Production (Utilities) Heavy Water Plant (Manuguru) Gautaminagar - 507 116 Khammam Dist. Telangana State

PRODUCTION (UTILITIES)
HEAVY WATER PLANT (MANUGURU)

GAUTAMINAGAR – 507 116
KHAMMAM DIST.
TELANGANA STATE
OPERATION MANUAL
UNINTERRUPTED POWER SUPPLY SYSTEM

(DOC. NO. PU/III/87)
COPY NO.
Rev. No. 0.00 Date: 18.05.2015
DESCRIPTION NAME DESIGNATION SIGNATURE

A. SWARUP OM SO/D
PREPARED BY RAFIQUE AHMED SO/F
V.V. UPADHYAYA DY.PM (U)
REVIEWED BY MAHENDRA GIRI P.M (U)
APPROVED BY R.K.GUPTA D.G.M (U)
HWP–M CONTENTS Doc.No.PU/III/87/A
S.No Document No. of

Document Description
. No. pages
1. Contents PU/III/87/A 1
2. Abbreviations PU/III/87/B 1
3. Distribution list PU/III/87/C 1
4. Amendment sheet PU/III/87/D 1
5. Preface PU/III/87/E 1
6. Introduction PU/III/87/1 2
7. System Description PU/III/87/2 4

System Instrumentation, Controls &
8. PU/III/87/3 14
Logics
9. Start-up PU/III/87/4 2
10. Shutdown PU/III/87/5 1
11. Annunciations & Actions PU/III/87/6 2
12. Power Supply PU/III/87/7 3
13. Routines PU/III/87/8 1
14. Trouble Shooting PU/III/87/9 1
15. Annexure PU/III/87/10 1
16. Technical Specifications PU/III/87/10.1 3
17. Log Sheets PU/III/87/10.2 1
18. Orders to Operate (OTOs) PU/III/87/10.3 5
19. Drawings PU/III/87/10.4 4
Prepared by: Reviewed by: Approved by:
Revision No: 0.00 Date: 18.05.2015 Page 1 of 1

Doc.No.PU/III/87/
HWP–M ABBREVIATIONS B
S. No. Abbreviations Description

1. ACDB Alternating Current Distribution Board
2. AM Auxiliary Module
3. AUX Auxiliary
4. CBA Circuit Breaker Alternate
5. CBB Circuit Breaker Battery
6. CBI Circuit Breaker Input
7. CD DC link filter capacitor
8. CO capacitors Output ac filter
9. FA Fuse Alternate static switch
10. FB Fuse Battery circuit
11. FD Fuse DC link
12. LED Light Emitting Diode
13. LI Line Inductors
14. MDU Main Distribution Unit
15. MIS Module Isolator Switch
16. SCVS Servo Controlled Voltage Stabilizer
17. UPS Uninterrupted Power Supply

Doc.No.PU/III/87/
HWP–M DISTRIBUTION LIST C
0. MASTER COPY
1. Dy. GENERAL MANAGER (U) (Soft copy)
2. PRODUCTION MANAGER (U) (Hard copy)
3. TECHNICAL SERVICES MANAGER (Soft copy)
4. DY.PRODUCTION MANAGER (U) (Soft copy)
5. Dy. SHIFT SUPERINTENDENT (Hard copy)
6. LIBRARY (Soft copy)
7. HRD SECTION (Soft copy)
8. RTC FIELD STAFF OF THE UNIT (Hard copy available in Dy.SS cabin)
9. GENERAL SHIFT ENGINEERS (Soft copy)
Revision No: 0.00 Date:18.05.2015 Page 1 of 1

HWP–M AMENDMENT SHEET Doc.No.PU/III/87/D
Current
New revision
S.No Doc. Page revision
Remarks
. No. No.
No. Date No. Date
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
The copyholder shall make entry in this amendment sheet regarding the details of
amendments.
Revision No:0.00 Date:18.05.2015 Page 1 of 1

Doc.No.PU/III/871/
HWP–M PREFACE E
PREFACE
This Operation Manual has been prepared with an intention to provide
sufficient information to the Operation Personnel to guide them in operating the
system as intended. Though every effort has been made to include all details
required for operation, it may be noted that it is difficult to foresee each and every
contingency that may arise during operation of the system and no amount of written
instruction can replace an EXPERIENCED OPERATOR especially when coping-up
with unforeseen operating condition.
Standard Orders To Operate given shall be used as a GUIDANCE for
preparing final OTOs which depends on conditions of the process existing at that
time and also one may have to ascertain the conditions from field.
Sd/-
(M. SUBBARAMAIAH)

