UPS

Title UPS Strategy Maintenance Sheet # 1 of 11 Owner GDH -
Electrical
Engineering
Strategy # PML201.10 Issue date 30-01-2012 Security Restricted
Discipline Electrical Review date 24-01-2014 Revision 5.0
1. STRATEGY COVERAGE
System/Equipment Systems/Equipment Other Relevant

# Function
Included Not Included Strategies
To provide AC Uninterruptible Battery PML201.03 HV
uninterrupted clean Power Supply (AC UPS) Switchgear Switchgear
1
power supply to Vital DC Uninterruptible PML201.04 LV
loads Power Supply (DC UPS) Switchgear
UPS units must supply Battery Charger PML201.13
power to the vital Lighting
service loads for the PML201.09 - Battery
defined minimum
duration e.g:
ESD and Process
Control Systems
Fire and Gas
2
System.
PA Audio and
Visual Alarms.
SOLAS
Communications.
Navigation Aids
and Helideck
Lighting.
To provide an
uninterrupted power
supply for vital
services when normal
power fails.
3*
Applicable assurance
task:
ER005 - 1.1 UPS
Discharge Function
Test
* = (PS) Performance Standard
SAP BP GAME Object SAP GAME SAP BP Class

SAP BP Description EIS Description
Object Type Type Description (EIS_)
other UPS
E_UPS_X None Available
component
AC
AC Uninterruptible
E_UPS_AC Uninterruptible EIS_EL_ACUPS
ELUP UPS Control Unit Power Supply
Power Supply
DC
DC Uninterruptible
E_UPS_DC Uninterruptible EIS_EL_DCUPS
Power Supply
Power Supply
ELBC Battery charger M_PAC_CHGR Battery charger None ELBC
EIS_EL_POWSTA power stabiliser
CMST Power Stabil./Supply None Available
EIS_EL_PSUNIT power supply unit
Electrical
Engineering
2. DOMINANT FAILURE MODES
Hidden Age
Failure Modes
Failure Related
Power Component Failure N N
Control Component Failure Y N
Battery Failure N Y
Low electrolyte in battery N N
Fail to provide power during mains failure N N
Large reduction in Battery Cell Capacity Y N
Reduced Battery bank Voltage Due To Failed Cell Y N
Mechanical Damage N N
Connections Overheating N N
Terminals Failure N N
Corrosion N Y
Insulation Failure. Y N
Contamination N N
Electrolyte degradation Y Y
Ground Fault Y N
Ventilation Failure Y Y
Alarm Failure Y N
Excessive Temperature Y N
3. MAINTENANCE ACTIVITIES
Applicable Optimiza-
Failure modes
Type Intent to Standard Text Freq tion Comments
covered
(Extent) Method
Mechanical Operator to
Damage monitor for
Corrosion abnormal
Alarm noise,
Operational Checks
Operator to
indication indication,
monitor for signs
alarm,
of UPS
temperature, All 1M PMO
malfunctions.
Electrolyte
Report any
level in
defects.
battery
corrosion and
report
defects.
Mechanical
Damage in
Condition Based Maintenance
UPS and
battery
UPS Panel
indication
Visual UPS and
Failure XX_TL_PML201-
Inspection of battery 6M RCM
Corrosion 10_01
UPS charger
Contamination
Ground Fault
Ventilation
Failure
Connections
Overheating
Electrical
Engineering
Failure modes
covered
(Extent) Method
Low
electrolyte
level in
battery
Connections
Overheating
Excessive
Temperature
Sign of
electrolytic
capacitor
failure
Ventilation
Failure Major UPS and
XX_TL_PML201-
Alarm and Inspection of battery 2Y RCM
10_02
indication UPS charger
Failure
Mechanical
failure
Ground fault
Electric
Component
Failure
Battery
leakage
Electronic
Component
Failure.
Functional
Drift in value
Testing to
of electronic UPS power Specialist vendor
diagnose for XX_TL_PML201-
components and Control 2Y RCM visit may be
deterioration 10_03
End of Unit required.
of
expected life
components
of electrolytic
capacitor and
cooling fan
Spare cells
Failure of required.
Functional
battery cell Specialist vendor
Test for UPS
capacity. XX_TL_PML201- visit may be
Minimum All SCE 2Y RCM
Battery Failure 10_ER005_1.1 required.
Autonomy
Controller
Time
Failure Performance
Standard
Maintenance
Preventative
N/A N/A N/A N/A N/A N/A N/A

