AC UPS for Marine and Oil & Gas Applications YOUR POWER IN SAFE HANDS

Transcription

1 AC UPS for Marine and Oil & Gas Applications YOUR POWER IN SAFE HANDS

2 AC UPS for Marine and Oil & Gas Applications The Secure Power range from Dale Power Solutions Contents 1 Introduction 2 The Erskine UP7000 AC UPS System 4 UPS Battery Capacity Testing 6 Safety & Maintainability 8 User Interface 9 Special Solutions 10 Specifications 11 Configurations 12 About Dale Keeping the power flowing.

3 The Erskine UP7000 AC UPS System Regen allows safer battery capacity tests Features 3 Range 5kVA to 500kVA 3 Custom solutions to meet the demanding requirements of major Marine and Oil & Gas and client specifications 3 Single or dual / parallel configurations 3 Galvanic isolation 3 High overload capability 01

4 AC UPS for Marine and Oil & Gas Applications The UP7000 raises the standard for secure power to critical controls and safety systems Reliability Proven and robust electronic controls of the UPS ensure the level of reliability and availability demanded. If required, dual or parallel configurations are available for the most critical applications. Power system friendly With near unity power factor and sinusoidal current drawn from the AC supply, the UP7000 pulse width modulated IGBT rectifier is the obvious choice to minimise harmonics and other power quality issues. Outstanding cost savings As the UP7000 can perform fully controlled battery discharge tests without the requirement of sending specialist trained engineers and suitable load banks to site, the lifetime operating cost savings can be significant with reduced personnel on board and their associated logistics. Special solutions To meet dedicated requirements and specifications of global offshore Marine and Oil & Gas clients, the AC secure power system is custom designed and configured. Custom designed systems can be configured from a comprehensive range of options available. Inherently safer design The UPS can perform a fully controlled discharge test of its battery with no need for maintenance personnel accessing potentially live circuits. Battery discharge energy is safely regenerated back onto the AC supply so eliminating potentially hazardous manual battery testing with load banks. User friendly With a large TFT colour touch screen operator panel the user interface provides immediate access to all important measured UPS operating values while the flow of power through the UPS is displayed on a multi-coloured mimic. Maintainability The UP7000 has been designed to allow safe and efficient servicing with all elements of the equipment readily accessible and properly shrouded. Regenerative capacity test simplifies maintenance, enhances safety and eases scheduling around ongoing operations. 02

5 MAINTENANCE BYPASS STATIC SWITCH BYPASS SUPPLY IGBT CHARGER INVERTER UPS AC OUTPUT AC INPUT SUPPLY ISOLATION TRANSFORMER ISOLATION TRANSFORMER BATTERY Elements of the UPS The UPS is configured from five main elements: Battery, IGBT rectifier, IGBT inverter, static bypass and maintenance bypass. The UPS output is controlled by an electronic static switch While in normal mode of operation, the inverter output supplies the load. Under fault or extreme overload conditions the fully rated static switch will transfer to the bypass supply to provide the maximum current for fault protection device clearance. The Maintenance Bypass provides the capability to isolate the static elements of the UPS and power the load from the bypass supply during UPS maintenance. Energy storage is provided by the battery The battery is generally of lead acid or nickel cadmium type as dictated by the application requirements. The battery autonomy is sized to the requirement of the UPS load including any design factors that may be required. The inverter generates a sinusoidal AC output from the DC bus The AC waveform has high static and dynamic regulation to cope with changing load conditions. A high overload ability maximises the load fault protection device clearance capability of the inverter feeding distribution breakers or fuses. IGBT power modules Both the rectifier and the inverter are based on pulse width modulated IGBT power modules providing high dynamic response and superior power quality with low harmonics. As required by Marine and Oil & Gas clients specifications, transformers are included in both the rectifier input and the inverter output to provide full galvanic isolation between the UPS battery, the AC supply and the AC output. The pulse width modulated IGBT rectifier operates in two modes: While in normal operation, the IGBT rectifier converts the AC mains supply to a regulated DC bus from which the battery is charged and inverter powered. The IGBT rectifier pulse width modulation operates with near unity input power factor and imposes minimal harmonics on the AC mains supply. While performing battery capacity testing, the IGBT rectifier operates as a grid synchronised inverter, taking current from the DC bus and regenerating the energy back onto the AC mains supply. The level of DC current regenerated is automatically controlled to achieve the required battery discharge test without requiring load banks