Doc.No.PU/III/871/
HWP–M INTRODUCTION 1
1.0 The Captive Power Plant, HWP (M) has Uninterrupted Power Supply
(UPS) System of 2 X 80 KVA, 110V AC, 1 phase, 50 Hz rating as the
CLASS-II power supply. These power are used for the following purposes
for Unit-1, 2, 3 and common system-
a) Control desk Operator Stations.
b) MP, NT, BMS and TG I&P CPUs and related network switches.
c) Field Analyzer panels such as On line Oxygen Analysers
d) Turbovisory Panels & SER Supervisory Station
e) Generator Relay Panels, Thyristor Panel and Annunciation.
f) TCP, BCP, GCP and Hydra step.
g) Sampling system
h) Unit Variable Frequency Drives.
i) Air compressors control system.
j) Common MP and NT CPUs
1.1 The present UPS system is commissioned due to increased class II loads.
1.2 The input power supplies for UPS system are taken from NESG, Fire
Protection MCC and DGSWGR.
1.3 For details of power circuit refer to the Drg. No-0-87-FS-01
1.4 In case of failure of UPS supply of 110V (Class-II), following system will be
affected:-
a) TG-1, 2&3 will trip on shaft vibration very high.
b) All running air compressors will trip.
c) All VFD related motors will trip.
d) Following protections of Generators will become non-functional.
1) Negative sequence
2) Rotor earth fault
3) Over fluxing protection of generator transformer
e) Hydra step will not function. Drum level protection based on hydra
step will be non functional.
f) CPUs are powered through UPS hence no information and
communication from and to system and monitors of all units will go

Doc.No.PU/III/871/
HWP–M INTRODUCTION 1
off. However system will be in service with I/O module based on field
inputs to the system.
g) SER (Sequence Event recorder) will not work.
h) All analyzers i.e., water, steam & on- line O 2 meter will not function
and will show zero value.
i) Telephonic communication (fed from UPS) will be non-functional.

HWP-M SYSTEM DESCRIPTION Doc.No.PU/IIII/87/2
Captive Power Plant, HWP (M) has Uninterrupted Power Supply (UPS) System
of 2 X 80 KVA, 110V AC, 1 phase, 50 Hz rating as the CLASS-II power supply.
2.1Components of UPS system:-
Main Distribution Unit:-This unit is a part of our installation. It distributes the
Mains (utility) and/or Generator power to our facility and supplies input power to
our UPS system.
Auxiliary Module: - An auxiliary module consisting of a Servo control Voltage
stabilizer to provide a stable alternate supply to the load incase of failure of both
UPS modules.
UPS module: - Consist of two UPS module (without battery).
Battery module: - This module comprises the battery pack for supplying power to
the UPS module in the event of a mains failure.
Output Distribution Module:- Output of the UPS system needs to be distributed to
various loads. Each module comprises switches, fuses for each load.
List of distribution modules are attached in annexure
2.2Component of an UPS system:
Auxiliary
Module
L
Mains Distribution UPS
Output
Distribution
O
Unit Module Module A
D
S
Battery
Module
Prepared By: Reviewed By: Approved By:
Revision No. 0.00 Date :18.05.2015 Page 1 of 5

2.3 UPS Module:- In CPP UPS system two UPS module are used as a parallel
redundant configuration system. Each UPS modules are having following
components:
A rectifier
An inverter
Battery
Static switch
input and output circuit breakers
Keypad-LCD-LED Mimic console
an annunciation system
Rectifier: - It converts the AC mains to regulated DC power, supplies DC power to
the inverter and charges the battery when main power supply is present.
Inverter: - It converts DC supply into frequency & voltage controlled AC supply.
Battery: - Stores energy while main supply is present. Delivers energy (DC
supply) to the inverter when main supply is absent.
Static Switch THS4 & THS5:- It is Bi-directional, solid state transfer switch.
Normally it connects the inverters output to the load through CBI, rectifier,
inverter, static switch (THS4) and MIS. Automatically it transfers the load to an
Alternate supply if both UPS fails or overload, through CB1, SCVS, CBA, static
switch (THS5) and MIS and again automatically re-transfers the load from the
alternate supply to the UPS module, once the inverters are healthy or the
overload condition has ceased.
2.4 Flow Diagram of UPS system:-

I/P O/P I/P O/P
L
AC Rectifier
DC D/C InverterA/C
O
A
D
Battery S
Bank

If both UPS modules are to be given for maintenance then 110V supply can
be extended through CB1, SCVS and by manual closing of CBO. In that case
both MIS; both CBA and both CBI must be in open condition. This can be done
parallelly or independently as per requirement.
Flow of Power: - The input supply voltage is 415V, 3-phase, 50 Hz, AC for UPS-
1, 2 and Alternate power supply (bypass) which are getting power supplies from
DGSWGR, fire protection MCC and NESWGR respectively. It is stepped down to
380V, 3 phases, 50 Hz AC in UPS-1&2 by input isolation transformer (TF1)and
415V, 3 phase to 1-phase through bypass transformer.
It is further fed to rectifiers of UPS-1 & 2 as an input for converting it from AC to

DC power. Rectified DC power is fed to inverter and also utilized to charge the
dedicated UPS battery bank .Through inverter it is again converted from DC to
AC power at approx 187V. With the help of output isolation transformer (T2) this
187V AC is further stepped down to 110V AC and supplied through static switch
(THS4) to different UPS loads.
In Alternate input of UPS system after TF1, 1PH, AC is fed to SCVS and output is
1PH, 110V AC. This 110V AC is fed to UPS loads via static switch (THS5) or via
CBO as per our requirement.