Electrical
Engineering
Failure modes
covered
(Extent) Method
Power and
control failure
Spares as
Maintenance
Connections
Corrective
recommended
Overheating
by OEM need All N/A
Terminals
to be kept in
Failure
stock
Ground Fault
4. SAP IMPLEMENTATION
Task List:
- SCE UPS Control Unit PM Tasks
- UPS Control Unit PM Tasks
General Task List

SCE UPS Control Unit PM Task List Group Maintenance
Header XXXXXQ1 XX02
Tasks Name Strategy:
Description
Reference Object
ALL Application Level Item
Type
Discipline/ Complia
Count MA Packag Dura
Operation Standard Text Work nce MIC No.
er /ID T e Freq tion
centre Category
6M-AC/DC
XX_TL_PML201-
0010 UPS Minor PIM DUMELEC 6M I
10_01
Inspection
2Y-AC/DC
XX_TL_PML201-
0020 UPS Major PIM DUMELEC 2Y I
10_02
Inspection
2Y-UPS
Discharge XX_TL_PML201- 500000
0030 PFT DUMELEC 2Y A
Function 10_ER005_1.1 01
Test
General Task List

UPS Control Unit PM Task List Group Maintenance
Header XXXXXX01 XX02
Tasks Name Strategy:
Description
Reference Object
ALL Application Level Item
Type
Discipline/ Complia
Count MA Packag Dura
Operation Standard Text Work nce MIC No.
er /ID T e Freq tion
centre Category
6M-AC/DC
XX_TL_PML201-
0010 UPS Minor PIM DUMELEC 6M I
10_01
Inspection
2Y-AC/DC
XX_TL_PML201-
0020 UPS Major PIM DUMELEC 2Y I
10_02
Inspection
2Y-AC/DC,
DC/DC
XX_TL_PML201-
0030 UPS PFT DUMELEC 2Y I
10_03
Functional
Test
Electrical
Engineering
5. STANDARD TEXT
Failure modes
Intent to Standard Text Freq tion Comments
covered
(Extent) Method
Mechanical
Damage in
UPS and
battery
Leakage of
electrolyte in
battery
UPS Panel
Visual UPS and
indication / XX_TL_PML201-
Inspection of battery 6M RCM
alarm Failure
UPS charger 10_01
Corrosion
Contamination
Ground Fault
Ventilation
Failure
Connections
Overheating
A.) Objective:
Visual Inspection to check the UPS for basic faults and to check if it is fit for purpose
B.) Required Steps:

1. Perform a visual inspection on UPS panel, no Alarms exist, all Indication/LEDs are working properly
and active when required.
2. Check all switches/push buttons are labeled, undamaged and normal condition.
3. Ensure identification label is legible, correct and securely attached.
4. Visually inspect UPS control cards for signs of corrosion, contamination and damage.
5. Check the condition of electrolytic capacitors for any leakage on terminal or deformation in shape.
6. Ensure the UPS is properly sealed as per Manufacturer design and no dust accumulation (or
mechanical damage) is observed.
7. Check cables, glands and earthing for security.
8. Ventilation: Check that the UPS panel ventilation system is operational, clean and clear of
obstructions. Fans are working properly with no abnormal sound. Clean & dry panel air filters if
applicable.
9. Record panel temperature on 4 different locations, mark the locations, as they will be used whenever
there is temperature recording to be carried out.
10. Verify the meter readings on panel are okay.
11. Use the LCD display to check and record the status of the rectifier, battery, inverter and static switch
(If applicable).
12. Visual inspection on rectifier, battery, inverter and static switch (If applicable) for any burning smell or
abnormality.
13. Distribution boards inspection: Visual inspection on all main Circuit Breakers, outgoing circuit
breakers for loose connection/overcurrent or overheated parts.
14. Visually inspect cabling and wiring, including control cabinet, for broken or burned insulation.
Ability to carry out this work depends on the equipment maintaining IP20 protection with doors open
and for terminals to be visible without removing covers
15. Record results of the survey in maintenance management system, raising any corrective notifications
as necessary.
C.) Minimum Assurance Tasks:

