Description & Procedure for Charging the UPS Panels of DB Electronics make:

30 KVA, 3 Phase/1 Phase UPS System was supplied by M/S DB Electronics Private Limited for M/S Indorama Synthetics Private Limited, Butibori, Nagpur - Maha Rashtra State for their 2 x 15 MW Coal Fired Thermal Power Plant. This is a Co-generation Power plant installed for their Synthetic Rayon Industry supplying electrical power and also the process steam required for the industry. This UPS system was commissioned during the year 2006. Here it is to be noted that 30 KVA Capacity UPS was chosen for a Power Plant of 2 x 15 MW Capacity. The following equipment panels are available for the 30 KVA UPS Systems: 1) UPS 1 30 KVA Capacity. 2) UPS 2 30 KVA Capacity. 3) SCVS & ACDB 30 KVA Capacities. 4) Cable Alley attached to the UPS Panels. 5) 200 AH Battery Banks 2nos (One for each UPS Panel). Purpose of the UPS System: To supply quality AC Power supply for the DCS Panels, Electronic Controllers, Plant Control Monitors in the Control Room, for the Engineering Room through which the total control logic circuits were installed for conducting all Plant Operations, for the Turbo Supervisory Panels, AVR panels, Local Turbo Supervisory Panel, for the Barring Gear Motor local panel, for the hooter in the control room, for the SWAS Electronic Panels showing the analyzers out put and also for the Large Video Screens erected in the Control Room etc. The following cables are required for commissioning the UPS System: a) 3 Core - 3 Phase AC Power supply cables to be laid from the AC Distribution Board in the Switch Gear Room to the UPS Panels 3nos. (One each for the UPS1 , UPS2, & for the SVDC Panel). b) Two Core - 1 Phase AC Power supply output cables from the SCVS Panels to the static bypass manual switch of UPS Panels 1 & 2 2 nos. c) Two Core - 1 Phase AC Power supply cables from the output switch of UPS Panels 1 & 2 to the Cable Alley Chamber 2 nos. 1

d) Two Core - 1 Phase AC Power output supply cables from the common output terminals in the Cable Alley chamber to the 100 A Main in the ACDB on the rear side of the SCVS & ACDB Panel. e) Two Core 1 Phase AC Power supply cable to the 100 amps main in the UPS supply Distribution Board of BJD 01 Panel. f) The UPS supply will be distributed to various DCS Panels through MCCBs on the front side of the BJD01 Panel (Main Panel for UPS power supply for all the DCS Panels and for other special purposes. g) Further Single Core Stranded Copper cables are required for the following purposes: a) For connecting the UPS 1 to the Battery 1 2 Cables b) For connecting the UPS 1 to the Battery 1 2 Cables c) For the Body - Earth connection of UPS Panels to the Electronic Earth Pit 2 Cables. d) For the Body - Earth connection of the UPS supply Distribution Board BJD 01 to the Electronic Earth Pit 2 Cables. All the above AC Power Supply cables from the Switch Gear Room to the UPS panels, the inter panel AC Power cables and the Stranded Copper cables from the UPS 1 & 2 to the Battery Banks, from the UPS Panel Body to the Electronic Earth Pit and from the UPS Distribution Board Panel Body to the Electronic Earth Pit are to be connected as shown in the following sketches, showing the location details of Input & output terminals and the various switches available in the UPS Panels.

VOLTS 3 AC INPUT VOLTMETER AMMETER

MIMIC PT

SELECTOR SWITCH FOR VOLTMETER

SCVS & ACDB

UPS - 1
I O I O

UPS - 2

CABLE ALLEY

3 AC INPUT TO MAIN SWITCH

OUTPUT CONTACTOR

OUTPUT STATIC 3 AC FROM I/P MAIN BATTERY SWITCH BYPASS SWITCH SWITCH BANK 1 (MANUAL)

OUTPUT STATIC 3 AC FROM I/P MAIN BATTERY SWITCH BYPASS SWITCH SWITCH BANK 2 (MANUAL)