Panel and Mimic console view of UPS system:-


HWP–M SYSTEM INSTRUMENTATION Doc No. PU/III/87/3
CONTROL AND LOGICS
3.1 Instrumentation:
For monitoring the UPS performance and to recognize faulty operations,
sufficient and necessary metering is provided for all the modules of the
system.
The details of panel mounted instruments is given in Table-1
The major components used in UPS-1 & 2, auxiliary and ACDB-1, 2, 3, & 4
are given in Table-2, 3 & 4.
3.2 CONTROLS:
a) UVR stands for under Voltage Release. This prevents the static switch from
closing when there is no voltage on incoming side.
b) The DC and AC Regulators control the DC bus and UPS output voltage and
the quality. Any deviation in the parameter under control leads to prompt
opening of the static switches, thereby isolating the load fed from faulty
source.
c) For overloading, an alarm and inverse time delay logic for opening of static
switch are given. On the event of load current exceeding 100%, over load
alarm is activated. The extent of over load decides opening time as under.
125% overload - 600 sec.
150% overload - 10 sec.
300% overload - 1 cycle
d) The OVER TEMPERATURE (90 deg. C) is sensed by INVERTER heat sink
mounted Thermostats. A delay of 5 min. is incorporated before opening the
static switch of inverters.
e) A STATIC ISOLATOR DRIVE blows out the INVERTER output series fuses
when REVERSE power or any monitored ‘fuse failure’ occurs. The monitored
fuses include those which affect the output quality. The Reverse power is set
at 30% of inverter rating. Under this condition, automatic changeover to
standby mains is done provided SCVS is not inhibited.
f) When the UPS output frequency is beyond ±3% band, Output frequency error
alarm is generated.
3.3 LOGICS:
a) Opening interlocks for 110V AC Bypass Static Switch:

CONTROL AND LOGICS
Manual ‘OPEN/OFF’ command from software
and/or
Short circuit release (on dead short)
b) Condition for static bypass inhibit:
UPS & Bypass supply voltage exceed 8% amplitude difference.
and/or
UPS & Bypass supply voltage exceed 20° phase difference
and/or
Static Bypass fuse failure
e) Tripping conditions for the breakers CBI, CB1, CBA, MIS and CBB are given
for Thermal over load at maximum current of 800A.
f) Tripping condition for the breaker CBB is given for End of Battery terminal
voltage at 335V.

CONTROL AND LOGICS
Monitoring & Control:-

CONTROL AND LOGICS

CONTROL AND LOGICS

CONTROL AND LOGICS

CONTROL AND LOGICS

CONTROL AND LOGICS

CONTROL AND LOGICS

CONTROL AND LOGICS

CONTROL AND LOGICS
Table-1 Metering Details:-

S/N Description Rating Ckt. Make
Ref.
1 Input volt meter(on Aux. panel) 0-500V AC VM1 Rishabh

/Meco
2 Input current meter(on Aux. panel) 0-300A AM1 Rishabh

/Meco
3 Input Frequency meter(on Aux. panel) 45-55Hz FM1 Rishabh

/Meco
4 Output volt meter(on Aux. panel) 0-150V VM2 Rishabh

/Meco
5 Output current meter(on Aux. panel) 0-1000A AM2 Rishabh

/Meco
6 Input volt meter(on ACDB-1,2,3 & 4) 0-150V VM1 Rishabh

/Meco
7 Input current meter(on ACDB-1,2,3 & 4) 0-1000A AM1 Rishabh

/Meco
8 Input PF meter(on ACDB-1,2,3 & 4) 0.5-1-0.5, PF1 Rishabh

110V AC /Meco
9 Volt meter(on Battery junction Box) 0-500V DC VM1 Rishabh

/Meco
10 Ammeter(on Battery junction Box) 300-0- AM1 Rishabh

300A /Meco
11 Input and output Voltage, Current, ---- ---- Hi-Rel

Frequency of UPS-1 & 2 module(on Mimic)

CONTROL AND LOGICS
Table-2 Major components used in UPS-1 & 2:-

Ref.
1 Input isolation transformer 140KVA, TF1 Hi-Rel
415/380, 3PH-
3PH
2 Output isolation transformer 80KVA, T2 Hi-Rel
187:187/110:110,
1Ph
3 Input MCCB 400A, TP, 415V, CBI GE/Schneider
50KA
4 Bypass MCCB 400A CBA GE/Schneider
5 Output MCCB 400A MIS GE/Schneider
6 Thyristor(Static switch) HN370CH THS7- R-IR/Hi-Rect
8
7 Rectifier Input fuses 200A FR-1- GE
6
8 DC fuse 300A FB-FD GE
9 Bypass fuse 800A FA GE
Table-3 Major components used in auxiliary:-

CONTROL AND LOGICS

Ref.
1 Servo Controlled Voltage 80KVA, SCVS Hi-Rel
stabilizer(SCVS) 1P-1P,
110V O/P
2 Bypass input isolation transformer 3P-1P, TF1 Hi-Rel/Arya
415V/230V
3 Input MCCB 400A, TP, CB1 GE/Schneider
415V,
50KA
4 Manual Bypass MCCB 400A CBO GE/Schneider
Table-4 Major components used in ACDB-1,2,3,4:-

