METHOD STATEMENT FOR THE

TESTING AND COMMISSIONING OF

UPS SYSTEM

1.0      Scope :

This Method Statement defines the procedures to be followed for the Testing and
Commissioning of UPS System.

2.0      PURPOSE :

This Work Method Statement (WMS) is to ensure installation of RIELLO –

(AROS) UPS systems (MST Series (MST 160 PAR) & MHT Series (MHT 400
PAR & MHT 600 PAR) is correct and as per agreed procedures and that working of
the system is correct and as per client requirements.
The aim and /or benefits of complying with this WMS include:  Program Compliance,
Health, Safety and Quality and Environmental company policy compliance.

3.0      REFERENCES

3.1.1        Project Specification
3.1.2        Project Drawing
3.1.3        Electrical Equipment Data Sheets

4.0      DEFINITION

None
5.0      RESPONSIBILITIES

5.1 Project Manager will be responsible for the following:

5.1.1Overall responsible for the implementation of this method statement.

5.1.2Responsible for ensuring that the work is performed in accordance with the
specification and with the time & constraints.
5.1.3 Submit progress report as per contractual requirements to Main Contractor.
5.1.4 Ensure that all required submittal are made in timely manner.
5.1.5 Coordination with the Contractor, Company, Engineers, Safety personnel and
subcontractor for the safety and quality during the execution of the project.
5.2 QA/QC Department will be responsible for the following:
5.2.1        QA/QC Department will perform all preliminary checks prior to the commissioning of
the system.
5.2.2        Ensure all installations are as per approved shop drawings and as per approved
material submittals.
5.2.3        Ensure the works comply with the contract requirements to serve the purpose.
5.2.4        Ensure the work is completed as per quality requirements. Contractor shall inspect
the same work to initiate ITR for company approval.

5.3 Commissioning Team:
5.3.1        All Pre-Commissioning and Commissioning activities are the responsibility of
Commissioning Team.
5.3.2        Pre-commissioning and Commissioning shall be carried out by Specialist Contractor
under the direct supervision of MEP Electrical Commissioning Engineers.
5.3.3        Contractor Commissioning manager shall check the commissioning works prior to
submission to the Commissioning Agent for witnessing and approval.
5.3.4        In case of failure in any test, the Specialist Contractor will rectify, and MEP
Commissioning team to re-offer the test to Commissioning Agent for re-witnessing
and approval.
5.3.5        Final Testing & Commissioning Report shall be submitted to consultant for approval.

5.4 Safety Officer/ Engineer will be responsible for the following:

5.4.1        Tool Box talk has to be conducted and all the hazards have to be identified before
starting the commissioning.
5.4.2        To make sure that the Personnel Protective Equipment (PPE) are used by the Task
Force during executions of work at site.
5.4.3        Risks related to the activity shall be assessed and addressed as required.
5.4.4        To provide training for the work force in order to execute the activity safely.