Electrical
Engineering
N/A
Failure modes Applicable Optimiza-
Intent Standard Text Freq Comments
covered to (Extent) tion Method
Connections
Overheating
Excessive
Temperatur
e
Ventilation
Failure
Electric
Component
Major UPS and
Failure XX_TL_PML201-
Inspection of battery 2Y RCM
Sign of
UPS charger 10_02
electrolytic
capacitor
failure
Alarm and
indication
Failure
Mechanical
failure
Ground
fault
A.) Objective:
Major Inspection to check the UPS for major faults and to check if it is fit for purpose
B.) Required Steps:

1. Transfer system to maintenance bypass supply and isolate UPS.
2. Check and clean the ventilation fans and filters and ensure they are free to rotate. Check that all the
ventilation inlets and outlets are free from dirt and debris, which may have lodged in the ventilation
grilles. This includes the base of the unit.
3. Check and record the following measurements, as per manufacturers recommendations:
a. Rectifier and inverter input currents (current probe)
b. Rectifier and inverter input and output voltages (tester/oscilloscope)
c. Battery current (current probe)
d. Verification of synchronization between Bypass supply and inverter (oscilloscope)
4. Inspect distribution board internals components for accumulation of dirt/dust and use a vacuum
cleaner with a soft brush to clean.
5. Check all bus bars and terminals are tight, firmly supported, clean and intact.
6. Check Electronic boards, plug-in modules, connectors, ribbons and rack mounted equipment for
security, damage and overheating
7. Check the condition of electrolytic capacitors for any leakage on terminal
8. Carry out insulation resistance testing between all phases and between phase to ground.
9. Check fuses for correct rating, type and security of fuse holders.
10. Check and record earth continuity test value between earth point and a recognized earth boss.
11. Function tests all RCDs & MCBs on distribution panel.
12. Mechanically operate all MCBs by switching through open/tripped/closed positions and confirm
smooth operation.
13. Check the condition of any contactor contacts and for signs of overheating/pitting. Clean or replace
as required.
14. Function test alarms.
15. Check Anti-condensation heater for correct operation.
Electrical
Engineering
16. Inspect the Rectifier, DC bus, Inverter, Static switch and bypass of any abnormality
17. Thermo graphic (Infrared) survey on the UPS (Rectifier, DC bus, Inverter, Static switch, maintenance
by-pass, Distribution boards (as applicable) if safe to do so with doors open.
as necessary.
19. Return UPS to online condition using maintenance bypass switch and transfer controls on UPS.

N/A
Failure modes
Intent to Standard Text Freq tion Comments
covered
(Extent) Method
Functional Testing
UPS power Specialist vendor
Power and control to diagnose for XX_TL_PML201-
and Control 2Y RCM visit may be
Component Failure deterioration of
Unit 10_03 required.
components
A.) Objective:
Functional Test to carry out full function tests to ensure the UPS operates as designed.
B.) Required Steps:

Carry out function test and verification of settings as per vendors manual where available.
1. Transfer system to maintenance bypass supply and ensure load is unaffected.
2. Carry out Fault Diagnosis as per OEM where available
3. Functional testing of the static switch by transferring the load from UPS to bypass mode and back to
UPS by manual initiation of uninterrupted transfer as per OEM.
4. Check that battery comes in line when rectifier fails
5. Record the output waveform of the inverter using an Oscilloscope.
6. Record the DC ripple
7. Verify the parameter settings for the UPS
8. Return UPS to online condition using maintenance bypass switch and transfer controls
as necessary.