Ref.
1 Incomer MCCB 800A CBI-1 GE/Siemens/L&T
2 Tie MCCB 400A CB1, GE/Siemens/L&T
CB1-3

HWP–
M START-UP Doc. No. PU/III/87/4
4.1 Startup of UPS system from cold i.e. from fully shutdown condition:-
Note: Ensure that all the work permits on the system are cleared and startup
authorisation is existing.
Preconditions:-
Input(Mains) supply CBI OFF

Alternate(Bypass) supply CBA OFF
Battery Isolater CBB OFF
Module Isolator Switch MIS OFF
Mains, Alt. & Batt. Supply at - Available
terminals
Procedure:-
1. Connect the parallel control cables going to redundant UPS module

on parallel control card H10 from the UPS module.
2. Switch CBI to ON position of both UPS.
3. Switch CBA to ON position of both UPS.
4. Wait for 5 minutes.
5. Switch CBB to ON position of both UPS.
6. Give start command to both UPS one by one. The UPS module
inverter can be started or stopped using the START/STOP key for 3
sec. in pressed condition.
7. Confirm HI-REL UPS ON display of both UPS.
8. Switch MIS to ON position of both UPS.
9. Close the front door. Energization completed.
4.2 Startup/Re-connecting of one UPS module:-

 Re-connecting of a UPS module to the common AC bus, is done after
completing the necessary repairs/ maintenance of faulty module.
 Ensure that all the work permits on the system are cleared and
reconnecting authorization is existing.
Preconditions:-Ensure following for the UPS module which is to be reconnected
Input(Mains) supply CBI OFF
Alternate(Bypass) supply CBA OFF
Battery Isolater CBB OFF
Module Isolator Switch MIS OFF
Mains, Alt. & Batt. Supply at terminals - Available
Procedure:-

HWP–
M START-UP Doc. No. PU/III/87/4
 Reconnect the parallel control cables to going to redundant UPS module

on parallel control card H10 from the UPS module to be reconnected.
 Switch CBI to ON position.
 Switch CBA to ON position.
 Wait for 5 minutes.
 Switch CBB to ON position.
 START the inverter from the front panel. The UPS module inverter can be
started or stopped using the START/STOP key for 3 sec. in pressed
condition.
 Check the front panel LCD for any pending faults. Incase of pending fault-
DO NOT proceed - Consult E/M.
 Switch MIS to ON position in case NO faults are pending.
 Close the front door. Reconnection completed.
4.3 Start / Stop :

The UPS module inverter can be started or stopped using the START / STOP
key given on the front panel LCD mimic console.
Start / Stop key
This key works to toggle the state of the UPS inverter.
Note:
The START/STOP key must be kept depressed for aprox 3 sec,s in order to
initiate the action.
The UPS inverter is designed for continuous operation, as such start / stop
operation may not be required.
It is recommended that the UPS be left ON as far as possible.

HWP–M SHUTDOWN Doc. No. PU/III/87/5
1) Isolation of a UPS module(Say UPS-1):-
Note: - Isolation is required to repair/maintain a faulty module only.

Ensure that authorization exists for isolating UPS-1 module.
Preconditions:-
Module Faulty(Pending Faults Fault -

displayed on LCD)
Procedure:-
1. Open the Front door of the UPS-1 module.
2. Switch MIS to OFF position.
3. Switch CBB to OFF position.
4. Switch CBA to OFF position.
5. Switch CBI to OFF position.
6. Wait for 5 minutes.
7. Remove the parallel control cables to going to redundant UPS module on

parallel control card H10 from the UPS module to be disconnected.
8. Close the front door. Module de-energization completed.

HWP-M ANNUNCIATIONS & ACTIONS Doc.No.PU/III/87/6
S.
Alarm Possible cause Actions
No.
1. Input Under 1. Mains failure/ 1. If supply problem, restore
voltage supply problem the same.
(-15% of 415V) 2. Calibration error 2. If the condition is persist,
Inform E/M.
2. Input over voltage 1. Mains supply 1. Check voltage from

(+10% OF 415V) problem supply side, if it is not ok
2. Calibration error isolate the UPS module.
Other wise inform to E/M
3. Battery discharging 1. Mains supply 1. Power is being drawn

(375V) voltage is too low or from the reserve (battery)
has failed. unless the main supply
2. Charger Failure resumes.
2. Check the backup time
available/ordered & initiate
load shutdown action
accordingly.
4. End of discharge 1. Reserve (battery) 1. We have aprox 5 min of
(335V) power has been battery backup left. Initiate
nearly exhausted. load shutdown immediately.
5. Inverter Under 1. The inverter output 1. Remove excess load.
voltage(99V) is overloaded & Alt 2. If persisting inform E/M.
supply is not
available for
transfer.
2. Calibration error.
6.0 Alarms/Annunciations:-
The pending alarms are indicated by the summary alarm LED on the LED mimic. Details of the alarm are
available on the LC display.
6. Inverter Overload 1. The inverter output 1. Remove excess load
(581A at 0.8 P.F.) is over loaded & Alt immediately or else the
supply is not available inverter may trip.
for transfer. 2. If persisting inform E/M.
2. Calibration error
7. Alternate supply 1. Alternate supply 1. Check voltage from
Under voltage(99V) problem supply side, if it is not
2. Auxiliary module ok isolate Alt supply. If
(stabilizer) problem. If persisting inform to
incorporated. E/M
3. Calibration
error.
8. Alternate supply 1. Alternate supply 1. Check voltage from