6 AC UPS for Marine and Oil & Gas Applications UPS Battery Capacity Testing Traditional UPS Battery Capacity Testing using load banks presents a range of issues which are particularly challenging in critical remote offshore applications. Energy Flow Traditional Battery Capacity testing Specialised Technician Intervention Required: 3 Switch UPS to Bypass 3 Isolate battery 3 Hook up trailing cable to load bank MAINTENANCE BYPASS Critical loads are not supported by battery during the test BYPASS SUPPLY RECTIFIER SUPPLY RECTIFIER INVERTER PLANT LOAD OFF-LINE STATIC BYPASS Battery energy converted to heat HVAC design must cope with TRAILING CABLE BATTERY LOAD BANK Operational Constraints Operations and maintenance must coordinate the battery test around any operational constraints and other work scopes. Logistics The load bank must be shipped offshore well in advance of the planned work, incurring rental costs and presenting a burden on logistics. Personnel Specialist trained and certified test engineers must be mobilised to site. This may require occupying valuable helicopter seats and offshore accommodation needed by other key personnel. Compromise Load In order to test the battery, the UPS will usually be switched to bypass or one half of dual redundant system disabled, compromising UPS availability and therefore critical plant load security during the test. HVAC Temporary ventilation may be required if the existing HVAC has not been designed to handle the heat output of the load bank. Live Working The engineer must isolate the battery and connect trailing cables to the load bank, manually configure the load bank for the required current and commence the discharge test, an inherently hazardous process on live equipment. 04

7 Regenerative UPS Battery Capacity Testing addresses these issues as the IGBT based rectifier/charger recovers the energy by regenerating current to the power grid. Energy Flow REGEN Battery Capacity testing Specialised Technician Not Required: 3 Do not switch UPS to Bypass 3 Do not isolate battery 3 Does not require trailing cable and load bank MAINTENANCE BYPASS BYPASS SUPPLY RECTIFIER SUPPLY RECTIFIER INVERTER PLANT LOAD Controlled regenerative power returned into AC supply ON-LINE Constant power or constant current battery discharge maintained regardless of plant load variations STATIC BYPASS Plant AC load maintained by battery and on-line inverter throughout the test Minimal compromise to load security BATTERY No increase in HVAC loading True on-line regen battery test The UPS does not get switched to maintenance bypass therefore critical plant loads remain supported by the battery and inverter which remain on line throughout the test. After the required capacity has been drawn from the battery and the DC voltage remains above the minimum value, the test is successful, the battery test data is stored in memory and the rectifier reverts to normal charge operation. Key safety and cost benefits: 3 Reduced need for live working 3 Fewer engineer-days on site 3 Less compromise to critical loads 3 Greater flexibility when to test 3 Logistics of load banks gone 3 HVAC issues avoided 3 Battery testing simplified Programmed battery test current is maintained by controlling energy fed back into the network while load current continues to be delivered through the inverter. Load banks are not required. Multiple scenarios are configurable with either constant current or constant power discharge while the test duration can be time-controlled, Ah-controlled or kwh-controlled. If necessary, the capacity test can also be programmed without energy recovery to the network. 05

8 AC UPS for Marine and Oil & Gas Applications Safety & Maintainability Features The UP7000 range of industrial AC UPS secure power systems meet the restricted access requirements to BS EN :2008. Accessibility of the UPS is ensured with ready access to power switching and control modules which are readily serviceable from front of the UPS without requiring removal of adjacent modules. Guarding minimises the risk during maintenance of unintentional bridging by conductive materials that might be present and circuits at hazardous voltages are located or guarded to make contact unlikely. The terminals are fully shrouded to protect against accidental contact. Electrical segregation provided between sections (rectifier, bypass, battery and inverter) to enable maintenance to be undertaken safely. Separate parts of the system can be isolated for maintenance without disrupting the load. Back feed is precluded and no shock hazard exists at the input terminals after interruption of the input power. The UPS is designed to cope with input voltage depressions and transients and non-linear loads that could be expected in Marine and Oil & Gas applications. Bypass static switching device is fully rated for both continuous and short circuit duties when it may be required to clear a load fault. 10ms 1000% In is provided as standard with the option of 1000ms 400% In available if requested. Maintenance bypass switch enables isolation of the static transfer switch from the bypass source and connects the output directly to the bypass source without interruption of the load power. High availability levels required for supporting high integrity control and safety systems is achieved by dual parallel redundant UPS. The individual rectifiers, bypasses and inverters all have independent control systems to make a single point of failure unlikely. In the event of a component failure, only one inverter will shut down. 06