N/A
Optimiza-
Failure modes Applicable
Intent Standard Text Freq tion Comments
covered to (Extent)
Method
Failure of
battery cell
capacity.
Functional Test Spare cells required.
Battery Failure
for UPS XX_TL_PML201- Specialist vendor
Control All SCE 2Y RCM
Minimum visit may be
Component 10_ER005_1.1
Autonomy Time required.
Failure.
Controller
Failure
A.) Objective:
Electrical
Engineering
Functional Test to ensure that the identified vital service systems UPS units ( AC or DC ) must supply
power to the vital service loads for the defined minimum duration, when normal power fails and battery
discharge takes place.
B.) Required Steps:

ASSURANCE ACTIVITIES:
NOTE: This Discharge Function Test would require to switchover the UPS to bypass or to provide the
power supply from the second UPS/Battery unit to ensure the continued operation of equipment. The UPS
should be isolated and battery should be disconnected for discharge function test.
Note: In order to perform a discharge test correctly, special equipment will be required.
TEST EQUIPMENT:
Battery Load Unit.
PRIOR WORK
1. Prior to commencing any testing it is essential that a valid permit to work be in place.
2. All personnel involved in the testing shall be made aware of precautions and testing limits allowed
3. OEM Switch off/on procedures to be followed.
TEST PROCEDURE
The battery should be tested in its "as found" condition. But if the battery was discharged for power
outage, recharge it from the partially discharged condition for 24 hours. The test discharge rate should not
be corrected for temperature or battery age.
1. Visual check no Alarms are present in the UPS.
2. Measure and record the ambient temperature in the room and UPS enclosure in deg C.
3. Record the batteries temperature in deg. C.
4. Read and record the battery terminal float voltage.
5. Transfer system to maintenance bypass supply and ensure load is unaffected.
6. Determine the number of Battery Load Units to be connected into single system to provide discharge
rate.
7. Set-up Battery Load Units, and arrange for alternate power to the load through other UPS or through
maintenance bypass supply.
8. Follow the Battery Load Unit instructions.
9. Carry out load test of batteries with the Battery Load Unit as per the load unit manufacturers
recommendations by connecting the batteries to the appropriate battery load unit and discharging to
prove that the system/voltage /time parameters remain within acceptable limit for the particular UPS
application. To allow comparison of performance against battery OEM literature, the discharge rate
shall be one for which there is OEM information available e.g C1, C5, C10
10. During the test, measure individual cell voltage to detect the defective cells.
11. Ensure that batteries will be not be discharged to below minimum voltage according to OEM
recommendation.
12. Record the individual cell voltages and the battery terminal voltage and battery discharge power as
per performance every 10 min. The individual cell voltage level should be not less than minimum
design voltage.
Note: If at any stage during the test, either the battery cell(s) or test equipment is displaying signs of
distress, then the test must be aborted.
13. When test complete record the elapsed time.
14. Follow to Load Unit instruction to end the test.
POST TEST OBSERVATION:

1. Observe the battery for abnormal inter-cell connector heating.
2. Check the level of electrolyte of each cell.
3. Record the specific gravity of electrolyte of each cell.
4. Close the Battery Disconnect Breaker.
Electrical
Engineering
5. Switch on the UPS charger/rectifier primary supply. Ensure that charger voltage output increases to
the expected level on the LED display.
6. Switch on the battery disconnect breaker to charge the batteries.
7. Check and record the battery charger performance (High Rate/Floating Charging).
8. Carry out hot spot checks on charger.
9. Switchover from maintenance Bypass to normal UPS operation and put the UPS in to service. Refer to
the Platform Operating Procedures Manual
10. Check no UPS Alarm has presented.
as necessary.