6.0      METHOD OF WORK

6.1 Material
6.1.1        None

6.2 Tools & Testing Equipment’s

6.2.1        Fluke Category 6 Cable tester

6.2.2        OTDR
6.2.3        Set of Mobile scaffolds
6.2.4        Aluminum ladder

6.3 Preliminary Checks
6.3.1        All Electrical works are installed as per the approved construction drawings.
6.3.2        Proper cable size should be installed for the input and output.
6.3.3        Check type, size and rating of all protective devices and compare with the approved
drawing and schedules.
6.3.4        All material uses must have an approved material submittal.
6.3.5        Make sure that the temperature in the installation room for UPS system and
batteries is within the manufacturer’s recommendations as given below:
 UPS: 0 to +40 ċ.
Batteries: 20 to 25 ċ
6.3.6        Ensure proper cleanliness in the Installation room.
6.3.7        The position where the UPS system is installed should not be exposed to direct
sunlight.
Positioning
6.3.8        Make sure that the floor is strong enough to withstand the weight of UPS and
battery cabinets.
6.3.9        A place of at least one meter should be available in front of the UPS for easy
access.
6.3.10    Minimum 20 Cm should be available at the rear side of the UPS for flow of Air from
the cooling fans and Min 40 cm for Maintenance operation of the Fan.
6.3.11    No objects should be kept at the top of the UPS.
6.3.12    UPS Identification (Label) to be done.
6.3.13    Proper Cable size is installed for Earthing at all the Equipment’s. (UPS & its
associated equipment’s).
Cable Termination:
6.3.14    Connect the Input power cable to the SWIN breaker or switch provided inside the
UPS when opened from the front.
6.3.15    Connect the Output power cables to the SWOUT breaker or switch provided.
6.3.16    Pull out the battery cables from the battery cabinet to the UPS and connect it to the
battery terminals shown in the UPS.
6.3.17    Labelling to be done for each cable & Panels.

6.4 Pre-Commissioning Power Checks

6.4.1        Verify that wiring have been carried out as per drawing.
6.4.2        Input & output cables should be easily identified.
6.4.3        Ensure that Input & Output power cables have connected to the respective
terminals in the UPS.
6.4.4        Make sure that the minimum spacing requirement for the UPS has been maintained
as per the Manufacturer’s recommendation given below:
Front: one meter for door access
Rear: 20 cm for Air flow from cooling Fan.
Rear: 40 cm for Maintenance of cooling Fan.
6.4.5        Make sure that the wires are properly laid between UPS and battery cabinet.
6.4.6        Batteries inside the battery cabinet should be properly arranged as recommended
by the battery supplier.
6.4.7        Check for proper tightness in the connections between the batteries.
6.4.8        Check for proper Earthing in the UPS panel and also in the Battery cabinet.
6.4.9        Check for proper tightness of power parts.
6.4.10    Check continuity of all power fuses.

6.5 Commissioning
6.6 Ups Start-up: (Refer Functional & Commissioning Report)
6.6.1        Verify that all breakers or switches and fuses in the UPS are kept open.
6.6.2        Verify that the fuses in the battery cabinet are kept open.
6.6.3        Apply mains voltage to the UPS input and record:
R - Y………………. R - N ………………….
R - B………………. Y - N …………………
B - Y………………. B – N …………………
6.6.4        Make sure that the recorded input voltage is within the limit of the UPS.
6.6.5        Measure the overall battery voltage from the battery cabinet to the UPS and make a
record of it.
6.6.6        Close reserve input breaker or switch inside the UPS and wait for a while for the
UPS to display the absence of battery & output.
6.6.7        Close fuses in the battery cabinet.
6.6.8        Close battery fuse holder in the UPS.
6.6.9        Close UPS output breaker or switch and now the UPS displays Normal Operation.
6.6.10    Make sure that the SWMB switch in the UPS is always kept open under Normal
operation.
6.6.11    Initiate the battery test manually via the Mimic panel for checking the healthiness of
the battery.
6.6.12    Check that the UPS is upgraded with the latest version of the firmware.

6.7 UPS function Tests: (Refer Functional & Commissioning Report)

6.7.1        Make sure that batteries are fully charged before commencement of test.
6.7.2        Simulate a power black – out by switching off the Input supply and verify that the
inverter will run on batteries without any interruption.
6.7.3        Make sure the presence of Mains failure alarm in the Mimic Panel.
6.7.4        Re- close the input supply.
6.7.5        Verify that the loads are transferred to bypass temporarily and then to Input
displaying Normal operation.
6.8 Performance Test: (Refer Performance Test Procedure)
Carry out the following actions in the UPS:
6.8.1        Load test
6.8.2        Battery discharge test
6.8.3        Integration of UPS with BMS 
6.9 Final Assembly:
6.9.1        Shut down the ups and open the input/bypass breakers or switches and battery
fuses
6.9.2        Wait to allow the DC bus bar to fully discharge the Voltage
6.9.3        Carry out a final visual examination to verify that any connections disturbed during
commissioning are correctly refitted.
6.9.4        Fit the ups panels
6.9.5        The machine is now commissioned and can be put into service as required. Where
possible turn the ups on and leave it running for several hours before connecting the
load. This allows the battery to charge fully and assures that full autonomy will be
available if the ups is called to operate on battery.