9 Serial communications and diagnostics The UPS has the capability for connection to an Integrated Control and Safety System via fibre optic link, Modbus RS485, Profibus or Ethernet TCP/IP for remote network or web monitoring. The condition of individual sections including rectifier, inverter, and where included, battery monitoring system, is continuously monitored. Alarms and events can be logged. All measured values as displayed on the TFT screen are available over the serial link to enable trending of information including operating load and environmental conditions. Protection of the inverter Is achieved without relying on software control. The inverter power modules hardware inherently limits current under load fault conditions using on board hardware based protection. To allow discrimination of distribution protective devices, inverter short circuit capability up to 150% is standard with higher ratings available if requested. Electrostatically shielded full isolation transformers are provided on the input, bypass and output to allow independent grounding of the load and to provide protection against primary power surges and lightning transients in accordance with BS EN Distribution boards are designed to meet individual project requirements and comprise either fused switch disconnects, or circuit breakers. Selective coordination ensures faults on the outgoing ways can be cleared when operating on the inverter. The switching devices provide isolation in accordance with BS EN

10 AC UPS for Marine and Oil & Gas Applications User Interface The UPS user interface provides indication of measured UPS operating values. The settings can be changed and operating mode selected. Display measurements and features: 3 AC voltage, current and frequency of each power section and UPS output 3 Temperature of each power section 3 Battery voltage, current and Ah discharged 3 Rectifier and inverter DC currents 3 Comprehensive indication of alarms and status indications. 3 Event history capable of recording the previous 512 events 3 Access to UPS settings via a three level password system protecting the UPS configuration against unauthorised changes. The flow of power through the UPS is displayed on a multi-coloured mimic display with colour coded symbols. Measured values are displayed alongside the associated measurement points. 08

11 Special Solutions To meet dedicated client requirements and specifications the AC secure power system is custom designed and configured. Custom designed systems can be configured from a comprehensive range of options available. Typical options: System 3 Dual and parallel redundant schemes 3 Increased rectifier ratings for larger batteries 3 Different battery technologies 3 Charging temperature compensation 3 Bypass isolation transformers 3 Automatic voltage regulators 3 Charger and battery isolation 3 Customer specific distribution isolators, circuit breakers or fuses CONSTRUCTION 3 Battery enclosures or stands 3 Battery Fuse boxes or Ex breakers with ESD trips 3 Anti-condensation heaters 3 Panel lighting 3 Top or bottom cable entry 3 Custom paint specification 3 Increased enclosure ingress protection ratings 3 Larger enclosure sizes for more complex solutions ALARMS & COMMUNICATION 3 Remote communications 3 Analogue metering 3 Configurable remote alarms 3 Earth fault monitoring 3 Battery impedance 3 Battery voltage imbalance 3 Individual cell monitoring of cell voltage, impedance and temperature 09

12 AC UPS for Marine and Oil & Gas Applications Specifications Standard OptionS Comments AC Input Supply phase & voltage 380, 400, 415, Other on 400VAC +/- 10% request Supply wiring Three phase 4 wire Three phase with protective earth 3 wire Supply Frequency 50Hz +/- 5% 60Hz +/-5% Supply Power Factor 0.99 At full load at minimum load Supply current distortion 5% THDi At full load AC Output Phases 1-phase, 3-phase, 2-wire neutral with protective earth Output Voltage 220, 230, 240, 380, 400, 415, 254 VAC (1ph) 440 VAC (3ph) Output kva 5kVA to 120kVA 10kVA to 500kVA Up to 8 units can be operated in parallel Output Static voltage regulation +/- 1% 0-100% load variation Performance Dynamic voltage regulation +/- 4% 100% load step, 4ms recovery to within static limits Overload capability 150% for 1 minute Greater on request 125% for 10 minutes Greater on request 110% for 20 minutes Greater on request Short circuit capability 200% for 5 Sec Greater on request to EN pt 1 Waveform Distortion Sinusoidal <3% with linear load Crest factor (load current) <2.3 <3.0 Frequency 50Hz +/- 0.1% 60Hz +/-0.1% Load power factor range 0 lag to 0 lead Output power de-rated if power factor deviates from 0.8 lag General Operating temperature range -10 C to +40 C Storage temperature range Operating altitude -20 C to +70 C 0 to 1000m Operating humidity 10% to 90% RH Non condensing Tropicalisation Tropicalised PCB's. Safety BS EN EMC BS EN Enclosure Noise Level At 1M < 50 to 70 db(a) Depends on rating IP Rating IP31 IP41 or IP42 Cooling Natural or power module assisted Dependant on rating and load Dual Power Plant Fans Fans Supervision Terminals for Inter Enclosure Wiring Door Locks Padlockable Door Stays ACH Control by thermostat as standard, hygrostat optional Gland Plate Eye Bolts Cable Entry Bottom Top Option for top cable entry through top of bypass panel only Wiring Idents Wiring Crimps Earth Bus Bar Labels External labels screw fixed Document Wallet Cabinet Lamp Rear Door Access LSZH Cabling Enclosure finish RAL7035 Other on request Dale Power Solutions Ltd reserves the right to make changes in specification without notice or liability. All information is subject to Dale Power Solutions Ltd own data & is considered accurate at time of publishing. 10

