Check List - Inspection for AC UPS

Form: PEC-BMS-EN-FRM-E-0548 Rev 0

Notes:
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 Points

1.0

GENERAL

1.1

"Inspection Check List- Preambles"(Document No: PEC-BMS-EN-FRM-E-0540) checked for general guidelines.

1.2

Dwgs/ 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:
-

Checker

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 60146-2

2.0

DESIGN, VISUAL & GENERAL ARRANGEMENT INSPECTION

2.1

Visual GA & Dimensional Checks:

2.1.1 Check for surface finish/ painting (shade and thickness per PO), uniformity of shade across panels.
2.1.2 Check if the overall and shipping section dimensions are as per approved drawings.
2.1.3 Check floor plan, fixing arrangement & gland plate dimension for cables are as per approved drgs.
2.1.4 Check nameplate, rating plate, mimic diagram, component & warning labels as per approved documents.
2.1.5 Verify adherence to IP rating and gaskets provided to maintain the IP ratings.
2.1.6 Check the assembly of components on the panel front door and inside the panel as per approved drawings.
2.1.7 Check alignment of the doors and shall be without any sag.
2.1.8 Check component labels in line with agreed tagging philosophy for both front door and inside components.
2.1.9 Check terminals and terminal block arrangement and its identification against approved drawings.
2.1.10 Check the colour and size of internal wiring against PO specifications.
2.1.11 Check wire identification (ferrules/ tagging) against termination drawings & ferrules/ lugs as per spec.
2.1.12

Check 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.

2.1.13 Check that no more than one wire is terminated in any terminal and wires are properly terminated.
2.1.14 Ensure that all components are easily accessible with enough space for maintenance.
2.1.15 Check that shrouds are provided for all accessible live parts.
2.1.16 Check cubicle lighting operated through door switches, if shown in drawing.
2.1.17 Check for panel front door grounding and earthing points for the UPS.
2.1.18 Check earth bus size and external earthing terminals against drawings.
2.1.19 Check tin-plating is provided for earth busbar, if specified.
2.1.20 Check for drawing pockets / document holder on the rear side of panel door.
2.2

Cable Termination Checks:

2.2.1 Check space for easy termination of specified incoming & outgoing cables & in particular battery cables.
2.2.2 Check power terminals size for its adequacy to accept specified number / size of cables.
2.2.3 Check cable termination arrangement including termination height from gland plate.
2.2.4 Check gland plate material & verify the thickness of gland plate( 3/4mm thick) for proper glanding.
2.2.5 Check gland plates are removable and supplied undrilled.
2.2.6 Check the provision of safety shrouds to prevent inadvertent contact with cable side live terminals.
2.2.7 Check that cables after termination do not affect accessibility of components from front (if front access).
2.3

Bill of Material Checks:

2.3.1

Check 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.

2.4

Checks on auxiliary devices & component rating verification:

2.4.1 Check anticondensation heater location, rating incl. watts, voltage. Check heater control (Thermostat).
2.4.2 Check functioning of the cubicle lighting circuit (if cubicle lighting is indicated in drg.)
2.4.3 Check the rating of the fuse, MCCB, MCB's etc., as per approved drg.
2.4.4 Check number of outgoing feeders in the UPS distribution board as per SLD (if in vendor scope).
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Petrofac E & C
Business Management System
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Sr. No.

Check Points

2.4.5

Check 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.

2.5

Checks on Battery Isolation Switch Enclosure:

Checker

2.5.1 Verify hazardous area certification for battery isolation box & ensure certificate number is marked on it.
2.5.2 Check material (Cast Iron / Cast Aluminium) of battery isolation box against PO spec / approved drawings.
2.5.3

Check 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.

2.5.4

Check 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).

2.5.5 Check space inside isolation switch for termination of battery cables, considering the no. & size of cables.
2.5.6 Check if cable entry (top/ bottom), no. of cable entries and cable entry sizes as per approved drawings.
2.5.7 Check if cable entries are provided with Ex-d plugs (if specified) & verify material of the plugs.
2.5.8 Verify with a sample cable gland if all threads fully engage in the entries provided on the enclosure.
2.6

Checks on Battery Racks / Cells:

2.6.1 Check rack BOQ w.r.t drawings (If rack material is in packed condition then verify packing list w.r.t BOQ).
2.6.2 Review Internal test report furnished by battery vendor (not applicable if battery dispatch in dry condition).
2.6.3

Check if batteries are dispatched in electrolyte filled, charged and then discharged condition (to increase the
storage time at site), as specified in PO specifications.

3.0

TESTS: (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.

3.1

ROUTINE TEST:

3.1.1 Insulation 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.
3.1.2 Light 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.
3.1.3 Functional test (IEC 60146-1-1; Cl - 4.2.2.2 and IEC 62040-3; Cl - 6.6.6 to 6.6.10)
3.1.3.1 Verify functioning of the control / protective devices, alarms & signaling devices (lamps / mimic displays)
3.1.3.2 Check the output voltage variations by simulating an AC Input failure condition (IEC 62040-3; Cl - 6.6.6)
3.1.3.3 Check the output voltage variations by simulating an AC Input return condition (IEC 62040-3; Cl - 6.6.7)
Check 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).
3.1.3.4
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).
3.1.3.5

Verify 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.

Check 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).
3.1.3.6 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.
3.1.4 Check Aux. devices; control equipment; protective devices (IEC 60146-1-1 Cl 4.2.7; 4.2.9; 4.2.10)
3.1.4.1 Verify the wiring and functioning of auxiliary and control circuit based on approved schematics.
3.1.4.2

Check proper functioning of control components and indicators e.g., Push buttons, selector switches,
indication lamps, MCB, auxiliary relays etc., in line with approved schematics.

3.1.4.3 Verify functioning of mimic panel / LCD display unit according to specification.
3.1.4.4 Verify functioning of the communication channels with the remote control system.
3.1.4.5 Check if the protocol used for remote communication is as per the specification. (if specified).
3.1.4.6 Check communication port based on medium of communication (RS 485 / fiber optic port) is as specified.
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Petrofac E & C
Business Management System
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Check Points

3.1.4.7

Check 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.

3.1.4.8

Check 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.

3.2

Checker

TYPE TEST: (to be conducted, if specified in PO / ITP)

3.2.1 Perform Input Voltage & frequency tolerance test as per IEC 62040-3 Cl 6.3.2
3.2.2 Perform Input Inrush current test as per IEC 62040-3 Cl 6.3.3
3.2.3 Measure the DC Components in the Output; the values shall be as specified in IEC 62040-3 Cl 6.3.4.6
3.2.4 Perform UPS Dynamic Stability tests (as listed below) as per IEC 62040-3 Cl 6.3.6 / 7 / 8:
Record the transient performance of the output voltage waveform for a Change of operating mode (from
3.2.4.1 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.
3.2.4.2

Record 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.

Record the transient performance of the output voltage waveform for a Change of operating mode (from
3.2.4.3 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.
3.2.4.4

Record 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.

Perform 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)
3.2.4.5 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.
Measure the outut voltage waveform and its fundamental & harmonic content under steady state conditions
3.2.4.6 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.
Measure the outut voltage waveform and its fundamental & harmonic content during the transition of UPS
3.2.4.7 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.
3.2.4.8

Repeat 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.

For 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.
3.2.4.9
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.
3.3

OPTIONAL TEST: (to be conducted, if specified in PO / ITP)

Perform Synchronization test by synchronizing the UPS output to an external source (i.e. bypass) as per IEC
3.3.1 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.
3.3.2 Perform UPS efficiency test as per IEC 62040-3 Cl 6.6.11
3.3.3 Check Battery ripple current as per IEC 62040-3 Cl 6.6.17
3.3.4 Verify UPS Overload capability test as per IEC 62040-3 Cl 6.6.18
3.3.5 Verify Short Circuit Test & Protection device test as per IEC 62040-3 Cl 6.6.19 & 6.6.20
3.3.6

Perform 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.

3.3.7 Check operation of overvoltage devices by simulating UPS output overvoltage as per IEC 62040-3 Cl 6.6.22
Perform Output voltage variation test at various load conditions (0%, 25%, 50%, 100%) and operating
3.3.8 conditions (nominal, min. & max. input voltage) as per IEC 62040-3 Cl 6.6.23. Verify the output voltage
regulation at all conditions.
3.3.9

Measure the Harmonic Component of input voltage & current (THD) under rated linear load condition as per
IEC 62040-3 Cl 6.6.26.

3.3.10 Conduct Earth fault test on UPS & measure UPS output transients as per IEC 62040-3 Cl 6.6.27.
3.3.11 Perform Audible noise test on UPS system as specified in IEC 62040-3 Cl 7.3.
3.3.12

Verify 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)

3.3.13

Verify 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)

4.0

PUNCH LIST POINTS:-

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Petrofac E & C
Business Management System
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Sr. No.

4.1

Check Points

Checker

Check 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.
Name

Date

Checker
Approver

_____________________________ _______________________________________________________ _____________________________

Petrofac E & C
Business Management System
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