UPS 1 OUTPUT

UPS 2 OUTPUT

TOTAL OUTPUT

FRONT ELEVATION OF UPS PANELS WITH DOORS OPEN

END VIEW OF UPS PANELS

SCVS & ACDB

1 TO 11 MCB

CABLE ALLEY

UPS - 2

UPS - 1
1 TO 4 MCB

ACDB TOTAL 15 NOS MCBs

BYPASS SUPPLY I/P FROM SVCS

I/P 3 UPS-2 TO O/P TO BATTERY AC FROM CABLE BANK2 FROM MCC ALLEY UPS-2

UPS-1 BYPASS SUPPLY I/P O/P TO FROM SCVS CABLE ALLEY PANNEL

BATTERY-1 3 AC I/P FROM I/P TO UPS-1 MCC

100A MAIN I/P ACDB FROM TOTAL O/P TERMINALS OF CABLE ALLEY

REAR SIDE OF UPS PANELS WITH DOORS OPEN

3 Phase Input Power supply & 1 phase output power supply details of the UPS System: 3 Ph AC Input supply 1 Ph AC Output Supply From the Feeder No: 12 of ACDB To the rear side terminals of UPS 1 & 2 For SCVS & ACDB Panel In the 3.0 Mts MCC Room as a standby supply when the UPS fails From the Feeder No: 5 of ACDB From the output switch of the For UPS 1 Panel In the 3.0 Mts MCC Room UPS 1 Panel to the Cable Alley From the Feeder No: 6 of ACDB From the output switch of the For UPS 2 Panel In the 3.0 Mts MCC Room UPS 2 Panel to the Cable Alley Description

SCVS & ACDB

UPS - 1

UPS - 2

CABLE ALLEY

3 AC I/P MAIN SWITCH

TO BATTERY 1

TO BATTERY 2

TO CABLE ALLEY

FRONT SIDE OF UPS PANELS WITH DOORS OPEN

After completion of all cable connections, 1) Their continuity shall be checked along with the termination correctness.

2) All cables, the UPS Panels and also the UPS Distribution Board BJD 01 shall be checked for their Insulation Resistance values. 3) All Earth connecting cables shall be checked for their continuity. 4) Earth Resistance of the Electronic Earth Pits shall be checked for individual pits and also for the combination of the earth pits and recorded. These earth resistance values shall be less than the specified values or otherwise some more number of earth pits are to be established and inter connected to bring down the combined earth resistance of the electronic pits under subject. Functional concept of the UPS System: It is a 3 Ph AC input/1 Ph AC output UPS System of 30 KVA capacities i.e. UPS 1, UPS 2 & SCVS with ACDB, all are designed for 30 KVA capacities. It contains one stabilizer panel called SCVS Panel which converts the input AC supply into DC supply and delivers to the Battery Banks 1 & 2 of the UPS 1 & UPS 2 respectively with all charger functions. The SCVS Panel supplies the standby 1 Ph AC supply to UPS 1 & 2. It has got one ACDB also on its rear side with one number 100 Amps Main Switch and 15 nos of MCBs as UPS feeders. The 100 Amps Main Switch receives the 1 Ph AC from the total out put terminals of the Cable Alley. When the 3 Ph AC input main switch is closed, its output contactor closes in auto and starts delivering the DC supply to the Battery Banks 1 & 2 and the strand by AC supply through the UPS Panels I & II. UPS 1 & UPS 2 will share the total load equally during normal conditions. In case of any failure of either of the UPS Systems the UPS which is healthy will take the entire load on to it. When once the defect of the failed UPS is rectified the load will be shared by both the UPS Panels automatically. If both the UPS Systems fail the entire load will come on to the Stabilizer Panel (SCVS Panel) through the UPS panels 1 & 2 through the built in logic circuits. In case the 3 Ph Ac supply fails to all the three panels the back up UPS Battery Banks will share the load equally through the respective UPS Panels. 4

Very Important Note: Battery to UPS supply mains shall never be opened in the UPS Panels 1 & 2 even in the even of station supply failure. Charging procedure of the UPS Panels and the simultaneous indications that can be observed on the mimic bus display on the UPS Panels: The following are to be ensured before charging the UPS Panels: All out going feeders of the ACDB on the rear side of the SCVS & ACDB Panel shall be kept in OFF position including the 100 Amps Main Switch to the BJD 01 of the UPS Panels. The 100 Amps Main Switch provided on the other end of the main UPS supply cable in the BJD 01 also shall be kept opened.