13 Configurations Standard Option Comments System Single Dual (2 x Single) Parallel Redundant Rectifier Type IGBT Standard dual rectifier & inverter, single bypass Other configurations available Rectifier Input Circuit Breaker MCCB With thermal & magnetic protection Padlockable in both positions Input Transformer Isolating With taps to suit different input voltage options Input soft start Limits input inrush current to transformer and rectifier Input On/Off Switch On TFT Display DC Earth Fault Boost Charge Facility For Ni-Cad batteries only. Disabled for VRLA batteries Diesel Generator Bypass/Static Switch Bypass Static Switch Location Depends on rating Bypass Enclosure Enables isolation of remainder of system for maintenance Bypass Transformer Phase-Neutral, Phase-Neutral or Arrangement of phases and without bypass Phase-Phase, with taps to suit application transformer bypass transformer input and output voltages Voltage Stabiliser Bypass Input Circuit Breaker MCCB Thermal & magnetic protection. Padlockable in both positions Bypass Switch MCCB type isolator 3 way rotary Padlockable in all positions Bypass Static Switch Fast Acting Fuse Link Fit link when fuse not in circuit Input Protection Overload Condition % 10ms Battery Battery Protection Internal MCCB Internal MCCB Type isolator interfaced with external device. (Exd if required) Vent Fan Fail Boost Inhibit NTC Reverse polarity protection Regen Battery Test Voltage Depression Battery Test Battery Load Test Terminals Battery Bus Tie Black Start Facility Manual Auto Blocking Diode Inverter Type IGBT PWM 1ph IGBT PWM 3ph Padlockable in both positions Can be interfaced with ESD signal. Output Isolating Transformer With taps to suit different input voltage options AC Earth Fault Input On/Off Switch On TFT Display UPS Output Load Switch Crest Factor <2.3 <3.0 Overload Condition 1 150% 1min Greater on request Overload Condition 2 125% 10 min Greater on request Overload Condition 3 110% 20 min Greater on request Short circuit capability 200% for 5 Sec Greater on request to EN pt 1 Options Remote contacts Load on Inverter Load on Bypass Battery Discharging Battery Low Volts Bypass Mains Failure Common UPS Alarm Optional 8-way relay card relay card with configurable contact assignment Serial Interfaces Choice of SNMP, Modbus RS485, Profibus, Ethernet TCP/IP, Fibre AC Distribution Specific requirements to be confirmed per project: e.g. Double or Triple Pole MCB's Bus Tie, MCB Common Trip Incomer Switch 11

14 AC UPS for Marine and Oil & Gas Applications Dale Power Solutions Delivering secure back-up power across the globe Established since 1935, Dale Power Solutions has become a global leader in bringing technology and engineering together to create innovative solutions, protecting critical power supplies for customers through our standby power systems. With an annual turnover in excess of 30million, it is through Dale Power Solutions commitment to excellence, combined with our mission to deliver outstanding client service has earned Dale Power Solutions its prestigious reputation it enjoys today as one of the world's most trusted providers of standby power solutions. Dale Power Solutions provides a comprehensive and bespoke design capability service to our customers, taking initial concepts through design, project management, manufacturing, installation and commissioning processes, followed by complete maintenance and servicing on a worldwide basis to more than 8,000 generators and UPS systems. Our professional structure, financial strength and the necessary quality assurance, health and safety, and product accreditations meet the demands of the world's most discerning clients. These accreditations include: Proud of our pedigree proud to be your partner. 12

15 AC UPS for Marine and Oil & Gas applications Critical power continuity guaranteed

16 Dale Power Solutions Ltd Head Office, Factory 1, Scarborough Salter Road Eastfield Industrial Estate Scarborough North Yorkshire YO11 3DU Tel : produced by adverset media solutions limited Factory 2, Filey Tel : Aberdeen BRANCH Tel: London CITY BRANCH Tel: Middle EasT BRANCH Tel: Your power in safe hands