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Operation of the Diesel Rotary

 

STANDARD OPERATING PROCEDURE

Title

Procedure for Operating Diesel Rotary Uninterruptible Power Supply(DRUPS)

Department

Engineering

SOP Number & Version

00

Supersended

NA

 

 


 


1.0 Objective:

1.1 To establish a detailed operational procedure for the Diesel Rotary UPS.

2.0 Scope:

2.1 This procedure governs the operation of the Diesel Rotary UPS installation at Stalink Private Limited.

3.0 Responsibility:

S.NO

Role

Responsibility

3.1

Engineering Personnel

Accountable for running the Diesel Rotary UPS(DRUPS) according to this procedure.

3.2

Engineering Head/ Designee

Accountable for the complete execution of this SOP.

3.3

QA Head/ Designee

Responsible for authorizing this SOP.

 

4.1 Diesel Rotary UPS:

A power backup system that utilizes a diesel-fueled engine-generator set to ensure a consistent, clean, and reliable electricity supply during utility power failures.

5.0 Safety and Instruction:

5.1 Staff must wear appropriate safety gear, such as gloves, protective eyewear, and safety footwear, along with any other required Personal Protective Equipment (PPE).

5.2 Operations must only take place outdoors in a location with proper ventilation.

5.3 A fire suppression device must be readily available near the generator at all times.

6.0 Procedure:

Key Points of SOP:

·        When the unit is in "SECURED LOAD" mode, the critical load is protected by the installation, operating in either normal or emergency condition.

·        When the unit is initially in "OFF" mode, the Quality Assurance (QA) is completed as soon as the unit enters "BY-PASS" mode.

·        Voltage, Current, Frequency, and Power Factor are displayed on the Human Machine Interface (HMI) for the mains, load, and stato-alternator voltage. Information regarding the battery charger voltage and current is also shown on the HMI.

6.1 Program Switch Different Operating Mode:

6.1.1 OFF

6.1.2 BY-PASS

6.1.3 SECURE LOAD

6.1.4 HMI CONTROLLED

6.2 Off Mode:

6.2.1 Switching to the "OFF" position may result in a power interruption for the critical load. Pressing the "OFF CONFIRMATION" button is necessary to ensure the rotary UPS unit is shut down.

When the program switch is in "OFF" position, circuit breakers QD1, QD2, and QD3 are in the open position. The unit is stopped, and the critical load is not powered. The blue indicator light on the control panel will be illuminated. When the unit is off, the blue indicator light switches off on the Control Panel.

6.3 By-pass Mode:

6.3.1 When set to "BY-PASS" mode, circuit breaker QD3 is closed. Circuit breaker QD2 is in the open position. The critical load is supplied by the mains power through the automatic by-pass breaker, and therefore, the load is not secured.

6.3.2 If the unit was previously in "OFF" mode, QD3 closes immediately when switching to "BY-PASS" mode.

6.4 Secure Load Mode:

6.4.1 When the unit is in "SECURED LOAD" mode, the essential load is protected by the installation, whether operating under normal or emergency conditions.

6.4.2 Circuit breaker QD3 (the automatic by-pass) is open.

6.4.3 When the load is secured, the blue lamp on the control panel is either constantly lit or blinking.

6.5 HMI Controlled Mode:

6.5.1 When the main program switch is set to the "HMI CONTROLLED" position, two bypass-keys can be selected: "STOP" or "RUN".

6.5.2 These define the unit's behavior during the bypass and startup phases.

6.6 Alarm Acknowledgement:

6.6.1 The acknowledgement feature allows an operator to clear warnings and alarms after the cause has been resolved and any repairs completed. When pressed for 1 second, warnings and alarms related to the entire unit are reset. When pressed for 5 seconds, warnings and alarms related to the entire installation are also reset. If an alarm occurs while in a KS unit stop, the unit must be put into "BY-PASS STOPPED" mode. Otherwise, even if the issue is cleared, the warning or alarm will not be acknowledged, and the unit cannot restart. If an alarm persists throughout the installation, the entire unit must be set to by-pass mode. Even if the issue is cleared, the alarm will not be acknowledged, and the unit cannot restart.

6.7 Horn Stop:

6.7.1 The HORN STOP function enables the operator to silence the horn that sounds following a warning or alarm condition, for a duration of 5 minutes.

6.8 Lamp Test:

6.8.1 The "LAMPS TEST" function permits an operator to verify the indicator lights on the control panel.

6.9 Start/Stop Engine:

6.9.1 The "start/stop engine" function allows an operator to start and stop the engine to operate in idle mode. (The system does not transition into emergency mode.)

6.10 Installation in By-pass / Secure Load Again:

6.10.1 When the program switch is in the "HMI CONTROLLED" position, the "INSTALLATION IN BY-PASS / SECURE LOAD AGAIN" function can be initiated via the HMI.

6.11 Mains Failure test:

6.11.1 This function allows an operator to simulate a mains power failure. This function is only active when the unit is operating in normal run mode. Confirmation is required via the HMI whenever an alarm is present on any running machine.

6.12 Forcing Independent Mode:

6.12.1 This function enables the operator to force the installation to operate in an independent mode.

6.13 Engine Exemption:

6.13.1 This function allows the operator to activate the engine exemption functionality.

6.14 Monthly Test:

6.14.1 The HMI enables the operator to activate/deactivate the installation monthly test.

6.15 Accumulator Deactivation:

6.15.1 The HMI allows an operator to request the accumulator to be deactivated (meaning the accumulator will not accelerate to its full rated speed).