HWP-M ANNUNCIATIONS & ACTIONS Doc.No.PU/III/87/6
over voltage(121V) problem supply side, if it is not

2. Auxiliary module ok isolate Alt supply. If
(stabilizer) problem if persisting inform to
incorporated. E/M
3. Calibration error.
9. Alternate supply 1. Alternate supply
frequency out of problem.
sync limits.
10. Static switch 1. Inverter is 1. Remove excess load.
transfer to Alternate overloaded 2. Check fault log- if the
2. Inverter has inverter has tripped-
tripped Inform E/M
3. Manual transfer 3. Manual transfer- re-
has been transfer the load back
initiated. to the inverter.
11. MCB trip - Control 1. Inform E/M.
CBALT transformer
CBM failure
CBF1-- - Control
transformer
failure
- Fan failure
12. Service mode 1. The service mode 1. Ensure that this is being
accessed software has been done by an authorized
accessed. person.

HWP–M POWER SUPPLY Doc. No. PU/III/87/7
7.1 Input power supplies:-
Sl.
Module No. & Switchgear Purpose
No.
6.4R Module on 415V, 50 Hz, 3 Phase Fire

01. Input AC Power to UPS-I.
Protection MCC.
8.8F Module on 415V, 50 Hz, 3 Phase DG

02. Input AC Power to UPS-II.
Switchgear.
Dedicated battery bank for inverter of UPS-1

03. Only for UPS-1 & 2 loads.
& 2.
Standby Mains to UPS

04. 6.4F Module on 415, 50 Hz, Phase NESG.
System.
7.2 Out going power supplies:-
AC DISTRIBUTION BOARD – 1
FEEDER
DESCRIPTION TYPE RATIN
NUMBER
G
INCOME
INCOMER FROM UPS MCB 800 A
R
TIE BKR TIE FROM ACDB-4 MCB 400 A
01 BMS CPU PANEL FF
02 NT CPU PANEL FF
03 MP CPU PANEL FF
04 GENERATOR CONTROL DESK FF
05 GRP, THYRISTOR, ANNUNCIATION FF
06 SAMPLING FF
07 FIELD ANALYZER FF
08 TURVOVISORY PANEL, SER FF
09 GCP, TCP, BCP, HYDRASTEP FF
10 TGIP CPU PANEL FF
11 SG VFD FEEDER-1 FF

INCOME
R
01 BMS CPU PANEL FF
02 NT CPU PANEL FF
03 MP CPU PANEL FF
06 SAMPLING FF
08 SER, TURVOVISORY PANEL FF
FEEDER
DESCRIPTION TYPE RATIN
NUMBER
G
INCOME
R
01 BMS CPU PANEL FF
02 NT CPU PANEL FF
03 MP CPU PANEL FF
06 SAMPLING FF
08 TURVOVISORY PANEL, SER FF

INCOME
R
TIE BKR U-1 TIE TO ACDB-1 MCB 400 A
TIE BKR U-2 TIE TO ACDB-2 MCB 400A
TIE BKR U-3 TIE TO ACDB-3 MCB 400A
110/230 VOLT T/F HOST COMPUTER
01 FF
ROOM
02 COOLING WATER PUMP HOUSE FF
03 `SPARE FF
AIR COMPRESSOR CONTROL
04 FF
SUPPLY
05 U-1 MP PANEL-56 FF
06 COMMON MP AND NT CPU PANEL FF
07 CCP FF
08 6C COMMON FF
SPARE FF
SPARE FF
110/230V TRANSFORMER IN HOST COMPUTER ROOM FEEDS ENGINEER
STATION, TELEPHONE EXCHANGE, DYSS AND L-DESK COMPUTERS,
WALKIE-TALKIE CHARGERS, MASTER STATION AND 230V IN MCR.

HWP–M
ROUTINES & SAFETY Doc. No. PU/III/87/8
PRECAUTIONS
8.1 Fill the log sheet at least thrice in a shift at regular intervals.
8.2 Ensure that UPS battery charging is in service and its voltage is 380V.
8.3 Ensure that UPS battery bank is in healthy condition (E/M Section).
8.4 Ensure that the room ambient air temperature is less than 45°C.
8.5 Ensure that 415V supply is within the specified tolerance of +10% and –15%
in magnitude and ±6% in frequency.
8.6 Ensure that only under mains failure condition the battery ammeter is reading
discharging current. Minimize the time of mains failure by putting DG set into
service promptly.
8.7 Check the alarms on digital mimic (if any) and record the occurrence of an
alarm in detail and refer to E/M at once.
Safety Precautions:-
8.8 Follow the energization and de- energization procedure in steps & in the
sequence mentioned in the procedure.
8.9 Non compliance to the procedure can result in serious injury to the personnel
as well as damage to the equipment.
8.10 Energizising & reconnecting should be performed by authorised personnel
only,
8.11 The UPS module has High voltage supplies connected to the input/output
terminals. Don’t open safety shrouds or touch metallic parts, wires, PC cards
etc. without ensuring that there are NO voltage present.
8.12 Energization of a module shall be done after the necessary installation
checks.
8.13 The UPS inverter is designed for continuous operation; as such start/stop
operation may not be required. So, it is recommended that the UPS be left ON
as far as possible.
8.14 The service mode allows access to vital settings, calibration, etc. Tampering
with these can result in serious damage to the equipment. DO NOT attempt to
gain forced access to this mode.
8.15 DO NOT use corrosive chemicals or soap to clean the panels. DO NOT open
the front door or rear cover while cleaning. DO NOT attempt cleaning the UPS