5 3 AC I/P FOR BYPASS

1 3 AC I/P FOR UPS

3 TO LOAD

BATTERY

7 +

TWO BANKS OF 180 CELLS EACH

CHARGING OPERATIONS/OBSERVATIONS ON THE MIMIC DISPLAY

------ Flashing LED indicates fault condition.To reset press ON switch for two seconds LED 1 2 3 4 5 Functions Input o Inverter Load on Inverter Load on Bypass Bypass ok 5

6 7 Charging Procedure of the UPS Panels:

Load on manual Bypass Load on battery

1) Switch on the 3 Ph AC input supplies to UPS 1, UPS 2 & SCVS Panels from the AC Distribution Board in the 3.0 Mts MCC Room. 2) Check up the mimic bus on the UPS Panels and identify the status of the various LEDs to appear as described here below: LEDs 1, 2, 5 & 7: LEDs 3 & 6: LED 4 (Static Bypass): They will be flickering. They will not glow indicating OFF status. It will glow indicating ON status.

The status of the above LEDs can be interpreted as described here below: Since the input supplies are not switched ON for all the three panels, only the mimic bus system is getting the supply and hence exhibiting the following status: Since the UPS 1 & UPS 2 are not in service the auto static bypass switch which will be in auto logic has got closed and hence the LED 4 is ON. 3) Check up the 3 Ph AC input voltages for the UPS 1, UPS 2 & SCVS Panels and note the same. Panel UPS 1 UPS 2 SCVS (Stabilizer) R-Y 415 V 413 V 417 V Y- B 413 V 414 V 417 V BR 412 V 412 V 412 V

4) Switch ON the input main for the UPS 1 and check up the LEDs on the mimic bus. It shall be as detailed below: LEDs 1, 2 & 3: They will be glowing i.e. ON status indicating that the UPS 1 is made through and the 230 Volts UPS supply is available at the total out put terminals in the Cable Alley. LEDs 5 & 7: They will be flickering indicating that the input supplies are not switched ON for the bypass supply and for the Battery Bank. LEDs 4 & 6: They will not glow i.e. OFF status indicating that the static bypass and manual; bypass are in OFF position.

The status of the above LEDs can be interpreted as described here below: Since the UPS 1 is in service there is no necessity of the auto static bypass switch to assume the ON position or the manual static bypass switch to be switched ON. 5) Switch ON the input main for the UPS 2 and check up the LEDs on the mimic bus. It shall be as detailed below: LEDs 1, 2 & 3: They will be glowing i.e. ON status indicating that the UPS 1 is made through and the 230 Volts UPS supply is available at the total out put terminals in the Cable Alley. LEDs 5 & 7: They will be flickering indicating that the input supplies are not switched ON for the bypass supply and for the Battery Bank. LEDs 4 & 6: They will not glow i.e. OFF status indicating that the static bypass and manual; bypass are in OFF position. The status of the above LEDs can be interpreted as described here below: Since the UPS 2 is in service there is no necessity of the auto static bypass switch to assume the ON position or the manual static bypass switch to be switched ON. 6) Switch on the out put switches of UPS 1 & UPS 2 and check up the out put voltages at the UPS 1, UPS 2 and the total out put terminals in the Cable Alley. Phase to Neutral: Phase to Earth: Neutral to Earth: 240 V 240 V 0.1 V

7) Check up the Battery voltages and the UPS out put voltages on the rear side of the UPS Panel 1 & UPS Panel 2. Panel UPS 1 UPS 2 Battery -1 Voltage 385 V 385 V UPS out put Voltage 240 V 240 V

Then switch ON the Battery Supply input main switches in the UPS Panels 1 & 2 and check up the Battery voltage and the charging current on the Electronic Display unit and note the same. Description Battery Bank 1 Battery Bank 2 DC Volts 405 V 420 V Charging Current 3 Amps 8 Amps 7