6.10 Integrity of mechanical and electrical connections

The assembly of electrical modules like, Inverter capacitors, output isolation

transformer,
IGBT module assembly, rectifier module assembly, module control cards & fuse
holders/switch assembly shall be visually checked for its firmness/arrangement
within the
enclosure.
The electrical connections of the above assemblies shall be firm & tight without any
loose
connections.
Procedure:
 Check that the following
6.10.1    Cables / wires are dressed properly and neatly arranged / bundled. Cabling & wiring
6.10.2    form the origin to termination
6.10.3    Wiring interconnection terminations in the power modules are protected
6.10.4    The safety earth networks within the UPS panel. Check that the safety earth
networks are terminated at two or more studs.
6.10.5    The external signal terminations.
6.10.6    The internal mounting arrangements of all components.

S.No Check Result

1 All wiring and terminations to client access are as per the drawings.
2 All power cables are of stranded copper conductors adequately sized as
per UPS system rating.
3 Each enclosure and enclosure group are to be provided with safety earth networks
within the enclosure. Each earth network is terminated at earth strip (provided at
bottom) through copper cables.
4 The external signal terminations for remote alarms are provided through 15 pin D-type
connectors.

6.11 Component type & labeling verification

The installed equipments & its upstream/downstream arrangements are clearly
identified
with an external labeling, visualizing the connected components of its own range. In
case of
shared downstream output distribution network, the identification of individual UPS
tapping
shall be clearly categorized.
Procedure:
Check the following
6.11.1    Labeling is done on all the enclosures
6.11.2    Labeling on the upstream/downstream of the UPS are reflecting its nature. (i.e., Sub
enclosure located at downstream of UPS are clearly identified)
S. No Check Result
1 Labeling on enclosures are marked on the front fascia of the enclosures

6.12 Ratings of installed components

The switches/fuses/breakers, those are connected internally to the UPS & as well as
external for distribution, are in accordance with the rating of the UPS system.
Procedure:
Check the following
6.12.1    The switches/fuses of the UPS’s are rated as per the specified
6.12.2    Input / output power cable are sized to carry the designed load
6.12.3    The UPS stream breakers installed are set to carry the current that UPS will incur during its
permissible overload condition.
6.12.4    The downstream breaker ratings are selected & installed in accordance to the load
connected
6.12.5    External maintenance bypass switch ratings are equivalent to the UPS ratings.
S. No Check Result
1 All the ratings of the components installed & connected shall be sized
in sequence to its distribution with a permissible tolerance to sustain
the overload
 6.12.6    Light Load test
This test is carried out to verify that the UPS switch is correctly connected and all
manual/automatic functions operate properly. It is also to verify the operation of in-built alarm
& communication status availability. The load applied is limited for economic reasons to a
percentage of rated value.
The following points should be checked
a)          Output voltage and frequency and the correct operation of LCD panel;
b)          Operation of all control switches, meters and other means to put units into operation;
Procedure:
6.12.7                  The UPS is loaded lightly up to about 25% load.
6.12.8                  Check the operation of all MCB, Isolators & control switches.
6.12.9                  Measure the UPS parameters such as Output voltage, frequency & other analog values.
6.12.10              Monitor and record the various display messages, measurement values of UPS
parameters, alarm messages etc for correctness, by simulating fault conditions.
6.12.11              Refer the various alarm messages as per enclosed list.
6.12.12              Check and record the various parameters programmed /set at factory, through control and
display panel
S. No Check Result
1 The proper operation of UPS system with respect to all functions and
parameters are ensured before loading the UPS system to its full
capacity. The output voltage is 400V+ 2% and output frequency is
50 + 0.05% Hz.