HWP–M
ROUTINES & SAFETY Doc. No. PU/III/87/8
PRECAUTIONS
module from inside. This requires de-energization and will be done during
scheduled maintenance visit by authorized service persons.
8.16 In case of problems, seek service support from E/M only. DO NOT try to
repair / replace components on your own.

HWP–M TROUBLE SHOOTING Doc. No. PU/III/87/9
9.0 TROUBLE SHOOTING:-
S.
Fault Possible cause Actions
No.
1. DC over voltage 1.Rectifier control 1. Inform E/M
problem 2. Inform E/M
2. Calibration error
2. Inverter over 1. Inverter 1. Inform E/M
voltage control
problem.
2. Calibration
error.
3. Inverter 1. The inverter 1. Remove the excess load.
Overload trip. output was 2. Try starting the inverter & if
(This trip is severely unsuccessful. Inform E/M
inverse time overloaded &
acting i.e. more Alt supply
the overload was not
faster the trip) available for
transfer.
2. Calibration
error
4. Inverter Limb 1 1. The inverter 1. Try starting the inverter
or Limb 2 fault- output was severely & if unsuccessful. Inform
Trip overloaded & Alt E/M
supply was not
available for transfer.
5. CPU fault- Trip 1. Control 1. Inform E/M

system
failure.
2. Serial link
between
system
manager &
system
control failure.
6. Over 1. Cooling Fan 1. Inform E/M
temperature Trip failure 2. Reduce the load and try to
2. Excess load start the unit- if unsuccessful-
3. Ambient Inform E/M
temperature 3. Measure the ambient
above temperature at aprrox 1 mt
specified from the unit- if found in
limits. excess of specified limits- take
actions to reduce it (room
ventilation, A/C etc.)- Wait for

HWP–M TROUBLE SHOOTING Doc. No. PU/III/87/9
aprox 20 min to allow cooling &

try to start the unit- if
unsuccessful. Inform E/M

HWP–M ANNEXURES Doc.No.PU/III/87/10
ANNEXURES

HWP–M TECHNICAL SPECIFICATIONS Doc.No.PU/III/87/10.1
A. TECHNICAL SPECIFICATIONS OF UPS MODULE:

a) Input:
i) Input Voltage : 415V, 3 phase, 4 wires
ii) Input Voltage tolerance : +10%, -15%
iii) Input frequency : 50 Hz
iv) Frequency tolerance : +6%
v) Input power factor : 0.8
vi) Full load input current : 131 amps.
vii) Input current distortion : 12%
viii) Soft start : 15 to 20 seconds
ix) Input circuit : twelve pulses fully controlled
thyristor bridge rectifier.
x) Min. input voltage without battery discharge: -15%
xi) Input isolation transformer (TF1):140KVA, 415/380V, 3PH-3PH
b) Output:
i) Module output rating KVA : 80 KVA
KW : 64 KW
ii) Output voltage : 110V AC, 1 phase, 2 wires
iii) Output frequency : 50 Hz
iv) Full load current : 727 amps.
v) Load power factor : 0.8
vi) Voltage adjustment range : +5%,
vii) Voltage regulation O-FL : +1%,
viii) 1. Mains synchronization : 50 Hz ± 0.01 % free run
tracking 50 Hz ± 5% Bypass
2. Slew Rate : 0.1 Hz/Sec.
ix) Output voltage harmonics : THD<2.5% for Linear loads
: THD<4.5% for non linear loads
x) Overload rating : 125% for 600 sec.
150% for 10 sec.
300% for 1 cycle

xi) Overload trip : 600 sec. at 125%

10 sec. at 150%.
1 cycle at 300%
xii) Current limit : Set at 150% of the output
power.
xiii) Transient response 50% load : ±8%.
Step Loss/Return of AC input : ±5%, with fully charged
battery.
Manual transfer UPS to : ± 6%, with static bypass
Bypass or vice-versa connected.
xiv) Output isolation transformer (T2) :80 KVA, 187V/110V, 1PH-1PH
c) DC (Recommended)
i) Nominal DC bus voltage : 372 V
ii) Battery isolation : Manually closed circuit breaker with
magnetic trip.
iii) Discharge battery voltage : 325V
iv) DC bus volts ripple : <2% rms.
v) Max. battery current : 90A
vi) Max. DC current : 260A
B. TECHNICAL SPECIFICATIONS OF SCVS:

a) Rating
1) Voltage : 110V AC.
2) Current : 727 amps.
3) Paralleled output of Inverter : 110V AC, 1 phase, 2 wire
Bypass Supply Voltage : 110V AC, 1 phase, 2 wire
4) Manual transfer of UPS to : +6%, with static bypass
Bypass connected and not inhibited
5) Static transfer of UPS to : +6%, with static bypass
bypass : connected and not inhibited.