After switching ON the Battery Input Mains in the UPS Panels, check up the status of the LEDs on the mimic buses of UPS Panels 1 & 2. The status of the LEDs shall be as detailed below: LEDs 1, 2 & 3: LED 5: LEDs 4, 6 & 7: ON This is OK because the UPS is charged. Flickering- since the 3 Phase AC input supply is not switched ON OFF- This is also OK because the automatic static bypass the manual bypass will not be assuming the ON status as long as UPS 1 & UPS 2 are in service i.e. LEDs 4 & 6 will be OFF. Further the LED 7 also will be in OFF position because the Battery will not supply the load as long as the UPS 1 & UPS 2 is in service. 8) Switch ON the 3 Phase AC input supply main in the SCVS (Stabilizer) Panel and check up the out put voltage to be 240 Volts. 9) Check up the status of LEDs on the mimic bus of the UPS Panels 1 & 2. The status shall be as detailed below: LEDs 1, 2, 3 & 5: ON This is OK because the UPS 1, UPS 2 & SCVS Panel are in service. LEDs 4, 6 & 7: OFF This is also OK because the automatic static bypass the manual bypass will not be assuming the ON status as long as UPS 1 & UPS 2 are in service i.e. LEDs 4 & 6 will be OFF. Further the LED 7 also will be in OFF position because the Battery will not supply the load as long as the UPS 1 & UPS 2 is in service. 10) Check up the bypass voltages in the UPS Panel 1 & UPS Panel 2 to be 240 Volts and also the total out put UPS voltage in the ACDB to be 240 Volts. Now the UPS System can be declared as available on AC mode for full load operation. Procedure to put the UPS in Battery mode: 1) Switch OFF the 3 Phase AC input supply to UPS 1, thus the UPS loads are transferred to Battery 1 2) Check up the status of the LEDs on the mimic bus of UPS panel. It shall be as detailed below: LED 1: LEDs 2, 3, 5 & 7: Flickering since the input supply main is kept switched OFF ON- This is OK because the Battery is feeding the loads through the circuit 7 2 3 paths and also because the SCVS is kept switched ON. LEDs 4 & 6: OFF This is OK since the automatic static bypass 4 and the manual bypass 6 are not in service. 8

Special Note: The static bypass switch comes into service in auto when the input supply fails to UPS 1 & UPS 2. Its status is not shown on the mimic bus. Procedure to put the UPS on Static Bypass Operation: 1) In the event of failure of the inverter (LED 2), load gets transferred to Static Bypass LED 4 automatically. 2) To put the load on the Static Bypass (LED 4) when the inverter is ON change the Force Transfer Switch (S 4) from Inverter to Static Bypass position (Available on the rear side of the front door).Then the load gets connected to the Static Bypass. Procedure to put the UPS on Manual Bypass Operation: 1) Change the Force Transfer to bypass switch (s 4) from Inverter to Static Bypass position. 2) Switch ON the bypass switch to manual bypass position. 3) Then switch OFF the out put switch of the UPS. Then the load gets connected to the Manual Bypass. Procedure to shut down the UPS System 1) Switch OFF the out put switch. 2) Switch OFF the bypass supply in the SCVS Panel. 3) Switch OFF the battery breaker. 4) Switch OFF the 3 Phase AC input main on the front side of the UPS Panel. 5) Switch OFF the 3 Phase incoming supply to all the UPS Panels in the 3.0 Mts MCC Room. 6) Note: 1) Press reset switch to reset the inverter fault. 2) The load will be supplied with the UPS power as soon as the AC input power supply is switched ON even if no LEDs are ON when the load is on standby supply. Purpose of the Manual Bypass: This feature is intended for the maintenance facility for the UPS System by transferring the load to bypass mode manually.

DOs & DONTs: DOs: If the system trips due to out put under voltage or over voltage, press the RESET switch on the front panel before restarting the system i.e. (1) Green Switch for ON. DONTs: Do not operate the Battery switch, if the charger out put voltage is not available or the input AC supply is not available. Acceptance Tests to be conducted at site after commissioning the UPS: 1) Load test shall be conducted in the presence of the Company Commissioning Engineer by connecting a temporary Load. Each UPS System shall be loaded to its full load current and the observations shall be recorded. 2) Procedure dictated to put the UPS in Battery mode shall be tried and verified. 3) Procedure dictated for the Static Bypass Operation shall be tried and verified 4) Procedure dictated for the Manual Bypass Operation shall be tried and verified. 5) Procedure dictated to shut down the UPS System shall be tried and verified. 6) The UPS system shall be kept in service again after shutting down as per the procedure. 7) The status of the LEDs at different stages of the progressive operations carried out for commissioning the UPS Systems shall be verified for the correctness of the mimic bus logic. 8) The Hooter supplied shall be tested for its function. 9) The IR values of the panel wiring, Cables measured independently as well as the combined values shall be noted systematically. 10) The individual earth resistance of the electronic earth pits and also the combined earth resistance of all electronic earth pits looped shall be recorded with proper remarks.