6.13 Analog signals
S. No Check Result
1 AC input voltage (each phase of AC Mains input to UPS & Static
Bypass)
2 AC input current (each phase of AC Mains input to UPS & Static
Bypass)
3 AC output voltage (each phase of AC output of UPS inverter/Static
Bypass)
4 AC output current (each phase of AC output of UPS inverter/Static
Bypass)
5 AC input Mains frequency
6 AC UPS inverter output frequency
7 DC voltage (of Battery system)

6.14 Status signals
S. No Check Result
1 Static bypass Switch positions (given by corresponding LED
indication on display panel)
2 Inverter running in synchronized/free running mode (appears as
”Normal operation” for synchronized mode and “disturbances on
3 bypass line/ bypass volt fail or SWBY, FSCR off display” for free
running
mode on LCD panel)
4 Other status signals as per standard design.

6.15 Alarm signals
S. No Check Result
1 Battery Low voltage alarm (appears as “pre-alarm, low voltage on
 battery”)
2 Loss of input power (appears as “main line voltage fail or SWIN off”)
3 Loss of output power (appears as “output off, close SWOUT or
SWMB”)
4 Other alarm signals as per standard design.

6.16 AC Input Failure Test

The test is performed with a charged battery and is carried out by tripping input circuit
breakers or may be simulated by switching off all UPS rectifiers and bypass feeders at the
same time. Output voltage variations are to be checked for specified limit.
Procedure:
6.16.1                  The UPS is switched-on to full load with charged batteries.
6.16.2                  Any phase of the output voltage is continuously monitored.
6.16.3                  The Rectifier/Charger is switched off by switching off the Input isolator of the UPS system.
6.16.4                  The load is supplied by the inverter through the batteries without interruption of supply to
the load.
6.16.5                  The output frequency and the rate of change of frequency is noted when the UPS
operation shifts to battery mode when the Mains fail. (That is the transition from the bypass-
synchronized frequency to the inverter
S. No Check Result
1 The output voltage should be steady without any break when the
rectifier/charger is off and batteries starts supplying power to the
load. The output voltage variation shall be less than +/-2%.

6.17 AC Input Return Test

A.C. input return test is performed by restoring the AC input power, or simulated by
switching on rectifier and bypass feeder at the same time.
Proper operation of UPS rectifiers shall be measured. Output voltage and frequency
variations are to be observed.
Procedure:
6.17.1                  This test can be performed after the AC Input Failure Test, that is, when the UPS is on
6.17.2                  battery mode (batteries to be in partially charged or fully charged condition).
6.17.3                  The output voltage waveform of the UPS system is to be monitored.
6.17.4                  The rectifier is switched on by switching on the UPS Input MCB.
6.17.5                  The rectifier will take on the load and continue to charge the batteries.
6.17.6                  The output voltage is monitored for no break during the period the rectifier is back in
6.17.7                  service.
6.17.8                  On switching on the Bypass switch, the output frequency will follow the bypass frequency, provided
the same is within tolerance.
S. No Check Result
1 The output voltage should be steady without any break in output voltage, when the
rectifier/charger is back in service. The output voltage variation shall be < +/- 2%. The
output frequency shall follow the bypass frequency, provided the same is within
tolerance of 50 Hz +/- 5%.

Full Load Test

Load tests are performed by connecting a resistive load (full load) or the actual connected
load to the UPS output. In case of load less than the rated, the results shall be calculated by
appropriate substitution of specified rating. Load tests are necessary for testing output
voltage and frequency, temperature rise. Load tests are performed to prove transient
voltage deviations specified under step load conditions. Output voltage & current harmonics
with the actual load shall be measured.
Procedure:
6.17.9                  UPS system is loaded to actual load, that is, 100% rated load. If the actual load is >100% of its rated
load, then the appropriate values in the specification shall be referred.
6.17.10              The UPS parameters such as steady state output voltage, frequency, power factor, output power,
input voltage, input frequency, input power etc. are recorded during the test.
S. No Check Result
1 The operation of the UPS system at full load (actual load) is checked for proper
operation. The measured values are checked against the specified limits & its
tolerance.