1.1 UPS Discharge Function Test
The identified vital service systems UPS units ( AC or DC ) must supply power to the vital service loads for
the defined minimum duration.
1. ESD and EDP Systems,
2. Fire and Gas System,
3. PA Audio and Visual Alarms,
4. SOLAS Communications,
5. Navigation Aids and Helideck Lighting
Assurance measure: UPS Minimum Autonomy Time >= (Time)

Electrical
Engineering
6. IMPLEMENTATION CONSIDERATIONS
Category* Consideration
Execution Frequency may require adjustment according to system criticality.

A specialist vendor/OEM may be required for the AC/DC, DC/DC UPS Functional Test due to the
Resources specialist knowledge and experience required
A specialist vendor may be required for battery discharge testing.
USP thermographic inspection is performed together with chargers and batteries
Other
OEM O&M manual will give recommended intervals for replacement of fans and these
should be adhered to
To keep UPS in a clean, dry atmosphere, proper ventilation and appropriate room temperature has
Environment
to be provided
*Criticality, Medium, Spare Parts, Environment, Legislation, Execution, Policy, Interferences, Resources, Other
7. REFERENCES
Source Document Title & Number
Shell Design RPM 63.10.08.50 Gen Maintenance of Electrical Installations and Equipment.
Engineering Practice
DEP 80.64.10.10 Shell Design and Engineering Practice Electrical Safety Rules
(DEP)
IEE Recommendations for Electrical and Electronic Equipment of Mobile and Fixed Offshore
International Installations.
Standards
IEC 62040 Uninterruptable power system (UPS).
Electrical
Engineering
8. CHANGE LOG
Date Changes by Changes/ Comments Revision
23-05-2011 Shell Review on draft strategy 0.2

Split up into two separate strategies:
PML201.10 UPS
21-06-2011 Shell 0.3
and
PML201.09 Battery & Charger
12-08-2011 ADD Energy Consolidation Rework 0.4
31-10-2011 Jan Buraczynski Rework 0.5
24-11-2011 Justin van Loon Final Review (IDC) 1.0
07-01-2012 S.K.Dwivedi Review 1.1
24-01-2012 Peter Freeman Review 1.2
30-01-2012 Pim Dekker Strategy ready for PTE approval 2.0
30-01-2012 Wim de Wilt Strategy approved by PTE 3.0
Removed reference to IC002 tasks in line
14-03-2012 Belinda Ikazoboh 3.1
with assignment sheet
Updated in line with PTE ( Peter freeman)
22-10-2012 Belinda Ikazoboh 3.2
comments
Regrouped task lists to create SCE and non-
01-11-2012 Tiemon Dokter 3.3
SCE task lists
30-10-2012 Wim de Wilt Strategy approved by GDH 4.0
27-09-2013 Justin Brunsting Template changes 4.1
24-01-2014 Wim de Wilt Strategy approved by PTE 5.0

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Title UPS Strategy Maintenance Sheet # 1 of 11 Owner GDH -

System/Equipment Systems/Equipment Other Relevant

SAP BP GAME Object SAP GAME SAP BP Class

2. DOMINANT FAILURE MODES

N/A N/A N/A N/A N/A N/A N/A

General Task List

General Task List

B.) Required Steps:

C.) Minimum Assurance Tasks:

B.) Required Steps:

C.) Minimum Assurance Tasks:

B.) Required Steps:

C.) Minimum Assurance Tasks:

B.) Required Steps:

POST TEST OBSERVATION:

C.) Minimum Assurance Tasks:

Assurance measure: UPS Minimum Autonomy Time >= (Time)

Execution Frequency may require adjustment according to system criticality.

Source Document Title & Number

Date Changes by Changes/ Comments Revision

23-05-2011 Shell Review on draft strategy 0.2

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