10

UPS System for the Ash Handling Plant PLC: There was a separate small UPS of 2000 KVA, 1 Phase AC/1 Phase AC ,Portable UPS System dedicated to the Ash Handling Plant PLC System at the 2 x 15 MW Co-generation Power Plant of M/S Indorama synthetics Private Limited, Butibori, Nagpur - Maha Rashtra State. Details of the 2000 KVA UPS: AC input voltage: 180 260 Volts AC out put voltage: 220 230 volts UPS Back up Battery Voltage: 144 Volts (12 cells of 13.5 volts each in series with a maximum voltage of 162 volts) Capacity of the Battery: VA Capacity of the Battery: 7 AH 2000 VA

On the rear side of the UPS Unit, there is one triple pole MCB with the following terminal connections:

+Ve FROM BATTERY TO INVERTER

NEUTRAL AC INPUT PHASE

Notes: 1) ve of the Battery is directly connected to the Inverter. 2) On the front side of the UPS Unit, there is one Double Pole MCB for switching on the inverter out put supply to the load circuit. 3) On the rear side of the UPS Unit two numbers of 3 pin Power sockets are provided as the UPS out put supply.

11

4) On the front side of the UPS Unit one mimic diagram is available to indicate the functional status of the UPS.

Sketch showing the UPS System with its Bypass

AC INPUT

BATTERY

INVERTER

UPS OUT 220-230V

BYPASS

Details of Power supply Source to the Ash Plant: 1 Ph AC supply was extended to the Ash Plant PLC Panel from the newly installed MCBs in the Ash Plant & Coal Plant MCC Panels located in the Ash Plant Control Room building. The following are the Terminal Details in the Ash Handling Plant PLC Cabinet: Description of cables laid AC supply for UPS from the MCC PLC Cabinet TB Details ------- To UPS mobile Unit - (3 core cable with earth lead.) ---- UPS supply to the PLC cabinet from the UPS Panel (2 Core x 4 mm sq copper cable through the 15 amps plug socket available on the rear side of the unit.) Special Notes on the Functional Concept of the dedicated UPS of the Ash Handling Plant PLC: 1) If the three pole MCB available on the rear side of the UPS Unit is switched OFF the total UPS will get switched OFF, i.e. a) AC input supply to the UPS is switched OFF & b) Battery supply to the Inverter also is switched OFF. 2) If the Double Pole MCB available on the front side of the UPS Unit is switched OFF, 12

a) The Inverter gets switched OFF & b) The input AC supply to the UPS Unit will go to the out put terminals of the UPS Unit, thus bypassing the Battery + Inverter combined circuit. Hence the Raw AC supply will be delivered directly to the out put terminals of the UPS. Tests were conducted after commissioning the UPS Unit and the following were the observations: 1) AC input voltage: 240 Volts. UPS out put voltage: 226 Volts OK

2) Discharging & Charging operations of the UPS Battery: Connected Load to the Battery: 400 W sodium Vapour lamp. Time Battery UPS out put Load % Observed Battery Level Hrs - Mts Voltage Voltage Current (Amps) Load Level 15 40 146 V 224 V 1.99 20 % - One LED 100 % - Five LEDs 16 10 142 V 223 V 1.86 20 % - One LED 80 % - Four LEDs 16 40 135 V 223 V 1.74 40 % - Two LEDs 60 % - Three LEDs

16 41 Hrs: Annunciation appeared on the UPS Panel and found that the Battery level has fallen to 40%. 16 50 Hrs: Annunciation appeared and found that the Battery level has fallen to 20 % 16 52 Hrs: Battery tripped due to low voltage condition and the glowing LED lamps also came to OFF. Note: The UPS Battery was kept under charging at 16 53 Hrs and the following were the various observations during charging operation: Time Battery UPS out put Voltage 225 V 225 V Load Current (Amps) ------141 V 225 V --% Observed Load Level

Hrs - Mts Voltage 16 55 17 00 17 05 17 15 138 V 139 V

Battery Level

20 % - one LED 60 % - Three LEDs 20 % - one LED 20 % - one LED 20 % - one LED 80 % - Four LEDs 100 % - Five LEDs 100 % - Five LEDs

The Battery Charging was continued keeping the inverter circuit in OFF condition, so as to achieve full charging of the Battery. 13