6.15.2 The accumulator will only be deactivated when the machine is in "BY-PASS RUNNING" mode, and "SECURE LOAD" mode is not requested.

6.16 Alarm and Event Display:

6.16.1 All alarms or events concerning the unit and the entire installation are reported on the HMI. Information about the unit's current operating mode is also displayed.

6.17 Mechanical and Physical Value Monitoring:

6.17.1 Bearing temperatures, accumulator speed, and day tank fuel level are all shown on the HMI.

6.18 Hour Meter:

6.18.1 The total running time for both the stato-alternator and the engine is displayed on the HMI.

6.19 Electrical Information:

6.19.1 Voltage, Current, Frequency, Power Factor, and Power are displayed on the HMI for mains, load, and stato-alternator voltages. Information about the battery charger's voltage and current is also displayed on the HMI.

6.20 Setting and Parameters Change:

6.20.1 The HMI permits an operator to modify specific settings like PLC date and time, and automatic tests timing. A "user password" is required to modify these settings. Some internal parameters can also be adjusted through these interfaces. A different, reserved password is required for Engineering/ED engineers to change those specific parameters.

6.21 Installation in By-Pass / Secure Load Again Switch:

6.21.1 A three-position rotating key switch is available for transferring the entire unit to and from by-pass mode. The central position is neutral. The left and right positions are momentary.

6.21.2 On unit securing the load:

If turned to the "INSTALLATION IN BY-PASS" position, this momentary key switch allows an operator to force the installation into automatic by-pass mode (closing of QD3) and to disconnect the unit from the load. (The unit will either stop or continue running, depending on the chosen by-pass type).

6.21.3

When the installation is in by-pass mode with the machines running on mains (due to a general by-pass request or a critical over-load) and "SECURED LOAD" mode is still selected, the machines run.

6.21.4

When the program switch is on "HMI CONTROLLED" position, the "INSTALLATION IN BY-PASS / SECURE LOAD AGAIN" function can be initiated via the HMI.

6.22 Off Mode Operating and Transitions:

6.22.1 Mains power is either present or absent.

6.22.2 Automatic by-pass QD3 is open.

6.22.3 Breakers QD1 and QD2 are open.

6.22.4 The diesel engine is shut down.

6.22.5 The electromagnetic clutches are open.

6.22.6 The stato-alternator is stopped (or slowing down).

6.22.7 The critical load can be supplied directly by the mains via the manual by-pass.

6.23 Automatic By-pass Mode Operating and Transitions:

6.23.1 Mains power is present.

6.23.2 Automatic by-pass QD3 is closed.

6.23.3 Breakers QD1 can be closed or open (depending on the selected by-pass mode).

6.23.4 Breaker QD2 is open.

6.23.5 The diesel engine is shut down.

6.23.6 The electromagnetic clutches are usually open.

6.23.7 The stato-alternator is running or not running (depending on the selected by-pass mode).

6.23.8 The critical load is supplied directly by the mains.

6.24 Secure Load Mode Operating and Transition:

6.24.1 Mains power is present.

6.24.2 Breakers QD1 and QD2 are closed.

6.24.3 The diesel engine is stopped.

6.24.4 The electromagnetic clutches are open.

6.24.5 The kinetic energy accumulators are rotating at the rated speed.

6.24.6 The critical load is supplied by the mains through the unit.

6.24.7 Power factor is improved.

6.25 Transitions from Normal Mode to Emergency Mode:

6.25.1 Occurs in the event of mains disturbance or failure.

6.25.2 The unit disconnects from the mains (QD1 opens).

6.25.3 During the diesel engine startup and electromagnetic clutches closing, the kinetic energy accumulators provide the necessary energy.

6.25.4 Ensure that all alternators and remote radiator fans are operating correctly while the Diesel Engine is running (ED condition).

6.25.5 The diesel engine supplies power to the critical load without any interruption.

6.25.6 During Engine running, record all parameters listed  once every hour.

6.26 Transitions from Emergency Mode to Normal Mode:

6.26.1 When the mains power is restored.

6.26.2 The unit reconnects to the mains (QD1 closes) without any interruption to the critical load.

6.26.3 The electromagnetic clutches open.

6.26.4 The diesel engine runs in idle mode for 5 minutes for cooling down.

6.26.5 The diesel engine stops.

6.26.6 The remote radiator fan stops.

6.26.7 The unit is immediately prepared to handle a subsequent mains failure.

6.26.8 While in Secure Load mode, record the temperature reading every two hours, along with all the parameters specified .


7.0 Abbreviations:

S.NO

Abbreviation

Definition

7.1

DRUPS

Diesel Rotary Uninterruptible Power Supply

7.2

TANGEDCO

Tamil Nadu Generation and Distribution Corporation Limited

7.3

QA

Quality Assurance

7.4

SOP

Standard Operating Procedure

7.5

HMI

Human Machine Interface

7.6

PLC

Programmable Logic Controllers

7.7

ED

Euro Diesel

7.8

UPS

Uninterruptible Power Supply

  

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Location: Chennai, Tamil Nadu, India

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