Simulation of Parallel Redundant UPS fault

Description & Aim of the Test:
This test shall be required for UPS incorporating parallel redundancy. The test shall be conducted with
rated load applied to both the UPS and failure is simulated on one of the unit. During this time the
redundant unit running healthy shall take up the entire load of the other without any interruption at the
output.
Procedure:
6.17.11              Initially both the UPS systems will supply the full load, as per specifications, sharing the full load
equally. (That is, each UPS system will supply 50% load. The output current and voltage waveform is
recorded.)
6.17.12              The Output Isolator of Inverter of UPS 1 is switched off. The load on inverter of UPS 1 will be
transferred to the inverter of UPS 2 without an interruption of power to the load. (The inverter of UPS
2 will then take on the full load of both the inverters).
6.17.13              The Output Isolator of UPS 1 is switched on. The load is immediately shared between the two UPS
units, without any interruption of power to the load.
6.17.14              The Output Isolator of Inverter of UPS 2 is switched off. The load on inverter of UPS 2 will be
transferred to the inverter of UPS 1 without any interruption of power to the load. (The inverter of UPS
1 will then take on the full load of both the inverters)
6.17.15              The Output Isolator of UPS 2 is switched on. The load is immediately shared between the two UPS
units, without any interruption of power to the load.
S. No Check Result
1 The operations should be satisfactory without any interruption of power to the load
for all the above conditions.

Rated Stored Energy Time (Battery Discharge Test)

Description & Aim of the Test:
This test is a load test to prove the actual possible time of battery operation.
Discharge time with rated load shall then be calculated. The test shall be performed with a fully
charged battery. Active power output of the UPS and the battery voltage shall be recorded during the
test.
Since new batteries often do not provide full capacity during a starting-up period, the discharge test
may be repeated after a reasonable recharge time if the original test has failed.
Procedure:
6.17.16              The UPS is loaded to full load (100% rated) or actual load with batteries fully charged.
6.17.17              The Input Isolator of Rectifier of UPS is switched off.
6.17.18              The battery starts discharging and supplying power to load through the inverter.
6.17.19              Active power output of the UPS and battery voltage is recorded during the test.
6.17.20              The battery backup time is monitored and recorded.
6.17.21              The battery should disconnect automatically from the UPS after the reach of end cell
6.17.22              voltage.
S. No Check Result
1 The back-up duration shall be ____ minutes for the specified project load or
appropriate if the actual load is <100%.

Restart Test
Automatic or other restart means are to be tested after a complete shutdown of UPS
Procedure:
6.17.23              To simulate a complete shutdown of the UPS, the upstream input breaker to UPS is switched off.
6.17.24              The UPS load is fed by the batteries.
6.17.25              The batteries are disconnected.
6.17.26              The UPS will automatically shutdown.
6.17.27              The input switch of the Rectifier of the UPS and input switch of static bypass is switched On.
S. No Check Result
1 The UPS should automatically restart after a complete shutdown.

6.18 Safety

6.18.1    All appropriate safety personal protective equipment shall be worn by workmen

such as Helmet, cover all clothing, safety shoes, goggles and gloves whenever
required.
6.18.2    Only approved scaffoldings and safety belts can be used on high level works.
6.18.3    All works will be done with the presence of safety officers.

7.0      ATTACHMENT

a)       ITR Battery Discharge Test

b)      ITR Enclosure Interior Test
c)       ITR Full Load Test
d)      Light Load Test
e)      Panel Messages and Measurement Report
f)        Pre-Commissioning Checklist
g)       Pre-Commissioning T&C Report
h)      UPS Load Test Procedure
i)        Risk Assessment