6) Response time : Recovery to 95% in 50

m.secs.
to nominal value in 100

m.secs.
7) No. of parallel modules : 2

connected
8) Transfer to alternative source : In case of a failure of both
the modules.
9) Transfer time : Less than 5 m.secs.
Automatic transfer
(synchronous)
10) Redundancy : 200%.
11) Servo controlled voltage stabilizer: 80KVA, 1PH-1PH, 110V O/P
12) Bypass input isolation transformer (TF1): 3PH-1PH, 415V/230V
C. TECHNICAL SPECIFICATIONS OF BATTERY BANK :-

a) Type : SMFB-VRLA
b) Capacity : 450AH
c) No. of Cells : 186
d) Make : HBL-NIFE

HWP–M LOG SHEETS Doc. No. PU/III/87/10.2

HWP-M Order to Operate Doc.No.PU/III/87/10.3
1) OTO FOR MAINTENANCE OF UPS-1 & 2 SYSTEMS & its ALTERNATE SUPLLY.
ORDER TO OPERATE Form/SWP No. :
Order to operate must be listed in the order in which the issuer intends them to be performed and
must be performed in the order in which they are listed.The operator who is delegated to perform the
operations listed shall check the positions and tagging of any devices which must be in any particular
position while the operations are being performed. State the required condition or position of the
apparatus. The order meant that the equipment must be left in the state or position indicated.
_________________________________________________________________________
PURPOSE OF ORDER: TO ISOLATE UPS FOR PREVENTIVE MAINTENANCE
Permit No To issue [ ] To clear [ ] (Tick whichever is applicable)
S.NO EQUIPMENT STATUS REQUIRED TAG NOS. INITIALS
PLACE
01 Take approval for giving UPS system for maintenance.
02 Inform I/M Regarding Shut Down Of UPS. They Will Make Arrangements For
Keeping their Disks Un-erased. Alternate Supply To Be Arranged For Air Compressor
Control Supply.
03 Telephone Exchange Has A Battery Bank Which Can Serve Upto 8 Hrs. Work On
UPS Should Be Completed Within This Time.
04 O/G Module No.6.4F On NESG To OFF, REMOVE FUSES &
UPS(bypass) TAG
05 O/G Module No.6.4R On Fire Protection OFF, REMOVE FUSES &
MCC To UPS-2 TAG
06 O/G Module No.8.8F On DGSWGR To OFF, REMOVE FUSES &
UPS-1 TAG
07 Fuses Near UPS Battery Bank To Be
Removed By E/M
08
Total no. of Tags : 3
Prepared by Time Date
Checked by Time Date
Issued by Time Date
Performed by Time Date
Sheet 1/1
Revision No: 0.00 Date18.05.2015 Page 1 of 5

2) OTO FOR MAINTENANCE OF UPS MODULE – 1 ONLY.
_________________________________________________________________________
PURPOSE OF ORDER: TO ISOLATE for UPS-1 MAINTENANCE.
PLACE
01 Take approval for giving UPS MODULE - 1 for maintenance.
02 Ensure that the load of UPS module-1 has been shifted to UPS module-2 or Alternate
supply.(Note down the currents before & after load shifting)
03 Open the static switch THS4 & THS5 of UPS ENSURE OPEN
module-1 with the help of E/M.
04 Note down the currents in both the cases (Before & after opening the switches).
05 O/G Module No.8.8F On DG SWGR To OFF, REMOVE FUSES &
UPS module-1 TAG
06 CBI of UPS module-1 OFF and Tag
07 CBB of UPS module-1 OFF and Tag
08 CBA of UPS module-1 OFF and Tag
09 MIS of UPS module-1 OFF and Tag
10 UPS module-1 related fuses to be removed
by E/M for positive isolations.
Total no. of Tags: 5

Issued by Time Date
Sheet 1/1

3) OTO FOR MAINTENANCE OF UPS MODULE – 2 ONLY.
_________________________________________________________________________
PURPOSE OF ORDER: TO ISOLATE for UPS-2 MAINTENANCE.
PLACE
01 Take approval for giving UPS MODULE - 2 for maintenance.
02 Ensure that the load of UPS module-2 has been shifted to UPS module-1 or Alternate
supply.(Note down the currents before & after load shifting)
module-2 with the help of E/M.
MCC To UPS module-2 TAG
06 CBI of UPS module-2 OFF and Tag
07 CBB of UPS module-2 OFF and Tag
09 MIS of UPS module-2 OFF and Tag

Issued by Time Date
Sheet 1/1
4) OTO FOR MAINTENANCE OF UPS MODULE – 1&2 BOTH.

