outdoor duty. The sheet and all sections shall be powder coated shade of grey RAL9002.

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.. Also, the base frame shall be mounted on Anti-vibration pads (AVM) to limit the vibration.

Provision shall be made on the base to lift the complete set for transportation purposes. The frame shall be constructed of box girder to lower the overall weight. 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.

4.8. Power Conditioning Devices:

Power conditioning arrangement shall be provided to maintain the output voltage constant in the event of mains-side voltage sags. Also, additional function of isolation of output voltage from input voltage distortion i.e. harmonics on the input voltage shall not affect the output.



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5. ELECTRICAL & CONTROL PANELS:

5.1. Breaker Panel:

Switchboard panel with rating IP-42 containing input circuit breakers and protection equipment, output circuit breaker with protection equipment per module.

Circuit-breakers shall be 4-pole ACB, 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 electrical- motorised spring charging, a closing coil, and a trip coil and under voltage release. The circuit breakers shall be equipped with shutters, push button covers and counter. Circuit breakers shall be withdraw able to facilitate maintenance and service.

5.2. Control Panel:

A control panel with rating IP-42 containing the control equipment, protection equipment, alarms, switchgear for auxiliary supply circuits, etc., shall be provided for each rotary 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

-Indications for Rotary UPS Healthy/In operation/ Fail to start/ Trip shall be provided to DCS

-Auxiliary transformers

-A electronic control unit for frequency regulation, voltage control and synchronisation

-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 minimum1.6 mm thick sheet metal construction, with minimal ingress protection of IP42. 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.



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5.3. Choke Panel:

A choke panel with rating IP-42, 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.

5.4. Wiring:

Power and control cabling between Rotary UPS and associated electrical and control panels including support arrangement. Entry of cables in all panels shall be from bottom.

Colour 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. Bus bars shall be manufactured of solid copper bars and the neutral bus bar shall have the same cross sectional area as the phase bus bars. Bus bars 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.

5.5. Auxiliary Equipment:

Radiator cooler

A radiator cooler shall be provided for each diesel UPS power module. The radiator cooler shall be free-standing and vertical mount type. 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. 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 signalling 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 exceeds±90% 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



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a suitable breather. The tank shall be provided with a drain cock to allow the tank to be completely drained.

Exhaust silencer An exhaust silencer shall be provided, specifically designed to reduce noise created by the engine exhaust with a minimum of 45 dB to meet the CPCB requirements Ventilation System Ventilation system of adequate capacity shall be provided for UPS set and panels wherever applicable. Note: All the piping work inside battery limit including connection between day tank and engine fuel tank will be provided by supplier.

6. TECHNICAL SPECIFICATIONS

Electrical characteristics The diesel UPS system shall meet the following general operating criteria: Diesel UPS system specification: Nominal output power minimum 1720 kVA (net available output), at puff. 0.8, lagging, capable of DOL starting Industrial duty S1, 55 kW squirrel cage induction motor with 8 times the starting current and voltage drop limited to 20% at the motor terminals during starting. Input voltage 415V Voltage tolerance ± 10 % Input frequency 50Hz Steady state tolerance ± 5 % Output voltage 415V Steady state tolerance ± 1 % Transient tolerance (at utility interruption) ± 5 % during 500 msec Output frequency 50 Hz Normal operation ± 1 % Diesel operation Steady state tolerance ± 0.5 % Transient state tolerance ± 1 % Waveform at linear loads Max. Total harmonic distortion ≤ 3.5 % Max. harmonic distortion per single harmonic ≤ 3.0 % Reduction of higher harmonics from utility 95 % General system performance: Radio interference level (EN 55.011) Class A Diesel engine operating with diesel fuel – all types of diesel fuel available in India.

7. ENVIRONMENTAL CONDITIONS

7.1.1. The diesel UPS system shall be designed to operate under following continuous environmental conditions:



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Temperature 11 °C up to + 45 °C during operation Humidity 92 %, non-condensing Altitude below 1000 m above sea level

8. TESTING

8.1.1. All the tests shall be performed in accordance with relevant IS/IEC standards

8.1.2. 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 Q & CR form and this specification.

8.1.3. 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,

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,

All tests shall be recorded properly by the Manufacturer and included in the manuals for future reference

8.1.4. 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. Following tests shall be conducted (but not limited to):

Insulation resistance test on alternator, control panel and cabling Checking the engine safeties for satisfactory operation Checking vibration levels Full Load test Noise level test Testing of individual protective devices on engine and alternator and

ensuring that the wiring is carried out properly The rotary UPS shall be deemed to be commissioned after satisfactory performance of all associated equipment.

8.1.5. Type test certificate carried out on identical design and type of the rotary UPS set and accessories of the same rating are to be furnished along with the tender. These reports should not be more than five years old.

.



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9. DRAWINGS & DOCUMENTS

9.1.1. Foundation plan showing location of foundation channel, floor plans etc.

9.1.2. Supporting calculations for arriving at Diesel engine/alternator ratings at the specified ambient condition covering the following.

Rated BHP of engine at 38 Deg.C as given by manufacturer

Rated BHP of engine at 38 Deg.C considering the derating factor as given by manufacturer

Rated BHP of engine at 45 Deg.C after deduction of mechanical auxiliary loads connected on engine shaft.

Efficiency & Power factor of alternator at 100% load to calculate the output of DG set at site conditions.

Alternator rating at 45 Deg.C as given by manufacturer

Derating factors to be considered for site ambient conditions as given by the manufacturers.

Alternator rating at 50 Deg.C after considering the above derating factors.

Electrical auxiliary load connected on alternator

9.1.3. GA & Foundation layout of the panels

9.1.4. GA & Foundation layout of DG sets covering dimension of various equipments i.e. alternator, engine and coupling (if applicable).

9.1.5. Connection / terminal wiring diagram for DG set, Control panel, electrical and control panels, flywheel (if applicable) etc.

9.1.6. GA & foundation layouts of electrical and control panels.

9.1.7. Data sheet of DG set, Engine and other applicable equipments.

9.1.8. Installation, Operation & Maintenance manuals:

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. Manuals of the main sub-assemblies in the purchased equipment, including but not limited to: - diesel engine, - generator, - circuit breakers.



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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.