_________________________________________________________________________
PURPOSE OF ORDER: TO ISOLATE for UPS-1 & 2 MAINTENANCE.
PLACE
01 Take approval for giving UPS MODULE -1 & 2 for maintenance.
02 Ensure that the loads of UPS module-1 & 2 have been shifted to Alternate supply by
closing the CBO with the help of E/M.(Note down the currents before & after load
shifting)
module-1 & 2 with the help of E/M.
05 O/G Module No.8.8F On DG SWGR To OFF, REMOVE FUSES &
UPS module-1 TAG
MCC To UPS module-2 TAG
07 CBI of UPS module-1 & 2 OFF and Tag
08 CBB of UPS module-1 & 2 OFF and Tag
09 CBA of UPS module-1 & 2 OFF and Tag
10 MIS of UPS module-1 & 2 OFF and Tag

Issued by Time Date
Sheet 1/1
5) OTO FOR MAINTENANCE OF UPS ALTRNATE SUPLLY System (SCVS).

position while the operations are being performed. State the required condition or position of the apparatus.
The order meant that the equipment must be left in the state or position indicated.
_________________________________________________________________________
PURPOSE OF ORDER: TO ISOLATE FOR MAINTENANCE OF UPS ALTRNATE SUPLLY
System(SCVS).
PLACE
01 Take approval for giving UPS Alternate Supply system (SCVS) for maintenance.
02 Ensure that the any one of the UPS module is in service.
03 Ensure that UPS loads are not feeding by its Alternate Supply system (SCVS). Note
the currents readings
04 Ensure that CBO is in open condition Open and Tag
05 Open the static switch THS5 of UPS Ensure open
module-1 & 2 with the help of E/M.
07 O/G Module No.6.4F On NESG To UPS OFF, REMOVE FUSES &
TAG
08 CB1 of UPS alternate supply OFF and Tag
Total no. of Tags : 4

Issued by Time Date
Sheet 1/1

HWP-M Drawings Doc.No.PU/III/87/10.4
Block Diagram of UPS system

Single Line Diagram of UPS system

Single line diagram of AC distribution board-1, 2, 3 and common(4)

Internal components of UPS module

Production (Utilities) Heavy Water Plant (Manuguru) Gautaminagar - 507 116 Khammam Dist. Telangana State

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PRODUCTION (UTILITIES)

HEAVY WATER PLANT (MANUGURU)

UNINTERRUPTED POWER SUPPLY SYSTEM

Rev. No. 0.00 Date: 18.05.2015

DESCRIPTION NAME DESIGNATION SIGNATURE

S.No Document No. of

3. Distribution list PU/III/87/C 1

4. Amendment sheet PU/III/87/D 1

7. System Description PU/III/87/2 4

10. Shutdown PU/III/87/5 1

11. Annunciations & Actions PU/III/87/6 2

12. Power Supply PU/III/87/7 3

13. Routines PU/III/87/8 1

14. Trouble Shooting PU/III/87/9 1

15. Annexure PU/III/87/10 1

16. Technical Specifications PU/III/87/10.1 3

17. Log Sheets PU/III/87/10.2 1

18. Orders to Operate (OTOs) PU/III/87/10.3 5

19. Drawings PU/III/87/10.4 4

Prepared by: Reviewed by: Approved by:

Revision No: 0.00 Date: 18.05.2015 Page 1 of 1

S. No. Abbreviations Description

4. CBA Circuit Breaker Alternate

5. CBB Circuit Breaker Battery

6. CBI Circuit Breaker Input

7. CD DC link filter capacitor

8. CO capacitors Output ac filter

9. FA Fuse Alternate static switch

10. FB Fuse Battery circuit

11. FD Fuse DC link

12. LED Light Emitting Diode

13. LI Line Inductors

14. MDU Main Distribution Unit

15. MIS Module Isolator Switch

16. SCVS Servo Controlled Voltage Stabilizer

17. UPS Uninterrupted Power Supply

Prepared by: Reviewed by: Approved by:

Revision No: 0.00 Date: 18.05.2015 Page 1 of 1

1. Dy. GENERAL MANAGER (U) (Soft copy)

2. PRODUCTION MANAGER (U) (Hard copy)

3. TECHNICAL SERVICES MANAGER (Soft copy)

4. DY.PRODUCTION MANAGER (U) (Soft copy)

5. Dy. SHIFT SUPERINTENDENT (Hard copy)

6. LIBRARY (Soft copy)

7. HRD SECTION (Soft copy)

9. GENERAL SHIFT ENGINEERS (Soft copy)

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Revision No: 0.00 Date:18.05.2015 Page 1 of 1

Prepared by: Reviewed by: Approved by:

Revision No:0.00 Date:18.05.2015 Page 1 of 1

This Operation Manual has been prepared with an intention to provide

sufficient information to the Operation Personnel to guide them in operating the

instruction can replace an EXPERIENCED OPERATOR especially when coping-up

with unforeseen operating condition.

Standard Orders To Operate given shall be used as a GUIDANCE for

Prepared by: Reviewed by: Approved by:

Revision No: 0.00 Date: 18.05.2015 Page 1 of 1

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Revision No: 0.00 Date: 18.05.2015 Page 1 of 2

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Revision No: 0.00 Date: 18.05.2015 Page 2 of 2

2.2Component of an UPS system: